Steam Drum Calulation

STEAM DRUM
STRESS CALCULATIONS
EQUIPMENT NAME : STEAM DRUM
QUANTITY : ONE
PROJECT : BIRLA CARBON BLACK Co.,

EGYPT
CONSTRUCTION CODE : ASME Section-I, 2004 Edition./ADDENDA 2006.
ASME 'S' STAMP : YES "S" STAMP
MANUFACTURER'S NAME : ENMAS GB POWER SYSTEMS

STRESS CALCULATIONS
GB ENGINEERING
Enterprises Pvt. Ltd. MFR'S
EQPT. STEAM DRUM SERIAL NO. GBE/1750/009
STATUS OF CALCULATION DUE TO REVISION IN DRAWING
Sl. Rev. Page of Reason For Revision Pages Prep. Appr.

Drawing No. IA
No. Calculation Affected
1 10-10-01-3061 00 - - -
2 10-10-01-3062 00 - - -
3 10-10-01-3063 00 - - -
4 10-10-01-3064 00 - - -
5 10-10-01-3065 00 - - -
6 30-10-01-3023 00 - - -
STRESS CALCULATIONS Sheet 03
GB ENGINEERING Rev. 00
Enterprises Pvt.Ltd
EQPT : STEAM DRUM Mfr's Serial No :GBE/1750/009
INDEX
S.No. DESCRIPTION SHEET Nos.
01 Cover Sheet 01
02 Revision status - Drawing 02
03 Index 03
04 Revision status - Stress calculation 04
05 List of drawings 05
06 List of standards/codes 06
07 Design data 07
08 Material constructions 08
09 Allowable stress 09
10 Hydrostatic test pressure 10
11 Radiographic Examinations 11
12 Heat treatment & Post weld heat treatment 12
13 Shell Thickness calculation 13
14 dished head thickness calculation 14
15 Manhole ring thickness calculations 15
16 Manhole door thickness calculations 16
17 Nozzle (Stubs) thickness calculations 17 - 31
18 openings in shell and dished head 32
19 List of openings 33
20 Compensation calculations for openings in shell & dished head 34 - 43
21 Requirements of attachment welds 44 - 56
22 Weld strength calculations 57 - 67
23 Hydrostatic test Endcover thickness calculations 68 - 76
24 Calculation of Minimum Required thickness for the stub End Plate 77
25 Calculation of stress during Hydrostatic test for Stub End Plate 78
26 Static Head Calculation 79
27 Weight & Loading Calculation 80 & 81
28 External Loading calculation 82
29 Safety Valves Requirement 84

STRESS CALCULATION Sheet 04
GBENGINEERING Rev. 00
Enterprises Pvt.Ltd MFR'S SERIAL GBE/1750/
EQPT : STEAM DRUM
NO. 009
REVISION STATUS FOR STRESS CALCULATIONS
PAGE REV.No. PAGE REV.No. PAGE REV.No.
No. 0 1 2 3 4 5 6 No. 0 1 2 3 4 5 6 No. 0 1 2 3 4 5 6
1 X 36 X 71 X
2 X 37 X 72 X
3 X 38 X 73 X
4 X 39 X 74 X
5 X 40 X 75 X
6 X 41 X 76 X
7 X 42 X 77 X
8 X 43 X 78 X
9 X 44 X 79 X
10 X 45 X 80 X
11 X 46 X 81 X
12 X 47 X 82 X
13 X 48 X 83 X
14 X 49 X 84 X
15 X 50 X
16 X 51 X
17 X 52 X
18 X 53 X
19 X 54 X
20 X 55 X
21 X 56 X
22 X 57 X
23 X 58 X
24 X 59 X
25 X 60 X
26 X 61 X
27 X 62 X
28 X 63 X
29 X 64 X
30 X 65 X
31 X 66 X
32 X 67 X
33 X 68 X
34 X 69 X
35 X 70 X
DOC NO. PREPARED CHECKED APPROVED AI REVIEW

Enterprises Pvt. Ltd. MFR'S SERIAL
EQPT : STEAM DRUM GBE/1750/009
NO.
1.0 LIST OF DRAWINGS
S.No. Description Drawing No. Rev.Nr.

1 Steam Drum 10-10-01-3061 0
2 Detail of Steam Drum Belts and Welding. 10-10-01-3062 0
3 Stub Welding Details-I for Steam Drum 10-10-01-3063 0
4 Stub Welding Details-II for Steam Drum 10-10-01-3064 0
5 Manhole Door Assembly 10-10-01-3065 0
6 Dished End 30-10-01-3023 0
NO.
2.0 LIST OF STANDARDS / CODES
1 ASME Section-I, 2004 Edition / Addenda 2006.
2 ASME Section II, Part-A, 2004 Edition/ Addenda 2006.
3 ASME Section-II, Part-D, 2004 Edition/ Addenda 2006.
4 ASME B 16.5,2003
5 ASME B 36.10M,2000
NO.
3.0 DESIGN DATA
Construction code : ASME Section-1, Edition 2004 / Addenda 2006.

Fluid Handled : Steam and Water
MAWP ((Internal pressure) : 79 kg/cm2 (g)
Design Temperature. : 294 O
C
Hydrostatic Test Pressure : 118.5 Kg/cm (g)
Hydrostatic Test Temperature : Ambient ( not less than 70o F )
Joint efficiency : 1.0
Radiography : FULL (Ref. Pg No.11)
Post Weld Heat Treatment : YES (Ref. Pg No.12)
Corrosion Allowance : NIL
Loadings : Applicable
NO.
4.0 MATERIAL OF CONSTRUCTION
1 Shell : SA 516 Gr.70
2 Stubs & Sleeves : SA 105
3 Dished Heads : SA 516 Gr.70
4 Nozzle pipes : SA 106 Gr. B
5 Hydrostatic End plate : IS 2062
6 Manhole cover plate : SA 516 Gr.70

Sheet 09
GB ENGINEERING
STRESS CALCULATIONS Rev. 00
Enterprises Pvt. Ltd.
EQPT: STEAM DRUM MFR'S SERIAL NO. GBE/1750/009
5. Allowable stress Values
As per ASME Sec-II Part-D 2004Edition/addenda 2006.
Min. Yeild Strength at Allowable stress ('s') at Min. Yeild

ambient temperature 'Y' design temperature Strength at
S. Material of Page Line
ambient P.No. Gr.No.
No. construction No. No.
Temp. Stress Stress Temp. Stress Stress temperature
(oC ) (Mpa) (Kg/cm) (oC ) (Mpa) (Kg/cm) (0.9 x Y) kg/cm
1 SA-106 Gr B 21 240 2447.3 294 118 1203.3 2203 1 1 10 5
2 SA 516 Gr.70 21 260 2651.3 294 136.24 1389.3 2386 1 2 14 20
3 SA 105 21 250 2549.3 294 129.84 1324 2294 1 2 14 6
Conversion factor:
To convert MPa to kg/cm multiply by 10.1972
NO.
6.0 Hydrostatic Test Pressure Calculation PG 99
01. Max. Allowable working pressure 'P' : 79 kg/cm(g)

02. Design pressure : 79.09 kg/cm(g)
03. Hydrostatic Test pressure : 1.5 x 79
= 79 x 1.5 = 118.5 kg/cm
04. Hydrostatic Test Temperture = Amp Temp min 21C (70F)
NO.
7.0 Radiographic Examination of Welds as per PW-11
S.
Equipment As per Requirement
No.
100% Radiography shall be

1 All longitudinal butt welded joints in drum Table PW 11
done for all thickness.
100% Radiography shall be

done. If, circumferential welds
2 All circumferential welds in drum Table PW 11
in drum exceed NPS 10
(DIN 250) or 29 mm thick.
Conclusions:
Head and shell thickness is 63 mm. Hence the RT is required as per table PW 11
for L..S/C.S on drums and L.S on Manhole ring.
MFR'S
EQPT: STEAM DRUM GBE/1750/009
SERIAL NO.
Post Weld Heat Treatment PW 39
SL.
Equipment As per Requirement
No
For Drum, PWHT shall be done after completion

