Calculation of Secondary Superheater 01.02.2012 00

7/30/2019 Calculation of Secondary Superheater 01.02.2012 00

1/45

STRESS CALCULATION

EQUIPMENT : SECONDARY SUPPERHEATER

QUANTITY : ONE

CLIENT : SINCHAISRI COMPANY LTD.

PHANOMTUAN, KANCHANABURI, THAILAND.

ENGINEERING : ENMAS GB POWER SYSTEMS PROJECTS LIMITED,

DESIGN & CONSTRUCTION CODE : ASME BOILER & PRESSURE VESSEL CODE,

SECTION - I, 2007 EDITION

MANUFACTURER : G.B. ENGINEERING ENTERPRISES PVT. LTD.,

D - 99 DEVELOPED PLOTS ESTATE

THUVAKKUDY,

TRICHY - 620 015, INDIA.

Enterprises Pvt.Ltd Equip. SECONDARY SUPPERHEATERMFR'S

SERIAL No.GBE/XXXX/0XX

STRESS CALCULATIONSheet 01

GB ENGINEERING Rev. 00


2/45

02. Index

Cover Sheet

Index

Revision Status - Drawing

Revision Status - Stress Calculation sheet

List of Drawings

List of Standards/CodesDesign Data

Hydrostatic Test Pressure

Material Constructions

Allowable Stress

Radiographic Examinations

Heat Treatment

Calculation of minimum required thickness for tubes

Calculation of minimum required thickness for inlet header

Calculation of Max. allowable stress during hydro test for inlet header

Calculation of minimum required thickness for Nozzles

Calculation of Max. allowable openig on inlet header

Compensation check for inlet header

Calculation of end plate thickness for inlet header

Calculation of Max. allow. stress during hydro test for header end plate

Minimum requirements for attachments weld on inlet header

Calculation of minimum required thickness for inlet header

Calculation of Max. allowable stress during hydro test for inlet header

Calculation of minimum required thickness and M/C End

Calculation of Max. allowable openig on outlet header

Compensation check for outlet header

Calculation of end plate thickness for inlet header

Calculation of Max. allow. stress during hydro test for header end plate

Minimum requirements for attachments weld on inlet header

07 41

08 42 to 44

04 36

05 37

06 38 & 40

01 29

02 30

03 31 To 35

07 24 & 25

08 26 To 28

Secondary Superheater outlet header

04 20

05 21

06 22 & 23

01 15

02 16

03 17 to 19

Secondary Superheater tubes

01 13 & 14Secondary Superheater inlet header

10 10

11 11

12 12

07 7

08 8

09 9

04 4

05 5

06 6

01 1

02 2

03 3



S.No. Description Sheet No.




3/45

03. STATUS OF CALCULATION DUE TO REVISION IN DRAWING

S.

NoRev.

PREPARED CHECKED APPROVED DOCUMENT NO. DATE

REV.NO. DESCRIPTION PREPARED CHECKED APPROVED

SCL/XXX/XXX 02.02.2012

Checked Approved

Enterprises Pvt.Ltd Equip. SECONDARY SUPPERHEATERMFR'S SERIAL

No.GBE/XXXX/0XX

Drawing No.Page Of

CalculationReason For Revision

Pages

AffectedPrepared




4/45

04. REVISION STATUS FOR STRESS CALCULATIONS

0 1 2 3 4 0 1 2 3 4 0 1 2 3 4

30

28

29

26

27

24

25

22

23

20

21

18 48

19

16 46

17 47

14 44

15 45

12 42

13 43

10 40

11 41

8 38

9 39

6 36

7 37

4 345 35

2 32

3 33

No. No. No.

1 31

Sheet REV. No. Sheet REV. No. Sheet REV. No.

Enterprises Pvt.Ltd Equip. SECONDARY SUPPERHEATERMFR'S SERIAL

No.GBE/XXXX/0XX




5/45

05.LIST OF DRAWINGS PREPARED

Arrangement of Secondary Superheater

Secondary superheater inlet and outlet headers

Secondary superheater coil

Tube bends for secondary supperheater coil

3 WAAA0200-1-F-05-06-0045 00

4 WAAA0200-1-F-05-06-0046 00

1 WAAA0200-1-F-05-05-0047 00

2 WAAA0200-1-F-05-07-0006 00

Enterprises Pvt.Ltd Equip. SECONDARY SUPPERHEATER MFR'S SERIAL No. GBE/XXXX/0XX

S.No. Description Drawing No. Rev.




6/45

06.LIST OF STANDARDS / CODES

1 ASME Section-I, 2007 Edition

2 ASME Section II, Part-A, 2007 Edition

3 ASME Section-II, Part-D, 2007 Edition

4 ASME B36.10M, 2004

5 ASME Section - VIII, Division - 1, 2007 Edition






7/45

07. DESIGN DATA

Design & Construction code : ASME Boiler & Pressure Vessel Code,

Section - I, 2007 Edition

Fluid Handled : Superheated Steam

Max. Allowable Working Pressure : bar (a) = kg/cm2

(a)

Design Pressure : bar (a) = kg/cm2

(a)

Design Temperature : oC [ SA 213 Gr.T22 ]

: oC [ SA 213 Gr.T11 ]

: oC [SA 106 Gr. B]

: oC [SA 335Gr. P11]

Hydrostatic Test Pressure(PG-99) : bar (a) = kg/cm2 (a)

Hydrostatic Test Temp.(PG-99) : 21 C ( Not less than 70oF)

Radiography : (Ref page No. 11)

Post Weld Heat Treatment : (Ref page No. 12)

Corrosion allowance : mm

Notified body : LLOYD'S Register Verificaton Limited

Volume : 2600 ( Litres )

