12525-2500116-0 - Strength Calculation For Superheater 3 Unit I

G.B. ENGINEERING ENTERPRISES PVT. LTD.
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: 0
TIRUCHIRAPPALLI
DATE
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Doc.No : 12525-2500116
PAGE : 1 of 9
BOILER MAKER'S NO. : GB - 101

Strength Calculation for
SUPER HEATER 3
DESIGN DATA
S.No
Design Code
Description
Design Pressure
bar(g)
Hydrotest pressure
bar(g)
Design Temperature
C
SH-3 Main Inlet Header
160
240
428
SH-3 Inlet Connection Pipe
160
240
428
SH-3 Intermediate Inlet Header
160
240
428
160
240
428
159
240
473+50
3
4
5
SH-3 Inlet Connection Tube

IBR 1950 With Latest
SH 3 Tubes
Amendments
SH-3 Outlet Connection Tube
159
240
479
SH-3 Intermediate Outlet Header
159
240
479
SH-3 Outlet Connection Pipe
159
240
479
SH-3 Main Outlet Header
159
240
472
6
7
REV.
TIRUCHIRAPPALLI
DATE
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Doc.No : 12525-2500116
PAGE :
2 of 9
HEADER THICKNESS CALCULATION : Reg 342(a) and Reg 270
WP x D
T =
---------------
+ 0.762
mm
-------------- Eqn (72)
2 f E - WP
Where ,
WP =
Design Pressure of Header in bar (g)
Max. Internal diameter in mm
Permissible Working stress at the working metal temp in MPa ( As per ASME Sec. II Part-D [Metric] )
Required thickness to be calculated in mm
Ligament Efficiency
Super Heater 3 Drawings

1
2
3
4
5
6
Super Heater-3 Assembly

Arrangement and Details of SH-3 Main Inlet Header.
Arrangement and Details of SH-3 Intermediate Inlet Header.
Arrangement and Details of SH 3 Inlet and Outlet Coils
Details of SH 3 Inlet and Outlet Coils
Arrangement and Details of SH-3 Intermediate Outlet Header.
Arrangement and Details of SH-3 Main Outlet Header.
Size
Sl.
No.
Drawing. No.
DU No.
Part
No.
OD
Nom. Thk. Min.Thk *
mm
mm
mm
mm
Material
Specification
12525 01 01339
12525 01 01337
12525 01 01341
12525 01 01344
12525 01 01345
12525 01 01350
12525 01 01351
Design
Design
Temp.
Pr. (WP)
bar (g)
Stress
Value
(f)
MPa
Ligament
Efficiency
E **
Reqd.
Thk. (T)
mm
Provided
Minimum
Thk.
mm
12525 01 01337
10-4440-001,
10-4440-002
01
323.9
265.6
33.32
29.16
SA-335 Gr.P22
428
160.0
114.0
0.82
25.5
29.16
12525 01 01341
10-4440-004
01
141.3
108.0
19.05
16.67
SA-335 Gr.P22
428
160.0
114.0
0.81
11.0
16.67
12525 01 01350
10-4440-006
01
141.3
108.0
19.05
16.67
SA-335 Gr.P22
479
159.0
96.9
0.81
13.0
16.67
12525 01 01351
10-4440-008,
10-4440-009
01
323.9
262.7
35.0
30.63
SA-335 Gr.P22
472
159.0
101.7
0.82
28.4
30.63
PROVIDED THK > REQUIRED THK.

HENCE SAFE.
* Min. Thk. = Nom.Thk - Mill Negative Tolerance

** Least Value of Ligament efficiency (Ref. Page 3 of this Calculation)
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TIRUCHIRAPPALLI
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PAGE : 3 of 9
Doc.No : 12525-2500116
CALCULATION OF LIGAMANT EFFICIENCY FOR HEADER : IBR Reg.215
Long. Efficiency
SL.
No.
Drawing No.
DU No.
P. No.
02
Diagonal Efficiency
Cir.Efficiency
Hole
dia or
mean
dia (d)
Pitch
(Least
Value)
P
E1=
(P-d)/P
Angle
108.0
608
0.82
Hole
dia or
mean
dia (d)
Circ.
Pitch
Pc
E2 =
2(Pc-d)/Pc
Long.
Pitcha
Hole
dia or
mean
dia (d)
Angle
Governing
efficiency Lower
Value of E1, E2,
E3
Cos
Sin
E3
0.82
12525 01 01337
10-4440-001,
10-4440-002
02, 03
280
88.7
39.18
228.2
0.78
0.63
1.06
0.53
0.32
0.82
0.82
12525 01 01341
10-4440-004
02, 04
34.6
180
0.81
60
34.6
58
96.0
0.53
0.85
0.92
0.60
0.32
0.89
0.81
12525 01 01350
10-4440-006
02, 04
34.0
180
0.81
60
34.0
58
96.0
0.53
0.85
0.92
0.60
0.32
0.90
0.81
12525 01 01351
10-4440-008,
10-4440-009
02
108.0
608
0.82
0.82
02, 03
135
85.1
340.35
1.5
1.50
REV.
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TIRUCHIRAPPALLI
DATE
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Doc.No : 12525-2500116
PAGE : 4 of 9
MAXIMUM UNCOMPENSATED HOLES IN HEADER: IBR Reg.187