1 Table PW 39(1)a Yes
of all welding
Conditions:
1)a Postweld heat treatment is not mandatory for circumferential butt welds in pressure parts with a
nominal wall thickness of 19 mm or less at the joints.
Conclusions:
Head and shell thickness is 63 mm. Hence the PWHT is required after completion of all
welding as per PW 39(1)a.
Enterprises Pvt.Ltd MFR'S SERIAL
NO.
01. CALCULATION OF CYLINDRICAL SHELL THICKNESS FOR INTERNAL PRESSURE

AS PER PG-27.2.2
Sl
DESCRIPTION UNIT DATA
No
01 Item SHELL FOR STEAM DRUM
Drg No. 10-10-01-3062
Part No 01,02,03,04,05,06
02 Material Specification SA 516 Gr.70
03 P = Max.Allowable working pressure kg/cm(g) 79
04 T = Design temperature o
C 294
05 D = Inside diameter of cylinder mm 1829
06 R = Inside radius of cylinder mm 914.5
07 Nominal Thickness (before rolling) mm 63
08 Nominal Thickness (after rolling) mm 61

Max. Allowable stress of shell material
09 S= kg/cm 1389.3
at design temperature.
10 Y = Min. yield strength with ambient Temp. kg/cm 2651.3
11 E = Joint Efficiency 1.0
12 y = Temperature coefficient (Ref.PG-27.4 Note 6) 0.4
C= Min. allowance for threading and structural
13 mm 0
stability (Ref.PG-27.4 Note 3)
Minimum required thickness (PG-27.2.2)
14 PR mm 53.84
t= +C
SE ( 1 y ) P
Minimum thickness as per code: (PG-16.3)
15 mm 6.00
For boiler plate minimum thickness
16 Greater of 14 & 15 mm 53.84
17 Required thickness = mm 53.84
18 Provided thickness = mm 61
19 Provided Thickness > Required Thickness HENSE SATISFACTORY
Stress at Hydrostatic pressure (PG -99)

20 Ph = Hydrostatic Pressure kg/cm 118.5
stress during Hydrostatic pressure
21 Ph[ R+(1 y )(tC )] kg/cm 1848

=
E (tC )
22 90% of yield strength kg/cm 2386
23 22 > 21 HENCE SATISFACTORY
* PG-16.4 : Maximum under tolerance permissible on calculated thickness of plate material is 0.01" .
EQPT : DISHED HEAD GBE/1750/009
NO.
01. CALCULATION OF DISHED DISH HEADTHICKNESS FOR INTERNAL PRESSURE

AS PER PG-27.2.2
Sl
No
01 Item DISHED HEAD
Drg No. 30-10-01-3023
Part No 01
02 Material Specification SA 516 Gr.70
03 P = Max.Allowable working pressure kg/cm(g) 79
C 294
05 D = Inside diameter of cylinder mm 1829
06 R = Inside radius of cylinder mm 914.50
07 Nominal Thickness mm 63
08 Min. Thickness (after dishing) mm 55.0

Max. Allowable stress of shell material
09 S= kg/cm 1389.3
at design temperature.
10 Y = Min. yield strength with ambient Temp. kg/cm 2651.3
11 E = Joint Efficiency 1.0
12 y = Temperature coefficient (Ref.PG-27.4 Note 6) 0.4
Min. allowance for threading and structural
13 C = mm 0
stability (Ref.PG-27.4 Note 3)
14 (a) Depth of dish mm 457.25
(b) One quarter of the inside dia of head mm 457.25
14 (a) = 14(b) HENCE SATISFACTORY
Minimum required thickness (PG-27.2.2)
15 PR mm 53.84
t= +C
SE ( 1 y ) P
Minimum thickness as per code: (PG-16.3)
16 mm 6.00
For boiler plate minimum thickness
17 Greater of 15 &16 mm 53.84
19 Provided thickness = mm 55
20 Provided Thickness > Required Thickness HENSE SATISFACTORY
Stress at Hydrostatic pressure (PG -99)

21 Hydrostatic Pressure Ph kg/cm 118.5
stress during Hydrostatic pressure
22 Ph[ R+(1 y )(tC )] kg/cm 2041

=
E (tC )
23 90% of yield strength kg/cm 2386
24 22 < 23 HENCE SATISFACTORY
* PG-16.4 : Maximum under tolerance permissible on calculated thickness of plate material is 0.01" .
NO.
6.0 CALCULATION OF NOZZLE THICKNESS FOR INTERNAL PRESSURE - AS PER PG - 27.2.2 & PG - 43
Sl
No
01 Item MAN HOLE RING

Drg No: 10-10-01-3062
Part No. 07
02 Material specification SA 516 GR 70
03 P = Maximum Allowable Working pressure kg/cm(g) 79
04 T= Design Temperature o
C 294
05 D = Outside diameter of Nozzle mm 536
06 Nominal thickness mm 63
07 Negative tolerance on thickness % 0
08 Minimum thickness available mm 59
09 S = Maximum allowable stress at Design temp. kg/cm 1389.3
10 Y = Minimum yield strength at Ambient temp. kg/cm 2651.3
Minimum allowance for stability mm
11 C = 0.00
(As per PG-27.4, Note-3)
12 y = Temp.coefficient (As per PG-27.4.,Note-6) 0.4
13 E = Efficiency 1
Minimum thickness required
14 PD mm 14.90
t = +C
( 2 SE +2 yP )
Required thickness of seamless shell
15 mm 53.84
[ As per PG - 43.1]
16 Standard wall thickness of pipe mm 9.53
17 Min.thickness of std. wall pipe [As per PG 43.2] mm 9.53
18 Smaller of (15) & (17) [As per PG - 43] mm 9.53
19 Minimum thickness (Asper PG-16.3) mm 6.00
20 Greater of 14 ,18 & 19 mm 14.90
22 Provided thickness = mm 59.00
23 Provided thickness > Required thickness HENCE SATISFACTORY
Stress at Hydrostatic pressure (PG.99)

24 Ph = Hydrostatic test pressure kg/cm 118.5
Stress during hydrostatic test
25 Ph ( D 2 y ( t C ) ) kg/cm 491
=
2 E ( t C )
26 90 % of yield strength (0.9xY) kg/cm 2386

Enterprises Pvt.Ltd MFR'S GBE/1750/
EQPT : DISHED HEAD
SERIAL NO. 009
5.0 Calculation of thickness of Manhole door As per PG 31.3.2
Sl
No
01 Item MANHOLE COVER PLATE
Drg No. 10-10-01-3065
Item No. 01
03 T = Design Temperature o
C 294
04 Cover Plate Material SA 105
05 d = Manhole Cover Effective Diameter mm 406.00
06 Nominal Cover Plate Thickness mm 80.00
07 C= Constant (As per Fig.No.PG-31( m )) 0.3
08 S = Maximum allowable stress for cover Plate kg/cm 1324
Minimum thickness required mm

t 54.32
09 t = d
CP
S
12 Provided Thickness > Required Thickness HENCE SATISFACTORY

