non circular air cooler design calculations

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Revision:

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COVER PAGE

MECHANICAL DESIGN CALCULATIONS

C5437-HCHE1

04.06.143

Client : SNGPL

HEADER BOX

Jord Job No : C5437

Project : COMPRESSOR GAS STATION CC3

JORD INTERNATIONAL PTY LTD ABN 42 102 636 215Main Office: 38 Oxley Street, St Leonards, NSW, Australia 2065

Tel: [612] 8425 1500 Fax: [612] 8425 1555

JORD INTERNATIONAL PTE LTD REG 200106859WRegional Office: 190 MacPherson Road #09-02 Wisma Gulab, Singapore, 348548

Tel: [65 ] 6879 4088 Fax: [65 ] 6879 4099

E-mail: [email protected] Web: www.jord.com.au

Tag No : HE1

Total No Pages : 50

Equipment : GAS COMPRESSOR AIR COOLER

Client : SNGPL

1 KM RS KS18 mm PLATE REVISED TO 20 mm & TI /PI REMOVED

25 mm PLATE REVISED TO 28 mm2

16.05.14KM RS

Description

0 AR RS

KS

KS 25.03.14

04.06.14

ISSUED FOR APPROVAL

Revision Created Checked Approved Date

Page No: 2 of 50Date:Revision:Document No:Tag No:

0 1 2

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18 20 � � 04.06.14

04.06.143

10EVALUATION OF JOINT & LIGAMENT EFFICIENCY AS PER APPENDIX 13

THK. EVALUATION OF TUBE SHEET OF NOZZLE HEADER AS PER APPENDIX 13-9 (c)

INPUT DATA FOR RETURN HEADER AS PER APPENDIX 13-9 (c) & 13-5

VESSEL SKETCH FOR RETURN HEADER AS PER FIG. 13-2 (a) (10)

INPUT DATA FOR NOZZLE HEADER AS PER APPENDIX 13-9 (c) & 13-5

COVER PAGE

LATEST APPLICABLE REVISION STATUS OF ENTIRE DOCUMENT

C5437-HCHE1

LATEST REV. STATUSDATE

INDEX

SR. NO.

DESCRIPTIONSHEET

NO.

2 INDEX

EVALUATION OF MATERIALS AS PER APPENDIX 13-3, UCS-23 & UHA-23

LATEST APPLICABLE DRAWINGS / DOCUMENTS

APPLICABLE LOADINGS AS PER UG-22

EVALUATION OF DESIGN PRESSURE AS PER UG-21, UG-98 AND APPENDIX 3-2

THICKNESS EVALUATION OF STAY PLATE & END PLATE OF NOZZLE HEADER AS PER APPENDIX 13-9 (c) & UG-34

APPLICABLE STANDARDS & REFERENCES

VESSEL SKETCH FOR NOZZLE HEADER AS PER FIG. 13-2 (a) (10)

DESIGN DATA

THICKNESS EVALUATION OF TOP & BOTTOM PLATE OF NOZZLE HEADER AS PER APPENDIX 13-9 (c)

THK. EVALUATION OF PLUG SHEET OF NOZZLE HEADER AS PER APPENDIX 13-9 (c)

18 20 � � 04.06.14

19 21 � � 16.05.14

20 22 � 25.03.14

21 23 � 25.03.14

22 24 � � � 04.06.14

23 25 � 25.03.14

24 26 � � 04.06.14

25 27 � � 04.06.14

26 28 � � 16.05.14

27 29 � � 16.05.14

28 30 � 25.03.14

29 31 � 25.03.14

30 32 � � 16.05.1431 33 � � 16.05.1432 34 � � 16.05.14

33 35 � � � 04.06.14

34 36 � � 04.06.14

35 37 � 25.03.14

36 38 � 25.03.14

39 � � � 04.06.1440 � � � 04.06.1441 � � 04.06.1442 � � � 04.06.1443 � � � 04.06.1444 � 25.03.14

37MAWP (HOT & CORRODED) CALCULATION FOR NOZZLE HEADER , RETURN HEADER,TUBES, NOZZLE & FLANGES

38MAP (NEW & COLD) CALCULATION FOR NOZZLE HEADER, RETURN HEADER, TUBES, NOZZLE & FLANGES

5

THICKNESS EVALUATION OF TOP & BOTTOM PLATE OF RETURN HEADER AS PER APPENDIX 13-9 (c)

THK. EVALUATION OF TUBE SHEET OF RETURN HEADER AS PER APPENDIX 13-9 (c)

THK. EVALUATION OF PLUG SHEET OF RETURN HEADER AS PER APPENDIX 13-9 (c)

THICKNESS EVALUATION OF STAY PLATE & END PLATE OF RETURN HEADER AS PER APPENDIX 13-9 (c) & UG-34

THICKNESS EVALUATION OF TUBE AS PER UG-31 AND UG-27

REINFORCEMENT REQUIREMENT FOR NOZZLE AS PER APPENDIX 13-4

FULL RADIOGRAPHY REQUIREMENT AS PER UW-11

REINFORCEMENT REQUIREMENT IN Z-DIRECTION AS PER UG-39 & UG-37

INSPECTION OPENING AS PER UG-46.

REINFORCEMENT REQUIREMENT FOR NOZZLE AS PER U-2 (g)

WELD DESIGN AS PER FIG. UG-34 (g)WELD DESIGN AS PER FIG. 28-1 (b)

IMPACT TEST REQUIREMENT AS PER UG-20 (f), UCS-66

GOVERNING THICKNESS AS PER UCS-66 & UW-40 (f)

POST FORMING HEAT TREATMENT REQUIREMENT AS PER UG-79, UCS-79 & POST WELD HEAT TREATMENT REQUIREMENT AS PER UW-2, UCS-56

WELD DESIGN AS PER FIG. UW-16.1 (a)

NOZZLE THICKNESS CALCULATION AS PER UG-45

FLANGE RATING CHECK AS PER ASME B16.5-2013


0 1 2

39 45 � � 04.06.14

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47 � � 04.06.14

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49 � 25.03.1450 � 25.03.14

DATE

16.05.143

LATEST REV. STATUS

40NOZZLE HEADER, RETURN HEADER - STRESS DURING HYDROSTATIC TEST CONDITION AS PER U-2 (g)

HYDROSTATIC TEST PRESSURE CALCULATION AS PER UG-99 (b)

SR. NO.

DESCRIPTIONSHEET

NO.

INDEX

C5437-HCHE1

42 NOZZLE LOAD CALCULATION U-2(g)

TUBE,NOZZLE & FLANGES - STRESS DURING HYDROSTATIC TEST CONDITION AS PER U-2 (g)


REV. REVISION CHECKEDNO DATE BY

1 16.05.14

2 04.06.14 1-5,7,14,18,20,24,26-27,35-36, 39-48

18 mm PLATE REVISED TO 20 mm & TI /PI REMOVED

REVISION REMARKS

RS KS

04.06.143

C5437-HCHE1

APPROVEDBY

1-5, 7, 14, 15,21 ,24, 28, 29, 32-35, 39, 40, 42, 43,

4625 mm PLATE REVISED TO 28 mm RS KS

LATEST APPLICABLE REVISION STATUS OF ENTIRE DOCUMENT

REVISED SHEET NO.


1 D

Rev.

04.06.143

C5437-HCHE1

SR. NO. DESCRIPTION DRAWING NO.

C5437-HD-002HEADER DETAILS

LATEST APPLICABLE DRAWINGS / DOCUMENTS


ASME BOILER AND PRESSURE VESSEL CODESECTION VIII DIVISION 1 - 2013 EDITIONASME BOILER AND PRESSURE VESSEL CODESECTION II PART D (METRIC) - 2013 EDITIONPIPE FLANGES AND FLANGED FITTINGSASME B 16.5 - EDITION 2013API STANDARD 661, 7TH EDITION JULY 2013, PETROLEUM, PETROCHEMICAL & NATURAL GAS INDUSTRIESAIR COOLED HEAT EXCHANGERS

04.06.143

C5437-HCHE1

APPLICABLE STANDARDS & REFERENCES

SR. NO. DESCRIPTION

1

2

3

4


2 -3 -4 -

6 ºC

MPa (g)

8 ºC

MPa (g)

10 MPa (a)

11 ºC

12 MPa (g)13 MPa (g)

15.340PNEUMATIC TEST PRESSURE NOT REQUIRED UG-100HYDROSTATIC TEST PRESSURE AT TOP UG-99

8.616

OPERATING TEMPERATURE - INLET / OUTLET 65.56 / 51.672

OPERATING PRESSURE - INTERNAL

DESIGN TEMPERATURE 121.11 UG-20

MINIMUM DESIGN METAL TEMPERATURE -1.11 @ 11.8MPa (g) UG-20

5DESIGN PRESSURE INCLUDING STATIC HEIGHT - INTERNAL / EXTERNAL UG-21, UG-98MPa (g) 10.205 / NIL

7

SERVICE (LETHAL / NON-LETHAL) NON LETHALTYPE OF VESSEL HORIZONTAL

HE1

CODE STAMP YES

1 DESIGN & MANUFACTURING CODE -

ASME BOILER & PRESSURE VESSEL CODE SECTION VIII DIVISION - 1

EDITION 2013 & API STANDARD 661, 7TH EDITION JULY 2013

04.06.143

DESIGN DATA

SR. NO DESCRIPTION UNIT VALUECODE

REFERENCE

C2884-HC-01

9 MAXIMUM ALLOWABLE PRESSURE ( MAP - NEW & COLD ) INTERNAL / EXTERNAL

15.16 / NIL

MAXIMUM ALLOWABLE WORKING PRESSURE ( MAWP - HOT & CORRODED ) INTERNAL / EXTERNAL 11.8 / NIL

13 MPa (g)14 mm15 -16 -

17 -

18 -19 -20 -21 -22 -

--

kg / m3

kgkgkg

25 L26 -

NOTE :i REFER APPENDIX 13 FOOT NOTE-1 FOR JOINT EFFICIENCY

ii SINCE HEADER BOX IS BEING SUPPORTED IN STRUCTURE, THE STRUCTURE SHALL TAKE CARE OFWIND & SEISMIC REACTION.

INSPECTION BY AI

DENSITY 64.875

24

UG-22

23

1455.00

OTHER APPLICABLE LOADING AS PER UG-22 REFER SHEET NO. 8

HYDROSTATIC 10661.00

PRODUCTION TEST COUPONS NOT REQUIRED

NOT APPLICABLE ii

WEIGHTEMPTY

CAPACITY

9212.00

OPERATING 9306.00

WIND DESIGN CODE / WIND SPEED NOT APPLICABLE ii UG-22

UG-22

SWEET NATURAL GAS

SEISMIC DESIGN CODE / ZONE

FLUIDTYPE PROCESS GASCONDITION

YES

REFER NDT TABLE OF C5437-HD-002

IMPACT TEST NOT REQUIRED

UW-2, UCS-56, UCS-79 API 661

UG-20(f), UG-84

POST WELD HEAT TREATMENT (PWHT)

CORROSION ALLOWANCE 3.175 (EXCEPT TUBE) UG-25APPENDIX 13

UW-11, API-661JOINT EFFICIENCY 1 ii

RADIOGRAPHY / ULTRASONIC EXAMINATION

PNEUMATIC TEST PRESSURE NOT REQUIRED UG-100


SR. NO. UG - 22SUB-

CLAUSEINTERNAL DESIGN PRESSURE AS PER UG-21EXTERNAL DESIGN PRESSURE AS PER UG-21WEIGHT OF VESSEL AND NORMAL CONTENTSUNDER OPERATING OR TEST CONDITIONS, INCLUDING ADDITIONAL HEAD DUE TO STATICHEAD OF MEDIUM / WATERSUPERIMPOSED STATIC REACTIONS FROM WEIGHT OF ATTACHED EQUIPMENTS SUCH ASMOTORS, MACHINERY, OTHER VESSELS, PIPING, LININGS, AND INSULATION;ATTACHMENT OF INTERNALS, VESSEL SUPPORT,LUGS, RINGS, SKIRTS, SADDLES , LEGS ETC.CYCLIC OR DYNAMIC REACTION DUE TO PRESSURE OR THERMAL VARIATIONS OR FROM EQUIPMENT MOUNTED ON A VESSEL ANDMECHANICAL LOADINGSWIND REACTIONSSNOW REACTIONSSEISMIC REACTIONSIMPACT REACTIONS SUCH AS THOSE DUE TO

DESCRIPTION

aAPPLICABLE

NOT APPLICABLE

4

APPLICABILITY

1

04.06.143

C5437-HCHE1

APPLICABLE LOADINGS AS PER UG - 22

6

NOT APPLICABLE ii

c APPLICABLE

NOT APPLICABLE i

f

NOT APPLICABLEe

7

d NOT APPLICABLE

b

3

NOT APPLICABLE i

2

NOT APPLICABLE i

APPLICABLE

5

gFLUID SHOCKSTEMPERATURE GRADIENTS AND DIFFERENTIALTHERMAL EXPANSION

TEST PRESSURE & COINCIDENT STATIC HEAD ACTING

i SINCE HEADER BOX IS BEING SUPPORTED IN STRUCTURE, STRUCTURE SHALL TAKECARE OF WIND, SEISMIC & SNOW REACTION.

ii NO IMPACT REACTIONS ARE ANTICIPATED IN OPERATION.

iii DIFFERENTIAL THERMAL EXPANSION HAS BEEN TAKEN INTO ACCOUNT BY MEANS OF SLIDING PADS WHICH WILL ALLOW HEADERS TO MOVE.

NOT APPLICABLE ii

10 j APPLICABLEDURING THE TEST

9ABNORMAL PRESSURES SUCH AS THOSE CAUSED

i

7

8 APPLICABLE iiih

NOT APPLICABLEBY DEFLAGRATION

g


�� EVALUATION OF STATIC PRESSURE IN OPERATING / HYDROSTATIC TEST CONDITION :

PART STATIC STATIC DESCR- HEIGHT HEIGHTIPTION FLUID HYDRO.

mm mmINLET

NOZZLEHEADER

BOXOUTLETNOZZLE

�� EVALUATION OF DESIGN PRESSURE :

A) INTERNAL DESIGN PRESSURE = 10.204 MPa (g) (AS PER CLIENT)

B) EXTERNAL PRESSURE = NIL MPa (g)

0.001 1032MAXIMUM STATIC HEIGHT / PRESSURE 1032 0.01

1032 0.01010.204 NIL 1032 0.001

710 0.00010.204 NIL

0.0033220.000

0.007710

WATER FORDESIGN CORRECTION FLUID FOR

10.204 NIL

MPa (g) MPa (g)PRESSURE MPa (g) OPERATING

(IF ANY)HYDRO. TEST

MPa (g)

322

04.06.143

EVALUATION OF DESIGN PRESSURE AS PER UG-21, UG-98 & APPENDIX 3-2

INTERNAL DIFF. PRESS.

