DESIGN AND THERMAL STRESS ANALYSIS OF HOT REHEAT

LINE FOR 500MW COAL BASED POWER STATION

A THESIS
SUBMITTED IN PARTIAL FULFILLMENT OF THE
REQUIREMENTS FOR THE A WARD OF THE DEGREE
OF

MASTER OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
(THERMAL) ' ^ V ^ \ V - 0 • ^ / ^ " V ^

BY
VINEET KUMAR
(ROLL NO. 209475)

UNDER THE SUPERVISION OF

Dr. GULSHAN SACHDEVA

ASSISTANT PROFESSOR

DEPARTMENT OF MECHANICAL ENGINEERING

NATIONAL INSTITUTE OF TECHNOLOGY
(Institute of National Importance)
KURUKSHETRA-136119, INDIA
 DECLARATION

I, VINEET KUMAR a student of M.Tech (Thermal) of Mechanical Engineering Department

at National Institute of Technology, Kurukshetra, declare that I ownfiiUresponsibility for the
information, results, conclusion, etc provided in this thesis entitled "DESIGN AND
THERMAL STRESS ANALYSIS OF HOT REHEAT LINE FOR 500MW COAL
BASED POWER STATION" submitted to National Institute of Technology, Kurukshetra,
Haryana for the award of M.Tech (Thermal) degree. I have completely taken care in
acknowledging the contribution of others in this academic w6rk. I further declare that in case
of any violation of intellectual property rights or copyrights found at any stage, I as the
candidate will be solely responsible for the same.

Date: lj//S./io/i
^{kv-^
Place: Kurukshetra VINEET KUMAR
 CERTIFICATE

This is to certify that the thesis report entitled "DESIGN AND THERMAL STRESS
ANALYSIS OF HOT REHEAT LINE FOR 500MW COAL BASED POWER
STATION", submitted by Mr. VINEET KUMAR, in partial fulfillment of the requirement
for the award of the degree of Master of Technology in Thermal Engineering to National
Institute of Technology, Kurukshetra, Haryana, India, is a record of student's own work
carried out under my supervision and guidance. To the best of my knowledge, this thesis has
not been submitted in part or full elsewhere in any other University or Institution for the
award of any degree. It is further understood that by this certificate the undersigned do not
endorse or approve any statement made, opinion expressed or conclusion drawn there in but
approve the thesis only for the purpose for which it is submitted.

Dr. GULMIAN SACHDEVA

Assistant Professor
Deptt. of Mechanical Engineering
National Institute of Technology
Kurukshetra-136119
 ACKNOWLEDGEMENTS

The thesis has been made possible by bountifiil mercy and grace of God. It is my great
pleasure to express my sincere thanks to all the magnanimous persons who rendered their full
support to my work directly or indirectly.

I would like to express my special and sincere gratitude to my supervisor Dr. Gulshan
Sachdeva, Assistant Professor, Mechanical Engineering Department, National Institute
of Technology, Kurukshetra, who has constantly given valuable suggestions and
encouragement apart from providing useful material and facilities for completion of this
work. Without his inspiration and generous guidance the work would have not been
successful. I have learned many things from him pertaining to dissertation and which would
lead to success in my future career.

I express my special gratitude to Dr. S.S. Rattan, Chairman, Mechanical Engineering

Department, NIT Kurukshetra for all possible support in using various facilities of the
department for this work.

I would like to extend my deep appreciation to my Father Sh. Hari Ram Khandelwal, Mother
Smt. Om Wati Devi, Sisters Anita and Sangeeta for their love and moral support. I am
thankful to all my close friends especially to Mr. Shiv Kumar Sharma (M.Tech. from NITK),
Ravi Kant Kush (M.Tech. from NITK), Manoj, Ravi Kant Ravi who were always present
there to help me during my thesis work.

(VINEET KUMAR)
 ABSTRACT

Piping is very important for any process industry. It is the piping which connects all the
equipments to make a plant able to carry out the process. Thus, piping forms the arteries,
veins, and capillaries of the plant, taking the process fluid from one location to another.
While doing this it has to encounter high pressures, high temperatures and sometimes ultra
low pressures and temperatures as well. Pipes are routed in all the nooks and comers carrying
the process fluid and thus it has to take many bends. Further, if pipe is subjected to higher
operating temperature, in order to take care of expansion, loops are required to be introduced
to make the piping system flexible thus preventing overstressing during operation.

The force due to pipe loading, and thermal effects must not pass on to equipment
beyond the allowable limit. I have used CAESAR II for carrying out stress analysis. Firstly,
isometric drawing based on the pipe routing prepared. Then based on the isometric input a 3D
model is developed in CAESAR 11 environment. After that the boundary conditions, load
data, restraints, support data are specified as input in Caesar II and analysis is done.

Commercially available Piping flexibility analysis software called "CAESAR 11"

helps the designer to apply various loading conditions to the piping model, which otherwise
would have been a tedious and a cumbersome job. The designer gets real time behaviour of
the piping model in CAESAR II and he can better analyze the exact practical situation. He
can decide the location of supports, expansion loops, restraints, expansion bellows etc. Thus a
really well performed analysis helps in avoiding catastrophes due to pipe failure during load
conditions.
 CONTENTS

Description Page No.

Declaration 1
Certificate 2
Acknowledgement 3
Abstract 4
Contents 5-7
List Of Figures 8
List of Table 9
Nomenclature 10-12

CHAPTER 1 INTRODUCTION 13-17

1.1 Power Plant Piping System 13
1.2 Classification of Piping System 13
1.2.1 High Pressure Piping or Power Cycle Piping 13
1.2.2 Low pressure piping or station piping 14
1.3 Design Considerations for Power Cycle Piping 14
1.3.1 General Considerations 14
1.3.2 Design Pressure 15
1.3.3 Design Temperature 15
1.3.4 Design flow 15
1.4 Material allowable stress 16

CHAPTER 2 LITERATURE REVIEW 18-20

CHAPTER 3 METHOD OF CALCULATION OF VARIOUS DESIGN 21-31

PARAMETERS FOR PIPING DESIGN
3.1 Material Selection 21
3.2 Pipe Sizing 22
3.2.1 Considerations that have an Impact on Velocity 22
Selection
 3.2.2 Recommended Range of Velocities 23
3.2.3 Calculation of inside diameters 24
3.2.4 Pipe Wall Thickness Calculation 24
3.3 Thermal Insulation for Pipes 25
3.3.1 Method of calculation 26
3.3.2 Additional heat losses due to components in a 27
pipeline
3.3.3 Surface temperature and coefficients 27
3.4 Pipe Routing (Layout) 28
3.5 Stress Analysis 29
3.5.1 Stresses due to Sustained Loads 29
3.5.2 Thermal Expansion Stress Range 29
3.5.3 Importanceof Stress Analysis 31
3.5.4 Suggested Pipe Support Spacing (ASMEB 31.1) 31

CHAPTER 4 DESIGN OF HOT REHEAT PIPING SYSTEM 32-55

4.1 Hot Reheat Line 32
4.2 Physical Boundaries and Components 32
4.3 Design Philosophy for HRH Line (500MW) 36
4.3.1 Determination of Pressure, Temperature and Flow 36
data for most adverse conditions
4.3.2 Material Selection based on temperature and 38
pressure range
4.3.3 Pipe sizing based on recommended velocity and 38
pressure drop
4.4 Pipe Routing / Pipe Layout 52
4.5 Insulation Thickness Calculation 54

CHAPTER 5 PIPING MODEL IN CAESAR 5.0 56-59

5.1 Inputs required while making model in CAESAR 5.0 56
5.2 Piping Model Built in Caesar 5.0 57
CHAPTER 6 RESULTS AND DISCUSSION 60-80
6.1 Code Compliance Evaluation 60
6.2 Stress Analysis Report 69
6.3 Conclusion 80
References 81-82
 LIST OF FIGURES

Figure No. Description Page No.

Figure 1.1 Stress vs Temperature (Material under tension) 16

Figure 1.2 Relationship between deformation and time 17
(creep rate)
Figure 3.1 Clearance with respect to structures and other 28
equipments
Figure 3.2 3D Model in CAESAR II environment 30
Figure 4.1 Hot Reheat Line coming out from Reheater 33
Outlet Header
Figure 4.2 Hot Reheat Line from Reheater Outlet Header 33
towards TG Hall
Figure 4.3 Main Steam, Hot Reheat and Cold Reheat Line 34
from Boiler to TG Hall
Figure 4.4 Main Steam, Hot Reheat and Cold Reheat Line 34
bending to form Y-connection
Figure 4.5 Hot Reheat Line strainers located before 35
Interceptor Valve
Figure 4.6 Division of Hot Reheat Line into various sections 41
for pressure drop calculation
Figure 4.7 Estimation of Friction Factor (Moody Chart) 45
Figure 4.8 Hot Reheat Line Layout in Caesar II Environment 51
Figure 5.1 Various inputs required while making model in 55
CAESAR 5.0
Figure 5.2 Piping Model Bulk in Caesar Environment 56
Figure 5.3 Piping Model Built in Caesar Environment up 57
to Y-piece
Figure 5.4 Piping Model Built in Caesar Environment from 58
Y-piece to Intermediate Turbine Inlet

8
 LIST OF TABLES

Table No. Description Page No.

Table 3.1 Material Specifications for pipes and pipes 20

fittings
Table 3.2 Recommended range of velocities for 22
various systems
Table 3.3 Suggested Pipe Support Spacing (ASME B 30
31.1)
Table 4.1 Calculation of Inside diameters based on 39
recommended velocity & Pressure drop
Table 4.2 Pressure Drop Calculation by using simple 46
Ms-Excel software
Table 4.3 Calculation of pressure drop 47
Table 4.4 Thickness calculation as per ASME B 31.1 49
Table 4.5 Thickness calculation as per IBR (Reg. 350) 49
Table 4.6 Selection of Pipe Thickness 50
Table 4.7 Calculation of Insulation thickness 54
 NOMENCLATURE

ID Inside diameter in mm
Q flow in tonnes/hr
Vs specific volume in m^/kg
V Velocity in m/s
I Stress Intensification factor
MA Resultant Moment loading on cross section due to weight and
other sustained loads (mm- N)
Sh Basic material Allowable stress at maximum (hot) temperature
SL Sum of longitudinal stresses due to pressure, weight, and other
sustained loads
Z Section Modulus (mm^)
f Stress range reduction factor for cyclic conditions for total
number (N) of fiill temperature cycles over total number of
years the system is expected to be in operation(f= 1, for
N=7000 and less)
Sc basic material allowable stress at minimum (cold) temperature
from allowable stress tables
hf head loss due to friction (m)
f friction factor
L length of pipe work (m)
V velocity of fluid (m/s)
g acceleration due to gravity (m/s^)
Rh hydraulic radius
ff Fanning friction factor
e internal roughness of the pipe
Ap pressure drop in Pascals (Pa)
V velocity in metres per second (m/sec)
L length of pipe or hose in metres (m)

10
d inside diameter of pipe or hose in metres (m)
tmin Minimum pipe wall thickness in mm
D Outside diameter of pipe in mm
S Allowable design stress in kg/cm'^
E Weldjoint efficiency factor (=1)
C Corrosion allowance (= 0.75 mm) as per IBR
A Corrosion allowance (= 1.6 mm ) as per NTPC specification
P Internal design pressure in kg/cm^
Y Coefficient having values as given in Table 104.1.2(A) of
ASMEB31.1

11
Greek symbols
P Density of the fluid in kilograms per cubic metre (870-890
kg/m' for hydraulic oil)

Subscripts

A Resultant Moment loading on cross section

h maximum (hot) temperature
L Sum of longitudinal stresses
C minimum (cold) temperature
f head loss due to friction (m)
h hydraulic radius
f Fanning friction factor
min Minimum pipe wall thickness

12
 CHAPTER 1
INTRODUCTION

1.1 Power Plant Piping System:

Piping is very important for any process industry. It is the piping which connects all
these equipment to make a plant able to carry out the process. Thus, piping forms the
arteries, veins, and capillaries of the plant, taking the process fluid from one location
to another. While doing this it has to encounter high pressures, high temperatures and
sometimes ultra low pressures and temperatures as well. Pipes are routed in all the
nooks and comers carrying the process fluid and thus it has to take many bends.
Further, if pipe is subjected to higher operating temperature, in order to take care of
expansion, loops are required to be introduced to make the piping system flexible thus
preventing overstressing during operation. Piping Engineering is a truly
multidisciplinary subject. It draws its knowledge base from chemical, mechanical,
civil, electrical, metallurgical, instrumentation, control engineering, to name a few.

1.2 Classification of Piping System:

In a Power Plant the piping system is classified broadly into two categories:
1. High pressure piping or Power Cycle piping
2. Low pressure piping or Station Piping

1.2.1 High Pressure Piping or Power Cycle Piping:

Main steam system
Cold reheat system
Hot reheat system
HP/LP Bypass Piping system
Extraction Steam system
Auxiliary Steam system
Feed water system
Condensate system
Heater drains and Vents system

13
 • SV Exhaust, misc. drains from equipment & piping system

1.2.2 Low pressure piping or Station piping:

Raw water
Ash water
Circulating water
Auxiliary cooling water
Clarified water
Air preheater wash water
Clarifier sludge
Condenser make up water
Boiler fill & Deaerator fill water
DM water
Drinking water,
instrument air & Plant air.

Various aspects related to engineering of power cycle piping systems were studied
during the on-job training. In order to understand and familiarize various activities
involved in the design of piping system. Design of Hot Reheat steam piping system
for a typical 500MW Coal based Power plant has been taken for the case study. The
major criteria / aspects involved in Power Cycle piping design are discussed as under:

1.3 Design Considerations for Power Cycle Piping:

1.3.1 General:
All the piping systems shall be designed to operate without replacement and with
normal maintenance for a plant service life of 30 years and shall withstand the
operating parameter fluctuations and cycling which can be normally expected during
this period.

Power plant piping falls under the requirements of Power Piping Code, ASME B31.1.
The Code address such items as materials, allowable stress levels to be used, design

14
 rules to be satisfied and welding requirements including mandatory inspections and
testing. In addition to the above, it references allowable ASTM Material
specifications and various ANSI, AWWA and MSS standards covering requirements
of valves and fittings.

In addition to the above, requirements as laid down in Indian Boiler Regulations

(latest edition) shall also be met completely.

1.3.2 Design Pressure:

The design pressure is obtained from the highest operating pressure, normal or
incidental, after adding of a design margin. Lines under vacuum will also require a
determination of the lowest negative pressure.

1.3.3 Design Temperature:

The design temperature is obtained from the highest operating temperature, normal or
incidental, after addition of a design margin. As per ASME B 31.1, the design
temperature shall be based on the expected continuous operating condition plus the
equipment manufacturer guaranteed maximum temperature tolerance.

1.3.4 Design Flow:

The maximum flow as per heat balance diagrams corresponds to VWO condition with
0% MU and 77 mm Hg (a), at this condition, both the Half and Full flow are to be
determined for designing Hot Reheat line for a 500 MW coal based power station.

