Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
Document no.

ASME01
P34- -CS-01691

Revision No.

ASME
CALCULATIONS FOR
ECONOMISER OUTLET HEADER (DEMO VESSEL)
AS PER
A S M E SECTION I
EDITION 2015

1 of 29

Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
Document no.

ASME01
P34- -CS-01691

Sr. No.

1
2
3
4
5
6
7
8
8.1
9
10
11
12
13
14

CONTENTS
Description
Front Page
Contents
Revision control sheet
General
Design data
Material, Size And Allowable Stresses
Openings In Economiser Outlet Header
Ligament Efficiency Calculations For Header
Header Thickness Calculations
Tube Stub Thickness Calculations
MHH (Master Handhole) Plug Of Header
1
Weld calculation of MHH Plug
Hemispherical Head Thickness Calculations
Hole Compensation Calculations For Header
Hydrotest Blank Thickness Requirement Calculation
Membrane Stresses Developed During Hydrostatic Test
PWHT & RT Requirements
Nozzle Attachment Weld Size Calculations

Revision No.

Page No.
1
2
3
4
5
6
7
8-9
10
11
11
12
13
14-19
19
20-21
22
23

2 of 29

Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
Document no.

ASME01
P34- -CS-01691

Revision No.

REVISION CONTROL SHEET

Page No.
Rev.0
Rev.1
1
First Issue
2
First Issue
Sr no. 8.1 added.
3
First Issue
4
First Issue
Design pressure and Hydrostatic Test
Pressure converted in to kg/cm2
5

First Issue

6
7
8
9

First Issue
First Issue
First Issue

10

First Issue

11

First Issue

First Issue

13
14

First Issue
First Issue

15
16
17
18
19
20
21
22
23

First Issue
First Issue
First Issue
First Issue
First Issue
First Issue
First Issue
First Issue
First Issue

Rev.3

To convert Unit of Pressure from MPa to

kg/cm2, ASME SEC-I, A-393 is used.Also
values of temperature and pressure are
rounded up.

Working of calculation is explained as

marked.
calcuation reference is given and working
of calculation is given.

First Issue

12

Rev.2

Sr no. 8 taken on page no.11

Tube tolerance note is given and working

of calculation is given as marked.

Sr no. 8.1 added.

Working of calculation is explained as

marked and perimeter of shoulder for
MHH plug is changed.

Reviewed & Approved for page no. 1 of 23

Rev..
0
Prepared By
DJP
Checked By
RBW
Approved By
C.B.
Date
10/12/2015

Working of calculation is explained as

marked.

Working of calculation is corrected.

to 23 of 23.
1
DJP
RBW
C.B.
26/02/2016

DJP
RBW
C.B.
10/3/2016

3 of 29

Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
Document no.

ASME01
P34- -CS-01691

Revision No.

2
Reference

1) GENERAL
Equipment Name :
Name of the Customer:

Economiser Outlet Header (Demo Vessel)

The Babcock and Wilcox Company

Reference Documents :
S. NO.

Document no. & Description

Revision no. Effect on

design calc.
with date
0
First Issue
13/07/2015

Page numbers revised

Tramsmittal BW-TBWES-0290
ECO OUTLET HEADER

P34-1 -002589
ASSEMBLY & DETAIL
ECONOMIZER OUTLET HEADER

0
15/12/2015

First Issue

First Issue

P34-3 -001622
DETAIL OF FORGED HEMI HEAD

0
15/12/2015

First Issue

First Issue

First Issue

First Issue

First Issue

Code of Design & Construction:

Type of construction :
Loading :

ASME Section I,Edition 2015

Welded
Economiser Outlet Header is subjected to internal pressure only.

PG-22

Corrosion Allowance :

None

CIS 31.3

Note :
Rounding off of the figures used in calculations is done to maximum 3 digits after decimal.

4 of 29

Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
Document no.

ASME01
P34- -CS-01691

Revision No.

2
1
Reference

2) DESIGN DATA:
1. Maximum Allowable Working Pressure :
M.A.W.P. =
4350 psi(g)
= 4350 x 0.0068948
1 PSI =
=
29.992 MPa(g)

0.0068948

B&W Doc. no. CIS 31.3

A-393

Mpa(g)

2. Design Pressure for Boiler :

Design Pressure [ P ] =

M.A.W.P. + Max.Hydrostatic Head in the boiler acting on any of

the boiler component

In design calculations P as per above formula will be used in various formula as given in code to calculate
required thicknesses of pressure part components.
Calculated thicknesses then will be compared with actual component thk. for suitability check.
Max Hydrostatic Head

P =

29.992

=0
mm of water column
= 0
MPa(g)
10
=9.81
0
MPa(g)
^6
+ 0 =
29.992
MPa(g)

29.992
MPa(g)
=
29.992
N/mm2
To mention above design pressure in drawing , we will convert it into kg/cm 2 as calculated below :
Now,
1 lbm =
0.4535924 kg
(from ASME SEC-I, A393)
and
1 lbf =
4.448222 N
(from ASME SEC-I, A393)
So,
1 N = ( 1 / 4.448222 ) =
0.224809
lbf
therefore,
1N=
0.224809 x 0.4535924 = 0.101972
kg
So, P = (29.992 x 100) x 0.101972
=
306
kg/cm2

B&W Doc. no. CIS 31.3

Hence,Adopted Design Pressure [ P ]=

and Hydrostatic Test Pressure =

=
=

(1.5 x MAWP)
1.5 x 29.992
44.988 MPa(g)

PG-99.1

To mention above Hydrostatic Test Pressure in drawing , we will convert it into kg/cm2 as calculated below :
So, Hydrostatic Pressure
=
(44.988 x 100) x 0.101972
2
=
459 kg/cm2

3. Design Metal Temperature

700 F

Design Metal Temperature for Ecomiser Outlet Header,

Hemis head and MHH Plug =
Now, (F - 32 ) x 1.8 = C
So, ( 700F -32 ) x 1.8 =
371
C
2
Design Metal Temperature for Tube stub :
Mean temperature of Tube stub

Design Metal temperature of Tube stub =

700 F

CIS 31.3

CIS 31.3

371 C

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Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
Document no.

ASME01
P34- -CS-01691

Revision No.

