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- IBR Calculation
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- Safety Valve Sizing Calculations as Per IBR 1950
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You are on page 1of 36

: 894.00 sq.m

INDEX

DESCRIPTION EVAPORATOR I & II - INLET HEADER - OUTLET HEADER - TUBES 290.00 290.00 318.00 75 75 75 TEMP, C PRESSURE, Kg/cm

PREPARED

CHECKED

SHEET 2 OF 36

BOILER MAKER'S No. : VWHA054 1.DESIGN CALCULATIONS FOR STEAM DRUM 1.1 WORKING PRESSURE OF STEAM DRUM (IBR 270) REFERENCE DRAWING No.: VWHA054-03-01-0-002 /00 & VWHA054-03-01-2-008/00

2 x f x E x (T - 0.03) W.P = ---------------------D+T-0.03 WHERE, WP = Working Pressure in Kg/cm2 = 75.00 Kg/cm2 Eqn.72

f = Allowable Stress for SA516 Gr.70(As per ASME Sec -II part - D at Metal Working Temp.290C = T = Thickness of Drum in Inches = D = Max. Int. Dia of Drum in Inches = E = Ligament Efficiency 1.2 LONGITUDINAL LIGAMENT EFFICIENCY CALCULATION (IBR 215) SL.NO. 1 2 3 4 LOCATION/TITLE Bet. SV Stub & PG Stub (S1A & S2A / S9A & S16A) Bet. PG Stub&Aux. Stub (S2A & S4A) Bet.Air Vent & Remote Pr. Tran. (S16A & S9A) Bet. S.H. Riser & PT stub (S3 & S9A) Bet. IBD Stub & Down comer Stub (S8A \ S8B & S15A) Bet. Riser Stubs (S7C & S7D) Bet. Riser Stubs (S7A & S7B / S7E & S7F) P 250 230 230 225 D 50.45 42.85 35.4 65.15 = 56 2.20 1220 mm

1383.7 Kg/cm2

808

137.7

0.83

6 7

500 375

66.3 66.3

0.87 0.82

SHEET 3 OF 36 1.3 CIRCUMFERENTIAL LIGAMENT EFFICIENCY SL.NO. 1 LOCATION / TITLE Between Riser Stubs (S7A & S7G / S7F & S7H-20 Deg.) P 222.7 D 66.3 E 0.70 E1 1.40

1.4 DIAGONAL LIGAMENT EFFICIENCY SL.NO. 1 2 LOCATION / TITLE Between Riser Stubs (S3 & S7E -70 Deg.) Between Riser Stubs (S7B & S7G -20 Deg.) b 285 375 a 779.46 222.7 D 80.6 66.3 E 0.91 1.00

Between Feed Inlet Stub & 3 Riser Stub (S10A & S6B30dEG.)

200

334.05

88.55

0.81

Since the point of intersection falls in the right of curve in IBR Fig. 15 the longitudinal efficiency is to be calculated as follows P-d 250 - 50.45 --------- = ----------------------P = 0.80 250

Where, P = Longitudinal Pitch of Tube Holes d = Diameter of the Tube Holes P1 = Diagonal Pitch of the Tube Holes E = Ligament Efficiency E1 = Equt. Longitudinal Ligament Efficiency = 2 X Circ. Ligament Efficiency

0.71

2 x 1384 WP =

0.71

x ( 2.20

- 0.03)

86.24 Kg/cm2>

75.00

Kg/cm2

Hence Safe

SHEET 4 OF 36 2.MINIMUM THICKNESS (T1) OF UNPIERCED SEAMLESS SHELL AS PER IBR 270

D X WP T1 =

------------- + 0.03

2 f E - WP

48.03 x =

75.00 + 0.03

1.93 Inch

49.1

mm

49.1 56.00

mm mm

SHEET 5 OF 36 2.0 MAX. DIA OF UNCOMPENSATED HOLE IN STEAM DRUM (IBR 187) REF. DRG. No.: VWHA054-03-01-0-002 / 00 ; VWHA054-03-01-2-008/00 PxD K =

------------1.82 x f x e

Eqn.20

Where, P = Design Pressure D = Outer Dia. Of Shell = = = e = Actual Thk. Of Shell = = f = Allowable Stress 75 x 52.44 K = = 75.00 Kg/cm2 1332 mm 52.44 Inch 56 mm 2.20 Inch 1383.70 Kg/cm2

Max. Dia. Of Uncompensated Opening = LIST OF OPENINGS IN STEAM DRUM Sl.No. 1 SV Stub 2 PG , PT, RPG,LT & AV Stub 3 Super Heater Riser 4 Water Wall Riser 5 Dowcomer 6 Intermittent Blowdown 7 Feed Inlet Stub Description

8.0

Ins

203.20 mm

Material Pipe / Tube Size DiaxThk(mmxmm) Specification 63.5 x 9.525 33.4 x 6.35 88.9 x 7.62 60.3 x 5.54 219.1 x 18.26 48.3 x 7.14 76.2 x 9.52 SA 105 SA 106 Gr.B SA 106 Gr.B SA 106 Gr.B SA 106 Gr.B SA 106 Gr.B SA 106 Gr.B

Note : Compensation is not Required for Openings < 203.20 mm Therefore S.No 1, 2,3,4,6 & 7. Not requires compensation.