C5437-HCHE1

STATIC PR. OF STATIC PR. OF

C) STATIC PRESSURE OF FLUID FOR OPERATING = 0.001 MPa (g)

D) OTHER LOADINGS AS PER UG - 22 = NOT APPLICABLE - REFER SHEET 8 FOR LOADINGS

�� CONCLUSION :

DESIGN PRESSURE INCLUDING STATIC PRESSURE = 10.205 MPa (g)

CONVERSION :

1 mm OF WATER = 9.80665E-06 MPaDENSITY = 64.875 kg / m3

FOR EVALUATION OF COMPONENT THICKNESS


MAXIMUM ALLOWABLE STRESS VALUES AS PER UCS-23 & UHA-23 :

THE MAXIMUM ALLOWABLE STRESS VALUES AT THE TEMPERATURE INDICATED FOR MATERIALS CONFORMINGTO THE SPECIFICATION LISTED IN ASME SECTION II, PART D. ( METRIC )

SR. PART PAGE / P NO / ACTUAL PERMI- STRESS STRESSNO. DESCRIP- LINE GROUP DESIGN SSIBLE VALUE VALUE

TION NO. NO TEMP. DESIGN AT ATSEC II D oC TEMP DESIGN ROOM

oC TEMP. TEMP.MPa MPa

7 ROUND PLUG SA-182 Gr.F316

TRANSITION NOZZLE

SA-234 Gr.WPB

6 COUPLING

4 TUBES 121.11

5

NIL

138.00

538

92.4092.40482

14 / 21 1 / 1

EVALUATION OF MATERIALS AS PER APPENDIX 13-3,UCS-23 & UHA-23

1 121.1122 / 6

APPLICABLE

2

121.11

HEADER PLATES

04.06.143

18 / 32 1 / 2 121.11 538 NIL

1 / 2

C5437-HCHE1

NOTE

FLANGES

3 HEADER PLUGS

538 138.00 138.00 NIL

NIL

121.11

816 138.00 138.00121.11

NIL

NIL118.00 118.00

SA-105N 18 / 32

538

138.00

138.00538

138.00SA-105N

138.00

SA-516 Gr.70 N

121.11

1 / 2

1 / 1

SPECIFICATION CAUTIONARYMATERIAL

138.00 NIL

SA-179 6 / 11

SA-105N 18 / 32 1 / 2

78 / 1 8 / 1

YIELD STRENGTH OF MATERIALS

SR. PART PAGE /NO. DESCRIP- LINE

TION NO. AT ATSEC II D DESIGN ROOM

TEMP. TEMP.MPa MPa

HEADER PLATES

169.24 207.007 ROUND PLUG SA-182 Gr.F316 638 / 12

2

7 ROUND PLUG SA-182 Gr.F316

6 COUPLING SA-105N

574 / 5

HEADER PLUGS

578 / 17

FLANGES

3

5 TRANSITION NOZZLE

MATERIAL

578 / 17

578 / 30

4

1

SA-105N

TUBES

223.62

NIL

241.00

816 138.00 138.00121.11

179.00

262.00

248.00

161.31

217.47

235.62SA-516 Gr.70 N

SA-105N

248.00

STRENGTHYIELD

SPECIFICATION

SA-234 Gr.WPB

78 / 1 8 / 1

SA-179 566 / 10

223.62

578 / 17


�� LIGAMENT EFFICIENCY OF MULTIDIAMETER HOLES ON PLUG SHEET AS PER APPENDIX 13-6 :

INPUT DATA : VALUE UNITSp = PITCH DISTANCE BETWEEN TWO PLUG HOLE = 63.500 mm

do = DIAMETER OF HOLE OF LENGTH T0 = 39.000 mmT0 = LENGTH OF HOLE OF DIAMETER do = 0.800 mmd1 = DIAMETER OF HOLE OF LENGTH T1 = 28.700 mmT1 = LENGTH OF HOLE OF DIAMETER d1 = 1.800 mmd2 = DIAMETER OF HOLE OF LENGTH T2 = 28.575 mmT2' = LENGTH OF HOLE OF DIAMETER d2 = 27.400 mmt2' = THICKNESS OF PLUG SHEET = 30.000 mmC = CORROSION ALLOWANCE = 3.175 mm

A) CALCULATION :

t2 = ( t2' - C ) = 26.825 mmb0 = ( p - d0 ) = 24.500 mm

04.06.143

C5437-HCHE1

EVALUATION OF JOINT & LIGAMENT EFFICIENCY AS PER APPENDIX 13

b0 = ( p - d0 ) = 24.500 mmb1 = ( p - d1 ) = 34.800 mmb2 = ( p - d2 ) = 34.925 mmT2 = ( T2' - C ) = 24.225 mm

B) LIGAMENT EFFICIENCY OF PLATE SUBJECTED TO MEMBRANE STRESS :

DE = EQUIVALENT UNIFORM DIAMETER OF MULTIDIAMETER HOLE.

= ( 1 / t2 ) * ( d0 * T0 + d1 * T1 + d2 * T2 ) = 28.894 mmem = MEMBRANE LIGAMENT EFFICIENCY.

= ( p - DE ) / p = 0.545

C) LIGAMENT EFFICIENCY OF PLATE SUBJECTED TO BENDING STRESS :

X = DISTANCE FROM BASE OF PLATE TO NEUTRAL AXIS

= = 13.293 mm

I = MOMENT OF INERTIA.

= [ (1/12) * {(b0*T03) + (b1*T1

3) + (b2 * T23)} ] + [ (b0*T0) * {(T0/2) + T1 + T2 - X }2 ]

+ [ (b1*T1) * {(T1/2) + T2- X }2 ] + [ (b2*T2) * {(T2/2) - X }2 ] = 54722.192 mm4

c2i = DISTANCE FROM NEUTRAL AXIS OF CROSS SECTION OF PLATEWITH MULITIDIAMETER HOLES TO THE INSIDE SURFACE.

= X = 13.293 mmc2O = DISTANCE FROM NEUTRAL AXIS OF CROSS SECTION OF PLATE

WITH MULITIDIAMETER HOLES TO THE EXTREME OUTSIDE SURFACE.= - ( t2 - X ) = -13.532 mm

c = THE LARGER OF c2i OR c2o = 13.532 mmDE = EQUIVALENT UNIFORM DIAMETER OF MULTIDIAMETER HOLE.

= p - ( 6 * I / t22 * c) = 29.781 mm

eb = BENDING LIGAMENT EFFICIENCY.= ( p - DE ) / p = 0.531

[ {(b0*T0) * ({T0/2} + T1 + T2)} + {(b1*T1) * ({T1/ 2} + T2)} +

{(b2*T2) * (T2/ 2)} ] * [ (b0*T0) + (b1*T1) + (b2*T2) ] - 1


�� LIGAMENT EFFICIENCY OF TUBE SHEET AS PER APPENDIX 13-4 (g) AND UG - 53 (b) (1) :

INPUT DATA : VALUE UNITS

LONGITUDINAL PITCH OF TUBE HOLES, p = 63.500 mmDIAMETER OF TUBE HOLES, d = 25.750 mm

CALCULATION :

LIGAMENT EFFICIENCY OF TUBE SHEET , e = [ p - d ] / p 0.594

EVALUATION OF JOINT & LIGAMENT EFFICIENCY AS PER APPENDIX 13

04.06.143

C5437-HCHE1

�� LIGAMENT EFFICIENCY OF STAY PLATE OF NOZZLE HEADER AS PER APPENDIX 13-4 (g) AND UG - 53 (b) (1) :


LONGITUDINAL PITCH OF HOLES, p = 255.000 mmDIAMETER OF HOLES, d = 65.000 mm

CALCULATION :

LIGAMENT EFFICIENCY OF STAY PLATE , U = ( p - ( d + 2 * C ) ) / p = 0.720

�� LIGAMENT EFFICIENCY OF STAY PLATE OF RETURN HEADER AS PER APPENDIX 13-4 (g) AND UG - 53 (b) (1) :


LONGITUDINAL PITCH OF HOLES, p = 248.000 mmDIAMETER OF HOLES, d = 75.000 mm

CALCULATION :

LIGAMENT EFFICIENCY OF STAY PLATE , U = ( p - ( d + 2 * C ) ) / p = 0.672

�� JOINT EFFICIENCY FACTOR "E"AS PER APPENDIX 13-5 :

a) NO CATEGORY "A" & "B" BUTT WELDS ARE ENVISAGED ON ANY OF THE FLAT COMPONENTS.

b) AS PER APPENDIX 13-5 FOOT NOTE - 1 , THE JOINT EFFICIENCY AS PER UW-12 IS NOT APPLICABLETO CATEGORY "C" & "D" JOINTS WHICH ARE NOT BUTT WELDED. SINCE STRESSES IN THESE JOINTS ARE CONTROLLED BY THE APPLICABLE RULES FOR SIZING SUCH JOINTS AS PER FIG. UW - 13.2 & UG - 34. HENCE E = 1 HAS BEEN CONSIDERED IN ALL CALCULATION.


04.06.143

C5437-HCHE1

VESSEL SKETCH FOR NOZZLE HEADER AS PER FIG. 13.2 (a) SKETCH (10)

FIG . 13. 2(a) SKETCH (10) - VESSELS OF RECTANGULAR CROSS SECTION HAVING MORE THAN TWO COMPARTMENTOF UNEQUAL SIZE. AS PER 13 - 9 (F) (2), HEADER BOX HAS BEEN ANALYSED BY SELECTING THE COMPARTMENT HAVING THE MAXIMUM DIMENSIONS AND THEN ANALYSING THE STRUCTURE PER 13 - 9 (c).



P = DESIGN PRESSURE = 10.205 MPaT = DESIGN TEMPERATURE = 121.110 OCS = ALLOWABLE STRESS - PLATE = 138.000 MPa

H' = INSIDE LENGTH OF SHORT SIDE = 110.000 mmh' = INSIDE LENGTH OF LONG SIDE = 97.000 mmt1' = THICKNESS OF TOP/BOTTOM PLATE (SHORT SIDE) = 28.000 mmt2' = THICKNESS OF TUBE/PLUG PLATE (LONG SIDE) = 30.000 mmC = CORROSION ALLOWANCE OF PLATE / SHEET = 3.175 mmt4' = THICKNESS OF STAY PLATE = 20.000 mm U = STAY PLATE LIGAMENT EFFICIENCY = 0.720E = JOINT EFFICIENCY FACTOR = 1.000

Ew = NOZZLE WELD EFFICIENCY = 1.000TP = TUBE PITCH = 63.500 mmRT = TUBE INSIDE RADIUS = 10.590 mmDP = TUBE PLUG DIAMETER = 28.575 mmDH = TUBE HOLE INSIDE DIAMETER = 25.750 mmD' = LARGE SPAN MEASURED PERPENDICULAR TO SHORT SPAN = 332.000 mmCF = END PLATE ATTACHMENT FACTOR AS PER APP. - 13.4 (f) = 0.200t5 = THICKNESS OF END PLATE = 30.000 mm

CALCULATIONS :

04.06.143

C5437-HCHE1

INPUT DATA FOR NOZZLE HEADER AS PER APPENDIX 13-9 (c) & 13-5

h = h' + ( 2 * C ) = 103.350 mmH = H' + ( 2 * C ) = 116.350 mm� = RECTANGULAR VESSEL PARAMETER = H / h = 1.126t1 = ( t1' - C ) = 24.825 mmt2 = ( t2' - C ) = 26.825 mmt4 = ( t4' - 2 * C ) = 13.650 mmD = ( D' + 2 * C ) = 338.350 mml1 = ( t1 )

3 / 12 = 1274.931 mm3

l2 = ( t2 )3 / 12 = 1608.563 mm3

K = VESSEL PARAMETER = ( l2 / l1 ) * � = 1.421e = TUBE SHEET LIGAMENT EFFICIENCY = 0.594

em = MEMBRANE LIGAMENT EFFI. FOR PLUG SHEET = 0.545eb = BENDING LIGAMENT EFFI. FOR PLUG SHEET = 0.531Z = MIN ( 2.5, {3.4 - ( 2.4 * H ) / D } AS PER UG-34 (c) (3) = 2.500

c1 = DIST. FROM NEUTRAL AXIS OF C/S TO EXTREME FIBERS = t1 / 2 = 12.413 mmc2 = DIST. FROM NEUTRAL AXIS OF C/S TO EXTREME FIBERS = t2 / 2 = 13.413 mmc2i = DIST. FROM NEUTRAL AXIS OF C/S TO EXTREME FIBERS = 13.293 mmc2o = DIST. FROM NEUTRAL AXIS OF C/S TO EXTREME FIBERS = -13.532 mm


PLUS ( + ) SIGNIFIES TENSION STRESS & MINUS ( - ) SIGNIFIES COMPRESSION STRESS

A) MEMBRANE STRESS ON SHORT SIDE PLATE, Sm : VALUE UNITS

Sa = ALLOWABLE STRESS = ( 1.0 * S ) = 138.000 MPa [ 13.4 (b) ]

Sm = [ P * h / 2 * t1 ] * [ 3 - { ( 6 + K * ( 11 - �2 ) / ( 3 + 5 * K ) } ]= [ P * h / 2 * t1 * E ] * [ 3 - { ( 6 + K * ( 11 - �2 ) / ( 3 + 5 * K ) } ] = 22.043 MPa [ 13.9 (c) (1) (13) ]

% ALLOWABLE = ( Sm / Sa ) * 100 = 15.97% SAFE

B) BENDING STRESS ON SHORT SIDE, Sb :

Sa = ALLOWABLE STRESS = ( 1.5 * S ) - Sm = 184.957 MPa [ 13.4 (b) ]

(Sb)N = [P * c1 / 24 * I1] * [-3 * H2 + 2 * h2 * {(3 + 5 *�2 * K) / (3 + 5 *K)} ] = [P * c1 / 24 * I1 * E] * [-3 * H2 + 2 * h2 * {(3 + 5 *�2 * K) / (3 + 5 *K)} ] = -63.032 MPa [ 13.9 (c) (2) (16) ]

