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STRESS CALCULATIONS
QUANTITY : ONE
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
01 Cover Sheet 01
03 Index 03
05 List of drawings 05
06 List of standards/codes 06
07 Design data 07
08 Material constructions 08
09 Allowable stress 09
11 Radiographic Examinations 11
19 List of openings 33
4 ASME B 16.5,2003
5 ASME B 36.10M,2000
STRESS CALCULATIONS Sheet 07
GB ENGINEERING Rev. 00
Enterprises Pvt. Ltd. MFR'S SERIAL
EQPT : STEAM DRUM GBE/1750/009
NO.
Conversion factor:
To convert MPa to kg/cm multiply by 10.1972
STRESS CALCULATIONS Sheet 10
GB ENGINEERING Rev. 00
Enterprises Pvt. Ltd. MFR'S SERIAL
EQPT : STEAM DRUM GBE/1750/009
NO.
S.
Equipment As per Requirement
No.
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.
STRESS CALCULATIONS Sheet 12
GB ENGINEERING Rev. 00
Enterprises Pvt. Ltd.
MFR'S
EQPT: STEAM DRUM GBE/1750/009
SERIAL NO.
SL.
Equipment As per Requirement
No
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.
STRESS CALCULATIONS Sheet 13
GB ENGINEERING Rev. 00
Enterprises Pvt.Ltd MFR'S SERIAL
EQPT : STEAM DRUM GBE/1750/009
NO.
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
* PG-16.4 : Maximum under tolerance permissible on calculated thickness of plate material is 0.01" .
STRESS CALCULATIONS Sheet 14
GB ENGINEERING Rev. 00
Enterprises Pvt.Ltd MFR'S SERIAL
EQPT : DISHED HEAD GBE/1750/009
NO.
Sl
DESCRIPTION UNIT DATA
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
04 T = Design temperature o
C 294
07 Nominal Thickness mm 63
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
18 Required thickness = mm 53.84
19 Provided thickness = mm 55
20 Provided Thickness > Required Thickness HENSE SATISFACTORY
* PG-16.4 : Maximum under tolerance permissible on calculated thickness of plate material is 0.01" .
STRESS CALCULATIONS Sheet 15
GB ENGINEERING Rev. 00
Enterprises Pvt.Ltd MFR'S SERIAL
EQPT : STEAM DRUM GBE/1750/009
NO.
6.0 CALCULATION OF NOZZLE THICKNESS FOR INTERNAL PRESSURE - AS PER PG - 27.2.2 & PG - 43
Sl
DESCRIPTION UNIT DATA
No
Sl
DESCRIPTION UNIT DATA
No
01 Item MANHOLE COVER PLATE
Item No. 01
03 T = Design Temperature o
C 294
Sl
DESCRIPTION UNIT DATA
No
Sl
DESCRIPTION UNIT DATA
No
Sl
DESCRIPTION UNIT DATA
No
Sl
DESCRIPTION UNIT DATA
No
Sl
DESCRIPTION UNIT DATA
No
Sl
DESCRIPTION UNIT DATA
No
Sl
DESCRIPTION UNIT DATA
No
Sl
DESCRIPTION UNIT DATA
No
Sl
DESCRIPTION UNIT DATA
No
Sl
DESCRIPTION UNIT DATA
No
Sl
DESCRIPTION UNIT DATA
No
Sl
DESCRIPTION UNIT DATA
No
Sl
DESCRIPTION UNIT DATA
No
Sl
DESCRIPTION UNIT DATA
No
Sl
DESCRIPTION UNIT DATA
No
Sl
DESCRIPTION UNIT DATA
No
01 Item SHELL DISHED HEAD
PD
06 K = Factor K= 0.999 1.101
1 . 82 St
d = Maximum permissible diameter of uncompensated
d= 8.08 [ Dt (1 - K)]1/3
(Var.No.)
Remarks
N Description Dia mpensated
o (mm) hole d (mm)
SATURATED
02 01 02 STEAM STUB
250.88 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
Dished
12 06 MANHOLE RING 418 35.63 Compensation Check Required
Head
STRESS CALCULATIONS Sheet 34
GB ENGINEERING Rev. 00
Enterprises Pvt.Ltd EQPT. SHELL Mfr's Serial No.: GBE/1750/009
9.0 Compensation check calculation As per PG-32.1
Sl
DESCRIPTION UNIT DATA
No
01 Item DOWN COMER STUB
GB ENGINEERING Rev. 00
Enterprises Pvt. Ltd. MFR'S
EQPT. STEAM DRUM GBE/1750/009
SERIAL NO.
