Page 1 of 25

INDEX

SECTION DESCRIPTION PAGE NO

I BOILER GENERAL DATA 3

II LIST OF DRAWINGS 4

III DESIGN DATA 5

IV STRENGTH CALCULATIONS 6

1.0 ECONOMISER-I OUTLET TO ECONOMISER-II INLET PIPING 6

ECONOMISER-II INTERMEDIATE-I TO INTERMEDIATE-II

2.0 8
PIPING
3.0 ECONOMISER-II TO STEAM DRUM INLET PIPING 10

4.0 STEAM DRUM TO PRIMARY SUPER HEATR INLET PIPING 12

PRIMARY SUPER HEATER TO SECONDRY SUPER HEATER

5.0 14
LINK PIPING
6.0 DE SUPER HEATER PIPING WITH DE SUPERHEATER 16
7.0 MAINSTEAM PIPING UP TO MAIN STEAM STOP VALVE 19
FEED WATER PIPING
8.0 24
(CONTROL STATION TO ECONOMISER-I INLET)

SECTION: I

Page 2 of 25
BOILER GENERAL DATA:

Boiler No. : 111

Boiler Type : Single Drum Water Tube

Boiler Capacity : 90 TPH

Design Code : IBR

Maximum Working Pressure : 80 Kg/cm2 (g)

Maximum Working Pressure of Economiser : 83 Kg/cm2 (g)

Maximum Metal Working Temperature : Refer Section IV

Super Heater Outlet Steam Pressure : 69 Kg/cm2 (g)

Super Heater Outlet Steam Temperature : 490 ± 5 0C

Page 3 of 25
 SECTION: II

LIST OF DRAWINGS:

Sl.
Description Drawing No. Revision
No.
ECONOMISER-I OUTLET TO ECONOMISER-II INLET
1 8005-15-03-2-002 00
PIPING
ECONOMISER-II INTERMEDIATE-I TO INTERMEDIATE-II
2 8005-15-03-2-003 00
PIPING

3 ECONOMISER-II TO STEAM DRUM INLET PIPING 8005-15-07-1-001 00

4 STEAM DRUM TO PRIMARY SUPER HEATR INLET PIPING 8005-03-51-1-002 00

PRIMARY SUPER HEATER TO SECONDRY SUPER HEATER

5 8005-03-51-2-001 00
LINK PIPING

6 DE SUPER HEATER PIPING 8005-03-46-2-001 00

7 DE SUPERHEATER 8005-03-46-2-002 00

8 MAINSTEAM PIPING UP TO MAIN STEAM STOP VALVE 8005-03-49-1-001 00

FEED WATER PIPING

9 8005-15-03-1-001 00
(CONTROL STATION TO ECONOMISER-I INLET)

SECTION: III

Page 4 of 25
DESIGN DATA:

MAX MAX METAL

Size
WORKING WORKING
Sl.No. Description OD Thick PRESSURE TEMPERATURE Material

mm mm Kg/cm² ºC

Economiser-I outlet to Economiser-II

1.0 114.3 6.02 83 224 SA 106 GR B
inlet piping.
Economiser-II intermediate to
2.0 114.3 6.02 83 224 SA 106 GR B
Economiser-I intermediate piping
Economiser-II to steam drum inlet
3.0 114.3 6.02 80 224 SA 106 GR B
piping.
Drum to primary super heater inlet
4.0 219.1 10.31 80 295 SA 106 GR B
piping
Primary super heater outlet to
5.0 168.3 7.11 80 331 SA 106 GR B
secondary super heater inlet piping.
Secondary super heater outlet to
6.0 tertiary super heater inlet piping with 219.1 12.7 80 409 SA 335 P11
de super heater
12.7/
7.0 Main steam piping 219.1 80 495 SA 335 P22
18.26

8.0 Feed water piping 114.3 8.56 83 140 SA 106 GR B

Page 5 of 25
 SECTION IV:

STRENGTH CALCULATIONS:

1.0 ALLOWABLE STRESS CALCULATION CHART FOR ECONOMISER –I OUTLET TO ECONOMISER-II INLET PIPING:

Max.Metal ASME
Allowable
Working UTS Allowable Et UTS/ 2.7 Et/ 1.5
Sl.No. Description Material Stress
temperature Stress
ºC Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2

ECONOMISER – I OUTLET TO ECONOMISRE-II INLET PIPING

1 Main pipe SA 106 GR B 224 4231.76 1203.24 2071.62 1567.32 1381.88 1203.24

2 Elbow SA 234 WPB 224 4231.76 1203.24 2071.62 1567.32 1381.88 1203.24

Allowable stress value as per ASME sec II Part-D Table 1A.

Et values are as per ASME sec II Part-D Table Y1.

Minimum UTS values are taken from ASME sec II Part-D Table 1A.

Allowable stress = Minimum of Et/1.5 or UTS/2.7 or ASME Allow. Value.

Page 6 of 25
1.1 PIPE THICKNESS CALCULATIONS FOR ECONOMISER-I OUTLET TO ECONOMISER-II INLET PIPING:
(As per IBR Reg. No. 350)

2 x f x E x (T – C)
WP= Working pressure =
(D - T + C)

D = External diameter of pipe in mm

f = Allowable stress in Kg/Cm2 (Refer page no. 44)

T = Minimum provided thickness of tube in mm

= Nominal thickness – Negative tolerance

E = Ligament efficiency = 1

C = Corrosion allowance = 0.75 mm

Pmax = Maximum working pressure (i.e) Design pressure inKg/cm 2 (g)

= 83 Kg/cm2 (g)
Size
Sl. T f WP
Description OD x Thk Material Remark
No.
mm x mm mm Kg/Cm2 Kg/Cm2

ECONOMISER-I OUTLET TO ECONOMISER-II INLET PIPING:

WP > Pmax
1 Main pipe 114.3 x 6.02 SA106Gr.B 5.27 1203.24 99.03
Hence Safe
WP > Pmax
2 Elbow 114.3 x 6.02 SA 234WPB 5.27 1203.24 99.03
Hence Safe

Notes:

 12.5% of –Ve tolerance considered on pipe thickness

Page 7 of 25
2.0 ALLOWABLE STRESS CALCULATIONS FOR ECONOMISER-II INTERMEDIATE-I TO INTERMEDIATE-II PIPING:

Max.Metal ASME
Allowable
Sl. Working UTS Allowable Et UTS/ 2.7 Et/ 1.5
Description Material Stress
No. temperature Stress
ºC Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2

ECONOMISER-II INTERMEDIATE-I TO INTERMEDIATE-II PIPING

1 Main pipe SA 106 GR B 224 4231.76 1203.24 2071.62 1567.32 1381.88 1203.24

2 Elbow SA 234 WPB 224 4231.76 1203.24 2071.62 1567.32 1381.88 1203.24

Allowable stress value as per ASME sec II Part-D Table 1A.

Et values are as per ASME sec II Part-D Table Y1.

Minimum UTS values are taken from ASME sec II Part-D Table 1A.

Allowable stress = Minimum of Et/1.5 or UTS/2.7 or ASME Allow. Value.

Page 8 of 25
2.1 PIPE THICKNESS CALCULATIONS FOR ECONOMISER-II INTERMEDIATE-I TO INTERMEDIATE-II
PIPING:
(As per IBR Reg. No. 350)

2 x f x E x (T – C)
WP= Working pressure =
(D - T + C)

D = External diameter of pipe in mm

f = Allowable stress in Kg/Cm2 (Refer page no. 44)

T = Minimum provided thickness of tube in mm

= Nominal thickness – Negative tolerance

E = Ligament efficiency = 1

C = Corrosion allowance = 0.75 mm

Pmax = Maximum working pressure (i.e) Design pressure inKg/cm 2 (g)

