Title: ASME CODE CALCULATIONS FOR 1X365 TPH BOILER

Project: M/s Jacobs Netherlands BV A/c Schoonebeek Oil Field Redevelopment Project
Boiler No.:- PH0351 Specification No. PF5-HR-CS-35356
Page No. 1 of 22

SR NO.
1 SRT project name Schoonebeek OilField Redevelopment

2 SRT project number 64989-12

SRT purchase order
3 64989/M20001
number
SRT requisition number
4 64989-12/M.02/0001 & 00
and issue
SRT document category
5 K01-0001
(Doc. Cat.)
ASME CALCULATIONS FOR DEAERATOR BANK
6 Document title
MODULE
7 Issue number 0

8 Issue date

9 Equipment name 365 TPH,HRSG on Fr.9E.GT

Equipment ID number /
10 A9101
Tag number
Client/End User
11
document number

! !"

# $ $ $ % "

" '( $

& $

! )
Title: ASME CODE CALCULATIONS FOR 1X365 TPH BOILER
Project: M/s Jacobs Netherlands BV A/c Schoonebeek Oil Field Redevelopment Project
Boiler No.:- PH0351 Specification No. PF5-HR-CS-35356
Page No. 2 of 22

CONTENTS
Sr.No. Description Page No.
Front Page 1
Contents 2
Revision control sheet 3
1 General 4
2 Design data 5
3 Material and allowable stresses 6
4 Ligament efficiency calculation for Deaerator bank headers 7
5 Ligament efficiency calculation for LP Downcomer 8
6 Header thickness requirement calculations 9
7 Hole compensation calculations for headers 10
8 Tube stub thickness requirement calculation 11
9 Hole compensation calculations for boiler bank headers 12-17
10 Endcover thickness requirement calculation 18
11 Boiler bank tube thickness calculations 19
12 Nozzle attachment weld size calculations 20
13 Nozzle weld strength calculations 20
14 Membrane stresses during hydro. Test 21-22
15 PWHT & RT reqmt. 22
Title: ASME CODE CALCULATIONS FOR 1X365 TPH BOILER
Project: M/s Jacobs Netherlands BV A/c Schoonebeek Oil Field Redevelopment Project
Boiler No.:- PH0351 Specification No. PF5-HR-CS-35356
Page No. 3 of 22

REVISION CONTROL SHEET

Page No. Rev.0 Rev.1 Rev.2 Rev.3

1 First Issue
2 First Issue
3 First Issue
4 First Issue
5 First Issue
6 First Issue
7 First Issue
8 First Issue
9 First Issue
10 First Issue
11 First Issue
12 First Issue
13 First Issue
14 First Issue
15 First Issue

Reviewed & Approved for page no. 1 of 22 to 22 of 22

Rev.No. 0
Prepared By V.A
Checked By SRB
Approved By ARP
Date 6-Jan-09
Title: ASME CODE CALCULATIONS FOR 1X365 TPH BOILER
Project: M/s Jacobs Netherlands BV A/c Schoonebeek Oil Field Redevelopment Project
Boiler No.:- PH0351 Specification No. PF5-HR-CS-35356
Page No. 4 of 22
REFERENCE
1) GENERAL

Equipment Name : HRSG

DUAL PRESSURE (HP+LP INTEGRAL DEAERATOR)
NATURAL CIRCULATION SINGLE DRUM SUPPLEMANTARY FIRED
HEAT RECOVERY STEAM GENERATOR

Name of the Customer: M/s Jacobs Netherlands BV

A/c Schoonebeek Oil Field Redevelopment Project

Reference Documents : Order Transfer Form

Customer's Purchase Order
Customers Specifications
Deaerator Bank Module Assy Drg.(RHS): PF5-0HR-08906
Deaerator Bank Module Assy Drg(LHS): PF5-0HR-08910
Top & Bottom HDR.for RHS Deaerator mod.(Hdr. No.37 to 50):PF5-0HR-08907
Top & Bottom HDR.for LHS Deaerator mod.(Hdr. No.37 to 50):PF5-0HR-08911
Assy & Det.of Downcomer Hdrs. For RHS Dear.Bank:PF5-2HR-45227
Assy & Det.of Downcomer Hdrs. For LHS Dear.Bank:PF5-2HR-45230
Code of Design & Construction:
ASME Section I, Edition 2007

Type of construction : Welded

Loading : Boiler is subjected to internal pressure and hydrostatic PG-22

head only.

