BABCOCK BORSIG POWER SYSTEMS LTD.

CHENNAI,INDIA

Page:1 of 11 DOC.No.:AK.110191.K.052.520.B01

BOILER MAKER'S NO. : 0612

PRESSURE PART STRENGTH CALCULATIONS PIPING FROM SH-1 OUTLET HDR TO SH-2 INLET HEADER

DESIGN DATA :
1. 2. 3. DESIGN CODE DESIGN PRESSURE CALCULATION PRESSURE SH-1 OUTLET TO ATTEMPERATOR ATTEMPERATOR TO SH-2 INL : : IBR 1950 205 kg/cm2( g )

: :

214 213

kg/cm2( g ) kg/cm2( g )

4.

CALCULATION TEMPERATURE SH-1 OUTLET TO ATTEMPERATOR ATTEMPERATOR TO SH-2 INL

: :

500 480

o o

C C

KS PREPARED

PRB CHECKED

NS APPROVED

0 REV.

10/4/2000 DATE

FILE NAME :\\ENTIRE NETWORK\IDEA\IDEA_BDC\20507 PIPING\AUSTRIAN\DOCUMENTS\HP STAGE 1DOC\135647670.xls.ms_office.XLS

BABCOCK BORSIG POWER SYSTEMS LTD. CHENNAI,INDIA

Page:2 of 11 DOC.No.:AK.110191.K.052.520.B01

PIPING FROM SH-1 OUT TO HP ATTEMPERATOR11/12): Reg.- 338(a) DRG.No : AK.110191.K.052.520.Z02 & Size : OD 320 x 40 THK (min) AK.110191.K.052.520.Z04 Material specification : 10CrMo 910 Under tolerance in % : 0 PARAMETERS : T D WP H P Tw C f SR Thickness in mm to be calculated OD of tube in mm Design pressure Hydraulic head+Pressure drop Calculation pressure = (WP+H) Working metal temperature 0 mm Allowable stress at working metal temperature Average stress to produce rupture in 100000 hours at Tw Sc = Average stress to produce 1% elongation in 100000hours at Tw Et = Yield point (0.2% proof stress) at Temperature Tw = = = = = = = = =

= = = = =

320 205 9 214 500

mm kg/cm2 kg/cm2 kg/cm2 o C

2 = 1376.14 kg/cm 2 = 1049.50 kg/cm 2 = 1885.83 kg/cm

Allowable stress is lower of the values for temp. above 454oC Et = 3058.10 1.5 1.5 Sr 1.5 Sc Therefore f =
2 917.43 kg/cm

2 1257.22 kg/cm

1376.14 1.5

2 917.43 kg/cm

2 1049.50 kg/cm

T =

2f(T-C) D -T+C PD 2f + P +

..

Equation (87)

= =

214x320 (2x917.43)+214 33.42 mm

KS PREPARED

PRB CHECKED

<Provided min. thickness of 40mm., Hence safe. NS 0 APPROVED REV.

10/4/2000 DATE

FILE NAME :\\ENTIRE NETWORK\IDEA\IDEA_BDC\20507 PIPING\AUSTRIAN\DOCUMENTS\HP STAGE 1DOC\135647670.xls.ms_office.XLS

BABCOCK BORSIG POWER SYSTEMS LTD. CHENNAI,INDIA

Page:3 of 11 DOC.No.:AK.110191.K.052.520.B01

PIPING FROM SH-1 OUT TO HP ATTEMPERATOR11/12): Reg.338(a) DRG.No : AK.110191.K.052.520.Z02 & REDUCER AK.110191.K.052.520.Z04 Size : OD 300 x 30 THK Material specification : X10CrMoVNB 9-1 Under tolerance in % : 0 PARAMETERS : T D WP H P Tw C f SR Thickness in mm to be calculated OD of tube in mm Design pressure Hydraulic head+Pressure drop Calculation pressure = (WP+H) Working metal temperature 0 mm Allowable stress at working metal temperature Average stress to produce rupture in 100000 hours at Tw Sc = Average stress to produce 1% elongation in 100000hours at Tw Et = Yield point (0.2% proof stress) at Temperature Tw = = = = = = = = =