= 83 Kg/cm2 (g)
Size
Sl. T f WP
Description OD x Thk Material Remark
No. 2 2
mm x mm mm Kg/Cm Kg/Cm

ECONOMISER-II INTERMEDIATE-I TO INTERMEDIATE-II

WP > Pmax
1 Main pipe 114.3 x 6.02 SA106Gr.B 5.27 1203.24 99.03
Hence Safe
WP > Pmax
2 Elbow 114.3 x 6.02 SA 234WPB 5.27 1203.24 99.03
Hence Safe

Notes:

 12.5% of –Ve tolerance considered on pipe thickness

Page 9 of 25
3.0 ALLOWABLE STRESS CALCULATIONS FOR ECONOMISER-II TO STEAM DRUM INLET PIPING:

Max.Metal ASME
Allowable
Sl. Working UTS Allowable Et UTS/ 2.7 Et/ 1.5
Description Material Stress
No. temperature Stress
ºC Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2

ECONOMISER-II TO STEAM DRUM INLET PIPING:

1 Main pipe, AIR VENT, SPARE PIPE SA 106 GR B 224 4231.76 1203.24 2071.62 1567.32 1381.88 1203.24

2 Elbow SA 234 WPB 224 4231.76 1203.24 2071.62 1567.32 1381.88 1203.24

Thermowell, Thermowell boss

3 SA 105 224 4945.54 1387.61 2132.80 1831.68 1421.87 1387.61
stub

Allowable stress value as per ASME sec II Part-D Table 1A.

Et values are as per ASME sec II Part-D Table Y1.

Minimum UTS values are taken from ASME sec II Part-D Table 1A.

Allowable stress = Minimum of Et/1.5 or UTS/2.7 or ASME Allow. Value.

Page 10 of 25
3.1 PIPE THICKNESS CALCULATIONS FOR ECONOMISER-II TO STEAM DRUM INLET PIPING:
(As per IBR Reg. No. 350)

2 x f x E x (T – C)
WP= Working pressure =
(D - T + C)

D = External diameter of pipe in mm

f = Allowable stress in Kg/Cm2 (Refer page no. 44)

T = Minimum provided thickness of tube in mm

= Nominal thickness – Negative tolerance

E = Ligament efficiency = 1

C = Corrosion allowance = 0.75 mm

Pmax = Maximum working pressure (i.e) Design pressure inKg/cm 2 (g)

= 80 Kg/cm2 (g)
Size
Sl. T f WP
Description OD x Thk Material Remark
No.
mm x mm mm Kg/Cm2 Kg/Cm2

ECONOMISER-II TO STEAM DRUM INLET PIPING:

WP > Pmax
1 Main pipe 114.3 x 6.02 SA106Gr.B 5.27 1203.24 99.03
Hence Safe
WP > Pmax
2 Air vent pipe 33.4 x 4.55 SA106Gr.B 3.98 1203.24 257.75
Hence Safe
WP > Pmax
3 Elbow 114.3 x 6.02 SA 234WPB 5.27 1203.24 99.03
Hence Safe
WP > Pmax
4 Thermowell boss stub 53 x 10 SA 105 10 1387.61 586.76
Hence Safe

Notes:

 12.5% of –Ve tolerance considered on pipe thickness

Page 11 of 25
4.0 ALLOWABLE STRESS CALCULATIONS FOR STEAM DRUM TO PRIMARY SUPER HEATER INLET PIPING:

Max.Metal ASME
Allowable
Sl. Working UTS Allowable Et UTS/ 2.7 Et/ 1.5
Description Material Stress
No. temperature Stress
ºC Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2

STEAM DRUM TO PRIMARY SUPER HEATER INLET PIPING:

Main pipe, Sample cooler, Air vent

1 SA 106 GR B 295 4231.76 1203.24 2071.62 1567.32 1381.88 1203.24
pipes

2 Elbow SA 234 WPB 295 4231.76 1203.24 2071.62 1567.32 1381.88 1203.24

Allowable stress value as per ASME sec II Part-D Table 1A.

