M/S DALMIA CEMENT (BHARAT) LTD

1X120 TPH CFBC BOILER

HEADER THICKNESS CALCULATION

Header & Piping Thickness Calculation

Sl.
No

Description

Outside
Design
Thickness No of
diameter
Pressure
(mm)
headers
(mm)
(kg/cm^2)

max
working
temp
deg.C

Design
Temp
Deg. C

Material

Allowable
Stress
(kg/m^2)

Minimum
Min. thick Ligament
thickness
available Efficiency
required
(mm)
(%)
(mm)

% Margin
Available

Allowance
mm

CONVECTION CAGE
1

FRONT/REAR ROOF
HDR(CG)

323.9

38.1

122

354

393

SA 106 Gr B

952.00

27.85

33.34

0.6500

19.70

5.49

Front Intermediate HDR(CG)

273

31.75

122

354

393

SA 106 Gr B

952.00

23.67

27.78

0.6500

17.36

4.11

Interconnecting HDR(CG)

168.3

21.95

122

354

393

SA 106 Gr.B

952.00

14.37

19.21

0.6500

33.69

4.84

FRONT BOTTOM HDR(CG)

273

31.75

122

354

393

SA 106 Gr.B

952.00

23.67

27.78

0.6500

17.36

4.11

REAR WALL BOTTOM

HDR(CG)

273

31.75

122

354

393

SA 106 Gr.B

952.00

23.67

27.78

0.6500

17.36

4.11

SIDE WALL(L&R)Bottom
HDR (CG)

219.1

28.58

122

354

393

SA 106 Gr.B

952.00

22.12

25.01

0.5500

13.07

2.89

SIDE WALL(L&R)TOP HDR

(CG)

219.1

28.58

122

354

393

SA 106 Gr.B

952.00

18.47

25.01

0.6500

35.38

6.54

739.4

SUPERHEATER
8

PSH outlet header

323.9

34.93

1.00

122

460.00

SA 335 P11

978.00

27.73

30.56

0.6500

10.23

2.84

wing wall I/L HDR

273

38.1

2.00

122

420.00

SA 335 P11

1019.00

27.53

33.34

0.5000

21.10

5.81

10

wing wall 0/L HDR

273

41.28

2.00

122

492.00

SA 335 P11

850.00

32.68

36.12

0.5000

10.54

3.44

11

SSH inlet header

323.9

31.75

1.00

122

465.00

SA 335 P11

973.00

22.09

27.78

0.8280

25.74

5.69

12

SSH outlet header

323.9

34.93

1.00

122

582.00

SA 335 P 91

830.00

25.51

30.56

0.8280

19.82

5.06

25.4

2.00

122

318

357

SA 106 Gr.B

1150.00

20.51

22.23

0.6500

8.38

1.72

CROSS OVER DUCT

13

COD FRONT header

273

14

COD REAR header

273

25.4

2.00

122

318

357

SA 106 Gr.B

1150.00

20.51

22.23

0.6500

8.38

1.72

15

COD SIDE header

273

28.58

4.00

122

318

357

SA 106 Gr.B

1150.00

23.80

25.01

0.5500

5.07

1.21

16

ECO inlet header

273.1

31.75

1.00

118

230

241

SA 106 Gr.B

1202.28

19.33

27.78

0.6030

43.71

8.45

17

ECO outlet header

219.1

20.62

2.00

118

276

287

SA 106 Gr.B

1202.28

12.39

18.04

0.8000

45.68

5.66

18

HANGER OUTLET HDR

219.1

20.62

2.00

118

289

300

SA 106 Gr B

1202.28

12.39

18.04

0.8000

45.68

5.66

ECONOMISER

BOILER FEED PUMP

36

feed water suction hdr

457.2

11.13

6.5

160

160

SA 106 Gr B

1202.2

2.00

9.74

0.95

386.15

7.74

37

feed water discharge hdr

323.9

28.58

155

160

160

SA 106 Gr B

1202.2

20.18

25.01

0.95

23.92

4.83

38

Feed water header

323.9

33.32

155

210

210

SA 106 Gr B

1202

23.31

29.16

0.8

25.06

39
40

Auxiliary steam header

Auxiliary steam header

323.9
114.3

10.31
8.56

1
1

6
21

250
300

250
300

SA 106 Gr B
SA 106 Gr B

1202
1202

1.85
1.99

9.02
7.49

0.7
0.7

388.37
276.37

PREPARED BY:
JRY

APPROVED BY:
JRK

M/S DALMIA CEMENT LTD

1X120 TPH CFBC BOILER

HEADER SIZING CALCULATION

Header Sizing
Sl.
No.

Description

Outsid Header
e dia
thk.
( mm) (mm)

Inside
dia
m

Fluid flow Operating Operating

(kg/hr)
pressure
temp.
(ksc(a))
(deg. C)

Specific
volume
(m3/kg)

Actual
velocity
(m/s)

Velocity
m/s/mmID

Velocity
m/s/mmID
(max limit)

CONVECTION CAGE
1

FRONT/REAR ROOF
HDR(CG)

Front Intermediate
HDR(CG)

Interconnecting HDR(CG)
FRONT BOTTOM
HDR(CG)
REAR WALL BOTTOM
HDR(CG)

4
5

SIDE WALL(L&R)Bottom
HDR (CG)
SIDE WALL(L&R)TOP
HDR (CG)

6
7

323.9
273

133900

107.5

354

#NAME?