128.595 131.130

1

85.73 87.420

535

480

385

501



85 86.680




8/45

08 Calculation of Design Pressure As per PG-99

Maximum Allowable working pressure = kg/cm2

(a) = bar(a)

(MAWP)

Design Pressure = MAWP + Hydrostatic Head

= 86.68 +

= kg/cm2

(a) = bar(a)

Upper elevation

Lower Elevation

Effective Static Head

Static head per meter

Static head for 7.4 m5 kg/cm2 0.74

3 mm 7400

4 kg/cm2 0.1

1 mm 19675

2 mm 12275

0.74

87.420 85.73

S.No. Description units Data



86.68 85.00




9/45

09 MATERIAL OF CONSTRUCTION

01 Tubes = SA 210 Gr.T11

= SA 213 Gr.T22

02 Inlet Header

Header = SA 106 Gr.B

Pipe = SA 106 Gr.B

Inspection Stub = SA 106 Gr.B

End Cover = SA 105

03 Outlet Header

Header = SA 335 Gr.P11

Inspection Stub = SA 182 Gr.F11 CL.1

End Cover = SA 182 Gr.F11 CL.1

Pipe = SA 335 Gr.P11






10/45

10 Allowable stress Values

As per ASME Section - II, Part-D, 2007 Edition

1

2

3

4

5

6

7

8 1881.39 4 1

1881.39 4 1

SA 182 Gr.F11 CL.1 21 205000 2090.43 501 75671.75 771.64

1881.39 4 1

SA 213 Gr.T22 21 205000 2090.43 501 80223.98 818.06

1 2

Outlet Header

SA 335 Gr.P11 21 205000 2090.43 501 75671.75 771.64

4 1

SA 105 21 250000 2549.30 385 110599 1127.8 2294.37

1 1

SA 213 Gr.T11 21 205000 2090.43 385 103199.9 1052.35 1881.39

1

Inlet Header

SA 106 Gr.B 21 240000 2447.33 385 98560.39 1005.04 2202.60

1

SA 213 Gr.T11 21 205000 2090.43 480 91093.63 928.9 1881.39 4

TubesSA 213 Gr.T22 21 205000 2090.43 535 57480.48 586.14 1881.39 5A

P.No.

Grou

p

No.TempoC

Stress

kPa

Stress

kg/cm2

TempoC

Stress

kPa

Stress

kg/cm2



S.

No

Material

construction

Min. yield strength at

ambient temperature"Y"

Allowable stress at design

temperature"S"

Min. yield

strength at

ambient

temp. (0.9xY)

kg/cm2




11/45

11 Radiographic Examination of Welds as per PW-11

Conclusion:

01.Header outside diameter is 219.1 mm and thickness is 18.26 mm.

02.Hence Radiographic Test is not required as per table PW 11 as above.

03 However our Manufacturer practice of Radiographic Test is as follows,

100% for Header joints

10% for tube joints

1Circumferential welds in Pipes,

tubs and Headers

Table PW 11,

(Not Subject to

furnace Radiant Heat)

(Steam)

100% radiography shall be

done. If, circumferential

weldsin drum exceed NPS 16

(DN 400 ) or 41 mm thicknss



S.No. Description Code Requirement




12/45

12 Heat Treatment

Conditions:

Material : P-No. 1, Group No. 1, 2, 3(a) (1) Postweld heat treatment is not mandatory for circumferential butt welds in pressure

parts with a nominal Wall thickness of 3/4 in. ( 19 mm ) or less at the joints.

for Combination groove and fillet welds attaching connections to a vessel as depicted in

Fig. 16.1(z), provided all of the following conditions are meet:

(a) both the tube and vessels are P-No.1, Group No. 1 or 2 material

(b) The dia. of the finished opening does not exceed that allowed in PG-32.1.2 or 2 in. ( 50mm ), whichever is less

(c)the nominal thickness of the weld does not exceed 3/8 in. (10 mm)

(d) the connections are not placed in the vessel such as to form ligaments, the efficiency

of which would affect the vessel thickness

(e) a minimum preheat of 200o

F (95oC) is applied when the thickness of either part exceeds 3/4 in. (19mm)

(f) for welds attaching nonload-carring studs not exceeding 1/2 in. (13mm) in diameter when

using an automatic arc stud welding or automatic resistance stud welding process.

( c ) For all P-No.1 Group No.1 materials, and for P-No.1 Group No.2 materials having a maximum

actual carbon Content of 0.30%, the postweld heat treatment requirement of PWT 11.2

for tubes welded to headers is not Mandatory when all of the following conditions are met:

1) The tubes do not exceed 2 in. ( 50 mm ) O.D. 3) The header thickness does not exceed 1/2 in. ( 13 mm ).

2) The header does not exceed NPS 8 (DN 200) 4) A minimum preheat of 200oF ( 95 C ) is applied.

Conclusions:

01. Header outside diameter is 219.1 mm and thickness is 18.26 mm.(Groove Cum fillet weld size more than 13mm)

02. Hence the Postweld heat treatment is required.

Material : P-No. 4, Group No. 1, 2

(1) for circumferential butt welds in pressure parts with all the following conditions

(a) a nominal base metal thickness of 16mm or less at the weld

(b) a max specified carbon content ( SA material specification carbon content except when further limited by

1 Secondary Superheater welds Table PW 39

(11)



S.No. Description Code




13/45

01 Calculation of tube thickness Under Internal Pressure As Per PG - 27.2.1

Item

Drg. No.