Corrosion Allowance : For Headers 2 mm

For Tubes 2 mm
Notes :
1. No credit is taken of the weld material in any of nozzle opening compensation calculations.
2. Rounding-off of the figures used in calculations is done to max. 3 digits.
3. Tube nipples are not used as stand pipes on any other equipments than Headers.
Title: ASME CODE CALCULATIONS FOR 1X365 TPH BOILER
Project: M/s Jacobs Netherlands BV A/c Schoonebeek Oil Field Redevelopment Project
Boiler No.:- PH0351 Specification No. PF5-HR-CS-35356
Page No. 5 of 22
REFERENCE
2) DESIGN DATA:

1. Maximum Allowable Working Pressure :

M.A.W.P. = 108.778 PSIG 0.750 MPa(g) 7.5 Bar(g)

2. Design Pressure for Boiler :

Design Pressure P ] (M.A.W.P. + max.Hydrostatic Head in the boiler acting on any of the PG-22.1
boiler component (except LP Drum since it is at the topmost elevation).
In design calculations P as per above formula will be used in various formulae as given in
code to calculate required thicknesses of pressure part components. Calculated thicknesses
then will be compared with actual component thk. for suitability check.
Max Hydrostatic Head = 0.214 MPa(g) [for 24400 mm of WC]

P = 0.750 + 0.214 = 0.964 MPa(g)

3. Design Metal Temperature

Design Metal Temperature = Max. of mean metal temperature but not less than
saturation temperature at Design Pressure
Temperature at Saturation Pressure = 334.4 DEG.F 168 DEG.C
(Sat. pressure = 109.778 PSIA)
Design Metal Temp. for saturated surface
other than tubes & Headers = 392 DEG.F 200 DEG.C

Design Metal Temp. for RH side Deaerator 392 DEG.F 200 DEG.C

Design Metal Temperature for Tubes :

PG-27.4
As all are heat absorbing tubes Design Metal Temperature shall be 392 DEG.F Note 2

Design Metal Temp. for Deaerator Bank

Tubes = 392 DEG.F 200 DEG.C

Design Metal Temp. for RH side Deaerator

Downcomer to Deaerator Bank Tubes = 392 DEG.F 200 DEG.C
Title: ASME CODE CALCULATIONS FOR 1X365 TPH BOILER
Project: M/s Jacobs Netherlands BV A/c Schoonebeek Oil Field Redevelopment Project
Boiler No.:- PH0351 Specification No. PF5-HR-CS-35356
Page No. 6 of 22

3) MATERIAL AND ALLOWABLE STRESSES:

All material used in Pressure Part are as per ASME Section II, A material specifications and are PG-5 to
selected as per PG-5 to PG-9 of ASME Secton I PG-9

Allowable Stresses taken from ASME Sec.II D at Design Metal Temperatures [DMT] specified in
the table as shown below.

As per Table 1A of ASME Sec.II, D

Component Description Material DMT [ 0 C] Allow. Stress [MPa]

Deaerator Bank Headers SA 106 Gr.B 200 117.903
Pipe Stubs On Deaerator Bank
SA 106 Gr.B 200 117.903
Headers
End Covers for Deaerator Bank
SA 105 200 137.900
Headers
Deaerator Bank Tubes SA 210 Gr. A1 200 117.903

Component Description Material DMT [ 0 C] Allow. Stress [MPa]

LP Downcomer Pipes SA 106 Gr.B 200 117.903
Cl. Stubs On LP Downcomer SA 106 Gr.B 200 117.903
Pipe Stubs On LP Downcomer SA 106 Gr.B 200 117.903
End Covers for LP Downcomer and
SA 105 200 137.900
Cleaning Stubs
Connecting Pipes SA 210 Gr.A1 200 117.903
Title: ASME CODE CALCULATIONS FOR 1X365 TPH BOILER
Project: M/s Jacobs Netherlands BV A/c Schoonebeek Oil Field Redevelopment Project
Boiler No.:- PH0351 Specification No. PF5-HR-CS-35356
Page No. 7 of 22

