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Strength Calculation As Per Ibr Boiler Maker'S No.: Atpl-Rb002

The document summarizes strength calculations for an inlet header as per IBR regulations. It provides calculations for ligament efficiency, minimum required thickness, and maximum allowable working pressure. The calculations are shown for item 1, which is made of SA 106 GR B material, with a design pressure of 85.3 kg/cm2, design temperature of 324°C, and minimum provided thickness of 28mm. The least ligament efficiency is 0.36.

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mohan babu
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669 views9 pages

Strength Calculation As Per Ibr Boiler Maker'S No.: Atpl-Rb002

The document summarizes strength calculations for an inlet header as per IBR regulations. It provides calculations for ligament efficiency, minimum required thickness, and maximum allowable working pressure. The calculations are shown for item 1, which is made of SA 106 GR B material, with a design pressure of 85.3 kg/cm2, design temperature of 324°C, and minimum provided thickness of 28mm. The least ligament efficiency is 0.36.

Uploaded by

mohan babu
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as XLSX, PDF, TXT or read online on Scribd
  • Attachment Part - First Model: Presents the strength calculations for the attachment part of the first design model, including detailed numerical analyses and parameters.
  • Natural Wall Unit Header: Contains the strength calculation specifications for the natural wall unit header using regulations outlined by the governing body.
  • Economizer 1 - Model 1: Details the structural calculations for economizer model 1, focusing on various compliance metrics and strength assessments.
  • Economizer 2 - Model 2: Provides comprehensive calculation data for economizer model 2, covering structural integrity and regulatory conformance checks.
  • Natural Wall Presence: Documents the strength evaluation process for the natural wall presence with relevant tables and calculation metrics.
  • Natural Wall Diffuser: Focuses on the strength validations of the natural wall diffuser, detailed through tabular data and regulatory criteria.
  • Return Wall Options: Analyzes the return wall configuration options, emphasizing tube wall thickness evaluations and compliance standards.
  • Injector Tubes: Covers the evaluation criteria and calculations for injector tubes, addressing expected stress and resultant design features.
  • Free Leader End Plates: Summarizes the strength assessments and structural calculations for the free leader end plates as part of the engineering evaluation.

STRENGTH CALCULATION AS PER IBR BOILER MAKER'S No.

: ATPL-RB002

Page 01 of 08
Date 06.02.2019
Calculation of ligament efficiency
NAME OF THE PART : INLET HEADER as per Regulation No.: 215

(LP-LD) [2 * (CP - CD)] 2


LONGITUDINAL LIGAMENT EFFICIENCY(E1) = CIRCUMFERENTIAL LIGAMENT EFFICIENCY(E2) = DIAGONAL LIGAMENT EFFICIENCY(E3) =
LP CP A+B + (A-B)^2 + 4C^2

Cos^2 α + 1 Cos α * Sin α


A= B= (1/2)*{1-[(d * Cos α)/a]} * (Sin^2 α +1) C=
2 * [1-((d *Cos α) / a)] 2 * [1-((d *Cos α) / a)]
1 1
Cos α = Sin α =
(1 + (b^2 / a^2)) (1+(a^2/b^2))

LD = Longitudinal average diameter


LP = Longitudinal pitch
CD = Circumferential average diameter
CP = Circumferential pitch

Header Size in mm Hole Diameter [Link]. [Link]. Diagonal ligament Efficiency


[Link].
Sl. No. Drawing No. / Rev Variant no. Item No. Material OD Thk d1 d2 [Link](d) Pitch Effi. Angle Pitch Effi. Angle [Link] Effi.
No. specification
[Link](a) Cos α Sin α A B C
mm mm mm mm (LD,CD)mm (LP) mm (E1) (Θ) (CP)mm (E2) (Θ) (b)mm (E3) E1/E2/E3

