Year of Introduction
60/70MW
1965
110/120MW
1966
200/210MW
1972
250MW
1991
500MW
1979
660MW
2004
63
490
60/70MW
260
96
540
110/120MW
375
139
540/540
200/210MW
690
137/156
250MW
805
156
540/540
500MW
1670
179
540/540
660MW
2245
256
540/568
800MW
2600
256
568/595
540/540
Base
0.5%
1.3%
1.6%
2.1%
3.0%
3.6%
5.0%
The
Codes
Design and Construction
ASME
BS
IBR
COMPARISON OF CODES
DESIGN PRESSURE
IBR 1950
ASME SEC.I
BS 1113
DESIGN PRESSURE
WITH PRESSURE DROP
DRUM DESIGN
PRESSURE
DRUM DESIGN
PERSSURE
DRUM DESIGN
PRESSURE
50C
50C
35C
35C
DESIGN TEMPERATUE
ALLOWANCE
RADIATION
50C
CONVECTION
39C
ECONOMISER
11C
25C
(15 + 2 Se) C
Max. 50C
WATER WALL
28C
50C
50C
TUBE THICKNESS
FORMULA tmin
FACTOR OF SAFETY
ACTUAL METAL
TEMPERATURE 371C
(MIN)
PD
--------- + *C
2f + P
PD
--------- + 0.005D
2f + P
PD
--------2f + P
Et
1.5 ,
SR
1.5
Et
1.5 ,
SR
1.5
Et
1.5 ,
SR
1.3
R
2.7
SC
R
3.5
SC
Et
1.5 ,
SR
1.0
Se - ACTUAL WALL
THICKNESS in mm.
P=DESIGN PR.
D=OUTSIDE DIA
f=ALLOWABLE STRESS
CORR. TO DESIGN
METAL TEMP.
PD
--------2f + P
R
2.7
REMARKS
R
2.4
Et = YIELD STRENGTH
R = TENSILE STRENGTH
SR = RUPTURE STRENGTH
SC = CREEP STRENGTH
FOR ASME MATERIALS ALLOWABLE STRESS CAN BE TAKEN DIRECTLY FROM ASME SEC.II PART-D
*C = CORROSION ALLOWANCE = 0.75mm FOR P 70 bar; 0 mm FOR P > 70 bar
PROPERTIES
IBR
ASME
SEC.I
BS 1113
DIN TRD
300
---
1.5
---
---
---
---
1.5
1.5
1.5
1.5
---
---
2.7
3.5
2.7
2.4
1.5
1.49
1.3
1.0
1.0
1.0
---
---
ASME
SA 106
SA 192
SA 209 - SA 210
SA 213 - SA 335
BS
3059-3602-3604
DIN
(GERMANY)
17175
VdTUV.B1
(Werkstoff-Nr.)
475C
885F
Gr.A
A192
NF A 49-213
(FRENCH)
Gr.C
Gr.A1
Gr.C
360
410
440460
490Nb
243
St.35.
8
St.45.
8
17
Mn4
19 Mn5
15
Mo3
1.030
5
1.040
5
1.048
1
1.0482
GOST
(RUSSIAN)
TY 14-3-460-75
JIS (JAPAN)
G3456 G3458
G3461 G3462
Gr.B
1.541
5
500C
930F
550C
1020F
560C
1040F
T1
P1
T2 / P2
T12/P
12
T11/P1
1
T22/P2
2
620
621
622
660
629
10Cr
Mo
9 10
1.7380
(14M
o
V63)
1.771
5
(X12Cr
MO 91)
1.7386
16
Mo5
1.542
3
15Ni
CuM
oNb
5
1.63
68
13Cr
Mo44
1.7335
20
15 XM
STPT
38
STB
35
STPT
42
STB
42
STPT
49
TU37C
TU42C
TU48C
STPA
12
STBA
12
TU52-C
TU15
D3
575C
1065F
600C
1110F
625C
1155F
T9/P9
12X
1M
F
(15XI
MI F)
STPA2
0
STBA2
0
STPA2
2
STBA2
2
STPA2
3
STBA2
3
STPA2
4
STBA2
4
STPA2
6
STBA2
6
TU15C
D
2.05
TU13C
D
4.04
TU10C
D
5.05
TU10
CD
9.10
TU Z10
CD9
This is indicative only. However, the actual maximum service temperature for various steels shall be limited as prescribed in the relevant codes.
Nominal
No.
Composition
01.
Carbon Steel
02.
Mo
03.
MATERIAL SPECIFICATION
ASME Section-I
Temp.