4) LIGAMENT EFFICIENCY CALCULATIONS FOR DEAERATOR BANK HEADERS

Equipment Data:

Header Outside Diameter [D] = 219.10 MM

Header Thickness = 18.26 MM

Thk. with 12.5% -ve tol. [ t ] = 15.978 MM

Allowable Stress [S] = 117.903 MPa(g)

Ligament Efficiency for panel tube holes (equal pitch) PG-52.2

Drilling Pattern -1

Equi.Tube Hole Dia.= 38.6 MM(FOR LIGAMENT)

Long. Pitch [p] = 90.000 MM

Diagonal Pitch [p'] = 86.992 MM

Longitudinal Ligament Efficiency =

E= [p - d ] / p
p
E = [ 90 - 38.6 ] / 90

E = 0.571

Diagonal Ligament Efficiency =

p'
p'/p = 0.967

From fig. PG-52.1,

As the point falls above the curve of equal efficiency for the diagonal
and longitudinal ligaments, The Governing Ligament Efficiency is = 0.571 Fig. PG-52.1

(REF.B&W MANUAL NO.56(1)-2U-2A3-69/4-27-90)

LIGAMENT EFFICIENCY CALCULATIONS.
EQUIVALENT HOLE DIA d= (d1+d2)/2 = 38.6 mm
(IN OUR CASE, d1 = d2 = 38.6 mm)
Title: ASME CODE CALCULATIONS FOR 1X365 TPH BOILER
Project: M/s Jacobs Netherlands BV A/c Schoonebeek Oil Field Redevelopment Project
Boiler No.:- PH0351 Specification No. PF5-HR-CS-35356
Page No. 8 of 22

5) LIGAMENT EFFICIENCY CALCULATIONS FOR LP DOWNCOMER

Equipment Data:

Header Outside Diameter [D] = 323.900 MM

Header Thickness = 25.400 MM

Thk. with 12.5% -ve tol. [ t ] = 22.225 MM

Allowable Stress [S] = 117.903 MPa(g)

Ligament Efficiency for panel tube holes (equal pitch) PG-52.2

Drilling Pattern -1

Equi.Tube Hole Dia.= (168.3 - 2*7.11)

Hence d = 154.080 MM

Long. Pitch [p] = 450.000 MM

Circum. Pitch [p'] = 276.400 MM (For 105 Deg.)

Longitudinal Ligament Efficiency =

E= [p - d ] / p
p
E = [ 450 - 154.08 ] / 450

E = 0.658
p'
Circumferential Ligament Efficiency =

E = [ p' - d ] / p'

E = [ 276.4 - 154.08 ] / 276.4

E = 0.443 Circum. Efficiency 0.885

Diagonal Ligament Efficiency =

p''
p''/p = 0.530

The Governing Ligament Efficiency is = 0.530 Fig. PG-52.1

Title: ASME CODE CALCULATIONS FOR 1X365 TPH BOILER
Project: M/s Jacobs Netherlands BV A/c Schoonebeek Oil Field Redevelopment Project
Boiler No.:- PH0351 Specification No. PF5-HR-CS-35356
Page No. 9 of 22

6) HEADER THICKNESS REQUIREMENT CALCULATIONS:

Minimum Required Header Thickness =

t = [ P D / {2S E + 2yP} ] + C PG-27.2.2

Where,
P = Header Design Pressure

D = Header Outside Diameter

S = Allowable Stress

E = Ligament Efficiency

y= 0.4 For ferritic steel below 900 DEG.F PG-27.4

Note 6
C= 0 Allowance for Structural Stability, threading etc. PG-27.4
Note 3

Corr.allow P D S E Reqd. Thk. Provided

Sr. No. Item ance incl.corr.all
(MM) MPa(g) (MM) MPa(g) ' t ' (MM) Thk. (MM)

Deaerator
1 2 0.964 219.1 117.903 0.571 3.559 15.978
Bank Headers

2 LP Downcomer 2 0.964 323.9 117.903 0.530 4.483 22.225

LP Downcomer
3 2 0.964 60.3 117.903 1.000 2.246 7.648
Drain Stub

Since the reqd thickness for Headers as calculated above

is less than provided thickness, the thickness of Headers are adequate.

