DESIGN OF Steam Drum

0 21-4-21 IFA SM MNB SMU
Initial Sign. Initial Sign. Initial Sign. Initial Sign.

Rev Date Description
Prepared By Checked By Approved By Client Approval
Client:
HUNZA SUGAR MILLS (PVT.) LTD

1-A, BLock A,New Muslim town, Lahore.
Tel No: 042-111-161-161
EPC Contractor
FABCON DESIGN AND ENGINEERING Project No:

227- Sundar Industrial Estate , Lahore.
Tel No: 0423-5297122 Email: info@fabconengg.com
Website: www.fabconengg.com
21-BO-016
Service Design, Manufacturing, Supply , Installation & Comissioning of 120 Tph Boiler
Document Title Mechanical Design Calculations of Boiler
Sheet Rev
Document No 21-BO-016-MDR
Document No 21-BO-016-MDR
1 0
Document No
Mechanical Design Calculations of Boiler
21-BO-016-MDR
3D Model of Boiler
Page 2
Document No
21-BO-016-MDR
Page 2
Document No
21-BO-016-MDR
3D Model of Boiler
Page 3
Document No
21-BO-016-MDR
Page 3
Document No
21-BO-016-MDR
Table of Contents
1. Design of Steam Drum
1.1 Sketch Page 7
1.2 Design Data Page 8
1.3 Design Summary Page 10
1.4 Calculations Page 12
2. Design of Front Wall
2.1 Sketch Page 30
2.4 Membrane Tubes Page 34
2.5 Wall Sub Header Page 35
2.6 Wall Sub Header Riser Page 37
2.7 Sub Header End Plate Page 41
2.8 Top Header Page 42
2.9 Bottom Header Page 51
2.10 Bottom Header Connecting Pipe Page 56
3. Design of Right & Left Wall
3.1 Sketch Page 59
3.4 Membrane Tubes Page 62
3.6 To Header End Plate Page 65
3.8 Bottom Header Drain Page 74
3.9 Bottom Header Flange Page 75
4. Design of Rear Wall
4.1 Sketch Page 77
4.4 Membrane Walls (Upper Side) Page 80
4.5 Membrane Walls (lower Side) Page 81
4.7 Top Header End Plate Page 84
4.9 Bottom header End Plate Page 94
4.10 Bottom header Connecting Pipe Page 95
5. Design of Suspension Wall
5.1 Sketch Page 97
5.4 Membrane Walls Page 100
5.5 Bottom header Page 101
5.6 Bottom Header End Plate Page 106
6. Design of Screen Wall
6.1 Sketch Page 108
6.4 Membrane Walls Page 111
6.5 Top header Page 112
6.6 Top Header End Plate Page 114
Page 4
Document No
21-BO-016-MDR
Table of Contents
6.7 Bottom header Page 116
7. Design of Evaporator
7.1 Sketch Page 123
7.4 Evaporators Coils Page 126
7.5 Evaporator Main Tubes Page 127
8. Design of Economizer
8.1 Sketch Page 130
8.4 Economizer Coils Page 133
8.5 Eco-1 Header Page 134
8.6 Eco-1 HeaderEnd Plate Page 136
8.7 Eco-2 Header Page 137
8.8 Eco-2 HeaderEnd Plate Page 139
9. Design of Superheaters
9.1 Sketch Page 141
9.4 Superheater 1A Coils Page 146
9.5 Superheater 1B Coils Page 147
9.6 Superheater 2 Coils Page 148
9.7 Superheater 1 Inlet Header Page 149
9.8 Superheater 1 Outlet & Superheater 2 inlet Header Page 154
9.10 SH 1 Outlet Header & Sh2 Inlet Header End Plate Page 156
9.11 Superheater 2 Outlet Header Page 157
9.12 Superheater 2 Outlet Headr End Plate Page 159
9.13 Desuperheater Loop Before Spray Page 160
10. Design of Downcommers
10.1 Sketch Page 162
10.4 Header # 1 Page 165
10.7 Header # 3 End Plate Page 168
Page 4
0 21-4-21 IFA SM MNB SMU
Initial Sign. Initial Sign. Initial Sign. Initial Sign.
Rev Date Description
Prepared By Checked By Approved By Client Approval
Client:
HUNZA SUGAR MILLS (PVT.) LTD

