THIS STANDARD IS: STD NO : 57-75-01

Updated INDEX : 1.9

DESIGN STANDARD DATE : 9 JULY 2003
OWNER : MEDS
PAGE : 1 OF 8

SUBJECT : DESIGN RULES FOR SUPERHEATER AND REHEATER TERMINALS, LINK

PIPING, DOWNCOMERS AND HANGERS FOR CONTROLLED AND NATURAL
CIRCULATION UNITS

PURPOSE : To advise Design Graphics of various temperatures and temperature

differences for use in determining allowable stresses, expansion stresses
and expansion movements of various components.

REMARKS: This Standard to be effective immediately.

NOTES: 1. This standard is being issued for historical purposes only.

SR. ENGINEERING TECHNICIAN

PREPARED BY: S. GARCIA STANDARDS ENGINEERING - 9809
PROGRAM MANAGER
APPROVED FOR CONTENT: T. MISKELL STANDARDS ENGINEERING - 9809
PROGRAM MANAGER
APPROVED FOR PUBLICATION: T. MISKELL STANDARDS ENGINEERING - 9809

This document contains proprietary data and shall not be reproduced

or disclosed without the permission of ALSTOM Power Inc.
SUBJECT: Design Rules for Superheater and STD NO. : 57-75-01
Reheater Terminals, Link Piping, INDEX : 1.9
Downcomers and Hangers for DATE : 9 JULY 2003
Controlled and Natural Circulation Units OWNER : MEDS
PAGE : 2 OF 8
______________________________________________________________________________________________________

UNITS: n ENGLISH; o METRIC; o BOTH; o NONE

PRODUCT LINE: CHECK THE PRODUCT LINE THE STANDARD IS APPLICABLE TO:

o ALL; n A = CONTROLLED CIRC. BOILERS o H = HEAT RECOVERY STEAM GENERATORS

o B = SUPERCRITICAL BOILERS o P = BOWL MILLS (PULVERIZERS)
o C = VU40 AND VU60 BOILERS o R = CHEMICAL RECOVERY BOILERS
o E = FLUIDIZED BED BOILERS (CFB) n S = SERVICES (AFTER MARKET USE)
n F = NATURAL CIRC. BOILERS (UTILITY)

Versions

Ver. 0 - Issued for historical purposes only.

Ver. 1 - Updated standard format; name change

to ALSTOM Power Inc.
SUBJECT: Design Rules for Superheater and STD NO. : 57-75-01
Reheater Terminals, Link Piping, INDEX : 1.9
Downcomers and Hangers for DATE : 9 JULY 2003
Controlled and Natural Circulation Units OWNER : MEDS
PAGE : 3 OF 8
______________________________________________________________________________________________________

1.0 Temperatures for Analysis of c. Hot Startup

Headers, Links and Terminals Above
the Roof Same as full load operation.

1.1 Hanger Rods in Roof Enclosure 1.2.2 For design criteria of drum
hanger roads, see Standard No. 18-65, Index
1.1.1 Temperature for expansion and 2.6.2.
flexibility analysis.
1.3 Division Panel Inlet and Outlet
a. Cold Startup Headers

While raising pressure use 1.3.1 Temperature for expansion and

100o F below steam-cooled roof temperature. At
10% load use 100o F above steam-cooled roof
temperature. Steam-cooled roof temperatures
are given in Paragraph 2.1.1.
b. Full Load Operation
Same as division panel outlet
temperature. If not division panel, use steam-
cooled roof temperature +100o F.
c. Hot Startup
Same as full load operation.
flexibility analysis.
a. Cold Startup (before any flow)
Use 500o F for the division panel
inlet and outlet header temperature and 700o F
for the steam-cooled roof temperature.
b. Full Load Operation
Refer to the Predicted
Performance Sheet of the Superheater, Reheater
and Economizer Section of the Design
Performance Letter.

1.2 Drum Hangers 1.3.2 Temperature for establishing

allowable stresses.
1.2.1 Temperatures for expansion and
flexibility analysis. Use the design temperature
taken from the sheets titled "Headers, Piping and
a. Cold Startup Miscellaneous Data" of the Superheater, Reheater
and Economizer Section of the Design
Rods up to 4" in diameter will lag Performance Letter.
enclosure temperature by 50o F. Rods over 4" in
diameter will lag enclosure temperature by 1.4 Superheater Outlet Header
100o F.
1.4.1 Temperatures for expansion and
b. Full Load Operation flexibility analysis.