Material Specification

Design Pressure P

Design Temperature

Outside Diameter of tube D

Nominal Thickness

Under Tolerance on thickness

Minimum Thickness available

Thinnig allowance ( 10%)

Max. Allow. Stress value at Design Temp. SMin. Yield Strength at ambient Temperature Y

e

Corrosion Allowance C.A

Minimum required thickness

t = Minimum thickness available - C.A t

Provided Min. Thickness > Required Thickness

Stress at Hydrostatic Test Pressure (PG -99)

Hydrostatic test Pressure

Stress during Hydrostatic Test Pressure

( 0.9 x Y) 90% of Yield Strength (as per PG-99)

( 0.9 x Y ) > Shydro20 Hence Satisfactory

kPa 79239.75 808.02 kg/cm2

19 kPa 184500.00 1881.38 kg/cm2

17 bar (a) 128.595 131.130 kg/cm2(a)

18

15 mm 3.05

16 Hence Satisfactory

14

mm 2.83

12 Thickness factor for expanded tube end

(PG-27.4,Note:4)mm 0.00

13 mm 1.00

10 kPa 57480.48 586.14 kg/cm2

11 kPa 205000 2090.43 kg/cm2

08 mm 4.50

09 mm 4.05

06 mm 4.50

07 % 0.00

04 oC 535

05 mm 38.10

02 SA 213 Gr.T22

03 bar (a) 85.73 87.420 kg/cm2(a)

01 Secondary Superheater coils

WAAA0200-2-F-05-06-0046

Item No. 01


SERIAL No.GBE/XXXX/00X

S.No. DESCRIPTION Units Data



]eD005.0t[2

])eD005.0t(D[PS hhydro

eD005.0PS2

DPt min


14/45

01 Calculation of tube thickness Under Internal Pressure As Per PG - 27.2.1

Item

Drg. No.


Design Pressure P

Design Temperature

Outside Diameter of tube D

Nominal Thickness



Thinnig allowance ( 10%)

Max. Allow. Stress value at Design Temp. SMin. Yield Strength at ambient Temperature Y

e










kPa 110029.44 1121.99 kg/cm2

19 kPa 184500.00 1881.38 kg/cm2

17 bar (a) 128.595 131.130 kg/cm2(a)

18

15 mm 2.29


14

mm 1.90

12 Thickness factor for expanded tube end

(PG-27.4,Note:4)mm 0.00

13 mm 1.00

10 kPa 91093.633 928.90 kg/cm

2

11 kPa 205000 2090.43 kg/cm2

08 mm 3.66

09 mm 3.29

06 mm 3.66

07 % 0.00

04 oC 480

05 mm 38.10

02 SA 213 Gr.T11

03 bar (a) 85.73 87.420 kg/cm2(a)

01 Secondary Superheater coils

WAAA0200-2-F-05-06-0046

Item No. 02


SERIAL No.GBE/XXXX/00X




]eD005.0t[2

])eD005.0t(D[PS hhydro

eD005.0PS2

DPt min


15/45

01 Calculation of Header Thickness Under Internal Pressure As Per PG - 27.2.2

Item

Drg. No.

Var. No./Item No.


Design Pressure P

Design Temperature

Outside Diameter of Header D

Nominal Thickness



Max. Allow. Stress value at Design Temp. S

Min. Yield Strength at ambient Temperature Y

Temperature Co-efficient ( PG-27.4, Note-6 ) y

Min.allow. for structural stability(PG-27.4,Notes:3)CCorrosion Allowance C.A

Ligaments between openings (PG-52)

p = Longitudinal Pitch

d1 = Diameter of Hole - 1 ( Tube hole )


d = Average hole Diameter

EL

= Long. Ligament Efficiency

Least Ligament Efficiency E


Minimum required thickness ( E = 1 )

Greater of ( 19, 21 )

Required thickness


P id d Mi Thi k R i d Thi k25 H S ti f t

23 mm 11.31

24 mm 14.98

21Minimum thickness as per code (PG-16.3)

For boiler plate minimum thicknessmm 6.00

22 mm 11.31

mm 11.31

20 mm 9.21

17 0.808

19

mm 28.78

0.808

mm 28.78

mm 28.78

14

mm 150.00

12 mm 0.0013 mm 1.00

10 kPa 240000 2447.33 kg/cm2

11 0.40

8 mm 15.98

9 kPa 98560.389 1005.04 kg/cm2

6 mm 18.26

7 % 12.50

4 oC 385

5 mm 219.10

2 SA 106 Gr.B

3 bar (a) 85.73 87.420 kg/cm2(a)

1 Secondary superheater Inlet Header

WAAA0200-2-F-05-07-0006

01/01


SERIAL No.GBE/XXXX/038




p

dpE L

CPy2ES2

DPt min


16/45

02.Calculation of maximum allowable stress during Hydro test As Per PG - 27.2.2

Item

Drg. No.

Var. No./Item No.


Hydrostatic test Pressure Ph


Minimum thickness available t



Min.allow. for structural stability(PG-27.4,Notes:3) C

Efficiency E

Stress during Hydrostatic test Pressure


( 0.9 x Y ) > Shydro

11 kPa 216000.00 2202.60 kg/cm2


10

kPa 92298.95 941.19 kg/cm2

8 mm 0.00

9 0.808

6 kPa 240000 2447.33 kg/cm2

7 0.40

4 mm 219.10

5 mm 18.26

2 SA 106 Gr.B

3 bar (a) 128.15 131.130 kg/cm2(a)


MFB-F-10-05-07-0001

01/01






)Ct(E2

])Ct(y2D[P

S

h

hydro


17/45

01 Calculation of pipe thickness Under Internal Pressure As Per PG - 27.2.2

Item

Drg. No.

Item No.


Design Pressure P

Design Temperature

Outside Diameter of Pipe D

Nominal Thickness






Min. allow. for structural stability(PG-27.4,Note:3) C


Efficiency (PG - 27.4, Note:1) E


Minimum thickness as per code (PG-16.3)

Required Thickness (Greater of 15 & 16)








23 kPa 216000.00 2202.60 kg/cm2


21

22 kPa 78958.30 805.15 kg/cm2


20 bar (a) 128.60 131.14 kg/cm2(a)

17 mm 4.8018 mm 8.74

mm 4.80

16 mm N.A.