2
Reference

3) MATERIAL, SIZE AND ALLOWABLE STRESSES:

All material used in Pressure Part are as per ASME Section II, A (Edition 2015) material specifications
and are selected as per PG-6.1 & PG-9.1 of ASME Secton I.
As per Table 1A of ASME Sec.II, D (Edition 2015), applicability and Max. Temperature Limit
of material is checked as follow :
Component Description

Material

1. Ecomizer Top Header

2. Tube Stub
3. MHH Plug of Header
4. Forged Hemi Head
5. MHH Plug of Hemis Head
6. Hydrotest blank for Header

SA 106 Gr C
SA 210 Gr C
SA 181 - 70
SA 181 - 70
SA 181 - 70
SA 516 Gr 70

DMT [C]

Applicability

371.111
371.111
371.111
371.111
371.111
20.000

SEC I
SEC I
SEC I
SEC I
SEC I
SEC I

Max. Temp.
Limits

538 C
538 C
538 C
538 C
538 C
454 C

Allowable Stresses taken from ASME Sec.II D at Design Metal Temperatures [DMT] specified in the table as shown
below.
Allowable Stress
Component Description
Material
DMT [C]
[MPa(g)]
Notes
G10,S1,T1
1. Ecomizer Outlet Header
SA 106 Gr.C
371.111
124.867
G10,S1,T1
2. Tube Stub
SA 210 Gr.C
371.111
124.867
G10,S1,T2
3. MHH Plug of Header
SA 181 - 70
371.111
117.778
G10,S1,T2
4. Forged Hemi Head
SA 181 - 70
371.111
117.778
G10,S1,T2
5. MHH Plug of Hemis Head
SA 181 - 70
371.111
117.778
G10,S1,T2
6. Hydrotest blank for Header
SA 516 Gr 70
20.000
138.000
Now, for SA 106 Gr.C and SA 210 Gr.C
X1, C =
350
and
X2, C =
375
X, C =
371.111
As per Linear interpolation,
Y=Y1+(X-X1) (Y2-Y1)/(X2X1)=

Y1, MPa(g)=
Y2, MPa(g)=

So, Y=Y1+(X-X1) (Y2-Y1)/(X2X1)=

and

Y1, MPa(g)=
Y2, MPa(g)=

Page 22 to24
Page 22 to24
Page 18 to20
Page 18 to20
Page 18 to20
Page 18 to20

Page No.
ref. Sec-II D

Page 22 to24
Page 22 to24
Page 18 to20
Page 18 to20
Page 18 to20
Page 18 to20

135
123

135+(371.111-350) (123-135)/
(375-350)=

Simillary for SA 181 - 70,

X1, C =
350
X2, C =
375
X, C =
371.111

Page No.
ref. Sec-II D

124.867

Mpa(g)

117.778

Mpa(g)

122
117

122+(371.111-350) (117-122)/
(375-350)=

For, 6. Allowable Stress is taken at room temperature.

DMT - Design Metal Temperature [ for DMT refer Design Data ]
All notes are reviewed as per Table 1A from ASME SEC II, D (Edition 2015)
Thickness taken in below table are taken from Tranmittal BW-TBWES-0290 (Sr no.1-5) & same will be
checked in detail thickness calculation with respect to design inputs.
Component Description
Material
SIZE
1. Ecomizer Outlet Header
SA 106 Gr C
609.6 mm OD x 94.35 mm THK.
2. Tube Stub
SA 210 Gr C
63.5 mm OD x 7.112 mm THK.
3. MHH Plug of Header
SA 181 - 70
80 mm OD
4. Forged Hemi Head
SA 181 - 70
587.375 mm OD x 76.2 mm THK
5. MHH Plug of Hemis Head
SA 181 - 70
80 mm OD
6. Hydrotest blank for Header
SA 516 Gr 70
469.9 mm ID x 50 mm THK

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Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
ASME01
Document no. P34- -CS-01691
4) OPENINGS IN ECONOMISER OUTLET HEADER
Now,

Revision No.

2
Reference

dmax =

maximum permissible finished opening diameter for an uncompensated opening.

PG-32.1.1
8.08 [D t (1= K)] ^(13)
Where, D = Header Outside Diameter
609.600
mm
( from Sr. no.3 on page no.6 )
t = Header nominal Thickness
94.350
mm
( from Sr. no.3 on page no.6 )
P = Header Design Pressure
29.992
MPa(g)
( from Sr. no.2 on page no.5 )
S = Allowable Stress of header
124.867
MPa(g)
( from Sr. no.3 on page no.6 )
PG-32.1.1
K = ( P D ) / ( 1.82 x S x t )
= ( 29.992 x 609.6 ) / (1.82x124.867x94.35)
= 0.853

PG-32.1.1

Which is not greater than 0.990

Putting these values in above equation of dmax,

8.08 [609.694.35(1-0.853)]
dmax = ^(13)
=
164.606 mm
For, Tube Stub hole on header, Bore Diameter is finished opening.
Now, Bore Dia.
=
50.80
mm
& tolerance on bore dia is =
1/64
inch =
0.396
mm
So,
Finished Opening of tube stub = Bore Dia + Tolerance =
50.8 + 0.396 mm
= 51.196
mm
For MHH (Master Hand Hole) Plug of Header,
Max. Hole Size =
80.80 mm

B&W doc no. B0316678

B&W doc no. 60214C

B0316678

So, finished opening for tube stub and MHH Plug of header is less than the dmax of header as calculated above.

Now, we have group of openings of tube stubs which can be designed in accordance with the rules of
ligaments in PG-52 or PG-53.
Since, tube stubs are forming a definite pattern as shown in drawing no P34-1 -002589, PG -52 will be used.

PG-32.1.2
PG-52

Finished opening of MHH lug in Header is not formig any group of openings, so it will be checked to be a
single opening as per PG-32.1.3

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Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
Document no.

ASME01
P34- -CS-01691

Revision No.

0
Reference

5) LIGAMENT EFFICIENCY CALCULATIONS FOR HEADER

Equipment Data:
Header OD [D] =
Header Thk. [ t ] =
Header min.Thk. [ t ] =
(with 12.5% -ve tolerance)

609.6
94.35

mm
mm

82.556

mm

( from Sr. no.3 on page no.6 )

( from Sr. no.3 on page no.6 )
[94.35((100-12.5)/100)="82.556
"]

Ligament Efficiency for tube stub holes [ equal pitch ]

TUBE OD

HEADERTHK

SEATDEPTH

COUNTERBORE
DEPTH

THK

50.8
BORE DIA
63.9
TUBE SEAT DIA
69.9

Tube Stub OD =
63.500
Tube Stub Thickness =
7.112
Tube stub ID = 63.5-2x7.112
=
49.276
Bore Diameter +Tolerance = 50.8 + 0.396
=
51.196
Seat Diameter + Tolerance = 63.9 + 0.793
=
64.693
Seat Depth + Tolerance =
3.2 + 0.793
=
3.993
Counterbore Depth+ Tolerance =
7.9+0.793
8.693
Counterbore Dia. + Tolerance =
69.900
Allowable Stress for Tube Stub =
124.867
Allowable Stress for Header =
124.867
Stress Ratio (SR) =
=

mm
mm

(from Sr.no.3 on page no.6)

(from Sr.no.3 on page no.6)
(OD-2*Thickness)

mm
mm
B&W doc no. B0316678
B&W doc no. 60214C

mm
mm
mm
mm
Kgf/cm2
Kgf/cm2

(from Sr.no.3 on page no.6)

(from Sr.no.3 on page no.6)

Allowable Stress for Tube Stub

Allowable Stress for Header
124.867
124.867

=1

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Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
Document no.

ASME01
P34- -CS-01691

Revision No.

5) LIGAMENT EFFICIENCY CALCULATIONS FOR ECOMISER TOP HEADER (CONTD)

Equivalent Tube Stub Hole dia.
[d'] =
AREA I=
A1 =
=
=
AREA II=
A2 =
=
=
AREA III=
A3 =
=
=
AREA IV=
A4 =
=
=

Hole Area / Header thk.