BS 1113
Limit C
SA209 T1
St 35.8
St 45.8
427
15 Mo3
----
482
1 Cr Mo
SA335 P12
SA213 T12
13 Cr Mo 44
BS3059 P2 S2 620
BS3604 P1 620 440
535
04.
1 Cr Mo
SA213 T11
SA335 P11
----
552
05.
2 Cr 1 Mo
SA213 T22
SA335 P22
10 Cr Mo 910
BS3059 P2 S2 622-490
BS3604 P1, 622
577
06.
9 Cr 1 Mo V
SA213 T91
SA335 P91
X 10 Cr Mo V
Nb91
-----
635
07.
12 Cr 1 Mo V
-----
X 20 Cr Mo V 121
BS3059 P2 S2 762
BS3604 P1 762
700
08.
18 Cr 8 Ni
SA213 TP304 H
-----
704
09.
18 Cr 10 Ni Cb
SA213 TP347 H
-----
704
AREA
Tube
thickness
IBR
ASME SEC.I
Dished end
thickness
Flat end
thickness
PD
PD
+ C
PR
+ 0.75
fE 0.5 P
PR
fE (1 Y) P
PDK
PR
+ 0.75
2f
d
+ C
f
CP
d
f
PD
2f + P
2f + P
PR
fE 0.5 P
2f 0.2 P
CP
PD
+0.005D
2f + P
2f + P
Shell
thickness
BS 1113
PR
fE 0.5 PE
PDK
2P
R
1+
2f
P
Cd
f
1
2f P
P
Cd
f
DESCRIPTION
IBR
ASME SEC.I
BS 1113
-----
-----
+ 15%
5%
12.5%
+ 10%
10%
+ 12.5%
10.0%
DESCRIPTION
IBR
ASME SEC.I
BS 1113
TYPE
Minimum thickness
allowed for various
tube Diameters Seamless.
Up to D32
Up to D51
D51 to D76
D76 to D89
D89 to D114
Up to D38
D38 to D51
D51 to D70
D70 to D76
D76 to D95
D95 to D102
D102 to D127
Min. - 3 mm
Max. - 6.3 mm
for Water wall
tubes
Ovality
(Deviation from
circularity)
D Max. D Min.
2.03
2.34
2.64
3.25
3.66
x 100
D
shall not exceed
Up to D32
Up to D51
D51 to D76
D76 to D102
D102 to D127
+ 10%
5%
2.41
2.67
3.05
3.43
3.81
D Min.
x
100
D
shall not be more
than
50D
2(DMax.DMin.)
1.7
2.2
2.4
2.6
3.0
3.3
3.5
Provides calculation
for wall thickness
for inside & outside
of bend as per
TRD301 Annex-2.
+ 10%
10%
+ 15%
10%
x100
DMax + DMin
20D
Wall thickness
tolerance
+ 22%
0%
Material
ASME specification
Tubes
Pipes
Drum
SA 299
Water walls,
Economizer
Carbon Steel
SA192
SA210 Gr.A1
SA210 Gr.C
SA106 Gr.B
SA106 Gr.C
SH and RH
1 Cr Mo
SA213 T11
SA335 P11
2 Cr 1 Mo
SA213 T22
SA335 P22
9 Cr 1 Mo V
SA213 T91
SA335 P91
18 Cr 8 Ni
SA213 TP304 H
18 Cr 10 Ni Cb
SA213 TP347 H
ASME Specification
Oxidation limit
Carbon Steel
SA-210 A-1/ C
454C
2-1/4 Cr-1 Mo
SA-213 T-22
593C
9 Cr-1 Mo-V
SA-213 T91
649C
18 Cr-8 Ni
SA-213 TP304H
760C
18 Cr-10 Ni-Cb
SA-213 TP347H
760C
Erosion Allowance
The leading tubes of each section
are provided with additional
thickness to withstand the erosion
Erosion shield
The top most tube of the
horizontal section are provided
with erosion shields
<B>
Operational influence
on
tube metal temperatures
Cyclic Operation
Generation of Thermal sets are reduced to a
level which can be sustained without oil
support in Boiler (~40%).
Equipments are subjected to severe thermal
fatigue.
Oil consumption during start up is avoided.
Pressure Parts
SH / RH terminal tubes are to be designed with adequate
flexibility.
Pressure part hangers / attachment are to be designed
suitably.
Dissimilar metal welds to be avoided to the extent
possible.
Suitable SH / RH material selection.
