Thermax Limited (B&H Group)

A Division of Thermax Limited

TITLE ASME CODE CALCULATION FOR STEAM DRUM
CUSTOMER M/s.BANGGAI AMMONIA PLANT Specification No. P21-FM-CS-71955 REV.02
BOILER NO. WF144100 PROJECT NO. PF1441

GENERAL

Equipment Name Water Tube, Natural Circulation, Bottom Supported FM Boiler (117-97)
Name of Costumer M/s.BANGGAI AMMONIA PLANT
Reference Documents TL's Order Transfer Form

Boiler No Description Drawing No.

WF144100 Steam Drum (1234 ID x 70 Thk) P21-0FM-019630
WF144100 Dished End (1234 ID x 56 Thk - 2:1 Semi Ellipsoidal) P21-3FM-038872
WF144100 Manhole Rim P21-3FM-038872
WF144100 Bolt & Cross Bar Arrangement SD-01-131

Codes of Design & Construction: = ASME Section I, Edition 2013

Maximum allowable working Pressure = 5.64 MPa(g)
Design Metal Temperature = 301 °C
Corrosion Allowance for SA 516M Gr. 485 = 3.2 mm
Corrosion Allowance for SA 106M Gr. B = 1.7 mm

Registration with National Board Required

Steam Drum is subjected to internal Pressure and Hydrostatic Head only. No other
on the boiler. Loading due to piping is not significant as the piping stress analysis w
and flexibility will be maintained to an extent so that the loading on the main press
will be insignificant.

Seizmic & Wind load are not considered for each equipement.Since Entire pressure
single block. Seizmic & wind load are calculated for entire block and this load will tr
through base frame structure. Hence it is not considered in this calculation.

Type of Construction: Welded

Notes:
1 In Calculations conversion factor are used at least four significant figures and result
expressed to a minimum of three significant figures
2 Material that has been manufactured & certified to either U.S. customary or S.I. ma
be used.
3 All nozzles holes other than drilled holes for expanded tubes on drum shell are suffi
that their limit of compensation do not overlap.
4 Thinning due to dishing for Drum dished ends is considerd for safe design. Practical
than 10%
5 No creadit is taken of the weld material in any of nozzle opening compensation Cal
6 Minimum thickness of boiler plate and pipe >125 DN under Pressure Shall be not le
6mm or the minimum wall thickness of standard wall pipe listed in ASME B36.10M
7 The minimum thickness of any boiler plate under pressure shall be 6 mm.

NOTE :
= angka input ( dapat diubah)
= angka yang sudah muncul pada perhitungan
= hasil kalkulasi
S-71955 REV.02

iler (117-97) Reference

Drawing No. Rev. No.

P21-0FM-019630 1
P21-3FM-038872 2
P21-3FM-038872 2
SD-01-131 K

OTF
Thermax
Spesifications

atic Head only. No other external loads are acting PG-22

e piping stress analysis will be done seperately
oading on the main pressure part of the boiler page 13

ent.Since Entire pressure parts are considered as

block and this load will transfer to boiler footing
n this calculation.

ificant figures and result of conversion of units is PG-4

Page 2
U.S. customary or S.I. material specification may

es on drum shell are sufficiently spaced such

for safe design. Practical thinning will be less

ening compensation Calculation PG- 16.3

r Pressure Shall be not less than the smaller of Page 9
listed in ASME B36.10M, Table 1.
PG- 16.3
shall be 6 mm.

uncul pada perhitungan sebelumnya

1 Maximum Allowable Working Pressure:

M.A.W.P = 5.64 MPa(g)

2 Pressure used for Steam Drum calculations:

Pressure used for calculation [P] = Design pressure = M.A.W.P + Max. Hydrostatic head

In Design calculation P as per above formula will be used in various formulae as given in codeto
calculate required thickness of pressure part components.Calculated thickness will then be
compared with actual component thickness for suitability check

Design Pressure includes hydrostatic head

Hydrostatic Head = 0 MPa(g)
Therefore, pressure used for calculation is same as MAWP.
Hence, Design Pressure, P = 5.64 MPa(g)

3 Design Metal Temperature:

Design Metal Temperature = 301 °C
 Thermax
Spesification

P + Max. Hydrostatic head PG-22.1 Page 13

Thermax
Spesification
Material & Allowable Stress

All material used in Pressure Part are as per ASME Section II Part A, material specification and are selected as per PG
Allowable Stresses are taken from ASME Section II Part D at Design Metal Temperature[DMT] specified in table given

SR. No. Description Material DMT(°C) Allow. Stress (Mpa)

