Steam Drum, Water Wall & Evaporator - VWHA054

7/29/2019 Steam Drum, Water Wall & Evaporator - VWHA054

1/36

SHEET 1 OF 36

DESIGN CALCULATION FOR

BOILER MAKER'S No. VWHA054

TYPE OF BOILER : SINGLE DRUM WASTE HEAT RECOVERY BOILER (WHRB)

DESIGN CODE : IBR 1950

DESCRIPTION TEMP. C

STEAM DRUM 290.00 75

WATER WALL 318.00 75

EVAPORATOR I & II SEE INDEX

INDEX

DESCRIPTION TEMP, C PRESSURE, Kg/cm

EVAPORATOR I & II

- INLET HEADER 290.00 75

- OUTLET HEADER 290.00 75

- TUBES 318.00 75

PREPARED CHECKED APPROVED & DATE

NAME :N.CHANDRASEKARAN NAME : S.SATHISH KUMAR NAME :: P.VIMAL DATE

SIGN: SIGN : SIGN :

TOTAL HEATING SURFACEAREA

: 894.00 sq.m

Pr. Kg/cm2


2/36

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 = 75.00 Kg/cm2

f =1383.7 Kg/cm2

T = Thickness of Drum in Inches 56 mm

= 2.20 Inches

D = 1220 mm = 48.031 Inches

E =Ligament Efficiency

1.2 LONGITUDINAL LIGAMENT EFFICIENCY CALCULATION (IBR 215)

SL.NO. LOCATION/TITLE P D E

1 250 50.45 0.80

2 230 42.85 0.81

3 230 35.4 0.85

4 225 65.15 0.71

5 808 137.7 0.83

6 Bet. Riser Stubs (S7C & S7D) 500 66.3 0.87

7 375 66.3 0.82

Eqn.72

Working Pressure in Kg/cm2 =

Allowable Stress for SA516 Gr.70(As per ASME Sec -II

pa rt - D at Metal Working Temp.290C =

Max. Int. Dia of Drum in Inches =

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 (S7A & S7B /

S7E & S7F)


3/36

SHEET 3 OF 36

1.3 CIRCUMFERENTIAL LIGAMENT EFFICIENCY

SL.NO. LOCATION / TITLE P D E E1

1 222.7 66.3 0.70 1.40

1.4 DIAGONAL LIGAMENT EFFICIENCY

SL.NO. LOCATION / TITLE b a D E

1 285 779.46 80.6 0.91

2 375 222.7 66.3 1.00

3 200 334.05 88.55 0.81

P - d 250 - 50.45--------- = -----------------------

P 250

= 0.80

Where,

P = Longitudinal Pitch of Tube Holes

d = Diameter of the Tube Holes

P1 = Diagonal Pitch of the Tube Hole

E = Ligament Efficiency

From the above the Least Value of Ligament Efficiency,E = 0.71

2 x 1384 x 0.71 x ( 2.20 - 0.03)

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

48.031 + 2.20 - 0.03

= 86.24 75.00

Hence Safe

Between Riser Stubs (S7A &

S7G / S7F & S7H-20 Deg.)

Between Riser Stubs (S3 &

S7E -70 Deg.)

Between Riser Stubs (S7B &

S7G -20 Deg.)

Between Feed Inlet Stub &

Riser Stub (S10A & S6B-

30dEG.)

Since the point of intersec tion falls in the right of c urve in IBR Fig. 15 the longitudinal

efficiency is to be calculated as follows

E1 = Equt. Longitudinal Ligament Efficiency = 2 X Circ. Ligament Effic iency

Kg/cm2> Kg/cm2


4/36

SHEET 4 OF 36

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

D X WP

T1 = ------------- + 0.032 f E - WP

48.03 x 75.00

= ---------------------------------------- + 0.03

2 x 1383.7 x 0.71 - 75.00

= 1.93 Inch = 49.1 mm

49.1 mm

Provided Thickness = 56.00 mm

Min.Thickness Required =


5/36

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

P x D

K = -------------1.82 x f x e

Where,

P = Design Pressure = 75.00

1332 mm

= 52.44 Inch

56 mm

= 2.20 Inch

f = Allowable Stress = 1383.70

75 x 52.44

K = -----------------------1.82 x 1383.7 x 2.2

= 0.71

From Fig.9C(Graph), For the value of K = 0.71

And for D x e = 74592

8.0 Ins = 203.20 mm

LIST OF OPENINGS IN STEAM DRUM

Description

1 SV Stub 63.5 x 9.525 SA 105

2 PG , PT, RPG ,LT & AV Stub 33.4 x 6.35

3 Super Heater Riser 88.9 x 7.62

4 Water Wall Riser 60.3 x 5.54

5 219.1 x 18.26

6 48.3 x 7.14

7 Feed Inlet Stub 76.2 x 9.52

203.20 mm

Eqn.20

Kg/cm2

D = Outer Dia. Of Shell =

e = Ac tual Thk. Of Shell =

Kg/cm2

mm2

Max. Dia. Of Uncompensated Opening =

Sl.No. Tube Size DiaxThk(mmMaterialSpecification

SA 106 Gr.B

SA 106 Gr.B

SA 106 Gr.B

Dowcomer SA 106 Gr.B

Intermittent Blowdown SA 106 Gr.B

SA 106 Gr.B

Note : Compensation is not Required for Openings Y , Compensation Pad is required