= = = = =

300 205 9 214 500

mm kg/cm2 kg/cm2 kg/cm2 o C

2 = 2579.00 kg/cm 2 = 2171.20 kg/cm 2 = 3058.10 kg/cm

Allowable stress is lower of the values for temp. above 454oC Et = 3058.10 1.5 1.5 Sr 1.5 Sc Therefore f =
2 1719.33 kg/cm

2 2038.73 kg/cm

2579.00 1.5

2 1719.33 kg/cm

2 2171.20 kg/cm

T =

2f(T-C) D -T+C PD 2f + P +

..

Equation (87)

= =

214x300 (2x1,719.33)+214 17.58 mm

KS PREPARED

PRB CHECKED

<Provided min. thickness of 30mm., Hence safe. NS 0 APPROVED REV.

10/4/2000 DATE

FILE NAME :\\ENTIRE NETWORK\IDEA\IDEA_BDC\20507 PIPING\AUSTRIAN\DOCUMENTS\HP STAGE 1DOC\135647670.xls.ms_office.XLS

BABCOCK BORSIG POWER SYSTEMS LTD. CHENNAI,INDIA

Page:4 of 11 DOC.No.:AK.110191.K.052.520.B01

PIPING FROM SH-1 OUT TO HP ATTEMPERATOR11/12): Reg.338(a) DRG.No : AK.110191.K.052.520.Z02 & Welding boss AK.110191.K.052.520.Z04 Size : OD 40 x 11 THK (min) Material specification : 10CrMo 910 Under tolerance in % : 0 PARAMETERS : T D WP H P Tw C f SR Thickness in mm to be calculated OD of tube in mm Design pressure Hydraulic head+Pressure drop Calculation pressure = (WP+H) Working metal temperature 0 mm Allowable stress at working metal temperature Average stress to produce rupture in 100000 hours at Tw Sc = Average stress to produce 1% elongation in 100000hours at Tw Et = Yield point (0.2% proof stress) at Temperature Tw = = = = = = = = =

= = = = =

40 205 9 214 500

mm kg/cm2 kg/cm2 kg/cm2 o C

2 = 1376.14 kg/cm 2 = 1049.50 kg/cm 2 = 1885.83 kg/cm

Allowable stress is lower of the values for temp. above 454oC Et = 3058.10 1.5 1.5 Sr 1.5 Sc Therefore f =
2 917.43 kg/cm

2 1257.22 kg/cm

1376.14 1.5

2 917.43 kg/cm

2 1049.50 kg/cm

T =

2f(T-C) D -T+C PD 2f + P +

..

Equation (87)

= =

214x40 (2x917.43)+214 4.18 mm

KS PREPARED

PRB CHECKED

<Provided min. thickness of 11mm., Hence safe. NS 0 APPROVED REV.

10/4/2000 DATE

FILE NAME :\\ENTIRE NETWORK\IDEA\IDEA_BDC\20507 PIPING\AUSTRIAN\DOCUMENTS\HP STAGE 1DOC\135647670.xls.ms_office.XLS

BABCOCK BORSIG POWER SYSTEMS LTD. CHENNAI,INDIA

Page:5 of 11 DOC.No.:AK.110191.K.052.520.B01

PIPING FROM SH-1 OUT TO HP ATTEMPERATOR11/12): Reg.- 338(a) REDUCER DRG.No : AK.110191.K.052.520.Z02 & Size : OD 358 x 44 THK (min) AK.110191.K.052.520.Z04 Material specification : 10CrMo 910 Under tolerance in % : 0 PARAMETERS : T D WP H P Tw C f SR Thickness in mm to be calculated OD of tube in mm Design pressure Hydraulic head+Pressure drop Calculation pressure = (WP+H) Working metal temperature 0 mm Allowable stress at working metal temperature Average stress to produce rupture in 100000 hours at Tw Sc = Average stress to produce 1% elongation in 100000hours at Tw Et = Yield point (0.2% proof stress) at Temperature Tw = = = = = = = = =