15
1.4 Material Allowable Stress:
One of the major problems in the design of piping systems intended for long
service (such as 10, 15 or 25 years) at elevated temp is that the design values must be
based on extrapolation of relatively short time laboratory test data. In addition to the
relation between deformation and time (creep rate), it is also important to know the
total amount of deformation at the elevated temp, which the material can experience
before it ruptures. Otherwise the piping that is designed on the basis of extrapolated
creep data may fail because the particular material ruptured before attaining the
contemplated strain. Thus the engineer should consider stress to rupture data as well
as the creep data. In power cycle piping design the main steam and hot reheat are
subjected to creep operating continuously at temp of 540°C.

In power plant piping material are subjected to high temp and high stresses.
Due to this the strength of materials at high temp has become of practical importance.
Experiments indicate that the yield point and ultimate strength of materials in tension
depends very much on temperature.

Ultimate stress
Stress

Yield stress

Temperature

Figure 1.1 Stress vs Temperature (Material under tension)

16
Piping systems that operate under loads continuously at elevated temperature needs to
be studied in great depth. Experiments show that under such conditions a continuous
deformation may take place, which is an important factor to be considered while
establishing allowable stress for piping materials.

This phenomenon is generally known as creep. For commonly used piping materials
creep begins after 350-400°C. So for establishing allowable stress the designer should
identify whether piping systems fall under creep or not.
When the load is first applied there is an immediate elastic extension OA. The
specimen then begins to stretch at a slower rate in the region BC. At C the specimen
starts extending at very fast rate and finally at D it fractures. For the stress
encountered in practice the time to reach A is very short and the entire life time of the
specimen lies between B&C. So the designer shall restrict the stress value in such a
way that the time elapsed between point B&C shall be sufficient to give expected life
of this system. The slope of the portion BC representing the rate of extension at a
certain stress and temperature is therefore of practical interest.

Elongation

Time

Figure 1.2 Relationship between deformation and time (creep rate)

17
 CHAPTER!
LITERATURE REVIEW

In recent years, with the rapid development of China's national economy, oil, power,
chemical developing rapidly. Laying a large number of high temperature and high
pressure pipeline, the design level as a measure of whether a design unit in the fierce
market competition to win the key, here, one of the core technology pipe stress
analysis is more complicated. To this end, the design department has used pipe stress
analysis computer. CAESAR II pipe stress analysis software developed by the U.S.
pressure on the company COADE Pipe Stress Analysis of international authoritative
professional software. It can be calculated static analysis, dynamic analysis can also
be, CAESAR II to provide users with comprehensive international general pipeline
design specifications, software, easy to use and quick.

Fang Li [1] presented that high temperature and pressure piping systems such as static
analysis will need to calculate the conditions (temperature, pressure, etc.), pipe
material properties (Young's modulus, linear expansion coefficient, the basic
allowable stress, etc.), pipe size (diameter, wall thickness, length) space direction,
constrained methods as the basic data input the computer. These data are subject to
change along the pipeline, where the change in the establishment of nodes, so that the
entire piping system was divided into several units, each composed of two nodes.
CAESAR II input method used by one unit, the unit's input to fill in a form manner.
CAESAR II software program that is generally considered by three-dimensional x, y,
z in three directions, the program will generally set the first node coordinates (0,0,0).

Zhang Shujun, Li Guobin, Chen Bai-lian [2] determined the safety and reliability of
pipeline and pressure vessel design conventional methods, high temperature and high
pressure pipeline running at an early stage, allowing local pipe yield tightening
method, or by cold pre opposite direction of the stress. Temperature and high pressure
piping stress is broadly divided into based on the nature a stress, secondary stress and
peak stress categories, a stress refers to the internal pressure from the pipeline, gravity
and other external load, stress, self-limiting; secondary stress that is blocked by the

18
pipe deformation caused by normal stress and shear stress; peak stress is the local tube
structural discontinuity, a stress concentration or local thermal stress, attached to a
secondary stress. Static high pressure pipeline results generally include: piping stress
points, the constraints on the pipeline by the force, displacement of various points on
the pipeline,

R. N. Nevin [3] Some Aspects of the Design of Modem Piping System; R. N. Nevin
explained about the specifications, design stress, velocities & pressure drops,
selection of materials, joints. Welding & Non- destructive testing of welds, support &
anchor design. Piping flexibility and drainage for the design of a modem piping
system. The aspects of design of piping systems presented indicate clearly the need
for giving specialized attention to these matters. Correct design will reduce plant
outages and maintenance costs. Too frequently piping considerations play second
fiddle to the consideration of other plant, the result being that the piping is "thrown
together" just before the commissioning of the major plant. If due recognition is given
to its importance and design, manufacture and erection are properly planned, a saving
in initial capital cost can be made in many instances.

Blair, J. S. (1963). [4] The Design of High Temperature Steam Pipes; Ace. To Blair,
J. S., The object should be to arrange the piping such that it can absorb its own
expansion without being overstressed and without imposing excessive thrusts or
moments on plant to which it is connected. The complexity of the analysis is such that
it has become essential to resort to the use of an electronic digital computer-it is
estimated that the average high pressure flexibility analysis, if done manually, would
take one man six months. Besides determining the stresses in the pipes and the
moments and forces which would be imposed on plant to which the piping system
connects, and the moments and forces at anchor and restraint points so that these can
be designed, the analysis gives deflections at any point in the system.

Mao You Ren, Zhao Xiaozheng, Jiang-Tao Liu. [5] CAESAR II software piping
stress analysis in the Power Plant applications [J] .2006.3 (3) presented a theory
which enables spring supports to be designed and a check to be made that, due to
expansion movement, no fouls occur with other pipes, structural steelwork or items of

19
plant. Furthermore, the designer can ensure that joints do not occur at points of high
bending moment, thus ensuring that the erector does not have undue difficulty in
lining up the joint for welding (or flanging).

20
 CHAPTERS
METHOD OF CALCULATION OF VARIOUS DESIGN
PARAMETERS FOR PIPING DESIGN

3.1 Material Selection:

Piping system shall be of carbon steel for design temperature up to 400 deg. C and
alloy steel for design temperature above 400 deg. C. Pipes and fittings shall be of
seamless construction and shall generally conform to the following material
specifications:

Alloy Steel Carbon Steel

A. Pipes:

ASTMA335Gr.P-91 ASTM 106 Gr. B

Material
OR OR

ASTM A335 Gr.P22 ASTM 106 Gr.C (BFP and for

CRH design parameters & above)

B. Pine Fittines TAbove 50NB)

ASTMA234GR. WP91 ASTM A234 Gr. WPB (for

A 106Gr.B piping)
Material
OR OR

ASTM A234GR. WP22 ASTM A234 Gr. WPC (for A106

Gr. C piping)

C. Pipe Fittings (50 NB and Below)

ASTMA182Gr. F91

Material OR ASTM A105

ASTMA182Gr. F22

Table 3.1 Material Specifications for pipes and pipes fittings

21
3.2 Pipe Sizing:

Sizing of piping system is basically a matter of economic Choice. Normally a

preliminary pipe size is selected on velocity considerations and later pressure drop
calculations will confirm or revise the choices.

Inside diameters of piping are first calculated for the flow requirement of the system
considering a suitable value within the "Recommended range of velocities" for the
service application listed below at Para 1.3. Inside diameters thus calculated are then
checked for allowable pressure differentials for various systems. The allowable
pressure drop is 90% of the available pressure drop in the system which provides the
designer a 10% margin. In case the calculated pressure drop exceeds the allowable
value the pipe sizes are changed to contain the pressure drop within allowable limit

Please note that selection of pipe sizes, besides affecting initial cost, will also affect
operating costs due to their sensitivity to changes in pressure drop, heat losses and
maintenance requirements.

3.2.1 Considerations that have an Impact on Velocity Selection:

• Noise: - it can result form high velocity flow. Cavitation or two phase flow.

• Vibration: - it can result from excessive velocities encountered at changes in

direction of the fluid flow. However, vibration in piping system can also occur
because of many other reasons like inappropriate supporting system, too flexible
routing, two phase flow, passed on from the connected equipment etc.

• Erosion/corrosion: - these are caused apart from chemical action of the fluid by
excessive velocities, Cavitation and turbulence at tees, valves, bends etc.

• Flow distribution: It is an important consideration. The more even the cross sectional
velocity profile, more likely is the reduction in the above factors. Thus using
reasonable velocity ranges along with a simple piping layout results in smooth flow

22
 pattern. Also too low a velocity will cause higher pipe sizes thereby costly, more
weight on structure, hangers etc. Hence, piping design is a Trade-off between flow
velocity and size of the pipe.

• Cavitation: It can result from the collapse of bubbles close to a metallic surface at a
high velocity enough to cause erosion. NPSH of pumps including accepted margins
must be met to avoid Cavitation.

• Two phase flow: This can be best handled by avoiding piping arrangements that will
produce this condition. Piping layout should avoid flashing upstream of heater drains
control valves.

3.2.2 Recommended Range of Velocities:

Higher velocities will lead to smaller pipe sizes and higher pressure drops.
Excessively high velocities can cause noise, vibration and /or erosion. Velocities in
pump suction lines shall be kept sufficiently low in order to maintain pump's required
NPSH, including margin. In line with the considerations above, the recommended
range of velocities are indicated below.

Main steam Hot and cold Reheat piping 76 m/sec

HP bypass upstream 76 m/sec.

HPBP downstream 100 m/sec

LP bypass Upstream 76 m/sec.

LP bypass Downstream 100 m/sec.

Extraction Steam (Super heated) 60 m/sec

Extraction Steam (Saturated) 40 m/sec.

Feed water -suction 2-3 m/sec.

Feed Water Discharge 4.0 - 6.0 m/sec

Condensate Suction 15 m/sec.

23
 Condensate Discharge 3.0-5.0 m/sec

Auxiliary steam 40 m/sec

Table 3.2 Recommended range of velocities for various systems

3.2.3 Calculation of inside diameters:

Inside diameters of piping are first calculated for the flow requirements of HRH
system. If the Velocity, specific volume and flow through the line is known then
inside diameter can be calculated from the following formula:

ID = (595f x O x V ,
V
Where,
ID = Inside diameter in mm
Q = flow in tonnes/hr.
Vs = specific volume in m^/kg
V = Velocity in m/s.
Inside diameters thus calculated are checked for allowable pressure differentials for
various systems. The allowable pressure drop is 90% of the available pressure drop in
the system which provides the designer a 10% margin.

3.2.4 Pipe Wall Thickness Calculation:

Pipe wall thickness involves the determination of a minimum wall thickness in such a
way that the allowable stress in the given piping material is not exceeded under the
loads to which the piping is exposed. The minimum wall thickness of the piping is
calculated in accordance with the procedure and formula given in ASME B31.1.

For piping systems which are under IBR purview, pipe thickness calculation shall also
to be performed as per procedure and formula given in IBR Reg.350. In such cases,
based on the higher value of the two calculations, i.e., as per ASME & IBR (after
adding manufacturing tolerance), the next heavier commercial wall thickness shall
then be selected from thickness schedules (e.g. Sch.-40, Sch-80, etc) as contained in

24
 ANSI/ ASME B36.10 for OD controlled pipes and from manufacturer's schedules for
ID controlled pipes.

Allowable stresses of material are selected from Appendix-A of ASME B31.1 after
choosing the pipe material, its grade & construction type and design temperature.
Straight-line interpolations of allowable stress between the temperature points in the
stress tables are permitted. Allowance in the form of additional thickness has to be
selected for material removed in threading, bending, machining, expected corrosion,
erosion etc.. As per NTPC practice corrosion allowance of 1.6mm is considered for
pipe thickness calculation as per ASME B31 and an allowance of 0.75mm is
considered for thickness calculation as per IBR-1950.

3.3 Thermal Insulation for Pipes:

The insulation for piping systems is provided for energy conservation and for
prevention of injury to attending personnel. The insulating material and other design
criteria for thermal insulation are discussed subsequently. Design ambient temperature
is taken as 40°C (envisaged environment condition inside the TG hall) and nominal
surface temperature as 60°C.

Lightly bonded mineral wool as per IS 8183 in the form of pipe sections and machine
stitched mattresses is considered for insulation. The density of bonded mineral wool is
about 100 kg/m3 for temperatures below 400°C and 150 kg/m3 for temperature above
400°C. Thermal conductivity of this material being less by about 25 to 30%, less
quantity of material is required as compared to the unbonded mineral wool. As this
material is available in the form of machine stitched mattresses and snap-on type pipe
sections, it is easier to apply this type of insulation. Removing and replacement of
insulation at the time of maintenance is also much easier. This being of bonded type
there is no flaking off of mineral wool.

25
3.3.1 Method of calculation:
As we know that there is going to be considerable difference in the temp at the pipe
surface and the insulation surface. So, we cannot take the thermal conductivity of the
insulation to be constant over the entire range of thickness, because the K value of a
material is dependent on the temp. It is only practicable for insulation layer with
infinitesimal thickness such that the pipe and the insulation surface temp are same. To
take care of above we need to go for the iterative process as described below:
"We assume the thickness at a certain value. Assuming the constant value of K we
find the temp at the insulation surface. Now having got the two temp i.e. pipe and
insulation surface, we find the mean temp and hence the K value at that temp. Now
based on this new K value we again find the insulation surface temp.
Now again we find the new temperatures we find a new K and then again a new T.
This goes until the difference between the successive K and T values tends to saturate.
Thus we get the near accurate value of temp at the insulation surface with selected
thickness. This is all done by always keeping the principle of "heat by cond. = heat by
conv. + heat by radiation". We now go on carrying the same procedure by gradually
increasing the thickness. A stage will come when the insulation surface temp will tend
to 60°C or less. This will be the desired thickness of insulation."

Above process is used for pipes having higher value of insulation thickness. For pipes
which will have a thinner insulation layer or those whose operating temperature is less
we go for finding the thickness in one step instead of going for the iterative process.

This will indeed be a very tedious process, and will require great deal of labour if
tried manually. So we have developed a program in MS office excel on above lines to
make the job easy.

For calculation of the insulation thickness over a pipe having a fluid flowing through
it, we need two basic data. Temperature of the fluid & Pipe size (i.e. OD)
The guiding criteria which governs the insulation thickness is the allowable surface
temperature fi-om safety considerations. Generally, a pipe surface temp of 60°C max
is permitted. Sometimes the maximum allowable heat loss is also taken as guideline.

26
 In power cycle piping we are using light bonded mineral wool as the insulation
material. For operating temp < 400°C we are going for the material with bulk density
of 100 kg/m3, while for >= 400°C we are going for the material with bulk density of
150kg/m3.

3.3.2 Additional heat losses due to components in a pipeline:

For realistic calculation of heat losses, the following modifications are required to be
done:
a) Valves
Additional length in meter is to be added to the real length (L) or pipeline, to account
for the presence of valves in a piping system before calculating the heat loss.
b) Pair of Flanges
To account for the heat losses from a pair of flanges in a piping system (including the
flange pair when a valve is mounted).
c) Pipe suspensions
They also add to the heat loss, so a due consideration has to be taken for them.

