Header & Piping Sizing
9
M/S DALMIA CEMENT (BHARAT) LTD 1X120 TPH CFBC BOILER HEADER THICKNESS CALCULATION PREPARED BY: JRY APPROVED BY: JRK Header & Piping Thickness Calculation Description Material CONVECTION CAGE 1 FRONT/REAR ROOF HDR(CG) 323.9 38.1 1 122 354 393 SA 106 Gr B 952.00 27.85 33.34 0.6500 19.70 5.49 2 273 31.75 1 122 354 393 SA 106 Gr B 952.00 23.67 27.78 0.6500 17.36 4.11 3 Interconnecting HDR(CG) 168.3 21.95 4 122 354 393 SA 106 Gr.B 952.00 14.37 19.21 0.6500 33.69 4.84 4 FRONT BOTTOM HDR(CG) 273 31.75 1 122 354 393 SA 106 Gr.B 952.00 23.67 27.78 0.6500 17.36 4.11 5 REAR WALL BOTTOM HDR(CG) 273 31.75 1 122 354 393 SA 106 Gr.B 952.00 23.67 27.78 0.6500 17.36 4.11 6 219.1 28.58 2 122 354 393 SA 106 Gr.B 952.00 22.12 25.01 0.5500 13.07 2.89 7 219.1 28.58 2 122 354 393 SA 106 Gr.B 952.00 18.47 25.01 0.6500 35.38 6.54 SUPERHEATER 739.4 8 PSH outlet header 323.9 34.93 1.00 122 460.00 SA 335 P11 978.00 27.73 30.56 0.6500 10.23 2.84 9 wing wall I/L HDR 273 38.1 2.00 122 420.00 SA 335 P11 1019.00 27.53 33.34 0.5000 21.10 5.81 10 wing wall 0/L HDR 273 41.28 2.00 122 492.00 SA 335 P11 850.00 32.68 36.12 0.5000 10.54 3.44 11 SSH inlet header 323.9 31.75 1.00 122 465.00 SA 335 P11 973.00 22.09 27.78 0.8280 25.74 5.69 12 SSH outlet header 323.9 34.93 1.00 122 582.00 SA 335 P 91 830.00 25.51 30.56 0.8280 19.82 5.06 CROSS OVER DUCT 13 COD FRONT header 273 25.4 2.00 122 318 357 SA 106 Gr.B 1150.00 20.51 22.23 0.6500 8.38 1.72 14 COD REAR header 273 25.4 2.00 122 318 357 SA 106 Gr.B 1150.00 20.51 22.23 0.6500 8.38 1.72 15 COD SIDE header 273 28.58 4.00 122 318 357 SA 106 Gr.B 1150.00 23.80 25.01 0.5500 5.07 1.21 ECONOMISER 16 ECO inlet header 273.1 31.75 1.00 118 230 241 SA 106 Gr.B 1202.28 19.33 27.78 0.6030 43.71 8.45 17 ECO outlet header 219.1 20.62 2.00 118 276 287 SA 106 Gr.B 1202.28 12.39 18.04 0.8000 45.68 5.66 18 HANGER OUTLET HDR 219.1 20.62 2.00 118 289 300 SA 106 Gr B 1202.28 12.39 18.04 0.8000 45.68 5.66 BOILER FEED PUMP 36 feed water suction hdr 457.2 11.13 1 6.5 160 160 SA 106 Gr B 1202.2 2.00 9.74 0.95 386.15 7.74 37 feed water discharge hdr 323.9 28.58 1 155 160 160 SA 106 Gr B 1202.2 20.18 25.01 0.95 23.92 4.83 38 Feed water header 323.9 33.32 1 155 210 210 SA 106 Gr B 1202 23.31 29.16 0.8 25.06 39 Auxiliary steam header 