SHEET 6 OF 36 2.1 COMPENSATION CALCULATION FOR OPENINGS IN STEAM DRUM REF. DRG. No.: VWHA054-03-01-0-002 / 00 ; VWHA054-03-01-2-008/00 Outside Dia Thickness = = 1332 56 mm mm = 52.44 inch = 2.20 inch

dn = Internal Diameter of the Stub tn = Actual thickness of Stub (min) ts = Actual Thickness of header (min) es = Equivalent thickness of header en = Equivalent thickness of stub fn = The permissible stress for the material of the stub fs = The permissible stress for the material of the header P = Working pressure of the boiler y = Compensating area = (2 x (tn - en) x b1 x fn/fs) + (2 x tn x b2 x fn/fs) +( 2 x (ts - es)ci) for Nozzles without inside Projection, b2 = x = Sectional area = dn x es D = Internal diameter = 1220 1 mm = 48.03 Inches 150

E = Efficiency of Ligament =

b1 = 2.5 x ts (or) 2.5 x tn (or) actual outside projection whichever is least b2 = 2.5 x ts (or) 2.5 x tn (or) actual inside projection whichever is least Ci = (ts + 3) inch (or) dn/2 whichever is greater es = (PxD / (2 x fs x E - P)) + 0.03 en = (PxD / (2 x fn x E - P)) + 0.03

SL.NO 8

en inch 0.24

b1

inch 1.57

Sl.NO 8

SHEET 7 OF 36 2.2 STRENGTH CALCULATION FOR MANHOLE COVER [IBR 340(f) & 342(b)] REF. DRG. No.: VWHA054-03-01-0-002 / 00 ; VWHA054-03-01-2-008/00 f x (t - C)2 WP =

d2 x WP x K

------------d xK

2

Eqn.89(A)

Hence, t =

---------f

+C

Where, t = Provided Thickness mm d = Max. Internal Diameter mm K f = Allowable Stress for SA515-Gr.70 in Kg/cm2 C' in mm Min.Required Thickness mm Max. Pressure in Kg/cm2(g) Min.Required Thickness mm Provided Thickness mm Max. Pressure is Greater Than Hence Safe = = 47 410 0.19 1383.70 1 42.61 91.67 42.61 47.00 75.00 Kg/cm2(g) (t) (WP)

SHEET 8 OF 36

2.3 STRENGTH CALCULATION FOR TUBES / INTEGRAL PIPES (IBR 338) STUBS FOR STEAM DRUM VALVES REF. DRG. No.: VWHA054-03-01-0-002 / 00 ; VWHA054-03-01-2-008/00 Metal Working Temp. Max.working Pressure = = 290 75

o

Kg/cm2 WP x D Eqn.87 t =

WP Where,

2xfx(t-c) = ------------D-t+c

-------------2f + WP

+C

WP = Working Pressure in Kg/cm2 f = Allow Stress for material as per ASME section -II Part - D at Metal Working temp. t = Min.Thickness in mm = Nom.Thickness - Neg. Tolerance

D = External diameter of pipe in mm c = Corrosion allowance = 0.00 mm (for working pressure above 70 Kg/cm2) Negative Tolerance - % 0.00 12.50

Sl.No.

Pipe/Tube Size Dia x Thk (mmxmm) 63.5 33.4 88.9 60.3 219.1 48.3 76.2 x x x x x x x 9.525 6.35 7.62 5.54 18.26 7.14 9.52

Working Press. Kg/cm2 448.94 480 195 210.24 189.18 357.31 295.18

Material Specification SA 105 SA 106 Gr.B SA 106 Gr.B SA 106 Gr.B SA 106 Gr.B SA 106 Gr.B SA 106 Gr.B

3 Super Heater Riser 4 Water Wall Riser 5 Dowcomer 6 Intermittent Blowdown 7 Feed Inlet Stub

SHEET 9 OF 36

2.4 Strength Calculation for Tubes/Integral Pipes (IBR 338) REF. DRG. No.: VWHA054-03-01-0-002 / 00 ; VWHA054-03-01-2-008/00 Metal working Temp. : Max. working Pressure : 290 75

o

Kg/cm2

---------------D-t+c

Eqn.87

WP x D = -------------+C 2f + WP

f = Allow Stress for material as per ASME section -II Part - D at Metal Working temp. t = Min.Thickness in mm = Nom.Thickness - Neg. Tolerance

D = External diameter of pipe in mm c = Corrosion allowance = 0.00 mm (for working pressure above 70 Kg/cm2) Stress Value in Kg/cm2 1272 1202.53 Negative Tolerance - % 0.00 12.50 Working Press.Kg/ cm2 435.21 540.08 923.96 478.36 585.64 346.12 540.08

Sl.No. 1 Pipe

Description

Pipe/Tube Size t Req. Dia x Thk (mmxmm) (mm) 21.30 21.30 14.00 13.90 33.40 33.40 21.30 x x x x x x x 3.73 3.73 3.73 2.20 6.25 4.00 3.73 0.72 0.61 0.40 0.40 0.96 0.96 0.61

Material Specification SA 106 Gr.B SA 105 SA 105 SA 105 SA 105 SA 105 SA 105

SHEET 10 OF 36 WATERWALL ASSEMBLY STRENGTH CALCULATION FOR WATER WALL HEADER : IBR 270 & 342a Ref.Drg.No : VWHA054-03-21-0-003 / 00 , VWHA054-03-21-0-004 / 00,VWHA054-03-21-0-005 / 00, VWHA054-03-21-0-007 / 00. Material size(Dia x Thk)= Material Spec. = 219.1 x 15.09 mm

WP

Eqn.72

Hence, Where,

t = Min. thickness required in mm WP = Working Press. In Kg/cm2 = D = Internal dia. of pipe in mm = 75.00 Kg/cm2 192.69 mm = 7.59 Inches

f = Allow.Stress for material SA 106 Gr.B as per ASME section - II part-D at metal working temp.318 C = E = Least of the Ligament efficiency calculated Longitudinal Ligament Efficiency: S.No. Location / Title P1 101.00 202.00 850.00 P2 ----