D
P
T
f
e
=
=
=
=
=
Outside diameter of Header in mm

Working Pressure in bar (g)
Working Metal Temperature in C
Allowable Stress at Working Metal Temp. in MPa ( As per ASME Sec. II Part-D [Metric] )
Actual thickness of the Header in mm
Refer graph value (Fig 9b)

K
PxD
-----------------1.82 x f x e
------- Eqn. (20)
LIST OF HOLES IN HEADER
Sl.
No.
1
DRAWING. NO.
DU No.
Part
No.
OD
Thk. e
Work.
Pr.
P
mm
mm
bar (g)
MPa
323.9
29.2
160
428
Work.
Temp.
o
Stress
value
'f'
Dia.(OD)
x Thk.
114.0
0.86
Hole ID
Graph
value
mm
mm
mm
9443.3
108.0
89
Required
Compensation
Check
12525 01 01337
10-4440-001,
10-4440-002
02
03
323.9
29.2
160
428
114.0
0.86
9443.3
69.4
89
Not Required
12525 01 01341
10-4440-004
02,04
141.3
16.7
160
428
114.0
0.65
2355.3
34.6
76
Not Required
12525 01 01350
10-4440-006
02,04
141.3
16.7
159
479
96.9
0.76
2355.3
34.0
67
Not Required
10-4440-008,
10-4440-009
02
323.9
30.6
159
472
101.7
0.91
9919.4
108.0
76
Required
03
323.9
30.6
159
472
101.7
0.91
9919.4
62.2
76
Not Required
12525 01 01351
Note :
Refer Compensation calculation in Page 6 of this calculation.
REV.
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TIRUCHIRAPPALLI
DATE
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Doc.No : 12525-2500116
PAGE : 5 of 9
STUB THICKNESS CALCULATION : IBR Reg.156 & Reg.338(a)

WP x D
T = --------------- + C ------------------ Eqn. (87)
2f + WP
where,
WP =
D =
f
=
T
=
C =
Design Pressure in bar (g)

External dia of stub in mm
Permissible stress for the mtrl. at the design temp in MPa ( As per ASME Sec. II Part-D [Metric] )
Required thk. of stub to be calculated in mm
0 mm , for design pressure > 70 kg/cm2
MINIMUM THICKNESS OF BRANCH : IBR Reg.156(c)

tmin
0.015 do + 3.2
mm
where, do = the outside diameter of the branch (in mm.)
LIST OF BRANCH STUB

Size
Sl.
No.
Drawing. No.
1
12525 01 01337
2
3
12525 01 01351
4
DU No.
10-4440-001,
10-4440-002
10-4440-008,
10-4440-009
Part
No.
D (do)
Nom.Thk
Material
Specification
Design
Temp.
o
Design
Pressure
Stress
Value (f)
Reqd. Thk.
as per
Min.Reqd.
Thk. as
per
Reg.338(a)
Reg.156(c)
Provided
Minimum
Thk. *
bar (g)
MPa
"T" mm
mm
mm
SA-335 Gr.P22
428
160.0
114.0
9.27
5.32
16.67
11.13
SA-335 Gr.P22
428
160.0
114.0
5.83
4.53
9.74
141.3
19.05
SA-335 Gr.P22
472
159.0
101.7
10.24
5.32
16.67
88.9
15.24
SA-335 Gr.P22
472
159.0
101.7
6.45
4.53
13.34
mm
mm
02
141.3
19.05
03
88.9
02
03
PROVIDED THICKNESS > REQUIRED THICKNESS.
HENCE SAFE.
* Provided Minimum Thk. = Nom.Thk - Mill Negative Tolerance
LIST OF BRANCH TUBE