3.3.3 Surface temperature and coefficients:

It is often stipulated in practice, for operational reasons, that a certain surface
temperature, temperature of the surface above that of the air (also called excess
temperature) must not be exceeded. The surface temperature is not measure for the
quality of the thermal insulation, This depends not only on the heat transmission but
also on operating conditions, which cannot be readily determined or guaranteed by the
manufacturer. These include among other things: ambient temp, movement of the air,
state of the insulation surface, effect of adjacent bodies, meteorological condition, etc.
Reduction of heat loss by convection would mean reduction of air movement over the
surface and consequent reduction of convective heat transfer. Reduction of heat
transfer by radiation would mean reduction of surface emissivity and consequent
reduction of radiative heat transfer coefficient. Although the increase in total surface
resistance, which is reciprocal of the total surface coefficient will decrease the heat
flow, but would increase the surface temperature to a considerably greater extent.

27
3.4 Pipe Routing (Layout):
Layout is dictated by the relative positions of the connecting equipments and the
requirements of stress analysis of piping systems. Suitable clearance with respect to
structures and other equipments is to be maintained. Valves location must be
accessible for operation and maintenance. Distance between adjoining running pipes
must be kept sufficient to take care of the location of hanger lugs/clamps/pipe
movements, insulation on piping. The pipe routing should be such that clear
headroom of not less than 2.5 m above the walkways/ working area is available.

All high points in piping system shall be provided with vents. All low points need to
be provided with drains. No piping should be routed in the TG hall above the
operating floor. All access platforms for operation and maintenance of valves strainers
and other specialties and cross over-bridges shall be provided with suitable access.
Floor and valve sleeves pipe crossing shall be provided.

Figure 3.1 Clearance with respect to structures and other equipments

28
3.5 Stress Analysis:

This is a very important phase of the entire piping process. It is also called as
flexibility analysis. Stress analysis is done to assure the safe operation of pipe under
sustained load conditions. The stresses arise out of thermal expansion and contraction,
fluid weight, load variation and pipe weight itself
To validate the design as per ASME B31.1 Clause No. 104.8 and to meet the
IBR Regulation 370, the complete piping system must be analyzed between anchors
for the effects of thermal expansion, weight, other Sustained loads.

3.5.1 Stresses due to Sustained Loads:

The effects of pressure, weight, and other sustained mechanical loads shall meet the
requirements of

S,'L =•
(1000)4f„ Z

Where,
i = Stress Intensification factor
MA = Resultant Moment loading on cross section due to weight and other sustained
loads (mm- N)
Sh = Basic material Allowable stress at maximum (hot) temperature
SL = Sum of longitudinal stresses due to pressure, weight, and other sustained loads
Z = Section Modulus (mm^)

3.5.2 Thermal Expansion Stress Range:

The effects of thermal expansion shall meet the requirements of

s,:^'-^<s,+ns,-sj

Where,
f = Stress range reduction factor for cyclic conditions for total number (N) of fill 1
29
temperature cycles over total number of years the system is expected to be in
operation(f= 1, for N=7000 and less)

S,=fil.25S^+0.25S,)
Sc= basic material allowable stress at minimum (cold) temperature from allowable
stress tables
f(Sf, -S^)= Additional thermal expansion allowance when Sh>SL
MA = Range of resultant Moments due to thermal expansion (mm- N)

We use CAESAR II for carrying out stress analysis. Firstly, isometric drawing
based on the pipe routing prepared. Then based on the isometric input a 3D model is
developed in CAESAR II environment. We then specify the boundary conditions,
load data, restraints, support data and do the analysis. The software merely calculates
the stresses at various nodes. It is the designer whose wit and experience decides the
optimality of design.

• ^
Figure 3.2 3D Model in CAESAR II environment

30
3.5.3 Importance of Stress Analysis:
Pipes connect various equipment. The force due to pipe loading, and thermal effects
must not pass on to equipment beyond the allowable limit. The designer gets real time
behaviour of the piping model in CAESAR II and he can better analyze the exact
practical situation.
He can decide the location of supports, expansion loops, restraints, expansion bellows
etc. Commercially available Piping flexibility analysis software called "CAESAR 11"
helps the designer to apply various loading conditions to the piping model, which
otherwise would have been a tedious and a cumbersome job.
Thus a really well performed analysis helps in avoiding catastrophes due to pipe
failure during load conditions.

3.5.4 Suggested Pipe Support Spacing (ASME B 31.1):

Suggested Maximum Span

Nominal Water Steam, gas

Pipe size Service (ar air service

NPS ft m ft m

25 7 2.1 9 2.7

50 10 3.0 13 4.0

65 12 3.7 15 4.6

100 14 4.3 17 5.2

150 17 5.2 21 6.4

200 19 5.8 24 7.3

300 23 7.0 30 9.1

400 27 8.2 35 10.7

500 30 9.1 39 11.9

600 32 9.8 42 12.8

Table 3.3 Suggested Pipe Support Spacing (ASME B 31.1)

31
 CHAPTER 4
DESIGN OF HOT REHEAT PIPING SYSTEM

4.1 Hot Reheat Line:

The Hot Reheat (HRH) System conveys high pressure, superheated steam from the
steam generator reheater outlets to intermediate pressure turbine inlet. Safety valves
mounted at the reheater outlet provide over pressure protection for the steam
generator as well as the hot reheat piping. At full load, steam flows from the boiler to
the intermediate pressure turbine and no flow occurs in any of the branch lines.

4.2 Physical Boundaries and Components:

The hot reheat system starts at the steam generator reheater outlet nozzles and
terminates at the inlet of the intermediate pressure turbine nozzles. Two leads of hot
reheat line originate from the reheater outlet, join to form a single lead in CD bay for
pressure and temperature balancing and then again branch to two leads in the turbine
hall to terminate at the inlet of the intermediate pressure turbine nozzles. Tapings for
LP bypass is provided from the single lead of hot reheat line. All piping and related
valves, hangers, supports, instrumentation, drains and vents in these pipe lines are part
of the system. This includes the power assisted relief valves and silencers, the
mechanical safety valves and related atmospheric vents and the motor operated boiler
isolation valves in the reheater outlet piping.
To give some idea how Hot Reheat Line physically looks like I have included some
figures on the next page onwards, starting from Boiler area to turbine area. All the
three lines appears to be similar in photographs but can be recognized easily at site by
their diameters and location of valves.

32
 Figure 4.1 Hot Reheat Line coming out from Reheater Outlet Header

Figure 4.2 Hot Reheat Line from Reheater Outlet Header towards TG Hall

33
Figure 4.3 Main Steam, Hot Reheat and Cold Reheat Line from Boiler to TG Hall

Figure 4.4 Main Steam, Hot Reheat and Cold Reheat Line bending to form Y-
connection
34
Figure 4.5 Hot Reheat Line strainers located before Interceptor Valve

35
4.3 Design Philosophy for HRH Line (SOOmw):
Pipe sizing and piping system design has been done here considering the requirements
of ASME B 31.1 and IBR and following whichever is more stringent. A pipe wall
thiciaiess has been calculated by ASME B31.1 Code formula and also by IBR formula

Friction drop in the piping system has been calculated by using Darcy Weishbach
equation and the friction factor has been calculated by using the Colebrook Method.
Pipe flexibility analysis including the calculation of stresses set up in piping systems
has been carried out and results has been included in the text.

4.3.1 Determination of Pressure, Temperature and Flow data for

most adverse conditions:
The three basic parameters necessary for designing the Steam Piping includes
Temperature, Pressure and Flow which the piping system need to withstand in most
adverse circumstances. The Parameters are selected as follows:

I. Determination of design Pressure:

The Hot Reheat Pipeline from the reheater outlet to the First stop valve comes under
Boiler External piping and therefore comes under the purview of ASME Boiler &
Pressure Vessels code. The design pressure of this portion of HRH piping from
reheater outlet header up to and including interceptor valve shall not be less than the
design pressure of reheater outlet header. The HRH piping thereafter from Interceptor
valve outlet nozzle to IP turbine inlet is coming under Non-Boiler External piping and
the pipeline design is governed by Power Cycle Piping code ASME B31.1.

Design pressure from reheater header outlet to IP turbine inlet shall be the
greater of A & B.

1 (A) Maximum operating pressure at IPT inlet = 42.75 kg/cm^ (ata)

2 (A) Pressure drop (Ap) in HRH piping = 1.06 kg/cm^ (ata)

A. = 1 (A) + 1 (B)

36
 A. = 42.75 + 1.06 = 43.81 kg/cm^ (ata)

B. Minimum Reheater safety valve setting = 49.433 kg/cm^ (ata)

C. Selected design pressure of HRH piping (Greater of A & B) = 49.433 kg/cm^

(ata)

So the selected design pressure for HRH piping is 49.433 lig/cm^ (ata).

II. Determination of design Temperature:

A. AsperANSIB31.1
I. Reheater outlet temperature = 568°C
II. Boiler manufacturer specified tolerance = 5°C
III. Selected design temperature (As per ANSI B31.1) = 573°C

B. As per IBR
I. Selected design temp, (as per IBR) = 573°C.

III. Determination of design Flow:

The maximum flow as per heat balance diagrams corresponds to VWO condition with
0% MU and 77 mm Hg(a). at this condition the flow is 1358 T/hr at 42.75 kg/cm^ (a)
pressure and at a temperature of 568°C.

A. Full flow, T/hr. = 1358 T/hr.

B. Half flow, T/hr. = 679 T/hr.

37
4.3.2 Material Selection based on temperature and pressure
range:
• SA 335 P91 is a ferritic alloy that can withstand high temperature (570°C - 600°C)
and high pressure (up to 230 bar). It Is also called as 9Cr IMo steel based on its
composition.
• Chromium improves high temp, strength and increases oxidation resistance.
• Molybdenum increases the creep resistance when material operates at high
temperatures.
• So this material allows the designers to engineer components with less thickness. This
contributes to a higher thermal fatigue life of almost ten times.

So I have selected SA 335 P91 for the design of Hot reheat line for 500 MW unit.

4.3.3 Pipe sizing based on recommended velocity and pressure

drop:
Higher velocities will lead to smaller pipe sizes and higher pressure drops.
Excessively high velocities can cause noise, vibration and /or erosion. Velocities in
pump suction lines shall be kept sufficiently low in order to maintain pump's required
NPSH, including margin.

I. RECOMMENDED RANGE OF VELOCITIES:

In line with the considerations above, the recommended range of velocities are
indicated below.

Main steam Hot and cold Reheat piping 76 m/sec

HP bypass upstream 76 m/sec.

HPBP downstream 100 m/sec

LP bypass Upstream 76 m/sec.

LP bypass Downstream 100 m/sec.

38
 Extraction Steam (Super heated) 60 m/sec

Extraction Steam (Saturated) 40 m/sec.

Feed water -suction 2-3 m/sec.

Feed Water Discharge 4.0 - 6.0 m/sec

Condensate Suction 15 m/sec.

Condensate Discharge 3.0-5.0 m/sec

AuxiHary steam 40 m/sec

II. CALCULATION OF INSIDE DIAMETERS:

Inside diameters of piping are first calculated for the flow requirements of HRH
system. If the Velocity, specific volume and flow through the line is known then
inside diameter can be calculated from the following formula:

ID = ( 5 9 5 r x Q x V .
V

Where,
ID = Inside diameter in mm
Q = flow in tonnes/hr.
Vs = specific volume in m^/kg
V = Velocity in m/s.

Inside diameters thus calculated are checked for allowable pressure differentials for
various systems. The allowable pressure drop is 90% of the available pressure drop in
the system which provides the designer a 10% margin.

39
 SPECIFIC SELECTED
PIPE PIPE DESIGN DESIGN STEAM VOLUME PIPE ID (mm
FLOW
SEGMEN SECTIO PRESSUR TEMP, VELOCITY OF
(T/hr.)
T N E(Ksc) (°c) (m/s) STEAM
(m'/kg)

SEGMENT 43.0 0.0779 660.33

1-2 49.43 568 679.007
1

SEGMENT 52.0 0.0785 851.92

3-4 49.05 568 1358.01
2

SEGMENT 44.0 0.0793 658.20

4-5 48.56 568 679.007
3

SEGMENT 44.0 0.0793 658.20

4-6 48.56 568 679.007
4

Table 4.1 Calculation of Inside diameters based on recommended velocity &

Pressure drop

Inside diameters thus calculated are then checked for allowable pressure differentials
for HRH line. The allowable pressure drop is 90% of the available pressure drop in
the system which provides the designer a 10% margin.

40
ni.PRESSURE DROP CALCULATION:

Figure 4.6 Division of Hot Reheat Line into various sections for pressure
drop calculation

41
 After the layout and routing of the pipe is finalized, the next step involves sizing the
pipe, which is actually a trade-off between velocity and recommended pressure drop.
As per NTPC technical specification, the maximum velocity recommended for HRH
flow is 76 m/s. In order to obtain the optimum pipe size involving pressure drop
calculation the whole pipe is divided into four sections as mentioned below:
Section 1 From 1 to 3
Section 2 From 3 to 4
Section 3 From 4 to 5
Section 4 From 4 to 6

As per NTPC Specification,

1. Combined pressure drop in cold and hot reheat piping will not exceed 90% of the
pressure differential between HP turbine exhaust and IP turbine inlet valves minus
pressure drop in reheater.

Thus maximum allowable Ap = 90% of (HPT exhaust Pressure - IPT inlet Pressure -
pressure drop in the reheater)
= 0.9 X (46.87 - 42.75 - 2.65) kg/cm^
= 1.323 kg/cm^

2. The pressure drop in the complete reheat line from HPT exhaust to IPT inlet shall not
be more than 10% of the pressure at HPT exhaust.

Thus maximum allowable Ap = 10% of the pressure at HPT exhaust

= 10% of (46.87)
= 4.687 kg/cm^

So on the basis of above two conditions, the maximum allowable pressure drop shall
not be more than 1.323 kg/cm^.

42
IV. FINAL CALCULATED PRESSURE DROP:
Friction drop in the piping system has been calculated by using Darcy Weishbach
equation and the friction factor has been calculated by using the Colebrook Method.

Darcy-Weisbach Formula:
The flow of liquid through a pipe is resisted by viscous shear stresses within the liquid
and the turbulence that occurs along the internal walls of the pipe, created by the
roughness of the pipe material. This resistance is usually known as pipe friction and is
measured is feet or metres head of the fluid, thus the term head loss is also used to
express the resistance to flow.

Many factors affect the head loss in pipes, the viscosity of the fluid being handled, the
size of the pipes, the roughness of the internal surface of the pipes, the changes in
elevations within the system and the length of travel of the fluid.

The resistance through various valves and fittings will also contribute to the overall
head loss. A method to model the resistances for valves and fittings is described
elsewhere. In a well designed system the resistance through valves and fittings will be
of minor significance to the overall head loss, many designers choose to ignore the
head loss for valves and fittings at least in the initial stages of a design.

Much research has been carried out over many years and various formulae to
calculate head loss have been developed based on experimental data. Among these is
the Chezy formula which dealt with water flow in open channels. Using the concept
of 'wetted perimeter' and the internal diameter of a pipe the Chezy formula could be
adapted to estimate the head loss in a pipe, although the constant ' C had to be
determined experimentally.