Outside Dia =

dn = Internal Diameter of the Stub

fn = The permissible stress for the material of the stub

fs = The permissible stress for the material of the header

(2 x (tn - en) x b1 x fn/ fs) + (2 x tn x b2 x fn/ fs) +( 2 x (ts - es)c i)

x = Sec tional area = dn x es

Ci = (ts + 3) inch (or) dn/2 whichever is greate

es = (PxD / (2 x fs x E - P)) + 0.03

en = (PxD / (2 x fn x E - P)) + 0.03

dninch

tninch

ses

inchen

inch

Sl.NO b2inch

Ciinch

Xinch

Yinch


7/36

SHEET 7 OF 36

2.2 STRENGTH CALCULATION FOR MANHOLE COVER [IBR 340(f) & 342(b)]


WP = ------------- Hence, t = ---------- + C

f

Where,

t = Provided Thickness mm 47

d = Max. Internal Diameter mm 410

K 0.19

1383.70

C' in mm 1

42.61 (t)

91.67 (WP)

42.61

Provided Thickness mm = 47.00

Max. Pressure is Greater Than 75.00

Hence Safe

f x (t - C)2 d2 x WP x K

Eqn.89(A)

d2 x K

f = Allowable Stress for SA515-Gr.70in Kg/cm2

Min.Required Thickness mm

Max. Pressure in Kg/cm2(g)

Min.Required Thickness mm =

Kg/cm2(g)


8/36

SHEET 8 OF 36

2.3 STRENGTH CALCULATION FOR TUBES / INTEGRAL PIPES (IBR 338)

STUBS FOR STEAM DRUM VALVES


Metal Working Temp. = 290

75

2 x f x ( t - c ) WP x D

WP = ------------- t = -------------- + CD - t + c 2f + WP

Where,

f = Allow Stress for material as per ASME sec tion -II Part - D at Metal Working temp

D = External diameter of pipe in mm

c = Corrosion allowance = 0.00

Material

SA105 1272 0.00

1202.53 12.50

Description

1 SV Stub 63.5 x 9.525 1.82 9.525 448.94 SA 105

2 33.4 x 6.35 1.14 6.35 480

3 Super Heater Riser 88.9 x 7.62 3.02 7.62 195

4 Water Wall Riser 60.3 x 5.54 2.05 5.54 210.24

5 Dowcomer 219.1 x 18.26 7.45 18.26 189.18

6 Intermittent Blowdown 48.3 x 7.14 1.64 7.14 357.31

7 Feed Inlet Stub 76.2 x 9.52 2.59 9.52 295.18

oC

Max.working Pressure = Kg/cm2

Eqn.87

WP = Working Pressure in Kg/cm2

t = Min.Thickness in mm = Nom.Thickness - Neg. Toleranc

mm (for working pressure above 70 Kg/cm2)

Stress Value in Kg/cm2Negative

Tolerance - %

SA 106 Gr.B

Sl.No.Pipe/Tube Size

Dia x Thk(mmxmm)

t Req.(mm)

t Prov.(mm)

WorkingPress.Kg/cm2

MaterialSpecification

PG , PT, RPG,LT & AVStub

SA 106 Gr.B

SA 106 Gr.B

SA 106 Gr.B

SA 106 Gr.B

SA 106 Gr.B

SA 106 Gr.B


9/36

SHEET 9 OF 36

2.4 Strength Calculation for Tubes/Integral Pipes (IBR 338)


Metal working Temp. : 290

Max. working Pressure : 75

2 x f x ( t - c ) WP x D

WP = ---------------- t = ---------- + CD - t + c 2f + WP

Where,

f = Allow Stress for material as per ASME sec tion -II Part - D at Metal Working temp.



Material

SA 105 1272 0.00

1202.53 12.50

Description

1 Pipe 21.30 x 3.73 0.72 3.73 435.21

2 Reducer(LD) 21.30 x 3.73 0.61 3.73 540.08 SA 105

3 Reducer(SD) 14.00 x 3.73 0.40 3.73 923.96 SA 105

4 Tail Pipe 13.90 x 2.20 0.40 2.20 478.36 SA 105

5 Union 33.40 x 6.25 0.96 6.25 585.64 SA 105

6 Expander 33.40 x 4.00 0.96 4.00 346.12 SA 105

7 Expander 21.30 x 3.73 0.61 3.73 540.08 SA 105

oC

Kg/cm2

Eqn.87


t = Min.Thickness in mm = Nom.Thickness - Neg. Tolerance

mm (for working pressure above 70 Kg/cm2)