14 1.00

15

12 mm 0.00

13 mm 1.00

10 kPa 240000 2447.33 kg/cm2

11 0.40

08 mm 9.74

09 kPa 98560.389 1005.04 kg/cm2

06 mm 11.13

07 % 12.50

04 oC 385

05 mm 114.30

02 SA 106 Gr.B

03 bar (a) 85.73 87.420 kg/cm2(a)

01 Inspection stub

MFB-F-10-05-07-0001

03


SERIAL No.#REF!




CPy2ES2

DPtmin

)Ct(E2

])Ct(y2D[PS hhydro


18/45


Item

Drg. No.

Item No.


Design Pressure P

Design Temperature


Nominal Thickness



















23 kPa 216000.00 2202.60 kg/cm2


21

22 kPa 67108.98 684.32 kg/cm2


20 bar (a) 128.60 131.14 kg/cm2(a)

17 mm 7.0718 mm 14.98

mm 7.07

16 mm N.A.

14 1.00

15

12 mm 0.00

13 mm 1.00

10 kPa 240000 2447.33 kg/cm2

11 0.40

08 mm 15.98

09 kPa 98560.389 1005.04 kg/cm2

06 mm 18.26

07 % 12.50

04 oC 385

05 mm 168.30

02 SA 106 Gr.B

03 bar (a) 85.73 87.420 kg/cm2(a)

01 Inlet stub

MFB-F-10-05-07-0001

06


SERIAL No.#REF!




CPy2ES2

DPtmin

)Ct(E2

])Ct(y2D[PS hhydro


19/45


Item

Drg. No.

Item No.


Design Pressure P

Design Temperature


Nominal Thickness











Required Thickness (Greater of 15 & 16)t = Minimum thickness available - C.A t







23 kPa 216000.00 2202.60 kg/cm2


21

22 kPa 120836.09 1232.19 kg/cm2


20 bar (a) 128.60 131.14 kg/cm2(a)

17 mm 7.0718 mm 8.59

mm 7.07

16 mm N.A.

14 1.00

15

12 mm 0.00

13 mm 1.00

10 kPa 240000 2447.33 kg/cm2

11 0.40

08 mm 9.59

09 kPa 98560.389 1005.04 kg/cm2

06 mm 9.59

07 % 0.00

04 oC 385

05 mm 168.30

02 SA 106 Gr.B

03 bar (a) 85.73 87.420 kg/cm2(a)

01 Inlet stub machine end

MFB-F-10-05-07-0001

06


SERIAL No.#REF!




CPy2ES2

DPtmin

)Ct(E2

])Ct(y2D[PS hhydro


20/45

03 Calculation of maximum allowable opening as per ASME PG-32.1.2

Item

Drg. No.

Var. No./Item No.


Design Pressure P

Design Temperature


Minimum Thickness t



d = Maximum allowable diameter of

uncompensated opening ( as per Fig. PG-32 )

d = 8.08 [ D t ( 1 - K ) ](1/3)

dn = Diameter of the Opening

Opening List

Inlet Stub

Inspection Stub

Tube3 28.78 96.56 Hence Compensation is not required

1 139.76 96.56 Hence Compensation is required

2 92.04 96.56 Hence Compensation is not required

S.No Description

Actual

Opening

Allowable

Opening ( dn < d )

mm mm

9

mm 96.56

10 mm

8

0.57

6 mm 18.26

7 kPa 98560.389 1005.04 kg/cm2

4 oC 385

5 mm 219.10

2 SA 106 Gr.B

3 bar (a) 85.73 87.420 kg/cm2(a)


MFB-F-10-05-07-0001

01/01






tS82.1

DPK


21/45

Compensation check calculation as per ASME Section - I, PG - 33

Item

Drg. No.

Item No.

Shell Data:

Minimum Thickness of Shell t

Required Thickness of Seamless Shell tr

Max. allowable stress at design temp. Sv

Finished Diameter of opening d

Nozzle DataNozzle OD

Nominal Thickness of Nozzle tn

Required Thickness of Seamless Nozzle tnr


Max. allowable stress at design temp. Snfr1 = ( Sn / Sv )

Actual projection of nozzle I.S. of the dished head

2.5 x t

2.5 x tn

Minimum of 2.5 t and 2.5 tn

Actual projection of nozzle I.S. of the shell

F = Correction factor

Compensation available in dished head

( d - 2 tn ) ( t - F t r)

2 t ( t - F t r)

A1 = max. ( i, ii ) A1

Compensation available in Nozzle

2 ( tn - trn ) ( 2.5 t fr1 )

2 ( tn - trn ) ( 2.5 tn + te ) fr1A2 = min. ( i, ii ) A2

Compensation available in nozzle from inside projection

h = Projection of nozzle inside the shell

A3 = 2 tn fr1 h A3

Compensation available in reinforcement element

Outer diameter of the reinforcement element Dp

Thickness of the reinforcement element te

Max.allowable stress at Design temp. Sp

fr3 = Sp / Sv fr3A5 = ( Dp - d - 2 tn ) te fr3 A5

Total Compensation Area available

A avail = A1 + A2 + A3 + A5 mm2 1955.97

0.00

mm2 0.00

12

mm 0.00

mm 0.00

kPa 0 0.00 kg/cm2

10

mm 0.00

mm2 0.00

11

09

mm2 1021.65

mm2 1021.65mm

2 1021.65

08

mm2 934.32

mm2 330.51

mm2 934.32

mm 35.68

06 mm 0.00

07 1.00

05 mm 0.00

mm 45.65

mm 45.65

kPa 98560.389 1005.04 kg/cm2

04 1.00

mm 7.07

SA 106 Gr.B.