323.9 10.31 1 6 250 250 SA 106 Gr B 1202 1.85 9.02 0.7 388.37 40 Auxiliary steam header 114.3 8.56 1 21 300 300 SA 106 Gr B 1202 1.99 7.49 0.7 276.37 Sl. No Outside diameter (mm) Thickness (mm) No of headers Design Pressure (kg/cm^2) max working temp deg.C Design Temp Deg. C Allowable Stress (kg/m^2) Minimum thickness required (mm) Min. thick available (mm) Ligament Efficienc y (%) % Margin Available Allowance mm Front Intermediate HDR(CG) SIDE WALL(L&R)Bottom HDR (CG) SIDE WALL(L&R)TOP HDR (CG)
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Transcript of Header & Piping Sizing
M/S DALMIA CEMENT (BHARAT) LTD1X120 TPH CFBC BOILER
HEADER THICKNESS CALCULATION
PREPARED BY:JRY
APPROVED BY:JRK
Header & Piping Thickness Calculation
Description Material
CONVECTION CAGE
1 323.9 38.1 1 122 354 393 SA 106 Gr B 952.00 27.85 33.34 0.6500 19.70 5.49
2 Front Intermediate HDR(CG) 273 31.75 1 122 354 393 SA 106 Gr B 952.00 23.67 27.78 0.6500 17.36 4.11
3 Interconnecting HDR(CG) 168.3 21.95 4 122 354 393 SA 106 Gr.B 952.00 14.37 19.21 0.6500 33.69 4.84
4 FRONT BOTTOM HDR(CG) 273 31.75 1 122 354 393 SA 106 Gr.B 952.00 23.67 27.78 0.6500 17.36 4.11
5 273 31.75 1 122 354 393 SA 106 Gr.B 952.00 23.67 27.78 0.6500 17.36 4.11
6 219.1 28.58 2 122 354 393 SA 106 Gr.B 952.00 22.12 25.01 0.5500 13.07 2.89
7 219.1 28.58 2 122 354 393 SA 106 Gr.B 952.00 18.47 25.01 0.6500 35.38 6.54
SUPERHEATER 739.4
8 PSH outlet header 323.9 34.93 1.00 122 460.00 SA 335 P11 978.00 27.73 30.56 0.6500 10.23 2.84
9 wing wall I/L HDR 273 38.1 2.00 122 420.00 SA 335 P11 1019.00 27.53 33.34 0.5000 21.10 5.81
10 wing wall 0/L HDR 273 41.28 2.00 122 492.00 SA 335 P11 850.00 32.68 36.12 0.5000 10.54 3.44
11 SSH inlet header 323.9 31.75 1.00 122 465.00 SA 335 P11 973.00 22.09 27.78 0.8280 25.74 5.69
12 SSH outlet header 323.9 34.93 1.00 122 582.00 SA 335 P 91 830.00 25.51 30.56 0.8280 19.82 5.06
CROSS OVER DUCT
13 COD FRONT header 273 25.4 2.00 122 318 357 SA 106 Gr.B 1150.00 20.51 22.22 0.6500 8.38 1.72
14 COD REAR header 273 25.4 2.00 122 318 357 SA 106 Gr.B 1150.00 20.51 22.22 0.6500 8.38 1.72
15 COD SIDE header 273 28.58 4.00 122 318 357 SA 106 Gr.B 1150.00 23.80 25.01 0.5500 5.07 1.21
ECONOMISER
16 ECO inlet header 273.1 31.75 1.00 118 230 241 SA 106 Gr.B 1202.28 19.33 27.78 0.6030 43.71 8.45