% ALLOWABLE = [ (Sb)N / Sa ] * 100 = 34.08% SAFE

(Sb)Q = [ P * h2 * c1 / 12 * I1 ] * [ ( 3 + 5 * �2 * K ) / ( 3 + 5 * K ) ] = [ P * h2 * c1 / 12 * I1 * E ] * [ ( 3 + 5 * �2 * K ) / ( 3 + 5 * K ) ] = 105.092 MPa [ 13.9 (c) (2) (17) ]

% ALLOWABLE = [ (Sb)Q / Sa ] * 100 = 56.82% SAFE

C) TOTAL STRESS ON SHORT SIDE, ST :

Sa = ALLOWABLE STRESS = ( 1.5* S ) = 207.000 MPa [ 13.4 (b) ]

THICKNESS EVALUATION OF TOP & BOTTOM PLATE OF NOZZLE HEADER AS PER APPENDIX 13-9 (c)

04.06.14

C5437-HC3

HE1


(ST)N = Sm + (Sb)N = -40.989 MPa [ 13.9 (c) (3) (20) ]

% ALLOWABLE = [ (ST)N / Sa ] * 100 = 19.80% SAFE

(ST)Q = Sm + (Sb)Q = 127.135 MPa [ 13.9 (c) (3) (21) ]

% ALLOWABLE = [ (ST)Q / Sa ] * 100 = 61.42% SAFE

D) MINIMUM THICKNESS OF TOP & BOTTOM PLATE :

FOR MIN. THICKNESS, CONSIDERING t1' = 22.500 mm, t2' = 27.700 mm & t4' = 16.800 mm & OTHER INPUT DATA REMAINING SAME THEN,

Sm = 28.448 MPa(Sb)N = -100.495 MPa (Sb)Q = 176.944 MPa(ST)N = -72.047 MPa % ALLOWABLE = [ (ST)N / Sa ] * 100 = 34.81%(ST)Q = 205.392 MPa % ALLOWABLE = [(ST)Q / Sa ] * 100 = 99.22%

HENCE, t1 = 19.325 mm IS CONSIDERED AS THE MINIMUM REQUIRED THK. TO BE USED IN FOLLOWING CALCULATION.

i) COMPENSATION CALCULATION AS PER UG-37 & UG-39.ii) WELD DESIGN AS PER FIG. UG-34 (g)

E) SUMMARY OF THICKNESS:

API 661mm mm

1 1.5 + C 4.675 12.000 28.00

PROVIDED THK. REMARKCALCULATEDDESCRIPTION

MINIMUM THICKNESSSR. NO.

mmUG-16

mm

TOP / BOTTOM PLATE 22.500 SAFE

NOTE: THICKNESS MENTIONED ABOVE INCLUDES CORROSION ALLOWANCE



A) MEMBRANE STRESS ON LONG SIDE, Sm : VALUE UNITS


Sm = ( P * H ) / ( 2 * t2 )= ( P * H ) / ( 2 * t2 * e ) = 37.258 MPa [ 13.9 (c) (1) (14) ]


B) BENDING STRESS ON LONG SIDE, Sb :


(Sb)M = [ P * h2 * c2 / 12 * I2 ] * [ { 3 + K * ( 6 - �2 ) } / ( 3 + 5 * K ) ]= [ P * h2 * c2 / 12 * I2 * e ] * [ { 3 + K * ( 6 - �2 ) } / ( 3 + 5 * K ) ] = 122.705 MPa [ 13.9 (c) (2) (18) ]

% ALLOWABLE = [ (Sb)M / Sa ] * 100 = 72.29% SAFE

(Sb)Q = [ P * h2 * c2 / 12 * I2 ] * [ ( 3 + 5 * �2 * K) / ( 3 + 5 * K ) ] = 90.005 MPa [ 13.9 (c) (2) (19) ]


THICKNESS EVALUATION OF TUBE SHEET OF NOZZLE HEADER AS PER APPENDIX 13-9 (c)

04.06.143

C5437-HCHE1

C) TOTAL STRESS ON LONG SIDE, ST :


(ST)M = Sm + (Sb)M = 159.963 MPa [ 13.9 (c) (3) (22) ]

% ALLOWABLE = [ (ST)M / Sa ] * 100 = 77.28% SAFE

(ST)Q = Sm + (Sb)Q = 127.263 MPa [ 13.9 (c) (3) (23) ]


D) MINIMUM THICKNESS OF TUBE SHEET :

AS A CONSERVATIVE DESIGN, PLUG SHEET MINIMUM THICKNESS IS USED THROUGHOUT THE CALCULATION.REFER SHEET "THICKNESS EVALUATION OF PLUG SHEET OF NOZZLE HEADER AS PER APPENDIX 13-9 (c)" FOR MINIMUM THICKNESS.


API 661mm mm

1 1.5 + C 4.675 19.000 30.00

i RULES OF APPENDIX 28 IS APPLICABLE FOR CORNER WELD JOINT

SR. NO.

DESCRIPTIONMINIMUM THICKNESS PROVIDED

THK. REMARKUG-16 CALCULATED UW-13.2 (d)


mm mm mm

TUBE SHEET 27.700 NAi SAFE

Page No: 17 of 50Date:Revision:Document No:

Tag No:




Sm = ( P * H ) / ( 2 * t2 ) = ( P * H ) / ( 2 * t2 * em ) = 40.608 MPa [ 13.9 (c) (1) (14) ]% ALLOWABLE = ( Sm / Sa ) * 100 = 29.43% SAFE



(Sb)Mi = [ P * h2 * c2i / 12 * I2 ] * [ { 3 + K * ( 6 - �2 ) } / ( 3 + 5 * K ) ]= [ P * h2 * c2i / 12 * I2 * eb ] * [ { 3 + K * ( 6 - �2 ) } / ( 3 + 5 * K ) ] = 136.040 MPa [ 13.9 (c) (2) (18) ]% ALLOWABLE = [ (Sb)Mi / Sa ] * 100 = 81.76% SAFE

(Sb)Mo = [ P * h2 * c2o / 12 * I2 ] * [ { 3 + K * ( 6 - �2 ) } / ( 3 + 5 * K ) ]= [ P * h2 * c2o / 12 * I2 * eb ] * [ { 3 + K * ( 6 - �2 ) } / ( 3 + 5 * K ) ] = -138.486 MPa [ 13.9 (c) (2) (18) ]% ALLOWABLE = [ (Sb)Mo / Sa ] * 100 = 83.23% SAFE

(Sb)Qi = [ P * h2 * c2i / 12 * I2 ] * [ ( 3 + 5 * �2 * K) / ( 3 + 5 * K ) ] = 89.203 MPa [ 13.9 (c) (2) (19) ]% ALLOWABLE = [ (Sb)Qi / Sa ] * 100 = 53.61% SAFE

(Sb)Qo = [ P * h2 * c2o / 12 * I2 ] * [ ( 3 + 5 * �2 * K) / ( 3 + 5 * K ) ] = -90.807 MPa [ 13.9 (c) (2) (19) ]% ALLOWABLE = [ (Sb)Qo / ALLOWABLE STRESS ] * 100 = 54.57% SAFE



(ST)Mi = Sm + (Sb)Mi = 176.648 MPa [ 13.9 (c) (3) (22) ]% ALLOWABLE = [ (S ) / Sa ] * 100 = 85.34% SAFE

04.06.14

HE1

THICKNESS EVALUATION OF PLUG SHEET OF NOZZLE HEADER AS PER APPENDIX 13-9 (c)

3C5437-HC

% ALLOWABLE = [ (ST)Mi / Sa ] * 100 = 85.34% SAFE

(ST)Mo = Sm + (Sb)Mo = -97.878 MPa [ 13.9 (c) (3) (22) ]% ALLOWABLE = [ (ST)Mo / Sa ] * 100 = 47.28% SAFE

(ST)Qi = Sm + (Sb)Qi = 129.811 MPa [ 13.9 (c) (3) (23) ]% ALLOWABLE = [ (ST)Qi / ALLOWABLE STRESS ] * 100 = 62.71% SAFE

(ST)Qo = Sm + (Sb)Qo = -50.199 MPa [ 13.9 (c) (3) (23) ]% ALLOWABLE = [ (ST)Qo / Sa ] * 100 = 24.25% SAFE

D) MINIMUM THICKNESS OF PLUG SHEET :


Sm = 44.416 MPa(Sb)Mi = 162.412 MPa (Sb)Mo = -165.609 MPa(Sb)Qi = 108.794 MPa (Sb)Qo = -110.935 MPa(ST)Mi = 206.828 MPa % ALLOWABLE = [ (ST)Mi / Sa ] * 100 = 99.92%(ST)Mo = -121.193 MPa % ALLOWABLE = [ (ST)Mo / Sa ] * 100 = 58.55%(ST)Qi = 153.210 MPa % ALLOWABLE = [(ST)Qi / Sa ] * 100 = 74.01%(ST)Qo = -66.519 MPa % ALLOWABLE = [(ST)Qo / Sa ] * 100 = 32.13%

HENCE, t2 = 24.525 mm IS CONSIDERED AS THE MINIMUM REQUIRED THK. TO BE USED IN FOLLOWING CALCULATION.i) WELD DESIGN AS PER FIG. APPENDIX-28.ii) WELD DESIGN AS PER FIG.UG-34 (g).


API 661mm mm

1 1.5 + C 4.675 19.000 30.00


mm

NAi

MINIMUM THICKNESS PROVIDED THK. REMARKDESCRIPTION UG-16 CALCULATED

SAFE


mm mm

SR. NO.

PLUG SHEET 27.700

UW-13.2 (d)


Tag No:

1) THICKNESS EVALUATION - STAY PLATE AS PER APPENDIX 13-9 (c) :


A) MEMBRANE STRESS ON STAY PLATE, Sm : VALUE UNITS


Sm = [ P * h / 2 * t4 ] * [ ( 6 + K * ( 11 - �2 ) / ( 3 + 5 * K ) ]= [ P * h / 2 * t4 * U ] * [ ( 6 + K * ( 11 - �2 ) / ( 3 + 5 * K ) ] = 105.265 MPa [ 13.9 (c) (1) (15) ]


B) TOTAL STRESS ON STAY PLATE , ST :


(ST) = Sm = 105.265 MPa [ 13.9 (c) (3) (24) ]

% ALLOWABLE = [ (ST) / Sa ] * 100 = 76.28% SAFE

C) MINIMUM THICKNESS OF STAY PLATE :


THK. EVALUATION OF STAY & END PLATE OF NOZZLE HEADER AS PER APPENDIX 13-9 (c) & UG-34

04.06.143

C5437-HC

HE1

Sm = 137.161 MPa(ST) = 137.161 MPa % ALLOWABLE = [ (ST) / Sa ] * 100 = 99.39%

2) THICKNESS EVALUATION - END PLATE AS PER APPENDIX 13-4 ( f ) & UG-34 :

A) END PLATE THICKNESS :

t5 = [ H * { ( CF * Z * P ) / S * E } 1/2 ] + C = 25.548 mm [ UG-34 (c) (3) ](Minimum Thickness Required)

3) SUMMARY OF THICKNESS:

API 661mm mm

1 1.5 + 2 * C 7.850 12.000 20.000

2 1.5 + C 4.675 12.000 30.000

SR. NO. DESCRIPTIONMINIMUM THICKNESS PROVIDED

THK. REMARKUG-16 (b) CALCULATED

mm mm

END PLATE 25.548


STAY PLATE 16.800 SAFE

SAFE


04.06.143

C5437-HCHE1

VESSEL SKETCH FOR RETURN HEADER AS PER FIG. 13.2 (a) SKETCH (10)

FIG . 13. 2(a) SKETCH (10) - VESSELS OF RECTANGULAR CROSS SECTION HAVING MORE THAN TWO COMPARTMENTOF UNEQUAL SIZE. AS PER 13 - 9 (F) (2), HEADER BOX HAS BEEN ANALYSED BY SELECTING THE COMPARTMENT HAVING THE MAXIMUM DIMENSIONS AND THEN ANALYSING THE STRUCTURE PER 13 - 9 (c).

SINCE NOZZLE & RETUTN HEADER HAVING SAME INSIDE LENGTH OF SHORT SIDE ( H ), ONLY NOZZLE HEADER IS ANALYSED SELECTING THE COMPARTMENT HAVING MAXIMUM DIMENSION



P = DESIGN PRESSURE = 10.205 MPaT = DESIGN TEMPERATURE = 121.110 OCS = ALLOWABLE STRESS - PLATE = 138.000 MPa

H' = INSIDE LENGTH OF SHORT SIDE = 100.000 mmh' = INSIDE LENGTH OF LONG SIDE = 97.000 mmt1' = THICKNESS OF TOP/BOTTOM PLATE (SHORT SIDE) = 28.000 mmt2' = THICKNESS OF TUBE/PLUG PLATE (LONG SIDE) = 30.000 mmC = CORROSION ALLOWANCE OF PLATE / SHEET = 3.175 mmt4' = THICKNESS OF STAY PLATE = 20.000 mm U = STAY PLATE LIGAMENT EFFICIENCY = 0.672E = JOINT EFFICIENCY FACTOR = 1.000

Ew = NOZZLE WELD EFFICIENCY = 1.000TP = TUBE PITCH = 63.500 mmRT = TUBE INSIDE RADIUS = 10.590 mmDP = TUBE PLUG DIAMETER = 28.575 mmDH = TUBE HOLE INSIDE DIAMETER = 25.750 mmD' = LARGE SPAN MEASURED PERPENDICULAR TO SHORT SPAN = 332.000 mmCF = END PLATE ATTACHMENT FACTOR AS PER APP. - 13.4 (f) = 0.200t5 = THICKNESS OF END PLATE = 28.000 mm

CALCULATIONS :

04.06.143

C5437-HCHE1

INPUT DATA FOR RETURN HEADER AS PER APPENDIX 13-9 (c) & 13-5

h = h' + ( 2 * C ) = 103.350 mmH = H' + ( 2 * C ) = 106.350 mm� = RECTANGULAR VESSEL PARAMETER = H / h = 1.029t1 = ( t1' - C ) = 24.825 mmt2 = ( t2' - C ) = 26.825 mmt4 = ( t4' - 2 * C ) = 13.650 mmD = ( D' + 2 * C ) = 338.350 mml1 = ( t1 )