When outside of roof housing, a. One consideration in the design

use drum saturated steam temperature up to top
of drum and room temperature (assume 100o F)
above top of drum. When inside of roof housing,
use drum saturated steam temperature.
of the terminals should be to design the terminals
for the sum of the maximum expansion difference
between the end of the terminal at the header
and the anchor of the terminal, during startup
and full load operation.
SUBJECT: Design Rules for Superheater and
Reheater Terminals, Link Piping,
Downcomers and Hangers for
Controlled and Natural Circulation Units
______________________________________________________________________________________________________
b. Superheater outlet header
temperatures (header located in doghouse).
Use 300o F for the header
temperature during start up.
For full load operation, refer to
the Predicted Performance Sheet of the
Superheater, Reheater and Economizer Sections
of the Design Performance Letter.
c. Peg fin steam-cooled roof
construction (superheater outlet header in
doghouse).
Side-to-side and front-to-rear
anchor movement is governed by the water wall
temperature. The water wall temperatures are as
follows:
At startup (with flow), use 500o F.
For full load operation, use the
design temperature taken from the sheets titled
"Headers, Piping and Miscellaneous Data" of the
Boiler Circulation System Section in the Design
Performance Letter.
d. Fin welded roof construction
(superheater outlet header in doghouse).
Side-to-side and front-to-rear
anchor movement is governed by the roof
temperature. Refer to Paragraph 2.0 for the
temperatures of the steam-cooled roof at various
loads.
e. Superheater outlet header in
front enclosure.
Anchor movement is governed
by water wall temperatures.
STD NO. : 57-75-01
INDEX : 1.9
DATE : 9 JULY 2003
OWNER : MEDS
PAGE : 4 OF 8
During startup, use a ∆ T
between superheater outlet header and water
wall of 250o F. This assumes the superheater
outlet header at 170o F and the water wall at
420o F.
For full load operation, use the
design temperature taken from the sheets titled
"Headers, Piping and Miscellaneous Data" of the
Boiler Circulation System Section and the
Superheater, Reheater and Economizer Section of
the Design Performance letter.
1.4.2 Temperatures for establishing
allowable stresses.
These temperatures are to be the
design temperatures taken from the sheets titled
"Headers, Piping and Miscellaneous Data" of the
Superheater, Reheater and Economizer Section of
the Design Performance Letter.
1.5 Reheater Outlet Headers
1.5.1 Temperature for expansion and
flexibility analysis.
a. One consideration in the design
of the terminals should be to design the terminals
for the sum of the maximum expansion difference
between the end of the terminal at the header
and the anchor of the terminal, during startup
and full load operation.
b. Temperature for reheater outlet
header located in doghouse.
Use 325o F for the reheater
outlet header temperature during startup.
For full load operation, refer to
the Predicted Performance Sheet of the
Superheater, Reheater and Economizer Section of
the Design Performance Letter.
SUBJECT: Design Rules for Superheater and
Reheater Terminals, Link Piping,
Downcomers and Hangers for
Controlled and Natural Circulation Units
______________________________________________________________________________________________________
c. Peg fin steam-cooled roof
construction (reheater outlet header in doghouse).
Side- to-side and front-to-rear
anchor movement is governed by the water wall
temperature. The water wall temperatures are as
follows:
At startup (with flow), use 500o F.
For full load operation, use the
design temperature taken from the sheets titled
"Header, Piping and Miscellaneous Data" of the
Boiler Circulation System Section in the Design
Performance Letter.
d. Fin welded roof construction
(reheater outlet header in doghouse).
Side-to-side and front-to-rear
anchor movement is governed by the roof
temperature. Refer to Paragraph 2.0 for the
temperatures of the steam-cooled roof at various
loads.
e. Reheater outlet header in front
enclosure.
Anchor movement is governed
by water wall temperatures.
During startup, use a ∆ t between
reheater outlet header and water wall of 300o F.
This assumes the reheater outlet header at 120o F
and the water wall at 420o F.
For full load, use the design
temperature taken from the sheets titled
"Headers, Piping and Miscellaneous Data" of the
Boiler Circulation System Section and the
Superheater, Reheater and Economizer Section in
the Design Performance Letter.
1.5.2 Temperatures for establishing
allowable stresses.
STD NO. : 57-75-01
INDEX : 1.9
DATE : 9 JULY 2003
OWNER : MEDS
PAGE : 5 OF 8
These temperatures are to be the
design temperatures taken from the sheets titled
"Header, Piping and Miscellaneous Data" of the
Superheater, Reheater and Economizer Section in
the Design Performance Letter.
1.6 All intermediate headers and link
piping (including divisional panel
links).
1.6.1 Temperature for expansion and
flexibility analysis.
a. One consideration in the design
of the terminals should be to design the terminals
for the sum of the maximum expansion difference
between the end of the terminal at the header
and the anchor of the terminal during startup and
full load operation.
b. Intermediate headers and link
piping temperatures.
For cold startup (before any
flow), use 100o F below the water wall
temperature. The water wall temperature is
300o F.
For full load operation, refer to
the Predicted Performance Sheet of the
Superheater, Reheater and Economizer Section of
the Design Performance Letter.
c. Peg fin steam-cooled roof
construction (headers in doghouse).
Side-to-side and front-to-rear
anchor movement is governed by the water wall
temperature. The water wall temperatures are as
follows:
At startup (before flow), use
300o F.
SUBJECT: Design Rules for Superheater and STD NO. : 57-75-01
Reheater Terminals, Link Piping, INDEX : 1.9
Downcomers and Hangers for DATE : 9 JULY 2003
Controlled and Natural Circulation Units OWNER : MEDS
PAGE : 6 OF 8
______________________________________________________________________________________________________