Minimum Unpierced Header Thickness tmin (by substituting E=1.0 in above formula):

Sr. No. Item P D S E tmin

MPa(g) (MM) MPa(g) (MM)

1 Deaerator Bank Headers 0.964 219.100 117.903 1.000 0.893

2 LP Downcomer 0.964 323.900 117.903 1.000 1.320

Title: ASME CODE CALCULATIONS FOR 1X365 TPH BOILER
Project: M/s Jacobs Netherlands BV A/c Schoonebeek Oil Field Redevelopment Project
Boiler No.:- PH0351 Specification No. PF5-HR-CS-35356
Page No. 10 of 22

7) HOLE COMPENSATION CALCULATIONS FOR HEADERS: PG-32

Maximum Permissible Dia. Of Opening =

1/3
d = 8.08 [ D t ( 1 - K ) ] FIG.PG-32

Where,

D = Header Outside Diameter

t = Header Minimum Thickness

K = ( P D ) / ( 1.82 x S x t ) PG-32.1.2

P = Header Design Pressure

S = Allowable Stress

Hence by substitution

D t P S K d
Sr. No. Item
(MM) (MM) MPa(g) MPa(g) (MM)

1 Deaerator Bank Headers 219.100 15.978 0.964 117.903 0.062 120.113

2 LP Downcomer 323.900 22.225 0.964 117.903 0.065 152.532

Since maximum hole size on Deaerator Bank Headers [ which is 154.08 MM] for Riser Stubs PG
and I/C Pipe Stubs is Greater than above calculated diameter 'd', 32.1.3.2
Compensation calculation is required

Since maximum hole size on LP Downcomer [ which is 154.08 MM] for I/C Pipe Stubs
is Greater than above calculated diameter 'd',
Compensation calculation is required
Title: ASME CODE CALCULATIONS FOR 1X365 TPH BOILER
Project: M/s Jacobs Netherlands BV A/c Schoonebeek Oil Field Redevelopment Project
Boiler No.:- PH0351 Specification No. PF5-HR-CS-35356
Page No. 11 of 22

8) PIPE STUB THICKNESS REQUIREMENT CALCULATION:

Equipment Data:

Pipe Description : Deaerator Bank Riser & I/C Pipes

Design Pressure [P] = 0.964 Mpa(g)

Pipe Outside Diameter [D] = 168.300 MM

Pipe nominal thickness = 7.110 MM

Thk. with 12.5% -ve tol. [ t ] = 6.221 MM

Allowable Stress [S] = 117.903 Mpa(g)

C = 0 MM PG-27.4
Note 4
Pipe Thickness Requirement Calculation :

t = (PD /[2SE+ 2yP]) + C PG-27.2.1

Hence by substitution,

t = ( 0.964 * 168.3 / [ 2 * 117.903 * 1+ 2 * 0.4 * 0.964 ] ) + 0

t = 0.686 MM

t reqd.= 0.686+2 mm corrosion allowance

= 2.686 MM

The above calculated thickness is less than minimum provided [ 6.221 mm] thickness.
Hence thickness provided is adequate.
Title: ASME CODE CALCULATIONS FOR 1X365 TPH BOILER
Project: M/s Jacobs Netherlands BV A/c Schoonebeek Oil Field Redevelopment Project
Boiler No.:- PH0351 Specification No. PF5-HR-CS-35356
Page No. 12 of 22

9) HOLE COMPENSATION CALCULATION FOR DEAERATOR BANK HEADER:

Total cross section area in a given plane for which compensation is required:

A = d x tr x F PG-33.2.1

Area requirement :

Where
d= 154.1 MM

tr = 0.893 MM

F= 1 PG-33.2

tn= 6.221 MM

A = 154.08 x 0.893 x 1

A= 137.560 SQ. MM
Title: ASME CODE CALCULATIONS FOR 1X365 TPH BOILER
Project: M/s Jacobs Netherlands BV A/c Schoonebeek Oil Field Redevelopment Project
Boiler No.:- PH0351 Specification No. PF5-HR-CS-35356
Page No. 13 of 22