Stress Value inKg/cm2

NegativeTolerance - %

SA 106 Gr.B

Sl.No.Pipe/Tube SizeDia x Thk (mmxmm)

t Req.(mm)

t Prov.(mm)

WorkingPress.Kg/

cm2

MaterialSpecification

SA 106 Gr.B


10/36

SHEET 10 OF 36

WATERWALL ASSEMBLY

STRENGTH CALCULATION FOR WATER WALL HEADER : IBR 270 & 342a

219.1 x 15.09 mm

Material Spec . =

2 x f x E (t-0.03)

WP = -------------------D + t - 0.03

WP x D

Hence, t = ------------------- + 0.032 x f e + WP

Where,

t =Min. thickness required in mm

WP = 75.00

D = 192.69 mm = 7.59 Inches

f =

1202.53

E =Least of the Ligament efficiency calculated

Longitudinal Ligament Efficiency:

Location / Title P1 P2 d E

1 Bet. WW Stubs 101.00 -- 42.88 0.58

2 Bet. WW Stubs 202.00 -- 42.88 0.79

3 Bet. Riser 850.00 -- 64.30 0.92

Circumferential Ligament Efficiency

Location / Title P1 d E E*

1 Bet. WW Stubs(42) 74.77 42.88 0.43 0.85

2 Bet. WW Stubs(83) 147.77 42.88 0.71 1.42

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)=

SA 106 Gr.B

Eqn.72

Working Press. In Kg/ cm2 = Kg/cm2

Internal dia. of pipe in mm =

Allow.Stress for material SA 106 Gr.B as per ASME

sec tion - II pa rt-D at metal working temp.318 C = Kg/cm2

S.No.

S.No.


11/36

SHEET 11 OF 36

Diagonal Ligament Efficiency.

Location / Title b a d E

1 71.21 101.00 42.88 0.71

2 160.22 101.00 53.59 0.91

3 Bet. WW Stub (41) 72.99 101.00 42.88 0.72

4 Bet. WW Stub (83) 147.77 101.00 42.88 0.93

5 160.22 101.00 91.32 0.70

6 Bet. WW Stub (180) 320.46 101.00 42.88 1.00

From Graph E Value can be Calculated

Where,

P/P1/P2 = Pitch of tube holes,mm d = Diameter of tube holes, mm

p' = Diagonal pitch of tube holes, mm E = Ligament Efficiency

Least of the Ligament Efficiency from the above calculations = 0.58

From the above calculations it is understood that the least value of Ligament Efficiency.

E = 0.58

75.00 x 7.59

t = -------------------------------- + 0.03

2 x 1202.5 x 0.58 + 75.00

= 0.42 Inches

=

= 0.4725 Inches

12.00 mm

Provided Thickness, t = 15.09 mm

Working Pressure calculation for provided thickness

t =Minimum thickness provided in mm

= 12.5 %)

=15.09 - 1.89

=13.20 mm = 0.52 Inches

D =

=219.1 - 2 x 13.20

=192.69 mm = 7.59 Inches

2 x 1202.5 x 0.58 x( 0.52 -0.03)

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

7.59 + 0.52 - 0.03

= 83.94 75.00

S.No.

Bet.WW Stubs (40)

Bet.Riser &WW Stub(90)

Bet. WW Stub & Header

(90)

Nom.Thickness + Neg.Tolerance (12.50%)

Min.Thickness Required ,t =

Nom.Thickness+Neg.Tolerance (

Max.Internal Diameter of pipe in mm

Kg/cm2> Kg/cm2


12/36

SHEET 12 OF 36

CONDITION FOR COMPENSATION FOR OPENINGS IN WW HEADER ( IBR 187 )

219.1 x 15.09 mm

Material Spec. = SA 106 Gr.B

P x D

K = ---------------

1.82 x f x e

Where,

P= 75.00

D =Outer diameter of the shell in mm = 219.1 mm

= 8.63 Inches

f =

1202.53

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

= 0.569

219.1 x 13.20

= 2892.94

88.9 mm

LIST OF OPENINGS IN WW HEADER

Header Size = 219.1 x 15.09 mm

Description Material

1 Stub SA 210 Gr.A1

2 Stub

3 Riser stub

88.9 mm


Header size(Dia x Thk) =

The maximum diameter of any unreinforced opening shall not exceed 'd' as shown in figs 9B &

9C subject to a maximum of 203 mm

Eqn.20

Max.Working Pressure in Kg/cm2 = Kg/cm2

Allow.Stress for material SA 106 Gr.B as per ASME section - II part-

D at metal working temp.318 C = Kg/cm2

Header DiaxThk =

mm2

Considering the a bove K value & Drum dia x Thickness value, from figure 9B & 9C,

Maximum size of an unreinforced opening should be =

S.No. Pipe / Tibe Size

51.00 x 4.06 thk

168.30 x 14.27 Thk SA 106 Gr.B

60.3 x 5.54 Thk SA 106 Gr.B

Note:Compensation is not required for the openings < dia.

i.e. Sl.Nos.1 & 3.