= = = = =

358 205 9 214 500

mm kg/cm2 kg/cm2 kg/cm2 o C

2 = 1376.15 kg/cm 2 = 1049.95 kg/cm 2 = 1783.89 kg/cm

Allowable stress is lower of the values for temp. above 454oC Et = 1783.89 1.5 1.5 Sr 1.5 Sc Therefore f =
2 917.43 kg/cm

2 1189.26 kg/cm

1376.15 1.5

2 917.43 kg/cm

2 1049.95 kg/cm

T =

2f(T-C) D -T+C PD 2f + P +

..

Equation (87)

= =

214x358 (2x917.43)+214 37.39 mm

KS PREPARED

PRB CHECKED

<Provided min. thickness of 44mm., Hence safe. NS 0 APPROVED REV.

10/4/2000 DATE

FILE NAME :\\ENTIRE NETWORK\IDEA\IDEA_BDC\20507 PIPING\AUSTRIAN\DOCUMENTS\HP STAGE 1DOC\135647670.xls.ms_office.XLS

BABCOCK BORSIG POWER SYSTEMS LTD. CHENNAI,INDIA

Page:6 of 11 DOC.No.:AK.110191.K.052.520.B01

PIPING FROM HP ATTEMPERATOR11/12) TO SH2 INL: Reg.338(a) : AK.110191.K.052.520.Z03 & DRG.No AK.110191.K.052.520.Z05 Size : OD 296 x 28 THK (min) Material specification : 13CrMo44 Under tolerance in % : 0 PARAMETERS : T D WP H P Tw C f SR Thickness in mm to be calculated OD of tube in mm Design pressure Hydraulic head+Pressure drop Calculation pressure = (WP+H) Working metal temperature 0 mm Allowable stress at working metal temperature Average stress to produce rupture in 100000 hours at Tw Sc = Average stress to produce 1% elongation in 100000hours at Tw Et = Yield point (0.2% proof stress) at Temperature Tw = = = = = = = = =

= = = = =

296 205 8 213 480

mm kg/cm2 kg/cm2 kg/cm2 o C

2 = 1936.79 kg/cm 2 = 1355.75 kg/cm 2 = 1804.28 kg/cm

Allowable stress is lower of the values for temp. above 454oC Et = 3058.10 1.5 1.5 Sr 1.5 Sc Therefore f =
2 1202.85 kg/cm

2 1202.85 kg/cm

1936.79 1.5

2 1291.19 kg/cm

2 1355.75 kg/cm

T =

2f(T-C) D -T+C PD 2f + P +

..

Equation (87)

= =

213x296 (2x1,202.85)+213 24.08 mm

KS PREPARED

PRB CHECKED

<Provided min. thickness of 28mm., Hence safe. NS 0 APPROVED REV.

10/4/2000 DATE

FILE NAME :\\ENTIRE NETWORK\IDEA\IDEA_BDC\20507 PIPING\AUSTRIAN\DOCUMENTS\HP STAGE 1DOC\135647670.xls.ms_office.XLS

BABCOCK BORSIG POWER SYSTEMS LTD. CHENNAI,INDIA

Page:7 of 11 DOC.No.:AK.110191.K.052.520.B01

PIPING FROM HP ATTEMPERATOR11/12) TO SH2 INL: Reg.338(a) : AK.110191.K.052.520.Z03 & DRG.No REDUCER AK.110191.K.052.520.Z05 Size : OD 358 x 44 THK (min) Material specification : 13CrMo44 Under tolerance in % : 0 PARAMETERS : T D WP H P Tw C f SR Thickness in mm to be calculated OD of tube in mm Design pressure Hydraulic head+Pressure drop Calculation pressure = (WP+H) Working metal temperature 0 mm Allowable stress at working metal temperature Average stress to produce rupture in 100000 hours at Tw Sc = Average stress to produce 1% elongation in 100000hours at Tw Et = Yield point (0.2% proof stress) at Temperature Tw = = = = = = = = =

= = = = =

358 205 8 213 480

mm kg/cm2 kg/cm2 kg/cm2 o C

2 = 1936.79 kg/cm 2 = 1355.75 kg/cm 2 = 1804.28 kg/cm

Allowable stress is lower of the values for temp. above 454oC Et = 3058.10 1.5 1.5 Sr 1.5 Sc Therefore f =
2 1202.85 kg/cm

2 1202.85 kg/cm

1936.79 1.5

2 1291.19 kg/cm

2 1355.75 kg/cm

T =

2f(T-C) D -T+C PD 2f + P +

..