1 P00643066/0 - SA 106 GR B 219.1 28 49 49 49 76.2 0.36


P00643064/0

2 P00643066/0 - SA 106 GR B 219.1 28 51 51 51 1219 0.96


P00643064/0

3 P00643066/0 - SA 106 GR B 219.1 28 140 140 140 838 0.83


P00643064/0

P00643066/0
4 P00643064/0 - SA 106 GR B 219.1 28 49 49 49 8.80 60.00 100.06 0.09 1.00 0.98 0.51 0.09 1.00 1.00

5 P00643066/0 - SA 106 GR B 219.1 28 49 140 94.5 38.10 90.00 150.09 0.25 0.97 1.36 0.38 0.31 0.69 0.69
P00643064/0

P00643066/0
6 P00643064/0 - SA 106 GR B 219.1 28 49 51 50 38.10 90.00 150.09 0.25 0.97 0.78 0.66 0.18 1.10 1.10

7 P00643066/0 - SA 106 GR B 219.1 28 49 26 37.5 180 300 1.75


P00643064/0

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STRENGTH CALCULATION AS PER IBR BOILER MAKER'S No.: ATPL-RB002

Page 02 of 08

Strength calculation for header Date 06.02.2019


NAME OF THE PART : WATER WALL INLET HEADER as per Regulation No.: 342(a)&270

P*D 2 * f * E * (T - 0.762)
MIN. REQUIRED THK. (Tc) = +0.762 [Link] WORKING
2 *f * E - P PRESSURE(Pmax) = D + (T - 0.762)

P = Design Pressure in kg/cm²(g)


D = Maximum internal diameter of header in mm.
f = Maximum Permissible stress for the Material at Maximum Metal Working Temperature in kg/cm². (As per ASME Section-II, Part-D)
T = Minimum provided thickness, that is nominal thickness less permissible negative tolerance in mm
E = Least ligament efficiency.(This value taken from page no : 01 of 05)

Design Design Size in mm Neg.


Sl. No. Drawing No. / Rev No. Var No. Item No. Material T Maximum E Tc P(Max)
specification pressure in temperature f in Kg/cm² Tolereance in mm ID (D) in mm in Kg/cm²
Kg/cm²(g) in °C OD Thick in %

1 P00643064 / 0 - SA 106 GR B 85.3 324 1203.27 219.1 28 12.5 24.50 170.1 0.36 19.34 106.10

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STRENGTH CALCULATION AS PER IBR BOILER MAKER'S No.: ATPL-RB002

Page 03 of 08

Calculation of Uncompensated Hole in Date 08.09.2018


NAME OF THE PART : ECONOMISER - I
Shell as per Regulation No:-187

P*D
Maximum Uncompensated Hole for Shell, K = -------------------
Where, 1.82 * F * e
P = Design Pressure in kg/cm2 C = 0.762
D = External Diameter of the Shell in mm e = Actual thickness of the Shell in mm
F = Maximum Permissible stress for the Material at Maximum Metal Working Temperature in kg/cm2. ( As per ASME Section-II, Part-D )
Uncompensated Hole from Graph 9B & 9C, K vs ( D * e )

Size Neg.
P Design Temp. F e
Sl. Material D Thk. Tol. K From Graph Dia. Of Hole Compensation
No. Drawing No./[Link] Var. No. Item No. Specification value D*e value Drilled Check
kg/cm 2
C
o
kg/cm 2
mm mm % mm

1 P00643064 / 0 - - 85.4 299 SA 106 GR.B 1203.27 168.3 14.27 12.5 12.49 0.53 2102.07 69 140.00 Required

2 P00643064 / 0 - - 85.4 299 SA 106 GR.B 1203.27 76.1 12.7 12.5 11.11 0.27 845.47 71 51.00 Not Required

3 P00643064 / 0 - - 85.4 299 SA 106 GR.B 1203.27 63.5 6.3 12.5 5.51 0.45 349.89 58 49.00 Not Required

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STRENGTH CALCULATION AS PER IBR BOILER MAKER'S No.: ATPL-RB002

Page 04 of 08
NAME OF THE PART : ECONOMISER - I Calculation of Nozzle Compensation for Shell as per Regulation - 279
Date 08.09.2018

P = Design Pressure in Kg/cm² ds = Inside Diameter of header in mm b = Smaller value of ( 2.5 * ts or 2.5 * tn )
dn = Inside Diameter of Nozzle in mm ts = Actual Thickness of header in mm bi = Inside Projection of Nozzle
tn = Actual Thickness of Nozzle in mm es = Equivalent Thickness of header in mm Ci = ts + 76 or Dn/2 , whichever is greater
en = Equivalent Thickness of Nozzle in mm fs = Allowable Stress of header in kg / cm2 Cw = Fillet Weld area
fn = Allowable Stress of Nozzle in kg / cm2 E = 1 = 0 [ It is not considered since it is negligible]
Dn = Maximum Diameter of the Opening in mm
Minimum Required Thickness for unpierced header, es = [ ( P * ds ) / ( 2 * fs * E - P ) ] + 0.762
Minimum Thickness Required for Nozzle, en = [ ( P * dn ) / ( 2 * fn * E - P ) ] + 0.762
Area Removed X = Dn * es
Area Available Y = [ 2 * ( tn - en ) * b * ( fn / fs ) ] + [ 2 * tn * bi * ( fn / fs ) ] + [ 2 * ( ts - es ) * Ci ] + CW,