10.0 Minimum requirements for attachments weld on Shell (As per PW-16)
Sl
DESCRIPTION UNIT DATA
No
01 Item DOWNCOMER STUB
03 Conditions
tmin = Smaller of 3/4" (or) thickness of either of
t1+t21.25tmin
t1&t26.35 mm
04 Applicable sketch from Fig.PW-16.1 Sketch (d)
(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
GB ENGINEERING Rev. 00
Enterprises Pvt. Ltd. MFR'S
EQPT. STEAM DRUM GBE/1750/009
SERIAL NO.
10.0 Minimum requirements for attachments weld on Shell (As per PW-16)
Sl
DESCRIPTION UNIT DATA
No
01 Item MAN HOLE RING
03 Conditions
tmin = Smaller of 3/4" (or) thickness of either of
t1+t21.25tmin
t1&t26.35 mm
04 Applicable sketch from Fig.PW-16.1 Sketch (d)
(e) 4 (e) > 4 (c) & 4 (f) > 4 (d) HENCE SATISFACTORY
05 t1 mm 11.9
t2 mm 20.7
(a) t1 + t2 mm 32.6
GB ENGINEERING Rev. 00
Enterprises Pvt. Ltd. MFR'S
EQPT. STEAM DRUM GBE/1750/009
SERIAL NO.
10.0 Minimum requirements for attachments weld on Shell (As per PW-16)
Sl
DESCRIPTION UNIT DATA
No
01 Item FEED WATER SLEEVE
03 Conditions
tmin = Smaller of 3/4" (or) thickness of either of
t1+t21.25tmin
t1&t26.35 mm
04 Applicable sketch from Fig.PW-16.1 Sketch (d)
(e) 4 (e) > 4 (c) & 4 (f) > 4 (d) HENCE SATISFACTORY
05 t1 mm 13.2
t2 mm 22.6
(a) t1 + t2 mm 35.8
GB ENGINEERING Rev. 00
Enterprises Pvt. Ltd. MFR'S
EQPT. STEAM DRUM GBE/1750/009
SERIAL NO.
10.0 Minimum requirements for attachments weld on Shell (As per PW-16)
Sl
DESCRIPTION UNIT DATA
No
FEEDWATER HEATER INLET &
01 Item
OUTLET SLEEVE.
Drg No. 10-10-01-3063
03 Conditions
tmin = Smaller of 3/4" (or) thickness of either of
t1+t21.25tmin
t1&t26.35 mm
(e) 4 (e) > 4 (c) & 4 (f) > 4 (d) HENCE SATISFACTORY
05 t1 mm 38.8
t2 mm 17.3
(a) t1 + t2 mm 56.1
(b) 1 1/4 x tmin mm 23.8
GB ENGINEERING Rev. 00
Enterprises Pvt. Ltd. MFR'S
EQPT. STEAM DRUM GBE/1750/009
SERIAL NO.
10.0 Minimum requirements for attachments weld on Shell (As per PW-16)
Sl
DESCRIPTION UNIT DATA
No
01 Item SAFETY VALVE STUB
03 Conditions
tmin = Smaller of 3/4" (or) thickness of either of
t1+t21.25tmin
t1&t26.35 mm
04 Applicable sketch from Fig.PW-16.1 Sketch (d)
(e) 4 (e) > 4 (c) & 4 (f) > 4 (d) HENCE SATISFACTORY
05 t1 mm 18.8
t2 mm 18.8
(a) t1 + t2 mm 37.6
GB ENGINEERING Rev. 00
Enterprises Pvt. Ltd. MFR'S
EQPT. STEAM DRUM GBE/1750/009
SERIAL NO.
10.0 Minimum requirements for attachments weld on Shell (As per PW-16)
Sl
DESCRIPTION UNIT DATA
No
01 Item LEVEL ELEMENT SLEEVE
03 Conditions
tmin = Smaller of 3/4" (or) thickness of either of
t1+t21.25tmin
t1&t26.35 mm
(a) tmin mm 14
(e) 4 (e) > 4 (c) & 4 (f) > 4 (d) HENCE SATISFACTORY
05 t1 mm 28.3
t2 mm 9.8
(a) t1 + t2 mm 38.1
GB ENGINEERING Rev. 00
Enterprises Pvt. Ltd. MFR'S
EQPT. STEAM DRUM GBE/1750/009
SERIAL NO.