Bore Diameter x (Header Thickness - (Counterbore Depth+Seat Depth))

51.196 (82.556 - (8.693+3.993))
3577.065
mm2
Tube Stub ID x (Counterbore Depth+Seat Depth)
49.276 (8.693+3.993)
625.115
mm2
(Tube Stub Seat Diameter - Tube ID) x (Seat Depth)
(64.693 - 49.276) 3.993
61.560
mm2
(Counterbore Diameter - Tube Stub ID) x Counterbore Depth x (1-SR )
(69.9-49.276 ) 8.693 (1-1)
0
mm2
AREA I+AREA II+AREA III+AREA IV
Equivalent Tube Stub Hole dia.
(d')=
HEADER THICKNESS
d' =
d' =

3577.065 + 625.115 + 61.56 + 0

82.556
51.647

mm

LONGITUDINAL LIGAMENT EFFICIENCY :

Tube Stub Hole Pitch [p] =
228.6
mm

B&W Doc No. B0316678

Now, Considering -ve tolerance of 1/16 inch (1.5 mm) ,

B&W Doc No. 60211c

228.6 - 1.5

227.10

Longitudinal Efficiency, E = [ P - d' ] / P

E = [ 227.1 - 51.647 ] / 227.1
E=
0.773

mm

co

co

CIRCUMFERENTIAL EFFICIENCY:
= angle between adjacent openings =
Dmean =
OD-Thk = 609.6-94.35=

(D_Mean (515.25)20/36
Circumferential Pitch (Pc) = )/360=
0=
Circumferential Efficiency =

co

P'
co

20.000
515.250 mm

PG-52.2.1
FIG.PG-52.2

Pc

Tube Stub Hole Pitch [p] =

co

PG-52.1
B0316678

P = 227.1
89.928 mm

2 x [ Pc - d' ] / Pc
= 2 x [ 89.928 - 51.647 ] / 89.928
= 0.851

Now, P/2 =
113.550
mm
( (227.1/2) ^2+ 8
( (P/2) ^2+
So, from Pythagoras Equation, P' = P_c ^2 )= 9.928 ^2 )=
144.847 mm
Now, (P'/ P) x100 =
(144.847 /227.1) x100 =
63.781 %
and ( P-d' ) / P
=
(227.1 - 51.647) / 227.1 =
77.258 %
2
Considering values of (P'/P)*100 as 63.781 % and 77.258 % as longitudinal efficiency, we will graph the
required Equivalent Longitudinal Efficiency on Diagonal Element from fig. PG52.1 as below:
So, Equivalent Longitudinal Efficiency on Diagonal Element =
71.700
%
So, Diagonal Efficiency =
0.717
Hence, Governing Ligament Efficiency for Header =
0.717

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Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
Document no.

ASME01
P34- -CS-01691

Revision No.

0
Reference

6 ) HEADER THICKNESS CALCULATIONS:

With reference to Sr. no.3 of page no.6, the requirements of Appendix A-317 can be used in place of the requirements
of PG-27 to determine the minimum required thickness of tube stub, header as design temperatures are not exceeding
those given for the various materials listed in Section II, Part D, Subpart 1, Tables 1A.

A-317

So,
Minimum Required Header Thickness =
A-317.2.1

t = D_i (e^(( PSE) )1) 2+C+f

Where,
P=
D=
S=
E=
f=
Di =

Adopted Design Pressure

=
Outside Diameter of Header
=
Allowable Stress
=
Ligament Efficiency
=
thickness factor for expanded tube ends=
Maximum ID of Header

29.992
609.600
124.867
0.717
0.000
444.488

C = Allowance for Structural Stability =

and threading etc
So,

MPa(g)
mm
MPa(g)

(from Sr.no.2 on page no.5)

(from Sr.no.3 on page no.6)
(from Sr.no.3 on page no.6)
(from Sr.no.5 on page no.9)

mm

2 (from Sr.no.5 on page no.8)

0.000 mm

A-317.3
Note-4
A-317.3
note 3

444.488 (e^(( 29.992 (124.867 x 0.717) )

t = )-1) 2+0+0=
t = 444.488 (e^(( 29.992/89.529) )-1)
2
t = 444.488 (e^((0.335) )-1) 2
2

t = 444.488 (1.397-1) 2
t=

88.438 mm

Since the required thickness (88.438 mm) is more than provided thickness
82.556
mm
thickness provided is NOT adequate as per PG-52 for tube stub openings.
Now, Minimum unpierced header thickness [by substituting E=1.0 in above formula]:
tr =

444.488(e^(( 29.992 124.867 x 1 ) )1)2+0+0

tr = 444.488(e^(( 0.24) )-1)2

tr = 444.488(1.271-1)2
tr =

60.338 mm

Now, as per PG-32.2.2, Multiple openings that are not designed as ligaments shall comply with PG-38.
82.556
mm is checked with PG-38 as shown on page 14-19.
So, the provided thickness

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Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
Document no.

ASME01
P34- -CS-01691

Revision No.

1
Reference

7) TUBE STUB THICKNESS CALCULATIONS:

Discription = 63.5 OD Tube Stub connection on Ecomizer Header
These tubes are ordered without under tolerances as 7.112 mm minimum thickness.
Minimum Required Header Thickness =
t = Di (e^(( PSE) )1) 2+C+f
Design Pressure [P] =
29.992
MPa(g)
Tube Stub O.D. [D] =
63.500
mm
Tube Stub Thickness =
7.112
mm
Allowable Stress [S] =
124.867
MPa(g)
ID of Tube [Di] =
49.276
mm
(OD - 2 x thk )
C=
0
f=
0
t = 49.276 (e^(( 29.992 124.867 x 2
1 ) )-1) 2+0+0
t = 49.276 (e^(( 0.24) )-1) 2 = 49.276
2
t = (1.271-1)
6.689 mm

A-317.2.1
(from Sr.no.2 on page no.5)
(from Sr.no.3 on page no.6)
(from Sr.no.3 on page no.6)
(from Sr.no.3 on page no.6)

The above calculated thickness is less than min provided Tube Stub thickness (7.112) mm, so
The Thickness Provided for the tube stubs are adequate.
Now,
Using Minimum Required Header Thickness formula omitting C factor, we will find the thickness
of Tube Stub for Reinforcement Consideration. Which is already calculated above.
trn =

6.689

A-317.3,
note 3,note 4

PG-33.3

mm

8 ) MHH (Master HandHole) Plug of Header

Selection of MHH plug is based on the trmperature and Pressure ratings given in B&W manual 2U-2U33,
page no.39.
As per Table for SA106C Header material,
Type B of MHH plug can be used for 700F and 5000 psi.
For, this Economiser Outlet Header,
Design Pressure
4350 psi
(from Sr.no.2 on page no.5)
Design Temeratre
700 F
(from Sr.no.2 on page no.5)
So, Type B which has 80 mm size can be use for Eco outlet Header and Hemis Head.
Now, Header has opening for MHH Plug & that need to be checked whether it is single opening or not.
For, MHH Plug , OD =
80.000 mm
B&W Doc no
Thk =
8.415 mm
(OD-ID)/2
B&W Doc no
Ls =
the distance between centers of the two openings measured on the surface
of the header .
X=
the limits of compensation parallel to the vessel wall given in PG - 36.2
Now, the limits of compensation from PG-36.2 ,
1) X1 = The diameter of finished opening =
80.800 mm
B&W Doc no

184396C
184396C
PG-32.1.1
PG-32.1.1
B0316678

2) X2 = The radius of finished opening + The thickness of vessel wall + The thickness of MHH Plug wall
The radius of finished opening =
80.8/2
=
40.400 mm
The thickness of vessel wall =
94.350 mm
The thickness of vent nozzle wall =
8.415 mm
So, X2 = 40.4+94.35+8.4151 =
143.165 mm
and X = Maximum (X1,X2) =
Now, Ls =

2X =

2x 143.165 =

143.165 mm
286.330 mm

(continued)

PG-32.1.3

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Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
Document no.