NO.
Sl
No
01 Item DOWNCOMER STUB MACHINED END
Drg No: 10-10-01-3063

Var No./Item No. 01/01
02 Material specification SA 105 SA 105
03 P = Maximum Allowable Working pressure kg/cm(g) 79 79
C 294 294
05 D = Outside diameter of Nozzle mm 450.56 406.4
06 Nominal thickness mm 45 22.92
07 Negative tolerance on thickness % 0 0
08 Minimum thickness available mm 45 22.92
09 S = Maximum allowable stress at Design temp. kg/cm 1324 1324
10 Y = Minimum yield strength at Ambient temp. kg/cm 2549.3 2549.3
11 C= 0 0
12 y = Temp.coefficient (As per PG-27.4.,Note-6) 0.4 0.4
13 E = Efficiency 1 1
14 PD mm 13.13 11.84
t = +C
( 2 SE +2 yP )
15 mm 53.84 53.84
[ As per PG - 43.1]
16 Standard wall thickness of pipe mm 9.53 9.53
17 Min.thickness of std. wall pipe [As per PG 43.2] mm 9.53 9.53
18 Smaller of (15) & (17) [As per PG - 43] mm 9.53 9.53
19 Minimum thickness (Asper PG-16.3) mm 6.00 6.00
20 Greater of 14 ,18 & 19 mm 13.13 11.84
21 Required thickness = mm 13.13 11.84
22 Provided thickness = mm 45 22.92
HENCE
SATISFACTORY
24 Ph = Hydrostatic test pressure kg/cm 118.50 118.50
25 Ph ( D 2 y ( t C ) ) kg/cm 545.84 1003.18
=
2 E ( t C )
26 90 % of yield strength (0.9xY) kg/cm 2294 2294
HENCE
SATISFACTORY
NO.
Sl
No
01 Item SATURATED STEAM STUB MACHINED END
Drg No: 10-10-01-3063

C 294 294
05 D = Outside diameter of Nozzle mm 375 273.1
06 Nominal thickness mm 62.06 11.11
08 Minimum thickness available mm 62.06 11.11
11 C= 0 0
14 PD mm 10.93 7.96
t = +C
( 2 SE +2 yP )
15 mm 53.84 53.84
[ As per PG - 43.1]
20 Greater of 14 ,18 & 19 mm 10.93 9.27
22 Provided thickness = mm 62.06 11.11
HENCE
SATISFACTORY
25 Ph ( D 2 y ( t C ) ) kg/cm 311 1409
=
2 E ( t C )
HENCE
SATISFACTORY
NO.
Sl
No
01 Item RISER STUB MACHINED END
Drg No: 10-10-01-3063

C 294 294
11 C= 0 0
14 PD mm 8.89 6.38
t = +C
( 2 SE +2 yP )
15 mm 53.84 53.84
[ As per PG - 43.1]
20 Greater of 14 ,18 & 19 mm 8.89 8.18
HENCE
SATISFACTORY
25 Ph ( D 2 y ( t C ) ) kg/cm 300 1392
=
2 E ( t C )
HENCE
SATISFACTORY
NO.
Sl
No
01 Item FEED WATER STUB

Drg No: 10-10-01-3063
02 Material specification SA 106 Gr B
C 294
05 D = Outside diameter of Nozzle mm 114.3
06 Nominal thickness mm 6.02
07 Negative tolerance on thickness % 12.5
08 Minimum thickness available mm 5.27
11 C = 0
13 E = Efficiency 1
14 PD mm 3.66
t = +C
( 2 SE +2 yP )
15 mm 53.84
[ As per PG - 43.1]
19 Minimum thickness (Asper PG-16.3) mm N.A
20 Greater of 14 ,18 & 19 mm 5.27

25 Ph ( D 2 y ( t C ) ) kg/cm 1238
=
2 E ( t C )

NO.
Sl
No
01 Item FEED SLEEVE

Drg No: 10-10-01-3063
02 Material specification SA 105
C 294
11 C = 0
13 E = Efficiency 1
14 PD mm 5.68
t = +C
( 2 SE +2 yP )
15 mm 53.84
[ As per PG - 43.1]
20 Greater of 14 ,18 & 19 mm 8.18

25 Ph ( D 2 y ( t C ) ) kg/cm 250.0
=
2 E ( t C )

NO.
Sl
No
FEED WATER HEATER ( INLET & OUTLET )

01 Item
STUB
Drg No: 10-10-01-3063
Var No./Item No. 05/01,06 / 01
C 294
11 C = 0
13 E = Efficiency 1
14 PD mm 5.38
t = +C
( 2 SE +2 yP )
15 mm 53.84
[ As per PG - 43.1]
20 Greater of 14 ,18 & 19 mm 6.22

25 Ph ( D 2 y ( t C ) ) kg/cm 1556
=
2 E ( t C )

NO.
Sl
No
FEED WATER HEATER (INLET &OUTLET)

01 Item
SLEEVE
Drg No: 10-10-01-3063
Var No./Item No. 05/02, 06/02
C 294
09 S = Maximum allowable stress at Design temp. kg/cm 1324
11 C = 0
13 E = Efficiency 1
14 PD mm 7.72
t = +C
( 2 SE +2 yP )
15 mm 53.84
[ As per PG - 43.1]
20 Greater of 14 ,18 & 19 mm 9.27

25 Ph ( D 2 y ( t C ) ) kg/cm 288
=
2 E ( t C )

NO.
Sl
No
01 Item PG,PT& VENT STUBS MACHINED END
Drg No: 10-10-01-3063

C 294 294
06 Nominal thickness mm 10 4.55
08 Minimum thickness available mm 10 4.55
11 C= 0 0
14 PD mm 1.29 0.97
t = +C
( 2 SE +2 yP )
15 mm 53.84 53.84
[ As per PG - 43.1]
19 Minimum thickness (Asper PG-16.3) mm N.A N.A
20 Greater of 14 ,18 & 19 mm 3.38 3.38
22 Provided thickness = mm 10 4.55
HENCE
SATISFACTORY
25 Ph ( D 2 y ( t C ) ) kg/cm 215 388
=
2 E ( t C )
HENCE
SATISFACTORY
NO.
Sl
No
01 Item SPARE STUB

Drg No: 10-10-01-3063
C 294
11 C = 0
13 E = Efficiency 1
14 PD mm 2.71
t = +C
( 2 SE +2 yP )
15 mm 53.84
[ As per PG - 43.1]
20 Greater of 14 ,18 & 19 mm 5.16

25 Ph ( D 2 y ( t C ) ) kg/cm 235
=
2 E ( t C )

NO.
Sl
No
01 Item SAFETY VALVE STUB MACHINED END
Drg No: 10-10-01-3063

C 294 294
11 C= 0 0
14 PD mm 3.21 3.15
t = +C
( 2 SE +2 yP )
15 mm 53.84 53.84
[ As per PG - 43.1]
20 Greater of 14 ,18 & 19 mm 6.02 6.02
HENCE
SATISFACTORY
25 Ph ( D 2 y ( t C ) ) kg/cm 233 288
=
2 E ( t C )
HENCE
SATISFACTORY
NO.
Sl
No
01 Item CD STUB MACHINED END
Drg No: 10-10-01-3064

02 Material specification SA 106 Gr B SA 106 Gr B
C 294 294
07 Negative tolerance on thickness % 12.5 12.5
09 S = Maximum allowable stress at Design temp. kg/cm 1203.3 1203.3
11 C= 0 0
14 PD mm 1.07 1.07
t = +C
( 2 SE +2 yP )
15 mm 53.84 53.84
[ As per PG - 43.1]
20 Greater of 14 ,18 & 19 mm 2.96 2.96
HENCE
SATISFACTORY
25 Ph ( D 2 y ( t C ) ) kg/cm 450 621
=
2 E ( t C )
HENCE
SATISFACTORY
NO.
Sl
No
01 Item LE & LG STUB

Drg No: 10-10-01-3064
Var No./Item No. 10/01,11/01,14/01,15/01
C 294
11 C = 0
13 E = Efficiency 1
14 PD mm 1.07
t = +C
( 2 SE +2 yP )
15 mm 53.84
[ As per PG - 43.1]
20 Greater of 14 ,18 & 19 mm 2.96

25 Ph ( D 2 y ( t C ) ) kg/cm 450
=
2 E ( t C )

NO.
Sl
No
01 Item LE,LG & CHEMICAL DOSING SLEEVE

Drg No: 10-10-01-3064
Var No./Item No. 10/02,11/02,13/02,14/02,15/02
C 294
11 C = 0
13 E = Efficiency 1
14 PD mm 1.92
t = +C
( 2 SE +2 yP )
15 mm 53.84
[ As per PG - 43.1]
20 Greater of 14 ,18 & 19 mm 5.16