1202.53 Kg/cm2

1 Bet. WW Stubs 2 Bet. WW Stubs 3 Bet. Riser Circumferential Ligament Efficiency S.No. Location / Title P1 74.77 147.77

d 42.88 42.88

E 0.43 0.71

E* 0.85 1.42

SHEET 11 OF 36 Diagonal Ligament Efficiency. S.No. Location / Title b 71.21 160.22 72.99 147.77 a 101.00 101.00 101.00 101.00 101.00 101.00 d 42.88 53.59 42.88 42.88 91.32 42.88 E 0.71 0.91 0.72 0.93 0.70 1.00

1 Bet.WW Stubs (40) 2 Bet.Riser &WW Stub(90) 3 Bet. WW Stub (41) 4 Bet. WW Stub (83) 5

From Graph E Value can be Calculated Where, P/P1/P2 = Pitch of tube holes,mm p' = Diagonal pitch of tube holes, mm Least of the Ligament Efficiency from the above calculations d = Diameter of tube holes, mm E = Ligament Efficiency = 0.58

From the above calculations it is understood that the least value of Ligament Efficiency. E = 0.58 75.00 x t = 2 x 1202.5 x = 0.42 7.59 + 0.03 0.58 + 75.00

--------------------------------

Inches

Working Pressure calculation for provided thickness t = Minimum thickness provided in mm = Nom.Thickness+Neg.Tolerance = 15.09 = 13.20 mm 1.89 = 0.52 Inches ( 12.5 %)

D = Max.Internal Diameter of pipe in mm = 219.1 = 192.69 2 x 13.20 7.59 0.58 Inches x( 0.52 -0.03)

mm = 2 x 1202.5 x

WP =

2

Kg/cm2

SHEET 12 OF 36 CONDITION FOR COMPENSATION FOR OPENINGS IN WW HEADER ( IBR 187 ) Ref.Drg.No : VWHA054-03-21-0-003 / 00 , VWHA054-03-21-0-004 / 00,VWHA054-03-21-0-005 / 00, VWHA054-03-21-0-007 / 00. Header size(Dia x Thk) = Material Spec. = 219.1 x 15.09 SA 106 Gr.B mm

The maximum diameter of any unreinforced opening shall not exceed 'd' as shown in figs 9B & 9C subject to a maximum of 203 mm PxD K=

--------------1.82 x f x e

Eqn.20

Where, P= Max.Working Pressure in Kg/cm2 D = Outer diameter of the shell in mm = = = 75.00 219.1 8.63 Kg/cm2 mm Inches

f = Allow.Stress for material SA 106 Gr.B as per ASME section - II partD at metal working temp.318 C = 1202.53 Kg/cm2 e = Actual Thickness of Shell = 13.20 mm = 0.52 Inches

75.00 x 8.63 K = -------------------------------1.82 x 1202.53 x 0.52 = Header DiaxThk 0.569 = 219.1 x 13.20

= 2892.94 mm2 Considering the above K value & Drum dia x Thickness value, from figure 9B & 9C, Maximum size of an unreinforced opening should be LIST OF OPENINGS IN WW HEADER Header Size S.No. 1 2 3 = 219.1 x 15.09 mm Pipe / Tibe Size 51.00 x 4.06 thk 168.30 x 14.27 Thk 60.3 x 5.54 Thk Material SA 210 Gr.A1 SA 106 Gr.B SA 106 Gr.B 88.9 mm = 88.9 mm

Note :Compensation is not required for the openings < dia. i.e. Sl.Nos.1 & 3.

SHEET 13 OF 36 COMPENSATION CALCULATION FOR OPENINGS IN WW HEADER Ref.Drg.No : VWHA054-03-21-0-003 / 00 , VWHA054-03-21-0-004 / 00,VWHA054-03-21-0-005 / 00, VWHA054-03-21-0-007 / 00. Header Size = 219.1 x 15.09 mm

dn = Internal Diameter of the Stub tn = Actual thickness of Stub (min) ts = Actual Thickness of header (min) es = Equivalent thickness of header en = Equivalent thickness of stub fn = The permissible stress for the material of the stub fs = The permissible stress for the material of the header P = Working pressure of the boiler Y= Compensating area = (2 x (tn - en) x b1 x fn/fs) + (2 x tn x b2 x fn/fs) +( 2 x (ts - es)ci) for Nozzles without inside Projection,b2 = X = Sectional area = dn x es D = Internal diameter = 192.69 mm 1 = 7.59 Inches 0 = 75.00 Kg/cm2 - tn=>(Thinning Allowance = 12.5% of Thickness)

E = Efficiency of Ligament =

b1 = 2.5 x ts (or) 2.5 x tn (or) actual outside projection whichever is least b2 = 2.5 x ts (or) 2.5 x tn (or) actual inside projection whichever is least Ci = (ts + 3) inch (or) dn/2 whichever is greater Ci2 = Actual available distance between compensating nozzles (or) Ci1 whichever is less es = (PxD / (2 x fs x E - P)) + 0.03 en = (PxD / (2 x fn x E - P)) + 0.03 dn inch 14.27 b2 Inch 14.27 0 5.64 tn inch 0.49 Ci1 Inch 3.52 Ci2 Inch 2.82 ts inch 0.52 X Sq.Inch 1.56 es inch 0.28 Y Sq.Inc 2.42 en inch 0.21 b1 Inch 1.23

SL.NO 2

SL.NO 2

COMPENSATION

Not Reqd.

SHEET 14 OF 36 STRENGTH CALCULATION FOR END PLATES [ IBR 340 (f) & 342 (b) ] Ref.Drg.No : Metal working temperature = Maximum working press. = 318.00 C 75.00 Kg/cm2 Plate Thickness Max. ID K in mm Required in mm Provided in mm 192.69 99.32 20.72 11.16 24 14 0.19 0.19 Working Press. In Kg/cm2 102.02 122.68

Sl.No.