Weisbach first proposed the equation we now know as the Darcy-Weisbach formula
or Darcy-Weisbach equation:

hf=f(L/D)x(v^/2g)

43
 Where,
hf= head loss (m)
f = friction factor
L = length of pipe work (m)
d = inner diameter of pipe work (m)
V = velocity of fluid (m/s)
g = acceleration due to gravity (m/s^)

Friction Factors:
Fanning did much experimentation to provide data for friction factors, however the
head loss calculation using the Fanning Friction factors has to be applied using the
hydraulic radius equation (not the pipe diameter). The hydraulic radius calculation
involves dividing the cross sectional area of flow by the wetted perimeter. For a round
pipe with fall flow the hydraulic radius is equal to Vi of the pipe diameter, so the head
loss equation becomes:

hf=ff(L/Rh)x(v'/2g)
where Rh = hydraulic radius, ff = Fanning friction factor

Darcy introduced the concept of relative roughness, where the ratio of the internal
roughness of a pipe to the internal diameter of a pipe, will affect the friction factor for
turbulent flow. In a relatively smoother pipe the turbulence along the pipe walls has
less overall effect; hence a lower friction factor is applied.

The work of many others including Poiseuille, Hagen, Reynolds, Prandtl, Colebrook
and White have contributed to the development of formulae for calculation of friction
factors and head loss due to friction.

The Darcy Friction factor (which is 4 times greater than the Fanning Friction factor)
used with Weisbach equation has now become the standard head loss equation for
calculating head loss in pipes where the flow is turbulent.

The Colebrook-White equation which provides a mathematical method for

calculation of the friction factor (for pipes that are neither totally smooth nor wholly
44
rough) has the friction factor term f on both sides of the formula and is difficult to
solve without trial and error (i.e. mathematical iteration is normally required to find f).

' e 9.35 ^
l/v7=1.14-21og, 10 + for Re > 4000
, ^ ReV/ /
where:
f = friction factor
e = internal roughness of the pipe
D = inner diameter of pipe work

The Moody Chart:

In 1944 LF Moody plotted the data from the Colebrook equation and this chart which
is now known as 'The Moody Chart' or sometimes the Friction Factor Chart, enables
a user to plot the Reynolds number and the Relative Roughness of the pipe and to
establish a reasonably accurate value of the friction factor for turbulent flow
conditions. The Moody Chart encouraged the use of the Darcy-Weisbach friction
factor and this quickly became the method of choice for hydraulic engineers. Many
forms of head loss calculator were developed to assist with the calculations, amongst
these around slide rule offered calculations for flow in pipes on one side and flow in
open channels on the reverse side. The development of the personnel computer from
the 1980's onwards reduced the time needed to perform the friction factor and head
loss calculations, which in turn has widened the use of the Darcy-Weisbach formula
to the point that all other formula are now largely unused.

45
 Turbulent flow
Kl :—W7K}-
0.03.
0.07 .. 0.05003
0.04000
O.CS '•
0.03000
0.05 •• 0.02000

0.04 •

0.03 (

002
Frdion factor
h
/=
d 2g

0.01 i
K,:~:-sir:.r

0C03' 0.00001
1,030,OCO 10,000,000 100,000,000

Figure 4.7 Estimation of Friction Factor (Moody Chart)

After the determination of friction factor, this value can be put in the Darcy-Weisbach
equation and from there the value of head loss due to friction can be determined and
Finally, pressure drop can be calculated using the following formula:
Ap = v^ X f X L X p

2D
Where
Ap = pressure drop in Pascals (Pa)
V = velocity in metres per second (m/sec)
f = friction factor
L = length of pipe or hose in metres (m)
p = density of the fluid in kilograms per cubic metre (870-890 kg/m^ for
hydraulic oil)
D = inside diameter of pipe or hose in metres (m)
I have used a simple Ms-Excel software to calculate pressure drop by inserting all the
required inputs. The output and complete input data for hot Reheat Line is shown on
the excel sheet on the next Page.

46
 'mu'm ifmim Aim :-
. 'i=i;;ii "y;; :::
ni""mm L iJil-IJ i ==
• 1."" M
IJt--i
1_ _j__j—

S" li lib
Ii5="' mm L lE ! ••'•
k:::..M :::
mum if nil!!! HIHH-:*
i:::::; LI.
iN-= '-mm L.... f t ! ••:..
_
I as
fl S i

, =;::::: Lll
U^-' .im|=: |... f t 1 .
_
J!! ri
Ill = 2
Aihu_fnk 1 m

1
J

i
|.„„p.|i|.>-|,p|...|.. p., f / j . 1 1 . | , . . | . ,
Table 4.2 Pressure Drop Calculation by using simple Ms-Excel software

47
 PIPE PRESSURE
PIPE SECTION SELECTED ID FLOW(T/hr)
SEGMENT DROP (in ksc)
(mm)
SEGMENT 1 1-3 661 679.007 0.352
SEGMENT 2 3-4 854 1358.014 0.416
SEGMENT 3 4-5 661 679.007 0.289
SEGMENT 4 4-6 661 679.007 0.210

TOTAL PRESSURE DROP

L06

Table 4.3 Calculation of pressure drop

As the final calculated pressure drop (1.06 kg/cm2) is less than maximum allowable
pressure drop (1.323 kg/cm^) in complete hot reheat line as per the NTPC
specification. Hence the pipe ID sizes are finalized.

V. PIPE THICKNESS CALCULATION:

L Design formula for thickness calculation as per ASME B 31.1

tmin= PD/2(SE+PY) + A (For OD controlled pipes)

tmin = (Pd+2SEA+2YPA)/2(SE+PY-P) (For ID controlled pipes)

2. Design formula for thickness calculation as per IBR (Reg. 350)

tmin = PD/(2SE + P) -h C (For OD controlled pipes)

tmin= Pd/(2SE-P) + C (For ID controlled pipes)

where.
t min = Minimum pipe wall thickness in mm
D = Outside diameter of pipe in mm

48
 d = Inside diameter of pipe in mm
S = Allowable design stress in kg/cm2
E = Weldjoint efficiency factor (=1)
C = Corrosion allowance (= 0.75 mm) as per IBR
A = Corrosion allowance (= 1.6 mm ) as per NTPC specification
P = Internal design pressure in kg/cm^
Y = Coefficient having values as given in Table 104.1.2(A) of
ASMEB31.1

As per ASTM A 530 for NFS 3 to 18 incl., for t/D > 5% the tolerance is +15%
and -12.5%. Thus for OD controlled pipes for this purpose in order to be in safer side
negative tolerance has been considered.

Manufacturing tolerance on thickness for OD controlled pipes = (-) 12.5%

Therefore,
treq "^ tmin/CSTS (sincc negative tolcrancc IS 12.5%)
Manufacturing tolerance on thickness for ID controlled pipes = +1.6

3. Thickness calculation as per ASME B 31.1

In this case for the chosen material SA335 P9I and seamless pipe the various
constants are
S= 961.405 kg/cm^
E=l
A=1.6
Y=0.7
Since for the purpose of pressure drop calculation the ID has been selected. Therefore
minimum thickness can be found out by the formula for ID controlled pipes.

tmm = (Pd+2SEA+2YPA)/2(SE+FY-P) (For ID controlled pipes)

Thus minimum thickness has been calculated for various design temperature zones as
follows:

49
 Design
PIPE PIPE CALCULATED
Pressure, OD(min)
SEGMENT SECTION THICKNESS(mni)
P(kg/cin^)

SEGMENT 1 1-3 49.43 711 19.24

SEGMENT 2 3-4 49.05 914 24.11

SEGMENT 3 4-5 48.56 711 18.94

SEGMENT 4 4-6 48.56 711 18.94

Table 4.4 Thickness calculation as per ASME B 31.1

4. Thickness calculation as per IBR (Reg. 350)

Minimum thickness can be found out by the following formula
tmin= Pd/(2SE-P) + C (For ID controlled pipes)
Thus minimum thickness has been calculated for various design temperature zones as
follows:

Design
PIPE PIPE CALCULATED
Pressure, OD(niin)
SEGMENT SECTION THICKNESS(nini)
P(lig/cm^)

SEGMENT 1 1-3 49.43 711 18.57

SEGMENT 2 3-4 49.05 914 23.48

SEGMENT 3 4-5 48.56 711 18.26

SEGMENT4 4-6 48.56 711 18.26

Table 4.5 Thickness calculation as per IBR (Reg. 350)

Hence it is found that the thickness calculated as per ASME B 31.1 are more in all
cases, thus they are considered further in calculation. Since OD controlled pipes are
economical, thus it is imperative that the designer goes for the next higher OD and
thickness if the pipe with calculated thickness and OD is not commercially available.

50
 Abiding by this principle the thickness of the pipe has been calculated including the
manufacturing tolerance and hence combination of next higher commercially
available OD and thickness has been chosen to serve the purpose as mentioned in the
table below.

CALCULAT THICKNESS SELECTED

Design SELECTE
PIPE PIPE ED INCLUDING THICKNES ID
Pressure D
SEGMENT SECTION THICKNESS MFG. S (mm)
(kg/cm') OD(mm)
(mm) TOL.(mm) (mm)
SEGMENT
1-3 49.43 19.24 21.98 25 711 661
1
SEGMENT
3-4 49.05 24.11 27.55 30 914 854
2
SEGMENT
4-5 48.56 18.94 21.64 25 711 661
3
SEGMENT
4-6 48.56 18.94 21.64 25 711 661
4

Table 4.6 Selection of Pipe Thickness

Based on the selected OD and thickness, ID has been found out and the Pressure Drop
Calculation has again been carried out for the pipe. The pressure drop is found as 1.06
kgfi'cm^ against maximum allowable 4.687 kgf/cm^. Hence the Pipe Size is finalized.

51
4.4 PIPE ROUTING / PIPE LAYOUT:

Figure 4.8 Hot Reheat Line Layout in Caesar II Environment

52
Layout is dictated by the relative positions of the connecting equipments and the
requirements of stress analysis of piping systems. Suitable clearance with respect to
structures and other equipments is to be maintained. Valves location must be
accessible for operation and maintenance. Distance between adjoining running pipes
must be kept sufficient to take care of the location of hanger lugs/clamps/pipe
movements, insulation on piping. The pipe routing should be such that clear
headroom of not less than 2.5 m above the walkways/ working area is available.

All high points in piping system shall be provided with vents. All low points
need to be provided with drains. No piping should be routed in the TG hall above the
operating floor. All access platforms for operation and maintenance of valves strainers
and other specialties and cross over-bridges shall be provided with suitable access.
Floor and valve sleeves pipe crossing shall be provided.

53
4.5 INSULATION THICKNESS CALCULATION:
DESIGN PARAMETERS:
Cold face temperature in °C 60
Ambient temperature in °C 40 / 45 (Inside TG / Outside)
Wind velocity in m/sec 0.5 / 0.25 (Inside TG / Outside)
Emissivity (Dimensionless) 0.2

INSULATION MATERIAL CHARACTERISTICS:

Material Bonded mineral (rock) wool
Mattresses
Material density in kg/m^ 150 (For hot face temp > 400°C)
Material density in kg/m^ 100 (For hot face temp < 400°C)
Cladding material ALUMINIUM

Thermal conductivity versus mean temperature equation:

(K is thermal conductivity in W/m/°C and T is the mean temperature in °C)

For 150 kg/m3 density material: K = 0.03 + 0.0002T

For 100 kg/m3 density material: K = 0.03 + 0.0002T

In this case bonded mineral rock wool of 150 kg/m^ has been taken as the insulation
and thickness of the following segments have been calculated for the design
parameters considered above.
The density of bonded mineral wool is about 100 kg/m3 for temperatures
below 400°C and 150 kg/m3 for temperature above 400°C. Thermal conductivity of
this material being less by about 25 to 30%, less quantity of material is required as
compared to the unbonded mineral wool. As this material is available in the form of
machine stitched mattresses and snap-on type pipe sections, it is easier to apply this
type of insulation. Removing and replacement of insulation at the time of
maintenance is also much easier. This being of bonded type there is no flaking off of
mineral wool. "For insulation thickness calculation we assume the thickness at a
certain value. Assuming the constant value of K we find the temp at the insulation
surface. Now having got the two temp i.e. pipe and insulation surface, we find the

54
mean temp and hence the K value at that temp. Now based on this new K value we
again find the insulation surface temp.
Now again we find the new temperatures we find a new K and then again a new T.
This goes until the difference between the successive K and T values tends to saturate.
Thus we get the near accurate value of temp at the insulation surface with selected
thickness. This is all done by always keeping the principle of "heat by cond. = heat by
conv, + heat by radiation". We now go on carrying the same procedure by gradually
increasing the thickness. A stage will come when the insulation surface temp will tend
to 60°C or less. This will be the desired thickness of insulation."

Segment Pipe Size (mm) Insulation thickness(mm)

1-3 €>711X25 425 mm (Outside TG)

3-4 (D914X30 445 mm (Outside TG),

325 mm (Inside TG)
4-5 0711X25 310 mm (Inside TG)
4-6 0)711 X 25 310 mm (Inside TG)

Table 4.7 Calculation of Insulation thickness

55
 CHAPTERS

PIPING MODEL IN CAESAR 5.0

5.1 Inputs required while making model in CAESAR 5.0:

'
s? w 5]

II II 1 1
-S -S
I 1"
I"
-§ J 1 I
•-5
•!6
«:i

g
(T3
s1
1
i
3
CD
1
1
1
!=i '^
§ 3

ole s t r e s s e s Bends Displacements Expansion Joints Forces/Moments

i 1 Haii£|^3 ^ ^

a§
•

.£2

- J 1
s j §

i
•

Q *« <t>
i
1
1
•1 iT :i-
^ cn
<=>
• CZI • <<f fif
•g i
1| ^ =- <£
C3

| 13 3 _**
1 -g - „
1 ?
•Q CC LU
1 11 i
Gc
•
13:
[Via
3:: iS li [3 J 3
EE ii J

• • • • • •
-
a a
1 1
1

i
s 5 fc^
•=3
iij
Levi
-S L h
1
.<.^
3?