25 Ph ( D 2 y ( t C ) ) kg/cm 232
=
2 E ( t C )

NO.
Sl
No
01 Item CONTINUOUS BLOW DOWN STUB

Drg No: 10-10-01-3064
C 294
11 C = 0
13 E = Efficiency 1
14 PD mm 1.54
t = +C
( 2 SE +2 yP )
15 mm 53.84
[ As per PG - 43.1]
20 Greater of 14 ,18 & 19 mm 3.22

25 Ph ( D 2 y ( t C ) ) kg/cm 596
=
2 E ( t C )

NO.
Sl
No
01 Item CBD SLEEVE

Drg No: 10-10-01-3064
C 294
11 C = 0
13 E = Efficiency 1
14 PD mm 2.71
t = +C
( 2 SE +2 yP )
15 mm 53.84
[ As per PG - 43.1]
20 Greater of 14 ,18 & 19 mm 5.74

25 Ph ( D 2 y ( t C ) ) kg/cm 228
=
2 E ( t C )

NO.
7.0 MAXIMUM DIAMETER OF OPENINGS IN SHELL & DISHED HEAD

As per PG-32.1.2
Sl
No
01 Item SHELL DISHED HEAD
03 D = Outside diameter mm 1951 1939
04 S = Maximum allowable stress at Design temp. kg/cm 1389.3 1389.3

05 t = Actual thickness mm 61 55
PD
06 K = Factor K= 0.999 1.101
1 . 82 St
d = Maximum permissible diameter of uncompensated
07 hole (As per Fig. PG-32) mm 35.63 35.63
d= 8.08 [ Dt (1 - K)]1/3
08 For compensation checking refer - LIST OF OPENINGS

NO.
8.0 LIST OF OPENINGS
S Stub Details Location Maximum
L Opening of Stub dia of unco-
IETM NO
(Var.No.)
Remarks
N Description Dia mpensated
o (mm) hole d (mm)
01 01 01 DOWNCOMER 360.56 Shell 35.63 Compensation Check Required
SATURATED
02 01 02 STEAM STUB
250.88 Shell 35.63 Compensation Check Required
03 01 03 RISERS 201.06 Shell 35.63 Compensation Check Required
FEEDWATER Dished
04 02 04 INLET
117 35.63 Compensation Check Required
Head
FEED WATER Dished
05 02 05,06 HEATER 171 35.63 Compensation Check Required
INLET/OULET Head
06 01 07 PT ,PG & VENT 24.3 Shell 35.63 Compensation Check Not Required
10,11 Dished
LT, LG
07 02 13,14 &CHEMICAL 38 35.63 Compensation Check Required
DOSING. Head
15
Dished
08 02 12 BLOWDOWN 53 35.63 Compensation Check Required
Head
10 01 09 SAFETY VALVE 64 Shell 35.63 Compensation Check Required
11 01 08 SPARE 53.94 Shell 35.63 Compensation Check Required
Dished
12 06 MANHOLE RING 418 35.63 Compensation Check Required
Head
Enterprises Pvt.Ltd EQPT. SHELL Mfr's Serial No.: GBE/1750/009
9.0 Compensation check calculation As per PG-32.1
Sl
No
01 Item DOWN COMER STUB
Drg. No. 10-10-01-3063

02 Shell Data:
Minimum thk of Shell t mm 61
Required thk of Shell tr mm 53.84
Max.allowable stress at Design temp. Ss kg / cm 1389.3
03 Nozzle Data:
Nozzle O.D D mm 450.56
Finished diamter of opening d mm 360.56
Minimum thk of nozzle tn mm 45
Required thk of nozzle trn mm 13.13
Material specification of nozzle SA 105
Max. Allowable stress at design temp Sn kg / cm 1324
fr1 = Sn/Ss 0.95
04 Pad plate Data:
Outer dia of the pad plate Dp mm 690
Thickness of the pad plate te mm 25
Max.allowable stress at Design temp. Sp kg / cm 1389.3
fr3 = Sp/Ss 1.00
Actual projection of nozzle Outside/inside the shell
2.5 x t+ t mm 213.50
2.5x tn + t mm 173.50
Minimum of 2.5t and 2.5tn y mm 173.50
Allowable projection of nozzle O.S /I.S of the shell mm 173.50
05 Correction factor F 1
06 Area to be compensated
(d+2tn) tr F A sq mm 24258.15
07 Compensation available as per PG 36.4.1
(a) Compensation available in Shell
i) (d- 2tn)(t-trF) sq mm 1937.21
ii) 2t(t-trF) sq mm 873.52
Max. of i (or) ii A1 sq mm 1937.21
(b) Compensation available in nozzle
i) 2(tn-trn) (2.5tfr1) sq mm 9263.47
ii) 2(tn-trn) (2.5tn+ te)fr1 sq mm 8352.31
Smaller of i (or) ii A2 sq mm 8352.31
(c) Compensation available in nozzle from inside projection
Actual projection of nozzle inside the shell h mm 121
Allowable projection of nozzle inside the shell mm 173.50
2 tnfr1h A3 sq mm 10378.15
(d) Compensation available in pad plate
=((Dp-d-(2*tn))*te*(Sp/Ss) A5 sq mm 5986.00
(f) Total compensation available
A1 + A2 + A3+ A5 sq mm 26653.67
(g) Total compensation required sq mm 24258.15
08 Available Area > Required Area HENCE SATISFACTORY

Sl
No
01 Item SATURATED STEAM STUB
Drg. No. 10-10-01-3063

02 Shell Data:
03 Nozzle Data:
Nozzle O.D D mm 375
Minimum thk of nozzle tn mm 62.06
fr1 = Sn/Ss 0.95
2.5 x t+ t mm 213.50
2.5x tn + t mm 216.15
(d+2tn) tr F A sq mm 20190.00
i) (d- 2tn)(t-trF) sq mm 907.60
i) 2(tn-trn) (2.5tfr1) sq mm 14814.92
( c) Compensation available in nozzle from inside projecti
2 tnfr1h A3 sq mm 7192.75
(d) Total compensation available
A1 + A2 + A3 sq mm 22915.27
(e) Total compensation required sq mm 20190.00

Sl
No
01 Item RISER STUB
Drg. No. 10-10-01-3063

02 Shell Data:
03 Nozzle Data:
Nozzle O.D D mm 305
fr1 = Sn/Ss 0.95
2.5 x t+ t mm 213.50
2.5x tn + t mm 190.93
(d+2tn) tr F A sq mm 16421.20
i) (d- 2tn)(t-trF) sq mm 695.38
i) 2(tn-trn) (2.5tfr1) sq mm 12482.43
( c) Compensation available in nozzle from inside projection
A1 + A2 + A3 sq mm 17531.46

Enterprises Pvt.Ltd EQPT. DISHED END Mfr's Serial No.: GBE/1750/009
Sl
No
01 Item FEED WATER STUB SLEEVE
Drg. No. 10-10-01-3063

Var No./Item No. 04
02 Shell Data:
03 Nozzle Data:
Nozzle O.D D mm 195
Finished diamter of opening d mm 117
fr1 = Sn/Ss 0.95
2.5 x t+ t mm 192.50
2.5x tn + t mm 152.13
03 Minimum of 2.5t and 2.5tn y mm 152.13
(d+2tn) tr F A sq mm 10482.6
i) (d- 2tn)(t-trF) sq mm 45.59
i) 2(tn-trn) (2.5tfr1) sq mm 8012.50
Actual projection of nozzle inside the shell h mm 130.0
A1 + A2 + A3 sq mm 15383.32

Sl
No
FEEDWATER HEATER INLET &
01 Item
OUTLET STUB SLEEVE
Drg. No. 10-10-01-3063
Var No./Item No. 05/02,06/02
02 Shell Data:
03 Nozzle Data:
Nozzle O.D D mm 265
fr1 = Sn/Ss 0.95
2.5 x t+ t mm 192.50
2.5x tn + t mm 172.13
(d+2tn) tr F A sq mm 14251.4
i) 2(tn-trn) (2.5tfr1) sq mm 9817.80
2 tnfr1h A3 sq mm 11571.95
A1 + A2 + A3 sq mm 20062.51