17 ECO outlet header 219.1 20.62 2.00 118 276 287 SA 106 Gr.B 1202.28 12.39 18.04 0.8000 45.68 5.66
18 HANGER OUTLET HDR 219.1 20.62 2.00 118 289 300 SA 106 Gr B 1202.28 12.39 18.04 0.8000 45.68 5.66
BOILER FEED PUMP
36 feed water suction hdr 457.2 11.13 1 6.5 160 160 SA 106 Gr B 1202.2 2.00 9.74 0.95 386.15 7.74
37 feed water discharge hdr 323.9 28.58 1 155 160 160 SA 106 Gr B 1202.2 20.18 25.01 0.95 23.92 4.83
38 Feed water header 323.9 33.32 1 155 210 210 SA 106 Gr B 1202 23.31 29.16 0.8 25.06
39 Auxiliary steam header 323.9 10.31 1 6 250 250 SA 106 Gr B 1202 1.85 9.02 0.7 388.37
40 Auxiliary steam header 114.3 8.56 1 21 300 300 SA 106 Gr B 1202 1.99 7.49 0.7 276.37
Sl. No
Outside diameter
(mm)
Thickness (mm)
No of headers
Design Pressure (kg/cm^2)
max working
temp deg.C
Design Temp Deg. C
Allowable Stress (kg/m^2)
Minimum thickness required
(mm)
Min. thick available
(mm)
Ligament Efficiency
(%)
% Margin Available
Allowance mm
FRONT/REAR ROOF HDR(CG)
REAR WALL BOTTOM HDR(CG)
SIDE WALL(L&R)Bottom HDR (CG)
SIDE WALL(L&R)TOP HDR (CG)
M/S DALMIA CEMENT LTD1X120 TPH CFBC BOILER
HEADER SIZING CALCULATION
PREPARED BY :JRA
APRROVED BY:JRK
Header Sizing Description
CONVECTION CAGE
1 323.9 38.1
0.24770 133900 107.5 354 Err:511 Err:511 Err:511 0.1200
2 273 31.75
0.2095 133900 107.5 354 Err:511 Err:511 Err:511 0.1200
3 Interconnecting HDR(CG) 168.3 21.950.1244 33475 107.5 354 Err:511 Err:511 Err:511 0.1200
4 273 31.750.2095 133900 107.5 354 Err:511 Err:511 Err:511 0.1200
5 273 31.750.2095 133900 107.5 354 Err:511 Err:511 Err:511 0.1200
6 219.1 28.58
0.16194 66950 107.5 354 Err:511 Err:511 Err:511 0.1500
7 219.1 28.580.16194 66950 107.5 354 Err:511 Err:511 Err:511 0.1200
SUPERHEATER
8 PSH outlet header 323.9 34.930.25404 140000 105 421.00 Err:511 Err:511 Err:511 0.1200
9 wing wall I/L HDR 273 38.1 0.1968 70000 103.5 395.00 Err:511 Err:511 Err:511 0.1500
10 wing wall 0/L HDR 273 41.280.19044 70000 100.00 454.00 Err:511 Err:511 Err:511 0.1200
11 SSH inlet header 323.9 31.75 0.2604 140000 99.00 440.00 Err:511 Err:511 Err:511 0.1500
12 SSH outlet header 323.9 34.93 0.25404 140000 96.00 545 Err:511 Err:511 Err:511 0.1200
Sl. No.
Outside dia ( mm)
Header thk.
(mm)
Inside dia m
Fluid flow (kg/hr)
Operating pressure (ksc(a))
Operating temp.
