This sheet isthe cover sheet for al subsequent sheels [a brief Gescription of the revision shall be entered on |document number on the cover sheet and equaly ap, having the same document number. The Revision index and the cover sheet, The last revision index shall be accled to the ples to all sheets having that cocument number. The new Irevision index is shown on all sheets. [STATUS OF REVISION |(KASEZ) KANDLA KU" Regd off: EPC CENTRE / [Ci46-3, TTC, MIDG AREA, THANE. BELAPUR ROAD, FFIL JOB NO:- {3 FUCNACE Faerica ITCH, GUJARAT. WORKS : PAWANA VILLAGE, NAVLMUMBAI-400705 Document No. = 201313 201313-M-D05 — ee ES a Rens] bas Naps [oa Rass Too or are ars Wik areata neers 1 BRE | 06.07.13, Ng 09.07.13) ae S.No. DESCRIPTION Nos of i__|DESIGN CALCULATIONS for EVAPORATOR 1 1 to. 23 REFeReNCE SHEETS CLIENT |LAMBION ENERGY SYSTEMS PROJECT BOILER SYSTEM Dacoment Ti DESIGN CALCULATIONS for EVAPORATOR.1 Page No Rev. No.FURNACE FABRICA (INDIA) LTD. Stress Calculations MAKER'S Nr, : 203813 [CLIENT LAMBION ENERGY SYSTEMS ‘Sheet 2 of 23 [EQUIPMENT NAME EVAPORATOR. Doc No. 203313-M-D05, EQUIPMENT.NO, 203313 [Revision No. i INDEX of CONTENTS Si. Nis Description Sheet Nrs [Cover Sheet index of Contents Revision Status Revision List Design Data Hydrostatic Test Pressure Calculations N ounone Tubes under Internal Pressure : PG - 27.2.1: EVAP.1 8 _|Inlet Header under Internal Pressure With Tube Connections : EVAP.1 }>Input date for Headers ; Internal Pressure Input data for Tube Connections : intemal Pressure Results : > MAWP & Check of Test Pressure for Headers > Results for Headers under Internal Pressure : PG-27.2.2 > Results for Tube Conn.'s on Header and Check for Ligament Efficiency 3 [Outlet Headers under internal Pressure With Tube Connections : EVAP.1 >Input data for Headers : internal Pressure Input data for Tube Connections : Internal Pressure Results : > MAWP & Check of Test Pressure for Headers > Results for Headers under Internal Pressure : PG-27.2.2 > Results for Tube Conn.'s on Header and Check for Ligament Efficiency 10 End Cover Thk. Cals : Header Pipe 125 DN 7109 10to 14 15019 20 to 23FURNACE FABRICA (INDIA) LTD. Stress Calculations MAKER'S Nr, : 20133 (CLIENT, LAMBION ENERGY SYSTEMS Shoot 3 of 23 EQUIPMENT NAME EVAPORATOR.1 Doe No. 201343-M-Dos EQUIPMENT NO. 201313, Revision No. a REVISION STATUS Page |Rev.0 |Rev.01 |Rev.02 |Rev.03 [Date | Page |Rev.00|Rev.01 |Rev.0z|Rev.03 |oate xe ee x 2 x 3 x 4 x 5 x 6 x 7 x 8 x 9 x 10 x i x 12 x 13 x 14 x 15 x 16 x x x x x x x xFURNACE FABRICA (INDIA) LTD. Stress Calculations MAKER'S Nr, : 20133 UPDATED (CLIENT. I LAMBION ENERGY SYSTEMS. [Sheet 4 of 23, EQUIPMENT NAME EVAPORATOR.1. Doc No. 201313-M-D05 [EQUIPMENT NO. 201313 Revision No, 1 REVISION LIST SI. Nes DESCRIPTION of REVISION ‘SHEETS REVISED REMARKS. A HEADERS SIZES UPDATED. DESIGN DATA peetero.FURNACE FABRICA (INDIA) LTD. Stress Calculations MAKER'S Nr. : 207313 [CENT TAMBION ENERGY SYSTEMS [sheet 5 of 23 EQUIPMENT NAME EVAPORATOR. Doc No. 201313.M-D05 EQUIPMENT NO. 201313, [Revision No. 1 DESIGN DATA Units Equipment Tag Nr. - 201813 Equipment Name 2 EVAPORATOR.A Tube Side Code of Construction - ASME SEC.1 2010 EDITION , 2011 ADDENDA Operating Pressure MPa 44/449 ke/em2 g JOperating Temperature