ASME01
P34- -CS-01691

Revision No.

2
Reference

8 ) MHH (Master HandHole) Plug of Header

From the drawing no.P34-1SJ-002044, between tube stub and MHH plug
Measured Longitudinal distance is =
931.900 mm
Angle
=
130.000 Degrees
Circumferantial distance
=
584.533 mm
So, Diagonal Distance
=
1100.053 mm
Which is note less than Ls. Therefore MHH Plug is a Single Opening.
Now,
One fourth of header inside diameter =
(1/4)* (Header OD - 2 * Header thk)
=
(1/4) * (609.6 - 2 * 94.35)
=
105.225 mm
So,
(a) " dmax " calculated by PG 32.2.2
=
164.606 mm
min
of
(105.225 mm and 60 mm )
=
(b) the smaller of one fourth of header
60.0 mm
inside diameter or 60 mm
And Larger of (a) & (b)

164.606 mm. (c)

As the diameter of finished opening (80.8 mm ) is less than above calculated value (c),
Compensation calculation is not required for single opening of MHH Plug inserted in Header.

PG-32.1.4

8.1 ) Weld of MHH plug to Header /Hemis Head

As per the drawing no. P34-1-002589,
Weld throat for MHH plug at Header and Hemis Head =
7.9
mm
Since, load is taken by the bottom shoulder of MHH plug, we will check the allowable load of the same.
Height of shoulder =7/8 inch =
22.225 mm
B&W Doc no 184396C
and Total Height of MHH Plug = (7/8) inch + (1.5) inch =
2.375
inch
So, Minimum thickness of MHH which will withstand pressure =
2.375 - 1 11/16 inch
=
2.375 - 1.688 inch
=
0.687 inch
=
17.450 mm
Now,
Perimeter of weld =

( as per the drawing no. P34-1-002589)

r = L/2 = 80.5 / 2 =
40.25 mm
and =127 (measured from drawing no. 184396C)

2
x(2r/360)

=2 x(2x40.25x127/360)

= 2 x 89.217
=
178.434 mm
Allowable stess of weld =
Min of allowable stress of Header/Hemis Head and MHH plug
=
117.778 Mpa
(from Sr.no.3 on page no.6)
Now, Allowable load for MHH weld =
=
=
And
Actual Load on shoulder =

Perimeter xshoulder height x 0.49 x allowable sress

178.434 x17.4498 x0.49 x117.778
179691.825 N

/4 L^2
P
= /4 x
80.5 ^2 x
29.992
= 152646.577 N

Where,

PW-15.2

P = Design Pressure
=
29.992 Mpa
(from Sr.no.2 on page no.5)

L=

80.5 mm
( as per the drawing no. P34-1-002589)
Since, Allowable load is more than actual load given at shoulder of MHH plug,
Weld between MHH plug and Header / Hemis Heaed is safe.

12 of 29

Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
Document no.

ASME01
P34- -CS-01691

Revision No.

9) HEMISPHERICAL HEAD THICKNESS CALCULATIONS:

Economizer Outlet header is having a HEMISPHERICAL HEAD at one end as a end clouser for which,
Minimum Required thickness of Hemis Head,
t=
Where,

P=
D=
tmin =
Di =
S=
w=
L=

PG-29.11

PL/(2Sw-0.2P)
Design Pressure
29.992 MPa(g)
Hemis head OD
587.375 mm
min available thickness
76.200 mm
Max. ID of Hemis Head
434.975 mm
Allowable Stress
117.778 MPa(g)
Not Applicable
Radius to which the head is dished, measured on the
concave side of the head = (Di / 2) = (434.975 /2 ) =

(29.992 x 217.488)/
and t = (2x117.778-0.2x29.992)=

( from Sr. no.2 on page no.5 )

( from Sr. no.3 on page no.6 )
( from Sr. no.3 on page no.6 )

(OD - 2 x tmin )
( from Sr. no.3 on page no.6 )

Tabe PG-26
217.488 mm

28.415 mm

Since the required thickness as calculated above is less than provided thickness
76.200
mm, thickness provided for head is adequate.

now, for HEMIS HEAD,

dmax = maximum permissible finished opening diameter for an uncompensated opening.
8.08 [D t (1= K)] ^(13)
Where,
K = 0.5 x ( P D ) / ( 1.82 x S x t )

PG-32.1.1
PG-32.1.4
PG-32.1.1
PG-32.1.5.3

= 0.5 ( 29.992 x 587.375 ) / (1.82x117.778x76.2)

= 0.540

Which is not greater than 0.990

Putting these values in above equation of dmax,

dmax = 8.08 [Dt(1-K)] ^(13)

PG-32.1.4

dmax = 8.08 [587.37576.2(1-0.540)] ^(13)

=

221.536 mm

For MHH (Master Hand Hole) Plug of Hemis Head,

Max. Hole Size =
80.80 mm
Counter bore Dia =
100.5 mm
Since, MHH plug is the only attachment to head , it is a single opening.
Now,
One fourth of hemis head inside diameter =
(1/4)* (Head OD - 2 * Head thk)
=
0.25 x (587.375 - 2 x 76.2)
=
108.744
mm
So,
(a) " dmax " caluclated by PG 32.2.2
=
221.536 mm 2
min
of
(108.774 mm and 60 mm )
=
(b) the smaller of one fourth of hemis head
=
60.000 mm
inside diameter or 60 mm
And Larger of (a) & (b) =
221.536 mm. (c)

B&W Doc no. B0316678

B&W Doc no. B0316678

As the diameter of finished opening (80.8 mm ) is less than above calculated value (c),
Compensation calculation is not required for single opening of MHH Plug inserted in Hemis Heaed.

13 of 29

Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
Document no.

ASME01
P34- -CS-01691

Revision No.

