CLIENT : EIL A/C IOCL Panipat

EQPT. : 25-V-101 PAGE: 1

Designed by: PZF JOB NO. PD-889 DR NO. PD-889 C REV. 0

DESIGN REPORT ( D R )

DESIGN CODE : IBR 1950 + Amendments up to June' 06

WORKS JOB NUMBER PD-889

NAME OF CLIENT : EIL A/C IOCL Panipat

EQUIPMENT : 25-V-101

DOCUMENT TITLE : DESIGN CALCULATION

REFERENCE DRAWINGS : 2006-PD-889 SHEET 1 R0

2006-PD-889 SHEET 2 R0
2006-PD-889 SHEET 3 R0
2006-PD-889 SHEET 4 R0
2006-PD-889 SHEET 5 R0
2006-PD-889 SHEET 6 R0

0 01.08.06 ( GAURAV GANDHI ) ( SUNIL UPPAL)

REV. DATE PREPARED BY APPROVED BY

2318/1299
 CLIENT : EIL A/C IOCL Panipat

EQPT. : 25-V-101 PAGE: 2

Designed by: PZF JOB NO. PD-889 DR NO. PD-889 C REV. 0

INDEX
REVISION NUMBER OF DESIGN REPORT 0 1 2 3
PAGE NO. PAGE DESCRIPTION LATEST PAGE REVISION
1 Cover page 0
2 Index 0
3 Calculation of steam drum shell thickness 0
4 Calculation of manway thickness 0
5 Calculation of head thickness 0
6 Calculation for maximum uncompensated opening in 0
shell
7 Compensation Calculation for Nozzle mk. N2 0

PREPARED BY PZF
APPROVED BY PZ
2319/1003
 CLIENT : EIL A/C IOCL Panipat

EQPT. : 25-V-101 PAGE: 3

Designed by: PZF JOB NO. PD-889 DR NO. PD-889 C REV. 0

CALCULATION OF STEAM DRUM SHELL THICKNESS

( AS PER REGULATION 270 )

Shell Material = SA 516 GR 70

Working Pressure ( inclusive of static head ) WP = 10.6 Kg/cm2 (g)

Working metal temperature t = 225 C

0

Drum Internal diameter = 2864 mm

Corrosion allowance c = 3.2 mm

Maximum (Corroded) Internal diameter of drum D = 2870.40 mm

Allowable Stress of material as per ASME Sec. II, part D-Table 1A f = 1406.00 kg/cm2
[As per Amendment to Regulation 271 dated 17 th November,2003]

Joint efficiency E = 1.0

Minimum required thickness of shell WP * D +c = 14.1 mm

( Refer Eqn. 72 of regulation 270) 2 * f * E - WP

Minimum finished shell thickness T = 18.0 mm

Provided Nominal thickness of Shell = 18.0 mm

Since provided shell thickness is more than the required minimum thickness, HENCE SAFE
 CLIENT :EIL A/C IOCL Panipat

EQPT. : 25-V-101 PAGE: 4

Designed by: PZF JOB NO. PD-889 DR NO. PD-889 C REV. 0

CALCULATION OF MANWAY NECK THICKNESS ( MKD. N5 A/B )

Manway Material = SA51670

Working Pressure WP = 10.6 Kg/cm2 (g)

Working metal temperature t = 225 C

0

Manway Inside diameter Dm = 554 mm

Factor ' c ' c = 3.2 mm

Allowable Stress of material as per ASME Sec. II, part D f = 1406 kg/cm2

Joint efficiency E = 1.0

Required thickness of manway WP*(Dm+2*c) +c Tm = 5.320 mm

( Refer Eqn. 72 of regulation 270) 2*f*E-WP

Provided thickness of manway Tn = 28 mm

Actual thickness of manway (Corroded ) Tn - c Tt = 24.8 mm

Outside diameter of manway d = 610.0 mm

Minimum thickness of head T = 19 mm

Maximum length of nozzle for reinforcement d x Tt L2 = 123.00 mm

( As per regulation 277 (d) )

Projection outside the internal surface of head L2' = 120 mm

Projection inside from the internal surface of head L2'' = 0 mm

Stress ratio Allowable stress of reinforcement material Sr = 1.000

Allowable stress of head material

Effective cross-section of reinforcement A = 5443.09 mm2

2 [ L2' (Tn - Tm) + L2'' (Tn-2c) ] Sr

Imaginary diameter d - A/(T-c) d' = 265.50 mm

 CLIENT :EIL A/C IOCL Panipat

EQPT. : 25-V-101 PAGE: 5

Designed by: PZF JOB NO. PD-889 DR NO. PD-889 C REV. 0

CALCULATION OF HEAD THICKNESS

( AS PER REGULATION 278 )