1-A, BLock A,New Muslim town, Lahore.
Tel No: 042-111-161-161
EPC Contractor
FABCON DESIGN AND ENGINEERING Project No:

227- Sundar Industrial Estate , Lahore.
Tel No: 0423-5297122 Email: info@fabconengg.com
Website: www.fabconengg.com
21-BO-016
Service Design, Manufacturing, Supply , Installation & Comissioning of 120 Tph Boiler
Document Title Mechanical Design Calculations of Steam Drum
Sheet Rev
Document No 21-BO-016-MDR-01
Document No 21-BO-016-MDR-01
6 0
Document No
Mechanical Design Calculations of Steam Drum
21-BO-016-MDR-01
1.1 Sketch
Page 7
Document No
21-BO-016-MDR-01
Page 7
Document No
21-BO-016-MDR-01
1.2 Design Data
Design Code = ASME Sec I 2019

Boiler Capacity = 120 tph
Type of Boiler = Water Tube Boiler
Boiler supports = Saddle Supports
Steam Head Dia x Length ID X L = 1500 x 10300
Operating Pressure = 91 barg
Design Pressure = 98 barg
Design Temperature = 310 C
o
Corrosion allowance (Head/ shell) : = 1 mm

Materials (C. steel) = SA-516 Gr 70
Allowable stress at Test Temperature = 138 Mpa
Allowable Stress at Design Temperature = 134.4 Mpa
Yield Stress = 260 Mpa
Radiography = RT-1
Joint Efficiency = 1
Head Manhole Type = Ring Type
Ring Material = SA-105
Allowable Stress at Test Temperature = 138 Mpa
Allowable Stress at Design Temperature = 127.4 Mpa
Nozzle : 1
Nozzle Designation = N1
Nozzle Material = SA-105
Allowable stress at Design Temperature = 127.4 Mpa
Corrosion Allowance = 1 mm
Nozzle Size = NPS 12
Qty = 2
Nozzle : 2
Nozzle Designation = N2, N3, N4, N6,N7, N8, N9, N10
Nozzle Size = NPS 6
Qty = 36
Nozzle : 3
Page 9
Document No
21-BO-016-MDR-01
Nozzle Size = NPS 4
Qty = 2
Nozzle : 4
Nozzle Size = NPS 6
Qty = 1
Nozzle : 5
Nozzle Size = NPS 3
Qty = 2
Nozzle : 6
Nozzle Designation = N12, N13
Nozzle Size = NPS 2
Qty = 5
Page 9
Document No
21-BO-016-MDR-01
1.3 Design Summary
Sr. No Design Parameter SUMMARY

1 Design Code ASME Sec I 2019
2 Type of Boiler Water Tube Boiler
3 Boiler Capacity tph 120
4 Operating Pressure Mpa 9.1
5 Design Pressure Mpa 9.8
6 Design Temperature o
C 310
7 ID of steam drum mm 1500
8 Length of steam drum mm 10300
9 Head of drum Ellipsoidal Head (2:1)
10 Straight Flange mm 50
11 Corossion Allowance mm 1
12 Radiography RT-1
13 Material of Construction SA-516 Gr 70
14 Thickness of Shell mm 70
15 Thickness of Head mm 70
16 MAWP Mpa 11.7
17 Weight of shell kg 26671
18 Weight of heads kg 6596
19 Hydrotest Pressure Mpa 14.7
Drum Manhole
Size of Manhole THK. Blind Thk Material Type Int. Proj
425 X 325 60 70 SA-516 Gr 70 Ring 145
Drum Nozzle
Nozzle Number N1
Size of Nozzle O.D I.D THK. Material Type Int. Proj
NPS 12 400 273 63.5 SA-105 Forged 110
Nozzle Number N2, N3, N4, N6,N7, N8, N9, N

Size of Nozzle O.D I.D THK. Material Type
NPS 6 240 146 47 SA-105 Forged
Nozzle Number N5
NPS 4 175 97 39 SA-105 Forged
Nozzle Number N7
NPS 6 240 146 47 SA-105 Forged
Nozzle Number N11

NPS 6 90 49 20.5 SA-105 Forged
Nozzle Number N12, N13
Page 10
Document No
21-BO-016-MDR-01

