TCE CONSULTING ENGINEERS LIMITED SECTION: TITLE

TCE.M6-ME-590-431
DESIGN GUIDE FOR SHEET i OF iii

PIPE WALL THICKNESS CALCULATIONS

DESIGN GUIDE FOR

PIPE WALL THICKNESS CALCULATIONS

FILE NAME: M6ME431R2.DOC

REV. NO. R0 R1 R2 ISSUE

INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD. BY VS Sd/- VS Sd/- PS

CKD. BY DP Sd/- DP Sd/- VS R2

APP. BY MSK/KG Sd/-/Sd/- MLN/RL Sd/-/Sd/- DP/RL

DATE 93.07.30 99.09.27 02.09.26

TCE FORM NO. 020R2

 TCE CONSULTING ENGINEERS LIMITED SECTION: TITLE
TCE.M6-ME-590-431
DESIGN GUIDE FOR SHEET i OF iii

PIPE WALL THICKNESS CALCULATIONS

REV. NO. R0 R1 R2 ISSUE

INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD. BY VS Sd/- VS Sd/- PS

CKD. BY DP Sd/- DP Sd/- VS R2

APP. BY MSK/KG Sd/-/Sd/- MLN/RL Sd/-/Sd/- DP/RL

DATE 93.07.30 99.09.27 02.09.26

TCE FORM NO. 020R2

 TCE CONSULTING ENGINEERS LIMITED SECTION: CONTENTS
TCE.M6-ME-590-431 DESIGN GUIDE FOR SHEET ii OF iii
PIPE WALL THICKNESS CALCULATIONS

CONTENTS

SL. NO. TITLE SH. NO.

1.0 SCOPE 1

2.0 WALL THICKNESS 1

3.0 DESIGN PRESSURES 2

4.0 DESIGN TEMPERATURES 5

5.0 WELD JOINT EFFICIENCY 7

6.0 COEFFICIENT ‘y’ 7

7.0 MILL TOLERANCES 7

8.0 BEND THINNING ALLOWANCE 7

APPENDIX - 1 - WELD JOINT EFFICIENCY, E 8

APPENDIX - 2 - VALUES OF COEFFICIENT ‘Y’ 9
APPENDIX - 3 - MILL TOLERANCES 10
APPENDIX - 4 - BEND THINNING ALLOWANCE 11
APPENDIX – 5 - FORMULAE FOR WALL THICKNESS BASED
ON COMMONLY USED CODES &
STANDARDS 13
APPENDIX – 6 - EXCEL FORMAT FOR CALCULATING WALL
THICKNESS 15

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PIPE WALL THICKNESS CALCULATIONS

REVISION STATUS

REV. NO. DATE DESCRIPTION

R0 93.07.30 --

R1 99.09.27 Generally revised.

Reformatted in MS WORD.

R2 02.09.26 Generally revised.

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1.0 SCOPE

This design guide indicates the procedure for calculating the thickness for
various services based on different codes and standards for Power Plant Piping.
In calculating the thickness enclosed format made on excel could be used
(Appendix – 6). This guide also indicates the guidelines for determining the
design pressures and temperatures. This guide is primarily applicable for ferrous
materials and piping systems not under vacuum. Piping systems under vacuum
shall be designed as per ASME Section VIII, Division-1.

2.0 WALL THICKNESS

2.1 The calculation of minimum wall thickness required for piping subject to internal
pressures shall be based on the formulae and recommendations of the
applicable codes and statutory codes (Indian Boiler Regulations - IBR for India).
Wall thickness shall be calculated based on the statutory codes at location of
installation (IBR in India) and the code of the country of origin of material (ASME
B 31.1 for American materials, BS 806 for British materials, DIN 2413 for DIN
materials etc.). Maximum of the above thickness shall be selected. However,
allowable stress values shall be taken from the respective codes (Eg. ASME B
31.1 for American materials).

2.2 A minimum corrosion/erosion allowance of 1mm shall be considered while

calculating wall thickness of pipes for all systems

2.3 Piping handling flashing liquids as in case of heater drain lines(downstream of

Heater drain control valves) shall be selected with extra wall thickness (one
higher schedule) to combat erosion.

2.4 Much greater wall thickness than called for by strength calculation may be
required to minimise noise and vibration at certain locations such as
downstream of high pressure reducing valves. (Primarily be downstream of
Pressure reducing and desuperheating station (PRDS) and High Pressure (HP)
bypass valves). This shall be determined based on the recommendations of the
valve supplier.