(deg. C)
Specific volume (m3/kg)
Actual velocity
(m/s)
Velocity m/s/mmID
Velocity m/s/mmID(max limit)
FRONT/REAR ROOF HDR(CG)
Front Intermediate HDR(CG)
FRONT BOTTOM HDR(CG)
REAR WALL BOTTOM HDR(CG)
SIDE WALL(L&R)Bottom HDR (CG)
SIDE WALL(L&R)TOP HDR (CG)
M/S DALMIA CEMENT LTD1X120 TPH CFBC BOILER
HEADER SIZING CALCULATION
PREPARED BY :JRA
APRROVED BY:JRK
CROSS OVER DUCT
13 COD FRONT header 273 25.40.2222 70000 111 318 Err:511 Err:511 Err:511 0.1200
14 COD REAR header 273 25.40.2222 70000 111 318 Err:511 Err:511 Err:511 0.1200
15 COD SIDE header 273 25.40.2222 70000 111 318 Err:511 Err:511 Err:511 0.1200
ECONOMISER
16 ECO inlet header 273.1 31.75 0.2096 140000 116 230 Err:511 Err:511 Err:511 2m/s
17 ECO outlet header 219.1 20.62 0.17786 70000 116 276 Err:511 Err:511 Err:511 2m/s
18 HANGER OUTLET HDR 219.1 20.62 0.17786 70000 116 289 Err:511 Err:511 Err:511 2m/s
M/S DALMIA CEMENT LTD1X120 TPH CFBC BOILER
HEADER SIZING CALCULATION
PREPARED BY :JRA
APRROVED BY:JRK
BOILER FEED PUMP
36 feed water suction hdr 457.2 11.13 0.43494 280000 6.5 160 Err:511 Err:511 Err:511 0.6-0.9
37 feed water discharge hdr 323.9 28.58 0.26674 280000 162 160 Err:511 Err:511 Err:511 1.5-2.4
38 Feed water header 323.9 33.32 0.25726 280000 162 230 Err:511 Err:511 Err:511 1.5-2.439 Auxiliary steam header 323.9 10.31 0.30328 15000 6 250 Err:511 Err:511 Err:511 1.5-2.6
Auxiliary steam header 114.3 8.56 0.09718 3000 21 300 Err:511 Err:511 Err:511 1.5-2.7
M/S BALASORE ALLOYS LTD2 X 140 TPH CFBC BOILER
HEADER THICKNESS CALCULATION
Piping Thickness Calculation
Sl.No Description Material
1406.4 9.53 1 6.4 160
SA 106 Gr B 1202.00 1.83 8.34 355.90
2
273 9.27 1 6.4 160
SA 106 Gr B 1202.00 1.47 8.11 449.97
3219.1 20.62 1 160 160
SA 106 Gr B 1202.00 14.42 18.04 25.10
4
273.1 25.4 1 160 160
SA 106 Gr B 1202.00 17.79 22.22 24.91
5219.1 15.09 1 160 160
SA 106 Gr B 1202.00 14.42 13.20 -8.45
6 Spray Piping to boiler attemperator-142.2 4.85 1 160 160
SA 106 Gr B 1202.00 3.38 4.24 25.43
7steam line from CSDH to PRDS - 1
114.3 13.49 1 96 540SA 335 P 22 520.50 10.40 11.80 13.49
8
355.6 9.53 1 7.00 250
SA 106 Gr B 1202.00 1.78 8.34 367.83
9 Feed water piping from eco to drum219.1 15.09 1 117.00 277
SA 106 Gr.B 1202.00 10.92 13.20 20.93
10 Drum to COD 219.1 15.09 1 122 318 SA 106 Gr.B 1202.00 11.33 13.20 16.52
11 COD to cage 219.1 15.09 1 122 325 SA 106 Gr.B 1202.00 11.33 13.20 16.52
12 PSH to DSH-1 273 21.44 1 122 421 SA 355 P11 1018.00 16.18 18.76 15.92
13 DSH-1 to WWSH SH 273 21.44 1 122 395 SA 355 P11 1043.00 15.83 18.76 18.48
14 WWSH to Final SH 323.9 25.4 1 122 454 SA 355 P11 984.00 19.66 22.22 13.06
18 Main steam pipe upto MSSV 323.9 25.4 1 122 555 SA 355 P91 1045.00 18.61 22.22 19.40
Main steam from MSSV to CSDH 406.4 50.8 1 105.5 540 SA 355 P22 520.50 38.15 44.45 16.52
Outside diameter
(mm)
Thickness (mm)
No of headers
per boiler
Design Pressure (kg/cm^2)
Design Temp Deg. C
Allowable Stress (kg/m^2)
Minimum thickness required
(mm)
Min. thick available
(mm)
% Margin Available
Feed water piping from deaerator to BFP suction
Feed water piping from BFP header to BFP
Feed water piping from BFP to BFP header
Feed water piping from BFP outlet to HP heater-I
Feed water piping from HP heater-I to economiser
steam line from PRDS-1 to ejector/gland sealing
M/S BALASORE ALLOYS LTD2 X 140 TPH CFBC BOILER
HEADER THICKNESS CALCULATION
CSDH 558.8 88.9 1 105.5 540 SA 355 P22 520.50 71.42 77.79 8.91
19Steam piping from CSDH to PRDS-II
60.3 8.74 1 97 540SA 355 P22 520.50 5.89 7.65 29.84
20114.3 6.08 1 21 250
SA106 Gr B 1202.00 1.74 5.32 205.78Steam piping from PRDS-II to termial
point
M/s DALMIA CEMENT (BHARAT) LTD.