13/36

SHEET 13 OF 36

COMPENSATION CALCULATION FOR OPENINGS IN WW HEADER


ts = Actual Thickness of header (min)

es = Equivalent thickness of header

en = Equivalent thickness of stub

P = Working pressure of the boiler = 75.00

Y= Compensating area

=

for Nozzles without inside Projection,b2 = 0

D = Internal diameter = 192.69 mm = 7.59 Inches

E = Efficienc y of Ligament = 1

b1 = 2.5 x ts (or) 2.5 x tn (or) ac tual outside projection whichever is least

b2 = 2.5 x ts (or) 2.5 x tn (or) actual inside projection whichever is least

Ci2 = Actual available distance between compensating nozzles (or) Ci1 whichever is less

SL.NO STUB SIZE

2 168.3 x 14.27 5.64 0.49 0.52 0.28 0.21 1.23

SL.NO STUB SIZE COMPENSATION

2 168.3 x 14.27 0 3.52 2.82 1.56 2.42 Not Reqd.

If X < Y Compensation Pad is not Required

If X > Y Compensation Pad is Required



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



Kg/cm2

(2 x (tn - en) x b1 x fn/fs) + (2 x tn x b2 x fn/ fs) +( 2 x (ts - es)c i)

X = Sec tiona l area = dn x es

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

dn

inch

tn

inch

ts

inch

es

inch

en

inch

b1

Inch

b2

Inch

Ci1

Inch

Ci2

Inch

X

Sq.Inch

Y


14/36

SHEET 14 OF 36

STRENGTH CALCULATION FOR END PLATES [ IBR 340 (f) & 342 (b) ]

Metal working temperature = 318.00 C

Maximum working press. = 75.00

Description

Plate Thickness

KRequired in Provided i

1 End Plate 219.1 x 15.09 192.69 20.72 24 0.19 102.02

2 End Plate 114.3 x 8.56 99.32 11.16 14 0.19 122.68

Material Stress Value

1,2 SA 515 Gr.70 1360.6

f x ( t - c )

WP = ------------- Hence ,t = ---------------- + Cd x k f

Where,

WP =

f = Allow stress for material as per ASME sec tion - II Part - D at Metal working temp.

c = Corrosion Allowance in mm = 1

t =Thickness of plate in mm

d = Max. internal diameter in mmk =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)]

Remarks

1 116.3 24 129.85 Not Required

D =

Where,

D =

T =

Ref.Drg.No :

Kg/cm2

Sl.No.

Header / Pipe

Size in mm

Dia x thk

Max. IDin mm

Working Press.

In Kg/cm2

Sl.No

d2 x WP x K

Eqn.89(A)

Working Pressure in Kg/ cm2

S.No.Hole Dia. In

mm

Thick of Plate

in mm

Max. Dia of Hole in

mm

(21/2x T )+ 23/

4)

Max. dia. Of uncompensated hole in mm

Min. thickness of the endplate in inches


15/36

SHEET 15 OF 36

WATERWALL ASSEMBLY


219.1 x 18.26 mm

Material Spec. =

2 x f x E (t-0.03)

WP =-------------------D + t - 0.03

WP x D

Hence, t = ------------------- + 0.03

2 x f e + WPWhere,


WP = 75.00

D = 187.15 mm = 7.37 Inches

f =

1202.53




1 Bet. WW Stubs 101.00 -- 42.88 0.58

2 Bet. WW Stubs 202.00 -- 42.88 0.79

Diagonal Ligament Efficiency.


1 315.47 99.00 40.14 1.00


Ref.Drg.No : VWHA054-03-21-0-003 / 00.

Material size(Dia x Thk)=

SA 106 Gr.B

Eqn.72

Working Press. In Kg/cm2 = Kg/cm2


Allow.Stress for material SA 106 Gr.B as per ASME

section - II part-D at metal working temp.318 C = Kg/cm2

S.No.

S.No.

Bet. WW Stub & Drain

Stub (180)


16/36

SHEET 16 OF 36

Where,





E = 0.58

75.00 x 7.37

t = -------------------------------- + 0.03

2 x 1202.5 x 0.58 + 75.00

= 0.41 Inches

=

= 0.4598 Inches

11.68 mm

Provided Thickness, t = 18.26 mm



= 12.5 %)

=18.26 - 2.28

=15.98 mm = 0.63 Inches

D =

=219.1 - 2 x 15.98

=187.15 mm = 7.37 Inches

2 x 1202.5 x 0.58 x( 0.63 -0.03)

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

7.37 + 0.63 - 0.03

= 104.06 75.00


Min.Thickness Required,t =

Nom.Thickness+Neg.Tolerance (


Kg/cm2> Kg/cm2


17/36

SHEET 17 OF 36


Ref.Drg.No : VWHA054-03-21-0-003 / 00.