3 / 12 = 1274.931 mm3

l2 = ( t2 )3 / 12 = 1608.563 mm3






A) MEMBRANE STRESS ON SHORT SIDE PLATE, Sm : VALUE UNITS


Sm = [ P * h / 2 * t1 ] * [ 3 - { ( 6 + K * ( 11 - �2 ) / ( 3 + 5 * K ) } ]= [ P * h / 2 * t1 * E ] * [ 3 - { ( 6 + K * ( 11 - �2 ) / ( 3 + 5 * K ) } ] = 21.413 MPa [ 13.9 (c) (1) (13) ]


B) BENDING STRESS ON SHORT SIDE, Sb :


(Sb)N = [P * c1 / 24 * I1] * [-3 * H2 + 2 * h2 * {(3 + 5 *�2 * K) / (3 + 5 *K)} ] = [P * c1 / 24 * I1 * E] * [-3 * H2 + 2 * h2 * {(3 + 5 *�2 * K) / (3 + 5 *K)} ] = -48.472 MPa [ 13.9 (c) (2) (16) ]

% ALLOWABLE = [ (Sb)N / Sa ] * 100 = 26.12% SAFE

(Sb)Q = [ P * h2 * c1 / 12 * I1 ] * [ ( 3 + 5 * �2 * K ) / ( 3 + 5 * K ) ] = [ P * h2 * c1 / 12 * I1 * E ] * [ ( 3 + 5 * �2 * K ) / ( 3 + 5 * K ) ] = 91.994 MPa [ 13.9 (c) (2) (17) ]


C) TOTAL STRESS ON SHORT SIDE, ST :


3C5437-HC

HE1

THICKNESS EVALUATION OF TOP & BOTTOM PLATE OF RETURN HEADER AS PER APPENDIX 13-9 (c)

04.06.14


(ST)N = Sm + (Sb)N = -27.059 MPa [ 13.9 (c) (3) (20) ]

% ALLOWABLE = [ (ST)N / Sa ] * 100 = 13.07% SAFE

(ST)Q = Sm + (Sb)Q = 113.407 MPa [ 13.9 (c) (3) (21) ]


D) MINIMUM THICKNESS OF TOP & BOTTOM PLATE :


Sm = 29.537 MPa(Sb)N = -90.642 MPa (Sb)Q = 175.798 MPa(ST)N = -61.105 MPa % ALLOWABLE = [ (ST)N / Sa ] * 100 = 29.52%(ST)Q = 205.335 MPa % ALLOWABLE = [(ST)Q / Sa ] * 100 = 99.20%

HENCE, t1 = 18.025 mm IS CONSIDERED AS THE MINIMUM REQUIRED THK. TO BE USED IN FOLLOWING CALCULATION.

i) COMPENSATION CALCULATION AS PER UG-37 & UG-39.ii) WELD DESIGN AS PER FIG. UG-34 (g)


API 661mm mm

1 1.5 + C 4.675 12.000 28.00


REMARKUG-16 CALCULATEDSR. NO.mm

DESCRIPTION

SAFE

mm

TOP / BOTTOM PLATE

PROVIDED THK.

21.200

MINIMUM THICKNESS





Sm = ( P * H ) / ( 2 * t2 )= ( P * H ) / ( 2 * t2 * e ) = 34.056 MPa [ 13.9 (c) (1) (14) ]




(Sb)M = [ P * h2 * c2 / 12 * I2 ] * [ { 3 + K * ( 6 - �2 ) } / ( 3 + 5 * K ) ]= [ P * h2 * c2 / 12 * I2 * e ] * [ { 3 + K * ( 6 - �2 ) } / ( 3 + 5 * K ) ] = 126.482 MPa [ 13.9 (c) (2) (18) ]

% ALLOWABLE = [ (Sb)M / Sa ] * 100 = 73.13% SAFE

(Sb)Q = [ P * h2 * c2 / 12 * I2 ] * [ ( 3 + 5 * �2 * K) / ( 3 + 5 * K ) ] = 78.788 MPa [ 13.9 (c) (2) (19) ]


THICKNESS EVALUATION OF TUBE SHEET OF RETURN HEADER AS PER APPENDIX 13-9 (c)

04.06.143

C5437-HCHE1



(ST)M = Sm + (Sb)M = 160.538 MPa [ 13.9 (c) (3) (22) ]

% ALLOWABLE = [ (ST)M / Sa ] * 100 = 77.55% SAFE

(ST)Q = Sm + (Sb)Q = 112.844 MPa [ 13.9 (c) (3) (23) ]


D) MINIMUM THICKNESS OF TUBE SHEET :

AS A CONSERVATIVE DESIGN, PLUG SHEET MINIMUM THICKNESS IS USED THROUGHOUT THE CALCULATION.REFER SHEET "THICKNESS EVALUATION OF PLUG SHEET OF RETURN HEADER AS PER APPENDIX 13-9 (c)" FOR MINIMUM THICKNESS.


API 661mm mm

1 1.5 + C 4.675 19.000 30.00



mm mm

TUBE SHEET 27.900 NAi SAFE

SR. NO.


THK. REMARKUG-16 CALCULATED UW-13.2 (d)

mm


Tag No:




Sm = ( P * H ) / ( 2 * t2 ) = ( P * H ) / ( 2 * t2 * em ) = 37.118 MPa [ 13.9 (c) (1) (14) ]% ALLOWABLE = ( Sm / Sa ) * 100 = 26.90% SAFE



(Sb)Mi = [ P * h2 * c2i / 12 * I2 ] * [ { 3 + K * ( 6 - �2 ) } / ( 3 + 5 * K ) ]= [ P * h2 * c2i / 12 * I2 * eb ] * [ { 3 + K * ( 6 - �2 ) } / ( 3 + 5 * K ) ] = 140.228 MPa [ 13.9 (c) (2) (18) ]% ALLOWABLE = [ (Sb)Mi / Sa ] * 100 = 82.54% SAFE

(Sb)Mo = [ P * h2 * c2o / 12 * I2 ] * [ { 3 + K * ( 6 - �2 ) } / ( 3 + 5 * K ) ]= [ P * h2 * c2o / 12 * I2 * eb ] * [ { 3 + K * ( 6 - �2 ) } / ( 3 + 5 * K ) ] = -142.749 MPa [ 13.9 (c) (2) (18) ]% ALLOWABLE = [ (Sb)Mo / Sa ] * 100 = 84.03% SAFE

(Sb)Qi = [ P * h2 * c2i / 12 * I2 ] * [ ( 3 + 5 * �2 * K) / ( 3 + 5 * K ) ] = 78.086 MPa [ 13.9 (c) (2) (19) ]% ALLOWABLE = [ (Sb)Qi / Sa ] * 100 = 45.96% SAFE

(Sb)Qo = [ P * h2 * c2o / 12 * I2 ] * [ ( 3 + 5 * �2 * K) / ( 3 + 5 * K ) ] = -79.490 MPa [ 13.9 (c) (2) (19) ]% ALLOWABLE = [ (Sb)Qo / ALLOWABLE STRESS ] * 100 = 46.79% SAFE



(ST)Mi = Sm + (Sb)Mi = 177.346 MPa [ 13.9 (c) (3) (22) ]% ALLOWABLE = [ (S ) / Sa ] * 100 = 85.67% SAFE

THICKNESS EVALUATION OF PLUG SHEET OF RETURN HEADER AS PER APPENDIX 13-9 (c)

04.06.143

C5437-HC

HE1

% ALLOWABLE = [ (ST)Mi / Sa ] * 100 = 85.67% SAFE

(ST)Mo = Sm + (Sb)Mo = -105.631 MPa [ 13.9 (c) (3) (22) ]% ALLOWABLE = [ (ST)Mo / Sa ] * 100 = 51.03% SAFE

(ST)Qi = Sm + (Sb)Qi = 115.204 MPa [ 13.9 (c) (3) (23) ]% ALLOWABLE = [ (ST)Qi / ALLOWABLE STRESS ] * 100 = 55.65% SAFE

(ST)Qo = Sm + (Sb)Qo = -42.372 MPa [ 13.9 (c) (3) (23) ]% ALLOWABLE = [ (ST)Qo / Sa ] * 100 = 20.47% SAFE

D) MINIMUM THICKNESS OF PLUG SHEET :


Sm = 40.271 MPa(Sb)Mi = 165.298 MPa (Sb)Mo = -168.525 MPa(Sb)Qi = 92.528 MPa (Sb)Qo = -94.334 MPa(ST)Mi = 205.569 MPa % ALLOWABLE = [ (ST)Mi / Sa ] * 100 = 99.31%(ST)Mo = -128.254 MPa % ALLOWABLE = [ (ST)Mo / Sa ] * 100 = 61.96%(ST)Qi = 132.799 MPa % ALLOWABLE = [(ST)Qi / Sa ] * 100 = 64.15%(ST)Qo = -54.063 MPa % ALLOWABLE = [(ST)Qo / Sa ] * 100 = 26.12%

HENCE, t2 = 24.725 mm IS CONSIDERED AS THE MINIMUM REQUIRED THK. TO BE USED IN FOLLOWING CALCULATION.i) WELD DESIGN AS PER FIG. APPENDIX-28.ii) WELD DESIGN AS PER FIG.UG-34 (g).


API 661mm mm

1 1.5 + C 4.675 19.000 30.00



mm mm

PLUG SHEET 27.900 NAi SAFE

SR. NO.


THK. REMARKUG-16 CALCULATED UW-13.2 (d)mm


Tag No:

1) THICKNESS EVALUATION - STAY PLATE AS PER APPENDIX 13-9 (c) :


A) MEMBRANE STRESS ON STAY PLATE, Sm : VALUE UNITS


Sm = [ P * h / 2 * t4 ] * [ ( 6 + K * ( 11 - �2 ) / ( 3 + 5 * K ) ]= [ P * h / 2 * t4 * U ] * [ ( 6 + K * ( 11 - �2 ) / ( 3 + 5 * K ) ] = 114.521 MPa [ 13.9 (c) (1) (15) ]


B) TOTAL STRESS ON STAY PLATE , ST :


(ST) = Sm = 114.521 MPa [ 13.9 (c) (3) (24) ]

% ALLOWABLE = [ (ST) / Sa ] * 100 = 82.99% SAFE

C) MINIMUM THICKNESS OF STAY PLATE :


HE1

THK. EVALUATION OF STAY & END PLATE OF RETURN HEADER AS PER APPENDIX 13-9 (c) & UG-34

C5437-HC

04.06.143

Sm = 137.017 MPa(ST) = 137.017 MPa % ALLOWABLE = [ (ST) / Sa ] * 100 = 99.29%

2) THICKNESS EVALUATION - END PLATE AS PER APPENDIX 13-4 ( f ) & UG-34 :

A) END PLATE THICKNESS :

t5 = [ H * { ( CF * Z * P ) / S * E } 1/2 ] + C = 23.625 mm [ UG-34 (c) (3) ](Minimum Thickness Required)

3) SUMMARY OF THICKNESS:

API 661mm mm

1 1.5 + 2 * C 7.850 12.000 20.000

2 1.5 + C 4.675 12.000 28.000


END PLATE 23.625 SAFE

STAY PLATE 17.750 SAFE

mm mmSR. NO. DESCRIPTION

MINIMUM THICKNESS PROVIDED THK. REMARKUG-16 (b) CALCULATED


�� UG-31 (a) :

THE REQUIRED WALL THICKNESS FOR TUBES UNDER INTERNAL PRESSURE SHALL BE DETERMINED IN ACCORDANCEWITH THE RULES FOR SHELLS IN UG-27.

�� THICKNESS EVALUATION OF TUBE AS PER UG-27 (c) :

INPUT DATA : VALUE UNIT

P = INTERNAL DESIGN PRESSURE = 10.205 MPa (g)T = DESIGN TEMPERATURE = 121.110 º C

Di = INSIDE DIAMETER OF TUBE (CORRODED) = 21.180 mmRi = INSIDE RADIUS OF TUBE (CORRODED) = 10.590 mmEl = LONGITUDINAL JOINT EFFICIENCY (SEAMLESS) = 1.000

Ec = CIRCUMFERENTIAL JOINT EFFICIENCY (SEAMLESS) = 1.000C = CORROSION ALLOWANCE = 0.000 mmS = MAX. ALLOWABLE STRESS AT DESIGN TEMPERATURE = 92.400 MPa

MOC = MATERIAL OF CONSTRUCTION = SA-179

1) CIRCUMFERENTIAL STRESS ( LONGITUDINAL JOINTS ) :(¡) CONSIDERING JOINT EFFICIENCY El = 1

ts = [ ( P * Ri ) / ( S * E - 0.6 * P ) ] + C = 1.253 mm

THICKNESS EVALUATION OF TUBE AS PER UG-31 AND UG-27

04.06.143

C5437-HCHE1

CHECK WHETHER,ts < (Ri/2 +c) YESP < (0.385 x S x EI) YES

HENCE ABOVE FORMULA IS OK.

2) LONGITUDINAL STRESS ( CIRCUMFERENTIAL JOINTS ) :(¡) CONSIDERING JOINT EFFICIENCY Ec = 1

ts = [ ( P * Ri ) / ( 2 * S * Ec + 0.4 * P ) ] + C = 0.572 mm

CHECK WHETHER,ts < (Ri/2 +c) YESP < (1.25 x S x EC) YES

HENCE ABOVE FORMULA IS OK.

3) MINIMUM THICKNESS REQUIRED AS PER UG 16 (b) (5) (d) tmin = 0.500 mm

4) CONCLUSION :a) REQUIRED TUBE THICKNESS IS GREATER OF 1), ts = 1.253 mm

2) & 3) ABOVE

b) PROVIDED NOMINAL TUBE THICKNESS ts = 2.110 mm

c) PROVIDED THICKNESS IS LAGER THAN THE REQUIRED THICKNESS DUE TO PRESSURE, HENCE SAFE.