0
Reference

10) HOLE COMPENSATION CALCULATIONS FOR HEADER:

Now, we will check limits of compansation for multiple openings of tube stubs in Eco outlet header.
For, Tube Stub , OD =
63.500 mm
(from Sr.no.3 on page no.6)
Thk =
7.112 mm
(from Sr.no.3 on page no.6)
Ls =
the distance between centers of the two openings measured on the surface
of the header .
X=
the limits of compensation parallel to the vessel wall given in PG - 36.2
Inside dia. Of Tube Stub =
OD - (2 * Thk)
=
63.5 - 2 x 7.112
=
49.276
mm

Now, the limits of compensation from PG-36.2 ,

1) X1 = The diameter of finished opening =

51.196 mm

2) X2 = The radius of finished opening + The thickness of vessel wall + The thickness of Tube Stub
Now, The radius of finished opening =
51.196/2
=
25.598 mm
The thickness of vessel wall =
94.350 mm
The thickness of vent nozzle wall =
7.112 mm
So, X2 = 25.598+94.35+7.112 =

127.060 mm

and X = Maximum (X1,X2) =

127.060 mm

Now, Ls =

2X =

2 x 127.06 =

Now, minimum center to center distance

between adjacent tube stub openings on the
longitudinal axis, P =

254.120 mm

PG-38

PG-32.1.1
PG-32.1.1

PG-36.2.1
PG-36.2.2

PG-32.1.3

227.100 mm

Now, minimum center to center distance

between adjacent tube stub openings on the
circumferential axis , Pc =

89.928 mm

Now, minimum center to center distance

between adjacent tube stub openings on the
diagonal, P' =

144.847 mm

Now, P,Pc and P' are less than Ls.So, Limits of compansation are overlaped as per PG-38 and
compansation calculation is required .

14 of 29

Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
Document no.

ASME01
P34- -CS-01691

Revision No.

10) HOLE COMPENSATION CALCULATIONS FOR HEADER: (Contd.)

Hole Compensation Calculation for Tube Stub on Headers :
Tube Stub OD
OD =
63.500
Diameter of finished opening
(Bore diameter)
Inside radius of the nozzle
under consideration,

mm

( from 3),page.(6) )
( from 4),page.(7) )

d =

51.196

mm

Rn =
=

49.276 / 2
24.638

mm

Header thk (with -ve tolerance 12.5%) t =

82.556
Tube stub thickness
tn =
7.112
Thickness of attached reinforcing pad, te =
0.00
( Since there is no reinforcing pad in our configuration)

mm
mm
mm

( from 5),page.(8) )
( from 3),page.(6) )

Header thickness
(with Ligament Efficiency =1.00)
Counterbore Depth
Seat diameter Depth

Now,

tr =

60.338

mm

( from 6),page.(10) )

a =
SEDP =
Seat diameter =

8.693
3.993
64.693

mm
mm
mm

( from 5),page.(8) )
( from 5),page.(8) )
( from 5),page.(8) )

Minimum of (2.5t) &

(2.5tn+te)
= Minimum of (2.5x82.556) & (2.5x7.112+0)
= Minimum of (206.39)
& (17.78 )
=
17.78
mm

And, Maximum of (d) & ( Rn + tn +t )

= Maximum of (51.196) & (24.638+ 7.112 +82.556)
= Maximum of (51.196 & (114.306)
=
114.306
mm

Allowable stress for tube stub

Allowable stress for header
Stress Ratio,
fr =
Weld Length for weld
between Tube stub & Header,

Sn =
Sh =
(Sn / Sh) =

124.867
124.867
1.00

MPa
MPa

WL =

9.90

mm

Required thickness of Tube Stub found by

the formula used for tr for the header,
(omitting the C factor)

trn =

6.689

For plane of tube stub at 0 with respect to longitudinal axis of a header,

For plane of tube stub at 90 with respect to longitudinal axis of a header,
(for Circumferential Plane)

( from 3),page.(6) )
( from 3),page.(6) )
( from 3),page.(6) )
(from dwg P34-1SJ-002044
detail at E)
mm

F=
F=

For plane of tube stub at 38.38 with respect to longitudinal axis of a header, F =
(for Diagonal Plane)

( from 7),page.(11) )

1.00
1- 0.5sin
1= ^2
^290
= 0.5sin0.500
1- 0.5sin
1= ^2
0.5sin ^238.38

=
0.807
Wd = width of the nozzle inserted into the vessel wall beyond tn
For,Fig.PW 16.1(z1) configuration, there is no width of nozzle beyond tn and the same is used for this connection.
So, Wd =
0

15 of 29

Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
Document no.

ASME01
P34- -CS-01691

Revision No.

10) HOLE COMPENSATION CALCULATIONS FOR HEADER: (Contd.)

PG-33

Hole Compensation Calculation for Tube Stub on Headers :

OD

Fig. PW 16.1
(z)

tn

Rn
trn

A11

SEDP

2.5t or 2.5tn+te
use smaller value

A12

tr

d
SEAT DIA
d or Rn+tn+t
use larger value

P(d/(d+d))

P(d/(d+d))

Pc

Tube Stub

AREA REQUIRED =

Area available in Header

A1 =A11 + A12

= (d+2tn) x tr x F
In above figure Tube stub is not inserted through the
required thickness of a seamless header tr.
So, we can put, tn = 0 for this configuration in
above equation only.
= d x tr x F
A11 = (2d-OD) x (t-Ftr) - ((seat dia-OD) x SEDP) (2Wd (t Ftr) (1 fr))
A12 = (OD-d) x ((t-tr)-(SEDP+a))

fig. PG-33.1

fig. PG-33.1

Area available in Tube Stub

projecting outward

A2 =

2 x (tn-trn) x (2.5tn+te) x fr

fig. PG-33.1

Area available in Tube Stub

projecting inward

A3 =

2 x ( tn x fr ) x (SEDP+a)

fig. PG-33.1

Area available in outward

Tube Stub weld

A4 =

(WL)2 x fr

fig. PG-33.1

From,Sr No. 5 on Page no.9 ,

P=
227.100 mm
Pc =
89.928 mm
P' =
144.847 mm

16 of 29

Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
Document no.

ASME01
P34- -CS-01691

Revision No.

10) HOLE COMPENSATION CALCULATIONS FOR HEADER: (Contd.)

Area Required In Longitudinal Plane = d x tr x F

= 51.196 x 60.338 x 1=

3089.06

mm2

To prevent any reinforcement available between the TUBE STUBS from being counted more than once,
the reinforcement limit is reduced such that the available reinforcement in the shell is divided and attributed to
either nozzles compensation in proportion to its relative size.

A-69

For adjacent opening in longitudinal plane, this limit is P [d /(d+d)] =

A-69

P [d/2d)] = P/2
= 227.1 /2
= 113.55

mm

Since, in Longitudinal plane, tube stub has its reinforcement restricted from both sides by adjacent tube stub ,
the reduced limit is applicable on both sides.
Now, Area available in Header for longitudinal Plane, A1 = A11+A12
A11 = ( 2 ( P/2 ) - OD) (t-Ftr) - { (seat dia-OD) x SEDP } { 2Wd (t Ftr) (1 fr) }
A11 = ( 2x 113.55 - 63.5) x (82.556 - 1x 60.338) - { (64.693 -63.5) x 3.993 } - ( 2 x 0 ( 82.556 - 1x60.338)(1-1)
A11 = 3630.101
mm2
A12 = (OD-d) x ((t-tr)-(SEDP+a))
A12 = (63.5 - 51.196) x ( (82.556 - 60.338)-(3.993+8.693
A12 = 117.282
mm2
So, A1 = A11 + A12
= 3630.101 + 117.282 =
Area available in Tube Stub projecting outward
A2 = 2 (tn-trn) (2.5tn + te) fr

3747.383

mm2

A2 = 2 (7.112-6.689) (2.5x7.112 + 0) x 1 =
Area available in Tube Stub projecting inward
A3 = 2 (tn x fr) (SEDP+a)