219.1 x 18.26 mm

Material Spec. = SA 106 Gr.B

P x D

K = ---------------

1.82 x f x e

Where,

P= 75.00D =Outer diameter of the shell in mm = 219.1 mm

= 8.63 Inches

f =

1202.53


75.00 x 8.63

K = -------------------------------

1.82 x 1202.5 x 0.63

= 0.470

219.1 x 15.98

= 3500.67

99.06 mm




1 Stub SA 210 Gr.A1

2 Stub

99.06 mm

Header size(Dia x Thk) =

The maximum diameter of any unreinforced opening shall not exceed 'd' as shown in figs 9B &

9C subject to a maximum of 203 mm

Eqn.20

Max.Working Pressure in Kg/cm2

= Kg/cm2

Allow.Stress for material SA 106 Gr.B as per ASME sec tion - II part-

D at metal working temp.318 C = Kg/cm2

Header DiaxThk =

mm2

Considering the above K value & Drum dia x Thickness value, from figure 9B & 9C,



51.00 x 4.06 thk

219.10 x 18.26 Thk SA 106 Gr.B

Note:Compensation is not required for the openings < dia.

i.e. Sl.Nos.1


18/36

SHEET 18 OF 36


Ref.Drg.No : VWHA054-03-21-0-003 / 00.







=

for Nozzles without inside Projection,b2 = 0

D = Internal diameter = 187.15 mm = 7.37 Inches

E = Efficiency of Ligament = 1

b1 = 2.5 x ts (or) 2.5 x tn (or) ac tual outside projection whichever is least

b2 = 2.5 x ts (or) 2.5 x tn (or) ac tual inside projection whichever is least

Ci2 = Actual available distance between compensating nozzles (or) Ci1 whichever is less

SL.NO STUB SIZE

2 219.1 x 18.26 7.37 0.63 0.63 0.27 0.27 1.57


2 219.1 x 18.26 0 3.68 3.63 1.98 3.79 Not Reqd.







Kg/cm2

(2 x (tn - en) x b1 x fn/ fs) + (2 x tn x b2 x fn/fs) +( 2 x (ts - es)ci)

X = Sec tional area = dn x es


es = (PxD / (2 x fs x E - P)) + 0.03

en = (PxD / (2 x fn x E - P)) + 0.03

dn

inch

tn

inch

ts

inch

es

inch

en

inch

b1

Inch

b2

Inch

Ci1

Inch

Ci2

Inch

X

Sq.Inch

Y


19/36

SHEET 19 OF 36


Metal working temperature = 318.00 C

Maximum working press. = 75.00

DescriptionPlate Thickness

KRequired in Provided i

1 End Plate 219.1 x 18.26 187.15 20.15 24 0.19 108.16

2 End Plate 114.3 x 8.56 99.32 11.16 14 0.19 122.68

2 End Plate 88.9 x 7.62 75.57 8.73 10 0.19 101.58


1,2 & 3 SA 515 Gr.70 1360.6

f x ( t - c )

WP = ------------- Hence ,t = ---------------- + Cd x k f

Where,

WP =

f = Allow stress for material as per ASME sec tion - II Part - D at Metal working temp.

c = Corrosion Allowance in mm = 1


d = Max. internal diameter in mm

k =0.19 for ends Integral with or flanged & butt welded and




Remarks

1 116.3 24 129.85 Not Required

D =

Where,

D =

T =

Ref.Drg.No :

Kg/cm2

Sl.No.

Header / Pipe

Size in mm

Dia x thk

Max. IDin mm

Working Press.

In Kg/cm2

Sl.No

d2 x WP x K

Eqn.89(A)

Working Pressure in Kg/cm2

S.No.

Hole Dia. In

mm

Thick of Plate

in mm

Max. Dia of Hole in

mm

(21/2x T )+ 23/

4)




20/36

SHEET 20 OF 36

WATERWALL HEADER


168.3 x 14.27 mm

Material Spec. =

2 x f x E (t-0.03)

WP = -------------------D + t - 0.03

WP x D

Henc t = ----------------- + 0.03

2 x f e + WP

Where,


WP = 75.00

D = 143.3275 mm = 5.64 Inches

f = 1202.53




1 Bet. WW Stubs 101.00 -- 42.88 0.575

2 850.00 -- 64.30 0.92

Ref.Drg.No:VWHA054-03-21-0-004/00,VWHA054-03-21-0-005/00,VWHA054-03-21-1-006/00.

Matl. size(DiaxThk)=

SA 106 Gr.B

Eqn.72

Working Press. In Kg/cm2 = Kg/cm2


Allow.Stress for material SA 106 Gr.B as per ASME sec tion

- II part-D at metal working temp.318 C = Kg/cm2

S.No.

Bet.Riser Stubs


21/36

SHEET 21 OF 36

CIRCUMFERENTIAL LIGAMENT EFFICIENY:


1 Bet. WW Stubs(45) 60.49 42.88 0.29 0.58

2 241.95 53.59 0.78 1.56

Diagonal Ligament Efficiency. (Equal Pitch)


1 Bet. WW Stubs 60.49 101.00 42.88 0.68

2 225.82 21.00 53.59 1

3 226.89 50.50 53.59 1


Where,





E = 0.58

75.00 x 5.64

t = --------------------------------------- + 0.03

2 x 1202.5 x 0.575 + 75.00

= 0.320 Inches

=

= 0.36 Inches

9.15 mm

Provided Thickness t = 14.27 mm

S.No.