10.0 Minimum requirements for attachments weld on Shell (As per PW-16)
Sl
DESCRIPTION UNIT DATA
No
01 Item BLOW DOWN SLEEVE
03 Conditions
tmin = Smaller of 3/4" (or) thickness of either of
t1+t21.25tmin
t1&t26.35 mm
(e) 4 (e) > 4 (c) & 4 (f) > 4 (d) HENCE SATISFACTORY
05 t1 mm 27.8
t2 mm 12.9
(a) t1 + t2 mm 40.7
GB ENGINEERING Rev. 00
Enterprises Pvt. Ltd. MFR'S
EQPT. STEAM DRUM GBE/1750/009
SERIAL NO.
10.0 Minimum requirements for attachments weld on Shell (As per PW-16)
Sl
DESCRIPTION UNIT DATA
No
01 Item CHEMICAL DOSING SLEEVE
03 Conditions
tmin = Smaller of 3/4" (or) thickness of either of
t1+t21.25tmin
t1&t26.35 mm
(a) tmin mm 14
(e) 4 (e) > 4 (c) & 4 (f) > 4 (d) HENCE SATISFACTORY
05 t1 mm 22.3
t2 mm 8.3
(a) t1 + t2 mm 30.6
GB ENGINEERING Rev. 00
Enterprises Pvt. Ltd. MFR'S
EQPT. STEAM DRUM GBE/1750/009
SERIAL NO.
10.0 Minimum requirements for attachments weld on Shell (As per PW-16)
Sl
DESCRIPTION UNIT DATA
No
01 Item LG SLEEVE (UPPER)
03 Conditions
tmin = Smaller of 3/4" (or) thickness of either of
t1+t21.25tmin
t1&t26.35 mm
(a) tmin mm 14
(e) 4 (e) > 4 (c) & 4 (f) > 4 (d) HENCE SATISFACTORY
05 t1 mm 27.3
t2 mm 6.7
(a) t1 + t2 mm 34.0
(b) 1 1/4 x tmin mm 17.5
GB ENGINEERING Rev. 00
Enterprises Pvt. Ltd. MFR'S
EQPT. STEAM DRUM GBE/1750/009
SERIAL NO.
10.0 Minimum requirements for attachments weld on Shell (As per PW-16)
Sl
DESCRIPTION UNIT DATA
No
01 Item LG SLEEVE (LOWER)
03 Conditions
tmin = Smaller of 3/4" (or) thickness of either of
t1+t21.25tmin
t1&t26.35 mm
04 Applicable sketch from Fig.PW-16.1 Sketch (d)
(a) tmin mm 14
(f) Provided t2 mm 8
(e) 4 (e) > 4 (c) & 4 (f) > 4 (d) HENCE SATISFACTORY
05 t1 mm 31.3
t2 mm 8.0
(a) t1 + t2 mm 39.3
24 21+22+23 599571
29 26+27+28 529899
24 21+22+23 520087
29 26+27+28 474320
{ (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
Strength of load carrying elements in path
number 1, As per Fig PW -16 (c) (1)
16 Internal fillet weld in shear
= 1/2 WL2(d+2tn) (factor in PW-15.2=0.49) x SV x fr1 kg 56237
17 Groove welds in tension
= 1/2 t2 x (d+2tn) (factor in PW-15.2=0.74) x Sv x fr1 kg 120042
18 16+17 176280
22 20+21 167735
{ (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
Strength of load carrying elements in path
number 1, As per Fig PW -16 (c) (1)
16 Internal fillet weld in shear
= 1/2 WL2(d+2tn) (factor in PW-15.2=0.49) x SV x fr1 kg 81016
17 Groove welds in tension
= 1/2 t2 x (d+2tn) (factor in PW-15.2=0.74) x Sv x fr1 kg 122351
18 16+17 203367
22 20+21 227672
{ (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
Strength of load carrying elements in path
number 1, As per Fig PW -16 (c) (1)
16 Internal fillet weld in shear
= 1/2 WL2(d+2tn) (factor in PW-15.2=0.49) x SV x fr1 kg 29706
17 Groove welds in tension
= 1/2 t2 x (d+2tn) (factor in PW-15.2=0.74) x Sv x fr1 kg 50787
18 16+17 80493
22 20+21 80493
{ (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
Strength of load carrying elements in path
number 1, As per Fig PW -16 (c) (1)
16 Internal fillet weld in shear
= 1/2 WL2(d+2tn) (factor in PW-15.2=0.49) x SV x fr1 kg 20178
17 Groove welds in tension
= 1/2 t2 x (d+2tn) (factor in PW-15.2=0.74) x Sv x fr1 kg 30472
18 16+17 50650
22 20+21 50650
{ (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
Strength of load carrying elements in path
number 1, As per Fig PW -16 (c) (1)
16 Internal fillet weld in shear
= 1/2 WL2(d+2tn) (factor in PW-15.2=0.49) x SV x fr1 kg 20178
17 Groove welds in tension