Head Material = SA 516 GR 70

Working Pressure ( inclusive of static head ) = 10.6 Kg/cm2 (g)
Inside Diameter of head = 2864 mm
Working Temperature 225 0
C
Nominal thickness of head Tnom = 22 mm

Outside Diameter of head D = 2908 mm

Ratio d' / D x T = 1.130
Height of the head H = 738.0 mm
Ratio H / D H/D = 0.25
Shape factor ( From FIG. - 23D ) K = 1.50
Factor of additive thickness C = 3.20
Allowable stress of matl as per ASME Sec. II, part D f = 1406.00 Kg/cm2
:
[As per Amendment to Regulation 271 dated 17 th November,2003] Ch
Min. required thickness of dish WP x D x K +C T' = 19.64 mm <
( Refer Eqn. 74 of regulation 278) 2xf

Adopted minimum thickness of head T = 19 mm

Since adopted minimum thickness is more than the required minimum thickness

FAIL
:
Check T/D <=0.1 and d/D
<=0.5

T/D 0.0065
d/D 0.2098
 CLIENT : EIL A/C IOCL PANIAPT

EQPT. : 25-V-101 PAGE: 6

DESIGNED BY PZF JOB NO. PD-889 DR NO. PD-889 C REV. 0

CALCULATION OF MAX. UNCOMPENSATED HOLES IN SHELL

( AS PER REGULATION 187 )

K = ( P * D ) / ( 1.82 * f * e )

Design pressure P = 10.6 Kg/cm2 (g)

O.D. of shell D = 1430 mm

Actual thickness of shell e = 40 mm

Allowable stress of shell f = 1406.0 Kg/cm2 (g)

( As per ASME Sec II, Part D)
[Ref. Ammendment dated 29.11.03]

K = 0.15
Also Drum dia ( D ) x Thickness( T ) in inches = 88.66

From Fig 9C, "d" for calculated value of K is = 8 inch

= 203.2 mm

Since Maximum Finished opening size of nozzles (173.08 mm) except N2 is less than above, so
reinforcement calculations are not required for nozzles on shell except N2.
 CLIENT : EIL A/C IOCL PANIAPT
PAGE
PLANT : 25-V-101 7

Designed by: PZF JOB NO. PD-889 DR NO. PD-889 C REV. 0

Reinforcement calculations C1

do

tx dn

b
h1

tn ts
don
Design code IBR (1950) + Latest Ammendments till June 2006
( Regulations 270, 271, 279 (a))
Nozzle mark No. Symbol N2 Unit
Inside diameter of shell D 1350.00 mm
Nominal bore NPS 10 inch
Product Form FAB/STD PIPE/FORGED FORGED
Design Pressure WP 0.473 Kgf/mm2g
Design temp. 343.000 0
C
Shell material SA516GR70
Nozzle material SA105
Allowable stress for shell fs 13.220 Kgf/mm2
Allowable stress nozzle fn 12.518 Kgf/mm2
Corrosion allowance C 3.000 mm
Joint efficiency E 1.0 UL
Outside dia. of nozzle do 273.00 mm
Internal diameter of nozzle = do - 2 * tx dn 230.12 mm
Minimum required WP * dn +C en 7.43 mm
thickness of nozzle 2 * fn*E - WP
( As per Equation 72 of Regulation 270)
Provided thickness of nozzle tx 21.440 mm
Required thickness of shell es 14.1 mm
Actual thickness of shell ts 40.0 mm
Is compensation calculations required YES
Length of thicker. portion of nozzle h1 92.0 mm
Outside dia. of SR nozzle don 360.0 mm
Provided thickness of thicker portion of nozzle tn 64.94 mm
Area to be compensated = dn * es Ar 3235.7 mm2
Limit of reinforcement parallel to shell C1 116.0 mm
= Max. ( ts + 76, dn/2 )
Limit of reinforcement normal to shell b 92.000 mm
Min.(2.5 * ts, 2.5 * tn ,h1)
Area available from shell As 6017.8 mm2
= 2 * ( ts - es )* C1
Area available from nozzle wall Aw 10019.7 mm2
= 2 * ( tn - en ) * b * MIN (1,fn / fs)
Total area available = As + An + Aw Aa 16037.53 mm2
Since Aa > A r , Hence SAFE