\^ -SB _>" -^^

• 1 3=1 ^ ;5 si cSi 0-5

><: >^ rJ S ^
JIZI Ci CI:!
'* 5 c3

Figure 5.1 Various inputs required while making model in CAESAR 5.0

56
5.2 Piping Model Built in Caesar 5.0:

Figure 5.2 Piping Model Built in Caesar Environment

57
Figure 5.3 Piping Model Built in Caesar Environment up to Y-piece

58
Figure 5.4 Piping Model Built in Caesar Environment from Y-piece to Intermediate
Turbine Inlet

59
 CHAPTER 6

RESULTS AND DISCUSSION

6.1 Code Compliance Evaluation:
LOAD CASE DEFINITION KEY

CASE 4 (SUS) W+Pl+H

Piping Code: B31.1 -2004, April 29, 2005

*** CODE COMPLIANCE EVALUATION PASSED ***

Code Stress Ratio is 10.9 at Node 330 LOADCASE: 4 (SUS) W+Pl+H

Code Stress: 10229.7 Allowable: 94281.5
Axial Stress: 1516.0 @Node 600 LOADCASE: 4 (SUS) W+Pl+H
Bending Stress: 9612.8 @Node 330 LOADCASE: 4 (SUS) W+Pl+H
Torsion Stress: 597.4 gNode 370 LOADCASE: 4 (SUS) W+Pl+H
Hoop Stress: 1395.8 @Node 590 LOADCASE: 4 (SUS) W+Pl+H
3D Max Intensity: 10247.7 @Node 330 LOADCASE: 4 (SUS) W+Pl+H

Code Allowable Code Allowable

Load Case From Stress Stress To Node Stress Stress
Node KPa KPa KPa KPa
4 (SUS) 10 2722.8 0.0 20 3330.0 0.0

4 (SUS) 20 3330.0 0.0 30 3358.1 0.0

4 (SUS) 30 2712.4 94281.5 38 2731.1 94281.5

4 (SUS) 38 4077.5 94281.5 39 6404.5 94281.5

4 (SUS) 39 6404.5 94281.5 40 10159.7 94281.5

4 (SUS) 40 6843.8 94281.5 50 6019.5 94281.5

4 (SUS) 50 6019.5 94281.5 58 3878.9 94281.5

4 (SUS) 58 5619.8 94281.5 59 3141.7 94281.5

4 (SUS) 59 3141.7 94281.5 60 2667.4 94281.5

4 (SUS) 60 1982.4 94281.5 70 1959.8 94281.5

4 (SUS) 70 2215.8 94281.5 78 2112.1 94281.5

4 (SUS) 78 2585.3 94281.5 79 2100.7 94281.5

60
 From Code Allovvable Code AUowable 1
Load Case Stress Stress To Node Stress Stress 1
Node
Kl'a KPa KPa KPa 1
4 (SUS) 79 2100.7 94281.5 80 2420.4 94281.5

4 (SUS) 80 1798.1 94281.5 90 2834.3 94281.5

4 (SUS) 90 2834.3 94281.5 100 2901.6 94281.5

4 (SUS) 100 2901.6 94281.5 110 4035.8 94281.5

4 (SUS) 110 4035.8 94281.5 120 3652.8 94281.5

4 (SUS) 120 3652.8 94281.5 130 2443.5 94281.5

4 (SUS) 130 0.0 0.0 140 0.0 0.0

4 (SUS) 140 1805.8 94281.5 150 2016.1 94281.5

4 (SUS) 150 2016.1 94281.5 158 1219.6 94281.5

4 (SUS) 158 1299.5 94281.5 159 2723.4 94281.5

4 (SUS) 159 2723.4 94281.5 160 2669.0 94281.5

4 (SUS) 160 2450.8 94281.5 170 2259.0 94281.5

4 (SUS) 170 2853.3 94281.5 180 1773.2 94281.5

4 (SUS) 180 2335.1 94281.5 190 1674.1 94281.5

4 (SUS) 190 2159.2 94281.5 200 1320.6 94281.5

4 (SUS) 200 2040.6 94281.5 208 1361.7 94281.5

4 (SUS) 208 1664.8 94281.5 209 878.3 94281.5

4 (SUS) 209 878.3 94281.5 210 2919.8 94281.5

4 (SUS) 210 2132.3 94281.5 220 2276.6 94281.5

4 (SUS) 220 2276.6 94281.5 228 1741.8 94281.5

4 (SUS) 228 1759.5 94281.5 229 1861.6 94281.5

4 (SUS) 229 1861.6 94281.5 230 956.5 94281.5

4 (SUS) 230 911.6 94281.5 240 2912.7 94281.5

4 (SUS) 240 2912.7 94281.5 250 969.7 94281.5

61
 Code Allowable Code Allowable
From
Load Case Stress Stress To Node Stress Stress
Node
KPa . KFa KPa KPa

4 (SUS) 250 969.7 94281.5 258 1027.1 94281.5

4 (SUS) 258 1090.4 94281.5 259 1592.6 94281.5

4 (SUS) 259 1592.6 94281,5 260 710.7 94281.5

4 (SUS) 260 707.6 94281.5 270 615.5 94281.5

4 (SUS) 270 1228.8 94281.5 279 1410.2 94281.5

4 (SUS) 279 1410.2 94281.5 280 1550.0 94281.5

4 (SUS) 280 1239.3, 290 1220.8 94281.5

4 (SUS) 290 im|k 295 749.3 0.0

4 (SUS) 300 Am 310 3467.2 0.0

4 (SUS) 310 9428L^ 320 3483.5 94281.5

0
4 (SUS) 320 2841^ 328 2851.8 94281.5

4 (SUS) 328 4280.1 94281.5 329 6493.7 94281.5

4 (SUS) 329 6493.7 94281.5 330 10229.7 94281.5

4 (SUS) 330 6901.7 94281.5 340 6104.3 94281.5

4 (SUS) 340 6104.3 94281.5 348 4072.0 94281.5

4 (SUS) 348 5882.9 94281.5 349 3473.9 94281.5

4 (SUS) 349 3473.9 94281.5 350 2736.7 94281.5

4 (SUS) 350 2000.9 94281.5 360 1963.7 94281.5

4 (SUS) 360 2190.3 94281.5 368 2017.0 94281.5

4 (SUS) 368 2385.6 94281.5 369 2356.2 94281.5

4 (SUS) 369 2356.2 94281.5 370 2009.3 94281.5

4 (SUS) 370 1591.7 94281.5 380 2695.3 94281.5

4 (SUS) 380 2695.3 94281.5 390 3332.5 94281.5

62
 From Code Allowable Code Allowable 1
Load Case Stress Stress To Node Stress Stress 1
Node
KPa KPa KPa KPa 1
4 (SUS) 390 3332.5 94281.5 400 4723.4 94281.5

4 (SUS) 400 4723.4 94281.5 410 4442.8 94281.5

4 (SUS) 410 4442.8 94281.5 420 3246.9 94281.5

4 (SUS) 420 0.0 0.0 430 0.0 0.0

4 (SUS) 430 2620.4 94281.5 440 2857.5 94281.5

4 (SUS) 440 2857.5 94281.5 448 2024.3 94281.5

4 (SUS) 448 2238.3 94281.5 449 1923.0 94281.5

4 (SUS) 449 1923.0 94281.5 450 2036.9 94281.5

4 (SUS) 450 1929.7 94281.5 460 1724.6 94281.5

4 (SUS) 460 2320.0 94281.5 470 1177.5 94281.5

4 (SUS) 470 1739.4 94281.5 480 1064.4 94281.5

4 (SUS) 480 1549.5 94281.5 490 787.7 94281.5

4 (SUS) 490 1516.7 94281.5 498 1093.8 94281.5

4 (SUS) 498 1268.8 94281.5 499 1326.4 94281.5

4 (SUS) 499 1326.4 94281.5 500 2953.9 94281.5

4 (SUS) 500 2168.3 94281.5 510 2299.8 94281.5

4 (SUS) 510 2299.8 94281.5 518 1777.0 94281.5

4 (SUS) 518 1818.3 94281.5 519 1596.6 94281.5

4 (SUS) 519 1596.6 94281.5 520 1680.7 94281.5

4 (SUS) 520 1618.5 94281.5 530 3650.0 94281.5

4 (SUS) 530 3650.0 94281.5 540 1544.4 94281.5

4 (SUS) 540 1544.4 94281.5 548 1061.9 94281.5

4 (SUS) 548 1062.0 94281.5 549 1536,5 94281.5

4 (SUS) 549 1 1536.5 94281.5 550 999.0 94281.5

63
 From Code Allowable Code Allowable 1
Load Case Stress Stress To Node Stress Stress 1
Node
KPa KPa KPa KPa

4 (SUS) 550 984.2 94281.5 560 923.1 94281.5

4 (SUS) 560 1501.8 94281.5 569 1414.5 94281.5

4 (SUS) 569 1414.5 94281.5 570 1351.7 94281.5

4 (SUS) 570 1197.5 94281.5 580 1124.2 94281.5

4 (SUS) 580 1124.2 0.0 295 1416.5 0.0

4 (SUS) 295 1024.9 0.0 590 974.6 0.0

4 (SUS) 590 974.6 94281.5 600 831.7 94281.5

4 (SUS) 600 2035.4 94281.5 608 1538.9 94281.5

4 (SUS) 608 1790.6 94281.5 609 976.4 94281.5

4 (SUS) 609 976.4 94281.5 610 969.8 94281.5

4 (SUS) 610 900.6 94281.5 620 2259.7 94281.5

4 (SUS) 620 2259.7 94281.5 630 1619.1 94281.5

4 (SUS) 630 1619.1 94281.5 640 1112.5 94281.5

4 (SUS) 640 1112.5 94281.5 650 3794.6 94281.5

4 (SUS) 650 3794.6 94281.5 658 1263.6 94281.5

4 (SUS) 658 1442.2 94281.5 659 1626.0 94281.5

4 (SUS) 659 1626.0 94281.5 660 1838.8 94281.5

4 (SUS) 660 1603.4 94281.5 670 5677.7 94281.5

4 (SUS) 670 5677.7 94281.5 678 2795.2 94281.5

4 (SUS) 678 3998.1 94281.5 679 1474.1 94281.5

4 (SUS) 679 1474.1 94281.5 680 1520.2 94281.5

4 (SUS) 680 1079.7 94281.5 690 1067.5 94281.5

4 (SUS) 690 1773.7 94281.5 700 1416.9 94281.5

64
 Code Allowable Code Allowable 1
ad Case From Stress Stress To Node Stress Stress 1
Node KPa KPa KPa KPa 1
4 (SUS) 700 2286.6 94281.5 708 2108.3 94281.5

4 (SUS) 708 2582.0 94281.5 709 1232.2 94281.5

4 (SUS) 709 1232.2 94281.5 710 1169.2 94281.5

4 (SUS) 710 1038.1 94281.5 720 2270.2 94281.5

4 (SUS) 720 2270.2 94281.5 730 1357.5 94281.5

4 (SUS) 730 1357.5 94281.5 740 1047.0 94281.5

4 (SUS) 740 1047.0 0.0 750 1854.8 0.0

4 (SUS) 750 1434.1 0.0 760 1562.4 0.0

4 (SUS) 760 1562.4 94281.5 770 1749.1 94281.5

4 (SUS) 770 0.0 0.0 780 0.0 0.0

4 (SUS) 780 0.0 0.0 790 0.0 0.0

4 (SUS) 780 0.0 0.0 800 0.0 0.0

4 (SUS) 800 1549.2 94281.5 810 1993.1 94281.5

4 (SUS) 810 1099.9 94281.5 818 1119.8 94281.5

4 (SUS) 818 2227.2 94281.5 819 1160.8 94281.5

4 (SUS) 819 1160.8 94281.5 820 2213.9 94281.5

4 (SUS) 820 1295.0 94281.5 830 2044.6 94281.5

4 (SUS) 830 2044.6 94281.5 839 2096.2 94281.5

4 (SUS) 839 2096.2 94281.5 840 1461.7 94281.5

4 (SUS) 840 1040.2 94281.5 850 1006.7 94281.5

4 (SUS) 850 1006.7 0.0 860 507.9 0.0

4 (SUS) 860 0.0 0.0 870 0.0 0.0

4 (SUS) 870 0.0 0.0 880 0.0 0.0

4 (SUS) 870 0.0 0.0 890 0.0 0.0

65
 From Code Allowable Code Allowable 1
Load Case Stress Stress To Node Stress Stress 1
Node
KPa KPa KPa KPa

4 (SUS) 890 0.0 0.0 900 0.0 0.0

4 (SUS) 890 0.0 0.0 910 0.0 0.0

4 (SUS) 910 655.2 0.0 920 1350.1 0.0

4 (SUS) 750 2020.2 0.0 930 696.7 0.0

4 (SUS) 930 696.7 0.0 940 1437.8 0.0

4 (SUS) 940 1437.8 94281.5 950 1630.7 94281.5

4 (SUS) 950 1630.7 94281.5 958 1470.7 94281.5

4 (SUS) 958 2207.2 94281.5 959 649.3 94281.5

4 (SUS) 959 649.3 94281.5 960 1670.2 94281.5

4 (SUS) 960 1166.7 94281.5 970 1258.1 94281.5

4 (SUS) 970 0.0 0.0 980 0.0 0.0

4 (SUS) 980 0.0 0.0 990 0.0 0.0

4 (SUS) 980 0.0 0.0 1000 0.0 0.0

4 (SUS) 1000 1336.8 94281.5 1010 1926.0 94281.5

4 (SUS) 1010 1012.6 94281.5 1018 1092.1 94281.5

4 (SUS) 1018 2174.5 94281.5 1019 1192.1 94281.5

4 (SUS) 1019 1192.1 94281.5 1020 2182.4 94281.5

4 (SUS) 1020 1267.3 94281.5 1030 1824.3 94281.5

4 (SUS) 1030 1824.3 94281.5 1039 1792.4 94281.5

4 (SUS) 1039 1792.4 94281.5 1040 1311.9 94281.5

4 (SUS) 1040 944.4 94281.5 1050 918.5 94281.5

4 (SUS) 1050 918.5 0.0 1060 508.6 0.0

4 (SUS) 1060 0.0 0.0 1070 0.0 0.0

66
 From Code Allowable Code Allowable 1
Load Case Stress Stress To Node Stress Stress 1
Node
KPa KPa KPa KPa 1
4 (SUS) 1070 0.0 0.0 1080 o!oT 0.0

4 (SUS) 1070 0.0 0.0 1090 0.0 0.0

4 (SUS) 1090 0.0 0.0 1100 0.0 0.0

4 (SUS) 1090 0.0 0.0 1110 0.0 0.0

4 (SUS) 1110 619.2 0.0 1120 1257.1 0.0

4 (SUS) 920 1350.1 94281.5 1130 1809.4 94281.5

4 (SUS) 1130 1809.4 94281.5 1140 1233.4 94281.5

4 (SUS) 1140 1233.4 94281.5 1149 1911.4 94281.5

4 (SUS) 1149 1911.4 94281.5 1150 2048.4 94281.5

4 (SUS) 1150 1236.0 94281.5 1158 1294.1 94281.5

4 (SUS) 1158 2049.2 94281.5 1159 2292.9 94281.5

4 (SUS) 1159 2292.9 94281.5 1160 1806.7 94281.5

4 (SUS) 1160 1276.0 94281.5 1170 1466.1 94281.5

4 (SUS) 1170 710.0 94281.5 1180 991.9 94281.5

4 (SUS) 1180 991.9 94281,5 1190 480.4 94281.5

4 (SUS) 1190 480.4 94281.5 1270 535.0 94281.5

4 (SUS) 1270 535.0 94281.5 1279 748.9 94281.5

4 (SUS) 1279 748.9 94281.5 1280 1177.0 94281.5

4 (SUS) 1280 1090.4 94281.5 1288 1760.0 94281.5

4 (SUS) 1288 3174.7 94281.5 1289 4631.3 94281.5

4 (SUS) 1289 4631.3 94281.5 1290 5364.1 94281.5

4 (SUS) 1290 2707.2 94281.5 1300 2720.9 94281.5

4 (SUS) 1300 491.7 94281.5 1380 311.9 94281.5

4 (SUS) 1120 1257.1 94281.5 1200 1414.9 94281.5

67
 Code Allowable Code Allowable
From
Load Case Stress Stress To Node Stress Stress
Node
KPa KPa KPa KPa

4 (SUS) 1200 1414.9 94281.5 1210 1011.8 94281.5

4 (SUS) 1210 1011.8 94281.5 1219 1840.4 94281.5

4 (SUS) 1219 1840.4 94281.5 1220 2047.9 94281.5

4 (SUS) 1220 1278.7 94281.5 1228 1078.4 94281.5

4 (SUS) 1228 1541.4 94281.5 1229 2591.0 94281.5

4 (SUS) 1229 2591.0 94281.5 1230 3378.7 94281.5

4 (SUS) 1230 1916.1 94281.5 1240 2083.5 94281.5

4 (SUS) 1240 1774.4 94281.5 1250 1985.3 94281.5

4 (SUS) 1250 1985.3 94281.5 1260 895.3 94281.5

4 (SUS) 1260 141.5 94281.5 1370 311.9 94281.5

68
6.2 Stress Analysis Report:
Piping Code: B31.1 -2004, April 29, 2005

CODE STRESS CHECK PASSED LOADCASE 4 (SUS) W+Pl+H

Code Stress Ratio is 10.9 at Node 330 LOADCASE: 4 (SUS) W+Pl+H

Code Stress: 10229.7 Allowable: 94281.5
Axial Stress: 1516.0 SNode 600 LOADCASE: (SUS) W+Pl+H
Bending Stress: 9612.8 @Node 330 LOADCASE: (SUS) W+Pl+H
Torsion Stress: 597.4 @Node 370 LOADCASE: (SUS) W+Pl+H
Hoop Stress: 1395.8 @Node 590 LOADCASE: (SUS) W+Pl+H
3D Max Intensity: 10247.7 (aNode 330 LOADCASE: 4 (SUS) W+Pl+H

