M/S DALMIA CEMENT (BHARAT) LTD

HEADER THICKNESS CALCULATION

1X120 TPH CFBC BOILER

Header & Piping Thickness Calculation

max Minimum
Outside Design Design Allowable Min. thick Ligament
Sl. Thickness No of working thickness % Margin Allowance
Description diameter Pressure Temp Material Stress available Efficiency
No (mm) headers temp required Available mm
(mm) (kg/cm^2) Deg. C (kg/m^2) (mm) (%)
deg.C (mm)

CONVECTION CAGE

FRONT/REAR ROOF
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
HDR(CG)

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

REAR WALL BOTTOM

5 273 31.75 1 122 354 393 SA 106 Gr.B 952.00 23.67 27.78 0.6500 17.36 4.11
HDR(CG)

SIDE WALL(L&R)Bottom HDR

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
(CG)

SIDE WALL(L&R)TOP HDR

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
(CG)

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

PREPARED BY: APPROVED BY:

JRY JRK
 M/S DALMIA CEMENT LTD
HEADER SIZING CALCULATION
1X120 TPH CFBC BOILER

Header Sizing
Sl. Description Outsid Header Inside Fluid flow Operating Operating Specific Actual Velocity Velocity
No. e dia thk. dia (kg/hr) pressure temp. volume velocity m/s/mmID m/s/mmID
( mm) (mm) m (ksc(a)) (deg. C) (m3/kg) (m/s) (max limit)

CONVECTION CAGE
FRONT/REAR ROOF 0.24770 133900 107.5 354 Err:511 Err:511 Err:511 0.1200
1 HDR(CG) 323.9 38.1
0.2095 133900 107.5 354 Err:511 Err:511 Err:511 0.1200
Front Intermediate
2 HDR(CG) 273 31.75
0.1244 33475 107.5 354 Err:511 Err:511 Err:511 0.1200
3 Interconnecting HDR(CG) 168.3 21.95
FRONT BOTTOM 0.2095 133900 107.5 354 Err:511 Err:511 Err:511 0.1200
4 HDR(CG) 273 31.75
REAR WALL BOTTOM 0.2095 133900 107.5 354 Err:511 Err:511 Err:511 0.1200
5 HDR(CG) 273 31.75
SIDE WALL(L&R)Bottom 0.16194 66950 107.5 354 Err:511 Err:511 Err:511 0.1500
6 HDR (CG) 219.1 28.58
SIDE WALL(L&R)TOP 0.16194 66950 107.5 354 Err:511 Err:511 Err:511 0.1200
7 HDR (CG) 219.1 28.58

SUPERHEATER
0.25404 140000 105 421.00 Err:511 Err:511 Err:511 0.1200
8 PSH outlet header 323.9 34.93
0.1968 70000 103.5 395.00 Err:511 Err:511 Err:511 0.1500
9 wing wall I/L HDR 273 38.1
0.19044 70000 100.00 454.00 Err:511 Err:511 Err:511 0.1200
10 wing wall 0/L HDR 273 41.28
11 SSH inlet header 323.9 31.75 0.2604 140000 99.00 440.00 Err:511 Err:511 Err:511 0.1500
0.25404 140000 96.00 545 Err:511 Err:511 Err:511 0.1200
12 SSH outlet header 323.9 34.93

PREPARED BY : APRROVED BY:

JRA JRK
 M/S DALMIA CEMENT LTD
HEADER SIZING CALCULATION
1X120 TPH CFBC BOILER

CROSS OVER DUCT

0.2222 70000 111 318 Err:511 Err:511 Err:511 0.1200
13 COD FRONT header 273 25.4
0.2222 70000 111 318 Err:511 Err:511 Err:511 0.1200
14 COD REAR header 273 25.4
0.2222 70000 111 318 Err:511 Err:511 Err:511 0.1200
15 COD SIDE header 273 25.4
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

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 1.5-2.4
39 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

PREPARED BY : APRROVED BY:

JRA JRK
 M/S BALASORE ALLOYS LTD
HEADER THICKNESS CALCULATION
2 X 140 TPH CFBC BOILER

Piping Thickness Calculation

Minimum
Outside No of Design Design Allowable Min. thick
Thickness thickness % Margin
Sl.No Description diameter headers Pressure Temp Material Stress available
(mm) required Available
(mm) per boiler (kg/cm^2) Deg. C (kg/m^2) (mm)
(mm)

