A TUVRheinland® Genau. Richtig. Dokumentation der Berechnung zu Priifung (documentation of the approval calculation) Abhitzekessel AHK 1600 / 10 Rev.B waste heat recovery AHK 1600 / 10 Rev.B Prifgrundiage: EN 12953 standard: EN 12953 Positionsplan position of calculation 1. Kesselmante! boiler shell 2. Vorderwand front boiler end plate 3. Hinterwand rear boiler end plate 4, Eckanker gusset stay 5. Mannlochdeckel man hole cover Zeichnungs-Nr. drawing-no. 1169-1-000 Rev.B Vorprif-Nr. approval-no. Wo170610 Projekt: Project: 1169/1 Berlin den Juni 2017 TUV Rheinland Industrie Service GmbH (Region NORD OST in Berlin / Postanschrif: 10882 Berlir/ Tel. 030 7562-1647 / Fax 030 7562-1673 / Email WOLFRO@de TUV.COM)wolfro TOV Industrieservice Gnbi Project: 1169/1 pate : 07.06.2017 Brewing no : Schneider ser wolfe Fllenaite i 7 Page rer 8 Cylindrical Shell Shell boilers acc. to EN 12953, 2016-5, ctions 7/8 name/ item : ‘1.1 boiler shell'// AHK_1600/10 safety concept . . . . 5 ~ acc. to EN-12953 ‘ calculation for. |} 1:1 - design edition of standard) < | : 0 - EN 12953, Section 7/8, Edition 2002 = design date Po = 10 Bar deaign pressure fe es 78 Gatedlation Pemperchure {TYPE DECLARATION Component. <2 + #1 = eylindrical shell calculation with outside or inside dianeter i 1 - outer dianeter Corrosion c2'= 0.75 mm acc to 5.8.2: 1 ~ Yes cylindrical shell, Tube Result at sizes: (act - req) / req, at other data: (allow - act) / act Data in percent as result stands for over-/undersize Main nent Fequired wall thickness of cyl. shell / pipe: ‘ce = 8.06 mm — pe/10-dos / {(2-fs-pc/10) -v + 2-pe/10) (17) = 6:00 minimum shell thickness acc to 7.1.1. a) ers = 8.75 mn analysis wall thickness = es - cl.s - ¢2.9 cls = 0:50 mm manufacturing tolerance 2:8 = 0.75 mm_—_corrosion allowance ee req. wall thicknesses of shell incl, allowances: See oe eos ee sy 1 = 0.40 mm with manufacturing tolerance <2 = 0.75 mm corrosion allowance effective length of shell lrs = 108.33 mm Yi(dis + ers) -ers) 8) dis = 1332.50 mn dos - 2-ers all efficiency caused by openings vall = 0.49 Pe/10-dis / ((2-fs ~ pe/10) -ers) [ay max diameter of an unreinforced isolated opening dob.max = 226.38 mm 2+((Irs / v.all) ~ 1rs} (28) ‘type of reinforcement 5 - manhole ring opening with internal Cover? :1 ~ Yes Consideration z,b at area comparison : 0 - No DIM Win 5-0 Rev.13.9 10.05.2017, 61 = 31.03.2017 © SOV-WORD Syatens Fasen,D 135-20063608 D:\DIbO_ WH Datan\Schneider\Continuance: shell boilers acc, to EN 12953, 2016-5, secticns 7/8 cy... Date 07.06.2017 Project: 1169/1 User : woltro Drawing no + Schneider page: zor 5 namo/ ites: 1.1 boiler shell /7 Aik 1600/70 Result Galculation of reinforcement of isolated opening [8.3]: existing mean stress: ta = pc/10-(2-ApsAES+Afb+0.7 -Afp) /y (2: (AfS+£b/fs “Afb+0.7 Apr) fa 98.1 N/mm? ts = 156.2 N/m? design stress = ~ S38 determined efficiency: vb = dis -(Afs+£b/fs-Afb+0.7-Afp) / (ers: (2-Ap+Afb-£b/fs “Afb)) S wb. =~ 0.780 aL = 2579 mn? with cross-sectional area as compensation Afs = 948 mn? cross-sectional area of main body | Af =~ 1631 mm? cross-sectional ‘area of nozzle Ap O mn? cross-sectional area of reinforcing pad ap = 192102 mm? pressure-loaded area type of reinforcement . . : 2 - nozzle, set-on without reinf. pad extruded nozzle... |: 0 - No inclination of nozzle. . :0 ~ no inclination Result required wall thickness of nozzli ecb = 4.51 mn (0.015 "dob + 3.2) | eb = 8.80 mn _ entered wall thickness el.b 1.10 mn manufacturing tolerance 2b = 0.75 mm corrosion allowance | 138 | eba = 6.47 mm ech + cl + 2 fs) eL = 0.81 mm with manufacturing tolerance 2 = 0.75 mm _ corrosion allowance Calculation of reinforcement of isolated opening [8.3]: ‘existing mean stres: | a NT TSpe/10(2 Aprats+atbe0.7-Atp) / (2-(afs+#h/fa-Afb+0.7 -AEp)) | ce 2 Pea Swan | | #2 2156.2 Nam design stress | co | determined efficiency: Woo = dla(Afssto/fe Afbs0.7-Afp) / (exs-(2-Ap+Afb-f5/f5-Atb)) won ete AE = -~—«'1199 mat with cross-sectional area as compensation és = 41003. mm Cross-sectional area of main bocy | Afb = 180. mt cross-sectional area of nozzle | ap = ""p.mm+ cross-sectional area of reinforcing pad | ap © i20e3 emt presmurecionded acet | Team “a0p.338 mm min(d(iaib + ers) ‘ers): ¥) dip” = “106-d0'mn “inside diameter of nossie te > ‘27/31 am minlV¢(dis sera) "ecs)? ib1) 13) irbi = 0.00 mm min(0.5-V((dis + ers) -ers); 1b2} (20) fype oF reinforcament . . : 2 - nozzle, set-on without eine. pad extriged norle ss): 0 No Dity_Win 5.0 Rav.33.9 10.05.20 :\DIMY_NIW_Daten\Schnesder\ 161 - 31.03.2017 © TOV-NORD Systems, Rasen D 135-20063605, |Continuance: shell boilers acc. to HN 12953, 2016-5, sections 7/8 cy... 07.06.2017 Project: 1169/2 wolfro Drawing no : Schneider aot 5 name/ Sten: 1.1 boiler shell // ANK_1600/10 | inclination of nozzle. . : 0 ~ no inclination ‘ Result | kequired wall thickness of nozzle 2 | ecb = 4.53 mn (0.015-dob + 3.2) |e = 6.30 mm entered wall thickness cl.b = 0.78 mm manufacturing tqlerance c2:b = 0.75 mm corrosion allowance 30% eba = 6.04 mn ecb + el + 2 si cl = 0.75 mn with manufacturing tolerance | 2 = 0.75 mm _corrosion allowance Calculation of reinforcenent of isolated opening (8.3): | existing mean stress: fa C/10-(2“Ap*AfS+AEb+0.7-Afp) / (2+(AEs+fb/fs -AEb+O.7 -AEp) ) ta = 97.5 W/m | fs = 156.2 N/mm? design stress 60 8 { determined efficiency: vb = dis -(AEs+£5/fs -AEb+0.7-Afp) / (ers -(2-AptAfb-fb/Es Afb) ) vb = 0.785 ag = 1085 mm* with cross-sectional area as compensation Afs = 990 mm? cross-sectional area of main body Afb = 95 mm* cross-sectional area of nozzle | Afp Omm cross-sectional area of reinforcing pad ap 102933 mnt _pressure-loaded area irs_b 108.33 mm —min(V((dib + ers) ers); w) ib 79.36 