DESIGN CALCULATIONS

SECTION I

EDITION 2013

J.O. XXXXX

XXXXXX
ENG. MGR. APPROVAL

XX / XX / XXXX

TABLE OF CONTENTS
1. HEADER (PIPE)
2. CAPS
3. MAXIMUM DESIGNED STEAMING CAPACITY
4. NOZZLES N1 & N4
5. NOZZLES N2 & N3
6. PRESSURE TEST

1. HEADER (PIPE)
1.1) DATA
SHELL MATERIAL
NOMINAL DIAMETER
OUTSIDE DIAMETER
DESIGN TEMPERATURE
FACTOR y
MAXIMUM ALLOWABLE VALUE STRESS
JOINT EFFICIENCY LONGITUDINAL WELD
M. ALLOWANCE FOR THREADING AND STRUCTURAL SATABILITY
CORROSION ALLOWANCE
DESIGN PRESSURE
TOTAL LENGTH
STATIC HEAD

SA-106, GR. B, SCH 100

DN = 450
D = 457 mm
T = 500 C
y = 0.483 (PG-27.4.6)
S = 31600 kPa (TABLE 1A, SECTION II, PART D)
E = 1 (PG-27.4.1)
C = N/A (PG-27.4.3)
CA = 1.5 mm
P = 3000 kPa
LG = 1016 mm
PH = 4.288 kPa (UG-98 (a))

1.2) HEADER THICKNESS UNDER INTERNAL PRESSURE PG-27.2.2

t=

t=

PD
+C
2SE + 2yP

(3004.288 kPa)(457 mm)

= 20.77 mm
(2)(31600 kPa)(1) + (2)(0.483)(3004.288 kPa)

(20.77 mm) > 6 mm (PG-16.3)

t + CA = 20.77 mm + 1.5 mm = 22.27 mm < 25.69 mm MINIMUM WALL TICKNESS THEREFORE

SA-53- TYPE S, GR. B, SCH 100 WITH 29.36 mm of NOMINAL WALL TICKNESS SHALL BE USED.

1.3) MAWP AT 500 C (PG.27.2.2)

t = 29.36 mm*0.875 = 25.69 mm 1.5 mm = 24.19 mm (THICKNESS UNDER PRESSURE).
P=

P=

2SE (t - C)
D - 2y (t - C)

(2)(31600 kPa)(1) (24.19 mm)

= 3525.58 kPa
457 mm - (2)(0.483)(24.19 mm)

2. CAPS.
2.1) DATA
HEAD MATERIAL
NOMINAL DIAMETER
OUTSIDE DIAMETER
DESIGN TEMPERATURE
FACTOR y
MAXIMUM ALLOWABLE VALUE STRESS
JOINT EFFICIENCY LONGITUDINAL WELD
ADDITIONAL THICKNESS
CORROSION ALLOWANCE
DESIGN PRESSURE
TOTAL LENGTH
STATIC HEAD

SA-234-WPB SCH 100

DN = 450
Do = 457 mm
T = 500 C
y = 0.483 (PG-27.4.6)
S = 31600 kPa (TABLE 1A, SECTION II, PART D)
E = 1 (PG-27.4.1)
A = N/A (A.6 ASME B31.1, 2012)
CA = 1.5 mm
P = 3000 kPa
LG = 1016 mm
PH = 4.288 kPa (UG-98 (a))

2.2) CAPS THICKNESS UNDER INTERNAL PRESSURE (PG-42.1.6), (104.1.1, ASME B31.1, 2012)
tm =

tm =

PDo
+A
2(SE + Py)

(3004.288 kPa)(457 mm)

= 20.77 mm
2[(31600 kPa)(1) + (3004.288 kPa)(0.483)]

(20.77 mm) > 6 mm (PG-16.3)

t + CA = 20.77 mm + 1.5 mm = 22.27 mm < 25.69 mm MINIMUM WALL TICKNESS THEREFORE

SA-234-WPB CAP, SCH 100 WITH 29.36 mm of NOMINAL WALL TICKNESS SHALL BE USED.