15.042

mm2

A3 = 2 (7.112x1) (3.993+8.693)=
Area available in outward Tube Stub weld
A4 =
(WL)2 fr =
Therefore total area available

180.446 mm2

(9.9)2 1
98.01 mm2
=
A1 + A2 + A3 + A4
=
3747.383+15.042+180.446+98.01

=
4040.88
mm2
Since total available area is more than total area required for compensation,
Header is adequately compensated.
Area Required In Circumferential Plane = d x tr x F
= 51.196 x 60.338 x 0.5 =
1544.532 mm2
For Circumferential Plane, reduced reinforcement limit is Pc [d /(d+d)] = Pc [d/2d)] = Pc/2
=
89.928 /2
=
44.964
mm
In Circumferential Plane, tube stub has its reinforcement restricted from one side , So reduced limit
is applicable on one side and other side remain unchanges as (Rn+tn+t)

Fig PG-33.1

Area available in Header for Circumferential plane , A1 =Ac+A 12

Ac = ( ( Pc/2 ) + (Rn+tn+t) - OD) x (t-Ftr) - { (seat dia-OD) x SEDP } { 2Wd (t Ftr) (1 fr) }
= ( 44.964 +114.306 - 63.5) x (82.556-0.5x60.338) - { (64.693 - 63.5) x 3.993 } - ( 2x0 ( 82.556 - 1x60.338)(1-1)
5012.339

mm2

Simce, A12 ,A2,A3 and A4 are same for circumferential plan,

Ac+A12+A2+A3+A4 =
Total area available in Circumferential Plane =
Since total available area is more than total area required for compensation,
Header is adequately compensated.

5423.119 mm2

17 of 29

Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
Document no.

ASME01
P34- -CS-01691

Revision No.

2
Reference

10) HOLE COMPENSATION CALCULATIONS FOR HEADER: (Contd.)

Area Required in Diagonal Plane =
d x tr x F
= 51.196 x 60.338 x 0.807=
2492.875 mm2
For Diagonal Plane, reduced reinforcement limit is P' [d /(d+d)] =
144.847 /2 =
72.424 mm
In Diagonal Plane, tube stub has its reinforcement restricted from one side, So reduced limit
is applicable on one side and other side remain unchanges as (Rn+tn+t)
Ad = ( ( P'/2 ) + (Rn+tn+t) - OD) x (t-Ftr) - { (seat dia-OD) x SEDP } { 2Wd (t Ftr) (1 fr) }

Fig PG-33.1

( 72.424 +114.306 - 63.5) x (82.556-1x60.338) - { (64.693 -63.5) x 3.993 } - ( 2x0 ( 82.556 - 1x60.338)(1-1)

2733.16
mm2
Since, A12 ,A2,A3 and A4 are same for Diagonal plane so,
Ad+A12+A2+A3+A4 =
Therefore total area available Diagonal Plane =
Since total available area is more than total area required for compensation,
Header is adequately compensated.
As per PG38.2, 1 1/3 of average diameter =
1 1/3 (d') = 1 1/3 (51.146) =
The minimum center to center distance for adjacent ope ni gs of tube stub is
Which is more than 1 1/3 of average diameter.

3143.940 mm2

68.863 mm
89.928 mm

1.6

Counterbore Depth

As per PG-38.4 and Figure PG-38,

For Longitudinal Pitch,
0.7F of Area 1234
=
0.7F of the cross-sectional area obtained by multiplying the center-to-center
distance of the openings by the required thickness of seamless shell
=
0.7F x P x tr
=
0.7(1) (227.1 x 60.338)
=
9591.932 mm2

Now, Area 5 = tn (Counterbore Depth + 1.6)

= 7.112(8.693+1.6)
=
73.204 mm2
Area 6 =
73.204 mm2
( since Area 5 and Area 6 are same)
Area 78 = (P-d') (Header Thickness - Counterbore depth - Seat depth)
= (227.1-51.196) (82.556 -8.693 -3.993)
=
12290.412 mm2
So,
Area 5678 = Area 5 + Area 6 +Area 78 =
73.204 + 73.204 + 12290.412 =
So, for longitudinal Plane Area 5678 is more than 0.7F of Area 1234.

12436.820 mm2

18 of 29

Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
Document no.

ASME01
P34- -CS-01691

Revision No.

10) HOLE COMPENSATION CALCULATIONS FOR HEADER: (Contd.)

For Circumferential Pitch,
0.7F of Area 1234
=

0.7F of the cross-sectional area obtained by multiplying the center-to-center

distance of the openings by the required thickness of seamless shell
=
0.7F x Pc x tr
=
0.7(0.5) (89.928 x 60.338)
=
1899.126 mm2
Area 5 and Area 6 remain same as calculated in prevoius page.
Area 78 = (Pc-d') (Header Thickness - Counterbore depth - Seat depth)
= (89.928-51.196) (82.556 -8.693 -3.993)
=
2706.205 mm2
Thus,
Area 5678 = Area 5 + Area 6 +Area 78 =
73.204 + 73.204 + 2706.205 =
So, for Circumferential Plane Area 5678 is more than 0.7F of Area 1234.
For Diagonal Pitch,
0.7F of Area 1234

2852.613 mm2

0.7F of the cross-sectional area obtained by multiplying the center-to-center

distance of the openings by the required thickness of seamless shell
=
0.7F x P' x tr
=
0.7(0.807) (144.847 x 60.338)
=
4937.101 mm2
Area 5 and Area 6 remain same as calculated in prevoius page.
Area 78 = (P'-d') (Header Thickness - Counterbore depth - Seat depth)
= (144.847-51.196) (82.556 -8.693 -3.993)
=
6543.395 mm2
Thus,
Area 5678 = Area 5 + Area 6 +Area 78 =
73.204 + 73.204 + 6543.395 =
So, for Circumferential Plane Area 5678 is more than 0.7F of Area 1234.

6689.803 mm2

11) Hydrotest Blank Thickness Requirement Calculation:

44.988 MPa(g)
(from Sr.no.2 on page no.5)
Hydrostatic Test Pressure =
Hemis head of following specification will be used for hydrotest blank for header.
Di = ID of Hemis Head =
469.900
mm
Minimum
available
Thickness
=
t=
50.000
mm
Material = SA 516 Gr 70
S = Allowable Stress is 90% of yield stress =
90 % of 262 MPa(g)
=
235.800 MPa(g)
( yeild stress is from Table Y1 of ASME SEC II D,Edition 2015 at room temperature )
As per PG 29.11,
L = Radius to which the head is dished, measured on the
concave side of the head = (469.9 /2 ) =
234.950 mm
and t = minimum required thickness of head = PL/(2Sw-0.2P )= 22.849 mm

PG-99.1

Since the required thickness of Head as calculated above is less than provided thickness.
the thickness of Hydrotest Blank is adequate.

19 of 29

Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
Document no.

ASME01
P34- -CS-01691

Revision No.