2.5 In case of carbon steel materials, the nominal wall thickness shall not be less
than values indicated below :

2.5.1 For IS - 1239 material Heavy Class

2.5.2 For IS-1978/IS-3589 pipes Pipe Size Thickness

NB200 to 6.35mm
NB300
NB350 to 7.1mm
NB450
NB500 to 8.0mm
NB800
NB850 to 10.0mm ISSUE
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NB1000
NB1100 to 12.0mm
NB1200

2.5.3 For ASTM materials (A106/A53 & Sizes

other low alloy steels)
>NB 65 mm STD wall
thickness
< NB 50 Sh. 80

Items 2.5.1 & 2.5.2 are primarily applicable for water system piping.

3.0 DESIGN PRESSURES

The design pressures of piping system which are used in the calculation of wall
thickness shall be determined as indicated below for different services.

3.1 Main Steam System

The design pressure for the main steam piping shall be :

3.1.1 Design pressure of the boiler, i.e. highest pressure at which any boiler drum
safety valve is set to lift except that for piping whose design stresses are time
dependent (for design temperature of piping exceeding 430 deg.C, piping in
creep range) and the total capacity of all safety valves on the superheater is not
less than 20% of the evaporating capacity of boiler, the lowest pressure at which
any superheater safety valve is set to lift.

3.1.2 When there is no superheater, the design pressure of the piping shall be the
design pressure of boiler.

3.2 Reheat System

3.2.1 Cold reheat system (CRH)

Design pressure shall be the highest pressure at which any safety valves on the
reheat system is set to lift. When no safety valves are mounted on the cold
reheat line, the design pressure of the CRH line shall be the highest pressure at
which any reheater outlet safety valve is set to lift, increased to take into account
of the pressure drop through reheater corresponding to most severe conditions
of operation (Boiler MCR condition or Turbine VWO condition).

3.2.2 Hot reheat system (HRH)

The design pressure for the HRH piping shall be to the lowest pressure to which
any safety valve on the reheat system is set to lift. ISSUE
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3.2.3 The Design Pressure of HP bypass upstream shall be that of main stream and
HP bypass downstream shall be designed for design pressure of cold reheat
piping. The design pressure for upstream of LP bypass pipe shall be same as
hot reheat pipe. Downstream of LP bypass shall be the maximum pressure
downstream of LP bypass valve.

3.3 Extraction Steam System & Heater Drain System

The design pressure for all uncontrolled extraction steam lines of the turbine
shall be 1.1 times the maximum possible working pressure of the lines. For
controlled extraction line, the design pressure shall be to the safety valve set
pressure on the extraction pipe. The design pressure for heater drain system
would be to that of corresponding extraction steam system.

3.4 Feed Water System

3.4.1 Feed pump discharge

(a) The feed water piping beyond the pump delivery nozzles of the feed
water pumps, shall be designed for the pump discharge pressure under
no flow condition for a water temperature of 15 deg.C. No additional
allowance to the design pressure need be made for pump overspeed
unless this exceeds full speed by more than 10%. But where this
exceeds this limit, the design pressure shall be increased by the effect of
the excess in overspeed over 10%.

(b) Where a safety valve or other protective device is fitted to restrict the
pressure to a lower value than the closed valve pressure defined above,
the design pressure shall be highest set pressure of the safety valves
thereof.

3.4.2 Feed Water Booster Pump Suction Line

The design pressure shall not be less than the sum of the highest set pressure
of safety valves on the deaerator / feed water tank and pressure due to static
head of the water in the suction line calculated for a water temperature of 15 deg.
C.

3.4.3 Feedwater Booster Pump Discharge Line

The design pressure shall not be less than the sum of the design pressures
calculated for the suction line of the booster pump and the differential head of the
booster pump for no flow conditions with a water temperature of 15 deg. C.
3.5 Piping System With Safety & Relief Valves

3.5.1 Piping downstream of pressure reducing devices such as control valves,

orifices, etc, shall be designed for the same pressure as applicable for piping
upstream of the devices unless the downstream piping systems are adequately
protected by safety and relief valves as under : ISSUE
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3.5.2 The combined relieving capacity of safety or relief valves provided to protect a
system shall equal or exceed the maximum possible mass flow the system may
be expected to handle under all normal or abnormal conditions of operation. In
case of safety valve located downstream of a control valve, for example, the
combined relieving capacity of the safety valves shall equal or exceed the
estimated flow through the control valve when the valve is wide open with
maximum upstream pressure.