NOZZLE SIZENOZZLE MATERIALNOZZLE LOCATION NOZZLE MARK NO.INPUT DATA :

P = INTERNAL DESIGN PRESSURE MPa (g)Pe = EXTERNAL DESIGN PRESSURE MPa (g)Sn = ALLOWABLE STRESS - NOZZLE MPaSv = ALLOWABLE STRESS - VESSEL MPaDo = OUT SIDE DIA. OF NOZZLE CONNECTION mmRo = OUT SIDE RADIUS OF NOZZLE CONNECTION mmEl = LONGITUDINAL JOINT EFFICIENCY

tstd = STD. WALL THK. OF PIPE (ASME B 36.10) mmC = CORROSION ALLOWANCE. mm

(A)t= (P*Ro) / (Sn*El + 0.4P) …..[APPENDIX 1-1(a)] mm

ta = REQUIRED THICKNESS = (ta + C ) mm

(B)(i) FOR INTERNAL PRESSURE ONLY

JOINT EFFICIENCY AS 1.0 mm- 1) TOP/ BOTTOM PLATE CALCULATED THK. WITH

19.325 18.025

MINIMUM THICKNESS OF NOZZLE AS PER UG-45:

12.332 5.222

9.157 2.047MINIMUM THICKNESS OF NOZZLE AS PER UG-45:

3.175 3.175

1 18.18 3.91

219.100 57.000109.55 28.5

118.000 138.000138.000 138.000

10.205 10.2050.000 0.000

SA-234 Gr.WPB SA-105N NOZZLE HEADER RETURN HEADER

04.06.143

C5437-HCHE1

NOZZLE THICKNESS CALCULATION AS PER UG-45

DN 200 DN 25 NPT

N1 - N4 V / D

JOINT EFFICIENCY AS 1.0 mm- 2) THE MINIMUM THICKNESS AS PER UG - 16 (b) : = 1.5 + C mm

tb1 = MAXIMUM OF 1) & 2) ABOVE mm(ii) FOR EXTERNAL PRESSURE ONLY

EFFICIENCY AS 1.0 mm- 2) THE MINIMUM THICKNESS AS PER UG - 16 (b) : = 1.5 + C mm

tb2 = MAXIMUM OF 1) & 2) ABOVE mm

(iii) tb3 = THK AS PER TABLE UG-45 mm

(iv) tb = MIN OF [tb3, MAX(tb1,tb2)] mm

(C) MIN.REQUIRED THK. IS tUG-45 = MAX (ta, tb) mm

(D) MINIMUM NOZZLE THK. PROVIDED mm(E) NOMINAL NOZZLE THK. PROVIDED mm 23.01 SCH 160 11.8 6000 #

SUMMARY :

N1 - N4 DN 200 SCH 160V / D DN 25 NPT 6000 #

C1 - C2 DN 50 SCH 160

20.134 11.800

12.332 6.135

10.335 6.135

10.335 6.135

0.000 0.0000.000 0.000

- 1) TOP/ BOTTOM PLATE CALCULATED THK. WITH 0 0

19.325 18.0254.675 4.675

19.325 18.025


�� APPENDIX 13-4 (j) (1) :

OPENINGS IN NONCIRCULAR VESSELS DO NOT REQUIRE REINFORCEMENT OTHER THAN THAT INHERENT IN THECONSTRUCTION, PROVIDED THEY MEET THE CONDITIONS GIVEN IN UG-36 (c) (3)

�� FINISHED OPENING DIAMETER AS PER UG-36 (c) (1) & FIG. UG-40 (b-3) :

INPUT DATA : N1 - N4

Dn = OUTER DIAMETER OF NOZZLE mm 219.100Wt = NOMINAL NOZZLE WALL THICKNESS mm 23.010

C = CORROSION ALLOWANCE mm 3.175tn = NOZZLE WALL THICKNESS (CORRODED) mm 19.835d = FINISHED DIA. OF CIRCULAR OPENING = (Dn - 2*tn) mm 179.430t1 = REQUIRED MINIMUM THICKNESS SHELL mm 19.325

�� REINFORCEMENT EXEMPTION AS PER UG-36 (c) (3) :

OPENINGS OF FOLLOWING SIZES IN THE VESSELS NOT SUBJECT TO RAPID FLUCTUATIONS IN PRESSURE ARE EXEMPTED FROM REINFORCEMENT PROVIDED :

UG-36 (c) (3) (a) : - FINISHED OPENINGS NOT LARGER THAN 89 mm DIAMETER FOR REQUIRED MINIMUM THICKNESS 10 mm OR LESS. - FINISHED OPENINGS NOT LARGER THAN 60 mm DIAMETER FOR REQUIRED MINIMUM THICKNESS GREATER THAN 10 mm.

39.75018.025

04.06.143

C5437-HCHE1

8.625

REINFORCEMENT REQUIREMENT FOR NOZZLE AS PER APPENDIX 13-4

V / D

57.00011.8003.175

UG-36 (c) (3) (b) : THREADED, STUDDED, OR EXPANDED CONNECTIONS IN WHICH THE HOLE CUT IN THE SHELLOR HEAD NOT GREATER THAN 60 mm DIAMETER.

UG-36 (c) (3) (c) : NO TWO ISOLATED UNREINFORCED OPENINGS IN ACCORDANCE WITH (a) OR (b) ABOVE, SHALLHAVE THEIR CENTERS CLOSER TO EACH OTHER THAN THE SUM OF THEIR DIAMETERS.

UG-36 (c) (3) (d) : NO TWO UNREINFORCED OPENINGS, IN A CLUSTER OF THREE OR MORE UNREINFORCED OPENINGS IN ACCORDANCE WITH (a) OR (b) ABOVE, SHALL HAVE THEIR CENTERS CLOSERTO EACH OTHER THAN THE FOLLOWINGS :

FOR CYLINDRICAL OR CONICAL SHELLS : (1 + 1.5 COS � ) (d1 + d2)FOR DOUBLY CURVED SHELLS & FORMED OR FLAT HEAD : : 2.5 * (d1 + d2 )

WHERE,� = THE ANGLE BETWEEN THE LINE CONNECTING THE CENTER OF THE OPENINGS

AND THE LONGITUDINAL AXIS OF THE SHELLd1, d2 = THE FINISHED DIAMETER OF THE TWO ADJACENT OPENINGS.

�� CONCLUSION :

A) OPENING IN VESSEL IS NOT SUBJECTED TO RAPID FLUCTUATION IN PRESSURE.B) OPENINGS ON TOP AND BOTTOM PLATE ARE SINGLE & ISOLATED FOR BOTH INLET & OUTLET HEADER.C) NOZZLE N1 - N4 : FINISHED DIAMETER OF OPENING IS 179.43 mm WHICH IS LARGER THAN 60.00 mm AND

REQUIRED MINIMUM THICKNESS OF SHELL IS 19.325 mm WHICH IS GREATER THAN 10 mm THICKNESS. SINCE OPENING IS LARGER THAN 60.00 mm, REINFORCEMENT NEEDS TO BE CHECKED AS PER UG-37 TO UG-42.

D) NOZZLE V / D : FINISHED DIAMETER OF OPENING IS 39.75 mm WHICH IS SMALLER THAN 60.00 mm AND REQUIRED MINIMUM THICKNESS OF SHELL IS 18.025 mm WHICH IS GREATER THAN 10 mm THICKNESS. SINCE OPENING IS NOT LARGER THAN 60.00 mm, HENCE REINFORCEMENT IS NOT REQUIRED AS PER UG-36 (c) (3) (a).

Page No: 28 of 50Date:Revision:

Document No:Tag No:

NOZZLE SIZENOZZLE MATERIALNOZZLE LOCATION NOZZLE MARK NO.INPUTS DATA :

t = NOMINAL THICKNESS OF THE SHELL SECTION IN CORRODED CONDITION mm

tr = REQUIRED THK.OF SEAMLESS SHELL / HEAD BASED ON CIRCUMFERENTIAL STRESS, USING E=1 mm

E1 = FACTORF = FACTOR

E1*t-F*tr = EXCESS THK IN SHELL OR HEAD mmP = INTERNAL DESIGN PRESSURE MPa (g)

Sn = ALLOWABLE STRESS - NOZZLE MPaSv = ALLOWABLE STRESS - VESSEL MPaDn = OUT SIDE DIA. OF NOZZLE CONNECTION mmRo = OUTSIDE RADIUS OF NOZZLE CONNECTION mmRn = INSIDE RADIUS OF NOZZLE CONNECTION (CORRODED) mmEl = LONGITUDINAL JOINT EFFICIENCYC = CORROSION ALLOWANCE. mm

Tn, Ti = NOMINAL THICKNESS OF NOZZLE mmtn, ti = NOZZLE THICKNESS IN CORRODED CONDITION mm

trn = (P*Rn) / (Sn*El + 0.4P) …..[APPENDIX 1-1(a)] mm tn-trn = EXCESS THICKNESS IN NOZZLE mm

fr1 = Sn/Svfr2 = Sn/Svd = I.D. OF FINISHED OPENING (CORRODED) mmh = DISTANCE NOZZLE PROJECTS BEYOND INNER

SURFACE OF VESSEL WALL mmleg1 = WELD FILLET SIZE FOR OUTWARD NOZZLE mmleg2 = WELD FILLET SIZE FOR INWARD NOZZLE mm

3

C5437-HC

24.825

NOZZLE HEADERN1 - N4

SA-234 Gr.WPB

04.06.14

HE1

REINFORCEMENT REQUIREMENT IN Z-DIRECTION AS PER UG-39 & UG-37

DN 200

19.32511

5.50010.205118.000138.000304.787152.394132.559

13.17523.0119.83512.7397.0960.8550.855

265.117

0.0009.0000.000leg2 = WELD FILLET SIZE FOR INWARD NOZZLE mm

tp = THICKNESS OF TOP/BTM PLATE STIFFNER (CORRODED) mmLp = LENGTH OF TOP/BTM PLATE STIFFNER (CORRODED) mmNp = NOS. OF TOP/BTM PLATE STIFFNERts = THICKNESS OF NOZZLE STIFFNER (CORRODED) mmLs = LENGTH OF NOZZLE STIFFNER (CORRODED) mmNs = NOS. OF NOZZLE STIFFNER

REINFORCEMENT CALCULATION : (a) A1 = AREA AVAILABLE IN SHELL OR HEAD

(i) = (E1*t-F*tr)*d - 2*tn(E1*t-F*tr)(1-fr1) OR mm2

(ii) = 2(E1*t-F*tr)*(t+tn) - 2*tn*(E1*t-F*tr)*(1-fr1) mm2

(iii) A1 = GREATER VALUE OF (i) OR (ii) ABOVE mm2

(b) A2 = AREA AVAILABLE IN NOZZLE PROJECTING OUTWARD (i) = 5 * t * ( tn - trn ) * fr2 OR mm2

(ii) = 5 * tn * ( tn - trn ) * fr2 mm2

(iii) A2 = SMALLER VALUE OF (i) OR (ii) ABOVE mm2

(c) A3 = AREA AVAILABLE IN INWARD NOZZLE(i) = 5 * t * ti * fr2 (ii) = 5 * ti * ti * fr2(iii) = 2 * h * ti * fr2(iv) A3 = SMALLER VALUE OF (i) OR (ii) OR (iii) ABOVE mm2

(d) A41 = AREA AVAILABLE IN OUTWARD NOZZLE WELD(i) = leg1 * leg1 * fr2 mm2

(e) A43 = AREA AVAILABLE IN INWARD NOZZLE WELD(i) = leg2 * leg2 * fr2 mm2

(f) A5 = AREA AVAILABLE IN STIFFNERS= Np * Lp * tp + Ns * Ls * ts mm2

(g) A' = REINFORCEMENT AREA AVAILABLE WITHOUT PAD(i) = A1+A2+A3+A41+A43+A5 mm2

(h) A = REINFORCEMENT AREA REQUIRED(i) = 0.5 * d * tr + 2 * tn * tr * ( 1 - fr1 ) mm2

CONCLUSION :-1) CHECK WHETHER A' > A2) CHECK WHETHER REINFORCEMENT IS REQUIRED

0.00018.65039.6501.00018.65063.6501.000

1426.522459.6391426.522

753.140601.754601.754

2105.2051682.044

0.0000.000

69.261

0.000

1926.545

4024.082

NOT REQUIRED

2672.798

YES SATISFIED

Page No: 29 of 50

Date:

Revision:

Document No:Tag No:

�

NOZZLE SIZENOZZLE MATERIALNOZZLE LOCATION NOZZLE MARK NO.INPUTS DATA :

t = NOMINAL THICKNESS OF THE SHELL SECTION IN CORRODED CONDITION mm

trf = MIN REQ FLAT HEAD THK, EXCLUSIVE OF CORROSION

AS PER 4.6.1 (USING E = 1) mmte = THICKNESS OF THE REINFORCINGPAD mm

E1 = FACTORW = WIDTH OF THE REINFORCING PAD mmP = INTERNAL DESIGN PRESSURE MPa (g)

Sn = ALLOWABLE STRESS - NOZZLE MPaSv = ALLOWABLE STRESS - VESSEL MPa

Don = OUT SIDE DIA. OF NOZZLE CONNECTION mmEl = LONGITUDINAL JOINT EFFICIENCY

C = CORROSION ALLOWANCE. mmTn, Ti = NOMINAL THICKNESS OF NOZZLE mmtn, ti = NOZZLE THICKNESS IN CORRODED COND. mm

trn = Din * [ EXP(P/SnEl) - 1] / 2 mm

Din = NOZZLE INSIDE DIAMETER (CORRODED) mmRn = NOZZLE INSIDE RADIUS (CORRODED)

Lpr1 = NOZZLE PROJECTION FROM THE OUTSIDE OF THE

VESSEL WALL mmLpr2 = NOZZLE PROJECTION FROM THE INSIDE OF THE

VESSEL WALL mmL41 = WELD LEG LENGTH OF THE OUTSIDE

NOZZLE FILLET WELD mmL42 = WELD LEG LENGTH OF THE PAD TO

04.06.14

3

C5437-HCHE1

REINFORCEMENT REQUIREMENT AS PER U - 2(g)

REFERENCE : ASME SECTION VIII DIVISION 2 CL. 4.5.12DN 200 DN 20

SA-234 Gr.WPB SA-312M Gr TP316L NOZZLE HEADER HEADER

N1 - N4 D1 - D2 / V1 - V2

24.825 11.800

19.325 4.2460.000 0.000

1 10.000 1.00010.205 0.358118.000 108.520138.000 108.520219.100 26.700

1 1

3.175 323.01 5.5619.835 2.5608.104 832.065

179.430 21.58089.715 10.790

322.000 21.580

0.000 0.000

9.000 9.000L42 = WELD LEG LENGTH OF THE PAD TO

VESSEL FILLET WELD mmL43 = WELD LEG LENGTH OF THE INSIDE

NOZZLE FILLET WELD mm

CALCULATIONS:

MAXIMUM UNIT MOMENT AT THE NOZZLE INTERSECTION :

Mo =Sv * trf4 / 6(t + Cp * te)

2

Cp = MIN [{(W + 0.5 * L42) * te / (Rn * t)}, 0.6]

NOZZLE PARAMETERS :

��n = 1.285 / (Rnm * tn) ̂0.5

C1 = SINH2 [CL] + SIN2 [CL]

C2 = SINH2 [CL] - SIN2 [CL]CL = MIN [ {�n (Lpr1 + t + Lpr2)}, 6.0 ]

C3 = (Lpr1 + t) / [Lpr1 + t + MIN {(�n)-1 , Lpr2)}]

Rnm = Rn + 0.5 * tnRxn = tn / ln [(Rn + tn) / Rn]

xt = 0.5 * �n * (te + L41) (for nozzle abutting vessel wall)

Ct = EXP [-xt]

DETERMINE MAXIMUM LOCAL PRIMARY MEMBRANE STRESSIN THE NOZZLE INTERSECTION:

PL = (2 * Mo * �n2 * Rnm * Ct * C1 * C3 / tn C2) + (P * Rxn / tn)

CONCLUSION :-

PL <= 1.5 Sn

PL <= 1.5 S * E for internal pressure

0 0

0 0

5205.079

0.00

0.029

40688.27593

40688.11978

6.000

1.000

99.633

99.303

0.131

0.877

89.659

SAFESAFE


�� AS PER UG - 44, THE FLANGE RATINGS SHALL BE IN ACCORDANCE WITH ASME B 16.5.