NPS 2 145 74 35.5 SA-105 Forged
Page 10
Document No
21-BO-016-MDR-01
SUMMARY
ASME Sec I 2019
Water Tube Boiler
120
9.1
9.8
310
1500
10300
Ellipsoidal Head (2:1)
50
1
RT-1
SA-516 Gr 70
70
70
11.7
26671
6596
14.7
Drum Manhole
Out. Project
70
Drum Nozzle
N1
Out. Project
290
N2, N3, N4, N6,N7, N8, N9, N10

Type
Forged
N5
Type
Forged
N7
Type
Forged
N11
Type
Forged
N12, N13
Page 10
Document No
21-BO-016-MDR-01
Type
Forged
Page 10
Document No
21-BO-016-MDR-01
1.4 CALCULATIONS
1.4.1 SHELL THICKNESS

(REF : PG - 27.2.2)
Reference Drawings = 21001-B03-025-00-1 OF 1

Minimum thickness = 6 mm (Ref: PG-16.3)
Design Pressure P = 9.8 Mpa
Inner Dia of Shell Di = 1500 mm
Shell Length c = 10300 mm
Material of Construction = SA-516 Gr 70
Joint Efficeincy E = 1
Material Allowable Stress S = 134.4 Mpa
PR/(SE-(1-y)P)+C PD/(2SE+2yP)+C
Required Thickness tr = OR
Temperature Co efficient y = 0.4 (Ref: PG 27.4.6)

tr = 59.4 mm
Used Thickness t = 70 mm
(2SE (t -C))/(D - (SE (t -C))/(R+(1-y)

MAWP = 2y(t -c)) OR (t -c))
= 11.7 Mpa
Allowable Stress for Hydrotest SE = 0.9 x Yield Stress

= 234.0 Mpa
Maximum Allowable Hydrotest Pressure MAHP = 20.4 Mpa
Weight of shell = 26671 Kg
1.4.2 LEFT HEAD THICKNESS
(REF : PG - 29.7)
Minimum Thickness = 6 mm (Ref: PG-16.3)
Inner Dia of Head D = 1500 mm
Corrosion Allowance c = 1 mm
Required Thickness tr = 59.4 mm
Used Thickness = 70 mm (Same thickness as used for
MAWP = 11.7 Mpa used for shell)
page 13
Document No
21-BO-016-MDR-01
Weight of Head = 3298 kg
75t/R_f (1-R_f/R_o )
% Strain = (Ref: PG 19)
= 6.688 % < 25%
Post forming heat Treatment Not (Ref: Table PG 20)

Required
Where,
Rf = Mean Radius of Head after Forming
Ro = Outer Radius ( Infinity for Flat Plate)
1.4.3 RIGHT HEAD THICKNESS
(REF : PG - 29.7)
Minimum Thickness = 6 mm
Inner Dia of Head D = 1500 mm
Required Thickness tr = 59.4 mm
Used Thickness = 70 mm (Same thickness as used for
MAWP = 11.7 Mpa used for shell)
Weight of Head = 3298 kg
% Strain = 75t/R_f (1-R_f/R_o ) (Ref: PG 19)
= 6.688 % < 25%
Post forming heat Treatment Not (Ref: Table PG 20)

Required
Where,
Rf = Mean Radius of Head after Forming
Ro = Outer Radius ( Infinity for Flat Plate)
1.4.4 Hydrotest Pressure
Hydrotest Pressure = 1.5 X MAWP (Ref: PG - 99)

= 14.7 Mpa
1.4.5 Post Weld Heat Treatment
(REF : PW - 39) Table PW-39.1
Holding Temperature = 595 - 705 C

o
Holding Time = 135 minutes
page 13
Document No
21-BO-016-MDR-01
1.4.6 Weight Summary
Empty Weight = 33,267 kg

Used Thickness = 70 mm
MAWP = 11.7 Mpa
MAHP = 20.4 Mpa
Volume of Tank = 76.3 m3
Hydrotest Weight = 76,341 kg
Hydrotest Pressure = 14.7 Mpa
page 13
Document No
21-BO-016-MDR-01
1.4.7 Header Manhole Reinforcement Calculations
(REF : PG - 32 & PG 33.3)