Deg ¢| 257.5 Operating Fluid Steam Design Pressure Mal 5.1 /52 kg/em2g Design Temperature Dez c| Tubes = 280 ; I Header = 265 ; OL Header = 265 Heat Transfer Area 664 \Corrosion Allowance mm| Headers & Tubes = 1.0mm Radiography 10 % Spot Tube to Tube ; 100 % for Headers Hydto Test Pressure MPa 7.65 / 78 kg/cm 2g Uoint Efficiency Factor > 1.0 Inspection By : AL-TUV,FURNACE FABRICA (INDIA) LTD. Stress Calculations [MAKER'S Nr. : 201313 [CUENT. TAMBION ENERGY SYSTEMS Sheet 6 of 23, EQUIPMENT NAME EVAPORATOR. Doc No. 201313-M-D05 EQUIPMENT.NO. 201313 Revision No. 1 Hydrostatic Test Pressure Calculations Design Pressure / MAWP 0 84 MPag Hydrostatic Test Pressure 1.5 x Design Pressure 7.65 MPag“TDRES PPI, Gylindrical shell ace. to ASME, sect, Edition 2010, Adcenda 2011a PRO 5 A D - IBM Deutschland Gnbd Release : 04.02.00 (01/2013) ate: 407.2013 17:51:zin Sheet: 1/ 3 order + WHRBOTLERSYSTEM No.: 201333 Drawing : GAOFEYAFORATORI No.: 201343-m-o12 Detaset : TUBES Ne.; 202313-m-D05 TUBES : INTERNAL PRESSURE Name: Dep. Tele: Protocol of input Determination of test pressure ASME 1 Naximum inside diameter incl, tolerafice of wall thickness yes Consideration of tolerance at nozzle reinforcement yes Load condi tions Design tenperature (Sc) 7 (°F) 280.0 Design pressure - internal, (Mea) / (psi) 5.1 WA.W.P. according to stamping (MPa) / (psi) Test pressure - internal (Mea) 7 (psa) Test: Safety factor against yield strength o.9 Geometry of cylinder Fosition number ruRES Besignation ‘TUBES : INT. PR. Product stendard dimensions ASHE B36. 10 (2008) tolerances SA-530 (20ita) Diameter inside / outside (mn) 42.2 Nominal-Pipe-gize Gn) Wall thickness |inc.allow.) given (nm) 3,56 minimum / xaximum (ne) Minimum corroded wall thickness ace. to code (nm) Wall thickness tolerance (mia) / (3) Corrosion allowance inside / outside (am) 1.0 0.0 Length of shall (nm) i488 Type of component, formula Heat absorb, tube (76-27) Efficiency fastor & Number of nozzles / number of nipple ficlds Compensation calculation Description of nozzle position absolute Material data Cylindrical Shei] Pos.-No. TUBES EROBAD material no. 153 Material designation / Type, Grade / Class sa-106 /3 / Free material input no Casting quality factor ace. to P6-25 1.0 Creep range: Steel group ace. to EG-26 Sh HO4PET Cylindrical shell acc. to ASME, Sect. © Edition 2010, Addenda 2011a PROBA D- 18M Deutschland Gmbk Release : 04.02.00 (01/2013) pate: 4.07.2013 17:51:2th Sheet: 2/ order + WHRAOTTERSYsren We. 201319 Drawing : GAOFEVAPORATORL No-: 201313-N-912 Uataset : TUBES News 201313-n-p05 ‘TUBES : INTERNAL PRESSURE Name Dep. Tel: Results calculation with Determination of test pressura ASME I Maximum inside diameter incl. tolerance ef wall thickness yes Load case Int.pressure Design pressure 5.100 MPa Allowable working pressure 21,151 Mpa Min. test pressure ambient temperature 7.650 MPa Allowable test pressure 20.412 Mpa Dasign temperature 280.00 *¢ Allowable temperature 462.68 °C Number of nozzles or openings 0 of ligament areas ° Maximum allowed dianeter for openings which do not require reinforcement acc.to PG-32.1.2 max 38.47 ne Heaults Cylindrical shell Positions Number: TUBES Designation: TURES : INT. PR. ‘Type of component: Abs. tube Galeul. forma = (27.2.1) Dimension series evandard (2004) Tolerances standard (2011a) Diameter inside/outside di/do {42,20 om Diameter net inside/outside d0i/d00 37.97 / 42.20 mm fall thickness - actual + — {s40,s7D) 3.56 mm Wall thickness - net 20 2.12 om Wall thickness - required w/o allowances = without openings x0 (PG-27.2.1) 1,10 na seferr.to i trid linrornativ) 1105 mm Wall thickness given t 3.58 nm Minus tolerance ce 12.508 9.04 mm Corrosion allowence inside/outside cai/eaz 1.00 / 9.00 mm Factor acc. PG-27.4, Note 4 e 0.00 mn Length of cylindrical shell L 1488.00 mm Weight s 5.05. kg Volume inside v 1.44 anaCylindrical shell ace, to AgME, se Edition 2010, addenda 2011a PR OB A D ~ IBM Deutschland Gnbit 04.02.00 (01/2013) Date: 4,07.2013 17:51:21n Sheets 3/ 3 ‘TUBES No.: 201313-M-pos: Material : PROBAD-No. : 133 Product form + Snls.2p. Cylinder : Specif. No.: sA-206 Type, Grade: B ——— class, cona Quality Forritic Notes G10, 81,71 Design tenperat. | Anbient temperat. Allowable stress 118.00 Ea 128,00 mea Mininum tensile streagth Nea. 415.00 MPa Mininum yield strength 192.80 Mpa 240.00 MPa Average creep rupture strength MPa. Yes End of results s**TNLET HEADER FETE Gylindeical shell acc. to ASME, ‘Sect. 1 Edition 2010, Addenda 2011a PROBA D ~ TAM Beurschland GnbE Release + 04.02.00 (01/2033) Date: 4.07.2013 17:51:29n Sheet: 1/ 5 Order : ‘WHREOTEERSYsvEM No.: 201313 Drawing : GAQFEVAPORATORL No.: 201313-n-o12 Dataset : INLETEEADER No.: 201313-N-D05 INLET HEADER-: INTERNAL PRESSURE Name Dep. Tels: Protocol of input Determination of test pressure Waximum inside diameter incl. tolerance of wall thickness Consideration “of tolerance at nozzle reinforeenent oad conditions Gesign temperature ("cy / (°P) 265.0 Besign pressure - internal (ea) / (psi) 5.1 M.A.W.P. according to stamping (MPa), / (psi) Test pressure - internal (weal / (psi) Test: Safety factor against yield strength a9 Geometry of cyl inde: Position number ™ BEA Designation INLET HEADER Product standard dinenstons ASME B36.10 (2004) tolerances 8A-530 (20314) Diameter inside / outside (ra) 142.3 Nominal~Pipe-Size (in) Wall thickness (inc.allow.) given (nm) 9.59 miaimon / maximum (mun) Minimum corroded wall thickness ace. to code (mn) Wall thickness tolerance (rm) / (8) Gorrosion allowance inside / outsi¢e (nm) 1.0 0.0 Allowance for threading and structural stability C (nm) 0.0 Length of shell (nm) 3300 ‘Type Of component, toxmila Pipe (20-27) Efficiency factor 5 Number of nozzles / number of nipple fields 1 Compensaticn calculation Description of nozzle position absolute Material data Cylindrical Shell Pos.-No. TH HEA . 153 Material designation / Type, Grade / Class sA-106 /3 / Free material input 6 Casting quality factor ace, to P¢-25 1.0 Creep range: Steel group acc. to PG-26 Shi- Jo+tolyFEIL Cylindrical shell acc. to ASME, Sect. r Edition 2010, Addenda 2011a 2 RO BAD - 18M Deutschland Gnbi Release : 04.02.00 (01/2013) ee: 4.07.2013 17:51:29 Sheet: 2/ Dataset ; INESTHEADER Now: 201313-¥-D05, General nipple dates 1 Position nunber ‘TUBE Cow Designation TUBE com. *s Type cf component, formula Heat absorb. tube (26-27) Type of connection sez on, fully welded Nipple field position Nipple 1: Distance to refor.point a1 (mm) 100.0 Circumferential position phi () 0.0 Nipple field configuration Regular rectangular pattern Longitudinel pitch pL (mm) 100.0 Number of nipples in longitudinal dicection Al 31 Circumferential pitch pe ra) Number of rows in circumferential direction ne 1 Longitudinal weld penetrates opening no Geometry Nipple POS.