P = INTERNAL DESIGN PRESSURE = 10.205 MPa (g)T = DESIGN TEMPERATURE = 121.110 º C

13.785PERMITTED MAWP w.r.t DESIGN TEMP., MPa (g)

PERMITTED MAWP w.r.t ROOM TEMP., MPa (g)

15.320

SELECTED RATING 900

TABLE

MATERIAL GROUP

MATERIAL SA-105N

1.1

SIZE DN 200

TYPE OF FLANGE

2-1.1

WNRTJ

HE1

04.06.143

C5437-HC

FLANGE RATING CHECK AS PER UG-44 & ASME B16.5-2013

NOZZLE MARK NO. N1 - N4

PROVIDED RATING

MPa (g)

900

Page No: 31 of 50

Date:

Revision:

Document No:Tag No:

�� INSPECTION OPENING AS PER UG-46 (d) :

FOR VESSELS 300 mm OR LESS IN INSIDE DIAMETER, OPENINGS FOR INSPECTION ONLY MAY BE OMITTED IF THEREARE AT LEAST TWO REMOVABLE PIPE CONNECTIONS NOT LESS THAN DN 20.

�� CONCLUSION :

A) NOZZLE HEADER INSIDE DIMENSION (SHORT SPAN) IS 110 mm WHICH IS LESS THAN 300 mm.B) RETURN HEADER INSIDE DIMENSION (SHORT SPAN) IS 100 mm WHICH IS LESS THAN 300 mm.C) NOZZLE HEADER HAVING PIPE CONNECTION OF SIZE DN 200 WHICH IS LARGER THAN DN 20.D) RETURN HEADER HAVING PIPE CONNECTION OF DN 25 WHICH IS LARGER THAN DN 20.E) SEPARATE INSPECTION OPENING IS NOT REQUIRED, SINCE ALL THE REQUIREMENT OF UG-46 (d)

ARE COMPLIED AS DEMONSTRATED.INLET / OUTLET / VENT / DRAIN PIPE ARE USED AS INSPECTION OPENING.

INSPECTION OPENING AS PER UG-46.HE1

04.06.14

3

C5437-HC


COMPONENTt tn tc = MIN (6, 0.7 * tmin)

04.06.143

C5437-HC

WELD DESIGN AS PER FIG. UW-16.1 (a)

FIG : UW 16.1 (a)

f = tc / 0.7fp

(min.)tmin = MIN(19,tn ,t)

HE1

RESULT

50°

mm mm mm

24.825 19.835 9.000 SAFE

24.825 8.625 9.000 SAFE

WHERE,t = NOMINAL THICKNESS OF TOP & BOTTOM PLATE / NOZZLE (CORRODED), mm

tn = NOMINAL THICKNESS OF NOZZLE (CORRODED), mmf = LEG SIZE OF FILLET WELD, mm

fp = PROVIDED LEG SIZE OF FILLET WELD, mm

�� CONCLUSION :

1) ALL REQUIREMENTS OF UW-16.1 (a) ARE SATISFIED AS DEMONSTRATED ABOVE.2) STRENGTH CALCULATIONS FOR NOZZLE ATTACHMENTS WELD AS PER FIG. UW-16.1 (a) IS NOT REQUIRED

AS PER UW-15 (b) (1) & UW-15 (b) (2).

8.571

mm mm mm

8.571

N1 - N4 - TOP/BTM PLATE - NOZZLE HEADER 19.000 6.000

V / D TOP/BTM PLATE - RETURN HEADER 8.625 6.000

Page No: 33 of 50Date:Revision:Document No:Tag No: HE1

WELD DESIGN AS PER APPENDIX 28 FIG. 28-1 (b)

04.06.143

C5437-HC

mm mm deg. deg. mm mm mm mm mm

31.00 16.564 32.50 15.00 28.00 30.00 16.564 0.59 13.44

31.00 16.564 32.50 15.00 28.00 30.00 16.564 0.59 13.44

WHERE, t = NOMINAL THICKNESS OF TUBE / PLUG SHEET, mmts = NOMINAL THICKNESS OF TOP / BOTTOM PLATE, mm

FOLLOWING CONDITION ARE SATISFIED TO MEET THE REQUIREMENTS OF APPENDIX 28.

APPENDIX 28-2 (f) (1)APPENDIX 28-2 (f) (2)APPENDIX 28-2 (f) (3)

a2 / ts > K SHOWN IN THE TABLE IN FIG. 28-1 (b) : CONSIDERING K = 0.6 AND a2 / ts = 0.55

�� CONCLUSION :1) ALL REQUIREMENTS OF APPENDIX 28 ARE SATISFIED AS DEMONSTRATED ABOVE.2) SINCE THE REQUIREMENT OF 28-2 (f) (4) IS SATISFIED, HENCE REQUIREMENT OF 28-2 (a) & 28-2 (b) IS

NOT APPLICABLE.3) SINCE VALUE FOR 'K' IS TAKEN AS 0.6, HENCE REQUIREMENT OF THROUGH-THICKNESS (Z DIRECTION) IS

NOT MANDATORY.

a2ts

SATISFIED CLAUSE

t - b(Ref)COMPONENTa(Ref.) b(Ref.) t

YESYES

CONDITIONS

YES

CONDITION

�

TOP / BOTTOM PLATE - TUBE / PLUG SHEET - NOZZLE HEADER

FIG : 28-1 (b)

a2 / ts

� > 15O

�

YES

TOP / BOTTOM PLATE - TUBE / PLUG SHEET - RETURN HEADER

� > 15O

a2 SHALL BE MEASURED FROM PROJECTED SURFACE OF PLATE

APPENDIX 28-2 (f) (4)


2 * trtr 1.25 * ts tw = MIN (2 * tr , 1.25 * ts, t)

04.06.14

HE1

FIG : UG-34 (g)

t / twtst

C5437-HC

WELD DESIGN AS PER UG-34 (g)

3

mm mm mm mm mm mm

22.373 24.825 19.325 38.650 31.031 26.825 SAFE

22.373 26.825 24.525 49.050 33.531 26.825 SAFE

20.450 24.825 18.025 36.050 31.031 24.825 SAFE

20.450 26.825 24.725 49.450 33.531 24.825 SAFE

WHERE,t = MINIMUM REQUIRED THICKNESS OF END PLATE (CORRODED), mm

ts = NOMINAL THICKNESS OF TOP / BOTTOM PLATE OR TUBE / PLUG SHEET (CORRODED), mmtr = REQUIRED THICKNESS OF TOP / BOTTOM PLATE OR TUBE / PLUG SHEET, mm

tw = GROOVE DEPTH ON END PLATE (CORRODED), mm

�� CONCLUSION :

1) ALL REQUIREMENTS OF UG-34 (g) ARE SATISFIED AS DEMONSTRATED ABOVE.2) 100 % NDT REQUIRED ON WELD SEAM BETWEEN TOP/ BOTTOM PLATE TO END PLATE.

COMPONENTmm

2 * trtr

22.373END PLATE - TOP /BOTTOM PLATE - NOZZLE HEADER

1.25 * tsRESULT

tw = MIN (2 * tr , 1.25 * ts, t)

END PLATE - TUBE /PLUG SHEET - NOZZLE HEADER

22.373

t / twtst

END PLATE - TOP /BOTTOM PLATE - RETURN HEADER

20.450

END PLATE - TUBE /PLUG SHEET - RETURN HEADER

20.450


P NO. / MATERIALGROUP CATEGORY

NO. CURVE OCA

1 SA-516 Gr.70 N 1 / 2 D -31.13

2 SA-516 Gr.70 N 1 / 2 D -32.38

3 SA-516 Gr.70 N 1 / 2 D -31.13

4 SA-516 Gr.70 N 1 / 2 D -39.80

5 SA-234 Gr.WPB 1 / 1 B -3.99

6 SA-105N 1 / 2UCS-66 (C)

(1) -29.00

7 SA-182 Gr.F316 8 / 1 UHA-51 ((d)

8 SA-105N 1 / 2 B -23.69

THICKNESS THK., UCS-66 (a) THK., UW-40 (f)mm

HEADER

TUBE / PLUG SHEET - HEADER 30.00 30.00 i 30.00 iii

MATERIAL SPEC.

COMPONENT GOVERNINGMDMT v

GOVERNING

HE1

04.06.143

C5437-HC

GOVERNING THICKNESS AS PER UCS-66, UHA-51 & UW-40 (f)

SR. NO.

COMPONENT / ITEM NO.

28.00 28.00 i 28.00 iii

30.00 i

STAY PLATE - HEADER 20.00 20.00 i 20.00 iii

mm mm

END PLATE NOZZLE HEADER 30.00 30.00 iii

TRANSITION NOZZLE -200 DN 23.01 23.01 i 23.01 iii

TOP / BOTTOM PLATE - HEADER

DN 25 - NPT- PLUG

DN 25 - NPT- COUPLING 11.80 11.8 i 11.8 iii

WNRF FLANGES - 200 DN - 23.01 i 23.01 iii

-196 oC

B

1 SA-105N 1 / 2 B -29.00

2 SA-179 1 / 1UCS-66 (d)

(4) (a) -105.00

i THICKNESS OF THINNER WELDED MEMBER AT CATEGORY "C" CORNER JOINT AS PER UCS-66 (a) (1) (b)

ii 1/4TH OF FLAT HEAD THICKNESS AS PER UCS-66 (a) (3).

iii DEPTH OF GROOVE WELD ATTACHING MEMBERS OF THE DIFFERENT THICKNESS.

iv THE DEPTH OF GROOVE OR THE THROAT OF FILLET WELD, WHICHEVER IS GREATER AS PER UW-40 (f) (3).

v THE MDMT IS -3.99 ˚C (WARMER TEMPERATURE) AS DEMONSTRATED ABOVE.

TUBES 2.110 - -

MISCELLANEOUS

PLUG 28.575 7.144 ii -


�� CHECK FOR UG 20 (f) FOR IMPACT TEST REQUIREMENT:

IMPACT TEST AS PER PROCEDURE MENTIONED IN UG-84 IS NOT REQUIRED IF ALL OF THE FOLLOWING CONDITIONARE SATISFIED :

SR. NO.

MATERIAL IS LIMITED TO P1, GROUP 1 OR 2 & THICKNESS IS NOT EXCEEDING13 mm FOR MATERIAL LISTED IN CURVE 'A' OR FIGURE UCS-66 AND 25 mmFOR MATERIALS LISTED IN CURVES 'B', 'C' OR 'D' OF FIG. UCS -66.VESSEL HYDRAULICALLY TESTED AS PER UG-99 ( b ) OR ( c ) OR APPENDIX 27 - 4.DESIGN TEMPERATURE NO WARMER THAN 343 ° C NOR COLDER THAN - 29 ° C.THERMAL OR MECHANICAL SHOCK LOADING IS NOT A CONTROLLING DESIGNREQUIREMENT ( REFER UG-22 )CYCLIC LOADING IS NOT CONTROLLING DESIGN REQUIREMENT. (REFER UG-22)

�� CONCLUSION :

5 YES

NO

2

3 YES

4 YES

04.06.143

C5437-HC

YES

IMPACT TEST REQUIREMENT AS PER UG-20 (f), UCS-66

HE1

CONDITION CONDITIONSSATISFIED

1

1) IMPACT TESTING OF ALL PARENT MATERIAL IS REQUIRED AS PER UG-20 (f).

2) ALL MATERIALS ARE EXEMPTED FROM IMPACT TEST UPTO -3.99 ºC. REFER SHEET "GOVERNING THICKNESS".

3) MDMT REQUIRED BY CUSTOMER = -1.11 OC PROPOSED (CERTIFIED) MDMT = -1.11 ºC @ 11.8 MPa (g).


�� POST FORMING AS PER UG-79, UCS-79 :

NOT APPLICABLE SINCE NO SECTION / PART IS BEING COLD FORMED.

�� POST WELD HEAT TREATMENT AS PER UW-2, UCS-56, UCS-68(b) :

POST WELD HEAT TREATMENT IS MANDATORY IF ANY OF THE FOLLOWING CONDITIONS EXIST :

SR.NO.

1 LETHAL SERVICE APPLICATIONUNFIRED STEAM BOILER SERVICE WITH DESIGN PRESSURE GREATER THAN 345 kPa MATERIALS OVER 32 mm NOMINAL THICKNESSAS DEFINED IN UW- 40 (f) FOR MATERIAL WITH MDMT COLDER THAN -48 °C AND COINCIDENT RATIO IS EQUAL TO OR GREATERTHAN 0.35

�� CONCLUSION:

1) POST WELD HEAT TREATMENT AS PER UCS 56 IS NOT MANDATORY.

NO UW -2(c)

3 NO TABLE UCS-56 FOR P-1,GROUP 1,2,3

04.06.143

C5437-HCHE1

POST FORMING HEAT TREATMENT REQUIREMENT AS PER UG-79, UCS-79, &

POST WELD HEAT TREATMENT REQUIREMENT AS PER UW-2, UCS-56

CONDITION APPLICABILITY REFERENCE

NO UW -2(a)

4 NO UCS-68(b)

2

1) POST WELD HEAT TREATMENT AS PER UCS 56 IS NOT MANDATORY.2) POST WELD HEAT TREATMENT AS PER API-661 IS MANDATORY.


�� FULL RADIOGRAPHY REQUIREMENT IS MANDATORY WHEN ANY OF THE FOLLOWING CONDITIONS EXIST :

SR. NO.