Et values are as per ASME sec II Part-D Table Y1.

Minimum UTS values are taken from ASME sec II Part-D Table 1A.

Allowable stress = Minimum of Et/1.5 or UTS/2.7 or ASME Allow. Value.

Page 12 of 25
4.1 PIPE THICKNESS CALCULATIONS FOR STEAM DRUM TO PRIMARY SUPER HEATER INLET PIPING:
(As per IBR Reg. No. 350)

2 x f x E x (T – C)
WP= Working pressure =
(D - T + C)

D = External diameter of pipe in mm

f = Allowable stress in Kg/Cm2 (Refer page no. 44)

T = Minimum provided thickness of tube in mm

= Nominal thickness – Negative tolerance

E = Ligament efficiency = 1

C = Corrosion allowance = 0.75 mm

Pmax = Maximum working pressure (i.e) Design pressure inKg/cm 2 (g)

= 80 Kg/cm2 (g)
Size
Sl. T f WP
Description OD x Thk Material Remark
No.
mm x mm mm Kg/Cm2 Kg/Cm2

STEAM DRUM TO PRIMARY SUPER HEATER INLET PIPING:

WP > Pmax
1 Main pipe 219.1 x 10.31 SA106Gr.B 9.02 1203.24 94.01
Hence Safe
Air vent pipe, Sample WP > Pmax
2 33.4 x 4.55 SA106Gr.B 3.98 1203.24 257.75
cooler pipe Hence Safe
WP > Pmax
3 Elbow 219.1 x 10.31 SA 234WPB 9.02 1203.24 94.01
Hence Safe

Notes:

 12.5% of –Ve tolerance considered on pipe thickness

Page 13 of 25
5.0 ALLOWABLE STRESS CALCULATIONS FOR PRIMARY SUPER HEATER TO SECONDRY SUPER HEATER LINK PIPING:
Max.Metal ASME
Allowable
Sl. Working UTS Allowable Et UTS/ 2.7 Et/ 1.5
Description Material Stress
No. temperature Stress
ºC Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2

PRIMARY SUPER HEATER TO SECONDRY SUPER HEATER LINK PIPING:

1 Main pipe SA 106 GR B 331 4231.76 1200.79 1851.36 1567.32 1234.24 1200.79

2 Elbow SA 234 WPB 331 4231.76 1200.79 1851.36 1567.32 1234.24 1200.79

Allowable stress value as per ASME sec II Part-D Table 1A.

Et values are as per ASME sec II Part-D Table Y1.

Minimum UTS values are taken from ASME sec II Part-D Table 1A.

Allowable stress = Minimum of Et/1.5 or UTS/2.7 or ASME Allow. Value.

Page 14 of 25
5.1 PIPE THICKNESS CALCULATIONS FOR PRIMARY SUPER HEATER TO SECONDRY SUPER HEATER LINK
PIPING:
(As per IBR Reg. No. 350)

2 x f x E x (T – C)
WP= Working pressure =
(D - T + C)

D = External diameter of pipe in mm

f = Allowable stress in Kg/Cm2 (Refer page no. 44)

T = Minimum provided thickness of tube in mm

= Nominal thickness – Negative tolerance

E = Ligament efficiency = 1

C = Corrosion allowance = 0.75 mm

Pmax = Maximum working pressure (i.e) Design pressure inKg/cm 2 (g)

= 80 Kg/cm2 (g)
Size
Sl. T f WP
Description OD x Thk Material Remark
No. 2 2
mm x mm mm Kg/Cm Kg/Cm

PRIMARY SUPER HEATER TO SECONDRY SUPER HEATER LINK PIPING:

WP > Pmax
1 Main pipe 168.3 x 7.11 SA106Gr.B 6.22 1200.79 80.70
Hence Safe
WP > Pmax
2 Elbow 168.3 x 7.11 SA 234WPB 6.22 1200.79 80.70
Hence Safe

Notes:

 12.5% of –Ve tolerance considered on pipe thickness

Page 15 of 25
6.0 ALLOWABLE STRESS CALCULATIONS FOR SECONDRY DE SUPER HEATER PIPING WITH DESUPERHEATER:

Max.Metal ASME
Allowable
Sl. Working UTS Allowable Et UTS/ 2.7 Et/ 1.5
Description Material Stress
No. temperature Stress
ºC Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2

DE SUPER HEATER PIPING:

1 Main pipe SA 335 P11 409 4231.76 1030.92 1545.46 1567.32 1030.31 1030.31

2 Elbow SA 234 WP11 409 4231.76 1030.92 1545.46 1567.32 1030.31 1030.31

3 Thermowell stub SA 182 F11 CL 1 409 4231.76 1087.4 2034.91 1567.32 1356.61 1087.4

4 Desuper heater SA 335 P11 409 4231.76 1030.92 1545.46 1567.32 1030.31 1031.31

Allowable stress value as per ASME sec II Part-D Table 1A.

Et values are as per ASME sec II Part-D Table Y1.

Minimum UTS values are taken from ASME sec II Part-D Table 1A.

Allowable stress = Minimum of Et/1.5 or UTS/2.7 or ASME Allow. Value.

Page 16 of 25
6.1 PIPE THICKNESS CALCULATIONS FOR DES SUPER HEATER
LINK PIPING WITH DE SUPER HEATER:
(As per IBR Reg. No.350)

2 x f x E x (T – C)
WP= Working pressure =
(D - T + C)

D = External diameter of pipe in mm

f = Allowable stress in Kg/Cm2 (Refer page no. 44)

T = Minimum provided thickness of tube in mm

= Nominal thickness – Negative tolerance

E = Ligament efficiency = 1

C = Corrosion allowance = 0.75 mm

Pmax = Maximum working pressure (i.e) Design pressure inKg/cm 2 (g)

= 80 Kg/cm2 (g)
Size
Sl. T f WP
Description OD x Thk Material Remark
No. 2 2
mm x mm mm Kg/Cm Kg/Cm

DE SUPER HEATER LINK PIPING:

Main pipe, Spare WP > Pmax
1 219.1 x 12.7 SA335 P11 11.11 1030.92 102.36
pipe Hence Safe
WP > Pmax
2 Elbow 219.1 x 12.7 SA234 WP11 11.11 1030.92 102.36
Hence Safe
WP > Pmax
3 Thermowell stub 53.00 x 10 SA 182F11CL 1 10.00 1087.4 459.81
Hence Safe
WP > Pmax
4 Desuperheater pipe 219.1 x 12.7 SA335 P11 11.11 1030.92 102.36
Hence Safe
WP > Pmax
5 Spray inlet sleeve 73 x 9.53 SA335 P11 8.34 1030.92 239.21
Hence Safe
Spray inlet stub & WP > Pmax
6 33.4 x 6.35 SA335 P11 5.56 1030.92 346.57
Drain stub Hence Safe

Notes:

 12.5% of –Ve tolerance considered on pipe thickness

Page 17 of 25
6.2 MAXIMUM UNCOMPENSATED HOLE DIA IN DESUPERHEATER:

(As per IBR Reg. No. 187)

PxD
K = Maximum uncompensated hole =
1.82 x f x e

P = Maximum design pressure = 80 Kg/cm2

D = Outside diameter of the pipe = 219.1mm

e = Actual thickness of the pipe = 11.113 mm

f = Permissible working stress = 1030.92 Kg/cm2

80x219.1
K =
1.82x1030.92x11.113

K = Maximum uncompensated hole = 0.84

d = Maximum diameter of opening = 60 mm (as per fig.9b/9c)

Maximum Provided hole in Desuperheater = 54 mm < 60 mm

Hence compensation calculation not required.