Mav
Axial Bending Torsion Hoop SIF SrP Code Allowable
Stress
NODF Stress Stress Stress Stress In Out Stress Stress
Inteiisitj'
KPa KPa KPa KPa Plane Plane KPa KPa
KPa
10 504.5 4803.7 571.1 826.6 5429.7 1.000 1.000 5308.2 0.0 0.0
20 813.6 5468.2 -652.6 1296.4 6074.8 1.000 1.000 6281.8 0.0 0.0

20 813.6 5468.2 652.6 1296.4 6415.9 1.000 1.000 6281.8 94281.5 6.7
30 854.3 S446.0 -652.6 1296.4 6094.6 1.000 1.000 6300.3 94281.5 6.7

30 208.7 5446.0 652.6 1296.4 6277.7 1.000 1.000 5654.7 94281.5 6.0
38 235.7 5431.3 -652.6 1296.4 6575.7 1.000 1.000 5667.1 94281.5 6.0

38 235.7 8246.3 652.6 1296.4 8827.8 1.536 1.280 8482.1 94281.5 9.0
39 434.0 10013.9 44.7 1296.4 10829.5 1.536 1.280 10447.9 94281.5 11.1

39 434.0 10013.9 -44.7 1296.4 10448.3 1.536 1.280 10447.9 94281.5 11.1
40 620.3 12541.3 680.3 1296.4 13240.2 1.536 1.280 13161.6 94281.5 14.0

40 620.3 8191.9 -680.3 1296.4 8916.6 1.000 1.000 8812.2 94281.5 9.3
50 620.3 7316.6 680.3 1296.4 8061.1 1.000 1.000 7936.9 94281.5 8.4

50 620.3 7316.6 -680.3 1296.4 8052.6 1.000 1.000 7936.9 94281.5 8.4
58 620.3 4624.4 680.3 1296.4 5426.6 1.000 1.000 5244.7 94281.5 5.6

58 620.3 7088.8 -680.3 1296.4 7828.3 1.536 1.280 7709.1 94281.5 8.2
59 759.6 3558.6 645.8 1296.4 4292.6 1.536 1.280 4318.2 94281.5 4.6

59 759.6 3558.6 -645.8 1296.4 4507.2 1.536 1.280 4318.2 94281.5 4.6
60 696.2 3151.9 197.4 1296.4 3739.3 1.536 1.280 3848.2 94281.5 4.1

60 696.2 2209.6 -197.4 1296.4 2932.6 1.000 1.000 2905.9 94281.5 3.1
70 673.8 2215.6 197.4 1296.4 2855.5 1.000 1.000 2889.3 94281.5 3.1

70 916.2 2215.6 -197.4 1296.4 3156.6 1.000 1.000 3131.8 94281.5 3.3
78 811.3 2245.2 197.4 1296.4 3018.1 1.000 1.000 3056.5 94281.5 3.2

78 811.3 3220.3 -197.4 1296.4 4050.9 1.536 1.280 4031.6 94281.5 4.3
79 675.7 2692.8 -364.4 1296.4 3346.6 1.536 1.280 3368.5 94281.5 3.6

79 675.7 2692.8 364.4 1296.4 3446.5 1.536 1.280 3368.5 94281.5 3.6
80 633.7 2275.9 -693.9 1296.4 3207.2 1.536 1.280 2909.7 94281.5 3.1

80 633.7 1493.1 693.9 1296.4 2539.5 1.000 1.000 2126.8 94281.5 2.3
90 633.7 2122.0 -693.9 1296.4 3069.1 1.000 1.000 2755.7 94281.5 2.9

69
 Max-
Axial Bending Torsion Hoop SIF SIF Code Allowable
Stress
NODH Stress Stress Stress Stress In Out Stress Stress
Intensity
KPa KPa KPa KPa Plane Plane KPa KPa
KPa

90 633.7 2122.0 693.9 1296.4 3085.4 1.000 1.000 2755.7 94281.5 2.9
100 633.7 1559.4 -693.9 1296.4 2579.9 1.000 1.000 2193.1 94281.5 2.3

100 633.7 1559.4 693.9 1296.4 2595.3 1.000 1.000 2193.1 94281.5 2.3
110 633.7 2316.4 -693.9 1296.4 3243.7 1.000 1.000 2950.1 94281.5 3.1

no 633.7 2316.4 693.9 1296.4 3260.3 1.000 1.000 2950.1 94281.5 3.1
120 633.7 1951.4 -693.9 1296.4 2917.9 1.000 1.000 2585.1 94281.5 2.7

120 633.7 1951.4 693.9 1296.4 2934.1 1.000 1.000 2585.1 94281.5 2.7
130 633.7 799.5 -693.9 1296.4 2105.5 1.000 1.000 1433.3 94281.5 1.5

130 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0
140 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0

140 633.7 254.6 693.9 1296.4 1888.7 1.000 1.000 888.4 94281.5 0.9
150 633.7 537.0 -693.9 1296.4 1992.1 1.000 1.000 1170.8 94281.5 1.2

150 633.7 537.0 693.9 1296.4 1984.5 1.000 1.000 1170.8 94281.5 1.2
158 633.7 399.2 -693.9 1296.4 1941.5 1.000 1.000 1033.0 94281.5 1.1

158 633.7 440.6 693.9 1296.4 1949.1 1.159 1.000 1074.4 94281.5 1.1
159 673.6 2928.0 -590.0 1296.4 3697.0 1.159 1.000 3601.6 94281.5 3.8

159 673.6 2928.0 590.0 1296.4 3790.0 1.159 1.000 3601.6 94281.5 3.8
160 496.5 2958.0 -169.3 1296.4 3726.1 1.159 1.000 3454.5 94281.5 3.7

160 496.5 2635.0 169.3 1296.4 3313.7 1.000 1.000 3131.4 94281.5 3.3
170 372.9 2530.7 -169.3 1296.4 3423.8 1.000 1.000 2903.6 94281.5 3.1

170 977.4 2530.7 169.3 1296.4 3524.5 1.000 1.000 3508.2 94281.5 3.7
180 280.7 1943.2 -169.3 1296.4 2931.3 1.000 1.000 2223.9 94281.5 2.4

180 842.6 1943.2 169.3 1296.4 2806.3 1.000 1.000 2785.8 94281.5 3.0
190 415.5 1583.1 -169.3 1296.4 2440.4 1.000 1.000 1998.7 94281.5 2.1

190 900.6 1583.1 169.3 1296.4 2506.8 1.000 1.000 2483.8 94281.5 2.6
200 357.5 1125.1 -169.3 1296.4 2060.0 1.000 1.000 1482.6 94281.5 1.6

200 1078.3 1125.1 169.3 1296.4 2244.6 1.000 1.000 2203.4 94281.5 2.3
208 636.3 752.4 -169.3 1296.4 1597.1 1.000 1.000 1388.7 94281.5 1.5

208 636.3 1110.9 169.3 1296.4 1811.4 1.536 1.280 1747.2 94281.5 1.9
209 552.0 478.7 -242.8 1296.4 1555.9 1.536 1.280 1030.7 94281.5 1.1
209 S52.0 478.7 242.8 1296.4 1590.7 1.536 1.280 1030.7 94281.5 1.1
210 633.7 2076.1 -155.2 1296.4 2709.4 1.536 1.280 2709.8 94281.5 2.9
210 633.7 1370.0 155.2 1296.4 2027.6 1.000 1.000 2003.7 94281.5 2.1
220 633.7 1509.4 -155.2 1296.4 2164.0 1.000 1.000 2143.1 94281.5 2.3
220 633.7 1509.4 155.2 1296.4 2165.5 1.000 1.000 2143.1 94281.5 2.3
228 633.7 984.1 -155.2 1296.4 1721.9 1.000 1.000 1617.8 94281.5 1.7
228 633.7 1014.0 155.2 1296.4 1729.5 1.159 1.000 1647.8 94281.5 1.7

70
 Max
Axial Bending Torsion Hoop SIF SIF Code Allowable
Stress
NOOK Stress Stress Stress Stress In Out Stress Stress
Intensity
KPa KPa KPa KPa Plane Plane KPa KPa
KPa
229 634.7 1315.0 11.4 1296.4 1955.5 1.159 1.000 1949.7 94281.5 2.1

229 634.7 1315.0 -11.4 1296.4 1955.4 1.159 1.000 1949.7 94281.5 2.1
230 629.7 407.6 340.8 1296.4 1635.2 1.159 1.000 1037.3 94281.5 1.1

230 629.7 355.8 -340.8 1296.4 1620.7 1.000 1.000 985.4 94281.5 1.0
240 629.7 2344.3 340.8 1296.4 3041.2 1.000 1.000 2974.0 94281.5 3.2

240 629.7 2344.3 -340.8 1296.4 3051.1 1.000 1.000 2974.0 94281.5 3.2
250 629.7 276.3 340.8 1296.4 1606.6 1.000 1.000 906.0 94281.5 1.0

250 629.7 276.3 -340.8 1296.4 1604.6 1.000 1.000 906.0 94281.5 1.0
258 629.7 497.1 340.8 1296.4 1659.2 1.000 1.000 1126.7 94281.5 1.2

258 629.7 573.1 -340.8 1296.4 1679.3 1.159 1.000 1202.8 94281.5 1.3
259 585.0 1172.8 300.8 1296.4 1935.2 1.159 1.000 1757.8 94281.5 1.9

259 S8S.0 1172.8 -300.8 1296.4 1994.9 1.159 1.000 1757.8 94281.5 1.9
260 375.2 557.3 136.5 1296.4 1511.5 1.159 1.000 932.5 94281.5 1.0

260 375.2 544.4 -136.5 1296.4 1589.6 1.000 1.000 919.6 94281.5 1.0
270 315.3 494.3 136.5 1296.4 1512.9 1.000 1.000 809.6 94281.5 0.9

270 928.4 494.3 -136.5 1296.4 1507.4 1.000 1.000 1422.6 94281.5 1.5
279 688.8 873.8 217.7 1296.4 1738.8 1.536 1.280 1562.5 94281.5 1.7

279 688.8 873.8 -217.7 1296.4 1660.9 1.536 1.280 1562.5 94281.5 1.7
280 662.7 1051.8 213.9 1296.4 1839.0 1.536 1.280 1714.5 94281.5 1.8

280 662.7 686.7 -213.9 1296.4 1592.2 1.000 1.000 1349.4 94281.5 1.4
290 607.6 745.6 213.9 1296.4 1622.3 1.000 1.000 1353.3 94281.5 1.4

290 607.6 745.6 -213.9 1296.4 1638.0 1.000 1.000 1353.2 0.0 0.0
295 560.0 362.5 193.6 1296.4 1508.4 1.000 1.000 922.5 0.0 0.0

300 458.8 2364.0 -383.2 826.6 2925.0 1.000 1.000 2822.8 0.0 0.0
310 755.4 2677.9 437.9 1296.4 3426.6 1.000 1.000 3433.3 0.0 0.0

310 755.4 2677.9 -437.9 1296.4 3543.2 1.000 1.000 3433.3 94281.5 3.6
320 796.2 2652.7 437.9 1296.4 3443.3 1.000 1.000 3448.9 94281.5 3.7

320 153.6 2652.7 -437.9 1296.4 3732.3 1.000 1.000 2806.3 94281.5 3.0
328 180.6 2636.1 437.9 1296.4 3806.8 1.000 1.000 2816.6 94281.5 3.0

328 180.6 4018.8 -437.9 1296.4 4950.2 1.536 1.280 4199.4 94281.5 4.5
329 393.0 6055.5 111.5 1296.4 6915.3 1.536 1.280 6448.4 94281.5 6.8

329 393.0 6055.5 -111.5 1296.4 6586.0 1.536 1.280 6448.4 94281.5 6.8
330 617.5 9452.8 -268.5 1296.4 10098.8 1.536 1.280 10070.2 94281.5 10.7

330 617.5 6172.0 268.5 1296.4 6810.7 1.000 1.000 6789.5 94281.5 7.2
340 617.5 5546.7 -268.5 1296.4 6201.7 1.000 1.000 6164.2 94281.5 6.5

340 617.5 5546.7 268.5 1296.4 6187.5 1.000 1.000 6164.2 94281.5 6.5
348 617.5 3506.6 -268.5 1296.4 4173.0 1.000 1.000 4124.0 94281.5 4.4

71
 Max
Axial Bending Torsion Hoop SIF SIF Code Allowable
Stress
NODK Stress Stress Stress Stress In Out Stress Stress
Intensity
KPa KPa KPa KPa Plane Plane KPa KPa
KPa
348 617.5 5360.1 268.5 1296.4 6001.6 1.536 1 1.280 5977.6 1 94281.5 1 6.3
349 701.3 2773.2 -401.8 1296.4 3447.2 1.536 1.280 3474.4 94281.5 3.7

349 701.3 2773.2 401.8 1296.4 3566.2 1.536 1.280 3474.4 94281.5 3.7
350 616.6 2373.3 -287.9 1296.4 3060.S 1.536 1.280 2989.9 94281.5 3.2

350 616.6 1577.8 287.9 1296.4 2283.0 1.000 1.000 2194.5 94281.5 2.3
360 594.2 1568.0 -287.9 1296.4 2296.4 1.000 1.000 2162.1 94281.5 2.3

360 851.4 1568.0 287.9 1296.4 2487.0 1.000 1.000 2419.4 94281.5 2.6
368 746.6 1522.7 -287.9 1296.4 2340.3 1.000 1.000 2269.3 94281.5 2.4

368 746.6 2016.4 287.9 1296.4 2822.4 1.536 1.280 2763.0 94281.5 2.9
369 625.7 1859.8 276.5 1296.4 2544.0 1.536 1.280 2485.5 94281.5 2.6