Description

Header / Pipe Size in mm Dia x thk 219.1 x 114.3 x 15.09 8.56 Material

SA 515 Gr.70

f x ( t - c ) WP =

------------d x k

----------------- + C

f

Where, WP = Working Pressure in Kg/cm2 f = Allow stress for material as per ASME section - II Part - D at Metal working temp. c = Corrosion Allowance in mm = t = Thickness of plate in mm d = Max. internal diameter in mm k = 0.19 0.28 for ends Integral with or flanged & butt welded and for ends directly strength 1

welded to the header Ref. IBR 342 (b). MAX. DIAMETER OF UNCOMPENSATED HOLE IN FLAT END PLATE : [IBR 366(2)] Hole Dia. In mm 116.3 D= Where, D= T= Max. dia. Of uncompensated hole in mm Min. thickness of the endplate in inches Thick of Plate in mm 24 (21/2 x T )+ 23/4) Max. Dia of Hole mm 129.85 in

S.No. 1

SHEET 15 OF 36 WATERWALL ASSEMBLY STRENGTH CALCULATION FOR WATER WALL HEADER : IBR 270 & 342a Ref.Drg.No : VWHA054-03-21-0-003 / 00. Material size(Dia x Thk)= Material Spec. = 219.1 x 18.26 mm

WP ------------------------= D + t - 0.03 WP x D Hence, Where, t = Min. thickness required in mm WP = Working Press. In Kg/cm2 = D = Internal dia. of pipe in mm = 75.00 Kg/cm2 187.15 mm = t =---------------------+ 0.03 2 x f e + WP

Eqn.72

7.37 Inches

f = Allow.Stress for material SA 106 Gr.B as per ASME section - II part-D at metal working temp.318 C = E = Least of the Ligament efficiency calculated Longitudinal Ligament Efficiency: S.No. Location / Title P1 101.00 202.00 P2 ---

1202.53 Kg/cm2

d 42.88 42.88

E 0.58 0.79

Diagonal Ligament Efficiency. S.No. 1 Location / Title Bet. WW Stub & Drain Stub (180) b 315.47 a 99.00 d 40.14 E 1.00

SHEET 16 OF 36 Where, P/P1/P2 = Pitch of tube holes,mm p' = Diagonal pitch of tube holes, mm Least of the Ligament Efficiency from the above calculations d = Diameter of tube holes, mm E = Ligament Efficiency = 0.58

From the above calculations it is understood that the least value of Ligament Efficiency. E = 0.58 75.00 x t = 2 x 1202.5 x = 0.41 7.37 0.58 + 75.00

-------------------------------- + 0.03

Inches

Working Pressure calculation for provided thickness t = Minimum thickness provided in mm = Nom.Thickness+Neg.Tolerance = 18.26 = 15.98 mm 2.28 = 0.63 Inches ( 12.5 %)

D = Max.Internal Diameter of pipe in mm = 219.1 = 187.15 2 x 15.98 7.37 0.58 Inches x( 0.63 -0.03)

mm = 2 x 1202.5 x

WP =

SHEET 17 OF 36 CONDITION FOR COMPENSATION FOR OPENINGS IN WW HEADER ( IBR 187 ) Ref.Drg.No : VWHA054-03-21-0-003 / 00. Header size(Dia x Thk) = Material Spec. = 219.1 x 18.26 SA 106 Gr.B mm

The maximum diameter of any unreinforced opening shall not exceed 'd' as shown in figs 9B & 9C subject to a maximum of 203 mm PxD K=

--------------1.82 x f x e

Eqn.20

Where, P= Max.Working Pressure in Kg/cm2 D = Outer diameter of the shell in mm = = = 75.00 219.1 8.63 Kg/cm2 mm Inches

f = Allow.Stress for material SA 106 Gr.B as per ASME section - II partD at metal working temp.318 C = 1202.53 Kg/cm2 e = Actual Thickness of Shell = 15.98 mm = 0.63 Inches

75.00 x 8.63 K =-------------------------------1.82 x 1202.5 x 0.63 = Header DiaxThk 0.470 = 219.1 x 15.98

= 3500.67 mm2 Considering the above K value & Drum dia x Thickness value, from figure 9B & 9C, Maximum size of an unreinforced opening should be LIST OF OPENINGS IN WW HEADER Header Size S.No. 1 2 = 219.1 x 18.26 mm Pipe / Tibe Size 51.00 x 4.06 thk 219.10 x 18.26 Thk Material SA 210 Gr.A1 SA 106 Gr.B 99.06 mm = 99.06 mm

Note:Compensation is not required for the openings < dia. i.e. Sl.Nos.1

SHEET 18 OF 36 COMPENSATION CALCULATION FOR OPENINGS IN WW HEADER Ref.Drg.No : VWHA054-03-21-0-003 / 00. Header Size = 219.1 x 18.26 mm

dn = Internal Diameter of the Stub tn = Actual thickness of Stub (min) - tn=>(Thinning Allowance = 12.5% of Thickness)

ts = Actual Thickness of header (min) es = Equivalent thickness of header en = Equivalent thickness of stub fn = The permissible stress for the material of the stub fs = The permissible stress for the material of the header P = Working pressure of the boiler Y= Compensating area = (2 x (tn - en) x b1 x fn/fs) + (2 x tn x b2 x fn/fs) +( 2 x (ts - es)ci) for Nozzles without inside Projection,b2 = X = Sectional area = dn x es D = Internal diameter = 187.15 mm 1 = 7.37 Inches 0 = 75.00 Kg/cm2

E = Efficiency of Ligament =

b1 = 2.5 x ts (or) 2.5 x tn (or) actual outside projection whichever is least b2 = 2.5 x ts (or) 2.5 x tn (or) actual inside projection whichever is least Ci = (ts + 3) inch (or) dn/2 whichever is greater Ci2 = Actual available distance between compensating nozzles (or) Ci1 whichever is less es = (PxD / (2 x fs x E - P)) + 0.03 en = (PxD / (2 x fn x E - P)) + 0.03 dn inch 18.26 b2 Inch 18.26 0 7.37 tn inch 0.63 Ci1 Inch 3.68 Ci2 Inch 3.63 ts inch 0.63 X Sq.Inch 1.98 es inch 0.27 Y Sq.Inc 3.79 en inch 0.27 b1 Inch 1.57

SL.NO 2

SL.NO 2

COMPENSATION

Not Reqd.