#NAME?

#NAME?

0.1200

0.2095

133900

107.5

354

#NAME?

#NAME?

#NAME?

0.1200

0.1244

33475

107.5

354

#NAME?

#NAME?

#NAME?

0.1200

0.2095

133900

107.5

354

#NAME?

#NAME?

#NAME?

0.1200

0.2095

133900

107.5

354

#NAME?

#NAME?

#NAME?

0.1200

0.16194

66950

107.5

354

#NAME?

#NAME?

#NAME?

0.1500

0.16194

66950

107.5

354

#NAME?

#NAME?

#NAME?

0.1200

0.25404

140000

105

421.00

#NAME?

#NAME?

#NAME?

0.1200

0.1968

70000

103.5

395.00

#NAME?

#NAME?

#NAME?

0.1500

0.19044

70000

100.00

454.00

#NAME?

#NAME?

#NAME?

0.1200

0.2604

140000

99.00

440.00

#NAME?

#NAME?

#NAME?

0.1500

0.25404

140000

96.00

545

#NAME?

#NAME?

#NAME?

0.1200

38.1
31.75

168.3

21.95

273

31.75

273

0.24770

31.75

219.1

28.58

219.1

28.58

SUPERHEATER
8

PSH outlet header

323.9

34.93

wing wall I/L HDR

273

38.1

10

wing wall 0/L HDR

273

41.28

11

SSH inlet header

323.9

31.75

12

SSH outlet header

323.9

34.93

PREPARED BY :
JRA

APRROVED BY:
JRK

M/S DALMIA CEMENT LTD

1X120 TPH CFBC BOILER

HEADER SIZING CALCULATION

CROSS OVER DUCT

13

COD FRONT header

273

25.4

14

COD REAR header

273

25.4

15

COD SIDE header

273

25.4

0.2222

70000

111

318

#NAME?

#NAME?

#NAME?

0.1200

0.2222

70000

111

318

#NAME?

#NAME?

#NAME?

0.1200

0.2222

70000

111

318

#NAME?

#NAME?

#NAME?

0.1200

#NAME?

#NAME?

#NAME?

2m/s

#NAME?

#NAME?

#NAME?

2m/s

#NAME?

#NAME?

#NAME?

2m/s

ECONOMISER
16

ECO inlet header

273.1

31.75

17

ECO outlet header

219.1

20.62

18

HANGER OUTLET HDR

219.1

20.62

PREPARED BY :
JRA

0.2096
0.17786
0.17786

140000

116

230

70000

116

276

70000

116

289

APRROVED BY:
JRK

M/S DALMIA CEMENT LTD

1X120 TPH CFBC BOILER

HEADER SIZING CALCULATION

BOILER FEED PUMP

36

feed water suction hdr

457.2

11.13

0.43494

280000

6.5

160

#NAME?

#NAME?

#NAME?

0.6-0.9

37
38
39

feed water discharge hdr

Feed water header
Auxiliary steam header
Auxiliary steam header

323.9
323.9
323.9
114.3

28.58
33.32
10.31
8.56

0.26674

280000
280000
15000
3000

162
162
6
21

160
230
250
300

#NAME?

#NAME?

#NAME?

1.5-2.4

#NAME?
#NAME?
#NAME?

#NAME?
#NAME?
#NAME?

#NAME?
#NAME?
#NAME?

1.5-2.4
1.5-2.6
1.5-2.7

PREPARED BY :
JRA

0.25726
0.30328
0.09718

APRROVED BY:
JRK

M/S BALASORE ALLOYS LTD

2 X 140 TPH CFBC BOILER

HEADER THICKNESS CALCULATION

Piping Thickness Calculation

Sl.No

Description

Feed water piping from deaerator to

BFP suction

Outside
diameter
(mm)

Thickness
(mm)

No of
headers
per boiler

Design
Pressure
(kg/cm^2)

Design
Temp
Deg. C

406.4

9.53

6.4

160

Feed water piping from BFP header to

BFP

273

9.27

6.4

160

Feed water piping from BFP to BFP

header

219.1

20.62

160

160

Feed water piping from BFP outlet to

HP heater-I

273.1

25.4

160

160

Feed water piping from HP heater-I to

economiser

219.1

15.09

160

160

42.2

4.85

160

160

114.3

13.49

96

540

355.6

9.53

7.00

250

219.1

15.09

117.00

277

Drum to COD

219.1

15.09

122

318

COD to cage

219.1

15.09

122

325

PSH to DSH-1

273

21.44

122

421

DSH-1 to WWSH SH

273

21.44

122

395

14

WWSH to Final SH

323.9

25.4

122

454

18

Main steam pipe upto MSSV

323.9

25.4

122

555

Main steam from MSSV to CSDH

406.4

50.8

105.5

540

CSDH

558.8

88.9

105.5

540

2
3

4
5
6
7

8
9
10
11
12
13

Spray Piping to boiler attemperator-1

steam line from CSDH to PRDS - 1
steam line from PRDS-1 to
ejector/gland sealing
Feed water piping from eco to drum