Bet. WW Stub & Riser

Stub(180)

S.No.

Bet. Riser Stub&ww Stub(168)

Bet. Riser Stub & ww

Stub(168.8)


Min.Thickness Required t =


22/36

SHEET 22 OF 36



= 12.5 %)

=14.27 - 1.78

=12.49 mm = 0.49 Inches

D =

= 143.33 - 2 x 12.49

=143.33 mm = 5.64 Inches

2 x 1202.5 x 0.58 x( 0.49 -0.03)

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

5.64 + 0.49 - 0.03

=104.65 75.00

Nom. Thickness - Neg. Tolerance (


Kg/cm2 > Kg/cm2


23/36

SHEET 23 OF 36



168.3 x 14.27 mmMaterial Spec. =

P x D

K = ------------

1.82 x f x e

Where,

P= 75.00

D =Outer diameter of the shell in mm = 168.3

= 6.63 Inches

f =

1202.53

e =Actual Thickness of Shell = 12.49 mm = 0.49 Inches

75.00 x 6.63

K = ----------------------------

1.82 x 1202.53 x 0.49

= 0.462

168.3 x 12.49

= 2101.4

83.82 mm




1 Stub SA 210 Gr.A1

2 Riser Stub

3 Top Header

83.82

Header size(Dia x Thk) =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

Eqn.20

Max.Working Pressure in Kg/cm2 =


- II part-D at metal working temp.318 C = Kg/cm2

Header DiaxThk =

mm2




51.00 x 4.06 thk

60.3 x 5.54 Thk SA 106 Gr.B

168.3 x 14.27 Thk SA 106 Gr.B

Note:Compensation is not required for the openings


24/36

SHEET 24 OF 36









=

for Nozzles without inside Projection, b2 = 0

139.76 mm = 5.50 Inches

E = Efficiency of Ligament = 1

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

SL.NO STUB SIZE

3 168.3 x 14.27 5.64 0.49 0.49 0.21 0.03 1.23


3 168.3 x 14.27 0 3.49 1.19 3.09 Not Required







Kg/cm2

(2 x (tn - en) x b1 x fn/ fs) + (2 x tn x b2 x fn/fs) +( 2 x (ts - es)ci)


D = Internal dia. =


es = (PxD / (2 x fs x E - P)) + 0.03

en = (PxD / (2 x fn x E - P)) + 0.03

dn tninch

tsinch

esinch

eninch

b1

b2Inch

CiSq.Inch

XSq.Inch

YSq.Inc


25/36

SHEET 25 OF 36



Metal working temp. = 318 C

Max. working press. = 75.00

Description

Plate Thickness

K

1 End Plate 168.30 x 14.27 146.895 16.03 20 0.19 119.80

2 End Plate 88.9 x 7.62 77.47 8.93 10 0.19 96.65


1,2 SA 515 Gr.70 1360.6

f x ( t - c )

WP = -------------- Hence, t = ----------------- + Cd x k f

Where,

WP =

f =Allow stress for material as per ASME sec tion - II Part - D at Metal working temp

c =Corrosion Allowance in mm = 1


d = Max. internal diameter in mm

k =0.19 for ends Integral with or flanged & butt welded and




Remarks

1 91 20 119.85 Not Required

D =

Where,

D =

T =

Kg/cm2

Sl.No.

Header / Pipe Size

in mmDia x thk

Max. ID inmm

Working

Press. InKg/cm2

Reqd. inmm

Providedin mm

Sl.No

d2 x WP x K

Eqn.89(A)

Working Pressure in Kg/cm2

S.No.

Hole Dia. In

mm

Thick of Plate in

mm

Max. Dia of Hole in

mm

(21/2x T )+ 23/

4




26/36

SHEET 26 OF 36

Strength Calculation for Tubes/Integral Pipes (IBR 338)

Metal working Temperature : 318

Max. working Pressure : 75.00

2 x f x ( t - c ) WP x D

WP = ---------------- t = ---------- + CD - t + c 2f + WP

Where,




Material

SA 210 Gr.A1 1202.53 0.00

1202.53 12.50

Description

1 WW Tubes 51.00 x 4.06 1.54 4.06 208.02 SA 210 Gr.A1

2 Riser Stub 60.30 x 5.54 2.05 5.54 210.243 Headers 168.30 x 14.27 5.73 14.27 192.73

3 Headers 219.10 x 15.09 7.45 15.09 154.23

4 Hand Hole Pipe 114.30 x 8.56 3.89 8.56 168.65

5 Hand Hole Pipe 88.90 x 7.62 3.02 7.62 195.00

6 Drain Pipe 33.40 x 3.38 1.14 3.38 233.65

7 Drain Stubs 33.40 x 6.35 1.14 6.35 479.93

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.

oC

Kg/cm2

Eqn.87


t = Min.Thickness in mm = Nom.Thickness - Neg. Toleran

mm (for working pressure below 70 Kg/cm2)

Stress Value in

Kg/cm2

Negative Tolerance

- %

SA 106 Gr.B

Sl.