3.5.3 When a safety/relief valve has been provided as above, the design pressure of
the piping system protected by the safety valve shall not be less than 1.1 times
the highest set pressure of the safety valves. The lowest set pressure of the
safety valve shall not be less than 1.1 times the maximum expected working
pressure of the system. Piping upto and including the bypass valves and
downstream isolating valve shall always be designed for upstream conditions.

3.6 Blow Down & Drain Systems

3.6.1 The design pressure upstream and including any shut off valves, control valve or
trap shall be that of the upstream component to which they are connected, but
not less than 7 bar (g), if the system is handling a flashing fluid.

3.6.2 The design pressure downstream of shut off valve, control valve or trap shall be
as indicated above except that where :

(a) The downstream pipe has a cross sectional area of not less than 2.5
times the combined simultaneous areas that can discharge into it and

(b) Further the downstream pipe discharges freely into an adequately vented
receiver.

Then the design pressure may be taken as half the upstream design pressure
but not less than 7 bar (g), if the system is handling a flashing fluid. If control
valve has bypass and isolators valves, piping upstream and these valves shall
be designed for upstream condition.

3.6.3 The design pressure of a blowdown vessel or a drain vessel shall be the
maximum pressure that can be imposed upon it in operation but not less than
the lower value of 7 bar (g) or 25% of the maximum permissible working
pressure of the boiler.

3.7 Miscellaneous Lines

3.7.1 The discharge lines of all pumps other than boiler feed system shall be
designed for a pressure not less than 1.1 times the pump discharge pressure
under no flow conditions for working temperature of 15 deg. C.

3.7.2 In general, the minimum design pressure for LP systems (except main cooling
water system) shall be 10 bar (g). ISSUE
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3.7.3 All piping connected to condenser shall be designed for vacuum condition of the
condenser.

4.0 DESIGN TEMPERATURES

4.1 Steam Piping

4.1.1 The design temperature for steam piping shall be

(a) For main steam piping, the rated temperature with plus tolerance at the
superheater outlet.

(b) For hot reheat piping, the rated temperature with plus tolerance at the
reheater outlet.

(c) For cold reheat piping, maximum temperature at the HP turbine exhaust
or the temperature set point on the downstream of HP bypass valve.

(d) For other steam piping, the highest rated temperature at the higher
temperature end of the pipes.

(e) The design temperature downstream of PRDS (Pressure reducing and

desuperheating) valve or HP/LP Bypass valve upto and including the first
bend on the downstream piping shall be isenthalpic temperature
(Temperature corresponding to enthalpy at upstream condition with
downstream pressure).

4.2 Feed Water System

4.2.1 The design temperature for feed suction piping shall be the saturation
temperature at the safety valve set pressure on the deaerator.

4.2.2 The design temperature for the feed discharge piping shall be the maximum
operating temperature under all conditions of operation based on heat balance
diagrams.

4.3 Blow Down, Drain And Other Systems

4.3.1 The design temperature T (in deg.C) for the blowdown systems shall be the
greater of :

(a) T = Ts-41 - (Based on BS – 806)

1.15

Where Ts is the design temperature (in deg.C) of the component from which the
drain or blowdown system operates. ISSUE
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OR

(b) The Saturation temperature at the design pressure of the system (as per
ASME B 31.1).

4.3.2 The design temperature T (in deg.C) of a drain or atmospheric vent shall be
determined from :

T = Ts-41 - (Based on BS – 806)

1.15
where

Ts is the design temperature in deg.C of the component from which the drain or
blowdown system originates.

The design temperature shall neither be higher than the highest temperature of
any pipe discharging into the vessel nor lower than the saturation temperature at
the vessel design pressure.

OR

Maximum operating temperature under all conditions of operation (as per ASME
B 31.1).

4.3.3 The design Temperature T (in deg.C) of safety valve discharge piping shall be :

T = Ts-41 - (Based on BS - 806)

1.15
OR

Maximum operating temperature under all conditions of operation (as per ASME
B 31.1).

Ts is the temperature (in deg.C) of steam at the safety valve body inlet.