2
Reference

12) MEMBRANE STRESSES DEVELOPED DURING HYDROSTATIC TEST

Membrane Stresses in Economiser Outlet Header
Header
Tube Stub

Material :

PG-99.1

SA 106 Gr C
SA 210 Gr C

(from Sr.no.3 on page no.6)

(from Sr.no.3 on page no.6)

29.992 MPa(g)
44.988 MPa(g)

M.A.W.P. =
Hydrostatic Test Pressure =

(from Sr.no.2 on page no.5)

(from Sr.no.2 on page no.5)

276 MPa(g)
Yield Stress for Header =
(At 20C Hydrotest Condition)

( From Table Y1 of ASME SEC. II D

Edition 2015 (page no.574 to 576) )

276 MPa(g)
Yield Stress for Tube Stub =
(At 20C Hydrotest Condition)

( From Table Y1 of ASME SEC. II D

Edition 2015 (page no.574 to 576) )

90% of Yield Stress [S'] =

(2760.9) MPa(g)
=
248.4 MPa(g)
Header Thickness requirement equation is
t=
Solving we get,

(For Header and Tube Stub)

PG-99.1

A-317.2.1

Di (e^(( PSE) )1) 2+C+f

P/(E log_e{[Di+2(t-C-f)/Di} )
S=

Where,
C=
f=
P=
E=
t=
Di =

0.000
0.000
44.988
0.717
82.556
444.488

Allowance for Structural Stability, threading etc.

thickness factor for expanded tube ends
MPa(g)

A-317.3
note-3,note-4
(from Sr.no.2 on page no.5)
(from Sr.no.5 on page no.9)
(from Sr.no.3 on page no.6)
(from Sr.no.6 on page no.10)

mm
mm

So, putting these values in above equation of 'S'

For, Economiser outlet Header,
44.988/(0.717 log_e{[444.488+2(82.556-0S = 0)]/444.488} )

198.63

MPa(g)

Since calculated stress for Header (198.3 Mpa(g)) is less than the 90% of yield stress, (248.4 Mpa(g))
Header is NOT subjected to general membrane stress greater than 90% of its yield strength .
Now, for Tube Stub,
Di =
49.276 mm
E=
1.000 Ligament Efficiency for seamless tube stub
t=
7.112
C=
0.000 Allowance for Structural Stability, threading etc.
f=
0.000 thickness factor for expanded tube ends
P=
44.988 MPa(g)
So, putting these values in above equation of 'S'
For,Tube Stub
S=

44.988/(1 log_e{[49.276+2(7.112-00)]/49.276} )

(from Sr.no.7 on page no.11)

(from Sr.no.3 on page no.6)
PG-27.4
note-3,note-4
(from Sr.no.5 on page no.9)

177.40

MPa(g)

Since calculated stress for Tube stub (177.4 Mpa(g)) is less than the 90% of yield stress, (248.4 Mpa(g))
Tube stub is NOT subjected to general membrane stress greater than 90% of its yield strength .

20 of 29

Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
Document no.

ASME01
P34- -CS-01691

Revision No.

2
Reference

12) MEMBRANE STRESSES DEVELOPED DURING HYDROSTATIC TEST (CONTD)

Membrane Stresses in Hemis Head

PG-99.1

SA 181-70

Material :

(from Sr.no.3 on page no.6)

248
MPa(g)
Yield Stress =
(At 20C Hydrotest Condition)

( From Table Y1 of ASME SEC. II D

Edition 2015 (page no.574 to 576) )

90% of Yield Stress [S'] = (248 0.9) MPa(g)

=

223.2

MPa(g)

Hemis Head Thickness Requirement equation is

t=

PG-29.11

PL/(2Sw-0.2P)

Solving we get,
S=

(P(L+0.2t))/2tw

Where,
P = Hydrostatic Test Pressure
L = Radius to which the head is dished,
measured on the concave side
of the head
t = Thickness of Tube Stub

44.988 MPa(g)
217.488 mm

76.200 mm

(from Sr.no.2, page no.5)

(from Sr.no.9, page no.13)

(from Sr.no.3, page no.6)

w = Weld joint strength reduction factor = Not Applicable

S=

(44.988
(217.488+0.2(76.2)))/2x76.2=

68.70

Table PG-26

MPa(g)

Since calculated stress for Hemis Head (68.7 Mpa(g)) is less than the 90% of yield stress, (248.4 Mpa(g))
MHH plug is NOT subjected to general membrane stress greater than 90% of its yield strength .

21 of 29

Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
Document no.

ASME01
P34- -CS-01691

Revision No.

13) PWHT & RT REQUIREMENTS

Postweld heat treatment (PWHT) is not mandatory for P no. 1 materials
when the nominal thickness of a weld as defined in PW-39.3 does not exceed 3/4 in. (19 mm).
As per ASME Sec. II, D, Edition 2015
Discription
Material
Economiser Top Header
SA 106M Gr C
Tube Stub
SA 210M Gr C
Hemis Head
SA 181-70
MHH Plug
SA 181-70

P No.
1
1
1
1

Table
PW-39-1
note (a)(1)

Group No. Page no.Ref

2
22
2
22
2
18
2
18

Nominal Thickness as per PW-39.3

1) For full penetration butt weld between Header Pipes,Nomonal Thickness is the thinner of the parts being joined.
= 82.556 mm
(MWT of Header as per drawing no. P34-1SJ-002044)
2)
Forjoined.
full penetration butt weld between Header and Hemis Head ,Nomonal Thickness is the thinner of the parts
being
= 76.2 mm

(3) For fillet weld between Header and tube stub the nominal thickness is the Weld Throat :
Weld Throat =
7 mm

B0316678

(4) For fillet weld between Header/Hemis Head and MHH Plug ,the nominal thickness is the Weld Throat
Weld Throat =
9.525 mm

B0316678

As per Table PW-39.1,

So, PWHT is required for above weld 1) and 2).
As per Table PW-39.1, over 50 mm to 125 mm weld thickness :
minimum holding time is :
2 hr plus 15 min for each additional inch (25 mm) over 2 in. (50 mm)
so, for 94.35 mm thk holding time will be :
2 hr and 30 min
minimum holding temperature:
1100 F
But, the actual PWHT will be carried out as per B&W Drawing No.B0316679 which gives,
Holding Time = 3 hr and 30 min (for 1)), 3 hr and 15 min (for 2))
Holding Temp.= 1100F to 1150F
= 595C to 621C
( ( 1150F-32) / 1.8 = 621C )
Required Volumetric Examination of Welded Butt Joints

PW-11

For any pressure part that is not subject to Furnace Radiant Heat and contains water,
RT is required if
Circumferential Welds in pipes, tubes
> DN 250 or 29 mm thick
and Headers
So,
RT for Pipe to Pipe weld of header
Required
OD 609.6 mm - 94.35 mm thickness
RT for Pipe to Hemis head of header
Required
OD 587.375 mm -76.2 mm thickness

Table PW-11

22 of 29

Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
ASME01
Specification no. P34- -CS-01691

Revision No.