DEAERATOR BANK HEADER HOLE COMPENSATION CALCULATIONS :

Total cross section area available:

Area available [A1] from Shell is larger of the areas given below: PG-36.4.1

A1 = d x [ t - Ftr ] and A1 = 2 x [t+tn] x [t - F tr ]

Where
Thickness of Header [t] = 15.978 MM

F = 1 Fig.PG-33

Required Header thk. [tr] = 0.893 MM

Dia in plane under consideration [d] = 154.08 MM

Nominal Thk of Nozzle [ tn ] = 6.2 MM

Hence by substitution
A1 = d x [ t- Ftr ] = 2324.253 SQ. MM

A1 = 2 x [t+tn] x [t - F tr ] = 669.724 SQ. MM

Hence compensation area available from Shell. [ A1 ] = 2324.253 SQ. MM

Area available [A2] from Nozzle on Hole d1 is smaller of the following PG-36.4.1

A2 = 2x [ tn - trn ] x[ 2.5xtxfr1] Here instead of '2.5t' actual nozzle out side =1290.85 MM>2.5t
and Hence 2.5t MM is used in calculation.
A2 = 2x[ tn - trn ] [ 2.5xtn + te]xfr1 Here instead of '2.5tn' actual nozzle out side =1290.85 MM>2.5tn
and Hence 2.5tn MM is used in calculation.
A3 = 0
Title: ASME CODE CALCULATIONS FOR 1X365 TPH BOILER
Project: M/s Jacobs Netherlands BV A/c Schoonebeek Oil Field Redevelopment Project
Boiler No.:- PH0351 Specification No. PF5-HR-CS-35356
Page No. 14 of 22

DEAERATOR BANK HEADER HOLE COMPENSATION CALCULATIONS :

Where
Allowable stress in Nozzle mat.[Sn] = 117.903 MPa(g)

Allowable stress in Shell mat.[Sv] = 117.903 MPa(g)

Ratio of Sn/Sv =[fr1] = 1.000

Thickness of Header [t] = 15.978 MM

.
Thickness of Nozzle [tn] = 6.22 MM
.
Reqd. seamless Nozzle thk[trn] = 2.686 MM

Thk. Of reinforcment Pad [te] = 0.000 MM [No external Pad]

Actual projection Outside Header = 154.000 MM

Actual projection Inside Header. h = 0.000 MM

Hence by substitution
A2 = 2x [ tn - trn ] x[ 2.5xtxfr1] = 282.439 SQ. MM

A2 = 2x[tn - trn][ 2.5xtn +te]xfr1 = 109.975 SQ. MM

A2 = 109.975 SQ. MM

Area of Nozzle Projecting Inward [A3] =

A3 = 0 = 0.000 SQ. MM

Compensation area available from nozzle [ A2 ] = 109.975 SQ. MM

Compensation area available from nozzle [ A3 ] = 0.000 SQ. MM

Total area available from Shell and Nozzle = A1 + A2 + A3

Area available = 2324.253 + 109.975 + 0 = 2434.228 SQ. MM

As compensation area available [ 2434.228 SQ. MM ] is greater than

the area required [ 137.56 SQ. MM ], the openings on Header
are adequately compensated.
Title: ASME CODE CALCULATIONS FOR 1X365 TPH BOILER
Project: M/s Jacobs Netherlands BV A/c Schoonebeek Oil Field Redevelopment Project
Boiler No.:- PH0351 Specification No. PF5-HR-CS-35356
Page No. 15 of 22

9) HOLE COMPENSATION CALCULATION FOR LP DOWNCOMER:

Total cross section area in a given plane for which compensation is required:

A = d x tr x F PG-33.2.1

Area requirement :

Where
d= 154.1 MM

tr = 1.320 MM

F= 1 PG-33.2

tn= 6.221 MM

A = 154.08 x 1.32 x 1

A= 203.358 SQ. MM
Title: ASME CODE CALCULATIONS FOR 1X365 TPH BOILER
Project: M/s Jacobs Netherlands BV A/c Schoonebeek Oil Field Redevelopment Project
Boiler No.:- PH0351 Specification No. PF5-HR-CS-35356
Page No. 16 of 22