Sl
No
01 Item BLOW DOWN STUB SLEEVE
Drg. No. 10-10-01-3064

02 Shell Data:
03 Nozzle Data:
Nozzle O.D D mm 93
fr1 = Sn/Ss 0.95
2.5 x t+ t mm 192.50
2.5x tn + t mm 105.00
(d+2tn) tr F A sq mm 5007.1
i) 2(tn-trn) (2.5tfr1) sq mm 3725.40
A1 + A2 + A3 sq mm 6422.30

Sl
No
LEVEL GAUGE LOWER & UPPER
01 Item
STUB SLEEVE
Drg. No. 10-10-01-3064
Var No./Item No. 14/02 & 15/02
02 Shell Data:
03 Nozzle Data:
Nozzle O.D D mm 66
fr1 = Sn/Ss 0.95
2.5 x t+ t mm 213.50
2.5x tn + t mm 96.00
i) 2(tn-trn) (2.5tfr1) sq mm 2561.40
A1 + A2 + A3 sq mm 4014.98

Sl
No
01 Item SPARE STUB
Drg. No. 10-10-01-3063

02 Shell Data:
03 Nozzle Data:
Nozzle O.D D mm 93
fr1 = Sn/Ss 0.95
2.5 x t+ t mm 213.50
2.5x tn + t mm 109.83
i) (d- 2tn)(t-trF) sq mm 106.54
i) 2(tn-trn) (2.5tfr1) sq mm 4163.70
A1 + A2 + A3 sq mm 5954.40

Sl
No
01 Item SAFETY VALVE STUB
Drg. No. 10-10-01-3063

02 Shell Data:
03 Nozzle Data:
Nozzle O.D D mm 110
fr1 = Sn/Ss 0.95
2.5 x t+ t mm 213.50
2.5x tn + t mm 119.13
i) (d- 2tn)(t-trF) sq mm 125.30
i) 2(tn-trn) (2.5tfr1) sq mm 4992.40
A1 + A2 + A3 sq mm 6796.28

Sl
No
Drg. No. 10-10-01-3062

02 Shell Data:
03 Nozzle Data:
Nozzle O.D D mm 536
Material specification of nozzle SA 516 Gr.70
Max. Allowable stress at design temp Sn kg / cm 1389.3
fr1 = Sn/Ss 1.00
04 Pad plate Data:
Outer dia of the pad plate Dp mm 750
Max.allowable stress at Design temp. Sp kg / cm 1389.3
fr3 = Sp/Ss 1.00
2.5 x t+ t mm 192.50
2.5x tn + t mm 202.50
(d+2tn) tr F A sq mm 28858.24
i) (d- 2tn)(t-trF) sq mm 348.00
i) 2(tn-trn) (2.5tfr1) sq mm 12127.50
(c) Compensation available in nozzle from inside projection
2 tnfr1h A3 sq mm 17346.00
(d) Compensation available in pad plate
=((Dp-d-(2*tn))*te*(Sp/Ss) A5 sq mm 4280.00
(f) Total compensation available
A1 + A2 + A3+ A5 sq mm 34101.50
(g) Total compensation required sq mm 28858.24

EQPT. STEAM DRUM GBE/1750/009
SERIAL NO.
10.0 Minimum requirements for attachments weld on Shell (As per PW-16)
Sl
No
01 Item DOWNCOMER STUB
Drg No. 10-10-01-3063
01 t = Minimum thickness of Shell t mm 61
02 tn = Nominal thickness of Stub (As per Fig PW-16.1d) mm 45
03 Conditions
tmin = Smaller of 3/4" (or) thickness of either of
weld parts (t or tn)

t1 = t2= Not less than smaller of 1/4" (or) 0.7 x t min
t1+t21.25tmin
t1&t26.35 mm
04 Applicable sketch from Fig.PW-16.1 Sketch (d)
(a) tmin mm 19.05
(b) 0.7 tmin mm 13.34
(c) Required t1 mm 6.35
(d) Required t2 mm 6.35
(e) Provided t1 mm 17.7
(f) Provided t2 mm 20.9
(e) 4 (e) > 4 (c) & 4 (f) > 4 (d) HENCE SATISFACTORY
05 t1 mm 17.7
t2 mm 20.9
(a) t1 + t2 mm 38.6
(b) 1 1/4 x tmin mm 23.8
(c) t1 + t2 > 1 1/4 tmin HENCE SATISFACTORY

SERIAL NO.
Sl
No
Drg No. 10-10-01-3062
03 Conditions

t1+t21.25tmin
t1&t26.35 mm
(a) tmin mm 19.05
(b) 0.7 tmin mm 13.34
05 t1 mm 11.9
t2 mm 20.7
(a) t1 + t2 mm 32.6
(b) 1 1/4 x tmin mm 23.8

SERIAL NO.
10.0 Minimum requirements for attachments weld on Shell

(As per PW-16)
Sl
No
01 Item SATUREATED STEAM STUB
Drg.No 10-10-01-3063
02 Nominal thickness of Shell t mm 61
03 Nominal thickness of Stub tn mm 62.06
04 Conditions (Shell to Nozzles)
Smaller of 3/4" (or) thickness of either of

tmin
Not less than smaller of 1/4" (or) 0.7 x tmin tc
05 Applicable sketch from Fig.PW-16.1 Sketch (h)
(a) tmin mm 19.05
(b) 0.7 tmin mm 13.34
(c) Required tc mm 6.35
(e) Provided tc mm 20.9
(f) Provided tc > Required tc HENCE SATISFACTORY

SERIAL NO.

(As per PW-16)
Sl
No
01 Item RISER STUB
Drg.No 10-10-01-3063

tmin
(a) tmin mm 19.05
(b) 0.7 tmin mm 13.34

SERIAL NO.
Sl
No
01 Item FEED WATER SLEEVE
Drg No. 10-10-01-3063
02 tn = Nominal thickness of Stub (As per Fig PW-16.1d) mm 38.85
03 Conditions

t1+t21.25tmin
t1&t26.35 mm
(a) tmin mm 19.05
(b) 0.7 tmin mm 13.34
05 t1 mm 13.2
t2 mm 22.6
(a) t1 + t2 mm 35.8
(b) 1 1/4 x tmin mm 23.8

SERIAL NO.
Sl
No
FEEDWATER HEATER INLET &
01 Item
OUTLET SLEEVE.
Drg No. 10-10-01-3063
Var No./Item No. 05/02,06/02
01 t = Minimum thickness of Shell mm 55
03 Conditions

t1+t21.25tmin
t1&t26.35 mm
(a) tmin mm 19.05
(b) 0.7 tmin mm 13.34

05 t1 mm 38.8
t2 mm 17.3
(a) t1 + t2 mm 56.1
(b) 1 1/4 x tmin mm 23.8

SERIAL NO.