For full load, use the design a. Cold Startup

temperature taken from the sheets titled
"Headers, Piping and Miscellaneous Data" of the Use 475o F for the steam-cooled
Boiler Circulation System Section in the Design wall temperature and 225o F for the feed water
Performance Letter. inlet temperature.

d. Fin welded roof construction b. Partial Load Operation

(headers in doghouse).
Side-to-side and front-to-rear
anchor movement is governed by the roof
temperature. Refer to Paragraph 2.0 for the
temperatures of the steam-cooled roof at various
loads.
Use 675o F for the steam-cooled
wall temperature and 300o F for the economizer
outlet temperature. (With the high pressure feed
water heater out of service, this 300o F
temperature could be attained with a 225o F feed
water inlet temperature).

e. Headers in front enclosure. c. Full Load Operation

Anchor movement is governed Use 700o F for the steam-cooled

by water wall temperatures.
At startup (before any flow) use
200o F for the header and 450o F for the front
water wall temperature.
At start of turbine (with flow), use
275o F for the reheater inlet header temperature
and 500o F for the front water wall temperature.
For full load operation, refer to
the Predicted Performance Sheet of the
Superheater, Reheater and Economizer Section of
the Design Performance Letter.
wall temperature and 425o F for the economizer
outlet temperature. (With the feed water heaters
out of service, this 425o F temperature could be
attained.)
2.0 Temperature for Analysis of Steam-
Cooled Roof
2.1 Temperature for expansion and
flexibility analysis.
2.1.1 At startup (before any flow), the
design temperatures to be used at various
sections of the roof are:

1.6.2 Temperatures for establishing a. Roof section in front of platen

allowable stresses. assembly - 700o F.

These temperatures are to be the b. Roof section between front of

design temperatures taken from the sheets titled
"Headers, Piping and Miscellaneous Data" of the
Superheater, Reheater and Economizer Section of
the Design Performance Letter.
1.7 Economizer
platen assembly and the water wall rear hanger
tubes - 600o F.
c. Roof section between water wall
rear hanger tubes and back pass steam-cooled
wall hanger tubes - 500o F.