= 1/2 t2 x (d+2tn) (factor in PW-15.2=0.74) x Sv x fr1 kg 30472
18 16+17 50650
22 20+21 50650
{ (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
Strength of load carrying elements in path
number 1, As per Fig PW -16 (c) (1)
16 Internal fillet weld in shear
= 1/2 WL2(d+2tn) (factor in PW-15.2=0.49) x SV x fr1 kg 28432
17 Groove welds in tension
= 1/2 t2 x (d+2tn) (factor in PW-15.2=0.74) x Sv x fr1 kg 42938
18 16+17 71370
22 20+21 71370
{ (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
Strength of load carrying elements in path
number 1, As per Fig PW -16 (c) (1)
16 Internal fillet weld in shear
= 1/2 WL2(d+2tn) (factor in PW-15.2=0.49) x SV x fr1 kg 20178
17 Groove welds in tension
= 1/2 t2 x (d+2tn) (factor in PW-15.2=0.74) x Sv x fr1 kg 30472
18 16+17 50650
22 20+21 50650
{ (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
Strength of load carrying elements in path
number 1, As per Fig PW -16 (c) (1)
16 Internal fillet weld in shear
= 1/2 WL2(d+2tn) (factor in PW-15.2=0.49) x SV x fr1 kg 10089
17 Groove welds in tension
= 1/2 t2 x (d+2tn) (factor in PW-15.2=0.74) x Sv x fr1 kg 35551
18 16+17 45640
22 20+21 52366
{ (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
Strength of load carrying elements in path
number 1, As per Fig PW -16 (c) (1)
16 Internal fillet weld in shear
= 1/2 WL2(d+2tn) (factor in PW-15.2=0.49) x SV x fr1 kg 10089
17 Groove welds in tension
= 1/2 t2 x (d+2tn) (factor in PW-15.2=0.74) x Sv x fr1 kg 35551
18 16+17 45640
22 20+21 52366
Sl
DESCRIPTION UNIT DATA
No
01 Item DOWNCOMER STUB
03 T = Design temperature o
C 21
t = d
CP
S
mm 46.91
Sl
DESCRIPTION UNIT DATA
No
01 Item SATURATED STEAM STUB
03 T = Design temperature o
C 21
10 Required thickness = t
CP
S
mm 32.64
Sl
DESCRIPTION UNIT DATA
No
01 Item RISER STUB
03 T = Design temperature o
C 21
CP 26.16
t = d
S
10 Required thickness = t mm 26.16
Sl
DESCRIPTION UNIT DATA
No
01 Item FEED WATER STUB
03 T = Design temperature o
C 21
10 Required thickness = t
CP
S
mm 13.50
Sl
DESCRIPTION UNIT DATA
No
FEED WATER HEATER INLET &
01 Item
OUTLET
03 T = Design temperature o
C 21
10 Required thickness = t
CP
S
mm 20.28
Sl
DESCRIPTION UNIT DATA
No
01 Item PG,PT & VENT STUBS
03 T = Design temperature o
C 21
10 Required thickness = t
CP
S
mm 3.16
Sl
DESCRIPTION UNIT DATA
No
01 Item SAFETY VALVE STUB
03 T = Design temperature o
C 21
Sl
DESCRIPTION UNIT DATA
No
01 Item LE,LG & CHEMICAL DOSING STUB
03 T = Design temperature o
C 21
10 Required thickness = t
CP
S
mm 3.31
Sl
DESCRIPTION UNIT DATA
No
01 Item BLOW DOWN STUB
03 T = Design temperature o
C 21
10 Required thickness = t
CP
S
mm 5.13
2. Header Data
(a) m = tr / ts 0.26
CxP
mm 5.89
=dx -------------------
S
(c) tw mm 10.32
16. Calculation of stress during Hydrostatic test for STUB End Plate
As per PG-31.3.2
Description SPARE
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
7.14 Kg/mm
C RA M 'RB D
1700 5000 1700
`
A B
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
Enterprises Pvt. Ltd.
MFR'S
EQPT. STEAM DRUM GBE/1750/009
SERIAL NO.
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
(19554 - 18294)
Z : 32 1955
: 171604364.1 mm3
: 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
GB ENGINEERING Rev. 00
Enterprises Pvt. Ltd. MFR'S
EQPT: STEAM DRUM GBE/1750/009
SERIAL NO.
Sl
DESCRIPTION UNIT DATA
No
01 Item STEAM DRUM DOWNCOMER
04 t = Thickness mm 26.19
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
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.