369 625.7 1859.8 -276.5 1296.4 2546.2 1.536 1.280 2485.5 94281.5 2.6
370 627.8 1797.2 652.4 1296.4 2748.2 1.536 1.280 2425.0 94281.5 2.6

370 627.8 1200.6 -652.4 1296.4 2277.7 1.000 1.000 1828.3 94281.5 1.9
380 627.8 2200.9 652.4 1296.4 3109.4 1.000 1.000 2828.7 94281.5 3.0

380 627.8 2200.9 -652.4 1296.4 3115.1 1.000 1.000 2828.7 94281.5 3.0
390 627.8 2507.7 652.4 1296.4 3390.3 1.000 1.000 3135.5 94281.5 3.3

390 627.8 2507.7 -652.4 1296.4 3396.2 1.000 1.000 3135.5 94281.5 3.3
400 627.8 3674.3 652.4 1296.4 4489.6 1.000 1.000 4302.1 94281.5 4.6

400 627.8 3674.3 -652.4 1296.4 4495.7 1.000 1.000 4302.1 94281.5 4.6
410 627.8 3304.2 652.4 1296.4 4136.8 1.000 1.000 3931.9 94281.5 4.2

410 627.8 3304.2 -652.4 1296.4 4142.8 1.000 1.000 3931.9 94281.5 4.2
420 627.8 2126.3 652.4 1296.4 3041.8 1.000 1.000 2754.1 94281.5 2.9

420 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0
430 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0

430 627.8 1520.4 -652.4 1296.4 2513.4 1.000 1.000 2148.1 94281.5 2.3
440 627.8 1783.1 652.4 1296.4 2735.8 1.000 1.000 2410.8 94281.5 2.6

440 627.8 1783.1 -652.4 1296.4 2741.3 1.000 1.000 2410.8 94281.5 2.6
448 627.8 989.8 652.4 1296.4 2160.5 1.000 1.000 1617.6 94281.5 1.7

448 627.8 1129.7 -652.4 1296.4 2235.4 1.159 1.000 1757.5 94281.5 1.9
449 673.6 1627.0 600.4 1296.4 2563.0 1.159 1.000 2300.5 94281.5 2.4

449 673.6 1627.0 -600.4 1296.4 2595.1 1.159 1.000 2300.5 94281.5 2.4
450 502.4 1884.9 237.1 1296.4 2674.0 1.159 1.000 2387.2 94281.5 2.5

450 502.4 1730.4 -237.1 1296.4 2499.6 1.000 1.000 2232.8 94281.5 2.4
460 378.8 1659.4 237.1 1296.4 2573.9 1.000 1.000 2038.2 94281.5 2.2

460 976.3 1659.4 -237.1 1296.4 2678.0 1.000 1.000 2635.7 94281.5 2.8
470 279.5 1274.5 237.1 1296.4 2295.3 1.000 1.000 1554.0 94281.5 1.6

470 841.4 1274.5 -237.1 1296.4 2169.6 1.000 1.000 2115.9 94281.5 2.2
480 414.4 1059.2 237.1 1296.4 1967.6 1.000 1.000 1473.6 94281.5 1.6

72
 Max
Axial Bending Torsion Hoop SIF SIF Code Allowable
Stress
NODI Stress Stress Stress Stress In Out Stress Stress
Intensity
KPa KPa KPa KPa Plane Plane KPa KPa
KPa

480 899.5 1059.2 -237.1 1296.4 2030.7 1.000 1.000 1958.7 94281.5 2.1
490 356.3 831.6 237.1 1296.4 1818.2 1.000 1.000 1187.9 94281.5 1.3

490 1084.6 831.6 -237.1 1296.4 2004.8 1.000 1.000 1916.2 94281.5 2.0
498 642.6 716.6 237.1 1296.4 1647.3 1.000 1.000 1359.1 94281.5 1.4

498 642.6 1096.1 -237.1 1296.4 1845.2 1.536 1.280 1738.7 94281.5 1.8
499 552.2 917.6 113.3 1296.4 1661.6 1.536 1.280 1469.8 94281.5 1.6

499 552.2 917.6 -113.3 1296.4 1693.0 1.536 1.280 1469.8 94281.5 1.6
500 627.8 1836.5 -103.3 1296.4 2466.6 1.536 1.280 2464.3 94281.5 2.6

500 627.8 1235.8 103.3 1296.4 1889.1 1.000 1.000 1863.6 94281.5 2.0
510 627.8 1364.2 -103.3 1296.4 2010.4 1.000 1.000 1991.9 94281.5 2.1

510 627.8 1364.2 103.3 1296.4 2004.2 1.000 1.000 1991.9 94281.5 2.1
518 627.8 896.6 -103.3 1296.4 1614.0 1.000 1.000 1524.3 94281.5 1.6

518 627.8 959.9 103.3 1296.4 1655.7 1.159 1.000 1587.7 94281.5 1.7
519 631.9 1254.2 -267.2 1296.4 2006.0 1.159 1.000 1886.1 94281.5 2.0

519 631.9 1254.2 267.2 1296.4 1993.9 1.159 1.000 1886.1 94281.5 2.0
520 631.7 996.2 -440.2 1296.4 1973.2 1.159 1.000 1627.9 94281.5 1.7

520 631.7 917.7 440.2 1296.4 1920.9 1.000 1.000 1549.4 94281.5 1.6
530 631.7 2936.7 -440.2 1296.4 3661.6 1.000 1.000 3568.5 94281.5 3.8

530 631.7 2936.7 440.2 1296.4 3675.5 1.000 1.000 3568.5 94281.5 3.8
540 631.7 1007.4 -440.2 1296.4 1979.8 1.000 1.000 1639.2 94281.5 1.7

540 631.7 1007.4 440.2 1296.4 1970.8 1.000 1.000 1639.2 94281.5 1.7
548 631.7 520.2 -440.2 1296.4 1754.7 1.000 1.000 1151.9 94281.5 1.2

548 631.7 523.1 440.2 1296.4 1750.6 1.159 1.000 1154.9 94281.5 1.2
549 587.1 1048.8 -139.4 1296.4 1754.4 1.159 1.000 1636.0 94281.5 1.7

549 587.1 1048.8 139.4 1296.4 1784.7 1.159 1.000 1636.0 94281.5 1.7
550 376.2 941.0 225.1 1296.4 1892.7 1.159 1.000 1317.2 94281.5 1.4

550 376.2 911.5 -225.1 1296.4 1912.2 1.000 1.000 1287.7 94281.5 1.4
560 316.3 913.6 225.1 1296.4 1926.4 1.000 1.000 1229.9 94281.5 1.3

560 895.2 913.6 -225.1 1296.4 1889.5 1.000 1.000 1808.8 94281.5 1.9
569 666.7 1120.4 -110.6 1296.4 1833.6 1.536 1.280 1787.1 94281.5 1.9

569 666.7 1120.4 110.6 1296.4 1818.0 1.536 1.280 1787.1 94281.5 1.9
570 645.2 1030.0 -179.9 1296.4 1783.5 1.536 1.280 1675.2 94281.5 1.8

570 645.2 798.7 179.9 1296.4 1612.2 1.000 1.000 1444.0 94281.5 1.5
580 590.2 824.3 -179.9 1296.4 1617.2 1.000 1.000 1414.5 94281.5 1.5

580 590.2 824.3 179.9 1296.4 1656.1 1.000 1.000 1414.5 0.0 0.0
295 542.5 1201.9 -162.8 1296.4 1945.8 1.000 1.000 1744.4 0.0 0.0

295 498.8 776.8 -187.0 1395.8 1795.3 1.000 1.000 1275.6 0.0 0.0

73
 Max
Axial Bending Torsion Hoop SIF SIF Code Allowable
Stress
NODK Stress Stress Stress Stress In Out
Intensity
KPa KPa KPa KPa Plane Plane
KPa
590 451.2 765.9 206.6 1395.8 1753.9 1.000 1.000 1217.1 0.0 0.0

590 451.2 765.9 -206.6 1395.8 1837.9 1.000 1.000 1217.1 94281.5 1.3
600 311.6 737.4 206.6 1395.8 1864.3 1.000 1.000 1049.0 94281.5 1.1

600 515.5 737.4 -206.6 1395.8 2334.7 1.000 1.000 2252.9 94281.5 2.4
608 964.7 686.5 206.6 1395.8 1833.3 1.000 1.000 1651.2 94281.5 1.8

608 964.7 984.1 -206.6 1395.8 2019.5 1.439 1.199 1948.8 94281.5 2.1
609 747.4 341.7 126.6 1395.8 1578.4 1.439 1.199 1089.1 94281.5 1.2

609 747.4 341.7 -126.6 1395.8 1569.9 1.439 1.199 1089.1 94281.5 1.2
610 675.5 362.9 7.3 1395.8 1544.7 1.439 1.199 1038.4 94281.5 1.1

610 675.5 300.1 -7.3 1395.8 1544.7 1.000 1.000 975.6 94281.5 1.0
620 675.5 1686.2 7.3 1395.8 2359.1 1.000 1.000 2361.7 94281.5 2.5

620 675.5 1686.2 -7.3 1395.8 2361.7 1.000 1.000 2361.7 94281.5 2.5
630 675.5 1050.7 7.3 1395.8 1755.5 1.000 1.000 1726.2 94281.5 1.8

630 675.5 1050.7 -7.3 1395.8 1755.4 1.000 1.000 1726.2 94281.5 1.8
640 675.5 538.3 7.3 1395.8 1544.7 1.000 1.000 1213.9 94281.5 1.3

640 675.5 538.3 -7.3 1395.8 1544.7 1.000 1.000 1213.9 94281.5 1.3
650 675.5 3250.6 7.3 1395.8 3923.6 1.000 1.000 3926.2 94281.5 4.2

650 675.5 3250.6 -7.3 1395.8 3926.2 1.000 1.000 3926.2 94281.5 4.2
658 675.5 703.8 7.3 1395.8 1545.0 1.000 1.000 1379.3 94281.5 1.5

658 675.5 898.6 -7.3 1395.8 1613.3 1.439 1.199 1574.2 94281.5 1.7
659 680.8 940.3 76.5 1395.8 1692.0 1.439 1.199 1621.0 94281.5 1.7

659 680.8 940.3 -76.5 1395.8 1681.5 1.439 1.199 1621.0 94281.5 1.7
660 682.2 1130.7 114.1 1395.8 1871.5 1.439 1.199 1812.9 94281.5 1.9

660 682.2 885.8 -114.1 1395.8 1677.4 1.000 1.000 1567.9 94281.5 1.7
670 682.2 4934.1 114.1 1395.8 5605.0 1.000 1.000 5616.3 94281.5 6.0

670 682.2 4934.1 -114.1 1395.8 5621.0 1.000 1.000 5616.3 94281.5 6.0
678 682.2 2181.6 114.1 1395.8 2857.0 1.000 1.000 2863.8 94281.5 3.0

678 682.2 3412.3 -114.1 1395.8 4100.8 1.573 1.311 4094.5 94281.5 4.3
679 498.0 1024.8 -66.1 1395.8 1910.0 1.573 1.311 1522.7 94281.5 1.6

679 498.0 1024.8 66.1 1395.8 1916.3 1.573 1.311 1522.7 94281.5 1.6
680 252.2 1197.0 -202.5 1395.8 2343.4 1.573 1.311 1449.3 94281.5 1.5

680 252.2 769.8 202.5 1395.8 1993.3 1.000 1.000 1022.0 94281.5 1.1
690 235.0 777.6 -202.5 1395.8 1974.7 1.000 1.000 1012.7 94281.5 1.1

690 941.3 777.6 202.5 1395.8 1806.0 1.000 1.000 1719.0 94281.5 1.8
700 417.2 1023.0 -202.5 1395.8 2020.9 1.000 1.000 1440.1 94281.5 1.5

700 1286.8 1023.0 202.5 1395.8 2371.0 1.000 1.000 2309.7 94281.5 2.4
708 1011.5 1155.1 -202.5 1395.8 2240.3 1.000 1.000 2166.6 94281.5 2.3

74
 Max
Axial Bending Torsion Hoop SIF SIF Code Allowable
Stress
N()i:)l, Stress Stress Stress Stress In Out Stress Stress
Intensity
KPa KPa KPa KPa Plane Plane KPa KPa
KPa
708 1011.5 1657.8 202.5 1395.8 2699.9 1.439 1.199 2669.3 94281.5 2.8
709 785.2 619.1 -95.4 1395.8 1601.4 1.439 1.199 1404.4 94281.5 1.5

709 785.2 619.1 95.4 1395.8 1568.7 1.439 1.199 1404.4 94281.5 1.5
710 682.2 539.3 61.8 1395.8 1556.8 1.439 1.199 1221.5 94281.5 1.3

710 682.2 431.1 -61.8 1395.8 1553.2 1.000 1.000 1113.3 94281.5 1.2
720 682.2 1732.0 61.8 1395.8 2402.5 1.000 1.000 2414.2 94281.5 2.6

720 682.2 1732.0 -61.8 1395.8 2417.4 1.000 1.000 2414.2 94281.5 2.6
730 682.2 838.8 61.8 1395.8 1612.8 1.000 1.000 1521.0 94281.5 1.6

730 682.2 838.8 -61.8 1395.8 1604.1 1.000 1.000 1521.0 94281.5 1.6
740 682.2 379.7 61.8 1395.8 1552.5 1.000 1.000 1061.9 94281.5 1.1

740 682.2 379.7 -61.8 1395.8 1552.3 1.000 1.000 1061.9 0.0 0.0
750 682.2 957.7 55.9 1395.8 1693.4 2.158 2.544 1639.8 0.0 0.0

750 628.3 807.9 -122.3 1296.4 1572.0 2.158 2.544 1436.2 0.0 0.0
760 628.3 756.0 167.8 1296.4 1593.5 1.000 1.000 1384.3 0.0 0.0

760 628.3 756.0 -167.8 1296.4 1590.0 1.000 1.000 1384.3 94281.5 1.5
770 628.3 902.8 167.8 1296.4 1672.8 1.000 1.000 1531.2 94281.5 1.6

770 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0
780 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0

780 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0
790 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0

780 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0
800 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0

800 764.6 435.5 -331.3 1296.4 1600.2 1.000 1.000 1200.1 94281.5 1.3
810 1208.6 489.2 331.3 1296.4 1949.6 1.000 1.000 1697.8 94281.5 1.8

810 310.8 489.2 -331.3 1296.4 1777.1 1.000 1.000 800.0 94281.5 0.8
818 329.0 497.1 331.3 1296.4 1603.4 1.000 1.000 826.1 94281.5 0.9

818 329.0 1193.9 -331.3 1296.4 2246.6 2.415 2.013 1522.9 94281.5 1.6
819 457.3 724.6 276.5 1296.4 1645.9 2.415 2.013 1181.9 94281.5 1.3

819 457.3 724.6 -276.5 1296.4 1768.2 2.415 2.013 1181.9 94281.5 1.3
820 620.8 2438.1 77.7 1296.4 3070.4 2.415 2.013 3059.0 94281.5 3.2

820 620.8 1062.8 -77.7 1296.4 1732.7 1.000 1.000 1683.7 94281.5 1.8
830 620.8 1264.4 77.7 1296.4 1907.4 1.000 1.000 1885.3 94281.5 2.0