(As per PW-16)
Sl
No
01 Item SPARE STUB
Drg.No 10-10-01-3063

tmin
(a) tmin mm 19.05
(b) 0.7 tmin mm 13.34

SERIAL NO.
Sl
No
Drg No. 10-10-01-3063
03 Conditions

t1+t21.25tmin
t1&t26.35 mm
(a) tmin mm 19.05
(b) 0.7 tmin mm 13.34
05 t1 mm 18.8
t2 mm 18.8
(a) t1 + t2 mm 37.6
(b) 1 1/4 x tmin mm 23.8

SERIAL NO.
Sl
No
01 Item LEVEL ELEMENT SLEEVE
Drg No. 10-10-01-3064
Var No./Item No. 10/02,11/02
03 Conditions

t1+t21.25tmin
t1&t26.35 mm
(a) tmin mm 14
(b) 0.7 tmin mm 9.80

05 t1 mm 28.3
t2 mm 9.8
(a) t1 + t2 mm 38.1
(b) 1 1/4 x tmin mm 17.5

SERIAL NO.
Sl
No
01 Item BLOW DOWN SLEEVE
Drg No. 10-10-01-3064
03 Conditions

t1 = t2= Not less than smaller of 1/4" (or) 0.7 x tmin
t1+t21.25tmin
t1&t26.35 mm
(a) tmin mm 19.05
(b) 0.7 tmin mm 13.34

05 t1 mm 27.8
t2 mm 12.9
(a) t1 + t2 mm 40.7
(b) 1 1/4 x tmin mm 23.8

SERIAL NO.
Sl
No
01 Item CHEMICAL DOSING SLEEVE
Drg No. 10-10-01-3064
03 Conditions

t1+t21.25tmin
t1&t26.35 mm
(a) tmin mm 14
(b) 0.7 tmin mm 9.80

05 t1 mm 22.3
t2 mm 8.3
(a) t1 + t2 mm 30.6
(b) 1 1/4 x tmin mm 17.5

SERIAL NO.
Sl
No
01 Item LG SLEEVE (UPPER)
Drg No. 10-10-01-3064
03 Conditions

t1+t21.25tmin
t1&t26.35 mm
(a) tmin mm 14
(b) 0.7 tmin mm 9.80

05 t1 mm 27.3
t2 mm 6.7
(a) t1 + t2 mm 34.0
(b) 1 1/4 x tmin mm 17.5

SERIAL NO.
Sl
No
01 Item LG SLEEVE (LOWER)
Drg No. 10-10-01-3064
03 Conditions

t1+t21.25tmin
t1&t26.35 mm
(a) tmin mm 14
(b) 0.7 tmin mm 9.80
(f) Provided t2 mm 8
05 t1 mm 31.3
t2 mm 8.0
(a) t1 + t2 mm 39.3
(b) 1 1/4 x tmin mm 17.5

SERIAL NO.
11.0 The minimum required strength of weld ( As per PG - 37 )
Sl
No
01 Item DOWN COMER STUB
02 Drg. No. 10-10-01-3063

03 Var No./Item No. 01/01
05 d1= O.D of Nozzle mm 450.56
06 tn= Nominal thickness of nozzle mm 45
07 d= Diameter of finished opening mm 360.56
08 tr= Required thickness of header [ E=1] mm 53.84
09 t= Actual Thickness of shell mm 61
10 Sn= Max. allowable stress for nozzle kg/mm 13.24
11 Sv= Max. allowable stress for header kg/mm 13.89
12 Sp= Max. allowable stress for pad plate kg/mm 13.89
13 Outer dia of the pad plate Dp mm 690
14 Thickness of the pad plate te mm 25
15 fr1= Sn/Sv 0.95
16 fr2= (lesser of Sn or Sp) /Sv 0.95
17 fr3= Sp /Sv 1.00
18 Ff= Factor 1.00
19 Weld leg mm
WL1 25.00
WL2.1 (Outside fillet) 25.00
WL2.2 (Inside Fillet) 30.00
t2 Weld leg mm 40.00
20 The required minimum strength to be provided by
the combined load carrying elements through each
load - carrying path.
W= (A-A1)SV
A= (d+2tn) tr F mm2 24258.15
A1= Max.of { (d- 2tn)(t-trF)

2t(t-trF)
} mm2
mm2
1937.21
873.52
A1= 1937.21
W= (A-A1)SV 310105
Strength of load carrying elements in path
number 1, As per Fig PW -16 (c) (1)
21 External fillet weld in shear
= 1/2 WL2.1 (Dp) (factor in PW-15.2=0.49) x SV x fr3 kg 184460
22 Groove welds in tension
= 1/2 t2 x (d+2tn) (factor in PW-15.2=0.74) x Sv x fr1 kg 277365
23 Internal fillet weld in shear
= 1/2 WL2.2 (d+2tn) (factor in PW-15.2=0.49) x SV x fr1 kg 137746
24 21+22+23 599571
25 24 >20 HENCE SATISFACTORY

= 1/2 WL1 (d+2tn) (factor in PW-15.2=0.49) x SV x fr1 kg 114788
29 26+27+28 529899

SERIAL NO.
Sl
No
02 Drg. No. 10-10-01-3062

04 Material specification SA 516 GR70
05 d1= O.D of Nozzle mm 536
06 tn= Nominal thickness of nozzle mm 63
12 Sp= Max. allowable stress for pad plate kg/mm 13.89
13 Outer dia of the pad plate Dp mm 750
14 Thickness of the pad plate te mm 20
15 fr1= Sn/Sv 1.00
16 fr2= (lesser of Sn or Sp) /Sv 1.00
17 fr3= Sp /Sv 1.00
18 Ff= Factor 1.00
19 Weld leg mm
WL1 20.00
WL2.1 (Outside fillet) 20.00
WL2.2 (Inside Fillet) 25.00
W= (A-A1)SV
A= (d+2tn) tr F mm2 28858.24
A1= Max.of { (d- 2tn)(t-trF)

2t(t-trF)
} mm2
mm2
329.44
127.60
A1= 329.44
W= (A-A1)SV 396351
= 1/2 WL2.1 (Dp) (factor in PW-15.2=0.49) x SV x fr3 kg 160400
24 21+22+23 520087

29 26+27+28 474320

SERIAL NO.
Sl
No
01 Item FEED WATER STUB SLEEVE
02 Drg. No. 10-10-01-3063

06 tn= Nominal thickness of nozzle mm 38.85
12 fr1= Sn/Sv 0.95
13 Ff= Factor 1.00
14 Weld leg mm
WL1 24.00
WL2 28.30
W= (A-A1)SV
A= (d+2tn) tr F mm2 10498.80
{ (d- 2tn)(t-trF)
} mm 45.94
2
A1= Max.of
2t(t-trF) mm 2
127.60
A1= 127.60
W= (A-A1)SV 144087
= 1/2 WL2(d+2tn) (factor in PW-15.2=0.49) x SV x fr1 kg 56237
18 16+17 176280

22 20+21 167735

SERIAL NO.
Sl
No
FEED WATER HEATER INLET / OUTLET
01 Item
STUB SLEEVE
02 Drg. No. 10-10-01-3063
03 Var No./Item No. 05/02,06/02
12 fr1= Sn/Sv 0.95
13 Ff= Factor 1.00
14 Weld leg mm
WL1 39.00
WL2 30.00
W= (A-A1)SV
A= (d+2tn) tr F mm2 14267.60
{ (d- 2tn)(t-trF)
} mm 90.02
2
A1= Max.of
2t(t-trF) mm 2
127.60
A1= 127.60
W= (A-A1)SV 196447
18 16+17 203367

22 20+21 227672

SERIAL NO.
Sl
No
02 Drg. No. 10-10-01-3063

12 fr1= Sn/Sv 0.95
13 Ff= Factor 1.00
14 Weld leg mm
WL1 26.50
WL2 26.50
W= (A-A1)SV
A= (d+2tn) tr F mm2 5922.40
{ (d- 2tn)(t-trF)
} mm 121.72
2
A1= Max.of
2t(t-trF) mm 2
873.52
A1= 873.52
W= (A-A1)SV 70144
18 16+17 80493

22 20+21 80493

SERIAL NO.
Sl
No
01 Item LEVEL ELEMENT STUB SLEEVE (UPPER)
02 Drg. No. 10-10-01-3064

12 fr1= Sn/Sv 0.95
13 Ff= Factor 1.00
14 Weld leg mm
WL1 30.00
WL2 30.00
W= (A-A1)SV
A= (d+2tn) tr F mm2 3553.44
{ (d- 2tn)(t-trF)
} mm 11.60
2
A1= Max.of
2t(t-trF) mm 2
127.60
A1= 127.60
W= (A-A1)SV 47595
18 16+17 50650