03

mm 168.30

mm 18.26

kPa 98560.389 1005.04 kg/cm2

mm 139.76

02

mm 18.26

mm 9.21

01 Inlet Stub

MFB-F-10-05-07-0001

06


SERIAL No.#REF!





22/45

06 Calculation of End plate thickness Under Internal Pressure As Per PG - 31.3

Item

Drg. No.

Var. No./Item No.

Design Pressure P

Design Temperature


End plate data


Inside diameter of the Header d

Provided Thickness of End Plate t

Allowable Stress value at design temperature S

Header data

Actual thicknes of header ts

Min. required thickness of seamless header tr

C = Calculation factor as per Fig [ PG-31 (g-1) ]

m = tr / ts

0.33 m

C = 0.33m with a minimum of 0.2

Selected 'C' C

Minimum required thickness of end plate

Required Thickness



Minimum weld size

tw = 2 trmin. not less than 1.25 ts, But need not be Greater than t

2 tr

1.25 ts

tw = Minimum weld Size20 mm 10.00

17

18 mm 18.42

19 mm 22.83

15 mm 29.00


mm 22.73

14 mm 22.73

mm 0.20

12 mm 0.20

13

11

mm 0.50

mm 0.17

09 mm 18.26

10 mm 9.21

07 mm 30.00

08 kPa 110598.988 1127.80 kg/cm2

04 mm 1.00

05 SA 105

06 mm 182.58

02 bar (a) 85.73 87.420 kg/cm2(a)

03 oC 385

01 Inlet header end Cover

MFB-F-10-05-07-0001

01/05






SPCdt min


23/45

06 Calculation of End plate thickness Under Internal Pressure As Per UG - 34

Item

Drg. No.

Var. No./Item No.

Design Pressure P

Design Temperature


End plate data





Header data



C = Calculation factor as per Fig [ UG-34 (b-2) & UW-13.3 (b)]

m = tr / ts

0.33 m


Selected 'C' C


Required Thickness



15 mm 19.00


mm 11.46

14 mm 11.46

12 mm 0.20

13

11

mm 0.50

mm 0.17

mm 0.20

09 mm 18.26

10 mm 9.21

07 mm 20.00

08 kPa 110598.988 1127.80 kg/cm2

04 mm 1.00

05 SA 105

06 mm 92.04

02 bar (a) 85.73 87.420 kg/cm2(a)

03 oC 385

01 Inlet header end Cap

MFB-F-10-05-07-0001

01/03






SPCdt min


24/45

07 Calculation of Stress at Hydrostatic Test Pressure (PG -99)

Item

Drg. No.

Var. No./Item No.


End plate data



Minimum Thickness of End Plate t

Minimum yield strength at Ambient temp. Y

Selected 'C' C


( 0.9 x Y) 90% of Yield Strength (as per PG-99) t


kg/cm2

09 kPa 225000 2294.37 kg/cm2

08

kPa 95260.97 971.40

06 kPa 250000 2549.30 kg/cm2

07 mm 0.20

04 mm 182.58

05 mm 30.00

02 bar (a) 128.60 131.130 kg/cm2(a)

03 SA 105

01 Inlet header end cover

MFB-F-10-05-07-0001

01/06






2

h

2

hydrot

PCdS


25/45


Item

Drg. No.

Var. No./Item No.


End plate data





Selected 'C' C




kg/cm2

09 kPa 225000 2294.37 kg/cm2

08

kPa 54468.37 555.42

06 kPa 250000 2549.30 kg/cm2

07 mm 0.20

04 mm 92.04

05 mm 20.00

02 bar (a) 128.60 131.130 kg/cm2(a)

03 SA 105

01 Inlet header end cap

MFB-F-10-05-07-0001

01/04






2

h

2

hydrot

PCdS


26/45

08 Minimum requirements for attachments weld as per PW - 16

Item

Drg. No.

Var. No./Item No.

Minimum thickness of Shell t

Nominal thickness of Stub tn

Conditions

tmin = the smaller of 3/4 in. (19 mm) or the

thickness of either of the weld parts (t,tn)

tc = Not less than the smaller of 1/4 in. or 0.7 tmin

Applicable Sketch from Fig.PW-16.1

tmin

0.7 tmin

Required tc

Provided tc

Required tc < Provided tc

Minimum groove size

tw = tn but not less than 1/4"

Required tw

Provided tw

Required tw < Provided tw11 Hence Satisfactory

08

09 mm 6.00

10 mm 6.50

mm 5.50


mm 2.56

mm 2.56

05

06 Sketch (z)

mm 3.66

04

02 mm 18.26

03 mm 3.66

01 Inlet header to panal stub

MFB-F-10-05-07-0001

01/02







27/45


Item

Drg. No.

Var. No./Item No.



Conditions





tmin

0.7 tmin

Required tc

Provided tc


mm 10.00


mm 9.99

mm 9.99

05

06 Sketch (a)

mm 14.27

04

02 mm 18.26

03 mm 14.27

01 Inlet header to riser stub

MFB-F-10-05-07-0001

01/06







28/45


Item

Drg. No.

Var. No./Item No.



Conditions





tmin

0.7 tmin

Required tc

Provided tc


mm 9.0007 Hence Satisfactory

mm 7.79

mm 7.79

05

06 Sketch (a)

mm 11.13

04

02 mm 18.26

03 mm 11.13

01 Inlet header to inspection stub

MFB-F-10-05-07-0001

01/03


SERIAL No.GBE/XXX/038





29/45

01 Calculation of Header Thickness Under Internal Pressure As Per PG - 27.2.2

Item

Drg. No.