mn inside diameter of nozzle Lrb = 20.02 mn —min(V((dis + ers) -ers); 1b1} 91 Arbi = 0.00 mm _—min{0.5-V((dis + ers) ers); 1b2) (20) | type of reinforcement . . : 0 - no reinforcement nforcenent of isolated opening (8.3) fa = pc/10-(2-Rp+AES+Afb+0.7-Afp) / (2: (AfS+fb/Es -Afb+0.7 -AEp)) 8 98.1 N/mm? fs = 156.2 N/mm? design stress 508 determined efficiency: vp = dis (Afstfb/fs Afb+0.7-Afp) / (ers:(2-AptAfb-fb/ts Afb) ) vb = 0.780 ae = 948 mm? with cross-sectional area as compensation Ags 948 mn? cross-sectional area of main body arb O mm cross-sectional area of nozzle Afp = O mm cross-sectional area of reinforcing pad | ap = 92528 nm? pressure-loaded area | Res saan type of reinforcement . . : 2 - nozzle, set-on without reinf. pad extruded nozzle. . . | :0 -No Diy Win 5-0 Rav.i3.9 10.05.2017, 161 = 31.03.2017 © FOV-WORD Systane Basen, 135-20069605 i \DInO_ WIN Datan\Schneidar\ |Gontimuance: shell boilers acc. to EN 12953, 2016-5, sections 7/8 Cy... Date : 07.06.2017 Project: 1163/2 User + wolfro | Drawing no : Schneider Pages tot 8 | name/ iten: 1.1 boiler shell /7 AiK_I600/I0~ ‘eS a etndig eaten the aot : inclination of nozzle. . : 0 ~ no inclination ee ‘ Result required well thickness of nozzle: : ecb 5.72 mm (0.018-dob + 3.2) eb 8.00,mm _ entered wall thickness cl.b = 1.00 mn manufacturing tolerance e2ib = 0.75 mm corrosion allowance | 408 ba = 740mm ec + cl + 2 125) el = 092mm with manufacturing tolerance | 2 = 0.75 mm __ corrosion allowance Calculation of reinforcement of isolated opening (8.3): existing mean stress: fa = Pe/10 (2 -Rp+RES+AEb+0.7-Afp) / (2-(AEs+fb/fs -AEb+0.7 -AEp)) fa = 14.7 w/t ts = 156.2 N/mm? design stress 368 J determined efficiency: vb = dis -(Afo+fb/fs-Afb+0.7-Afp) / (ers :(2-AptAtb-tb/fs -Afb)) vb = 0.667 aL = 1202 mm* with cross-sectional area as compensation Afs = 1003 mm* cross-sectional area of main body Afb = 199 mm? cross-sectional area of nozzle Afp = © mn: cross-sectional area of reinforcing pad ap = 131402 mm* _pressure-loaded area irs_b 108.33 mm min(V((dib + ers) -ers); w) ip = 155,80 mn inside dianeter of nozzle Leb = 382mm —nin(V(dis + ers) -ers); 1b1) 119) Lebii = 0.00 mm_—min(0.5-V((dis + ers) -ers); 152) (20) jeulation of adjacent openings [8.3.4] Cpeaiog: I. epee se a opening 2. eos am input distance of nozzles in circum. dir. : 0 ~ no distance Is nozzle 1 inclined away or towards nozzle 2: 0 - no inclination | Is nozzle 2 inclined away or towards nozzle 1 : 0 - no inclination Result | Pe = 300.00 mm centre-to-centre distance of adjacent openings PL = 500.00 mm with distance in longitudinal direction Pc = 0.00 mm distance in circumferential direction ° = 0.00" — angle relative to the axis of the main body existing stress fae = GE.2 N/mm? pc/10/2 +... aun fs = 156.2 N/mn? design stress 78 determined efficiency: vm = 0.868 dis/ers (42) ar 3871 mm* with