Size
Sl.
No.
Drawing. No.
DU No.
Part
No.
D (do)
Min.Thk
mm
mm
Material
Specification
Design
Temp.
o
Design
Pressure
Stress
Value (f)
bar (g)
MPa
Reqd. Thk.
as per
Min.Reqd.
Thk. as
per
Reg.338(a)
Reg.338(b)
mm
mm
mm
Provided
Minimum
Thk.
12525 01 01341
10-4440-004
02, 04
42.2
3.8
SA-213 Gr.T22
428
160.0
114.0
2.77
3.25
3.8
12525 01 01350
10-4440-006
02, 04
42.2
4.19
SA-213 Gr.T22
479
159.0
96.9
3.21
3.25
4.19
PROVIDED THICKNESS > CALCULATED THICKNESS & MIN. REQD.THK. AS PER CODE.
HENCE SAFE.
REV.
: 0
TIRUCHIRAPPALLI
DATE
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Doc.No : 12525-2500116
PAGE : 6 of 9
COMPENSATION CALCULATION FOR HEADER STUB OPENINGS : IBR Reg.279

dn
ts
tn
en
es
fn
fs
=
=
=
=
=
=
=
Inside dia of Nozzle/Stub

Actual thickness of Header
Actual thickness of Nozzle/Stub
Equivalent thickness of Nozzle/Stub
Equivalent thickness of Unpierced Header
Nozzle/Stub Allowable Stress
Header Allowable stress
Smaller of values = 2.5ts or 2.5tn
bi
Nozzle/Stub projection inside.
Ci
(ts + 76) or (dn/2), whichever is greater
Cw
Fillet weld area

Area Removed X
= dn x es
Available Compensation Area Y
P.No./
Mark
No.
Material
Specn.
12525 01 01337
03
12525 01 01351
03
Sl.
No.
Drawing. No.
= [ 2 (tn-en) b x (fn/fs) ] + [ 2 (ts - es ) Ci ] + [ 2tn x bi x fn/fs ] + CW
dn
ts
tn
en
es*
fn
fs
bi
Ci
Cw
Y
2
mm
mm
mm
mm
MPa
MPa
mm
mm
mm
mm
mm
SA-335 Gr.P22
108
29.2
16.7
9.27
20.8
114.0
114.0
42
105.2
363
2247.1
2735.7
ADEQUATE
SA-335 Gr.P22
108
30.6
16.7
10.24
23.0
101.7
101.7
42
106.6
363
2487.7
2516.9
ADEQUATE
Available Compensation Area Y > Area Removed X

Hence Adequate.
Min. Thickness of Unpierced Header (where E=1)

WP x D
es* =
Y>X
mm2
mm
---------------
+ 0.762
mm
-------------- Eqn (72)
2 f E - WP
Where ,
WP =
Design Pressure of Header in bar (g)
Max. Internal diameter in mm
Permissible Working stress at the working metal temp in MPa ( As per ASME Sec. II Part-D )
REV.
: 0
TIRUCHIRAPPALLI
DATE
: 08-06-2011
Doc.No : 12525-2500116
PAGE : 7 of 9
HEADER END CAP THICKNESS CALCULATION : IBR Reg.278

WP x D x K
T
------------------
+C
mm
2f
where ,
WP =
Working Pressure of Header Endcap in bar (g)
Outside dia of Endcap in mm
Permissible stress for the mtrl. at the working metal temp in MPa ( As per ASME Sec. II Part-D [Metric] )
Required thk. to be calculated in mm
Diameter of opening in mm
Height of the Head measured on its outside surface from the junction of the dished part with cylindrical shell in mm
Shape Factor (from IBR Fig.23D)
H/D
Depth Ratio
0.75
0 mm
mm
Size
Sl.
No.
Drawing. No.
DU No.
Part
No.
mm
Nom
Thk.
Mm
mm
H/D
K**
Material
Specification
Design
Design
Pr. (WP)
Temp.
bar (g)
Provided
Reqd.
Thk. (T)
mm
Minimum Thk. *
Stress
Value
(f)
MPa
mm
12525 01 01337
10-4440-001,
10-4440-002
04
323.9
33.32
81.0
0.25
1.05
SA-234 Gr.WP22
160
428
114.0
24.6
29.2
12525 01 01341
10-4440-004
03
141.3
15.88
35.3
0.25
1.05
SA-234 Gr.WP22
160
428
114.0
11.2
13.9
12525 01 01350
10-4440-006
03
141.3
15.88
35.3
0.25
1.05
SA-234 Gr.WP22
159
479
96.9
12.9
13.9
12525 01 01351
10-4440-008,
10-4440-009
04
323.9
33.32
81.0
0.25
1.05
SA-234 Gr.WP22
159
472
101.7
27.3
30.6