LP DOWNCOMER HEADER HOLE COMPENSATION CALCULATIONS :

Total cross section area available:

Area available [A1] from Shell is larger of the areas given below: PG-36.4.1

A1 = d x [ t - Ftr ] and A1 = 2 x [t+tn] x [t - F tr ]

Where
Thickness of Header [t] = 22.225 MM

F = 1 Fig.PG-33

Required Header thk. [tr] = 1.320 MM

Dia in plane under consideration [d] = 154.08 MM

Nominal Thk of Nozzle [ tn ] = 6.2 MM

Hence by substitution
A1 = d x [ t- Ftr ] = 3221.070 SQ. MM

A1 = 2 x [t+tn] x [t - F tr ] = 1189.348 SQ. MM

Hence compensation area available from Shell. [ A1 ] = 3221.070 SQ. MM

Area available [A2] from Nozzle on Hole d1 is smaller of the following PG-36.4.1

A2 = 2x [ tn - trn ] x[ 2.5xtxfr1] Here instead of '2.5t' actual nozzle out side =1290.85 MM>2.5t
and Hence 2.5t MM is used in calculation.
A2 = 2x[ tn - trn ] [ 2.5xtn + te]xfr1 Here instead of '2.5tn' actual nozzle out side =1290.85 MM>2.5tn
and Hence 2.5tn MM is used in calculation.
A3 = 0
Title: ASME CODE CALCULATIONS FOR 1X365 TPH BOILER
Project: M/s Jacobs Netherlands BV A/c Schoonebeek Oil Field Redevelopment Project
Boiler No.:- PH0351 Specification No. PF5-HR-CS-35356
Page No. 17 of 22

DEAERATOR BANK HEADER HOLE COMPENSATION CALCULATIONS :

Where
Allowable stress in Nozzle mat.[Sn] = 117.903 MPa(g)

Allowable stress in Shell mat.[Sv] = 117.903 MPa(g)

Ratio of Sn/Sv =[fr1] = 1.000

Thickness of Header [t] = 22.225 MM

.
Thickness of Nozzle [tn] = 6.22 MM
.
Reqd. seamless Nozzle thk[trn] = 2.686 MM

Thk. Of reinforcment Pad [te] = 0.000 MM [No external Pad]

Actual projection Outside Header = 200.000 MM

Actual projection Inside Header. h = 0.000 MM

Hence by substitution
A2 = 2x [ tn - trn ] x[ 2.5xtxfr1] = 392.878 SQ. MM

A2 = 2x[tn - trn][ 2.5xtn +te]xfr1 = 109.975 SQ. MM

A2 = 109.975 SQ. MM

Area of Nozzle Projecting Inward [A3] =

A3 = 2x tn x fr1x h = 0.000 SQ. MM

Compensation area available from nozzle [ A2 ] = 109.975 SQ. MM

Compensation area available from nozzle [ A3 ] = 0.000 SQ. MM

Total area available from Shell and Nozzle = A1 + A2 + A3

Area available = 3221.07 + 109.975 + 0 = 3331.045 SQ. MM

As compensation area available [ 3331.045 SQ. MM ] is greater than

the area required [ 203.358 SQ. MM ], the openings on Header
are adequately compensated.
Title: ASME CODE CALCULATIONS FOR 1X365 TPH BOILER
Project: M/s Jacobs Netherlands BV A/c Schoonebeek Oil Field Redevelopment Project
Boiler No.:- PH0351 Specification No. PF5-HR-CS-35356
Page No. 18 of 22
10) ENDCOVER THICKNESS REQUIREMENT CALCULATIONS:

Minimum thk of flat unstayed circular head = PG-31.3.2

t = d CP / S

Where,
d = Diameter or short span ( = O.D. - 2 * min. hdr. thk.)