cross-sectional area as compensation | Afso = 3680 mm* cross-sectional area of main body | Afbl+Afb2= 191 mm? cross-sectional area of nozzles AEpL+Atp2= O mn? cross-sectional area of reinf. pads pO 333125 mm? pressure-loaded area Apl+Ap2 ~ 2283 mn? _pressure-loaded area (nozzJes) Calculation of adjacent openings (8.3 Duwy_Win 5-0 Rev.i13.9 10.05.2017, 161 = 31.03.2017 © TOV-NORD Systema Hssen,D 1357 :\Di¥er_NIN_paten\schnesder\= = z Continuance: shell boilers acc. to EN 12953, 2016-5, sections 7/8 cy... Date : 07.06.2017 Project: 1169/1 User : woltro Drawing no : Schneider Page: sot 5. nane/ iten : “1.1 boiler shell // Aik 1600/10 opening)... . . . td - manhole opening 22 1 2. lt 2 = one / NS 114.3 Anput distance of nozzles in circumf. dir. : 0’ ~ no distance Is nozzle 1 inclined away or towards noza@le 2 : 0 ~ no inclinaticn Is nozzle 2 inclined away or towards nozzle 1 : 0 - no inclination Reoult . ee Po. = $00.00 mm cent re-to-centre distance of adjacent openings EL = 500-00 mn with distance in longitudinal direction 5 Bc = 0.00 mn distance in circumferential direction ° = 0.00 * angle relative to the axis of the main body existing stress: Fao = 95.6 N/mm? pc/l0/2 >... * “un ts = 156.2 N/mm? design stress 68 determined efficiency: vm = 0.801, dis/ers - ... (42) aE = 4102 mm? with cross-sectional area as compensation Afs0 = = 2361 mm* cross-sectional area of main body Afbl+Afb2= 1821 nm? cross-sectional area of nozzles AEp1+Afp2 Om cross-sectional area of reinf. pads pO) = 333125 mm? pressure-loaded area Apl+Ap2 = 1810 mm? pressure-loaded area (nozzles! Duy Win 5-0 Rev.i3.9 10.05.2017, 161 - 31.03.2017 © TUV-NORD Systems, D:\DiMe_WIW_Daten\chnesder\TOV RBB-Berlin, Version (DrWo) Alboinstr. 56, D-10882 Berlin Filename : Nachweis nach DIN/BS EN 12953-3 (Ebene Béden zul. d. TOV BD (Dr.Wo) ASME / CEN TC V1.330 Pos. POS. -Nr : 2.1 front wall " ABMESSUNGEN / dimensions Nennwd. Zuschlag Zuschlag c2 = = MATERIAL / material Bez.: Streckgrenze Schweinaht£. Sicherh " BELASTUNG / design data R.po2 v s in. Uberdruck PS = Ausl. Temp. 10.00 mm 0.50 mm 0.00 mm 214.00 N/mm? 1.00 1.50 10.0 bar Te = 235.0 °c " ERGEBNIS - Vergleichstabelle / result Faktor C4: Faktor y : vgl. ca iy, b/L 0.300 0.325 0.350 0.375 0.400 0.425 0.450 " AUSSCHNITTE / openings max dl (mm) 1.0 vgl. Tabelle 10.2-1 Bild 10.2-4 max 42 max bl {mm} (mm] Seay - - 1556 0.10 343.9 242.5 317.4 223.8 294.7 207.8 275.1 194.0 257.9 181.8 242.7 171.1 229.2 161.6 Handloch / hand hole Kopfloch / head hole Mannloch / man hole max b2 max b3 max b4 vgl. Kap. 11 mind. e mind. e mind. e (mom) (mm) 1.52 1.40 0.25 0.50 248.8 270.2 229.7 249.4 213.3 231.6 199.1 216.1 186.6 202.6 175.7 190.7 165.9 180.2 10.0 mm 15.0 mm 19.0 mm Seite 1 Datum : 5.5.2017 (rechteckige Platten) (mm) 1.26 0.75 zul b max b5 (mm) 1.10 1.00 343.9 317.4 294.7 275.1 257.9 242.7 229.2TOV RBB-Berlin, Version (Drwo) Alboinstr. 