22 20+21 50650

SERIAL NO.
Sl
No
01 Item LEVEL ELEMENT STUB SLEEVE (LOWER)
02 Drg. No. 10-10-01-3064

12 fr1= Sn/Sv 0.95
13 Ff= Factor 1.00
14 Weld leg mm
WL1 30.00
WL2 30.00
W= (A-A1)SV
A= (d+2tn) tr F mm2 3553.44
{ (d- 2tn)(t-trF)
} mm 11.60
2
A1= Max.of
2t(t-trF) mm 2
127.60
A1= 127.60
W= (A-A1)SV 47595
18 16+17 50650

22 20+21 50650

SERIAL NO.
Sl
No
01 Item BLOW DOWN STUB SLEEVE
02 Drg. No. 10-10-01-3064

12 fr1= Sn/Sv 0.95
13 Ff= Factor 1.00
14 Weld leg mm
WL1 30.00
WL2 30.00
W= (A-A1)SV
A= (d+2tn) tr F mm2 5007.12
{ (d- 2tn)(t-trF)
} mm 15.08
2
A1= Max.of
2t(t-trF) mm 2
127.60
A1= 127.60
W= (A-A1)SV 67791
18 16+17 71370

22 20+21 71370

SERIAL NO.
Sl
No
01 Item CHEMICAL DOSING STUB SLEEVE
02 Drg. No. 10-10-01-3064

12 fr1= Sn/Sv 0.95
13 Ff= Factor 1.00
14 Weld leg mm
WL1 30.00
WL2 30.00
W= (A-A1)SV
A= (d+2tn) tr F mm2 3553.44
{ (d- 2tn)(t-trF)
} mm 11.60
2
A1= Max.of
2t(t-trF) mm 2
127.60
A1= 127.60
W= (A-A1)SV 47595
18 16+17 50650

22 20+21 50650

SERIAL NO.
Sl
No
01 Item LG STUB SLEEVE (UPPER)
02 Drg. No. 10-10-01-3064

12 fr1= Sn/Sv 0.95
13 Ff= Factor 1.00
14 Weld leg mm
WL1 25.00
WL2 15.00
W= (A-A1)SV
A= (d+2tn) tr F mm2 3553.44
{ (d- 2tn)(t-trF)
} mm 71.60
2
A1= Max.of
2t(t-trF) mm 2
873.52
A1= 873.52
W= (A-A1)SV 37232
18 16+17 45640

22 20+21 52366

SERIAL NO.
Sl
No
01 Item LG STUB SLEEVE (LOWER)
02 Drg. No. 10-10-01-3064

12 fr1= Sn/Sv 0.95
13 Ff= Factor 1.00
14 Weld leg mm
WL1 25.00
WL2 15.00
W= (A-A1)SV
A= (d+2tn) tr F mm2 3553.44
{ (d- 2tn)(t-trF)
} mm 71.60
2
A1= Max.of
2t(t-trF) mm 2
873.52
A1= 873.52
W= (A-A1)SV 37232
18 16+17 45640

22 20+21 52366

Enterprises Pvt.Ltd MFR'S
EQPT : SHELL GBE/1750/009
SERIAL NO.
CALCULATION OF THICKNESS FOR WELDED COVER (HYDROSTATIC TEST)
Sl
No
01 Item DOWNCOMER STUB
Drg No. 10-10-01-3063
02 Ph = Hydrostatic Pressure kg/cm(g) 118.5
C 21
04 Cover Plate Material IS 2062
05 d = Internal Diameter mm 360.56
07 C = Constant (As per Fig.No.PG-31( f )) 0.2
09 Minimum thickness required
t = d
CP
S
mm 46.91
10 Required thickness = t mm 46.91

Enterprises Pvt.Ltd MFR'S
EQPT : SHELL GBE/1750/009
SERIAL NO.
Sl
No
01 Item SATURATED STEAM STUB
Drg No. 10-10-01-3063
C 21
09 Minimum thickness required

mm 32.64
t = d
10 Required thickness = t
CP
S
mm 32.64

EQPT : SHELL
SERIAL NO. 009
Sl
No
01 Item RISER STUB
Drg No. 10-10-01-3063
C 21
09 Minimum thickness required mm
CP 26.16
t = d
S

EQPT : DISHED END
SERIAL NO. 009
Sl
No
01 Item FEED WATER STUB
Drg No. 10-10-01-3063
C 21

13.50
t = d
CP
S
mm 13.50

EQPT : DISHED END
SERIAL NO. 009
Sl
No
FEED WATER HEATER INLET &
01 Item
OUTLET
Drg No. 10-10-01-3063
C 21

20.28
t = d
CP
S
mm 20.28

EQPT : SHELL
SERIAL NO. 009
Sl
No
01 Item PG,PT & VENT STUBS
Drg No. 10-10-01-3063
C 21

3.16
t = d
CP
S
mm 3.16

EQPT : SHELL
SERIAL NO. 009
Sl
No
Drg No. 10-10-01-3063
C 21
06 Nominal Cover Plate Thickness mm 16

9.09
t = d
CP
S

EQPT : DISHED END
SERIAL NO. 009
Sl
No
01 Item LE,LG & CHEMICAL DOSING STUB
Drg No. 10-10-01-3064
C 21

3.31
t = d
CP
S
mm 3.31

EQPT : DISHED END
SERIAL NO. 009
Sl
No
01 Item BLOW DOWN STUB
Drg No. 10-10-01-3064
C 21

5.13
t = d
CP
S
mm 5.13

EQPT: SHELL GBE/1750/009
SERIAL NO.
15. Calculation of Minimum Required thickness for the Header End Plate
As per PG-31.3.2
Sl
DESCRIPTION UNIT SPARE
No
(a) Drg No. 10-10-01-3063
(b) Material specification SA 105
(c) d = Inside diameter of the Header mm 53.94
(d) Provided Thickness of End plate mm 16.00
(e) P = Max.Allowable working pressure kg/cm.g 79
(f) Design temperature o

C 294
(g) S = Allowable stress value at Design temperature kg/cm 1324.00
2. Header Data
(a) ts = Actual thickness of header mm 19.53
(b) tr = Minimum required thickness of seamless header mm 5.16
3. C = Calculation factor as per Fig PG-31 (g)
(a) m = tr / ts 0.26
(b) 0.33 m 0.09
(c) C = 0.33 m with a minimum of 0.2 0.20
(d) Selected 'C' 0.20
(e) Minimum required thickness of End plate
CxP
mm 5.89
=dx -------------------
S
(g) Required Thickness = mm 5.89
4. Provided Thickness = mm 16.00

5 Provided Thickness > Required thicknes HENCE SATISFACTORY
6 Minimum weld size tw = 2 tr with minimum of 1.25 ts
(a) 2 tr mm 10.32
(b) 1.25 ts mm 24.41
(c) tw mm 10.32
(d) Provided Thickness mm 16.00

7 Provided Thickness > Required thicknes HENCE SATISFACTORY
EQPT: SHELL GBE/1750/009
NO.
16. Calculation of stress during Hydrostatic test for STUB End Plate
As per PG-31.3.2
Description SPARE
Drg No. 10-10-01-3063
02 t = Minimum thickness available mm 16.00
03 d = Inside Diameter of the Header mm 53.94
04 C = Calculation factor as per Fig PG-31 (g) 0.20
06 Stress during hydrostatic test
d 2 (CPh ) kg/cm
S= 2
269
(t CA )
07 As per PG-99, Maximum allowable stress (0.9 x Y) kg/cm 2386
08 (07) > (06) HENCE SATISFACTORY

SERIAL NO.
Static head calculation
01 Description Unit STEAM DRUM
01. Upper elevation ( DRUM NORMAL LEVEL ) mm 16050

02. Lower elevation ( DRUM BOTTOM ) mm 15085.5
03. Effective Static Head mm 964.50
04. Static head per meter kg/cm 0.100
05. Static head for 0.9645 m = kg/cm 0.096
Sheet 80
GB ENGINEERING
STRESS CALCULATIONS Rev. 00
SERIAL NO.
10.0 WEIGHT & LOADING CALCULATION (As per PG-22.1)
(01) weight of steam drum with : 60000 kgs

attachments & nozzle
(02) Length to which the above loads : 8400 mm

are distributed
(03) Uniformly distributed load acting on the

drum : 7.14 Kg/mm
7.14 Kg/mm
C RA M 'RB D
1700 5000 1700
`
A B
Since loading is symmetric, reaction at supports