Reference Drawings = 21001-B03-030
Nozzle Type = Set-Through
Inner Dia of Head Di = 1500 mm
Outside Dia of Head D = 1640 mm
Allowable Stress of Head Sv = 134.4 Mpa
Allowable Stress of Ring Sn = 127.4 Mpa
Temperature Co efficient y = 0.4
Head Thickness t = 70 mm
Manhole Thickness tn = 60 mm
Shell Corroded Thickness t = 69 mm
Stub Corroded Thickness tn = 59 mm
PD/1.82St = 0.94 (Ref: PG -32.1.1)
K = Min (0.99 , PD/ 1.82St) = 0.94
=
8.08[Dt 〖 (1-k)] 〗 ^(1/3) 155 (Ref: PG -32.1.4)
Min( 60, Di/4) = 60

Max hole dia without reinforcement dmax = 155 mm (Ref: PG -32.1.4)
Minimum Size for Ellipsoidal Manhole = 400 x 300 (Ref: PG -44.1)
Dia of Manhole Used d = 425 x 325
PG 32.2.1 Satisfied
Dia of Manhole hot and corroded d = 427 mm
Allowable stress in reinforcing element Sp = 134.4 Mpa

fr1 = Sn / Sv = 0.95
fr2 = Min(Sn, Sp ) / Sv = 0.95
fr3 = Sp / Sv = 1
Factor for Compensation in Pressure Stress F = 1
Max. Inward Noz Proj. = Min(2.5 t, 2.5tn+te) hmax = 150 mm (Ref: PG - 36.3)
Nozzle Inward Projection h = 145 mm
Nozzle Outward Projection L = 70 mm
Thickness of Reinforcing Pad te = 0 mm
Outer Dia of Reinforcing Pad Dp = 0 mm
Required Thickness of Head tr = 59.4 mm
Required Thickness of Nozzle trn = 0.0 mm (Ref: PG - 33.3)
Outer Weld Size:
Smaller of (19mm , Thinner Parts Joined) tmin = 19.0 mm (Ref: PW - 16)
Smaller of (0.7tmin , 6 mm) tc = 6.0 mm
Page 16
Document No
21-BO-016-MDR-01
Minimum Weld Size WL1min = 8.5 mm

Outward Nozzle Weld WL1 = 15.0 mm Weld Size is Ok
Width of Nozzle inserted into vessel wall wd = 0 mm (Ref: Fig. PG - 33.2)
Inner Weld Size:

Reinforcement Pad Weld
Smaller of (19mm , Thinner Parts Joined) tmin = 0.0 (Ref: PW - 16)
Smaller of (0.7tmin , 6 mm) tc = 0.0
Minimum Weld Size WL2min = 0.0
Outward Nozzle Weld WL3 = 0.0 mm Weld Size is smaller
Area Required for Reinforcement A = (d+2t_n)t_r F
= 32371 mm2
A11 = (d-2t_n )(t-Ft_r )-2w_d (t-Ft_r )(1-f_r1)
= 2967.3 mm2
A12 = 2t(t-Ft_r )-2w_d (t-Ft_r )(1-f_r1)
= 1325 mm2
Area Available in Shell A1 = Max ( A11 , A12 )
= 2967.3 mm2
A21 = 2(t_n-t_rn )(2.5tf_r1 )
= 19294.8 mm2
A22 = 2(t_n-t_rn )(2.5t_n+ t_e ) f_r1
= 16498.5 mm2
Area Available in Nozzle Proj. Outward A2 = Min ( A21 , A22 )
= 16498.5 mm2
Area Available In Nozzle Projecting Inward A3 = 2t_n f_r1 h
= 16218.9 mm2
Area Available In Outward Nozzle Weld A41 = ( 〖 WL 〗 _1 )^2 f_r2
= 213.3 mm2
Area Available In Inward Nozzle Weld A43 = ( 〖 WL 〗 _3 )^2 f_r1
= 213.3 mm2
Area Available In R/F Plate Nozzle Weld A42 = ( 〖 WL 〗 _2 )^2 f_r3
= 0.0 mm2
Area Available In R/f Pad A5 = (D_p -t -2t_n)t_e f_r3
= 0.0 mm2
Total Area Available = 36111.2 mm2
Reinforcement Requirement =
Reinforcement is Adequate
Page 16
Document No
21-BO-016-MDR-01
External Pressure Check
(Ref: PG- 28.2)
D = a2 / b = 556
D/t = 9.3
L/D = 0.13
A = 0.013
B = 88
Sb =Min ( 2S n , 1.8 Sny) = 254.8 Mpa
P_a1= [2.167/(D/t) -0.0833]B
= 13.3 Mpa
P_a2= 2Sb/(D/t) [1-1/(D/t) ]