1.7.1 Temperature for expansion and 2.1.2 At startup (with flow, the roof will
flexibility analysis. be 60o F above water wall temperature. The
water wall temperature at this time is 500o F.
SUBJECT: Design Rules for Superheater and
Reheater Terminals, Link Piping,
Downcomers and Hangers for
Controlled and Natural Circulation Units
______________________________________________________________________________________________________
2.1.3 For full load operation, the roof
temperature will be the same as first inlet header
temperature after drum (saturation temperature).
2.2 Temperature for establishing
allowable stresses
2.2.1 The same as full load operation
temperature (Paragraph 2.1.3) +50o F.
3.0 Temperature for Analysis of Radiant
Reheater Inlet Header (In front of
furnace with a fixed "welded" seal
construction)
3.1 Temperature for expansion and
flexibility analysis.
3.1.1 At startup (before any flow) use
200o F for radiant reheater inlet temperature and
450o F for the front water wall temperature.
3.1.2 At start of turbine (with flow) use
275o F for the reheater inlet header temperature
and 500o F for the front water wall temperature.
3.1.3 For full load operation, refer to
the Predicted Performance Sheet of Superheater,
Reheater and Economizer Section of the Design
Performance Letter.
3.2 Temperature for establishing
allowable stresses.
These temperatures are to be the
design temperatures taken from the sheets titled
"Headers, Piping and Miscellaneous Data" of the
Superheater, Reheater and Economizer Section of
the Design Performance Letter.
4.0 Temperature for Analysis of Radiant
Reheat Tubes Inside the Furnace
(The roof seal is to be a flexible
construction to permit vertical movement of
radiant reheat outlet header in both directions).
STD NO. : 57-75-01
INDEX : 1.9
DATE : 9 JULY 2003
OWNER : MEDS
PAGE : 7 OF 8
4.1 Temperature for expansion and
flexibility analysis.
4.1.1 At startup (before any flow), the
temperature of the front water wall tubes will rise
from 100o F to 500o, while the radiant reheat
tubes will rise from 500o F to 700o F. The design
temperature differential to be used at startup is
400o F.
4.1.2 At start of turbine (with flow), use
275o F for the radiant reheat tube temperature
and 500o F for the front water wall temperature.
4.1.3 For full load operation, refer to
the Predicted Performance Sheet of the
Superheater, Reheater and Economizer Section of
the Design Performance Letter.
5.0 Temperature for Analysis of
Downcomer
5.1 Controlled Circulation Units
The design temperature to be used is
25o F below saturated steam temperature.
5.2 Natural Circulation Units
The design temperature to be used is
125o F below saturated steam temperature.
5.3 If the pump is out of service, the
temperature between the inlet and outlet values
will be 200o F.
6.0 Mean Metal Temperature of Water
Wall Tubes for Determining
Allowable Stresses
Use saturation temperature +50o F except
in firing panel area where saturation temperature
+100o F is to be used.
SUBJECT: Design Rules for Superheater and STD NO. : 57-75-01
Reheater Terminals, Link Piping, INDEX : 1.9
Downcomers and Hangers for DATE : 9 JULY 2003
Controlled and Natural Circulation Units OWNER : MEDS
PAGE : 8 OF 8
______________________________________________________________________________________________________

7.0 Temperature Difference Between 10.0 Temperature Difference Between

Water Wall Outlet Header and Steam-Cooled Wall Inlet Header and
Nipples the Steam-Cooled Wall

For the purpose of calculating the thermal
expansion difference between header and
nipples, use:
∆T = T (nipples) -T (header) = + 15o F
based on a drum saturated temperature change
rate of 400o F/hr.
∆T = T (nipples) -T (header) = + 23 Fo
based on drum saturated temperature change
rate of 600o F/hr. (Sliding pressure operation.)
8.0 Temperature Difference Between
Economizer Outlet Tubing and
Reheat Inlet Header
8.1 The reheat inlet header will lag
economizer outlet tubing by 300o F prior to steam
flow.
For the purposes of thermal expansion
calculations at the point where the weld between
the wall tube fin stops (provided the point is
above the roof), use:
∆T = T (wall) -T (header) = 40o F startup
∆T = T (wall) -T (header) = 20o F cool
down
11.0 Temperature Difference Between
Extended Side Steam-Cooled Wall
and Water Wall Prior to
Syncronization
∆T = Steam Cooled Wall (525o F -water
wall (505o F) = 20o F

8.2 If there is a trip during operation, the

reheat inlet header will be hot while the
economizer outlet tubing will be running at
300o F. Refer to the Predicted Performance Sheet
of the Superheater, Reheater and Economizer
Section of the Design Performance Letter for the
reheater inlet temperature.

9.0 Temperature Difference Between

Center Wall and Outer Wall

For the purposes of thermal expansion

calculations, use:

∆T = T (center wall) -T (outer wall) = 20o F