1 LETHAL SERVICE APPLICATION [ UW-2 (a) ]ALL BUTT WELDS WITH MINIMUM NOMINAL THICKNESS EXCEEDING 38 mmOR EXCEEDS THE LESSER THICKNESS SPECIFIED IN UCS-57 i.e. 32 mmUNFIRED STEAM BOILER SERVICE WITH DESIGN PRESSURE GREATER THAN345 kPa CATEGORY B & C BUTT WELDS IN NOZZLES AND COMMUNICATING CHAMBERSTHAT EXCEED NEITHER DN 250 NOR 29 mm WALL THICKNESS.JOINT EFFICIENCY OF CATEGORY A & D BUTT WELDS ARE TAKEN FROM COLUMN (a) OF TABLE UW-12ALL BUTT WELDS JOINT BY ELECTRO GAS WELDING WITH ANY SINGLE PASS GREATER THAN 38 mm & ALL BUTT WELDS JOINED BY ELECTRO SLAG WELDINGULTRASONIC EXAMINATION IN ACCORDANCE WITH UW-53 MAY BE SUBSTITUTED FOR RADIOGRAPHY FOR THE FINAL CLOSURE SEAM OF APRESSURE VESSEL IF THE CONSTRUCTION OF THE VESSEL DOES NOT PERMIT INTERPRETABLE RADIOGRAPHS IN ACCORDANCE WITH CODEREQUIREMENTS.

�� CONCLUSION :

1) FULL RADIOGRAPHY AS PER UW-11 IS NOT MANDATORY.

NO4

5 NO

7 NO

6 NO

04.06.143

C5437-HC

3 NO

FULL RADIOGRAPHY REQUIREMENT AS PER UW-11

HE1

DESCRIPTION APPLICABILITY

NO

2 NO

2) NOZZLE PIPE TO FLANGE CATEGORY 'C' WELD JOINT AND NOZZLE PIPE TO BOX CATEGORY 'D' WELD JOINT ARE EXEMPTED AS DEMONSTRATED ABOVE.

3) RADIOGRAPHY IS NOT MANDATORY, SINCE VESSEL HAS A NON-CIRCULAR CROSS SECTION, DERIVED TO THE RULES OF APPENDIX 13 COMPRISING CATEGORY 'C' & 'D' CORNER JOINTS WHICH ARE CONTROLLED BY THE APPLICABLE RULES OF FIG. UW-13.2 AND UG-34.

4) SINCE BOX HEADER FOR AIR COOLED HEAT EXCHANGERS USING CORNER WELD JOINT CONSTRUCTED INACCORDANCE WITH FIG. 28-1, THE RULES OF UW-13 (e) (4) AND FIG. UW-13.2 ARE SUPPLEMENTED TO APPENDIX 28.

5) APPENDIX 28 REPLACES ONLY THE REQUIREMENT OF " a + b NOT LESS THAN 2ts" OF UW-13 (e) (4) ANDTHE WELD JOINT GEOMETRY OF FIG. UW-13.2.

6) AFTER PRODUCTION WELDING, THE BACK SIDE OF THE WELD SHALL BE SUBJECTED TO A VISUAL EXAMINATION TO ASSURE THAT COMPLETE FUSION AND PENETRATION HAVE BEEN ACHIEVED IN THE ROOT, EXCEPT WHERE VISUAL EXAMINATION IS LOCALLY PREVENTED BY AN INTERNAL MEMBER COVERING THE WELD AS PER APPENDIX 28 (c).

7) 100% RADIOGRAPHY / ULTRASONIC EXAMINATION IS PROVIDED AS PER TABLE 1 OF C5437-HD-002


INPUT DATA : (AS PER APPENDIX 13-9 (c) & 13-5) VALUE UNITS

MAWP = MAXIMUM ALLOWABLE WORKING PRESSURE = 11.800 MPaP = MAWP WITH STATIC HEIGHT = 11.801 MPaT = DESIGN TEMPERATURE = 121.110 OCS = ALLOWABLE STRESS AT DESIGN TEMP.- PLATE = 138.000 MPa

H' = INSIDE LENGTH OF SHORT SIDE = 110.000 mmh' = INSIDE LENGTH OF LONG SIDE = 97.000 mmt1' = THICKNESS OF TOP/BOTTOM PLATE (SHORT SIDE) = 28.000 mmt2' = THICKNESS OF TUBE/PLUG PLATE (LONG SIDE) = 30.000 mmt4' = THICKNESS OF STAY PLATE = 20.000 mmt5 = THICKNESS OF END PLATE = 30.000 mmC = CORROSION ALLOWANCE OF PLATE / SHEET = 3.175 mm

U = STAY PLATE LIGAMENT EFFICIENCY = 0.720E = JOINT EFFICIENCY FACTOR = 1.000

D' = LARGE SPAN MEASURED PERPENDICULAR TO SHORT SPAN = 332.000 mmCF = END PLATE ATTACHMENT FACTOR AS PER APP. - 13.4 (f) = 0.200

CALCULATIONS :h = h' + ( 2 * C ) = 103.350 mmH = H' + ( 2 * C ) = 116.350 mm� = RECTANGULAR VESSEL PARA METER = H / h = 1.126t1 = ( t1' - C ) = 24.825 mmt2 = ( t2' - C ) = 26.825 mmt4 = ( t4' - 2 * C ) = 13.650 mmD = ( D' + 2 * C ) = 338.350 mml1 = ( t1 )

3 / 12 = 1274.931 mm3

l2 = ( t2 )3 / 12 = 1608.563 mm3


04.06.143

C5437-HCHE1

NOZZLE HEADER - MAWP CALCULATION (HOT & CORRODED)

e = TUBE SHEET LIGAMENT EFFICIENCY = 0.594em = MEMBRANE LIGAMENT EFFI. FOR PLUG SHEET = 0.545eb = BENDING LIGAMENT EFFI. FOR PLUG SHEET = 0.531Z = MIN ( 2.5, {3.4 - ( 2.4 * H ) / D } AS PER UG-34 (c) (3) = 2.500


Sa (m) = ALLOWBALE STRESS FOR MEMBRANE STRESS = S = 138.00 MPaSa (T) = ALLOWBALE STRESS FOR TOTAL STRESS = 1.5 * S = 207.00 MPa

�� TOP / BOTTOM PLATESm = [ P * h / 2 * t1 * E ] * [ 3 - { ( 6 + K * ( 11 - �2 ) / ( 3 + 5 * K ) } ] = 25.490 138.00

(Sb)N = [P * c1 / 24 * I1 * E] * [-3 * H2 + 2 * h2 * {(3 + 5 *�2 * K) / (3 + 5 *K)} ] = -72.889(Sb)Q = [ P * h2 * c1 / 12 * I1 * E ] * [ ( 3 + 5 * �2 * K ) / ( 3 + 5 * K ) ] = 121.528(ST)N = Sm + (Sb)N = -47.399 207.00(ST)Q = Sm + (Sb)Q = 147.018 207.00

�� PLUG SHEET :Sm = ( P * H ) / ( 2 * t2 * em ) = 46.959 138.00

(Sb)Mi = [ P * h2 * c2i / 12 * I2 * eb ] * [ { 3 + K * ( 6 - �2 ) } / ( 3 + 5 * K ) ] = 157.316(Sb)Mo = [ P * h2 * c2o / 12 * I2 * eb ] * [ { 3 + K * ( 6 - �2 ) } / ( 3 + 5 * K ) ] = -160.145(Sb)Qi = [ P * h2 * c2i / 12 * I2 ] * [ ( 3 + 5 * �2 * K) / ( 3 + 5 * K ) ] = 103.154(Sb)Qo = [ P * h2 * c2o / 12 * I2 ] * [ ( 3 + 5 * �2 * K) / ( 3 + 5 * K ) ] = -105.009(ST)Mi = Sm + (Sb)Mi = 204.275 207.00(ST)Mo = Sm + (Sb)Mo = -113.186 207.00(ST)Qi = Sm + (Sb)Qi = 150.113 207.00(ST)Qo = Sm + (Sb)Qo = -58.050 207.00

�� STAY PLATE :Sm = [ P * h / 2 * t4 * U ] * [ ( 6 + K * ( 11 - �2 ) / ( 3 + 5 * K ) ] = 121.727

(ST) = Sm = 121.727 138.00

�� END PLATE AS PER APPENDIX 13-4 ( f ) & UG-34 (c) (3) :t5 = [ H * { ( CF * Z * P ) / S * E } 1/2 ] + CS = [ ( H2 * CF * Z * P ) / { ( t5 - C )2 * E ) } ] = 111.005 138.00

CONCLUSION : GOVERNING COMPONENT IS PLUG SHEET OF RETURN HEADER WITH MAWP OF 10.4 MPa

28.04%

88.21%

80.44%

22.90%

18.47%

72.52%54.68%98.68%

71.02%

34.03%

ALLOWABLE STRESS,MPa

% ALLOWABLEMPa



MAWP = MAXIMUM ALLOWABLE WORKING PRESSURE = 11.800 MPaP = MAWP WITH STATIC HEIGHT = 11.801 MPaT = DESIGN TEMPERATURE = 121.110 OCS = ALLOWABLE STRESS AT DESIGN TEMP.- PLATE = 138.000 MPa





3 / 12 = 1274.931 mm3

l2 = ( t2 )3 / 12 = 1608.563 mm3


e = MEMBRANE LIGAMENT EFFI. FOR PLUG SHEET = 0.545

HE1

RETURN HEADER - MAWP CALCULATION (HOT & CORRODED)

04.06.143

C5437-HC









(ST) = Sm = 132.432 138.00



23.67%

95.97%

78.47%

99.07%59.01%64.36%

MPa ALLOWABLE STRESS,MPa

% ALLOWABLE

17.94%

15.12%63.35%

31.10%


REFERENCE : APPENDIX-13 OF ASME SECTION VIII DIVISION 1.VALUE UNIT

MAWP = MAXIMUM ALLOWABLE WORKING PRESSURE = 11.800 MPaP = MAWP WITH STATIC HEIGHT = 11.801 MPa (g)T = DESIGN TEMPERATURE = 121.110 ºCC = CORROSION ALLOWANCE = 3.175 mm

MOCt = MATERIAL OF CONSTRUCTION FOR TUBE = SA-179St = ALLOWABLE STRESS AT DESIGN TEMPERATURE- TUBE = 92.400 MPa

Rot = OUTSIDE RADIUS OF TUBE = 12.700 mmtt = THICKNESS OF TUBE = 2.110 mm

MOCn1 = MATERIAL OF CONSTRUCTION FOR NOZZLE - N1 - N4 = SA-234 Gr.WPBStn1 = ALLOWABLE STRESS AT DESIGN TEMPERATURE- NOZZLE = 118.000 MPa

Ron1 = OUTSIDE RADIUS OF NOZZLE - N1 - N4 = 109.550 mmtn1 = THICKNESS OF NOZZLE - N1 - N4 = 20.134 mm

MOCn2 = MATERIAL OF CONSTRUCTION FOR NOZZLE - D - V = SA-182 Gr.F316Stn2 = ALLOWABLE STRESS AT DESIGN TEMPERATURE- NOZZLE = 138.000 MPa

Ron2 = OUTSIDE RADIUS OF NOZZLE - D - V = 28.500 mmtn2 = THICKNESS OF NOZZLE - D - V = 11.800 mm

E = JOINT EFFICIENCY - NOZZLE & TUBE = 1.000

04.06.143

C5437-HCHE1

TUBE ,NOZZLE & FLANGES - MAWP CALCULATION (HOT & CORRODED)

�� TUBE AS PER APPENDIX 1-1 (a) :

t = ( P * Ro ) / ( S * E + 0.4 * P )S = [ P * { Rot - 0.4 * ( tt ) } ] / [ E * ( tt ) ] = 66.309

�� NOZZLE AS PER APPENDIX 1-1 (a) :

t = ( P * Ro ) / ( S * E + 0.4 * P )

A) NOZZLE N1 - N4S = [ P * { Ron1 - 0.4 * ( tn1 - C ) } ] / [ E * ( tn1 - C ) ] = 71.510

A) NOZZLE V / DS = [ P * { Ron2 - 0.4 * ( tn2 - C ) } ] / [ E * ( tn2 - C ) ] = 34.274

�� FLANGE RATING AS PER ASME B16.5FOR # 900 RATINGPERMITTED MAWP w.r.t DESIGN TEMP. = 11.801


85.61%

118.000

13.785

60.60%

138.000 24.84%

92.400 71.76%

MPaALLOWABLE STRESS,MPa

% ALLOWABLE



MAP = MAXIMUM ALLOWABLE PRESSURE = 15.160 MPaP = MAP WITH STATIC HEIGHT = 15.161 MPaT = ROOM TEMPERATURE = 17.000 OCS = ALLOWABLE STRESS AT ROOM TEMP.- PLATE = 138.000 MPa


U = STAY / PARTITION PLATE LIGAMENT EFFICIENCY = 0.720E = JOINT EFFICIENCY FACTOR = 1.000



3 / 12 = 1829.333 mm3

l2 = ( t2 )3 / 12 = 2250.000 mm3



04.06.143

C5437-HCHE1

NOZZLE HEADER - MAP CALCULATION (NEW & COLD)









(ST) = Sm = 100.057 138.00


CONCLUSION : GOVERNING COMPONENT IS NOZZLE FLANGE WITH MAP OF 15.160 MPa


% ALLOWABLE

19.79%

18.85%65.93%

MPa

36.96%

72.51%

73.85%

93.04%44.87%70.21%21.67%



MAP = MAXIMUM ALLOWABLE PRESSURE = 15.160 MPaP = MAP WITH STATIC HEIGHT = 15.161 MPaT = ROOM TEMPERATURE = 17.000 OCS = ALLOWABLE STRESS AT ROOM TEMP.- PLATE = 138.000 MPa


U = STAY / PARTITION PLATE LIGAMENT EFFICIENCY = 0.672E = JOINT EFFICIENCY FACTOR = 1.000



3 / 12 = 1829.333 mm3

l2 = ( t2 )3 / 12 = 2250.000 mm3



HE1

RETURN HEADER - MAP CALCULATION (NEW & COLD)

04.06.143

C5437-HC









(ST) = Sm = 108.957 138.00



17.84%

78.95%

70.07%

93.04%49.39%62.00%


% ALLOWABLE

19.19%

11.44%58.62%

33.60%


REFERENCE : APPENDIX-13 OF ASME SECTION VIII DIVISION 1.VALUE UNIT

MAP = MAXIMUM ALLOWABLE PRESSURE = 15.160 MPaP = MAP WITH STATIC HEIGHT = 15.170 MPa (g)T = ROOM TEMPERATURE = 17.000 ºCC = CORROSION ALLOWANCE = 0.000 mm