Ref.
PW-16

14) NOZZLE ATTACHMENT WELD SIZE CALCULATIONS:

t=
tn =
tmin =
tc =

thickness of vessel shell or head

thickness of nozzle wall
the smaller of 3/4 in. (19 mm) or the thickness of either of the weld parts joined by fillet weld.
not less than the smaller of 1/4 in. (6 mm) or 0.7tmin

For, Welding of Tube stub to Header,

(Refer dwg : P34-1SJ-002044, Detail E)
t=
82.556 mm
tn =
7.112 mm
tmin = Minimum of 19mm,t and tn
tmin = Minimum of 19mm, 82.556mm and 7.112mm
tmin =
7.112 mm
So, 0.7tmin = 0.7 x 7.112 =

4.978

PW-16.2
PW-16.2
PW-16.2
PW-16.2

(from Sr.no.3 on page no.6)

(from Sr.no.3 on page no.6)

mm

Required, weld throat tc = Minimum of 6 mm and 0.7tmin

=
4.978 mm
and Provided Weld Throat =
7.000 mm
Since, provided weld size is greater than required ,
Weld sizes are adequate.
For, Welding of MHH Plug to Header and Hemis Head,
(Refer dwg : P34-1SJ-002044, Detail F)
t=
82.556 mm
tn =
8.415 mm
tmin = Minimum of 19mm,t and tn
= Minimum of 19mm,82.556mm,8.415mm
=
8.415 mm
0.7*tmin = 0.7 x 8.415 =

(from Sr.no.3 on page no.6)

(from Sr.no.8 on page no.12)

5.891 mm

Required, weld throat tc = Minimum of 6 mm and 0.7tmin

=
5.891 mm
and Provided Weld Throat =
7.900 mm
Since, provided weld size is greater than required ,
Weld sizes are adequate.
WELD STRENGTH CALCULATIONS:
As per PW-15.1.6 of ASME section I,
Weld Srength Calculations not reqiured for Fig.PW 16.1, illustrations (z1) welds.

23 of 29

Themax Babcock and Wilcox Energy Solutions Private Limited.

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
ASME01
Specification no. P34- -CS-01691

Revision No.

15) MHH PLUG THICKNESS CACULATION

With reference to Page no.12 , we will calculat the minimum thicjness rerquirement of MHH plug as per PG-31.
So,

d=
=

2.487 inch
63.1698 mm

(from B&W drawing no. 184396C)

Now,
t = d(CP/s)

where, C =
P (Mpa) =
S (Mpa) =

=
63.17((0.33x29.992)/117.778)
=
14.256 mm
Whereas the minimum provided thickness is
17.450

Since, the actual provided tickness is

17.450
14.256

0.2
29.992
117.778

PG-33.3.2
(Sr No. 2,Page 5 )
(Sr No. 3,Page 6 )

mm as calculated on page no. 12.

mm which is more than the calculated thickness

mm , so thickness of MHH plug is adequate.

24 of 29

Title:

ASME CALCULATION FOR ECONOMISER OUTLET HEADER (DEMO VESSEL)

Project no.
Document no.

Revision No.
Page No.

ASME
CALCULATIONS FOR
ECONOMISER TOP HEADER (DEMO VESSEL)
AS PER
A S M E SECTION I
EDITION 2010, Addenda 2011a

1
1 of 24

ASME DEMO VESSELE AMR

SR.
No.

Part No.

Component

3C10000875
TC10000228
3C10001187
BC10000215
-----

---

WNRF FLANGE

---

BLIND FLANGE #

9
10

-----

PLATE (ATTACHMENTS-pads)
Support Lug

1
2
3
4
5

Description

ECO HEADER PIPE

DN 150 * SCH 160

TUBE STUB

50.8 OD * 4.5 THK

VENT NOZZLE PIPE

DN 150 * SCH 160

END COVER (FORGED DISK)

168.3 OD * 45 THK

PLATE - HYDROTESTBLANK #

168.3 * 25 THK

PLATE - HYDROTESTBLANK #

50.8 * 16 THK
ASME B16.5 CL 600
50 DN * SCH 160
ASME B16.5 CL 600
50 DN * SCH 160

For Hydrostatic testing purpose only

No Extra Quantity is Taken

10 mm THK

OD/width
mm
168.3
50.8
60.3
168.3
168.3
50.8

Thk
mm
18.26
4.5
8.74
40
25
16

--

--

SA 105 M

--

--

SA 105 M

50

SA 516 M Gr 70
SA 516 M Gr 70

Material
SA 106 M Gr B
SA 210 M GR A1
SA 106 M Gr B
SA 105 M
SA 516 M Gr 70
SA 516 M Gr 70

Length
mm
1200
1000
110
40
25
16

1000

Quantity*
1
1
1
1
1
5

1
2

RAW WIEGHT
Kg
81.08
5.14
1.22
6.99
4.37
0.25

0.12

Finish Weight
Kg
81
5
1
7
4
1

0.12
5.00
112

Nozzle
description

O.D. 50.8 Tube

Stub

Nozzle connection
type (as per fig.)

PW-16.1(z)

Detail

Thk. of

Thk. of

at

Hdr (t)

nozzle
wall (tn)

HS1

94.35

7.11

Weld size
requirement
tmin.
tc
(smaller
(smaller
of
of 6mm &
19.05mm,
0.7tmin)
t & tn)

7.11

4.98

Weld sizes
provided
tf
(fillet
weld leg
size)

9.90

sec 2A to be refer for material spec

pag 6
wat is mean by hfs
tokearance 12.5 % why
chart for sa 106 b,CS-2 G10, S1, T1
check bore dia , seat dia etc logic behind that
fig dim. Arrow mix
check yeild tress

T1 Allowable stresses for temperatures of 370C and above are values obtained from time-dependent prop

equi hole dia Stress ration wat & why??

Tube thick calculatiuon MAWP or Design Pre.. ??
Calc. yeild Strength at 50 C
RT for End cover ??
Flange Material

Weld sizes
provided
tc

Remarks

(0.7tf)

6.9

Weld
sizes are
adequate.

ned from time-dependent properties

Actions to be taken on AIS review,

1 The alternate method of Compensation Calculations will be deleted.
2 Latest rev. of dwg cannot be incorporated with BOM.
3 It is not necessary that due to Rev. of dwg., BOM will be revised.
4 Welding no. from wds should be included with the dwg or not ??
5 In dwg HOU no. is given & same no. is indicated as E-item no. in BOM.
That cannot be changed at this time
6 BOM status : "Approved by Production" can not be changed at this time
7 Manufacturer's serial no. should be unique for unique item.
it can be made by Ti-project no. & HOU no.
For, ASME DEMO Vessel,
Ti-Project no :
ASME01P32
HOU. NO.
A200000100
So,
Manufacturer's serial no. : ASME01P32A200000100
8 PO copy from sales to project is not required by Engg.
(manual change)
10 Support Lug thickness calc. explanation
11 Why Pad plate is used ??
12 Signature date on drawing verification doc. (which date )
13 BOM sign with date: 03/04/203
14 Calc. , Specification & Dwg signature with date :
for first issue : 29/10/2012
for Rev.1 : 03/04/2013
15 Manual :3.3.2
"List of dwgs released through DDR " wil not have a doc. No.
16 Manual :3.3.1 (xii)
"..the drawings shall also indicate as a minimum, when applicable:"
g)
Material specifications and special requirements, if any.
i)
Special requirements such as heat treatment and other contractual
requirements as required.
j)
Requirement of test coupons, if any.