830 620.8 1264.4 -77.7 1296.4 1913.1 1.000 1.000 1885.3 94281.5 2.0
839 623.4 1290.7 173.0 1296.4 1970.7 2.415 2.013 1914.2 94281.5 2.0

839 623.4 1290.7 -173.0 1296.4 1972.8 2.415 2.013 1914.2 94281.5 2.0
840 626.1 777.3 231.7 1296.4 1661.5 2.415 2.013 1403.4 94281.5 1.5

840 626.1 364.2 -231.7 1296.4 1541.6 1.000 1.000 990.3 94281.5 1.1
850 626.1 334.9 231.7 1296.4 1537.7 1.000 1.000 961.0 94281.5 1.0

75
 Max
Axial Bending Torsion Hoop SIF SIF Code Allowable
Stress
NODH Stress Stress Stress Stress In Out Stress Stress
Intensity
KPa KPa KPa KPa Plane Plane KPa KPa
.KP"a

850 626.1 334.9 -231.7 1296.4 1537.2 1.000 1.000 961.0 0.0 0.0
860 433.6 70.7 90.3 912.2 1075.7 1.000 1.000 504.2 0.0 0.0

860 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0
870 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0

870 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0
880 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0

870 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0
890 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0

890 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0
900 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0

890 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0
910 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0

910 431.1 181.7 -75.9 912.2 1074.3 1.000 1.000 612.8 0.0 0.0
920 620.8 643.6 194.6 1296.4 1573.2 1.000 1.000 1264.5 0.0 0.0

750 676.0 1105.2 -45.1 1395.8 1809.8 2.158 2.544 1781.3 0.0 0.0
930 676.0 160.0 49.8 1395.8 1548.0 1.000 1.000 836.1 0.0 0.0

930 676.0 160.0 -49.8 1395.8 1548.0 1.000 1.000 836.1 0.0 0.0
940 510.9 1155.5 84.7 1064.0 1679.9 1.000 1.000 1666.4 0.0 0.0

940 510.9 1155.5 -84.7 1064.0 1675.3 1.000 1.000 1666.4 94281.5 1.8
950 510.9 1350.5 84.7 1064.0 1864.4 1.000 1.000 1861.4 94281.5 2.0

950 510.9 1350.5 -84.7 1064.0 1869.1 1.000 1.000 1861.4 94281.5 2.0
958 510.9 1187.9 84.7 1064.0 1708.7 1.000 1.000 1698.8 94281.5 1.8

958 510.9 2107.5 -84.7 1064.0 2623.9 2.120 1.766 2618.4 94281.5 2.8
959 509.2 388.5 307.8 1064.0 1396.5 2.120 1.766 897.7 94281.5 1.0

959 509.2 388.5 -307.8 1064.0 1396.1 2.120 1.766 897.7 94281.5 1.0
960 507.1 1696.7 94.5 1064.0 2214.8 2.120 1.766 2203.9 94281.5 2.3

960 507.1 952.0 -94.5 1064.0 1505.3 1.000 1.000 1459.1 94281.5 1.5
970 507.1 1090.4 94.5 1064.0 1621.9 1.000 1.000 1597.6 94281.5 1.7

970 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0
980 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0

980 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0
990 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0

980 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0
1000 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0

1000 757.6 955.6 -133.9 1296.4 1761.8 1.000 1.000 1713.3 94281.5 1.8
1010 1173.6 884.1 133.9 1296.4 2116.7 1.000 1.000 2057.7 94281.5 2.2

1010 260.8 884.1 -133.9 1296.4 1939.7 1.000 1.000 1144.9 94281.5 1.2

76
 A\ial Bending Torsion Hoop Max SIF SIF Code Allowable
Stress Ratio
ODH Stress Stress Stress Stress In Out Stress Stress
KPa [ntensitv %
KPa KPa KPa Plane Plane KPa KPa
KPa
1018 316.5 875.1 133.9 1296.4 1861.1 1.000 1.000 1191.6 94281.5 Tv
lOIS 316.5 2109.8 -133.9 1296.4 3002.1 2.415 2.013 2426.2 94281.5 2.6
1019 452.3 996.1 64.1 1296.4 1824.9 2.415 2.013 1448.4 94281.5 1.5

1019 452.3 996.1 -64.1 1296.4 1830.2 2.415 2.013 1448.4 94281.5 1.5
1020 626.3 1557.4 -38.0 1296.4 2181.7 2.415 2.013 2183.7 94281.5 2.3

1020 626.3 659.5 38.0 1296.4 1455.6 1.000 1.000 1285.8 94281.5 1.4
1030 626.3 1055.1 -38.0 1296.4 1710.0 1.000 1.000 1681.4 94281.5 1.8

1030 626.3 1055.1 38.0 1296.4 1706.7 1.000 1.000 1681.4 94281.5 1.8
1039 627.0 968.9 35.2 1296.4 1631.6 2.415 2.013 1595.9 94281.5 1.7

1039 627.0 968.9 -35.2 1296.4 1627.1 2.415 2.013 1595.9 94281.5 1.7
1040 627.5 587.5 80.8 1296.4 1473.3 2.415 2.013 1215.0 94281.5 1.3

1040 627.5 278.3 -80.8 1296.4 1457.1 1.000 1.000 905.8 94281.5 1.0
1050 627.5 249.2 80.8 1296.4 1456.6 1.000 1.000 876.6 94281.5 0.9

1050 627.5 249.2 -80.8 1296.4 1456.5 1.000 1.000 876.6 0.0 0.0
1060 434.2 50.1 31.5 912.2 1063.5 1.000 1.000 484.3 0.0 0.0

1060 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0
1070 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0

1070 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0
1080 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0

1070 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0
1090 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0

1090 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0
1100 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0

1090 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0
1110 0.0 0.0 0.0 0.0 0.0 0.000 0.000 0.0 0.0 0.0

1110 433.7 95.7 -43.7 912.2 1065.3 1.000 1.000 529.4 0.0 0.0
1120 626.3 409.7 112.2 1296.4 1474.8 1.000 1.000 1036.0 0.0 0.0

920 620.8 643.6 -194.6 1296.4 1575.7 1.000 1.000 1264.5 94281.5 1.3
1130 620.8 1138.8 194.6 1296.4 1857.1 1.000 1.000 1759.6 94281.5 1.9

1130 620.8 1138.8 -194.6 1296.4 1863.4 1.000 1.000 1759.6 94281.5 1.9
1140 620.8 598.2 194.6 1296.4 1560.1 1.000 1.000 1219.1 94281.5 1.3

1140 620.8 598.2 -194.6 1296.4 1562.3 1.000 1.000 1219.1 94281.5 1.3
1149 623.4 1137.6 215.2 1296.4 1872.7 2.415 2.013 1761.0 94281.5 1.9

1149 623.4 1137.6 -215.2 1296.4 1874.6 2.415 2.013 1761.0 94281.5 1.9
1150 626.1 1224.3 206.3 1296.4 1937.1 2.415 2.013 1850.4 94281.5 2.0

1150 626.1 515.4 -206.3 1296.4 1550.4 1.000 1.000 1141.5 94281.5 1.2
1158 626.1 585.6 206.3 1296.4 1568.1 1.000 1.000 1211.7 94281.5 1.3

77
 Max
Axial Bending Torsion Hoop SIF SIF Code Allowable
Stress
NODK Stress Stress Stress Stress In Out Stress Stress
Intensity
KPa KPa KPa KPa Plane Plane KPa KPa
KPa
1158 626.1 1227.1 -206.3 1296.4 1936.8 2.415 2.013 1853.2 94281.5 2.0
1159 671.3 1456.4 -49.9 1296.4 2126.6 2.415 2.013 2127.8 94281.5 2.3

1159 671.3 1456.4 49.9 1296.4 2130.1 2.415 2.013 2127.8 94281.5 2.3
1160 752.0 966.4 -295.9 1296.4 1911.0 2.415 2.013 1718.4 94281.5 1.8

1160 752.0 479.5 295.9 1296.4 1584.6 1.000 1.000 1231.4 94281.5 1.3
1170 878.1 581.2 -295.9 1296.4 1758.3 1.000 1.000 1459.2 94281.5 1.5

1170 -116.5 581.2 295.9 1296.4 2116.7 1.000 1.000 697.6 94281.5 0.7
1180 231.9 865.0 -295.9 1296.4 1996.8 1.000 1.000 1096.9 94281.5 1.2

1180 231.9 865.0 295.9 1296.4 2045.6 1.000 1.000 1096.9 94281.5 1.2
1190 168.5 358.5 -118.4 669.5 890.4 1.000 1.000 527.0 94281.5 0.6

1190 168.5 358.5 118.4 669.5 948.9 1.000 1.000 527.0 94281.5 0.6
1270 213.4 373.2 -118.4 669.5 866.5 1.000 1.000 586.7 94281.5 0.6

1270 213.4 373.2 118.4 669.5 930.5 1.000 1.000 586.7 94281.5 0.6
1279 362.6 449.6 4.7 669.5 853.3 1.123 1.000 812.2 94281.5 0.9

1279 362.6 449.6 -4.7 669.5 852.9 1.123 1.000 812.2 94281.5 0.9
1280 315.7 902.0 132.6 669.5 1238.9 1.123 1.000 1217.7 94281.5 1.3

1280 315.7 811.9 -132.6 669.5 1158.3 1.000 1.000 1127.5 94281.5 1.2
1288 315.7 1493.0 132.6 669.5 1820.5 1.000 1.000 1808.7 94281.5 1.9

1288 315.7 2952.8 -132.6 669.5 3279.2 1.988 1.656 3268.5 94281.5 3.5
1289 116.0 4625.5 191.0 669.5 5147.4 1.988 1.656 4741.5 94281.5 5.0

1289 116.0 4625.5 -191.0 669.5 4756.9 1.988 1.656 4741.5 94281.5 5.0
1290 -18.9 5489.4 140.7 669.5 6138.5 1.988 1.656 5508.2 94281.5 5.8

1290 -18.9 2765.1 -140.7 669.5 3159.0 1.000 1.000 2784.0 94281.5 3.0
1300 -30.1 2768.1 140.7 669.5 3433.6 1.000 1.000 2798.2 94281.5 3.0

1300 597.9 0.0 -0.0 882.6 1032.3 1.000 1.000 597.9 188171.7 0.3
1380 418.1 0.0 0.0 882.6 1032.3 1.000 1.000 418.1 188171.7 0.2

1120 626.3 409.7 -112.2 1296.4 1474.5 1.000 1.000 1036.0 188171.7 0.6
1200 626.3 575.9 112.2 1296.4 1492.1 1.000 1.000 1202.2 188171.7 0.6

1200 6263 575.9 -112.2 1296.4 1491.6 1.000 1.000 1202.2 188171.7 0.6
1210 626.3 90.3 112.2 1296.4 1462.0 1.000 1.000 716.6 188171.7 0.4

1210 626.3 90.3 -112.2 1296.4 1461.9 1.000 1.000 716.6 188171.7 0.4
1219 627.0 772.1 72.4 1296.4 1511.4 2.366 1.972 1399.0 188171.7 0.7

1219 627.0 772.1 -72.4 1296.4 1509.1 2.366 1.972 1399.0 188171.7 0.7
1220 627.5 1004.6 13.0 1296.4 1660.2 2.366 1.972 1632.1 188171.7 0.9

1220 627.5 508.8 -13.0 1296.4 1445.9 1.000 1.000 1136.3 188171.7 0.6
1228 627.5 255.2 13.0 1296.4 1445.6 1.000 1.000 882.6 188171.7 0.5

1228 627.5 598.9 -13.0 1296.4 1446.2 2.366 1.972 1226.4 188171.7 0.7
1229 736.3 726.5 -12.8 1296.4 1511.9 2.366 1.972 1462.8 188171.7 0.8

78
 Max
Axial Bending Torsion Hoop SIF SIF Code Allowable
Stress
NODH Stress Stress Stress Stress In Out Stress Stress
Intensity
KPa KPa KPa KPa Plane Plane KPa KPa
KPa

1229 736.3 726.5 12.8 1296.4 1510.0 2.366 1.972 1462.8 188171.7 0.8
1230 842.6 1473.2 -34.1 1296.4 2311.4 2.366 1.972 2315.8 188171.7 1.2

1230 842.6 623.0 34.1 1296.4 1521.1 1.000 1.000 1465.5 188171.7 0.8
1240 968.6 595.1 -34.1 1296.4 1625.6 1.000 1.000 1563.8 188171.7 0.8

1240 629.9 595.1 34.1 1296.4 1450.9 1.000 1.000 1225.1 188171.7 0.7
1250 787.3 561.2 -34.1 1296.4 1463.2 1.000 1.000 1348.5 188171.7 0.7

1250 787.3 561.2 34.1 1296.4 1448.1 1.000 1.000 1348.5 188171.7 0.7
1260 408.9 221.5 -13.6 669.5 821.1 1.000 1.000 630.3 188171.7 0.3

1260 247.6 0.0 0.0 882.6 1032.3 1.000 1.000 247.6 188171.7 0.1
1370 418.1 0.0 0.0 882.6 1032.3 1.000 1.000 418.1 188171.7 0.2

79
6.3 Conclusion:

• Code stress (as per the stress analysis report) at each node is less than the maximum
allowable stress, hence the HRH design is safe.

• In CAESAR II 5.0 software we can also change the input to see what are the affects of
those changes like; we can change material of piping and reduce weight which results
in low stress values in piping system, we can reduce insulation thickness which again
results in less material so less cost and low stress values.

• If anyhow we are able to reduce the weight we can also reduce the number of hangers
and other piping supports. Hence reduction in the cost of piping supports.

80
REFERENCES

[1] Fang Li. CAESAR II software pipeline with computation Several problems of
stress. Chemical Equipment [J] 2004.12 (6).

[2] Zhang Shujun, Li Guobin, Chen Bai-lian. AutoPSA and CAESAR II pipe stress
analysis in the comparison. Boiler manufacturing [J] .2008.1 (I)

[3] R. N. Nevin, Some Aspects of the Design of Modem Piping System

[4] Blair, J. S. (1963). The Design of High Temperature Steam Pipes: Proc. Joint
International Conference on Creep, 4-77.

[5] Mao You Ren, Zhao Xiaozheng, Jiang-Tao Liu, CAESAR II software piping
stress analysis in the Power Plant applications [J] .2006.3 (3)

[6] Indian Boiler Regulations containing Indian Boiler Regulations, 1950 and Indian
Boiler Act, 1923

[7] ASME B 16.34 - 2004, Valves - Flanged, Threaded and Welding end, An
American National Standard, The American Society of Mechanical Engineers, Three
Park Avenue. New York, NY 10016

[8] ASME B3I.1 - 2004, Power Piping, ASME Code for pressure piping, B31. An
American National Standard, The American Society of Mechanical Engineers, Three
Park Avenue. New York, NY 10016

[9] Peter Smith, "The fundamentals of Piping design"

[10] M. Mohitpour, H. Golshan, A. murray "Pipeline design and Construction

(Second edition)"

81
[11] J. Phillip Ellenberger, "Piping System and Pipeline, ASME Code simplified"

[12] Peter Smith, "Piping Materials- Selection and Applications"

82