Piping Sizing
Sl. No. Description
1 406.4 9.53 1 280000 6.4 160 Err:511 Err:511 0.6-0.9 0.6-0.9
2 273 9.27 1 140000 6.4 160 Err:511 Err:511 0.6-0.9 1.8-2.4
3 219.1 20.62 1 140000 160 160 Err:511 Err:511 1.5-2.4 1.8-2.4
4 273.1 25.4 1 280000 160 160 Err:511 Err:511 1.5-2.4 1.8-2.4
5 219.1 15.09 1 140000 160 160 Err:511 Err:511 3.00
6 42.2 4.85 1 7000 160 160 Err:511 Err:511 3.00
7 114.3 13.49 1 15000 96 540 Err:511 Err:511 35-50
8 355.6 9.53 1 15000 6.00 250 Err:511 Err:511 28-43
9 219.1 15.09 1 140000 116.00 277 Err:511 Err:511 2-3
10 Drum to COD 219.1 15.09 1 70000 111.5 318 0.01737 12.1 30-50 20-35
11 COD to cage 219.1 15.09 1 70000 109.5 325 Err:511 Err:511 50.00 20-35
12 PSH to DSH-1 273 21.44 1 140000 105 421 Err:511 Err:511 50.00 35-61
Outside dia
( mm)
Pipe thk.
(mm)
No of Lines
Fluid flow
(kg/hr)
Operating
pressure ksc(a)
Operating temp.
(deg. C)
Specific volume (m3/kg)
Actual velocity
(m/s)
Allowable Velocity
m/s
Allowable Velocity
m/s(AS PER Tender)
Feed water piping from deaerator to BFP suction
Feed water piping from BFP header to BFP
Feed water piping from BFP to BFP header
Feed water piping from BFP outlet to HP heater-I
Feed water piping from HP heater-I to economiser
Spray Piping to boiler attemperator-1
steam line from CSDH to PRDS - 1
steam line from PRDS-1 to ejector/gland sealing
Feed water piping from eco to drum
M/s DALMIA CEMENT (BHARAT) LTD.
13 DSH-1 to WWSH SH 273 21.44 1 140000 104.5 395 Err:511 Err:511 50.00 50-76
14 WWSH to Final SH 323.9 25.4 1 140000 100 454 Err:511 Err:511 50.00 50-76
18 Main steam pipe upto MSSV 323.9 25.4 1 140000 97 540.00 Err:511 Err:511 50 50-76
0 406.4 50.8 1 280000 97 540.00 Err:511 Err:511 50 50-77
0 CSDH 558.8 88.9 1 280000 97 540.00 Err:511 Err:511 50 50-78
Main steam from MSSV to CSDH
M/s DALMIA CEMENT (BHARAT) LTD.
19 60.3 8.74 1 3000 96 540 Err:511 Err:511 35-50 35-61
20 114.3 6.08 1 3000 21 250 Err:511 Err:511 50 20-30 25-40 30-50
Steam piping from CSDH to PRDS-II
Steam piping from PRDS-II to termial point