1 Steam Drum Shell Plate SA 516M Gr. 485 301 135.84
2 Dished End SA 516M Gr. 485 301 135.84
3 Manhole Rim SA 105M 301 128.84
4 Manhole Cover SA 516M Gr. 485 301 135.84
5 Risers Pipes SA 210M Gr. A1 301 118
6 Stand Pipes SA 106M Gr. B 301 118
7 Feedwater Thermal Sleeve SA 106M Gr. B 301 118
8 Chem. Dosing Thermal Sleeve SA 106M Gr. B 301 118
9 Manhole Bolt SA 150 301 128.84
10 Manhole Pin SA 150 301 128.84

DMT - Design Metal Temperature [ for DMT refer Design Data]

Applicable notes to Table 1A are reviewed

NOTES :
NOTES - GENERAL REQUIREMENTS
G10 - Design Metal Temperature 301 °C is less than 425 °C, hence this note is not applicable

NOTES - SIZE REQUIREMENTS

S1 - Design Metal Temperature 301 °C is less than 425 °C, hence this note is not applicable

NOTES - TIME-DEPENDENT PROPERTIES

T1 - Design Metal Temperature 301 °C is less than 425 °C, hence this note is not applicable
T2 - Design Metal Temperature 301 °C is less than 425 °C, hence this note is not applicable
and are selected as per PG-5 to PG-9 of ASME Section I PG-5 to PG-9
MT] specified in table given below As per Table 1A of ASME Section II, part D Page 2 to 6

Max. Temp.(°C) Applicable notes ASME Sec.II D

454 G10, S1, T2 Page 22, line 6
454 G10, S1, T2 Page 22, line 6
538 G10, S1, T2 Page 18, line 32
454 G10, S1, T2 Page 22, line 6
538 G10, S1, T2 Page 14, line 37
538 G10, S1, T2 Page 14, line 19
538 G10, S1, T2 Page 14, line 19
538 G10, S1, T2 Page 14, line 19
538 G10, S1, T2 Page 18, line 32
538 G10, S1, T2 Page 18, line 32

ot applicable

applicable

applicable
applicable
LIGAMENT EFFICIENCY CALCULATIONS FOR STEAM DRUM

Equipment Data
Drum Inside Diameter =
Corrosion Allowance =
As per Thermax tolerence Table on drawing
Permissible Fabrication tolerence on ,1234 mm Diameter =
Drum Inside Diameter (considering tolerance) =
Drum Inside Diameter (considering corrosion) =
Drum Thickness (Nominal) =
Drum Thickness (corroded condition) =
Calculation Pressure [P] =
Allowable Stress [S] =

Nominal Tube Tube Hole Groove Dia 'B' DIM 'Y' No. of Holes Groove
OD Dia 'A' Height
50.8 51.4 53 54 864 3

Ligament Efficiency Calculations for 50.8 dia. Tubes:

Calculations of equivalent of hole opening for 50.8 dia tube:
Tube Hole Dia. (Dim.'A') = 51.4 + 0.3 = 51.7 mm
Tube Hole Height = 70 - 6.8 = 63.2 mm
Grove Dia = 53 + 0.8 = 53.8 mm
Groove Height = 3 + 0.4 = 3.4 mm

Equivalent diameter of hole opening = 3633.28

70
=
= 51.904 mm
The governing pitch for longitudinal efficiency calculations of = 181 mm
50.8 dia. Tubes :

Longitudinal Ligament Efficiency for 50.8 dia. tubes:

When the pitch of the tubes on every tube row is equal :

E = [ P - nd ] / P
Where,
Logitudinal pitch of adjacent opening
(Considering shorter pitch) = 181 mm

Tolerance of longitudinal pitch + /- side = 1 mm

Pitch for calculation (Along -ve Tol.) = 180 mm

Equivalent diameter of hole opening

(Hole area / Header Thickness) = 51.904 mm

Substituting,
Longitudinal Ligament Efficiency = 76.192
180
= 0.4232888889

Circumferential Ligament Efficiency for 50.8 dia. tubes:

The equivalent longitudinal efficiency of circumferential ligaments:

2 x [ Pc - d ]
E =
Pc

Where ,
Governing Circumferential pitch of adjacent opening = 7 =
Angular tolerance for orientation on + /- side = 0.3 ( with 0.3 ° -ve Angular Tole

Pc = Circumferential pitch of adjacent opening (Considering shorter pitch)

= 76.4380667 mm for 6.7 degree angle

d = Equivalent diameter of hole opening = 51.904

Substituting ,
Equivalent longitudinal efficieny = 0.6419332078
of Circumferential Ligaments

Diagonal Ligament Efficiency between rows 'n' & 'p':

Hole along a diagonal: When a shell or drum is drilled for tube holes as shown in fig PG-52.5 the efiiciency of ligamen
given by Fig PG-52.1
 Longitudinal Pitch [p] = 76 mm
Diagonal Pitch [p'] = 84.528 mm
Diameter of holes [d] = 51.904 mm
Angle of diagonal with longitudinal = 65 °

p' / d = 1.6285450062

Equivalent Longitudinal Efficiency of Diagonal Ligament = 0.57

Governing Ligament Efficiency:

Longitudinal Ligament Efficiency for 50.8 dia. tubes: = 0.423289

Circumferential Ligament Efficiency for 50.8 dia. tubes: = 0.641933
Diagonal Ligament Efficiency between rows 'n' & 'p': = 0.57

Hence, Governing Ligament Efficiency = 0.423

 PG-52
Page-38
1234 mm
3.2 mm

4 mm
1238 mm
1244.4 mm
70 mm
66.8 mm
5.64 MPa(g)
135.84 Mpa

with +0.3 mm tolerance on diameter

with +0.4 mm tolerance on diameter

with +0.4 mm tolerance on diameter
 PG-52.2.1
Page 38

PG-52.3
page 40

6.7
( with 0.3 ° -ve Angular Tolerence)

mm

0.6419332078

PG- 53
Page 41
G-52.5 the efiiciency of ligament shall be
Page 41

Fig: PG-53.3
Page 42
DRUM SHELL THICKNESS REQUIREMENT CALCULATIONS

Equipment Data:
Drum Inside Diameter = 1244.4 mm (with Tolerance & C.A.)
Drum Inside Radius [ R] = 622.2 mm (with Tolerance & C.A.)
Design Pressure [P] = 5.64 MPa(g)
Allowable Stress [S] = 135.84 Mpa
Governing Ligament Efficiency[E] = 0.423
Drum Nominal Thickness = 70 mm
Drum Thickness (corroded condition) = 66.8 mm

Minimum Required Drum Shell Thickness [t]

t = PR / [SE - (1 - y)P] + C

Where,
Temperature Coefficient [y] = 0.4
Allowance for threading and Structural stability [C] = 0
Corrosion Allowance [CA] = 3.2 mm

Substituting,
t = 3509.208
54.07632
= 64.893617 mm

t = 68.093617 mm (with corrosion allowance)

Since the required thickness (68.1 mm) is less than the provided thickness (70 mm), the provided thickness is adequate.

Minimum thickness required for unpierced shell(E=1)

Substituting E = 1

t = 3509.208
132.456
t = 26.493386483 mm

Hence,
t = 29.693386483 mm (with corrosion allowance)

Evaluation of Single opening on Shell

Single openings are defined as opening that have minimum centre to centre distance
between adjacent opening not less than Ls= 2X.

where,
 X = Limit of compensation parallel to vessel wall =
d = Dia. of the finished opening
Rn = Radius of the finished opening
tn = Thickness of nozzle wall
t = Thickness of the vessel wall

d, t, tn, Rn all are considered in corroded condition

# Marked : Values considered in corroded condition
* Size of openings are taken as equivalent diameters.

Nozzle Name: Center to Center Distance (mm) Dia. Of finished Nozzle wall Thk. [tn]#
opening [d]*# (mm) (mm)
LHS RHS Min[LHS,RHS]
N9 350 700 350 66.9 16.55
N8 2000 350 350 46.22 7.04
N7 300 2000 300 24.1 9.43
N5 300 300 300 24.1 15.85
N13 2000 1500 1500 38.4 5.44

Hence, All nozzles on Drum Shell are Single Openings.

Compensation Calculation for Openings on Drum Shell:

Equipment Data:
Drum O.D [D] = 1378 mm
Nominal Shell thickness [t] = 66.8 mm (corroded thk.)
Design Pressure [P] = 5.64 Mpa(g)
Allowable Stress [S] = 135.84 Mpa

No compensation calculation is required for single opening, when dia of

finished opening 'd' does not exceed the larger of (a) or (b)

a) the smaller of one-fourth the inside diameter of the shell or 60 mm

1/4th of Shell I.D = 311.1 mm
Min of 1/4th shell I.D. & 60mm = 60 mm …………(a)

b) value of d max calculated in PG-32.1.2 for single opening

dmax = 8.08 [Dt (1 - K)]^(1/3)
where,
K = PD / 1.82St (Where K shall not exceed 0.
K = 0.470601

dmax = 295.1306 mm ……….(b)

Larger of ( a ) and ( b ) is = 295.1306 mm

Maximum hole size on the drum = 63.5 mm (Safety Valve Connection )
Conclusion:
Since the maximum finished opening size (63.5 mm) is less than the larger diameter calculated in (a) & (b) above, hence
compensation calculations are not required.