56, D-10882 Berlin Filename : Nachweis nach DIN/BS EN 12953-3 TOV BD (Dr.Wo) ASME / CEN TC V1.330 Pos. POS.-Nr.: 3.1 rear wall "= ABMESSUNGEN / dimensions Nennwd. Zuschlag Zuschlag = MATERIAL / material Bez.: Streckgrenze R.p02 Schwei8nahté. Sicherh. " BELASTUNG / design data in. Uberdruck Ps Ausl. Temp. Te " ERGEBNIS - Vergleichstabelle / result Faktor C4: vgl. Tabelle 10.2-1 Faktor y : vgl. ca a b/L 0.300 0.325 0.350 0.375 0.400 0.425 0.450 max di (mom) 1.0 = AUSSCHNITTE / openings Handloch / hand hole Kopfloch / head hole Mannloch / man hole (bene Béden zul. zul. 6ffnungen) ' = 10.00 mm = 0.50 mm = 0.00 mm 234.00 N/mm? 1.00 = 1.50 = 10.0 bar = 185.0 °C Bild 10.2-4 (rechteckige Platten) max d2 max bl max b2 max b3 max b4 (mm) {mm] (mm) (mm) {ron} Date 1ebe-1.S2n giedg 1.96 0.10 0.25 0.50 0.75 359.6 253.5 260.2 282.5 313.9 331.9 234.0 240.2 260.8 289.8 308.2 217.3 223.0 242.2 269.1 287.6 202.8 208.2 226.0 251.1 269.7 190.2 195.2 211.9 235.4 253.8 179.0 183.7 199.4 221.6 239.7. 169.0 173.5 186.3 203.3 : vgl. Kap. 11 mind. e = 10.0 mm mind. e = 15.0 mm mind. e = 19.0 mm a, Seite Datum : 5.5.2017 zul b max b5 {mm} 1.10 1.00 359.6 331.9 308.2 287.6 269.7 253.8 239.7 1AX Toveneintand® Genau. Richtig. Explanations to the calculation documents Eckanker > gusset stay + Abmessungen Ankerhéhe h Ankerdicke sa AnschluRwinkel & Ankerabstandswinkel « Bodendicke sb Manteldicke sm AuBendurchmesser Da Lange Durchmesser Flammrohr Da Fax 8-21 (1187) ' dimensions high of the gusset stay z thickness of the gusset stay connection angle 8 distance angle g-stay to g-stay thickness of front / rear end plate thickness of boiler shell outer diameter of the boiler shell length of the boiler shell diameter of the furnace VY YouveTUEV in Berlin, Version (Dr.Wo.) Seite 1 Alboinstr. 56, D-10882 Berlin Filename : Pos. : Datum : 5.5.2017 - TUEV BD (Dr.Wo) AD-Merk./TRD 1.470 -- Nachweis Eckanker / gusset stays / TRD, EN 12953 -- (Richtlinie 12/94, 2003/1) - ABMESSUNGEN / dimensions --> see drawing ' Ankerhéhe h 70.0 mm, Ankerdicke sa = ~ 10.0 mm AnschluBwinkel 8 28.5° 2 ‘ Ankerabstandswinkel a 20.0° Bodendicke sb 10.0 mm, Manteldicke sm = 10.0 mm AuSendurchmesser Da 1350.0 mm, Lange Ls 4000.0 mm Durchmesser Flammrohr Daf= 900.0 - MATERIAL / material Streckgrenze/yield point K 234.0 N/mm? Sicherheitsbeiwert/safety factor § es zul. Spannung/allow. stress zul.o = 156.0 N/mm? - BELASTUNG / loads Berechnungsdruck/design pressure PS = 10.0 bar zug. Druckfldche/allow. P-area Ap = 95000 mm? - ERGEBNIS: Eckanker / RESULT: gusset stay erf. A/ req. area erf A.A = 693 < vorh. A.A = 700 mm? min. Anschlu8 Boden / min connection plate 1.B = 111.51 mm min. Anschlug Mantel/ min connection shell 1.M = 205.38 mm max. Bogenlange E-E / min arc-length E-E 1.A = 244.22 mm Sxrtliche max Spannung/ ¢ = 216.1 