4.4 The design temperature of condensate lines, heater drains / vents and other
miscellaneous lines shall be the maximum operating temperature under all
conditions of operation based on the heat balance diagrams.

5.0 WELD JOINT EFFICIENCY

The weld joint efficiency as indicated by different codes is given in Appendix - 1.

Appropriate factor shall be considered based on the design code.

6.0 COEFFICIENT ‘y’

The value of coefficient ‘y’ considered in thickness calculation is given in

Appendix - 2.
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7.0 MILL TOLERANCES

Mill tolerances on pipe wall thickness are given in Appendix - 3. These shall be
considered based on the material standard. These tolerances considered in pipe
wall thickness shall be specified in the material specification sheets.

8.0 BEND THINNING ALLOWANCE

If the parent pipe is used for bends, then suitable allowance has to be provided
to account for thinning in the selection of thickness. The bend thinning allowance
as recommended by different codes is given in Appendix - 4. This allowance as
considered in calculating the pipe wall thickness shall be specified in the material
specification sheets and confirmation obtained from the manufacturers. If the
allowance by the manufacturer is higher calculation shall be revised
accordingly.

If standard elbows as per ANSI B16.9 is used, then pipe thinning allowance
need not be considered in calculating the thickness.

Appendix-5 gives the formulae for thickness calculations based on IBR, ASME
and BS Standards.

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PIPE WALL THICKNESS CALCULATIONS

APPENDIX - 1

WELD JOINT EFFICIENCY, E

1. AS PER ASME B31.1, 2001

The weld joint efficiency factors are already included in the allowable stress
valves given in the Appendix of ASEM B31.1. Hence this need not be
considered in the calculation.

2. AS PER IBR, 1995, REGULATION 350

E = 1 for seamless and electric resistance welded steel pipes and for electric
fusion welded pipes which comply with requirements of Chapter - II of
IBR (Fully radiographed or ultrasonically tested)

= 0.95 for electric fusion welded pipe complying with requirements of

Chapter – II

= 0.9 for welded steel pipes for values of thickness upto and including
22mm

= 0.85 for welded steel pipes for values of thickness over 22mm and upto
and including 29mm.

= 0.80 for welded steel pipes for values of thickness over 29mm.

3. AS PER BS 806, 1993

E = 1.0 for seamless and for electric resistance welded and induction welded
pipes complying with the requirements of BS 3601, BS 3602 : part 1 and
BS 3604 & BS 3605 Part – 1.

= 1.0 for Longitudinally arc welded pipes complying with the requirements
of BS3602 ; Part 2, and BS 3604, Part – 2

= 0.90 for submerged arc welded pipes complying with the requirements of
BS-3601.

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APPENDIX - 2

VALUES OF COEFFICIENT ‘Y’

1 As per ASME -B31.1

y is function of temperature and has the following values :

Temperature (oC) < 482 & 510 538 566 593 621 and
below above

Ferritic Steels 0.4 0.5 0.7 0.7 0.7 0.7

Austenitic Steels 0.4 0.4 0.4 0.4 0.5 0.7

The value of y may be interpolated for intermediate temperatures. For cast

iron and nonferrous materials y equals 0.4.

For pipe with a OD/tm wall thickness ratio less than 6, the value of y for
ferritic and austenitic steels designed for temperatures of 480 deg.C and
below shall be taken as :

y = ID___
ID + OD

Where tm = Minimum wall thickness (mm)

ID = Inside dia (mm)
OD = Outside dia (mm)

Note : y factor is not applicable for formulae as per IBR & BS-806.

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APPENDIX - 3

VALUES OF MILL TOLERANCES ON WALL THICKNESS OF PIPES

1. AS PER ASTM A530,

i. For seamless and welded pipes - Maximum negative tolerance 12.5%

(No filler metal added)

ii. For forged and bored pipes + 3.2 mm

-0 mm

NOTE : ASTM A 530 includes pipes supplied to material standards ASTM

A 106, A312, A333, A335, A358, A369, A376, A381, A405, A409,
A426, A430, A451, A452, A524, A608, A660, A671, A672 and
A691. (For pipes fabricated from plates, the thickness tolerance
will be based on that of plate).