END COVER THICKNESS REQUIREMENT CALCULATIONS

( AS PER PG-16.1 END COVER THICKNESS CALCULATION IS DONE AS PER BS-1113)

te = 1.15 x C x di x sqrt ( p / f ) ….. FOR PIERCED END COVERS (3.6.2.1)

where,
MAX. ID OF PIPE …..mm[di] = 131.78 mm
P = DESIGN PRESSURE …. = 5.64 MPa(g)
f = ALLOW ABLE STRESS ….. = 128.84 MPa
End Cover Thickness (Nominal) = 25 mm
End Cover Thickness (corroded condition) = 21.8 mm

Where, Factor [C] = 0.41

Required Thickness, mm
Description End cover dia. (mm) EndCover thk, mm Allowable stress, (including C.A.)
Mpa (g)
For Dia 168.3 x 18.26 thk. 168.3 21.8 128.84 13

Conclusion:
The above provided thickness for all end covers are less than the minimum provided
thickness. Hence, thicknesses provided are adequate.
(with Tolerance & C.A.)
(with Tolerance & C.A.)

PG-27.2.2
Page 17

PG-27.4.6, Page 18
PG-27.4.3, Page 18

thickness is adequate.

PG-32.1.3 Page 26

PG-36.2 Page 31
 PG-36.2 Page 31
max (d, Rn + tn + t)

Shell Thk. Rn+tn+t X=max[Rn+tn+t,d]

[t]# (mm) (mm) Ls=2*X Remark
(mm)
66.8 116.8 116.8 233.6 Single Opening
66.8 96.95 96.95 193.9 Single Opening
66.8 88.28 88.28 176.56 Single Opening
66.8 94.7 94.7 189.4 Single Opening
66.8 91.44 91.44 182.88 Single Opening

PG-32.1.4
Page 26

PG-32.1.4
Page 27
PG-32.1.1
Page 26,27

(Where K shall not exceed 0.990) PG-32.1.1

Page 26

alve Connection )
(a) & (b) above, hence

PG-16

Required Thickness, mm
(including C.A.) Remark

13 Safe
DISHED END THICKNESS REQUIREMENT CALCULATIONS

Equipment Data:
Inside Diameter of Dished End = 1234 mm (uncorroded condition)
= 1240.4 mm (corroded condition)
Dished End Minimum Thickness = 56 mm
Dished End Minimum Thickness afetr C.A. = 47.2 mm (Considering 10% thinning & C.A.)
Dished End Shape = 2:1 Semi-Ellipsoidal
Design Pressure [P] = 5.64 MPa(g)
Allowable Stress [S] = 135.84 MPa
Corrosion Allowance [CA] = 3.2 mm
Minimum Required Thickness for 2:1 Semi-Ellipsoidal Dished End:
Minimum Required head thk = Minimum thickness required for unpierced shell E=1

A blank head of a semi ellipsoidal form in which half the minor axis or the depth of the head is atleast equal to
one quarter of the inside diameter of the head shall be made atleast as thick as the required thickness of a seamless shell of
the same diameter as provided in PG-27.2.2

Inside Diameter of Head = 1234 mm

1/4th of I. D. of Head = 308.5 mm
Depth of Head = 308.5 mm
Dished End Minimum Thickness after C.A. = 47.2 mm

Required thickness of a
seamless shell of the same diameter = 29.693 mm

As the provided thickness (47.2 mm) for the dished end is greater than the required thickness of a seamless shell (29.693 mm)
adequate.

Minimum Required Thickness of Seamless Ellipsoidal Dished Head for Compensation Calculation:
If the opening and its compensation are in an ellipsoidal head in which one half of the minor axis is equal to one
fourth of inside diameter, and are located entirely within a circle the center of which coinside with center of
head and the diameter of which is equal to 80% of the shell inside diameter, tr is the thickness required for a
seamless hemispherical head of radius equal to 90% of the inside diameter of the shell.

diameter of which is equal to 80% of the shell inside diameter

Diameter of circle = 992.32 mm
Center of manhole coinside with the center of circle (i.e. center of head)
Diameter of manhole = 555.57 mm

Since, Diameter of manhole < Diameter of circle , the manhole opening is located entirely with in the circle.

Hence, the minimum thickness required for hemispherical dished head is,
 tr = PL / [2Sw - 0.2P]
where,
L = 90% of the inside diameter of the shell = 1110.6
w = weld joint strength reduction factor per PG-26 = 1

Substituting,
t = 23.15187 mm
t = 26.35187 mm (considering corrosion allowance)

Evaluation of single opening on Dished End:

Single openings are defined as opening that have minimum centre to centre distance between adjacent
opening not less than Lh = (A+B)/[2x(1-K)]

where,
Lh = The distance between the centres of two openings measured on the surface of the dished head
A,B = The finished opening diameters of any 2 openings under consideration
K = P*D / 1.82*S*t (where K shall not exceed 0.990)
= 0.599515
d = Diameter of the finished opening
Rn = Radius of the finished opening
tn = Thickness of nozzle wall
t = Thickness of the vessel wall

d, t, tn, Rn all are considered in corroded condition

Dia. of finished opening [d] (mm) Center to center [A+B]

Nozzles Lh = [A+B] / [2*(1-K)]
Nozzle 'A' Nozzle 'B' distance (mm) (mm)

Manhole & N1 (Feed

Water 632.91 138.1 400 771.012 963.77
Connection)

Manhole & N3 (LG 633.91 69.4 461 702.312 877.89

Connection)

Manhole & N10 (CBD 634.91 27.1 482.8 660.012 825.02

Connection)

The manhole and nozzle connections are not single openings. Hence, PG-38 shall be
used for compensation calculation.
 PG-29.7
Page 22
d condition)
ondition)

g 10% thinning & C.A.)