MOCt = MATERIAL OF CONSTRUCTION FOR TUBE = SA-179St = ALLOWABLE STRESS AT ROOM TEMPERATURE- TUBE = 115.000 MPa

Rot = OUTSIDE RADIUS OF TUBE = 12.700 mmtt = THICKNESS OF TUBE = 2.110 mm

MOCn1 = MATERIAL OF CONSTRUCTION FOR NOZZLE - N1 - N4 = SA-234 Gr.WPBStn1 = ALLOWABLE STRESS AT ROOM TEMPERATURE- NOZZLE = 118.000 MPa

Ron1 = OUTSIDE RADIUS OF NOZZLE - N1 - N4 = 109.550 mmtn1 = THICKNESS OF NOZZLE - N1 - N4 = 20.134 mm

MOCn2 = MATERIAL OF CONSTRUCTION FOR NOZZLE - D - V = SA-182 Gr.F316Stn2 = ALLOWABLE STRESS AT DESIGN TEMPERATURE- NOZZLE = 138.000 MPa

Ron2 = OUTSIDE RADIUS OF NOZZLE - D - V = 28.500 mmtn2 = THICKNESS OF NOZZLE - D - V = 11.800 mm

E = JOINT EFFICIENCY - NOZZLE & TUBE = 1.000

04.06.143

C5437-HCHE1

TUBE ,NOZZLE & FLANGES - MAP CALCULATION (NEW & COLD)




t = ( P * Ro ) / ( S * E + 0.4 * P )


A) NOZZLE V / DS = [ P * { Ron2 - 0.4 * ( tn2 - C ) } ] / [ E * ( tn2 - C ) ] = 30.571

�� FLANGE RATING AS PER ASME B16.5FOR # 900 RATINGPERMITTED MAP w.r.t ROOM TEMP. = 15.170


MPa

118.000 64.81%

74.12%


% ALLOWABLE

99.02%

115.000

15.320

138.000 22.15%

Page No: 45 of 50

Date:

Revision:

Document No:Tag No:

�� HYDROSTATIC TEST PRESSURE AS PER UG-99 (b) :

MAXIMUM ALLOWABLE WORKING PRESSURE = 11.800 MPa (g)

DESIGN TEMPERATURE = 121.11 °C

MIN. RECOMMENDED TEST TEMPERATURE = 17.000 °C

MINIMUM HYDROSTATIC TEST PRESSURE = 1.3 x MAWP x LOWEST RATIO r

1.000TUBES SA-179 92.40 92.40

TRANSITION NOZZLE

1.000

118.00SA-234 Gr.WPB

1.000NOZZLES SA-234 Gr.WPB 118.00 118.00

1.000

COUPLING SA-105N 138.00 138.00 1.000

138.00

118.00

ROUND PLUG SA-182 Gr.F316 138.00

1.000

PLUG SA-105N 138.00 138.00 1.000

1.000

SA-516 Gr.70 N 138.00 138.00

SA-105N 138.00FLANGES 138.00

HEADER PLATES

AT TEST TEMP. r = ST / SDPARTS MATERIAL ALLOWABLE STRESS ALLOWABLE STRESS

SD (MPa) ST (MPa)

RATIO AT DESIGN TEMP.

HE1

04.06.143

C5437-HC

HYDROSTATIC TEST PRESSURE CALCULATION AS PER UG-99 (b)

MINIMUM HYDROSTATIC TEST PRESSURE = 1.3 x MAWP x LOWEST RATIO r = 15.340 MPa (g)



P = HYDROSTATIC TEST PRESSURE WITH STATIC HEIGHT = 15.350 MPaT = HYDROSTATIC TEST TEMPERATURE = 17.000 OC

Sy = ALLOWABLE YIELD STRESS AT ROOM TEMP.- PLATE = 262.000 MPaH' = INSIDE LENGTH OF SHORT SIDE = 110.000 mmh' = INSIDE LENGTH OF LONG SIDE = 97.000 mmt1' = THICKNESS OF TOP/BOTTOM PLATE (SHORT SIDE) = 28.000 mmt2' = THICKNESS OF TUBE/PLUG PLATE (LONG SIDE) = 30.000 mmt4' = THICKNESS OF STAY PLATE = 20.000 mmt5 = THICKNESS OF END PLATE = 30.000 mmC = CORROSION ALLOWANCE OF PLATE / SHEET = 3.175 mm




3 / 12 = 1274.931 mm3

l2 = ( t2 )3 / 12 = 1608.563 mm3



HE1

NOZZLE HEADER - STRESS DURING HYDROTEST CONDITION AS PER U-2(g)

04.06.143

C5437-HC



Sa (m) = ALLOWBALE STRESS FOR MEMBRANE STRESS = 0.9 * Sy = 235.80 MPaSa (T) = ALLOWBALE STRESS FOR TOTAL STRESS = 1.5 * ( 0.9 * Sy ) = 353.70 MPa






(ST) = Sm = 158.335 235.80


SO, SAFE

SO, SAFE

SO, SAFESO, SAFESO, SAFESO, SAFE


% ALLOWABLE

SO, SAFE

MPa

SO, SAFESO, SAFE

SO, SAFE



P = HYDROSTATIC TEST PRESSURE WITH STATIC HEIGHT = 15.350 MPaT = HYDROSTATIC TEST TEMPERATURE = 17.000 OC

Sy = ALLOWABLE YIELD STRESS AT ROOM TEMP.- PLATE = 262.000 MPaH' = INSIDE LENGTH OF SHORT SIDE = 100.000 mmh' = INSIDE LENGTH OF LONG SIDE = 97.000 mmt1' = THICKNESS OF TOP/BOTTOM PLATE (SHORT SIDE) = 28.000 mmt2' = THICKNESS OF TUBE/PLUG PLATE (LONG SIDE) = 30.000 mmt4' = THICKNESS OF STAY PLATE = 20.000 mmt5 = THICKNESS OF END PLATE = 28.000 mmC = CORROSION ALLOWANCE OF PLATE / SHEET = 3.175 mm




3 / 12 = 1274.931 mm3

l2 = ( t2 )3 / 12 = 1608.563 mm3



HE1

RETURN HEADER - STRESS DURING HYDROTEST CONDITION AS PER U-2(g)

04.06.143

C5437-HC



Sa (m) = ALLOWBALE STRESS FOR MEMBRANE STRESS = 0.9 * Sy = 235.80 MPaSa (T) = ALLOWBALE STRESS FOR TOTAL STRESS = 1.5 * ( 0.9 * Sy ) = 353.70 MPa






(ST) = Sm = 172.259 235.80


SO, SAFE

SO, SAFE

SO, SAFE

SO, SAFESO, SAFESO, SAFE


% ALLOWABLE

SO, SAFE

SO, SAFESO, SAFE

SO, SAFE


VALUE UNIT

P = HYDROSTATIC TEST PRESSURE WITH STATIC HEIGHT = 15.350 MPa (g)T = HYDROSTATIC TEST TEMPERATURE = 17.000 ºCC = CORROSION ALLOWANCE = 3.175 mm

MOCt = MATERIAL OF CONSTRUCTION FOR TUBE = SA-179Syt = ALLOWABLE YEILD STRESS AT ROOM TEMPERATURE- TUBE = 179.000 MPaRot = OUTSIDE RADIUS OF TUBE = 12.700 mm

tt = THICKNESS OF TUBE = 2.110 mmMOCn1 = MATERIAL OF CONSTRUCTION FOR NOZZLE - N1 - N4 = SA-234 Gr.WPB

Sytn1 = ALLOWABLE YEILD STRESS AT ROOM TEMPERATURE- NOZZLE = 241.000 MPaRon1 = OUTSIDE RADIUS OF NOZZLE - N1 - N4 = 109.550 mm

tn1 = THICKNESS OF NOZZLE - N1 - N4 = 20.134 mmMOCn2 = MATERIAL OF CONSTRUCTION FOR NOZZLE -D - V = SA-182 Gr.F316

Sytn2 = ALLOWABLE YEILD STRESS AT ROOM TEMPERATURE- NOZZLE = 207.000Ron2 = OUTSIDE RADIUS OF NOZZLE - D - V = 28.500 mm

tn2 = THICKNESS OF NOZZLE - D - V = 11.800 mmE = JOINT EFFICIENCY - NOZZLE & TUBE = 1.000

Syt = ALLOWABLE STRESS AT ROOM TEMPERATURE- TUBE = 0.9 * Syt = 161.100Syn1 = ALLOWABLE STRESS AT ROOM TEMPERATURE- NOZZLE = 0.9 * Syn1 = 216.900Syn2 = ALLOWABLE STRESS AT ROOM TEMPERATURE- NOZZLE = 0.9 * Syn2 = 186.300

04.06.143

C5437-HCHE1

TUBE ,NOZZLE & FLANGES - STRESS DURING HYDROSTATIC TEST AS PER U-2(g)




t = ( P * Ro ) / ( S * E + 0.4 * P )


B) NOZZLE D - VS = [ P * { Ron2 - 0.4 * ( tn2 - C ) } ] / [ E * ( tn2 - C ) ] = 44.582

�� FLANGE RATING AS PER ASME B16.5FOR # 900 RATINGPERMITTED MAWP w.r.t ROOM TEMP. = 15.350 22.980(1.5 TIMES MAWP AT ROOM TEMP. AS PER CLAUSE 2.6)

161.100 SO, SAFE

ALLOWABLE STRES,MPa

SO, SAFE

SO, SAFE

186.300

216.900 SO, SAFE

MPa


INPUT DATA :NOZZLE SIZE DN 200NOZZLE MATERIAL SA-234 Gr.WPBNOZZLE LOCATION NOZZLE HEADER NOZZLE MARK NO. N1 - N4

P = INTERNAL DESIGN PRESSURE = 10.205 MPa (g)Sv = ALLOWABLE STRESS - VESSEL = 138.000 MPa

Dod = OUT SIDE DIA. OF NOZZLE = 219.100 mmWt = WALL THK. OF PIPE = 23.021 mmC = CORROSION ALLOWANCE. = 3.175 mmUt = PIPE UNDER TOLERANCE = 12.50%

Dhalf weld = WELD FILLET SIZE = 9 mmDH = INSIDE WIDTH OF HEADER = 110 mmDh = DISTANCE FROM PLATE TO FORCE LINE OF ACTION = 322 mmL = INSIDE WIDTH OF NOZZLE = 173.058 mm

Ta = THINNING ALLOWANCE = 0 mm

NOZZLE LOADING DATA :N = SAFETY MULTIFICATION FACTOR = 1

AS PER API MANUAL ENTRY

Mx = 3050 = 3050 N.mMy = 6100 = 6100 N.mMz = 2240 = 2240 N.mFx = 5690 = 5690 NFy = 13340 = 13340 N

04.06.143

C5437-HCHE1

NOZZLE LOAD CALCULATION INPUT DATA

Fy = 13340 = 13340 NFz = 8010 = 8010 N

STRESSES :Sts = EXISTING STRESS IN TUBESHEET ( = (ST)Q , REFER PAGE : ) = 127.263 MPaSps = EXISTING STRESS IN PLUGSHEET ( = (ST)Q1 , REFER PAGE : ) = -50.199 MPa


THIS CALCULATION IS BASED ON A CONSERVATIVE METHOD DEVELOPED BY JORD. THE COMPLEX GEOMETRY IS SIMPLFIED BY APPROXIMATING THE CONNECTION AS AN EFFECTIVE AREA, THE ONLY METHOD TO ACCURATELYCALCULATE THE RESULTING STRESS IS BY FEA

CALCULATION :

Did = INSIDE DIA. OF NOZZLE = 185.16325 mmDwld = WELD THICKNESS = D half weld + Wt - Ta- C - Ut * Wt = 25.97 mmRwld = WELD RADIUS = 0.5 * DH + Wt + D half weld = 87.02 mmDcnt = DISTANCE FROM WELD CENTRE TO NOZZLE CENTRE

= Di + 0.5 * D wld = 71.16 mmDI = WELD LENGTH = 2 * ( Rwld

2 - Di2 ) 1/2 * (Di / Rwld ) + L - DH = 149.59 mm

Di = DIASTANCE FORM NOZZLE CENTER TO WELD INTERNAL= 0.5 * DH + C = 58.18 mm

Aeff = TOTAL EFFECTIVE WELD AREA = 2 * ( Dwld * DI) = 7769.07 mm2

DESIGN LOADS

Mt = TENSILE MOMENT = My = 6100 N.m

Mb = BENDING MOMENT (due to moments), Mb = ( Mx2 + Mz

2 )1/2 = 3784.1908 N.mFt = TENSILE FORCE, = Fy = 13340 N.mFh = SHEAR FORCE = ( Fx

2 + Fz2 ) 1/2 = 9825.2837 N.m

Mbt = TOTAL BENDING MOMENT , Mbt = Mb+ Fh*Dh = 6947.9322 N.m

04.06.143

C5437-HCHE1

NOZZLE LOAD CALCULATION

EFFECTIVE SECTION PROPERTIES

Iyy = 2 *( ( Dwld3 * Dl ) / 12 + Dcnt

2 * Aeff / 2) = 3.98E+07 mm4

Zyy = Iyy / (Dwld + Di) = 4.73E+05 mm3

STRESS CALCULATION

St = AXIAL TENSION = Ft / At = 1.717 MPa

Sb = BENDING STRESS (yy axis) = Mbt / Zyy = 14.698 MPa

Fs = NET SHEAR STRESS ( TORSION ) = Mt / ( 2 * Dcnt ) = 42861.647 N

(ASSUMIN Mt TAKESN AS EQUAL AND OPPOSITE FORCES IN CONNECTION)

THEREFORE SHEAR STRESS IN CONNECTION Snsh = Fs / ( 0.5 * At ) = 11.034 MPa

Snt = NETT TENSILE STRESS = St + Sb = 16.415 MPa

Snc = NETT COMPRESSIVE STRESS = Sb - St = 12.981 MPa

Sa = MAX. ALLOWABLE COMBINED STRESS = 1.5 * Sv - MAX ( Sts,Sps ) = 79.737 MPa

CONCLUSION : THE RESULTANT STRESS IS LESS THAN THE ALLOWABLE STRESS, THEREFORE NOZZLE IS SAFE FOR SPECIFIED LOADINGS

non circular air cooler design calculations

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