P Design fn Dn dn tn fs ds ts es en b bi Ci X Y
Material
Sl. No. Drawing No./[Link] Item No.
specification
kg/cm2 temp.˚C kg/cm2 mm mm mm kg/cm2 mm mm mm mm mm mm mm mm2 mm2

01 P00643064 / 0 - 85.4 299 SA106 Gr.B 1203.27 94.82 94.82 9.74 1203.27 143.3 12.49 6.04 4.25 24.4 0 88.49 572.7 1408.9

Remarks : Area Available ( Y ) > Area Removed ( X ) , Hence, It is satisfactory

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STRENGTH CALCULATION AS PER IBR BOILER MAKER'S No.: ATPL-RB002

Page 05 of 08

Strength calculation for pipe Date 08.09.2018


NAME OF THE PART : ECONOMISER - I as per Regulation No.: 350(a)

P*D 2 * f * E * (T - C)
MIN. REQUIRED THK. (Tc) = +C [Link] WORKING PRESSURE(Pmax)
2*f *E+P = D-T+C

P = Design Pressure in kg/cm²(g)


D = Maximum External diameter of header in mm.
f = Maximum Permissible stress for the Material at Maximum Metal Working Temperature in kg/cm². (As per ASME Section-II, Part-D)
T = Minimum provided thickness, that is nominal thickness less permissible negative tolerance in mm
E = Efficiency factor, E=1 for seamless and electric resistance welded steel pipes.
C = 0.75mm

Size in mm
Material Design
Design pressure temperature Neg. T Tc P(Max)
Sl. No. Drawing No. / Rev No. Var No. Item No. f in Kg/cm² Tolereance Remarks
specification in Kg/cm²(g) in °C OD Thick in % in mm in mm in Kg/cm²

1 P00643064 / 0 P00643066 / 0 RIGHT - - SA 106 GR B 85.3 324 1203.27 168.3 14.27 12.5 12.49 6.51 180.40 -
& LEFT SIDE HEADER

2 P00643064 / 0 P00643066 / 0 RIGHT - - SA 106 GR B 85.3 324 1203.27 76.1 12.7 12.5 11.11 3.36 379.35 -
& LEFT SIDE HEADER

P00643064 / 0 P00643066 / 0 RIGHT


3 & LEFT SIDE HEADER - - SA 210 GR A1 85.3 324 1203.27 63.5 6.3 12.5 5.51 2.92 195.12 -

Remarks: Minimum provided thickness (T) > Minimum required thickness (Tc), Hence satisfactory

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STRENGTH CALCULATION AS PER IBR BOILER MAKER'S No.: ATPL-RB002

Page 06 of 08

Strength calculation for Tube Date 06.02.2019


NAME OF THE PART : WATER WALL FURNACE
as per Regulation No.: 338(a)

P*D 2 * f * (T-C) T-Tc


MIN. REQUIRED THK. (Tc) = +C [Link] WORKING PRESSURE(Pmax) BENDING ALLOWANCE = x 100
2 *f+P = (D-T+C) Tc

P = Design Pressure in kg/cm²(g)


f = Maximum Permissible stress for the Material at Maximum Metal Working Temperature in kg/cm². (As per ASME Section-II, Part-D)
T = Minimum provided thickness, that is nominal thickness less permissible negative tolerance in mm
C = If maximum working pressure is upto and including 70 kg/cm²(g), C = 0.75 mm, If maximum working pressure is exceeding 70 kg/cm²(g), C = 0 mm
D = External diameter of Tube in mm.

Design Design Size in mm Neg.