-No. TUBE Product standard dimensions ASME 36.10 (2008) tolerances SA-530 (20i1a) Diareter inside / outside (nm) 42.2 Nominal-Pipe-size (Gn) Drill hole diameter (mm) Wall thickness aiven (me) 3.56 minimum / maximum (0) Mininum corroded wall thickness acc. to code (no) Wall thickness tolerance (may 7 (8) Corrosion eliowance inside / outside (nm) 1.0 0.0 Nipple projection inside / outside (nm) 100.0 Material deta Nipple Pos.-No, TUBE CoN PROBAD material no. 193 Waterial designation / Type, Grade / Class SADE /B v ree material input no. Casting quality factor ace. to P6-25 1.0 Creep range: Steal group acc. to PC-26FEIL Cylindrical shell ace. to ASME, Sect. I Edition 2010, Addenda 20i1a PROBA D ~ TBM Deutschland Grol! Release : 04.02.00 (01/2013) bate: 407.2013 17:51:29) Sheet: 3/ Order: _WHRBOTLERSysTEM 201313 Drawing GAOFEVAFORATORI 201313-m-o12 Dataset : INLETHEADER No. 201313-N-Do5 INLET HEADER : INTERNAL PRESSURE ‘Name Dep. tel.: Results calculation with Determination of test pressure : Maximum inside diameter incl. tolerance of wall thickness yee Consideration of tolerance at nozzle reinforcement yes Load case Int -pressure Design pressure 5.100 Mpa Allowable working pressure 7.933 MPa ~ Main body without openings 22.783 Mpa Min. vest pressure anbient temperature 7.650 Mea Allowable tost pressure 141521 Mpa ~ Main body without openings 23.410 Mpa Design temperature 265.00 °c Allowable temperature 423.96 °C Number of nozales oz cponings 0 ef liganent areas 1 Ligament efficiency 0.620 Maximum slowed dianeter for openings which do net require reinforcement acc.to PG-32.1.2 dmax 77.21 am Results Cylindrical Shell Positions Number: IN HEA Designation: INLET HEADER Type of component: Pipe Calcul. forma : (27.2.2) Dimension series standard ASME 836.10 (2004) Tolerances standard 38-330 (2011a) Dianeter insids/outside di/de 4 141.30 mm Diameter net inside/outside d0i/dde 126.62 / 141.30 mm Wall thickness - actual t — (880,x5) 2.53 mm fall thickness - net +0 7134 an Wall thickness - required w/o allowances = without openings trO (PG-27.2.2) 3.00 nm weforr.to, di tri0 (PG-27.2.2) 2.61 mn ~ inclusive ligement efficiency trf |pG-27.2.2) 4.79 nm veferr.to di tril 4.60 nw Wall thickness given = 9.83 mm Minus tolerance cS 2.50% 1.19 mn Corrosion allowance inside/outside cai/eas 1.00 / 0.00 mn Factor acc. PC-27.4, Note 3 € 0.00 mm Factor acc. PG-27.4, Note 6 y 0.400FFT Cylindrical shell acc. to ASME, Sact. T Edition 2010, Addenda 20114 FRO SAD - IBM Deutschland GnbE Release : 04.02.00 (01/2013) Date Dataset : INLETHEADER Length of cylindrical sh Weight Volume inside Mat rial : PROBRD-No, : 153 Product form sms. 2p. Cylinder + Speci. Wo.: SA-106 Type, Grade: 5 Class, Cond Quality : Ferritic Notes 2 610/si,71 Design temperat. | Anbient tenperat. Allowable stress 118,00 Mpa 118.00 Mpa Minimun tensile strength Mpa 415.00 MBA Minimum yield strength 195.60 Mea 240.00 Mba Average Creep rupture strength Mpa Nipple field: No./ Position-No.