PG-29.7

equal to PG-29.7
s of a seamless shell of Page 22

PG-27.2.2

mless shell (29.693 mm), it is

PG-33.3-(b)
Page 28

PG-29.11
Page 22
 PG-29.11
Page 22

PG-32.1.3 Page 26

he dished head

Page 31

Comparison between (Lh) &

Lh = [A+B] / [2*(1-K)] Remark
(Centre to Centre Distance)

963.77 400 < 963.77 Not Single Opening

877.89 461 < 877.89 Not Single Opening

825.02 482.8 < 825.02 Not Single Opening

MANHOLE RIM THICKNESS REQUIREMENT CALCULATIONS

Equipment Data:
Manhole Rim Thickness (Nominal) = 45 mm
Manhole Rim Thickness = 41.8 mm (Corroded condition)
Inside major axis dimension of rim = 415 mm (Considering C.A. & Tolerance)
Outside major axis dimension of rim (a) = 500 mm
Inside minor axis dimension of rim = 310 mm (Considering C.A. & Tolerance)
Outside minor axis dimension of rim (b) = 395
Where D = a2 / b ………………PG-28.2
Manhole Rim ID [D] = 555.57
Manhole Rim OD [D] = 632.91
Design Pressure [P] = 5.64 MPa(g)
Allowable Stress [S] = 128.84 MPa
Manhole Gasket Thickness = 1.5 mm

Manhole rim is projected inward subjected to external pressure and for thickness calculations
PG-27 clause will be used as internal projection of rim past toe is equal to mahole rim thickness.

Hence, minimum required manhole rim thickness,

t=[PD]/[2SE+2yP]+C
where,
Weld joint strength reduction factor as per PG-26 [E] = 1
Temperature Coefficient [y] = 0.4
Allowance for threading and Structural stability [C] = 0 mm
Corrosion Allowance [C.A.] = 3.2 mm
Substituting,

t = 13.6145 mm
t = 16.8145 mm (with corrosion allowance)

As the required thickness (16.81 mm) is less than the provided thickness (45 mm), the provided thickness is adequate.

Minimum width of bearing surface for gasket for manhole rim = 17 mm

Maximum thickness of the gasket for a manhole rim = 6 mm

Since, the provided thickness (41.8 mm) is greater than 17 mm, the provided thickness is adequate.
Since, the gasket thickness used for manhole opening is 1.5 mm, which is less than 6 mm, the gasket thickness is OK.
 PG-28
Page 19
d condition)
ing C.A. & Tolerance)

ing C.A. & Tolerance)

……PG-28.2
PG-28.2
Page 19

PG-28.2
Page 19

PG-27.2.2
Page 17
PG.27.4.1 Page17
PG.27.4.6 Page18
PG.27.4.3 Page18

d thickness is adequate.

Acc. to PG-44.3 PG-44.3 Page 37

uate.
gasket thickness is OK.
MANHOLE COVER THICKNESS REQUIREMENT CALCULATIONS

Equipment Data:
Long Span of Manhole Cover [D] = 495 mm
Short Span of Manhole Cover [d] = 390 mm
Design Pressure [P] = 5.64 MPa(g)
Allowable Stress [S] = 135.84 MPa
Manhole Cover Thickness (Nominal) = 70 mm
Manhole Cover Thickness (corroded condition) = 66.8 mm
Corrosion Allowance [C.A.] = 3.2 mm
Minimum Required Thickness for Non-Circular Cover:
t = d x (ZCP / S)^(1/2)
where,
Z = 3.4 - [(2.4 x d) /D]
= 1.509090909
C = Factor depending on method of attachment
= 0.33
hence,
t = 56.07961119 mm
t = 59.27961119 mm (with corrosion allowance)

Since, the required calculated thickness (59.278 mm) is less than the provided thickness (70 mm), hence it is adequate

Manhole Bolt Load capacity & Pin design

Full load capacity of Bolt = P

Material of Construction = SA 105 (P No. 1 & Group No. 1)
Allowable Stress = 128.84 MPa (At DMT)
Tensile Strength = 483 MPa
Bolt Size d = M 30
Core dia. dc = 0.8 xd = 24

Door Studs shall be of welding quality steel having min. specified tensile strength of not less than 360 MPa. Those for Manhole

Since the tensile strength of SA 105 is 483 MPa which is greater than 360 MPa & also the provided bolt size is of M30, conditio
satisfied.