406.4 9.53 1 6.4 160

1 Feed water piping from deaerator to
BFP suction SA 106 Gr B 1202.00 1.83 8.34 355.90
Feed water piping from BFP header to 273 9.27 1 6.4 160
2 BFP SA 106 Gr B 1202.00 1.47 8.11 449.97
Feed water piping from BFP to BFP 219.1 20.62 1 160 160
3
header SA 106 Gr B 1202.00 14.42 18.04 25.10
Feed water piping from BFP outlet to 273.1 25.4 1 160 160
4 HP heater-I SA 106 Gr B 1202.00 17.79 22.23 24.91
Feed water piping from HP heater-I to 219.1 15.09 1 160 160
5
economiser SA 106 Gr B 1202.00 14.42 13.20 -8.45
42.2 4.85 1 160 160
6 Spray Piping to boiler attemperator-1 SA 106 Gr B 1202.00 3.38 4.24 25.43
114.3 13.49 1 96 540
7
steam line from CSDH to PRDS - 1 SA 335 P 22 520.50 10.40 11.80 13.49
steam line from PRDS-1 to 355.6 9.53 1 7.00 250
8 ejector/gland sealing SA 106 Gr B 1202.00 1.78 8.34 367.83
219.1 15.09 1 117.00 277
9
Feed water piping from eco to drum SA 106 Gr.B 1202.00 10.92 13.20 20.93
219.1 15.09 1 122 318
10 Drum to COD SA 106 Gr.B 1202.00 11.33 13.20 16.52
11 219.1 15.09 1 122 325
COD to cage SA 106 Gr.B 1202.00 11.33 13.20 16.52
273 21.44 1 122 421
12 PSH to DSH-1 SA 355 P11 1018.00 16.18 18.76 15.92
13 273 21.44 1 122 395
DSH-1 to WWSH SH SA 355 P11 1043.00 15.83 18.76 18.48
323.9 25.4 1 122 454
14 WWSH to Final SH SA 355 P11 984.00 19.66 22.23 13.06
323.9 25.4 1 122 555
18 Main steam pipe upto MSSV SA 355 P91 1045.00 18.61 22.23 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
 M/S BALASORE ALLOYS LTD
HEADER THICKNESS CALCULATION
2 X 140 TPH CFBC BOILER

558.8 88.9 1 105.5 540

CSDH SA 355 P22 520.50 71.42 77.79 8.91
60.3 8.74 1 97 540
19
Steam piping from CSDH to PRDS-II SA 355 P22 520.50 5.89 7.65 29.84
Steam piping from PRDS-II to termial 114.3 6.08 1 21 250
20 point SA106 Gr B 1202.00 1.74 5.32 205.78
 Piping Sizing

Operatin Allowable
Outside Pipe Fluid Operating Specific Actual Allowable
No of g Velocity
Sl. No. Description dia thk. flow temp. volume velocity Velocity
Lines pressure m/s(AS PER
( mm) (mm) (kg/hr) (deg. C) (m3/kg) (m/s) m/s
ksc(a) Tender)

Feed water piping from

1 406.4 9.53 1 280000 6.4 160 Err:511 Err:511 0.6-0.9 0.6-0.9
deaerator to BFP suction

Feed water piping from BFP

2 273 9.27 1 140000 6.4 160 Err:511 Err:511 0.6-0.9 1.8-2.4
header to BFP

Feed water piping from BFP to

3 219.1 20.62 1 140000 160 160 Err:511 Err:511 1.5-2.4 1.8-2.4
BFP header
Feed water piping from BFP
4 273.1 25.4 1 280000 160 160 Err:511 Err:511 1.5-2.4 1.8-2.4
outlet to HP heater-I
Feed water piping from HP
5 219.1 15.09 1 140000 160 160 Err:511 Err:511 3.00
heater-I to economiser
Spray Piping to boiler
6 42.2 4.85 1 7000 160 160 Err:511 Err:511 3.00
attemperator-1
steam line from CSDH to
7 114.3 13.49 1 15000 96 540 Err:511 Err:511 35-50
PRDS - 1
steam line from PRDS-1 to
8 355.6 9.53 1 15000 6.00 250 Err:511 Err:511 28-43
ejector/gland sealing
Feed water piping from eco to
9 219.1 15.09 1 140000 116.00 277 Err:511 Err:511 2-3
drum
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

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
Main steam from MSSV to
0 406.4 50.8 1 280000 97 540.00 Err:511 Err:511 50 50-77
CSDH
0 CSDH 558.8 88.9 1 280000 97 540.00 Err:511 Err:511 50 50-78

M/s DALMIA CEMENT (BHARAT) LTD.

 Steam piping from CSDH to
19 60.3 8.74 1 3000 96 540 Err:511 Err:511 35-50 35-61
PRDS-II
Steam piping from PRDS-II to
20 114.3 6.08 1 3000 21 250 Err:511 Err:511 50 20-30 25-
termial point

M/s DALMIA CEMENT (BHARAT) LTD.