Material

Allowable
Stress
(kg/m^2)

Minimum
thickness
required
(mm)

Min. thick
available
(mm)

% Margin
Available

SA 106 Gr B

1202.00

1.83

8.34

355.90

SA 106 Gr B

1202.00

1.47

8.11

449.97

SA 106 Gr B

1202.00

14.42

18.04

25.10

SA 106 Gr B

1202.00

17.79

22.23

24.91

SA 106 Gr B

1202.00

14.42

13.20

-8.45

SA 106 Gr B

1202.00

3.38

4.24

25.43

SA 335 P 22

520.50

10.40

11.80

13.49

SA 106 Gr B

1202.00

1.78

8.34

367.83

SA 106 Gr.B

1202.00

10.92

13.20

20.93

SA 106 Gr.B

1202.00

11.33

13.20

16.52

SA 106 Gr.B

1202.00

11.33

13.20

16.52

SA 355 P11

1018.00

16.18

18.76

15.92

SA 355 P11

1043.00

15.83

18.76

18.48

SA 355 P11

984.00

19.66

22.23

13.06

SA 355 P91

1045.00

18.61

22.23

19.40

SA 355 P22

520.50

38.15

44.45

16.52

SA 355 P22

520.50

71.42

77.79

8.91

M/S BALASORE ALLOYS LTD

2 X 140 TPH CFBC BOILER
19
20

Steam piping from CSDH to PRDS-II

Steam piping from PRDS-II to termial
point

HEADER THICKNESS CALCULATION

60.3

8.74

97

540

114.3

6.08

21

250

SA 355 P22

520.50

5.89

7.65

29.84

SA106 Gr B

1202.00

1.74

5.32

205.78

Piping Sizing
Outside Pipe
dia
thk.
( mm) (mm)

No of
Lines

Operatin
Fluid
Operating
g
flow
temp.
pressure
(kg/hr)
(deg. C)
ksc(a)

Specific
volume
(m3/kg)

Actual
velocity
(m/s)

Allowable
Allowable
Velocity
Velocity
m/s(AS PER
m/s
Tender)

Sl. No.

Description

Feed water piping from

deaerator to BFP suction

406.4

9.53

280000

6.4

160

#NAME?

#NAME?

0.6-0.9

0.6-0.9

Feed water piping from BFP

header to BFP

273

9.27

140000

6.4

160

#NAME?

#NAME?

0.6-0.9

1.8-2.4

Feed water piping from BFP to

BFP header

219.1

20.62

140000

160

160

#NAME?

#NAME?

1.5-2.4

1.8-2.4

Feed water piping from BFP

outlet to HP heater-I

273.1

25.4

280000

160

160

#NAME?

#NAME?

1.5-2.4

1.8-2.4

Feed water piping from HP

heater-I to economiser

219.1

15.09

140000

160

160

#NAME?

#NAME?

3.00

Spray Piping to boiler

attemperator-1

42.2

4.85

7000

160

160

#NAME?

#NAME?

3.00

steam line from CSDH to

PRDS - 1

114.3

13.49

15000

96

540

#NAME?

#NAME?

35-50

steam line from PRDS-1 to

ejector/gland sealing

355.6

9.53

15000

6.00

250

#NAME?

#NAME?

28-43

219.1

15.09

140000

116.00

277

#NAME?

#NAME?

2-3

219.1

15.09

70000

111.5

318

0.01737

12.1

30-50

20-35

10

Feed water piping from eco to

drum
Drum to COD

11

COD to cage

219.1

15.09

70000

109.5

325

#NAME?

#NAME?

50.00

20-35

12

PSH to DSH-1

273

21.44

140000

105

421

#NAME?

#NAME?

50.00

35-61

13

DSH-1 to WWSH SH

273

21.44

140000

104.5

395

#NAME?

#NAME?

50.00

50-76

14

WWSH to Final SH

323.9

25.4

140000

100

454

#NAME?

#NAME?

50.00

50-76

18

Main steam pipe upto MSSV

323.9

25.4

140000

97

540.00

#NAME?

#NAME?

50

50-76

M/s DALMIA CEMENT (BHARAT) LTD.

0
0

Main steam from MSSV to

CSDH
CSDH

406.4

50.8

280000

97

540.00

#NAME?

#NAME?

50

50-77

558.8

88.9

280000

97

540.00

#NAME?

#NAME?

50

50-78

M/s DALMIA CEMENT (BHARAT) LTD.

19
20

Steam piping from CSDH to

PRDS-II
Steam piping from PRDS-II to
termial point

60.3

8.74

3000

96

540

#NAME?

#NAME?

35-50

114.3

6.08

3000

21

250

#NAME?

#NAME?

50

M/s DALMIA CEMENT (BHARAT) LTD.

35-61

20-30 25-4