Allowable stress = P = P
( Area ) ( π / 4 ) x dc^2

Rearranging,
P = Allowable Stress x { ( π/ 4 ) x dc^2}
P = 58256.29 N

Checking of double shear failure of pin due to this full load as bolt is connected to manhole cover plate through this pin arrang
Checking of double shear failure of pin due to this full load as bolt is connected to manhole cover plate through this pin arrang

Full load capacity of Bolt P = 58256.2944 N

Material of Pin = SA 105 (P No. 1 & Group No. 1)
Pin Size d ( O.D ) = 28 mm
Yield stress of pin = 187.2 MPa
Allowable Shear Stress Value = 74.88 MPa
( 0.4 x yield stress )

Induced stress = P = P
2 x ( Area ) 2 x ( π / 4 ) x d^2

Induced stress = 47.3289795918 N/mm^2 = 47.32897959 MPa

As the induced stess (47.353 MPa) is less than the allowable stress (74.88 MPa), the pin is safe in shear.
 PG-31
Page23

PG-31.3.3
Page 23

ethod of attachment Figure PG-31

Page 24

(with corrosion allowance)

, hence it is adequate

)
ASME Sec II-D
Page 570, Line 9

360 MPa. Those for Manholes shall be not less than BS: 1113
Cl. 4.4.2.5
d bolt size is of M30, conditions of BS 1113 are ASME SecIID
page18,line 32

plate through this pin arrangement,

 plate through this pin arrangement,

& Group No. 1)

ASME SecIID
page18,line 32
COMPENSATION CALCULATIONS FOR OPENINGS ON DISHED ENDS

When limits of compensation overlap,the two openings shall be compensated in accordance with PG-33 with a
compensation that has an area equal to the combined area of the compensation required for separate opening.

When required, compensation shall be provided in such amount and distribution that the requirement of area of
compensation are satisfied for all plances through the center of the opening and normal to the vessel surface.

Elliptical manhole rim is used , so Plane-1 and Plane-2 are considered as shown in above figure.

Area Compensation Calculations :

As the manhole opening is adequately reinforced in both the planes, no additional reinforcement is required.

Area Compensation Calculations :

As all the openings are adequately reinforced, no additional reinforcement is required.

with PG-33 with a PG-38
eparate opening. Page32

irement of area of PG-33.1

e vessel surface. Page 27
ent is required.
STAND PIPE THICKNESS REQUIREMENT CALCULATIONS

Required thickness of pipe under internal pressure

t = [PD]/[2SE+2yP]+C --------------------- [a]
where,
P = Design Pressure = 5.64
D = Pipe O.D.
S = Allowable Stress = 118
S = Allowable Stress = 118
E = w, the weld joint strength reduction factor as per PG-26 = 1
Y = Temparature coefiicient = 0.4
C = Min allowance for threading and structural stability = 0

Required thk of seamless shell or head to which nozzle is attached -------------------- [b]
Standard pipe wall thickness listed in Table 2 of ASME B36.10M with - 12.5% Tol. -------------------- [c]

Reqd. thk of Stand Pipe is max. of [a] and [min of `b' & `c']

The above provided thickness for all nozzles are less than the minimum
provided thickness. Hence, thicknesses provided are adequate.

Negative tolerance not considered for forgings

# Values without corrosion allowance
@ Values with corrosion allowance
* Pipe wall thickness with 12.5% negative tolerence & corrosion alloavance
 Page 37

PG-27.2.2
Page 17
MPa(g)

MPa [For SA 106 Gr B]

MPa [For SA 210 Gr A1]
PG-27.4.1, Page 17
for ferritic steel below 480° C PG-27.4.6, Page 18
PG-27.4.3, Page 18

PG-43
Page 37
NOZZLE ATTACHMENT WELD SIZE REQUIREMENT CALCULATIONS

tc = not less than smaller of 6mm or 0.7 tmin

t1+t2 = thickness of lug hanger or bracket, 0.7 tmin but not less than 6mm
tmin = smaller of 19mm or thickness of either of the weld part
t = provided fillet weld leg size
t = thickness of shell or head
tn = thickness of nozzle wall
t1+t2 > 1.25 tmin, both t1 & t2 each shall be not less than the smaller of 6 mm or 0.7 tmin

* Thicknesses on nozzle insides are considered with corrosion allowance

Fig:PW- 16.2
Page 96

PW-16.2
Page 91
WELD STRENGTH CALCULATION FOR STAND PIPES

Weld connections type used:

1. PW-16.1 (a)
2. PW-16.1 (d)
3. PW-16.1 (h)
4. PW-16.1 (z)
b) opening designed by ligament rules of PG-52 or PG-53
c) opening with elements of compensation attached by full penetration weld as listed in PW-15.1.6

Weld strength calculations are not required for weld configurations shown in figure PW-16.1, sketches (a), (h) &
(z) as per clause PW-15.1.6