Var. No./Item No.


Design Pressure P

Design Temperature

Outside Diameter of Header DNominal Thickness






Min.allow. for structural stability(PG-27.4,Notes:3)C


Ligaments between openings (PG-52)

p = Longitudinal Pitch



d = Average hole Diameter

EL = Long. Ligament Efficiency

Least Ligament Efficiency E


Minimum required thickness ( E = 1 )

Greater of ( 19, 21 )

Required thickness


P id d Mi Thi k R i d Thi k25 H S ti f t

23 mm 14.36

24 mm 17.04

21Minimum thickness as per code (PG-16.3)

For boiler plate minimum thicknessmm 6.00

22 mm 14.58

mm 14.36

20 mm 11.87

17 0.819

19

mm 27.10

0.819

mm 27.10

mm 27.10

14

mm 150.00

12 mm 0.00

13 mm 1.00

10 kPa 205000 2090.43 kg/cm2

11 0.40

8 mm 18.04

9 kPa 75671.753 771.64 kg/cm2

6 mm 20.62

7 % 12.50

4 oC 501

5 mm 219.10

2 SA 335 Gr.P11

3 bar (a) 85.73 87.420 kg/cm2(a)

1 Outlet Header

MFB-F-10-05-07-0001

02/01






p

dpE L

CPy2ES2

DPt min


30/45

02.Calculation of maximum allowable stress during Hydro test As Per PG - 27.2.2

Item

Drg. No.

Var. No./Item No.




Minimum thickness available t



Min.allow. for structural stability(PG-27.4,Notes:3) C

Efficiency E

Stress during Hydrostatic test Pressure



11 kPa 184500.00 1881.38 kg/cm2


10

kPa 80277.95 818.61 kg/cm2

8 mm 0.00

9 0.819

6 kPa 205000 2090.43 kg/cm2

7 0.40

4 mm 219.10

5 mm 20.62

2 SA 335 Gr.P11

3 bar (a) 128.60 131.130 kg/cm2(a)

1 Outlet Header

MFB-F-10-05-07-0001

02/01


SERIAL No.GBE/XXXX./038




)Ct(E2

])Ct(y2D[PS hhydro


31/45


Item

Drg. No.

Item No.


Design Pressure P

Design Temperature


Nominal Thickness



















23 kPa 184500.00 1881.38 kg/cm2


21

22 kPa 35466.53 361.66 kg/cm2


20 bar (a) 128.60 131.14 kg/cm2(a)

17 mm 6.50

18 mm 19.00

mm 6.50

16 mm N.A.

14 1.00

15

12 mm 0.00

13 mm 1.00

10 kPa 205000 2090.43 kg/cm2

11 0.40

08 mm 20.00

09 kPa 75671.753 771.64 kg/cm2

06 mm 20.00

07 % 0.00

04 oC 501

05 mm 120.00

02 SA 182 F11 CL.1

03 bar (a) 85.73 87.420 kg/cm2(a)

01 Inspection stub

MFB-F-10-05-07-0001

03


SERIAL No.#REF!




CPy2ES2

DPtmin

)Ct(E2

])Ct(y2D[PS hhydro


32/45


Item

Drg. No.

Item No.


Design Pressure P

Design Temperature


Nominal Thickness



















23 kPa 184500.00 1881.38 kg/cm2


21

22 kPa 45760.17 466.63 kg/cm2


20 bar (a) 128.60 131.14 kg/cm2(a)

17 mm 10.30

18 mm 24.00

mm 10.30

16 mm N.A.

14 1.00

15

12 mm 0.00

13 mm 1.00

10 kPa 205000 2090.43 kg/cm2

11 0.40

08 mm 25.00

09 kPa 75671.753 771.64 kg/cm2

06 mm 25.00

07 % 0.00

04 oC 501

05 mm 190.00

02 SA 182 F11 CL.1

03 bar (a) 85.73 87.420 kg/cm2(a)

01 Sec. superheater outlet stub

MFB-F-10-05-07-0001

06


SERIAL No.#REF!




CPy2ES2

DPtmin

)Ct(E2

])Ct(y2D[PS hhydro


33/45


Item

Drg. No.

Item No.


Design Pressure P

Design Temperature


Nominal Thickness



















23 kPa 184500.00 1881.38 kg/cm2


21

22 kPa 89039.55 907.95 kg/cm2


20 bar (a) 128.60 131.14 kg/cm2(a)

17 mm 9.12

18 mm 11.49

mm 9.12

16 mm N.A.

14 1.00

15

12 mm 0.00

13 mm 1.00

10 kPa 205000 2090.43 kg/cm2

11 0.40

08 mm 12.49

09 kPa 75671.753 771.64 kg/cm2

06 mm 12.49

07 % 0.00

04 oC 501

05 mm 168.30

02 SA 182 F11 CL.1

03 bar (a) 85.73 87.420 kg/cm2(a)

01 Sec. superheater outlet stub

MFB-F-10-05-07-0001

06


SERIAL No.#REF!




CPy2ES2

DPtmin

)Ct(E2

])Ct(y2D[PS hhydro


34/45


Item

Drg. No.

Item No.


Design Pressure P

Design Temperature


Nominal Thickness



















23 kPa 184500.00 1881.38 kg/cm2


21

22 kPa 60268.90 614.57 kg/cm2


20 bar (a) 128.60 131.14 kg/cm2(a)

17 mm 4.82

18 mm 8.74

mm 4.82

16 mm N.A.

14 1.00

15

12 mm 0.00

13 mm 1.00

10 kPa 205000 2090.43 kg/cm2

11 0.40

08 mm 9.74

09 kPa 75671.753 771.64 kg/cm2

06 mm 11.13

07 % 12.50

04 oC 501

05 mm 88.90

02 SA 335 Gr.P11

03 bar (a) 85.73 87.420 kg/cm2(a)

01 Sec.superheater drain stub

MFB-F-10-05-07-0001

07


SERIAL No.#REF!