| 1 / TURE coN 1 Designation TUBE CoMN. 18 Type of Component, formule Abs’ tube (27.2.1) Type of Connection set-on, fully welded Configuration of nipple field |Regular rectangula te patton Nipple 1:Dist.to ref.pt.1i (mm)| 100.00 Circumfer.pos. phi (deg) 0.00 Bongit. direct. Pitch pl (mm)| 100,00 Nunber nl 34 Cixcumf-direct. Pitch pe (dey) Nonber ne 1 Material Nipple (tube) — PROBAD-No./ Prod.forn | is3_/ Smis.Pp. / Specif.-No./Type,Grade| Sh-106 /B K Class,Cond./ Quality fgerritic ‘ Notes Gi0,s1,71 All, stress design tenp.(MPa)| 118.00 anbient tenp.(Mea)| 118.00 tensile str. design tenp. (Mea) ambient tanp.(MPa)} 415.00 Yield stren. design temp. (MPa)| 195.60 mbiont temp. (MPa)| 240.00 Mean rupture strength (mea)PPT, Cylindrical she1l acc. to asME, sect. 1 Edition 2010, addenda 20112 ER OB AD - IBM Deutschland Gmbil Feeeece” = 2402.00 (01/2013) Data: -4.07.2013 17:51:29n Sheet: $/ § Dataset : INIETHEADER No.: 201313-m-D05 Nipple field: No./ Position-No.| 1 / TUBE CON / Dimension series standard ASME. 836,10 (2004 Tolerances standard SR-530 (20212) Diameter inside dni (mm) Outside dno (nm) 42.20 relevant ¢ (nm) 37.87 Wall thickness Wipple = actual th (nm)|g 3.56 s40,s7D = net ce) 2.12 = required w/o-allow. trn (im) 1210 (27.2.1) ref.to dni tent (mm) 3,05 (infor.) Minus tolerance etn (rm) 0.44 etn (8) 12.50 Corrosion inside cani (iam) 1.00 outside cana (nm) 0.00 Factor a.PG-27.4,Note 4 (mm) 0.09 Nipple-projection outside (mn}| 100.00 inside (mm) Allowable working pressure (yPa) 14.152 Allowable test pressure (MPa| 20.412 Ligament Ef€iciensy 6 Pitch ~ longitudinal 5 0.620 Pitch - circumferential £ *4* End of results. ***OUTLET HEADER FETE, Cylindeical shell acc, to ASHE, Set. 1 Edition 2010, Addenda 20114 BRO BAD = ISM Deutschland Gnbx Release : 04.02.00 (01/2013) pate: 4.07.2013 17:51:38 Sheet: 1/ § order WHRROTLERSYsTEM Nos: 201313 Drawing : GAOFEVAPORATORI Wo. 201313-n-o12 Dataset . OUTLETHEADER Nes: 201313-x-D05 OUTLETHEADER: INTERNAL PRESSURE Name: Dep. Tels: Protecel of input Determination of test pressre Maximum inside diameter incl. colerance of wall thickness Consideration of tolerance at nozzle reinforcement. oad conditions Design temperature oy 7 (8) Design pressure - internal (wea) / (psi) M.AW.P. according to stamping (MPa) / (psi) Test pressure - intert (ea) / (psd) Test: Safety factor against yield strength 08 Geometry of cylinder Position number ot HEA Designation OUTLET HEADER Product standard dinensions ASME 836.10 (2004) tolerances SA-530 (2oila) Dianeter inside / outside (in) 141.3 Noninal-Pipe-size (an) Wall thickness (inc.allow.) given [mm) 9.53 minimum / maximum (nm) Minimum corroded wall thickness acc. to code (reo) Wall thicknoss tolezancs (am) / (3) Corrosion allowance inside / outside Ira) 2.0 0.0 Allowance for threading and structural stability ¢ (nm) 0.0 Length of shell \m) 360 Type of component, cormita (26-27) Efficiency factor & Nanber of nozzles / number of nipple fields 1 Compensation calculation Description of nozzle position absolute Material data cylindrical sheli Pos.-No. OL # PROBAD naterial no. 253 Material designation / Type, Grade / Class sA-106 /B ’ free material input ne Casting quality factor ace. to PG-25 1.0 Grecp rance: Steel group acc. to PG-26