(04) TAKING MOMENTS ABOUT "A"
RB x 5000 = 7.14 x 8400 x (5000/2)
RB = 29988 kgs
Therefore
RA = 29988 kgs
(05) BENDING MOMENT
Let x be the distance from C where S.F.changes sign and bending moment will be maximum
7.14 x - RA = 0
7.14 x - 29988 = 0
x = 4200 mm
Sheet 81
GB ENGINEERING STRESS CALCULATIONS Rev. 00
MFR'S
SERIAL NO.
MM = Max. Bending Moment (at midspan)

MM = -7.14 X x X x/2 + RA (x-a)
MM = -7.14 x2 /2 + RA (x-a)
MM = -7.14 (4200) + 29988 (4200-1700)
2
2
MM = 11995200 kg-mm
Where
a = Distance between support centre
line and the Weld line : 1700 mm
:
(06) Section Modulus of the shell Z : (19554-18294)
32 1955
Where
a) Outside diameter of the shell D : 1955.0 mm
b) Inside diameter of the shell d : 1829.0 mm
(19554 - 18294)
Z : 32 1955
: 171604364.1 mm3
(07) Stress induced f : M/Z
: 0.070
: 0.07 Kg/mm2
: 7.00 Kg/cm2
(08) 10% of the allowable stress of the Material
: 0.1x1389.3 = 138.9
= 139.1 Kg/cm2
(09) Stresses imposed by effects other than working pressure & static head are less than 10%
of the allowable stress of the material.
Hence loading due to above need not be considered for calculation of thickness as per
PG-22.1
DESIGN CALCULATIONS SHEET Sheet 82
EQPT: STEAM DRUM GBE/1750/009
SERIAL NO.
EXTERNAL LOADING CALCULATIONS
Sl
No
01 Item STEAM DRUM DOWNCOMER
02 Drg.No REF SKETCH (SHEET No.83)

03 D = Downcomer size mm 406.4
04 t = Thickness mm 26.19
05 d = Internal dia of the downcomer 354.02
06 No of downcomers 2
07 L = Span length 4550
08 Material specification SA 106 Gr.B
Total load
09 ton 60.000
(Including steam drum attachments and water)
10 P = Load per downcmer ton 30.00
11 No of supports* 4
/ 4 x ( D -d )
2 2
12 A = Area of pipe = mm2 31283
13 I = Moment of ineratia = / 64 x {D4-d4} mm4 567965276.549677
14 r = Radius of gyration = I/A mm 134.74
x E x A
15 Pa = Allowable load = ton 5686.15
(L/r)2
16 Here Pa > P Hence satisfacotory
* - SUPOORT LOCATION ARE SHOWN IN ENCLOSED SKETCH

SERIAL NO.
SAFETY VALVE REQUIRMENT AS PER ASME SECTION-1 PG-67.
Sl
No
DATA
01. Boiler Capacity = 75 TPH
02. Total Heating Surface Area = 4695 m
03. No.of Safety Valves in Steam Drum = 2 Nos.

Sl
Description Code Code Discription
No
Condition to provide additional valves
No.of Safety Valves in Steam Drum PG 67.1
01.Heating surface area exceeds 500 sq.feet (47 m)
02.Design Steam Generating Capacity of Bolier exceeds
4000 lb/hr (1800 kg/hr)
(A) Heating Surface Area of this Boiler

(Ref Drg.No.10-01-03-3004)
Sl
Part Units
No
01. Economiser m 2329
02. Evaporator-1 m 973
03. Evaporator-2 m 973
04. Superheater module m 155
05. Primary Superheater m 130

06. Secondary Superheater m 135
Total heating surface area m 4695

The total heating surface area of this bolier is ( 4695 m ) greater than 47 m.
So Two Safety valves provided in this boiler steam drum.
Steam Generating Capacity of Boiler

(B) (Ref Deg.No.10-01-03-3004) kg/hr 75,000
Design Steam Generating Capacity of this bolier is ( 75000 kg/hr ) greater than 1800 kg/hr. So Two Safety valves
provided in this boiler steam drum.

Steam Drum Calulation

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Steam Drum Calulation

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STEAM DRUM

EQUIPMENT NAME : STEAM DRUM

PROJECT : BIRLA CARBON BLACK Co.,

CONSTRUCTION CODE : ASME Section-I, 2004 Edition./ADDENDA 2006.

ASME 'S' STAMP : YES "S" STAMP

MANUFACTURER'S NAME : ENMAS GB POWER SYSTEMS

STATUS OF CALCULATION DUE TO REVISION IN DRAWING

Sl. Rev. Page of Reason For Revision Pages Prep. Appr.

S.No. DESCRIPTION SHEET Nos.

02 Revision status - Drawing 02

04 Revision status - Stress calculation 04

10 Hydrostatic test pressure 10

12 Heat treatment & Post weld heat treatment 12

13 Shell Thickness calculation 13

14 dished head thickness calculation 14

15 Manhole ring thickness calculations 15

16 Manhole door thickness calculations 16

17 Nozzle (Stubs) thickness calculations 17 - 31

18 openings in shell and dished head 32

20 Compensation calculations for openings in shell & dished head 34 - 43

21 Requirements of attachment welds 44 - 56

22 Weld strength calculations 57 - 67

23 Hydrostatic test Endcover thickness calculations 68 - 76

24 Calculation of Minimum Required thickness for the stub End Plate 77

25 Calculation of stress during Hydrostatic test for Stub End Plate 78

26 Static Head Calculation 79

27 Weight & Loading Calculation 80 & 81

28 External Loading calculation 82

29 Safety Valves Requirement 84

DOC NO. PREPARED CHECKED APPROVED AI REVIEW

1.0 LIST OF DRAWINGS

S.No. Description Drawing No. Rev.Nr.

2.0 LIST OF STANDARDS / CODES

1 ASME Section-I, 2004 Edition / Addenda 2006.

2 ASME Section II, Part-A, 2004 Edition/ Addenda 2006.

3 ASME Section-II, Part-D, 2004 Edition/ Addenda 2006.

3.0 DESIGN DATA

Construction code : ASME Section-1, Edition 2004 / Addenda 2006.

4.0 MATERIAL OF CONSTRUCTION

1 Shell : SA 516 Gr.70

2 Stubs & Sleeves : SA 105

3 Dished Heads : SA 516 Gr.70

4 Nozzle pipes : SA 106 Gr. B

5 Hydrostatic End plate : IS 2062

6 Manhole cover plate : SA 516 Gr.70

5. Allowable stress Values

As per ASME Sec-II Part-D 2004Edition/addenda 2006.

Min. Yeild Strength at Allowable stress ('s') at Min. Yeild

1 SA-106 Gr B 21 240 2447.3 294 118 1203.3 2203 1 1 10 5

2 SA 516 Gr.70 21 260 2651.3 294 136.24 1389.3 2386 1 2 14 20

3 SA 105 21 250 2549.3 294 129.84 1324 2294 1 2 14 6

6.0 Hydrostatic Test Pressure Calculation PG 99

01. Max. Allowable working pressure 'P' : 79 kg/cm(g)

7.0 Radiographic Examination of Welds as per PW-11

100% Radiography shall be

100% Radiography shall be

Post Weld Heat Treatment PW 39

For Drum, PWHT shall be done after completion

01. CALCULATION OF CYLINDRICAL SHELL THICKNESS FOR INTERNAL PRESSURE

05 D = Inside diameter of cylinder mm 1829

06 R = Inside radius of cylinder mm 914.5

07 Nominal Thickness (before rolling) mm 63

08 Nominal Thickness (after rolling) mm 61