= 49.1 Mpa
Pa = Min (Pa1 , Pa2 ) = 13.3 Mpa
= No External stiffner
Required
Manhole Plate Calculations
(Ref: PG - 31.3.3)
Major Dia of Manhole D = 425 mm

Minor Dia of Manhole d = 325 mm
Correction Factor C = 0.33 (Ref: PG-31 fig)
Z = 3.4 - 2.4d/D = 1.56
Required Thickness tr = d√(ZCP/S)+CA
= 64.36 mm
Thickness of Plate Used t = 70 mm
Weight of Manhole = 137 kg

Weight of Manhole Plate = 238 kg
Page 16
Document No
21-BO-016-MDR-01
(Ref: PG -32.1.1)
(Ref: PG -32.1.4)
(Ref: PG -32.1.4)
Page 16
Document No
21-BO-016-MDR-01
Weld Size is Ok
(Ref: Fig. PG - 33.2)
Weld Size is Ok
Weld Size is smaller
(d-2t_n )(t-Ft_r )-2w_d (t-Ft_r )(1-f_r1)
2t(t-Ft_r )-2w_d (t-Ft_r )(1-f_r1)
Page 16
Document No
21-BO-016-MDR-01
(Ref: PG-31 fig)
Page 16
Document No
21-BO-016-MDR-01
1.4.8.1 Header Nozzles
Reinforcement Calculations for N1
(REF : PG - 32 & PG 33.3)

Material Used = Forged
Thickness of Nozzle t = 63.5 mm
(For forged Pipe only)
Inner Dia of nozzle d = 273 mm
Outer Dia of Nozzle do = 400 mm
Joint Efficeiny E = 1
Allowable Stress of Shell Sv = 134.4 Mpa
Allowable Stress of Pipe Sn = 127.4 Mpa
Shell Thickness t = 70 mm
Stub Corroded Thickness tn = 62.5 mm
Dia of Nearest Larger Opening = 100 mm
PD/1.82St = 0.94 (Ref: PG -32.1.1)

K = Min (0.99 , PD/ 1.82St) = 0.94
=
8.08[Dt 〖 (1-k)] 〗 ^(1/3) 155 (Ref: PG -32.1.4)
Min( 60, Di/4) = 60

Reinforcement Calculations are Needed
Cen. to Cen. Distance of Nearest Opening X = 590 mm

Limit of Compensation = 405 mm (Ref: PG -36.2)
PG - 36.2 Satisfied
Allowable stress in reinforcing element Sp = 134.4 Mpa

fr1 = Sn / Sv = 0.95
fr2 = Min(Sn, Sp ) / Sv = 0.95
fr3 = Sp / Sv = 1
Page 18
Document No
21-BO-016-MDR-01
Factor for Compensation in Pressure Stress F = 1
Max. Inward Noz Proj. = Min(2.5 t, 2.5tn+te) hmax = 156.25 mm (Ref: PG - 36.3)
Nozzle Inward Projection h = 110 mm

Nozzle Outward Projection L = 290 mm
Thickness of Reinforcing Pad te = 0 mm
Outer Dia of Reinforcing Pad Dp = 0 mm
Required Thickness of Shell tr = 59.4 mm
Required Thickness of Nozzle:
PR/(SE-(1-y)P)+C PD/(2SE+2yP)+C
Required Thickness trn = OR
= 15.9 mm
Used Thickness is Ok
Outer Weld Size:

Width of Nozzle inserted into vessel wall wd = 0 mm (Ref: Fig. PG - 33.2)
Inner Weld Size:

Reinforcement Pad Weld

Smaller of (19mm , Thinner Parts Joined) tmin = 0.0 (Ref: PW - 16)
Smaller of (0.7tmin , 6 mm) tc = 0.0
Minimum Weld Size WL2min = 0.0
Outward Nozzle Weld WL3 = 0.0 mm Weld Size is smaller
Area Required for Reinforcement A = (d+2t_n)t_r F
= 23640 mm2
A11 = (d-2t_n )(t-Ft_r )-2w_d (t-Ft_r )(1-f_r1)
= 1421.2 mm2
A12 = 2t(t-Ft_r )-2w_d (t-Ft_r )(1-f_r1)
= 1325 mm2
Area Available in Shell A1 = Max ( A11 , A12 )
= 1421.2 mm2
A21 = 2(t_n-t_rn )(2.5tf_r1 )
= 13796.5 mm2
A22 = 2(t_n-t_rn )(2.5t_n+ t_e ) f_r1
= 13796.5 mm2
Page 18
Document No
21-BO-016-MDR-01
Area Available in Nozzle Projecting Outward A2 = Min ( A21 , A22 )
= 13796.5 mm2
Area Available In Nozzle Projecting Inward A3 = 2t_n f_r1 h
= 13033.9 mm2
Area Available In Outward Nozzle Weld A41 = ( 〖 WL 〗 _1 )^2 f_r2
= 379.2 mm2
Area Available In Inward Nozzle Weld A43 = ( 〖 WL 〗 _3 )^2 f_r1
= 379.2 mm2
Area Available In R/F Plate Nozzle Weld A43 = ( 〖 WL 〗 _2 )^2 f_r3
= 0.0 mm2
Area Available In R/f Pad A5 = (D_p -t -2t_n)t_e f_r3
= 0.0 mm2
Total Area Available = 29009.9 mm2
Reinforcement Requirement = Reinforcement is Adequate
Page 18
Document No
21-BO-016-MDR-01
Reinforcement Calculations for N2, N3, N4, N6,N7, N8, N9, N10
(REF : PG - 32 & PG 33.3)

Thickness of Nozzle t = 47 mm
Inner opening of nozzle d = 146 mm
Joint Efficiency E = 1
PD/1.82St = 0.94 (Ref: PG -32.1.1)

K = Min (0.99 , PD/ 1.82St) = 0.94
=
8.08[Dt 〖 (1-k)] 〗 ^(1/3) 155 (Ref: PG -32.1.4)
Min( 60, Di/4) = 60

(Ref: PG -33.3)
Reinforcement is not Required
Page 19
Document No
21-BO-016-MDR-01
(Ref: PG -32.1.1)
(Ref: PG -32.1.4)
(Ref: PG -32.1.4)
Page 19
Document No
21-BO-016-MDR-01
(REF : PG - 32 & PG 33.3)

Nozzle Type = Set Through
Material Type = Forged
Inner dia of nozzle d = 97 mm
PD/1.82St = 0.94 (Ref: PG -32.1.1)

K = Min (0.99 , PD/ 1.82St) = 0.94
=
8.08[Dt 〖 (1-k)] 〗 ^(1/3) 155 (Ref: PG -32.1.4)
Min( 60, Di/4) = 60

Page 21
Document No
21-BO-016-MDR-01
(Ref: PG -32.1.1)
(Ref: PG -32.1.4)
(Ref: PG -32.1.4)
Page 21
Document No
21-BO-016-MDR-01
(REF : PG - 32 & PG 33.3)

Inner Dia of nozzle d = 146 mm
PD/1.82St = 0.94 (Ref: PG -32.1.1)

K = Min (0.99 , PD/ 1.82St) = 0.94
=
8.08[Dt 〖 (1-k)] 〗 ^(1/3) 155 (Ref: PG -32.1.4)
Min( 60, Di/4) = 60

Page 23
Document No
21-BO-016-MDR-01
(Ref: PG -32.1.1)
(Ref: PG -32.1.4)
(Ref: PG -32.1.4)
Page 23
Document No
21-BO-016-MDR-01
(REF : PG - 32 & PG 33.3)

PD/1.82St = 0.94 (Ref: PG -32.1.1)

K = Min (0.99 , PD/ 1.82St) = 0.94
8.08[Dt 〖 (1-k)] 〗 ^(1/3) 155

= (Ref: PG -32.1.4)
Min( 60, Di/4) = 60
Page 25
Document No
21-BO-016-MDR-01
(Ref: PG -32.1.1)
(Ref: PG -32.1.4)
(Ref: PG -32.1.4)
Page 25
Document No
21-BO-016-MDR-01
Reinforcement Calculations for N12, N13
(REF : PG - 32 & PG 33.3)