Sl. No. Drawing No. / Rev No. Var No. Item No. Material T Tc P(Max) Bending
specification pressure in temperature f in Kg/cm² Tolereance C
in mm in mm in Kg/cm² allowance in %
Remarks
Kg/cm²(g) in °C OD Thick in %

1 P00643063 / 0 - - SA 210 GR A1 82 324 1203.27 63.5 6.3 0 0 6.3 2.09 265.06 201.09 -
LEFT SIDE WATER WALL ASSEMBLY

2 P00643065 / 0 - - SA 210 GR A1 82 324 1203.27 63.5 6.3 0 0 6.3 2.09 265.06 201.09 -
RIGHT SIDE WATER WALL ASSEMBLY

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STRENGTH CALCULATION AS PER IBR BOILER MAKER'S No.: ATPL-RB002

Page 07 of 08

Calculation of Tube bend Date 06.02.2019


NAME OF THE PART : WATER WALL OPENING
thinning allowance as per Regulation No: -338 C(ii)

100
Allowable Bend Thinning Allowance Below the Min. Required Thickness (%) = ---------
4R +2
R = Mean Radius of Bend to the centre line of the tube (mm) , D
D = The ordered Outside Diameter of the tube (mm) ,
Tc = Minimum Required Thickness as per Equation 87 (IBR 338(a) ) (mm)

Size Neg. Thinning Allowable Allowable Bend Provided Bend Thinning


Tc R
D Thk Tol. Allowance Lowest thk. Thinning allow. allow.
Sl. No. Drawing No./[Link] [Link] Item No.
mm mm % mm mm % mm % %

P00643069 / 0
1 PRIMARY OPENING -(A90) - 63.5 6.3 0 2.09 228.60 6.10 1.96 68.89 66.83

P00643071 / 0 SECONDARY
2 OPENING-(A600) - 63.5 6.3 0 2.09 228.60 6.10 1.96 68.89 66.83

P00643073 / 0 SECONDARY
3 OPENING - (A1200) - 63.5 6.3 0 2.09 228.60 6.10 1.96 68.89 66.83

P00643075 / 0 BURNER
4 OPENING - 63.5 6.3 0 2.09 228.60 6.10 1.96 68.89 66.83

Remarks: Allowable Bend Thinning Allowance > Provided Bend Thinning Allowance, Hence satisfactory

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STRENGTH CALCULATION AS PER IBR BOILER MAKER'S No.: ATPL-RB002

Page 07 of 08

Calculation of Tube bend Date 06.02.2019


NAME OF THE PART : JUMPER TUBES
thinning allowance as per Regulation No: -338 C(ii)

100
Allowable Bend Thinning Allowance Below the Min. Required Thickness (%) = ---------
4R +2
R = Mean Radius of Bend to the centre line of the tube (mm) , D
D = The ordered Outside Diameter of the tube (mm) ,
Tc = Minimum Required Thickness as per Equation 87 (IBR 338(a) ) (mm)

Size Neg. Thinning Allowable Allowable Bend Provided Bend Thinning


Tc R
D Thk Tol. Allowance Lowest thk. Thinning allow. allow.
Sl. No. Drawing No./[Link] [Link] Item No.
mm mm % mm mm % mm % %

P00643067 / 0 JUMPER
1 TUBE-1 - - 63.5 6.3 0 2.09 228.60 6.10 1.96 68.89 66.83

P00643068 / 0
2 JUMPER TUBE-2 - - 63.5 6.3 0 2.09 228.60 6.10 1.96 68.89 66.83

Remarks: Allowable Bend Thinning Allowance > Provided Bend Thinning Allowance, Hence satisfactory

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STRENGTH CALCULATION AS PER IBR BOILER MAKER'S No.: ATPL-RB002

Page 08 of 08

Strength calculation for End plate Date 06.02.2019


NAME OF THE PART : INLET HEADER END PLATES
as per Regulation No.: 342(b)&340(f)

P*d^2*K f * (T-C)^2
MIN. REQUIRED THK. (Tc) = [Link] +C [Link] WORKING PRESSURE(Pmax) =
f (D^2 * K)

P = Design Pressure in kg/cm²(g)


d = Internal diameter of header in mm.
f = Maximum Permissible stress for the Material at Maximum Metal Working Temperature in kg/cm². (As per ASME Section-II, Part-D)
T = Thickness of the plate at the weakest part,in mm
K = 0.19, for ends integral with or flanged and butt welded to the header.
= 0.28, for ends directly strength welded to the header in an approved manner.
C = 1 mm.

Design
Design pressure d T Tc P(Max)
Sl. No. Drawing No. / Rev No. Var No. Item No. Material specification in Kg/cm²(g) temperature in f in Kg/cm² in mm in mm C K in mm in Kg/cm² Remarks
°C

1 SMALLER - SA 516 GR 70 82 324 1347.66 52.8 10 1 0.19 6.68 206.08 -

2 LARGER - SA 516 GR 70 82 324 1347.66 169 36 1 0.19 19.17 304.22 -

Remarks: Minimum provided thickness (T) > Minimum required thickness (Tc),Hence Satisfactory

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