HENCE SATISFACTORY.
**Shape Factor K (Curve for plain drum head) according to IBR reg.277(d) and Fig.23D
REV.
: 0
TIRUCHIRAPPALLI
DATE
: 08-06-2011
Doc.No : 12525-2500116
PAGE :
8 of 9
COIL TUBE THICKNESS CALCULATION : IBR Reg.156 & Reg.338(a)

WP x D
T = ---------------- + C ------------------ Eqn. (87)
2f + WP
where,
WP =
D
=
f
=
T
=
C
=

Outer dia of tube in mm
Permissible stress for the mtrl. at the design temp in MPa ( As per ASME Sec. II Part-D [Metric] )
Required thk. of tubes to be calculated in mm
0 mm , for design pressure > 70 kg/cm2
Description
Design Temp.
C
Design Pr.
bar(g)
Material Specification
Stress Value (f)

MPa
523
159.0
SA-213 Gr.T91
117.7
SH 3 Outlet Coils
LIST OF TUBES
Size
Sl.
No.
Drawing. No.
Description
Part No.
Material
Specification
Design
Temp.
Reqd. Thk.
Min.Reqd.
as per
Thk. as per
Reg.338(a)
Design
Pressure
Stress
Value (f)
Minimum
Provided Thk.
Reg. 338(b)
bar (g)
MPa
mm
mm
mm
D (do)
Thk
mm
mm
42.2
3.81
SA-213 Gr.T91
463
159.0
137.4
2.31
3.25
3.81
42.2
3.81
SA-213 Gr.T91
523
159.0
117.7
2.67
3.25
3.81
42.2
3.81
SA-213 Gr.T91
463
159.0
137.4
2.31
3.25
3.81
42.2
3.81
SA-213 Gr.T91
523
159.0
117.7
2.67
3.25
3.81
42.2
3.81
SA-213 Gr.T91
523
159.0
117.7
2.67
3.25
3.81
42.2
3.81
SA-213 Gr.T91
463
159.0
137.4
2.31
3.25
3.81
42.2
3.81
SA-213 Gr.T91
523
159.0
117.7
2.67
3.25
3.81
For DU No. : 10-440-005

1
VAR-I to VARIV : Tubes
02 & 03
3
VAR-VII : Tubes 02 to 04
4
5
VAR-III :Tubes
04
VAR-V, VAR-VI,
VAR-VIII to
VAR-XII
02 to 04
VAR-I to VARXII : Inlet Conn.

Tube
01
42.2
3.8
SA-213 Gr.T22
428
160.0
114.0
2.77
3.25
3.80
VAR-I to VARII: Outlet Conn.

Tube
04
42.4
4.19
SA-213 Gr.T22
479
159.0
96.9
3.21
3.25
4.19
10
VAR III & IV :

Outlet Coils
42.4
4.19
SA-213 Gr.T22
479
159.0
96.9
3.21
3.25
4.19
11
VAR-VII :
Tubes
05
42.4
4.19
SA-213 Gr.T22
479
159.0
96.9
3.21
3.25
4.19
12
VAR-V, VAR-VI,
VAR-VIII to
VAR-XII : Outlet
Conn. Tube
05
42.4
4.19
SA-213 Gr.T22
479
159.0
96.9
3.21
3.25
4.19
12525 01 01344,
12525 01 01345
PROVIDED THICKNESS > CALCULATED THICKNESS & MIN. REQD.THK. AS PER CODE.
HENCE SAFE.
REV.
: 0
TIRUCHIRAPPALLI
DATE
: 08-06-2011
Doc.No : 12525-2500116
PAGE : 9 of 9
CONNECTION PIPE & FITTINGS THICKNESS CALCULATION : IBR Reg.338(a)

WP x D
T = --------------- + C ------------------ Eqn. (87)
2f + WP
where,
WP =
D
=
f
=
T
=
C
=

External dia of Pipe/Fitting in mm
Permissible stress for the mtrl. at the design temp in MPa ( As per ASME Sec. II Part-D )
Minimum thk. of Pipe/Fitting to be calculated in mm
0 mm , for design pressure > 70 kg/cm
MINIMUM THICKNESS OF BRANCH : IBR Reg.156(c)

tmin
0.015 do + 3.2
mm
where, do = the outside diameter of the branch (in mm.)
Size
Sl.
No.
Drawing. No.
DU No.
Part No.
D (do)
Nom.Thk
mm
mm
Material
Specification
Design
Temp.
o
Reqd. Thk. Reqd. Thk.