CPy2ES2

DPtmin

)Ct(E2

])Ct(y2D[PS hhydro


35/45


Item

Drg. No.

Item No.


Design Pressure P

Design Temperature


Nominal Thickness



















23 kPa 184500.00 1881.38 kg/cm2


21

22 kPa 66893.57 682.13 kg/cm2


20 bar (a) 128.60 131.14 kg/cm2(a)

17 mm 1.81

18 mm 2.98

mm 1.81

16 mm N.A.

14 1.00

15

12 mm 0.00

13 mm 1.00

10 kPa 205000 2090.43 kg/cm2

11 0.40

08 mm 3.98

09 kPa 75671.753 771.64 kg/cm2

06 mm 4.55

07 % 12.50

04 oC 501

05 mm 33.40

02 SA 335 Gr.P11

03 bar (a) 85.73 87.420 kg/cm2(a)

01 Sec.superheater drain stub

MFB-F-10-05-07-0001

08


SERIAL No.#REF!




CPy2ES2

DPtmin

)Ct(E2

])Ct(y2D[PS hhydro

Sh 36


36/45

03 Calculation of maximum allowable opening as per ASME PG-32.1.2

Item

Drg. No.

Var. No./Item No.


Design Pressure P

Design Temperature


Minimum Thickness t



d = Maximum allowable diameter of

uncompensated opening ( as per Fig. PG-32 )

d = 8.08 [ D t ( 1 - K ) ](1/3)

dn = Diameter of the Opening

Opening List

Panal Stub

Inspection Stub

Tube3 27.1 93.10 Hence Compensation is not required

1 140 93.10 Hence Compensation is required

2 80 93.10 Hence Compensation is not required

S.No Description

Actual

Opening

Allowable

Opening ( dn < d )

mm mm

9

mm 93.10

10 mm 93.10

8

0.66

6 mm 20.62

7 kPa 75671.753 771.64 kg/cm2

4 oC 501

5 mm 219.10

2 SA 335 Gr.P11

3 bar (a) 85.73 87.420 kg/cm2(a)

1 Sec. superheater outlet Header

MFB-F-10-05-07-0001

02/01






tS82.1

DPK

Sheet 37


37/45

Compensation check calculation as per ASME Section - I, PG - 33

Item

Drg. No.

Item No.

Shell Data:

Minimum Thickness of Shell t

Required Thickness of Seamless Shell tr

Max. allowable stress at design temp. Sv

Finished Diameter of opening d

Nozzle Data

Nozzle OD

Nominal Thickness of Nozzle tn

Required Thickness of Seamless Nozzle tnr


Max. allowable stress at design temp. Snfr1 = ( Sn / Sv )

Actual projection of nozzle I.S. of the dished head

2.5 x t

2.5 x tn

Minimum of 2.5 t and 2.5 tnActual projection of nozzle I.S. of the shell

F = Correction factor

Compensation available in dished head

( d - 2 tn ) ( t - F t r)

2 t ( t - F t r)

A1 = max. ( i, ii ) A1

Compensation available in Nozzle

2 ( tn - trn ) ( 2.5 t fr1 )

2 ( tn

- trn

) ( 2.5 tn

+ te

) fr1

A2 = min. ( i, ii ) A2

Compensation available in nozzle from inside projection

h = Projection of nozzle inside the shell

A3 = 2 tn fr1 h A3

Compensation available in reinforcement element

Outer diameter of the reinforcement element Dp

Thickness of the reinforcement element te

Max.allowable stress at Design temp. Spfr3 = Sp / Sv fr3

A5 = ( Dp - d - 2 tn ) te fr3 A5

Total Compensation Area available

A avail = A1 + A2 + A3 + A5 mm2 2303.07

0.00

mm2 0.00

12

mm 0.00

mm 0.00

kPa 0 0.00 kg/cm2

10

mm 0.00

mm2 0.00

11

09

mm2 1515.57

mm

2 1837.50

mm2 1515.57

08

mm2 787.50

mm2 360.85

mm2 787.50

mm 51.5506 mm 0.00

07 1.00

05 mm 0.00

mm 51.55

mm 62.50

kPa 75671.753 771.64 kg/cm2

04 1.00

mm 10.30

SA 182 F11 CL.1

03

mm 190.00

mm 25.00

kPa 75671.753 771.64 kg/cm2

mm 140.00

02

mm 20.62

mm 11.87

01 Outlet Stub

MFB-F-10-05-07-0001

06


SERIAL No.#REF!




Sheet 38


38/45

06 Calculation of End plate thickness Under Internal Pressure As Per PG - 31.3

Item

Drg. No.

Var. No./Item No.

Design Pressure P

Design Temperature

Corrosion Allowance C.AEnd plate data





Header data



C = Calculation factor as per Fig [ PG-31 (g-1) ]

m = tr/ ts

0.33 m


Selected 'C' C


Required Thickness



15 mm 34.00


REV.NO. DESCRIPTION PREPARED CHECKED APPROVED

mm 26.77

14 mm 26.77

mm 0.20

12 mm 0.20

13

11

mm 0.50

mm 0.16

09 mm 20.62

10 mm 10.30

07 mm 35.00

08 kPa 75671.753 771.64 kg/cm2

04 mm 1.00

05 SA 182 F11 CL.1

06 mm 177.86

02 bar (a) 85.73 87.420 kg/cm2(a)

03 oC 501

01 Outlet header end plate

MFB-F-10-05-07-0001

02/05






S

PCdt min



39/45


Item

Drg. No.

Var. No./Item No.