C = Max. of ' 0.33m ' and ' 0.20 ' ts = Actual Provided Hdr. Thickness

m = tr / ts P = Design Pressure

tr = Required Header Thickness S = Allowable Stress

Hence by substitution,

For End Covers of 200 DN Deaerator Bank Headers

d ts tr m C P S Min. Reqd. Provided End

End Cover Cover Thk. ' t '
Thk. ' t ' (MM)
(MM) (MM) (MM) MPa(g) MPa(g) (MM)
187.145 15.978 0.893 0.056 0.200 0.964 137.900 6.998 40.000

For End Covers of 300 DN HP Saturated Supply

d ts tr m C P S Min. Reqd. Provided End

End Cover Cover Thk. ' t '
Thk. ' t ' (MM)
(MM) (MM) (MM) MPa(g) MPa(g) (MM)
279.450 22.225 1.320 0.059 0.200 0.964 137.900 10.449 56.000

For End Covers of 50 DN HP Saturated Supply Drain Stubs

Since the required thickness of End Cover as calculated above is less than
provided thickness, the thickness of End Cover is adequate.
Title: ASME CODE CALCULATIONS FOR 1X365 TPH BOILER
Project: M/s Jacobs Netherlands BV A/c Schoonebeek Oil Field Redevelopment Project
Boiler No.:- PH0351 Specification No. PF5-HR-CS-35356
Page No. 19 of 22

11) DEAERATOR BANK TUBE THICKNESS CALCULATIONS:

Equipment Data:

Tube Description : Deaerator Bank Tubes

Design Pressure [P] = 0.964 MPa(g)

Tube Outside Diameter [D] = 38.100 MM

Tube nominal thickness = 2.700 MM

Bending radius [R] = 0.000 MM

Tube thinning due to bending = 0.000 % For R/D = 0.000 REFER

ANNEX.-1
Tube thk. after thinning [t] = 2.700 MM

Allowable Stress [S] = 117.903 MPa(g)

e = 0 MM PG-27.4
Note 4
Tube Thickness Requirement Calculation :

t = ( P D / [ 2 S + P ] ) + 0.005 D + e PG-27.2.1

Hence by substitution,

t = ( 0.964 * 38.1 / [ 2 * 117.903 + 0.964 ] ) + ( 0.005 * 38.1 ) + 0

t = 0.346 MM

t reqd.= 0.346+2 mm corrosion allowance

= 2.346 MM

The above calculated thickness is less than minimum provided [ 2.7 MM] thickness.
Hence thickness provided is adequate.
ANNEXURE - 1

Chart of tube/pipe wall thining due to bending

25

20
% Thinning

15

10

0
0 1 2 3 4 5
R/D Ratio
Title: ASME CODE CALCULATIONS FOR 1X365 TPH BOILER
Project: M/s Jacobs Netherlands BV A/c Schoonebeek Oil Field Redevelopment Project
Boiler No.:- PH0351 Specification No. PF5-HR-CS-35356
Page No. 21 of 22

15) MEMBRANE STRESSES DEVELOPED DURING HYDROSTATIC TEST

Membrane Stresses in ----- Deaerator Bank LP Downcomer

Headers

M.A.W.P. [P] = 0.964 MPa(g) 0.964 MPa(g)

Hydrostatic Test Pressure = 1.446 MPa(g) 1.446 MPa(g) PG-99.1

Yield Stress for Header Material = 240.000 MPa(g) 240.000 MPa(g)

( 330 C - At Hydrotest Condition)

90% Yield Stress [S`] = 216.000 MPa(g) 216.000 MPa(g)

Header Outside Diameter [D] = 219.100 MM 323.900 MM

Header Thickness [t] = 15.978 MM 22.225 MM

Ligament Efficiency [E] = 0.571 0.530

y= 0.4 For ferritic steel below 900 DEG.F PG-27.4

Note 6
C= 0 Allowance for Structural Stability, threading etc.