N/mm? < 300.0 N/mm? - Magnetit peak stress (kl = 160.63, k2 = 6.58, fg = 1.0) - ERGEBNIS: Abmessungen bei Verw. ebener nicht gekrempt. Béden RESULT: limit dimensions for even plate - shell connection max Da < 2500.0 mm, max L = 5500.0 mm, sb < 25.0 mm Bodendicke/Manteldicke sb/sm = 1.00 < 1.8 Mindestabstand Eckanker - Flammrohr 200.0 mm (TRD 305 Ab.3.2.4) =-> Ausnahme fir L < 3000.0 75.0 + 0.025 L Mindestabstand Flammrohr - Flammrohr 120.0 mm (2003/1:3.3-10) Plammrohrwanddicke s> 20 > Anf. EN 12953 - WAERMEBELASTUNG / heating limit- EN 12953 Oel Gas P 265 GH max Q/allow. Q : 4250.0 5525.0 kW P 295 GH max Q/allow. Q : 5600.0 7280.0 kWTUEV in Berlin, Version (Dr.Wo.) Seite 1 Alboinstr. 56, D-10882 Berlin Pos. : Datum - TUEV BD (Dr.Wo) AD-Merk./TRD 1.470 - 5.5.2017 Nachweis Eckanker / gusset stays / TRD, EN 12953 = - - (Richtlinie 12/94, 2003/1) - ABMESSUNGEN / dimensions --> see drawing A Ankerhdhe hs 50.0 mm, Ankerdicke sa 10.0 mm Anschlu8winkel g 28.5° . Ankerabstandswinkel a = 20.0° Bodendicke sb = 10.0 mm, Manteldicke sm 20.0 mm AuSendurchmesser Da 1350.0 mm, Lange L 4000.0 mm Durchmesser Flammrohr Daf= 900.0 - MATERIAL / material Streckgrenze/yield point K= 234.0 N/mm? Sicherheitsbeiwert/safety factor $ 1's zul. Spannung/allow. stress zul.¢ 156.0 N/mm? - BELASTUNG / loads Berechnungsdruck/design pressure PS 10.0 bar zug. Druckfliche/allow. P-area Ap = 65000 mm? - ERGEBNIS: Eckanker / RESULT: gusset stay erim a’ /ireg aren ert wage ass < yore = eopraae min. Anschluf Boden / tin connection plate 1.B 79.65 mm min. Anschluf Mantel/ min connection shell 1.M = 146.70 mm max. Bogenlange E-E / min arc-length E-E 1.A = 244.22 mm ‘tliche max Spannung/ g = 202.6 N/mm? < 300.0 N/mm? - Magnetit. peak stress (kl = 160.63, k2 = 6.58, fg = 1.0) - ERGEBNIS: Abmessungen bei Verw. ebener nicht gekrempt. Béden RESULT: limit dimensions for even plate - shell connection max Da < 2500.0 mm, max L = 5500.0 mm, sb < 25.0 mm Bodendicke/Manteldicke sb/sm = 1.00 < 1.8 Mindestabstand Eckanker - Flammrohr 200.0 mm (TRD 305 Ab.3.2.4) ==> Ausnahme fiir L < 3000.0 75.0 + 0.025 L Mindestabstand Flammrohr - Flammrohr 120.0 mm (2003/1:3.3-10) Flammrohrwanddicke s> 20 --> Anf. EN 12953 - WAERMEBELASTUNG / heating limit- EN 12953 Oel Gas P 265 GH max Q/allow. Q 4250.0 5525.0 kW P 295 GH max Q/allow. Q 5600.0 7280.0 kwTUV Rheinland Industrie Service GmbH EN 12953-3 design man hole cover system of calculation internal elliptical doors dimensions - gasket diameter Day == 340-mm “Dg = 440mm wall thickness sq i= 24mm mill tolerance ey = 05mm corrosion design data / example design pressure Se dessign temperature ae ‘add cale, pressure in acc. to EN12053 as example Prix 0.5-PS. x= Sbar material P265GH (16 800°C min = 0.125, + 9:mm 13.875-mam tigas < 800°C ‘migj= 0.1254, + 7-mm min! = 11.875-mm DR. Wolf Tel. 090 7562 1647 WolfRo@de.tuv.com