Page 18 of 25
7.0 ALLOWABLE STRESS CALCULATIONS FOR MAINSTEAM PIPE:

Max.Metal ASME
Allowable
Working UTS Allowable Et UTS/ 2.7 Et/ 1.5
Sl.No. Description Material Stress
temperature Stress
ºC Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2

1 Main pipe SA 335 P22 495 4231.76 863.89 1774.28 1567.32 1182.85 863.89

2 Elbow SA 234 WP22 495 4231.76 863.89 1774.28 1567.32 1182.85 863.89

3 Thermowell stub SA 182 F22 CL 1 495 4231.76 863.89 1774.28 1567.32 1182.85 863.89

Allowable stress value as per ASME sec II Part-D Table 1A.

Et values are as per ASME sec II Part-D Table Y1.

Minimum UTS values are taken from ASME sec II Part-D Table 1A.

Allowable stress = Minimum of Et/1.5 or UTS/2.7 or ASME Allow. Value.

Page 19 of 25
7.1 PIPE THICKNESS CALCULATIONS FOR MAIN STEAM PIPE:
(As per IBR Reg. No.350)
2 x f x E x (T – C)
WP= Working pressure =
(D - T + C)

D = External diameter of pipe in mm

f = Allowable stress in Kg/Cm2

T = Minimum provided thickness of tube in mm

= Nominal thickness – Negative tolerance

E = Ligament efficiency = 1

C = Corrosion allowance = 0.75 mm

Pmax = Maximum working pressure (i.e) Design pressure inKg/cm 2 (g)

= 80 Kg/cm2 (g)
Size
Sl. T f WP
Description OD x Thk Material Remark
No. 2 2
mm x mm mm Kg/Cm Kg/Cm
WP > Pmax
1 Main pipe 219.1 x 12.7 SA 335 P22 11.11 863.89 85.77
Hence Safe
WP > Pmax
2 Pipe 219.1 x 18.26 SA 335 P22 15.98 863.89 129.05
Hence Safe
WP > Pmax
3 Pipe 88.9 x 7.62 SA 335 P22 6.67 863.89 123.21
Hence Safe
WP > Pmax
4 Auxiliary pipe, stub 48.3 x 5.08 SA 335 P22 4.45 863.89 143.13
Hence Safe
Pressure transmitter,
WP > Pmax
5 pressure gauge, Drain 33.4 x 4.55 SA 335 P22 3.98 863.89 185.06
Hence Safe
pipe
WP > Pmax
6 Elbow 219.1 x 12.7 SA 234 WP22 11.11 863.89 85.77
Hence Safe
WP > Pmax
7 Elbow 219.1 x 18.26 SA 234 WP22 15.98 863.89 129.05
Hence Safe
WP > Pmax
8 Thermowell stub 53 x10 SA 182 F22 CL1 10.00 863.89 365.30
Hence Safe
Startup vent steam WP > Pmax
9 98 x 15.5 SA 182 F22 CL1 13.56 863.89 259.86
stub Hence Safe
WP > Pmax
10 Safety valve stub 95.3 x 19.05 SA 182 F22 CL1 16.67 863.89 346.48
Hence Safe
Condensing loop
WP > Pmax
11 pipe, Spare pipe, at 21.3 x 3.73 SA 335 P22 3.26 863.89 231.19
Hence Safe
lager end
WP > Pmax
12 Reducer at larger end 21.3 x 3.73 SA 182 F22CL 1 3.26 863.89 231.19
Hence Safe
Reducer at smaller WP > Pmax
13 14 x 3.73 SA 182 F22CL 1 3.26 863.89 378.12
end Hence Safe
Notes:12.5% of –Ve tolerance considered on pipe thickness

Page 20 of 25
7.2 BRANCH & MAIN PIPE CALCULATIONS FOR MAIN STEAM PIPE:
(As per IBR Reg. No.362 C (I)

d1&d2 = Diameter of hole for branches in main pipe

D = d1+d2

L = Gap available between bore of the branches in mm

Condition: If L > D, then branch is not affected by other branch.