No.

Pipe/Tube SizeDia x Thk

(mmxmm)

t Req.

(mm)

t Prov.

(mm)

Working

Press.Kg/cm2

Material

Specification

SA 106 Gr.BSA 106 Gr.B

SA 106 Gr.B

SA 106 Gr.B

SA 106 Gr.B

SA 106 Gr.B

SA 106 Gr.B


27/36

SHEET 27 OF 36

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

63.5 x 6.35 mm

Material Spec. = BS 3059 P2 Gr. 360

2 x f x E (t-0.03)

WP = -------------------------D + t - 0.03

WP x D

Hence, t = --------------------- + 0.032 x f x E + WP

Where,


WP = 75.00

D = Internal diameter of pipe in m 52.3875 mm = 2.06 Inches

f =

934

E =



1 Bet. WW Stubs 101.00 -- 42.88 0.575

Where,

P/P1/P2 = Pitch of tube holes,m d = Diameter of tube holes, mm

E = Ligament Efficiency

Least of the Ligament Efficiency from the above calculati 0.575

From the above calculations it is understood that the least value of Ligament Efficienc

E= 0.575

75.00 x 2.06

t = ------------------------------------ + 0.03

2 x 934 x 0.575 + 75.00

= 0.16 Inches

=

= 0.19 Inches

4.70 mm

Provided Thickness, t 6.35 mm

Ref.Drg.No : VWHA054-03-21-3-010 / 00

Matl.size(DiaxThk)=

Eqn.72


Allow.Stress for material BS 3059 P2 Gr. 360 as per

ASME sec tion - II part-D at metal working temp.

318 C =

Kg/cm2

Least of te Ligament efficiency calculated

S.No.


Min.Thickness Required ,t


28/36

SHEET 28 OF 36



= 12.5 %)

=6.35 - 0.79= 5.56 mm = 0.22 Inches

D =

= 52.39 - 2 x 5.56

=52.39 mm = 2.06 Inches

2 x 934 x 0.58 x( 0.22 - 0.03 )

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

2.06 + 0.22 - 0.03

= 90.12 75.00

Nom.Thickness+Neg.Toleranc


Kg/cm2 > Kg/cm2


29/36

SHEET 29 OF 36

CONDITION FOR COMPENSATION FOR OPENINGS IN WW MAN HOLE ( IBR 187 )

Ref.Drg.No : VWHA054-03-21-3-010 / 00

63.5 x 6.35 mm

Material Spec. = BS 3059 P2 Gr. 36

P x D

K = ---------------

1.82 x f x e

Where,

P= 75.00

D =Outer diameter of the shell in mm = 63.5

= 2.50 Inches

f =

934

e = Ac tual Thickness of Shell = 5.56 mm = 0.22 Inc hes

75.00 x 2.50

K = -------------------------------1.82 x 934 x 0.22

= 0.504

63.5 x 5.56

= 352.82

48.26 mm




1 Tube BS 3059 P2 Gr. 360

2 WW Tube SA 210 Gr.A1

48.26 mm

Header size(Dia) =

The maximum diameter of any unreinforced opening shall not exceed 'd' as shownin figs 9B & 9C subject to a maximum of 203 mm

Eqn.20

Max.Working Pressure in Kg/cm2 = Kg/cm2

Allow.Stress for material BS 3059 P2 Gr. 360 as per ASME

sec tion - II part-D at metal working temp. 318 C = Kg/c m2

Header DiaxThk =

mm2


Maximum size of an unreinforced opening should be


63.50 x 6.35 thk

51.00 x 4.06 thk

Note:Compensation is not required for the openings Y Compensation Pad is Required





Kg/cm2

(2 x (tn - en) x b1 x fn/fs) + (2 x tn x b2 x fn/ fs) +( 2 x (ts - es)ci)



es = (PxD / (2 x fs x E - P)) + 0.03

en = (PxD / (2 x fn x E - P)) + 0.03

dn tn

inch

ts es

inch

en

inch

b1Inch

b2Inch

Ci1 XSq.Inch

Y


31/36

SHEET 31 OF 36

Strength Calculation for Tubes/Integral Pipes (IBR 338)

Ref.Drg.No : VWHA054-03-21-3-010 / 00

Metal working Temp : 318

Max. working Press : 75

f x ( t - c ) WP x D

WP = ---------------- t = ---------- + CD - t - c 2f + WP

Where,



c = Corrosion a llowance= 0.00

Material

SA 210 Gr.A1 1202.53 0.00

SA 105 1272 0.00

BS 3059 P2 Gr. 360 934 12.50

Description

1 Stub 51.00 x 4.06 1.54 4.06 208.02 SA 210 Gr.A1

2 Reducer LD 63.50 x 6.35 1.82 6.35 282.67 SA 105

3 Reducer SD 51.00 x 4.06 1.46 4.06 220.04 SA 105

4 Header Stub 63.50 x 6.35 2.76 6.35 179.12 BS 3059 P2 Gr. 360

oC

Kg/cm2

Eqn.87

WP = Working Pressure in Kg/ cm2

t = Min.Thickness in mm = Nom.Thickness - Neg. Tolerance

mm (for working pressure below 70 Kg/ cm2)

Stress Value in Kg/cm2 Neg.Tolerance - %

Sl.No.