SHEET 19 OF 36 STRENGTH CALCULATION FOR END PLATES [ IBR 340 (f) & 342 (b) ] Ref.Drg.No : Metal working temperature = Maximum working press. = 318.00 C 75.00 Kg/cm2 Plate Thickness Max. ID K in mm Required in mm Provided in mm 187.15 99.32 75.57 20.15 11.16 8.73 24 14 10 0.19 0.19 0.19 Working Press. In Kg/cm2 108.16 122.68 101.58

Sl.No.

Description

Header / Pipe Size in mm Dia x thk 219.1 x 114.3 x 88.9 x 18.26 8.56 7.62 Material

SA 515 Gr.70

f x ( t - c ) WP =

------------d x k

-----------------+ C

f

Where, WP = Working Pressure in Kg/cm2 f = Allow stress for material as per ASME section - II Part - D at Metal working temp. c = Corrosion Allowance in mm = t = Thickness of plate in mm d = Max. internal diameter in mm k = 0.19 0.28 for ends Integral with or flanged & butt welded and for ends directly strength 1

welded to the header Ref. IBR 342 (b). MAX. DIAMETER OF UNCOMPENSATED HOLE IN FLAT END PLATE : [IBR 366(2)] Hole Dia. In Thick of Plate mm in mm 116.3 D= Where, D= T= Max. dia. Of uncompensated hole in mm Min. thickness of the endplate in inches 24 (21/2 x T )+ 23/4) Max. Dia of Hole mm 129.85 in

S.No. 1

SHEET 20 OF 36 WATERWALL HEADER STRENGTH CALCULATION FOR WATER WALL HEADER : IBR 270 & 342a Ref.Drg.No:VWHA054-03-21-0-004/00,VWHA054-03-21-0-005/00,VWHA054-03-21-1-006/00.

168.3

x 14.27

mm

WP

------------------------D + t - 0.03 WP x D

Eqn.72

Hence t

--------------------- + 0.03

2 x f e + WP

Where, t = Min. thickness required in mm WP = Working Press. In Kg/cm2 = D = Internal dia. of pipe in mm = 75.00 Kg/cm2 143.3275 mm = 5.64 Inches 1202.53 Kg/cm2

Allow.Stress for material SA 106 Gr.B as per ASME section f = - II part-D at metal working temp.318 C = E = Least of the Ligament efficiency calculated

Longitudinal Ligament Efficiency: S.No. 1 2 Location / Title Bet. WW Stubs Bet.Riser Stubs P1 101.00 850.00 P2 --d 42.88 64.30 E 0.575 0.92

SHEET 21 OF 36 CIRCUMFERENTIAL LIGAMENT EFFICIENY: S.No. Location / Title P1 60.49 241.95 d 42.88 53.59 E 0.29 0.78 E* 0.58 1.56

Diagonal Ligament Efficiency. (Equal Pitch) S.No. Location / Title b 60.49 225.82 226.89 a 101.00 21.00 50.50 d 42.88 53.59 53.59 E 0.68 1 1

1 Bet. WW Stubs 2 Bet. Riser Stub&ww Stub(168) 3 Bet. Riser Stub & ww Stub(168.8)

From Graph E Value can be Calculated Where, P/P1/P2 = Pitch of tube holes,mm p' = Diagonal pitch of tube holes, mm d = Diameter of tube holes, mm E = Ligament Efficiency = 0.575

From the above calculations it is understood that the least value of Ligament Efficiency. E = 0.58 75.00 t = 2x x 5.64 + 0.03 0.575 + 75.00

--------------------------------------1202.5 x

SHEET 22 OF 36 Working Pressure calculation for provided thickness t = Minimum thickness provided in mm = Nom. Thickness - Neg. Tolerance = 14.27 = 12.49 1.78 mm = 0.49 Inches ( 12.5 %)

= 143.33 mm

2 x 1202.5 x 0.58 x( 0.49 -0.03) WP = ------------------------------------------------------5.64 + 0.49 0.03 = 104.65 Kg/cm2 > 75.00 Kg/cm2

SHEET 23 OF 36

CONDITION FOR COMPENSATION FOR OPENINGS IN WW HEADER ( IBR 187 ) Ref.Drg.No:VWHA054-03-21-0-004/00,VWHA054-03-21-0-005/00,VWHA054-03-21-1-006/00. Header size(Dia x Thk) = Material Spec. = 168.3 x 14.27 mm

SA 106 Gr.B

The maximum diameter of any unreinforced opening shall not exceed 'd' as shown in figs 9B & 9C subject to a maximum of 203 mm PxD K = -----------1.82 x f x e Where, P= Max.Working Pressure in Kg/cm2 D = Outer diameter of the shell in mm = = = 75.00 168.3 6.63 Inches Eqn.20

f = Allow.Stress for material SA 106 Gr.B as per ASME section - II part-D at metal working temp.318 C e = Actual Thickness of Shell 75.00 K = 1.82 = Header DiaxThk = 0.462 168.3 x 12.49 x = 6.63 0.49 = mm = 1202.53 Kg/cm2 0.49 Inches

12.49

---------------------------x 1202.53 x

= 2101.4 mm2 Considering the above K value & Drum dia x Thickness value, from figure 9B & 9C, Maximum size of an unreinforced opening should be = 83.82 mm LIST OF OPENINGS IN WW HEADER Header Size = 168.3 x 14.27 mm S.No. 1 2 3 Description Stub Riser Stub Top Header Pipe / Tibe Size 51.00 x 4.06 thk 60.3 x 5.54 Thk 168.3 x 14.27 Thk Material SA 210 Gr.A1 SA 106 Gr.B SA 106 Gr.B 83.82

Note:Compensation is not required for the openings < i.e. Sl.Nos.1 & 2.