2 AS PER BS-3602 AND BS-3604

i. for t__ < 3% Tolerance = + 15%

OD

ii. for t__ > 3% }

OD }
} Tolerance = + 12.5%
t__ }
and OD < 10% }

iii. for t__ > 10%

OD
and OD < 168.3mm Tolerance = + 12.5%

iv. for t > 10%

and OD > 168.3mm Tolerance = + 10%

NOTE : Above table is for guidance only. It is recommended to check the

tolerances as per the applicable standards and manufacturer.

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APPENDIX - 4

ALLOWANCE FOR PIPE WALL THINNING DUE TO PIPE BENDING

Maximum expected thinning due to pipe bending is ideally confirmed by the

fabricator since it depends on the bending procedure and equipment used.
When pipes are also supplied by the fabricator, it is adequate to specify to the
fabricator the minimum wall thickness required after bending, thus leaving the
responsibility for providing any additional thickness towards bending to the
fabricator.

Where pipe supplier is different from the fabricator or it is not possible to obtain
thinning allowances before hand from the fabricator, the following guidelines of
the codes may be considered.

1.0. As per ASME B31.1, 2001

The following are the recommended thinning allowance as a function of bending

radius :-

Radius of Bends Minimum Thickness Recommended

prior to Bending

6 pipe diameters or greater 1.06tm

5 pipe diameters 1.08tm

4 pipe diameters 1.14tm

3 pipe diameters 1.25tm

NOTE : (a) Interpolation is permissible for bending to intermediate

radii.

(b) tm is min required wall thickness for straight pipe.

(c) Pipe diameter is the nominal diameter as tabulated is

ANSI B36.10. Tables 2 and 4 and ANSI B36.19, Table-1.
For piping with a diameter not listed in these tables and
also for tubing, the nominal diameter corresponds with the
outside diameter.

APPENDIX – 4 (Contd.) ISSUE

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2.0 AS PER BS 806, 1993

i. For pipes bent to the following radii measured to centreline of pipe, the
thinning allowance due to bending shall be taken as 12.5%.

OD (mm) 26.9 33.7 42.4 48.3 60.3 76.1 88.9 101.6

Bend 65 75 100 115 150 190 230 265

Radius
(mm)

114.3 139.7 168.3 193.7 219.1 224.5 273.0 323.9 355.6 406.4 487.0

305 380 460 630 710 810 1020 1220 1500 1730 2030

ii. For pipes above 219.1 mm OD whose minimum required wall thickness
after bending is 32 mm or more, the thinning allowance may be assumed
as 10% provided the following minimum bending radii measures to
centreline of pipe are adopted.

OD (mm) 244.5 273.0 323.9 355.6 406.4 457.0

Bend
Radius 1140 1270 1520 1780 2030 2280
(mm)

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APPENDIX - 5

FORMULAE FOR WALL THICKNESS BASED ON COMMONLY

USED CODES & STANDARDS

1 ASME B-31.1

tm = PDo +A FOR OD based pipes

2 (SE + Py)

tm = Pd + 2 SEA + 2y PA FOR ID based pipes

2 (SE + Py – P)

2. IBR (REGULATION 350)

P = 2SE (tm -A) FOR OD based pipes

Do-tm +A

OR

tm = P Do +A FOR OD based pipes

2 SE + P

P = 2 SE(tm -A ) FOR ID based pipes

(d + tm + A)
OR

tm = Pd + 2SEA + PA FOR ID based pipes

2 SE - P

Where A = 0.75 mm (as per IBR), 1.0 mm is to be considered as per TCE

practice.

3. BS – 806

tm = P Do___ FOR OD based pipes

2 SE + P

tm = Pd ____ FOR ID based pipes

2 SE – P

tm = Pd + 2SEA + PA DEDUCED FORMULA

2 SE - P NOT GIVEN IN CODE

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APPENDIX – 5 (Contd.)

TERMINOLOGIES

tm = Minimum required wall thickness (mm)

P = Internal Design Pressure (kg/cm2)
Do = Outside Diameter (mm)
d = Inside diameter of pipe (mm)
S = Maximum allowable stress in material due to internal
pressure at design temperature (kg/cm2) as per respective
material standard.

E = Weld joint efficiency factor (Refer Appendix – 1)

A = Additional thickness (mm) for corrosion, erosion etc.
y = Coefficient (Refer Appendix – 2)

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APPENDIX-6
EXCEL FORMAT FOR CALCULATING WALL THICKNESS

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