as per
as per
Provided
Minimum
Thk. *
Design
Pressure
Stress
Value (f)
Reg.338(a)
Reg.156(c)
bar (g)
MPa
T mm
mm
mm
10-4440-003
03
141.3
15.88
SA-335 Gr.P22
428
160.0
114.0
9.27
5.32
13.90
10-4440-007
08
141.3
15.88
SA-335 Gr.P22
479
159.0
101.7
10.24
5.32
13.90
10-4440-010
11
88.9
11.13
SA-335 Gr.P22
428
160.0
114.0
5.83
4.53
9.74
10-4440-011
13
88.9
11.13
SA-335 Gr.P22
472
159.0
101.7
6.45
4.53
9.74
10-4440-003
04
141.3
15.88
SA-234 Gr.WP22
428
160.0
114.0
9.27
5.32
13.90
10-4440-007
141.3
15.88
SA-234 Gr.WP22
479
159.0
96.9
10.71
5.32
13.90
10-4440-010
12
88.9
11.13
SA-234 Gr.WP22
472
159.0
101.7
6.45
4.53
9.74
2
12525 01 01339
ELBOW
5
12525 01 01339
6
EQUAL TEE
7
12525 01 01339

HENCE SAFE.
DESCRIPTION
NAME
DATE
PREPARED BY
AEE
08-06-2011
CHECKED BY
SMR
08-06-2011
APPROVED BY
SAT
08-06-2011

12525-2500116-0 - Strength Calculation For Superheater 3 Unit I

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12525-2500116-0 - Strength Calculation For Superheater 3 Unit I

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G.B. ENGINEERING ENTERPRISES PVT. LTD.

BOILER MAKER'S NO. : GB - 101

SH-3 Main Inlet Header

SH-3 Inlet Connection Pipe

SH-3 Intermediate Inlet Header

SH-3 Inlet Connection Tube

SH-3 Intermediate Outlet Header

SH-3 Outlet Connection Pipe

SH-3 Main Outlet Header

G.B. ENGINEERING ENTERPRISES PVT. LTD.

HEADER THICKNESS CALCULATION : Reg 342(a) and Reg 270

-------------- Eqn (72)

Design Pressure of Header in bar (g)

Max. Internal diameter in mm

Required thickness to be calculated in mm

Super Heater 3 Drawings

Super Heater-3 Assembly

Nom. Thk. Min.Thk *

PROVIDED THK > REQUIRED THK.

* Min. Thk. = Nom.Thk - Mill Negative Tolerance

G.B. ENGINEERING ENTERPRISES PVT. LTD.

G.B. ENGINEERING ENTERPRISES PVT. LTD.

MAXIMUM UNCOMPENSATED HOLES IN HEADER: IBR Reg.187

Outside diameter of Header in mm

Refer graph value (Fig 9b)

------- Eqn. (20)

LIST OF HOLES IN HEADER

G.B. ENGINEERING ENTERPRISES PVT. LTD.

STUB THICKNESS CALCULATION : IBR Reg.156 & Reg.338(a)

Design Pressure in bar (g)

MINIMUM THICKNESS OF BRANCH : IBR Reg.156(c)

where, do = the outside diameter of the branch (in mm.)

LIST OF BRANCH STUB

PROVIDED THICKNESS > REQUIRED THICKNESS.

LIST OF BRANCH TUBE

G.B. ENGINEERING ENTERPRISES PVT. LTD.

COMPENSATION CALCULATION FOR HEADER STUB OPENINGS : IBR Reg.279

Inside dia of Nozzle/Stub

Smaller of values = 2.5ts or 2.5tn

Nozzle/Stub projection inside.

(ts + 76) or (dn/2), whichever is greater

Fillet weld area

Available Compensation Area Y

= [ 2 (tn-en) b x (fn/fs) ] + [ 2 (ts - es ) Ci ] + [ 2tn x bi x fn/fs ] + CW

Available Compensation Area Y > Area Removed X

Min. Thickness of Unpierced Header (where E=1)

-------------- Eqn (72)

Design Pressure of Header in bar (g)

Max. Internal diameter in mm

G.B. ENGINEERING ENTERPRISES PVT. LTD.

HEADER END CAP THICKNESS CALCULATION : IBR Reg.278

Working Pressure of Header Endcap in bar (g)

Outside dia of Endcap in mm

Required thk. to be calculated in mm

Shape Factor (from IBR Fig.23D)

PROVIDED THK > REQUIRED THK.

G.B. ENGINEERING ENTERPRISES PVT. LTD.

COIL TUBE THICKNESS CALCULATION : IBR Reg.156 & Reg.338(a)

Design Pressure in bar (g)

Stress Value (f)

For DU No. : 10-440-005

VAR-I to VARIV : Tubes

VAR-I to VARXII : Inlet Conn.