SHEET 24 OF 36

COMPENSATION CALCULATION FOR OPENINGS IN WW HEADER Ref.Drg.No:VWHA054-03-21-0-004/00,VWHA054-03-21-0-005/00,VWHA054-03-21-1-006/00. Header Size = 168.3 x 14.27 mm

dn = Internal Diameter of the Stub tn = Actual thickness of Stub (min) - tn=>(Thinning Allowance = 12.5% of Thickness)

ts = Actual Thickness of header (min) es = Equivalent thickness of header en = Equivalent thickness of stub fn = The permissible stress for the material of the stub fs = The permissible stress for the material of the header P = Working pressure of the boiler Y= Compensating area = (2 x (tn - en) x b1 x fn/fs) + (2 x tn x b2 x fn/fs) +( 2 x (ts - es)ci) for Nozzles without inside Projection, X = Sectional area = dn x es D = Internal dia. = 139.76 mm 1 = 5.50 Inches b2 = 0 = 75.00 Kg/cm2

E = Efficiency of Ligament =

b1 = 2.5 x ts (or) 2.5 x tn (or) actual outside projection whichever is least b2 = 2.5 x ts (or) 2.5 x tn (or) actual inside projection whichever is least Ci = (ts + 3) inch (or) dn/2 whichever is greater es = (PxD / (2 x fs x E - P)) + 0.03 en = (PxD / (2 x fn x E - P)) + 0.03 SL.NO STUB SIZE x 14.27 dn inch 5.64 tn inch 0.49 ts inch 0.49 es inch 0.21 en inch 0.03 b1 Inch 1.23

3 168.3

SL.NO

b2 Inch 0

Ci Sq.Inch 3.49

X Sq.Inch 1.19

Y Sq.Inc 3.09

3 168.3

SHEET 25 OF 36

STRENGTH CALCULATION FOR END PLATES [ IBR 340 (f) & 342 (b) ] Ref.Drg.No:VWHA054-03-21-0-004/00,VWHA054-03-21-0-005/00,VWHA054-03-21-1-006/00. Metal working temp. = 318 C Max. working press. = 75.00 Kg/cm2 Working Press. In Kg/cm2 0.19 0.19 119.80 96.65

Header / Pipe Size Plate Thickness Max. ID in in mm Reqd. in Provided mm Dia x thk mm in mm 168.30 x 14.27 146.895 16.03 20 88.9 x 7.62 Material SA 515 Gr.70 77.47 8.93 10

f = Allow stress for material as per ASME section - II Part - D at Metal working temp. c = Corrosion Allowance in mm t = Thickness of plate in mm d = Max. internal diameter in mm k = 0.19 for ends Integral with or flanged & butt welded and 0.28 for ends directly strength welded to the header Ref. IBR 342 (b). MAX. DIAMETER OF UNCOMPENSATED HOLE IN FLAT END PLATE : [IBR 366(2)] S.No. 1 Hole Dia. In mm 91

1 3 D = (2 /2 x T )+ 2 /4

Thick of Plate in mm 20

Where, D = Max. dia. Of uncompensated hole in mm T = Min. thickness of the endplate in inches

SHEET 26 OF 36

Ref. Drg. No: VWHA054-03-21-0-002 / 00, VWHA054-03-21-0-003 / 00, VWHA054-03-21-0-004 / 00, VWHA054-03-21-0-005 / 00, VWHA054-03-21-1-006 / 00, VWHA054-03-21-0-007 / 00, VWHA054-03-21-2-008 / 00, VWHA054-03-21-2-009 / 00, VWHA054-03-21-3-010 / 00. Metal working Temperature : Max. working Pressure : 318 75.00

o

Kg/cm2

2xfx(t-c) WP =

WP x D Eqn.87

---------------D-t+c

-------------t = +C 2f + WP

Where, WP = Working Pressure in Kg/cm2 f = Allow Stress for material as per ASME section -II Part - D at Metal Working temp. t = Min.Thickness in mm = Nom.Thickness - Neg. Tolerance

D = External diameter of pipe in mm c = Corrosion allowance = 0.00 mm (for working pressure below 70 Kg/cm2) Negative Tolerance -% 0.00 12.50

Sl. Description No. 1 2 3 3 4 5 6 7 WW Tubes Riser Stub Headers Headers Hand Hole Pipe Hand Hole Pipe Drain Pipe Drain Stubs

Pipe/Tube Size Dia x Thk (mmxmm) 51.00 x 4.06 60.30 x 5.54 168.30 x 14.27 219.10 x 15.09 114.30 x 8.56 88.90 x 7.62 33.40 x 3.38 33.40 x 6.35

t Req. (mm) 1.54 2.05 5.73 7.45 3.89 3.02 1.14 1.14

t Prov. (mm) 4.06 5.54 14.27 15.09 8.56 7.62 3.38 6.35

Working Press.Kg/cm2 208.02 210.24 192.73 154.23 168.65 195.00 233.65 479.93

Material Specification SA 210 Gr.A1 SA 106 Gr.B SA 106 Gr.B SA 106 Gr.B SA 106 Gr.B SA 106 Gr.B SA 106 Gr.B SA 106 Gr.B

SHEET 27 OF 36

STRENGTH CALCULATION FOR WATER WALL MAN HOLE : IBR 270 & 342a

Ref.Drg.No : VWHA054-03-21-3-010 / 00 63.5 x 6.35 mm Matl.size(DiaxThk)= Material Spec.