Pipe/Tube Size

Dia x

Thk (mmxmm)

t Req.

(mm)

t Prov.

(mm)

Working

Press.

Kg/cm2

Material

Specification


32/36

SHEET 32 OF 36

EVAPORATOR - I & II

STRENGTH CALCULATION FOR INLET/OUTLET HEADER : IBR 270 & 342a

219.1 x 18.26 mm

Material Spec . =

2 x f x E (t-0.03)

WP = ---------------D + t - 0.03

WP x D

Hence t = ---------------- + 0.032 x f e + WP

Where,

t =Min. thickness required in mmWP = 75.00

D =Internal diameter of pipe in mm = 182.6 mm = 7.19 Inches

f =

1202.53




1 Bet. Evaporator Coils 101.00 -- 36.38 0.64

2 Bet. Evaporator Coils 89.00 -- 36.38 0.59

3 250.00 -- 55.02 0.77

4 522.00 -- 55.02 0.89

Circumferential Ligament Efficiency


1 52.57 36.38 0.31 0.62

2 78.87 36.38 0.54 1.08

3 157.74 55.53 0.65 1.30

Diagonal Ligament Efficiency. (Equal Pitch)


1 Bet. Stub & Drain Stub 157.74 250.00 36.89 0.91

2 Bet. Coils (30 Deg) 52.27 89.00 36.38 0.69

3 Bet. Coils (45 Deg) 78.87 101.00 36.38 0.78

4 78.87 250.00 55.02 0.80


Ref.Drg.No : VWHA054-34-02-0-001 / 00 & VWHA054-34-02-1-002 / 00

Material size(Dia)=

SA 106 Gr.B

Eqn.72



- II part-D at metal working temp. 290 C = Kg/cm2

S.No.

Bet.Inlet Stub & stub

Bet.Inlet Stub & Stub

S.No.

Bet.Stubs (30 Deg)

Bet.Stubs (45 Deg)

Bet.Inlet & Drain Stub

S.No.

Bet.Inlet Stub & stub(45)


33/36

SHEET 33 OF 36

Where,


p' = Diagonal pitch of tube holes, m E = Ligament Efficiency


E = 0.60

75 x 7.19

t = ----------------------------- + 0.032 x 1202.53 x 0.6 + 75

= 0.39 Inches

=

= 0.43 Inches

11.01 mm

Provided Thickness t = 18.26 mm



= 12.5 %)

=18.26 - 2.2825

=15.98 mm = 0.63 Inches

D =

=219.1 - 2 x 15.97

= 187.15 mm = 7.37 Inches

2 x 1202.53 x 0.6 x (0.63 - 0.03)

WP = -------------------------------------7.37 + 0.63 - 0.03

= 108.64 75.00

*E = Eqvt.Longitudina l Ligament Eff. Due to Circumferential Ligament Eff. As per Reg. 215,

= 2 x Circ.Ligament Efficienc y.

From the above calculations it is understood that the least value of Ligament

Effic iency.


Min.Thickness Required t =

Nom.Thick- Neg.Tolerance (


Kg/cm2 > Kg/cm2


34/36

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

219.1 x 18.26 mm

Material Spec . =

P x D

K = ---------------

1.82 x f x e

Where,

P= 75.00

D =Outer diameter of the shell in mm= 219.1

= 8.63 Inches

f =

1202.53


75 x 8.63

K = -----------------------1.82 x 1202.53 x 0.63

= 0.469

219.1 x 15.98

= 3500.67

99.02 mm

LIST OF OPENINGS IN INLET/OUTLET HEADER



1 Tubes 44.50 x 4.06 SA210Gr.A1

2 O/L Stub 88.90 x 7.62

3 Drain Stub 33.40 x 6.35

4 I/L Stub 88.90 x 7.62

99.02 mm

Header size(Dia) =

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

Eqn.20

Max.Working Pressure in Kg/cm2 =

Allow.Stress for material SA 106 Gr.B as per ASME sec tion - II

part-D at metal working temp. 290 C = Kg/cm2

Header Dia x Thk =

mm2




SA 106 Gr.B

SA 106 Gr.B

SA 106 Gr.B

Note:Compensation is not required for the openings

Date post:	14-Apr-2018
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Steam Drum, Water Wall & Evaporator - VWHA054

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