2.3) MAWP AT 500 C (PG.27.2.2)

tm = 29.36 mm*0.875 = 25.69 mm 1.5 mm = 24.19 mm (THICKNESS UNDER PRESSURE).
P=

P=

2SE (tm - A)
Do - 2y (tm - A)

(2)(31600 kPa)(1) (24.19 mm)

= 3525.58 kPa
457 mm - (2)(0.483)(24.19 mm)

3. MAXIMUM DESIGNED STEAMING CAPACITY

3.1) DATA
TYPE OF FUEL TO GENERATE STEAM
HEAT OF COMBUSTION (SECTION 1, APPENDICE A, A-17)
VOLUME OF FUEL BURNED (ASSUMPTION)
DESIGN TEMPERATURE
DESIGN PRESSURE
STATIC HEAD

NATURAL GAS
H = 35700 kJ/m3
C = 250 m3/h
T = 500 C
P = 3000 kPa
PH = 4.288 kPa

3.2) WEIGHT OF STEAM GENERATED (APPENDICE A, A-12)

W=

C x H x 0.75
2558

(250 m3/h)(35700 kj/m3)(0.75)

W=
= 2616.79 kg/h
2558
MAXIMUN DESIGNED STEAMING CAPACITY WILL BE 2616.79 kg/h

4. NOZZLES N2 & N3.

4.1) DATA
NOZZLE MATERIAL
DN
OUTSIDE DIAMETER
OUTSIDE RADIUS
COUPLING CLASS
DESIGN TEMPERATURE
MAXIMUM ALLOWABLE VALUE STRESS
JOINT EFFICIENCY
CORROSION ALLOWANCE
MAWP
DESIGN PRESSURE
STATIC HEAD

SA-105, THREATED (ASME B16.11, 2011)

D = 25 (NPS 1)
Do = 44 mm (ASME B16.11, 2011)
Ro = 22 mm
3000
T = 500 C
Sn = 33600 kPa (SECTION II, PART D)
E = 1.0 (PG-27.4.1)
CA = 1.5 mm
P = 3525.58 kPa
P = 3000 kPa
PH = 4.288 kPa

4.2 NOZZLE THICKNESS PER (PG-43.2, ASME B36.10, 2004, SCH STD)
THICKNESS, SHALL NOT BE LESS THAN THE MINIMUM REQUIRED THICKNESS OF A SEAMLESS SHELL OR
HEAD AND THE MINIMUN WALL THICKNESS OF STANDARD WALL PIPE LISTED IN ASME B36.10M, 2004.
MINIMUM OF (B16.10, HEAD OR SHELL)
MINIMUM OF (3.38 mm, 20.77 mm)
t = 3.38 mm
3.38 mm + 1.5 mm = 4.58 mm (INCLUDING CORROSION ALLOWANCE)
4.58 < 5.556 mm = (6.35*0.875) (NPS 1 SCH 160, TABLE 7, B16.11, 2011) MINIMUM WALL TICKNESS THEREFORE
SA-105, THREADED COUPLING CLASS 3000, B16.11 WITH 6.35 mm of NOMINAL WALL TICKNESS SHALL
BE USED.
* NO CALCULATION TO DETERMINATE THE AVAILABILITY OF COMPENSATION REQUIRED PER (PG-32.1.4,
PG-32.1.5)

d SHALL BE SMALLER THAN a and b PG-32.1.4

a)
b)

dmax = 8.08 [Dt (1 k)] /

THE SMALLER OF [(1/4)*Di] OR 60 mm

WHERE:
k=

k=

PDo
1.82St

(3525.58 kPa)(457 mm)

= 0.954
1.82(31600 kPa)(29.36 mm)

VALIDATING:
K < 0.990;

0.954 < 0.990

a)

dmax = 8.08 [(457 mm)(29.36 mm) (1 0.954)]

b)

[(1/4)*398.28 mm] = 99.57 mm OR 60 mm => 60 mm

d = 23.7 mm (COUPLING CLASS 3000, DN 25)

23.7 mm < 60 mm NO REINFORCEMENT IS REQUIRED
* EXCEPTION STRENGHT OF REINFORCEMENT (PG-37.4 (a))
4.3 MINIMUM REQUIREMENTS FOR ATTACHMENT WELDS (PG-39.2, PW-15, PW-16.6 (c))
FIGURE PW-16.1 (W-1)
HEADER THICKNESS (tH) = 29.36 mm
COUPLING THICKNESS (tn) = 6.35 mm
tmin = SMALLER OF 19 mm OR 29.36 mm OR 6.35 mm = 6.35 mm
tc = NOT LESS THAN THE SMALLER OF 6 mm OR 0.7tmin = 4.445 mm
WELD LEG = tc / SEN 45 = 4.445/0.7071 = 6.286 mm
SIZE PURPOSED IS 7 mm
STRENGHT CALCULATIONS ARE NOT REQUIRED PER PW-15.1.6