WP

------------------------D + t - 0.03 WP x D

Eqn.72

Hence, Where,

t =

--------------------2 x f x E + WP

+ 0.03

t = Min. thickness required in mm WP = Working Press. In Kg/cm2 = 75.00 Kg/cm2 2.06 Inches 934 Kg/cm2

D = Internal diameter of pipe in mm 52.3875 = mm = f = Allow.Stress for material BS 3059 P2 Gr. 360 as per ASME section - II part-D at metal working temp. 318 C =

S.No.

Location / Title

P1 101.00

P2 --

d 42.88

E 0.575

Least of the Ligament Efficiency from the above calculations= 0.575 From the above calculations it is understood that the least value of Ligament Efficiency. E= 0.575 75.00 t= 2 = x 934 x 2.06 + 0.03 + 75.00

-----------------------------------x 0.575

0.16 Inches

SHEET 28 OF 36 Working Pressure calculation for provided thickness t = Minimum thickness provided in mm = Nom.Thickness+Neg.Tolerance = 6.35 = 5.56 - 0.79 mm = 0.22 Inches ( 12.5 %)

D = Max.Internal Diameter of pipe in mm = 52.39 2 x 5.56 2.06 x + 0.58 0.22 75.00 Inches x( 0.22 0.03 - 0.03 )

WP ------------------------------------------------------=

Kg/cm2

SHEET 29 OF 36 CONDITION FOR COMPENSATION FOR OPENINGS IN WW MAN HOLE ( IBR 187 ) Ref.Drg.No : VWHA054-03-21-3-010 / 00 6.35 mm

The maximum diameter of any unreinforced opening shall not exceed 'd' as shown in figs 9B & 9C subject to a maximum of 203 mm PxD K=

--------------1.82 x f x e

Eqn.20

Where, P= Max.Working Pressure in Kg/cm2 D = Outer diameter of the shell in mm = = = 75.00 63.5 2.50 Inches Kg/cm2

f = Allow.Stress for material BS 3059 P2 Gr. 360 as per ASME section - II part-D at metal working temp. 318 C e = Actual Thickness of Shell = 75.00 K = 1.82 = 0.504 x 5.56 x 934 mm = 2.50 x 0.22 = 0.22 934 Inches Kg/cm2

-------------------------------

Header DiaxThk = 63.5 x 5.56 = 352.82 mm2 Considering the above K value & Drum dia x Thickness value, from figure 9B & 9C, Maximum size of an unreinforced opening should be LIST OF OPENINGS IN WW HEADER Header Size = 63.5 x 6.35 mm = 48.26 mm

S.No.

Description

1 Tube 2 WW Tube

Note :Compensation is not required for the openings < i.e. Sl.Nos. : 2

48.26 mm

SHEET 30 OF 36 COMPENSATION CALCULATION FOR OPENINGS IN WW HEADER Ref.Drg.No Header Size : VWHA054-03-21-3-010 / 00 = 63.5 x 6.35 mm

dn = Internal Diameter of the Stub tn = Actual thickness of Stub (min) ts = Actual Thickness of header (min) es = Equivalent thickness of header en = Equivalent thickness of stub fn = The permissible stress for the material of the stub fs = The permissible stress for the material of the header P = Working pressure of the boiler = Y= Compensating area = (2 x (tn - en) x b1 x fn/fs) + (2 x tn x b2 x fn/fs) +( 2 x (ts - es)ci) for Nozzles without inside Projection, b2 X = Sectional area = dn x es D = Internal diameter = 50.8 = mm 1 = 2.00 Inches = 0 75.00 Kg/cm2 - tn=>(Thinning Allowance = 12.5% of Thickness)

E = Efficiency of Ligament

b1 = 2.5 x ts (or) 2.5 x tn (or) actual outside projection whichever is least b2 = 2.5 x ts (or) 2.5 x tn (or) actual inside projection whichever is least Ci = (ts + 3) inch (or) dn/2 whichever is greater Ci2 = Actual available distance between compensating nozzles (or) Ci1 whichever is less es = (PxD / (2 x fs x E - P)) + 0.03 en = (PxD / (2 x fn x E - P)) + 0.03 dn 6.35 inch 2.00 tn inch 0.22 ts inch 0.22 es inch 0.11 en inch 0.11

SL.NO 1 63.50

STUB SIZE x

SL.NO 1 63.50

b1 Inch 0.55

b2 Inch 0

Ci1

SHEET 31 OF 36 Strength Calculation for Tubes/Integral Pipes (IBR 338) Ref.Drg.No : VWHA054-03-21-3-010 / 00 318 75

o

Kg/cm2

fx(t-c) WP =

WP x D Eqn.87 t=

---------------D-t-c

-------------+C

2f + WP

Where, WP = Working Pressure in Kg/cm2 f = Allow Stress for material as per ASME section -II Part - D at Metal Working temp. t = Min.Thickness in mm = Nom.Thickness - Neg. Tolerance

D = External diameter of pipe in mm c = Corrosion allowance= 0.00 mm (for working pressure below 70 Kg/cm2) Stress Value in Kg/cm2 1202.53 1272 934 Pipe/Tube Size Dia x Thk (mmxmm) 51.00 63.50 51.00 63.50 x x x x 4.06 6.35 4.06 6.35 t Req. (mm) 1.54 1.82 1.46 2.76 t Prov. (mm) 4.06 6.35 4.06 6.35 Neg.Tolerance - % 0.00 0.00 12.50 Working Press. Kg/cm2 208.02 282.67 220.04 179.12 Material Specification SA 210 Gr.A1 SA 105 SA 105 BS 3059 P2 Gr. 360

Sl.No. 1 2 3 4

SHEET 32 OF 36

EVAPORATOR - I & II STRENGTH CALCULATION FOR INLET/OUTLET HEADER : IBR 270 & 342a Ref.Drg.No : VWHA054-34-02-0-001 / 00 & VWHA054-34-02-1-002 / 00 Material size(Dia)= Material Spec. = 219.1 x 18.26 mm