DETAIL OF BRANCHES ON PIPIES:

DESCRIPTION OF THE d1 d2 D L
Sl.No. Remark
ADJACENT BRANCHES
mm mm mm mm
PRESSURE GAUGE & PRESSURE L>D
1 24.3 24.3 48.6 275.7
TRANSMITTER Hence Safe
SAMPLING STUB & L>D
2 24.3 53 77.3 261.35
TEMPERATURE ELEMENT Hence Safe
TEMPERATURE ELEMENT & L>D
3 53 57.2 110.2 444.9
SAFETY VALVE STUB Hence Safe
SAFETY VALVE STUB & START- L>D
4 57.2 67 124.2 687.9
UP STEAM VENT STUB Hence Safe
START-UP STEAM VENT STUB L>D
5 67 24.3 91.3 254.35
& PRESSURE GAUGE STUB Hence Safe
PRESSURE GAUGE STUB & L>D
6 24.3 53 77.3 261.35
TEMPERATURE GAUGE STUB Hence Safe
TEMPERATURE GAUGE STUB & L>D
7 53 24.3 77.3 161.35
DRAIN STUB Hence Safe
L>D
8 DRAIN STUB & AUXILARY STUB 24.3 38.14 62.44 168.78
Hence Safe

Page 21 of 25
 P x D x1 PxD
Minimum required thickness of branch Tb = +C Minimum required Thickness of Main Tm = +C
(2 x f x E +P) X (X1….Xn) (2 x f x E +P) X

P = Design Pressure in Kg/Cm2

d = External Diameter of Branch in mm D = External Diameter of Main in mm

f = Max.Permissible stress for the material in Kg/Cm2 (Refer page no. 44) X = 1-B (1-sin (Y))

T&t = Minimum provided thickness of Main/Branch in mm B = Bore of branch / Bore of Main, (Bb/Bm)

= Nominal thickness – Negative tolerance E = Ligament efficiency = 1

E = Ligament efficiency = 1 Y = Angle between Branch & Main = 90

C = Corrosion allowance = 0.75 mm Bm = Bore of Main

IF (Y/(Y+90))>B, There is No reinforcement. Bb = Bore of branch

CALCULATION FOR MINIMUM REQUIRED THICKNESS OF BRANCH PIPE:

Design BRANCH
P
Sl. No. DESCRIPTION Temp. f d Thk Neg. Bb B* t Tb
Material Remark
kg/cm o Specification 2
2
C kg/cm mm mm Tol. % mm mm mm mm

t > Tb
01 Auxiliary Pipe 80 495 SA 335 P22 869.89 48.30 5.08 12.5 38.14 0.209 4.45 3.02
Hence Safe
t > Tb
02 Air vent 80 495 SA 182 F22 869.89 33.40 4.55 12.5 24.30 0.125 3.98 2.28
Hence Safe
Pressure gauge, t > Tb
03 80 495 SA 335 P22 869.89 33.40 4.55 12.5 24.30 0.133 3.98 2.28
pressure transmitter Hence Safe
t > Tb
04 Thermowell stub 80 495 SA 182 F22 CL 1 869.89 53.00 16.5 0 20 0.110 16.5 3.16
Hence Safe
t > Tb
05 Start up vent stub 80 495 SA 182 F22 CL 1 869.89 98.00 15.50 0 67.00 0.367 15.50 5.59
Hence Safe
t > Tb
06 Safety valve stub 80 495 SA 182 F22 CL 1 869.89 95.30 19.05 0 57.20 0.313 19.05 5.37
Hence Safe
* Bore of main refer page no: 23

Page 22 of 25
CALCULATION FOR MINIMUM REQUIRED THICKNESS OF MAIN PIPE:

Design MAIN
P
Temp. f d Thk Neg. Bm X T Tm Remark
Sl. No. DESCRIPTION Material
kg/cm o Specification T > Tm
C kg/cm2 mm mm Tol. % mm mm mm mm
2
Hence Safe
Main pipe thickness T > Tm
01 80 495 SA 335 P22 869.89 219.1 18.26 12.5 182.58 0.937 15.98 11.03
for auxiliary Pipe Hence Safe
Main pipe thickness T > Tm
02 80 495 SA 335 P22 869.89 219.1 12.7 12.5 193.70 0.962 11.11 10.76
for air vent Hence Safe
Main pipe thickness
T > Tm
03 for pressure gauge, 80 495 SA 335 P22 869.89 219.1 18.26 12.5 182.58 0.960 15.98 10.78
Hence Safe
pressure transmitter
Main pipe thickness T > Tm
04 80 495 SA 335 P22 869.89 219.1 18.26 12.5 182.58 0.967 15.98 10.71
for thermowell stub Hence Safe
Main pipe thickness
T > Tm
05 for start up vent 80 495 SA 335 P22 869.89 219.1 18.26 12.5 182.58 0.890 15.98 11.57
Hence Safe
stub
Main pipe thickness T > Tm
06 80 495 SA 335 P22 869.89 219.1 18.26 12.5 182.58 0.906 15.98 11.38
for safety valve stub Hence Safe

Page 23 of 25
8.0 ALLOWABLE STRESS CALCULATIONS FOR FEED WATER PIPING:

Max.Metal ASME
Allowable
Sl. Working UTS Allowable Et UTS/ 2.7 Et/ 1.5
Description Material Stress
No. temperature Stress
ºC Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2 Kg/cm2

FEED WATER PIPING

1 Main pipe, Bypass pipe, Vent pipe SA 106 GR.B 140 4231.76 1203.24 2194.39 1567.32 1462.93 1203.24

Elbow, Equal tee, Reducing tee,

2 SA 234 WPB 140 4231.76 1203.24 2194.39 1567.32 1462.93 1203.24
Reducer

Allowable stress value as per ASME sec II Part-D Table 1A.

Et values are as per ASME sec II Part-D Table Y1.

Minimum UTS values are taken from ASME sec II Part-D Table 1A.

Allowable stress = Minimum of Et/1.5 or UTS/2.7 or ASME Allow. Value.

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8.1 PIPE THICKNESS CALCULATIONS FOR FEED WATER PIPING:
(As per IBR Reg. No. 350)

2 x f x E x (T – C)
WP= Working pressure =
(D - T + C)

D = External diameter of pipe in mm

f = Allowable stress in Kg/Cm2 (Refer page no. 44)

T = Minimum provided thickness of tube in mm

= Nominal thickness – Negative tolerance

E = Ligament efficiency = 1

C = Corrosion allowance = 0.75 mm

Pmax = Maximum working pressure (i.e) Design pressure inKg/cm 2 (g)

= 109 Kg/cm2 (g)

Size
Sl. T f WP
Description OD x Thk Material Remark
No.
mm x mm mm Kg/Cm2 Kg/Cm2
FEED WATER PIPING
WP > Pmax
1 Main pipe 114.3 x 8.56 SA106Gr.B 7.49 1203.24 150.80
Hence Safe
WP > Pmax
2 Bypass pipe line 73.0 x 7.01 SA106Gr.B 6.13 1203.24 191.61
Hence Safe
WP > Pmax
3 Bypass after reducer 60.3 x 5.54 SA106Gr.B 4.85 1203.24 175.45
Hence Safe
WP > Pmax
4 Vent pipe 33.4 x 4.55 SA106Gr.B 3.98 1203.24 257.75
Hence Safe
Elbow , Equal Tee,
WP > Pmax
5 Reducing Tee at 114.3 x 8.56 SA 234WPB 7.49 1203.24 150.80
Hence Safe
larger end
Elbow, Reducer at WP > Pmax
6 73.0 X 7.01 SA 234WPB 6.13 1203.24 191.61
larger end Hence Safe
Reducing Tee at WP > Pmax
7 73.0 x 7.01 SA 234WPB 6.13 1203.24 191.61
smaller end Hence Safe
Reducer at smaller WP > Pmax
8 60.30 x 5.54 SA 234WPB 4.85 1203.24 175.45
end Hence Safe

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