SCOPE
Cyclic loadings which are caused due to
internal pressure, on the one hand, and due to
radial temperature differentials during start-up
(heating-up) and shut-down (cooling down), on the
other hand, in the areas subjected to maximum
loading thereby.
The components subjected to pressure and
temperature the maximum local peak stresses
occur on the inside of the edges of openings or on
branches in cylindrical shells.
Additional forces
rules
in preparation).
Customer training programme
STRESS
Basis for Establishing Stress values
a) At temperature below the range where creep and
stress rupture strength govern the selection of
stresses, the maximum allowable stress value is the
lowest of the following:1) One-fourth of the specified minimum
strength at room temperature (ST).
tensile
Tensile
10)
Thermal
2)
Compressive
11)
Tangential
3)
Shear
12)
Load induced
4)
Bending
5)
Bearing
14)
Circumferential
6)
Axial
15)
Longitudinal
7)
Discontinuity
16)
Radial
8)
Membrane
17)
Normal
9)
Principal
13)
Strain induced
SIMPLATN
Y
INPUT
MATL: SA213 T22,
SA 213 T11,
SA 213 TP347
SIZE: OD63.5X10.5,
OD54X12,
OD51X11,
OD44.5X11,
OD44.5X10
RESULT:
MAX.STRESS DUE TO
SUSTAINED LOAD: 1.58 Kg/mm^2
MEDIUM TEMP
:540 DEG C
Deflected VINPLAT
shape
Y
RESULT:
MAX.STRESS DUE TO
SUSTAINED LOAD:
1.58 Kg/mm^2
SIZE:OD63.5X10.5
MEDIUM PRESSURE:189 Kg/mm^2
MEDIUM TEMP
:540 DEG C
RH OUTLET HEADER
FLOW
ROOF ELEVATION
FLOW
FLOW
EXISTING ARRANGMENT
Committed to making a better world
RH OUTLET HEADERS
FLOW
ROOF ELEVATION
FLOW
PROPOSED SAIYAMEESE
ARRANGMENT
Committed
to making a better world
FLOW
Advanced materials
in
supercritical boilers
To withstand
temperature
the
higher
steam
pressure
and
for
less
stresses
in
critical
T23
T24
Carbon
0.04 0.10
0.05 0.10
Manganese
0.30 0.60
0.10 0.60
0.30 0.70
Phosphorus (max)
0.025
0.030
0.020
Sulfur (max)
0.025
0.010
0.010
Silicon
0.500 (max)
0.500 (max)
0.15 0.45
Chromium
1.90 2.60
1.90 2.60
2.2 2.6
Molybdenum
0.87 1.13
0.05 0.30
0.90 1.10
Titanium
0.05 0.10
Vanadium (min)
0.20 0.30
0.20 0.30
Others
B
N
Al
Cb
B
N
Al
1.45 1.75
0.02 0.08
0.0005 0.006
0.030 max
0.030 max
0.0015 0.0070
0.012 max
0.020 max
120
T24
T23
100
T22
80
60
T91
40
20
0
400
450
500
550
Tem perature (Deg.C)
600
650
T92
Carbon
0.08 0.12
0.07 0.13
Manganese
0.30 0.60
0.30 0.60
Phosphorus (max)
0.020
0.020
Sulfur (max)
0.010
0.010
Silicon
0.20 0.50
0.50 max
Chromium
8.00 9.50
8.50 9.50
Molybdenum
0.85 1.05
0.30 0.60
Titanium
Vanadium (min)
0.18 0.25
0.15 0.25
Others
Cb
N
Ni
Al
0.06 0.10
0.030 0.070
0.40 max
0.04 max
W
Cb
B
N
Ni
Al
1.50 2.00
0.04 0.90
0.001 0.006
0.03 0.07
0.40 max
0.04 max
Super 304H/347HFG
Super 304H
TP347HFG
Carbon
0.04 0.10
0.10
0.06 0.10
Manganese (max)
2.00
0.8
2.00
Phosphorus (max)
0.040
0.04
Sulphur (max)
0.030
0.030
Silicon
0.75 max
0.2
0.75 max
Nickel
9.00 13.00
9.0
9.00 13.00
Chromium
17.00 20.00
18.0
17.00 20.00
Columbium + Tantalum
8 x C-1.0
Others
Nb
Cu 3.0
N 0.1
0.4
120
TP347HFG
100
80
SUPER304H
T91
60
T92
40
TP 347H
20
0
550
575
600
625
650
675
700
Contd...
Committed to making a better world
Contd...
Committed to making a better world
Future Trends
Conclusions
in