--------------D + t - 0.03 WP x D

Eqn.72

Hence, Where,

---------------2 x f e + WP

+ 0.03

t = Min. thickness required in mm WP = Working Press. In Kg/cm2 D = Internal diameter of pipe in mm = = 75.00 Kg/cm2 182.6 mm = 7.19 Inches

f = Allow.Stress for material SA 106 Gr.B as per ASME section - II part-D at metal working temp. 290 C = E = Least of the Ligament efficiency calculated Longitudinal Ligament Efficiency: S.No. 1 2 3 4 Location / Title Bet. Evaporator Coils Bet. Evaporator Coils Bet.Inlet Stub & stub Bet.Inlet Stub & Stub P1 101.00 89.00 250.00 522.00 P2 ----d 36.38 36.38 55.02 55.02 E 0.64 0.59 0.77 0.89 1202.53 Kg/cm2

Circumferential Ligament Efficiency S.No. 1 2 3 Location / Title Bet.Stubs (30 Deg) Bet.Stubs (45 Deg) Bet.Inlet & Drain Stub P1 52.57 78.87 157.74 d 36.38 36.38 55.53 E 0.31 0.54 0.65 E* 0.62 1.08 1.30

Diagonal Ligament Efficiency. (Equal Pitch) S.No. 1 2 3 4 Location / Title Bet. Stub & Drain Stub Bet. Coils (30 Deg) Bet. Coils (45 Deg) Bet.Inlet Stub & stub(45) b 157.74 52.27 78.87 78.87 a 250.00 89.00 101.00 250.00 d 36.89 36.38 36.38 55.02 E 0.91 0.69 0.78 0.80

SHEET 33 OF 36

p' = Diagonal pitch of tube holes, mm E = Ligament Efficiency *E = Eqvt.Longitudinal Ligament Eff. Due to Circumferential Ligament Eff. As per Reg. 215, = 2 x Circ.Ligament Efficiency. Least of the Ligament Efficiency from the above calculations = 0.59

From the above calculations it is understood that the least value of Ligament Efficiency. E = 0.60 75 x 7.19 t = ----------------------------2 x 1202.53 x 0.6 + 75 = 0.39 Inches + 0.03

Working Pressure calculation for provided thickness t = Minimum thickness provided in mm = Nom.Thick- Neg.Tolerance = 18.26 - 2.2825 = 15.98 mm = 0.63 Inches ( 12.5 %)

= 108.64 Kg/cm2

>

75.00

Kg/cm2

SHEET 34 OF 36

CONDITION FOR COMPENSATION FOR OPENINGS IN INLET/OUTLET HEADER ( IBR 187 ) Ref.Drg.No : VWHA054-34-02-0-001 / 00 & VWHA054-34-02-1-002 / 00 Header size(Dia) = Material Spec. = 219.1 x 18.26 SA 106 Gr.B mm

--------------1.82 x f x e

Eqn.20

Where, P= Max.Working Pressure in Kg/cm2 = D = Outer diameter of the shell in mm= = 75.00 219.1 8.63 Inches

f = Allow.Stress for material SA 106 Gr.B as per ASME section - II part-D at metal working temp. 290 C = e = Actual Thickness of Shell 75 x 8.63 K = = 15.98 mm = 1202.53 Kg/cm2 0.63 Inches

= 3500.67 mm2 Considering the above K value & Drum dia x Thickness value, from figure 9B & 9C, Maximum size of an unreinforced opening should be LIST OF OPENINGS IN INLET/OUTLET HEADER Header Size = 219.1 x 18.26 mm = 99.02 mm

S.No. 1 2 3 4

Pipe / Tibe Size 44.50 x 4.06 88.90 x 7.62 33.40 x 6.35 88.90 x 7.62

Material SA210Gr.A1 SA 106 Gr.B SA 106 Gr.B SA 106 Gr.B < 99.02 mm

SHEET 35 OF 36

STRENGTH CALCULATION FOR END PLATES [ IBR 340 (f) & 342 (b) ] Ref.Drg.No : VWHA054-34-02-0-001 / 00 & VWHA054-34-02-1-002 / 00 Metal working temp. Max. working pressure = = 290 75.00 C Kg/cm2

Sl.No. 1 2

K 0.19 0.19

Plate Thickness

f x ( t - c ) WP. =

d2 x WP x K Eqn.89A Hence , t=

------------d x k Where,

-----------------+C

f

WP = Working Pressure in Kg/cm2 f = Allow stress for material as per ASME section - II Part - D at Metal working temp. c = Corrosion Allowance in mm t = Thickness of plate in mm d = Max. internal diameter in mm k = 0.19 0.28 for ends Integral with or flanged & butt welded and for ends directly strength = 1

welded to the header Ref. IBR 342 (b). MAX. DIAMETER OF UNCOMPENSATED HOLE IN FLAT END PLATE : [IBR 366(2)] Hole Dia. In mm 116.3

1 3 D = (2 /2 x T )+ 2 /4

S.No. 1

Thick of Plate in mm 24

Where, D = Max. dia. Of uncompensated hole in mm T = Min. thickness of the endplate in inches

SHEET 36 OF 36

Ref.Drg.No : VWHA054-34-02-0-001 / 00 & VWHA054-34-02-1-002 / 00 Metal working Temp. Max. working Pressure 2xfx(t-c) WP = ------------------D-t+c Where, WP = Working Pressure in Kg/cm2 f = Allow Stress for material as per ASME section -II Part - D at Metal Working temp. t = Min.Thickness in mm = Nom.thkness - Neg.Tolrance% D = External diameter of pipe in mm c=Corosion allowance 0.00 = mm (for working pressure above 70 Kg/cm2) Negative Tolerance -% 0.00 Eqn.87 t= = = Refer Table 75 Kg/cm2 WP x D

-------------+C

2f + WP

Temperature 318

Sl.No.

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