Nozzle Type = Set through
Nozzle Size = NPS 2
PD/1.82St = 0.94 (Ref: PG -32.1.1)

K = Min (0.99 , PD/ 1.82St) = 0.94
8.08[Dt 〖 (1-k)] 〗 ^(1/3)

= 155 (Ref: PG -32.1.4)
Min( 60, Di/4) = 60
Max hole Dia without reinforcement dmax = 155 mm (Ref: PG -32.1.4)
Cen.to Cen. Distance of Nearest Opening X = 400 mm

Limit of Compensation = 141 mm (Ref: PG -36.2)
PG - 36.2 Satisfied
Page 27
Document No
21-BO-016-MDR-01
(Ref: PG -32.1.1)
(Ref: PG -32.1.4)
(Ref: PG -32.1.4)
Page 27

DESIGN OF Steam Drum

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

DESIGN OF Steam Drum

Uploaded by

Copyright:

Available Formats

0 21-4-21 IFA SM MNB SMU

Initial Sign. Initial Sign. Initial Sign. Initial Sign.

HUNZA SUGAR MILLS (PVT.) LTD

FABCON DESIGN AND ENGINEERING Project No:

Document Title Mechanical Design Calculations of Boiler

HUNZA SUGAR MILLS (PVT.) LTD

FABCON DESIGN AND ENGINEERING Project No:

Document Title Mechanical Design Calculations of Steam Drum

1.2 Design Data

Design Code = ASME Sec I 2019

Corrosion allowance (Head/ shell) : = 1 mm

1.3 Design Summary

Sr. No Design Parameter SUMMARY

Nozzle Number N2, N3, N4, N6,N7, N8, N9, N

Nozzle Number N11

Nozzle Number N12, N13

Size of Nozzle O.D I.D THK. Material Type

N2, N3, N4, N6,N7, N8, N9, N10

1.4.1 SHELL THICKNESS

Reference Drawings = 21001-B03-025-00-1 OF 1

Temperature Co efficient y = 0.4 (Ref: PG 27.4.6)

(2SE (t -C))/(D - (SE (t -C))/(R+(1-y)

Allowable Stress for Hydrotest SE = 0.9 x Yield Stress

Weight of shell = 26671 Kg

1.4.2 LEFT HEAD THICKNESS

= 6.688 % < 25%

Post forming heat Treatment Not (Ref: Table PG 20)

1.4.3 RIGHT HEAD THICKNESS

= 6.688 % < 25%

Post forming heat Treatment Not (Ref: Table PG 20)

1.4.4 Hydrotest Pressure

Hydrotest Pressure = 1.5 X MAWP (Ref: PG - 99)

1.4.5 Post Weld Heat Treatment

(REF : PW - 39) Table PW-39.1

Holding Temperature = 595 - 705 C

Holding Time = 135 minutes

1.4.6 Weight Summary

Empty Weight = 33,267 kg

1.4.7 Header Manhole Reinforcement Calculations

(REF : PG - 32 & PG 33.3)

Min( 60, Di/4) = 60

Dia of Manhole Used d = 425 x 325

Dia of Manhole hot and corroded d = 427 mm

Allowable stress in reinforcing element Sp = 134.4 Mpa

Minimum Weld Size WL1min = 8.5 mm

Minimum Weld Size WL3min = 8.5 mm

Outward Nozzle Weld WL3 = 15.0 mm Weld Size is Ok

External Pressure Check

(Ref: PG- 28.2)

P_a2= 2Sb/(D/t) [1-1/(D/t) ]

Pa = Min (Pa1 , Pa2 ) = 13.3 Mpa

Manhole Plate Calculations

Major Dia of Manhole D = 425 mm

Required Thickness tr = d√(ZCP/S)+CA

Thickness of Plate Used t = 70 mm

Weight of Manhole = 137 kg

Weld Size is smaller

(d-2t_n )(t-Ft_r )-2w_d (t-Ft_r )(1-f_r1)

2t(t-Ft_r )-2w_d (t-Ft_r )(1-f_r1)

(Ref: PG-31 fig)

1.4.8.1 Header Nozzles

Reinforcement Calculations for N1

(REF : PG - 32 & PG 33.3)