Design Pressure P

Design Temperature


End plate data





Header data




m = tr / ts

0.33 m


Selected 'C' C


Required Thickness



15 mm 19.00


mm 12.04

14 mm 12.04

12 mm 0.20

13

11

mm 0.50

mm 0.16

mm 0.20

09 mm 20.62

10 mm 10.30

07 mm 20.00

08 kPa 75671.753 771.64 kg/cm2

04 mm 1.00

05 SA 182 F11 CL.1

06 mm 80.00

02 bar (a) 85.73 87.420 kg/cm2(a)

03 oC 501

01 Outlet header end Cap

MFB-F-10-05-07-0001

01/04






SPCdt min



40/45


Item

Drg. No.

Var. No./Item No.

Design Pressure P

Design Temperature


End plate data





Header data




m = tr / ts

0.33 m


Selected 'C' C


Required Thickness



15 mm 19.00


mm 10.45

14 mm 10.45

12 mm 0.20

13

11

mm 0.50

mm 0.16

mm 0.20

09 mm 20.62

10 mm 10.30

07 mm 20.00

08 kPa 75671.753 771.64 kg/cm2

04 mm 1.00

05 SA 182 F11 CL.1

06 mm 69.42

02 bar (a) 85.73 87.420 kg/cm2(a)

03 oC 501

01 Outlet header drain end Cap

MFB-F-10-05-07-0001

01/09






SPCdt min



41/45


Item

Drg. No.

Var. No./Item No.


End plate data





Selected 'C' C




kg/cm2

09 kPa 225000 2294.37 kg/cm2

08

kPa 66415.83 677.26

06 kPa 205000 2090.43 kg/cm2

07 mm 0.20

04 mm 177.86

05 mm 35.00

02 bar (a) 128.60 131.130 kg/cm2(a)

03 SA 182 F11 CL.1

01 Outlet header end plate

MFB-F-10-05-07-0001

01/05




STRESS CALCULATIONGB ENGINEERING Rev. 00

2

h

2

hydrot

PCdS



42/45


Item

Drg. No.

Var. No./Item No.



Conditions

tmin = the smaller of 3/4 in. (19 mm) or thethickness of either of the weld parts (t,tn)



tmin

0.7 tmin

Required tc

Provided tc


Minimum groove size

tw = tn but not less than 1/4"

Required tw

Provided tw

Required tw < Provided tw11 Hence Satisfactory

08

09 mm 6.00

10 mm 6.50

mm 5.50


mm 3.15

mm 3.15

05

06 Sketch (z)

mm 4.50

04

02 mm 20.62

03 mm 4.50

01 Inlet header to panal stub

MFB-F-10-05-07-0001

02/02







43/45


Item

Drg. No.

Var. No./Item No.



Conditions




tmin

0.7 tmin

Required tc

Provided tc


mm 17.50


mm 9.99

mm 9.99

05

06 Sketch (a)

mm 14.27

04

02 mm 14.27

03 mm 14.27

01 outlet header to riser stub

MFB-F-10-05-07-0001

02/06







44/45


Item

Drg. No.

Var. No./Item No.



Conditions




tmin

0.7 tmin

Required tc

Provided tc


mm 14.00


mm 13.30

mm 13.30

05

06 Sketch (a)

mm 19.00

04

02 mm 20.62

03 mm 20.00

01 outlet header to inspection stub

MFB-F-10-05-07-0001

02/03


SERIAL No.GBE/XXXX/XXX




45/45

P = Design Pressure in Kg/cm ds = Inside Diameter of End Plate in mm b = Smaller value of ( 2.5 * ts or 2.5 * tn )

dn = Inside Diameter of Nozzle in mm ts = Actual Thickness of End Plate in mm bi = Inside Projection of Nozzle

tn = Actual Thickness of Nozzle in mm es = Equivalent Thickness of End Plate in mm Ci = ts + 76 or Dn/2 , whichever is greater

en = Equivalent Thickness of Nozzle in mm fs = Allowable Stress of End Plate in kg/cm2 Cw = Fillet Weld area

fn = Allowable Stress of Nozzle in kg/cm2 E = 1 = 0 [ It is not considered since it is negligible]

Dn = Opening Diameter in mm

Minimum Required Thickness for End Plate, es = [ ( dn * ( P * K / fs ) ^ 0.5 ) + 1 ]

Minimum Thickness Required for Nozzle, en = [ ( P * dn ) / ( 2 * fn * E - P ) ] + 0.762

Area Removed X = Dn * esArea Available Y = [ 2 * ( tn - en ) * b * ( fn / fs ) ] + [ 2 * tn * bi * ( fn / fs ) ] + [ 2 * ( ts - es ) * Ci ] + CW,

P Design fn Dn dn tn fs ds ts es en b bi Ci X Y

k /cm2 Temp.C k /cm

2 mm mm mm k /cm2 mm mm mm mm mm mm mm mm

2mm

2

01 MFB-F-10-05-07-0001 09 87.42 501 SA 335 GR.P22 771.64 24.3 24.3 3.98 771.64 69.42 20.00 11.18 2.22 9.95 0 96 271.67 1728.46

Remarks : Area Available ( Y ) > Area Removed ( X ) , Hence, It is satisfactory

Prepared : D.Gunasekaran Checked : A.Shaheb john

Sl.

No.Drawing No.

Item

No.

Material

specification

G.B. ENGINEERING ENTERPRISES PRIVATE LIMITED,

TIRUCHIRAPPALLI.

PROJECT : M/s. SIAM CRYSTAL RICE COMPANY BOILER MAKER'S No. : GB- XXX Page : 07 of 07

CALCULATION OF NOZZLE COMPENSATION FOR END PLATE AS PER IBR - 279

Documents

Calculation of Secondary Superheater 01.02.2012 00