Equation (87)

= =

213x358 (2x1,202.85)+213 29.12 mm

KS PREPARED

PRB CHECKED

<Provided min. thickness of 44mm., Hence safe. NS 0 APPROVED REV.

10/4/2000 DATE

FILE NAME :\\ENTIRE NETWORK\IDEA\IDEA_BDC\20507 PIPING\AUSTRIAN\DOCUMENTS\HP STAGE 1DOC\135647670.xls.ms_office.XLS

BABCOCK BORSIG POWER SYSTEMS LTD. CHENNAI,INDIA

Page:8 of 11 DOC.No.:AK.110191.K.052.520.B01

PIPING FROM HP ATTEMPERATOR11/12) TO SH2 INL: Reg.338(a) : AK.110191.K.052.520.Z03 & DRG.No AK.110191.K.052.520.Z05 Size : OD 312 x 36 THK Material specification : 13CrMo44 Under tolerance in % : 10 PARAMETERS : T D WP H P Tw C f SR Thickness in mm to be calculated OD of tube in mm Design pressure Hydraulic head+Pressure drop Calculation pressure = (WP+H) Working metal temperature 0 mm Allowable stress at working metal temperature Average stress to produce rupture in 100000 hours at Tw Sc = Average stress to produce 1% elongation in 100000hours at Tw Et = Yield point (0.2% proof stress) at Temperature Tw = = = = = = = = =

= = = = =

312 205 8 213 480

mm kg/cm2 kg/cm2 kg/cm2 o C

2 = 1936.79 kg/cm 2 = 1355.75 kg/cm 2 = 1804.28 kg/cm

Allowable stress is lower of the values for temp. above 454oC Et = 3058.10 1.5 1.5 Sr 1.5 Sc Therefore f =
2 1202.85 kg/cm

2 1202.85 kg/cm

1936.79 1.5

2 1291.19 kg/cm

2 1355.75 kg/cm

T =

2f(T-C) D -T+C PD 2f + P +

..

Equation (87)

= =

213x312 (2x1,202.85)+213 25.38 mm

KS PREPARED

PRB CHECKED

<Provided min. thickness of 32.4mm., Hence safe. NS 0 APPROVED REV.

10/4/2000 DATE

FILE NAME :\\ENTIRE NETWORK\IDEA\IDEA_BDC\20507 PIPING\AUSTRIAN\DOCUMENTS\HP STAGE 1DOC\135647670.xls.ms_office.XLS

BABCOCK BORSIG POWER SYSTEMS LTD. CHENNAI,INDIA

Page:9 of 11 DOC.No.:AK.110191.K.052.520.B01

PIPING FROM HP ATTEMP11/12) TO SH2 INL: Reg.- 338(a)

DRG.No :

Weld boss Size

Material specification

AK.110191.K.052.520.Z03 & AK.110191.K.052.520.Z05

: OD 0

40

11

THK

: 13CrMo44

Under tolerance in % : PARAMETERS : T D WP H P Tw C f SR

Thickness in mm to be calculated OD of tube in mm Design pressure Hydraulic head+Pressure drop Calculation pressure = (WP+H) Working metal temperature 0 mm Allowable stress at working metal temperature Average stress to produce rupture in 100000 hours at Tw Sc = Average stress to produce 1% elongation in 100000hours at Tw Et = Yield point (0.2% proof stress) at Temperature Tw

= = = = = = = = =

= = = = =

40 205 8 213 480

mm kg/cm2 kg/cm2 kg/cm2 o C

2 = 1936.79 kg/cm 2 = 1355.75 kg/cm 2 = 1804.28 kg/cm

Allowable stress is lower of the values for temp. above 454oC Et = 3058.10 1.5 1.5 Sr 1.5 Sc Therefore f =
2 1202.85 kg/cm

2 1202.85 kg/cm

1936.79 1.5

2 1291.19 kg/cm

2 1355.75 kg/cm

T =

2f(T-C) D -T+C PD 2f + P +

..