Required Header Thickness

t = [ P D / {2S E +2y P} ] + C PG-27.2.2

Solving we get

S=[PD/{2(t-C)E}] + [(yP)/E]

Therefore [S] = 18.4 MPa(g) 21.0 MPa(g)

As S calculated above is < S` [90% of yield stress], primary membrane stresses

are within acceptable limit.
Title: ASME CODE CALCULATIONS FOR 1X365 TPH BOILER
Project: M/s Jacobs Netherlands BV A/c Schoonebeek Oil Field Redevelopment Project
Boiler No.:- PH0351 Specification No. PF5-HR-CS-35356
Page No. 22 of 22

MEMBRANE STRESSES DEVELOPED DURING HYDROSTATIC TEST

Membrane Stresses in ----- Deaerator Bank Tubes

M.A.W.P. [P] = 0.964 MPa(g)

Hydrostatic Test Pressure = 1.446 MPa(g) PG-99.1

Yield Stress for Tube Material = 255.000 MPa(g)

( 330 C - At Hydrotest Condition)

90% Yield Stress [S`] = 229.500 MPa(g)

Tube Outside Diameter [D] = 38.100 MM

Tube Thickness [t] = 2.700 MM

e= 0 MM PG-27.4
Note 4
Required Tube Thickness

t = ( P D / [ 2 S + P ] ) + 0.005 D + e PG-27.2.1

Solving we get

S = [ P D / 2 ( t - 0.005 D ) ] - ( P / 2 )

Therefore [S] = 10.254 MPa(g)

As S calculated above is < S` [90% of yield stress], primary membrane stresses

are within acceptable limit.

PWHT & RT REQUIREMENTS FOR HEADERS & TUBES

PWHT for Headers Required PW-39

Min. holding time =1.0 Hr 40 Min
Min holding temp. =1100 Deg. F (595 Deg. C)

PWHT for Downcomers Required PW-39

Min. holding time =2.0 Hr 15 Min
Min holding temp. =1100 Deg. F (595 Deg. C)

PWHT for Tubes Not required as per Table PW-39, Note 1-a

RT for Headers required- 100 % as per Table PW 11 PW-11

RT for tubes required- 100 % as per Table PW 11
 ASME CODE CALCULATIONS FOR 1X365 TPH BOILER
Title:
Project: M/s Jacobs Netherlands BV A/c Schoonebeek Oil Field Redevelopment Project
Boiler No.:- PH0351 Specification No. PF5-HR-CS-35356
Page No. 20 of 22

NOZZLE ATTACHMENT WELD SIZE CALCULATIONS:

DEAERATOR BANK HEADERS:

Weld size requirement Weld sizes provided

Nozzle Nozzle conn Detail Thk. of Thk. of tc (smaller of t1 (smaller of t2 (smaller of t1 + t2 tf (fillet weld tc t1 t2 t1+t2 Remarks
tmin.(smaller
desc. type (as per at Hdr. nozzle of 19MM,t & tn 0.25" & 0.25" & 0.25" & (1.25 tmin) leg size) (0.7tf) (0.7tf) (0.7tf)
fig.) (t) wall (tn) 0.7tmin) 0.7tmin) 0.7tmin)

150 O.D Weld sizes

PW-16.1(a) HA1 15.978 7.110 7.110 4.977 ----- ----- ----- 8.000 5.600 ---- ---- ----
Tubes. are adequate.

150 O.D Weld sizes

PW-16.1(a) HA1 22.225 7.110 7.110 4.977 ----- ----- ----- 8.000 5.600 ---- ---- ----
Tubes. are adequate.

80 O.D Weld sizes

PW-16.1(a) HA2 22.225 11.130 11.130 6.000 ----- ----- ----- 9.000 6.300 ---- ---- ----
Tubes. are adequate.

50 DN Weld sizes
PW-16.1(z) HB1 22.225 8.740 8.740 6.000 ----- ----- ----- 9.000 6.300 ---- ---- ----
Conn. are adequate.

HT /
38.1 od Weld sizes
- 15.978 2.700 2.700 1.890 ----- ----- ----- 6.700 4.690 ---- ---- ----
Tubes are adequate.
HT1

NOZZLE WELD STRENGTH CALCULATIONS:

Weld strength calculations are not required for weld configurations shown in figure PW-16.1, sketches (a) & (z) as per clause PW-15.1.6
Title: ASME CODE CALCULATIONS FOR 1X365 TPH BOILER
Project: M/s Jacobs Netherlands BV A/c Schoonebeek Oil Field Redevelopment Project
Boiler No.:- PH0351 Specification No. PF5-HR-CS-35356
Page No. of

Rev.No. 0
Prepared By
Checked By
Approved By
Date