Hence weld strength calculations are done for manhole rim as this nozzle not exempt in PG-32 from
compensation calculation and for level Gauge & LT Connection and for CBD Connection. having PW-16.1 (d)

Weld strength calculations

= Weld strength required = (A-A1)Sv

where,
A = Area reqd for compensation = (d+2tn)trF
Al = Area available in shell for compensation,
larger of below Larger of [ (d-2*tn)*(t-
F*tr ) ] & [ 2*t *(t-F*tr) ]

Sv = Allowable stress of shell/DE

Wa = Weld strength available = WL1 in shear + WL2 in shear PW-15
[ 0.49 x 0.5 x x WL1 x ( d + 2 tn + WL1 ) x Sv x fr1 ]
[ 0.49 x 0.5 x x WL2 x ( d + 2 tn + WL2 ) x Sv x fr1 ]

WL1 = Fillet weld size outside of Shell / D.E. d = Diameter of finished opening
WL2 = Fillet weld size inside of Shell / D.E. tn = Nominal thk of nozzle
t = Provided thk.of Shell / D.E. tr = Required thk of Shell / D.E.
F = As taken from figure PG-33.3 fr1 = sn/sv
sn = allowable stress of nozzle material sv = allowable stress of shell material
Since the weld strength available (Wa) is greater than the weld strength required (W), the welding is safe.
 PW-15.1.6
Page 89

PG-37.2
Page 32

ar PW-15
+ 2 tn + WL1 ) x Sv x fr1 ] + PW-15
+ 2 tn + WL2 ) x Sv x fr1 ] Page 90
HYDROSTATIC TEST, VOLUMETRIC EXAMINATION & PWHT REQUIREMENTS

a) Hydrostatic test Requirments

Drum shall be hydrostatically tested after completion.

Test Pressure shall be: = 1.5 X M.A.W.P.
= 1.5 X 5.64
= 8.46 MPa(g)

Considering 6% margin on hydrotest pressure,

Maximum allowable hydrotest pressure = 1.06 X 8.46
= 8.9676 MPa(g)

Minimum hydrostatic test temp shall be 20°C and shall not exceed 50°C

b) Volumetric Examination requirment of welded butt weld joints. PW

Steam Drum welds are not subjected to Furnace radiant heat.

The content of the Drum are Steam & water.
Since drum circumferential weld thickess (70 mm) is greater than 29 mm
Volumetric examination is required as per PW-11 as follows:
100% RT for steam drum shell butt joints is required.

Nozzles welds are not subjected to Furnace radiant heat.

The content of the Drum Nozzles are Steam & water.
Since Nozzle weld thickness is not greater than 29 mm and Pipe size is not greater than 250 DN.
Volumetric examination is not required as per PW-11.

c) Post Weld Heat Treatment (PWHT) requirments:

Since SA 516 Gr. 70 is Part No.1 & Group No. 2,

PWHT has to be carried out as per ASME Sec-I, PW-39.
for Steam Drum Assembly

Minimun holding time = 135 mins

Minimum holding temp = 595 °C
 PG-99
Page75

MPa(g)

MPa(g)

PW-11
Page 88

Table PW-11
Page 89

Table PW-11
Page 89

PW-39

Table PW-39-1
Page 102
CALCULATIONS FOR MEMBRANE STRESSES DEVELOPED DURING HYDROSTATIC TEST

As per PG-99.1 No part of boiler should be subjected to general membrane stress greater than 90% of its
yield stress at test temperature

Maximum Hydrostatic Test Temperature = 50 °C

Minimum Hydrostatic Test Temperature = 20 °C
(considering hydrostatic test pressure with 6% margin) = 1.06
Membrane stress for Steam Drum shell (at corroded condition):

The test pressure shall be = 1.5 X M.A.W.P.

M.A.W.P = 5.64 MPa(g)
Hydrostatic test pressure [P] = 8.46 MPa(g)
Hydrostatic test pressure with 6% margin [P'] = 8.9676 MPa(g)
Drum inside Radius [R] = 622.2 mm (Corroded condition)
Drum Thickness [t] = 66.8 mm (Corroded condition)

Required drum shell thickness, PG

PR
t =
SE - ( 1 - y ) P

PR
S = +
( t - C) x E

Where,
Governing Ligament Efficiency[E] = 0.423
Temperature Coefficient [y] = 0.4
Allowance for threading&structural stability [C] = 0 mm
Yield Strength at 50°C = 255.6 MPa
90% of yield strength at 50°C = 230.04 MPa

Substituting values we get

S = 186.28743 + 12
= 198.28743 MPa
As Stress calculated < 90% of yield stress, membrane stress are within acceptable limits

S' = 210.18467 MPa (considering hydrostatic test p

As Stress calculated < 90% of yield stress, membrane stress are within acceptable limits

Membrane stress for Dished End:

Hydrostatic test pressure[P] = 8.46 MPa(g)
Hydrostatic test pres. with 6% margin[P'] = 8.9676 MPa(g)
Drum inside Radius [R] = 617 mm
Dished End Thickness [t] = 47.2 mm (corroded condiion)
Yield Strength at 50°C = 255.6 MPa
90% of yield strength at 50°C = 230.04 MPa

For semi-ellipsoidal head, thickness required is equal to thickness of seamless shell

PR
t = + C
SE - ( 1 - y ) P
solving
PR P x (1- y)
S = +
(t-C)xE E

Where,
Governing Ligament Efficiency[E] = 1 (For a seamless shell)
Temperature Coefficient [y] = 0.4
Allowance for threading and Structural stability [C] = 0

S = 110.5894 + 5.076
S = 115.6654 MPa (considering hydrostatic test p
As Stress calculated < 90% of yield stress, membrane stress are within acceptable limits

S' = 122.6053 (considering hydrostatic test p

As Stress calculated < 90% of yield stress, membrane stress are within acceptable limits

Membrane stress calculation for nozzle pipes and manhole rim:

Hydrostatic test pressure[P] = 8.46 MPa(g)
Hydrostatic test pres. with 6% margin[P'] = 8.9676 MPa(g)

SA 106 Gr.B SA 105

Yield Strength at 50°C = 235.4 MPa 242 MPa
90% of yield strength at 50°C = 211.86 MPa 217.8 MPa

Required Pipe thickness is

t = (PD) / (2SE+2yP) + C
Rearranging,
S = {(PD) / [(t - c) x 2 xE]} - {( y x P) / E}

where,
Ligament Efficiency[E] = 1 (For a seamless shell)
Temperature Coefficient [y] = 0.4
Allowance for threading and Structural stability [C] = 0
No negative tolerance is considered for forgings.

Membrane Sterss calculation for Manhole Cover:

Hydrostatic test pressure[P] = 8.46 MPa(g)

Hydrostatic test pres. with 6% margin[P'] = 8.9676 MPa(g)
Manhole cover Thickness (corroded condition) = 66.8 mm
Yield Strength at 50°C = 255.6 = 255.6 MPa
90% of yield strength at 50°C = 230.04 MPa
Long span of Manhole Cover[D] = 495 mm
Short span of Manhole Cover[d] = 390 mm

Minimum required manhole cover Thhickness is

t = d x (ZCP / S)^(1/2)
where,
Z = 3.4 - [(2.4 x d) / D]
Z = 1.5090909

Factor depending on method of attachment

[C] = 0.33

Solving,
S = (d / t)^2 x ZCP
S = 143.60713 MPa (considering hydrostatic test p
As Stress calculated < 90% of yield stress, membrane stress are within acceptable limits

S' = 152.22356 MPa (considering hydrostatic test p

As Stress calculated < 90% of yield stress, membrane stress are within acceptable limits
 PG-99
Page 75
PG-99.2
Page 75

PG-99.1

(Corroded condition)
(Corroded condition)

PG-27.2.2
Page 17

P x (1- y)
E

PG-27.4.1, Page 17
PG-27.4.6, Page 18
PG-27.4.3, Page 18
ASME Sec II D
Table Y-1
Page 578, line30

(considering hydrostatic test pressure)

(considering hydrostatic test pressure with 6% margin)

ASME Sec II D
 Table Y-1
Page 578, line 30

PG-29.7
Page 22

P x (1- y)
E

amless shell)
PG-27.4.6, Page 18
PG-27.4.3, Page 18

(considering hydrostatic test pressure)

within acceptable limits

(considering hydrostatic test pressure with 6% margin)

within acceptable limits

SA 210 Gr.A1
249 MPa ASME Sec II D
Table Y-1
224.1 MPa

Page 578
PG-27.2.2
Page 17

PG-27.4.6
Page 18
amless shell) PG-27.4.3
Page 18
 ASME Sec II-D
Table Y-1
Page 578, line30

(considering hydrostatic test pressure)

(considering hydrostatic test pressure with 6% margin)

FLANGE SELECTION CALCULATION :

LONG WELDING NECK RF FLANGE & BLIND FLANGE

Flange details : 65 DN,Class 600, LONG WELDING NECK RF FLANGE & BLIND FLANGE
Material : SA 105M
Design Pressure : 5.64 MPa(g) = 56.4 bar(g)
Design temperature : 301 °C

According to ASME B16.5, Table-2-1.1

At 301 °C 65 DN,Class 600, LONG WELDING NECK RF FLANGE & BLIND FLANGE

can withstand pressure = 79.512 bar

Hence, 65 DN,Class 600, LONG WELDING NECK RF FLANGE & BLIND FLANGE is suitable for above stated conditions.
 ASME B 16.5
Page 23

ASME B16.5
Page 23

e stated conditions.