Equation (87)

= =

213x40 (2x1,202.85)+213 3.25 mm

KS PREPARED

PRB CHECKED

<Provided min. thickness of 11mm., Hence safe. NS 0 APPROVED REV.

10/4/2000 DATE

FILE NAME :\\ENTIRE NETWORK\IDEA\IDEA_BDC\20507 PIPING\AUSTRIAN\DOCUMENTS\HP STAGE 1DOC\135647670.xls.ms_office.XLS

BABCOCK BORSIG POWER SYSTEMS LTD. CHENNAI,INDIA

Page:10 of 11 DOC.No.:AK.110191.K.052.520.B01

PIPING FROM SH-1 OUT TO HP ATTEMPERATOR11/12 CALCULATION FOR MAX.UNCOMPENSATED OPENING IN SHELL AS PER IBR REGULATION -187 (AMENDMENT) Size OD 10CrMo 910 Under tolerance in % : 0
:

320

40

THK AK.110191.K.052.520.Z02 & AK.110191.K.052.520.Z04

Material specification

DRG.No:

PARAMETERS : d e D P f K K = = = = = = = Maximum allowable diameter of opening Actual thickness of Shell Outside Diameter of Shell Calculation pressure Allowable stress at working metal temperature Factor PD 1.82fe 214x320 1.82x917.43x40 Dxe= 320x40 = = 1.025

(1x40)

= = = =

40 320 214 917.43

mm mm kg/cm2 kg/cm2

2 12800 mm

2 19.840 inch

(When ' K ' has a value of unity or greater, the maximum size of an unreinforced opening should be 51 millimeter (2inches)) Maximum opening diameter in Shell = Hence compensation calculation need not be checked.

51 mm 40 mm

PRB PREPARED

NS CHECKED

NS APPROVED

0 REV.

30/11/00 DATE

FILE NAME :\\ENTIRE NETWORK\IDEA\IDEA_BDC\20507 PIPING\AUSTRIAN\DOCUMENTS\HP STAGE 1DOC\135647670.xls.ms_office.XLS

BABCOCK BORSIG POWER SYSTEMS LTD. CHENNAI,INDIA

Page:11 of 11 DOC.No.:AK.110191.K.052.520.B01

PIPING FROM SH-1 OUT TO HP ATTEMPERATOR11/12 CALCULATION FOR MAX.UNCOMPENSATED OPENING IN SHELL AS PER IBR REGULATION -187 (AMENDMENT) Size OD 13CrMo44 Under tolerance in % : 0
:

296

28

THK AK.110191.K.052.520.Z03 & AK.110191.K.052.520.Z05

Material specification

DRG.No:

PARAMETERS : d e D P f K K = = = = = = = Maximum allowable diameter of opening Actual thickness of Shell Outside Diameter of Shell Calculation pressure Allowable stress at working metal temperature Factor PD 1.82fe 213x296 1.82x1202.85x28 Dxe= 296x28 = = 1.029

(1x28)

= = = =

28 296 213 1202.85

mm mm kg/cm2 kg/cm2

2 8288 mm

2 12.846 inch

(When ' K ' has a value of unity or greater, the maximum size of an unreinforced opening should be 51 millimeter (2inches))

51 mm 40 mm

Hence compensation calculation need not be checked.

PRB PREPARED

NS CHECKED

NS APPROVED

0 REV.

30/11/00 DATE

FILE NAME :\\ENTIRE NETWORK\IDEA\IDEA_BDC\20507 PIPING\AUSTRIAN\DOCUMENTS\HP STAGE 1DOC\135647670.xls.ms_office.XLS