= 68.794 mm

5. NOZZLES N1 & N4
5.1 DATA
NOZZLE MATERIAL
DN
OUTSIDE DIAMETER
OUTSIDE RADIUS
COUPLING CLASS
DESIGN TEMPERATURE
MAXIMUM ALLOWABLE VALUE STRESS
JOINT EFFICIENCY
CORROSION ALLOWANCE
DESIGN PRESSURE
MAWP
STATIC HEAD

SA-105 THREATED (ASME B16.11, 2011)

50 (NPS 2)
D = 76 mm (ASME B36.10, 2004)
Ro = 38 mm
3000
T = 500 C
Sn = 33600 kPa (SECTION II, PART D)
E = 1.0 (PG-27.4.1)
CA = 1.5 mm
P = 3000 kPa
P = 3525.58 kPa
PH = 4.288 kPa

5.2 NOZZLE THICKNESS PER (PG-43.2, ASME B36.10, 2004, SCH STD)
THICKNESS, SHALL NOT BE LESS THAN THE MINIMUM REQUIRED THICKNESS OF A SEAMLESS SHELL OR
HEAD AND THE MINIMUN WALL THICKNESS OF STANDARD WALL PIPE LISTED IN ASME B36.10M, 2004.
MINIMUM OF (B16.10, HEAD OR SHELL)
MINIMUM OF (3.38 mm, 20.77 mm)
t = 3.91 mm
3.91 mm + 1.5 mm = 5.41 mm (INCLUDING CORROSION ALLOWANCE)
5.41 < 7.648 mm = (8.74*0.875) (NPS 1 SCH 160, TABLE 7, B16.11, 2011) MINIMUM WALL TICKNESS THEREFORE
SA-105, THREADED COUPLING CLASS 3000, B16.11 WITH 8.74 mm of NOMINAL WALL TICKNESS SHALL
BE USED.
* NO CALCULATION TO DETERMINATE THE AVAILABILITY OF COMPENSATION REQUIRED PER (PG-32.1.4,
PG-32.1.5)

d SHALL BE SMALLER THAN a and b PG-32.1.4

a)
b)

dmax = 8.08 [Dt (1 k)] /

THE SMALLER OF [(1/4)*Di] OR 60 mm

WHERE:
k=

k=

PD
1.82St

(3525.58 kPa)(457 mm)

= 0.954
1.82(31600 kPa)(29.36 mm)

a)

dmax = 8.08 [(457 mm)(29.36 mm) (1 0.954)]

b)

[(1/4)*398.28 mm] = 99.57 mm OR 60 mm => 60 mm

d = 45.82 mm (COUPLING CLASS 3000, DN 50)

* EXCEPTION STRENGHT OF REINFORCEMENT (PG-37.4 (a))
5.3 MINIMUM REQUIREMENTS FOR ATTACHMENT WELDS (PG-39.2, PW-15, PW-16.6 (c))
FIGURE PW-16.1 (W-1)
HEADER THICKNESS (tH) = 29.36 mm
COUPLING THICKNESS (tn) = 8.74 mm
tmin = SMALLER OF 19 mm OR 29.36 mm OR 8.74 mm = 8.74 mm
tc = NOT LESS THAN THE SMALLER OF 6 mm OR 0.7tmin = 6 mm OR 6.118 mm
WELD LEG = tc / SEN 45 = 6/0.7071 = 8.485 mm
SIZE PURPOSED IS 9 mm
STRENGHT CALCULATIONS ARE NOT REQUIRED PER PW-15.1.6

= 68.794 mm

6. PRESSURE TEST (PG-99.1)

MAXIMUM ALLOWABLE WORKING PRESSURE:

P = 3525.5 kPa

PRESSURE TEST = 1.5 MAWP

PRESSURE TEST = (1.5)(3525.58 kPa) = 5288.37 kPa
MINIMUM WATERTEMPERATURE FOR PRESSURE TEST:

T = 20 C