8. Heat Exchanger Mechanical Design Calculations Per ASME & TEMA - By Abdel Halim Galala

8/9/2019 8. Heat Exchanger Mechanical Design Calculations Per ASME & TEMA - By Abdel Halim Galala

1/136

Cairo Oil Refining Co. א א

Subsidery of Egyotian Gen. Petroleum Corp. א א א د

P.O. Box : Heliopolis 11757 Cairo A.R.E. د د א ص. : .س

Tel. : 202 - 2529821 (5 Lines) ط ط) ) - : ن

Fax : 202 - 2529826 ٢٠٢ - س:

E-mail : [email protected] [email protected] : א د

Shell & Tube Heat Exchanger

DESIGN CALCULATIONS

Code : ASME Section VIII, Division 1, Edition 2001, Addenda 2002

& TEMA Class R, 7th. Edition 1988.Code Stamp : U

Client : Amerya Petroleum Refining Co. (APRC)

Project : Design & Fabrication of Residue Cooler

Location : Alexandria, EGYPT

Item No. : E-323 A E-323 B E-514 C E-514 C

Serial No. : 7443-33-U-2008, 7443-33-U-2009, 7443-33-U-2010 & 7443-33-U-2011

Title : Heat Exchanger

Service : Residue Cooler

Type : AES

Job No. : 7443-33

Dwg. No. : 7443-33-1A Rev. : 1

Cooler capacity 1.910848 M3

Weight of exchanger, empty (erection), W 4152.911 Kg

Weight of contents, Wc 764 Kg

Total weight of vessel and contents, Wt 4917 Kg

MAWP : Shell Side 284.776 PSIG 20.04826 Kg/CM2G

Tube Side 71.7082 PSIG 5.04826 Kg/CM2G

Design Temp. : Shell Side 302oF 150

oC

Tube Side 140oF 60

oC

MDMT : Shell Side 29oF -2

oC

Tube Side 29 oF -2 oC

No. of saddles 2 Saddles

No. of anchor bolts per saddle 4 Bolts

Anchor bolts size 28 MM Dia.

By

Eng. Abdel Halim GalalaDesign General Manager

Design Sector ط ع א מ

Page : 1 of 136 Sheet 1 of 2 Date : 11.4.2004


2/136

DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 2 of 136 According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 2

Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1

Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004Job No. : 7443-33 Location : Alex.

Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC

Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D

A. Title (cont.)

DESIGN CALCULATIONSCode : ASME Section VIII, Division 1, Edition 2001, Addenda 2002

& TEMA Class R, 7th. Edition 1988.Client : Amerya Petroleum Refining Co.

Project : Design & Fabrication of Residue Cooler

Location : Alexandria, EGYPT

Item No. : E-323 A E-323 B E-514 C E-514 C

Serial No. : 7443-33-U-2008, 7443-33-U-2009, 7443-33-U-2010 & 7443-33-U-2011

Title : Heat Exchanger

Service : Residue Cooler

Type : AES

Job No. : 7443-33

Dwg. No. : 7443-33-1A Rev. : 1

Notes.

1. The calculated thicknesses are the min. required, where the actual thicknesses shown

on drawings shall be equal or may be greater.

2. The greater thicknesses at drawings are taken into consideration while calaculating the

MDMT and additional stresses due to incresed weight of vessel.

3

2

1 Issued for approval 11.4.2004 11.4.2004 11.4.2004

A. Halim A.H. Galala A.H.G

0 Issued for comments 4.7.2003 4.7.2003 4.7.2003

Designed by Reviewed by Approved by

Rev. Description Date Date Date

Revision Table Dwg. No. : 7443-33-1A Rev. : 1


3/136






B. Copyright.

Copyright 2002 by

CORC

A.H.Galala, the Design Manager, on behalf of

Cairo Oil Refining Co. (CORC) All rights reserved.

1st. date of issue - July, 4th., 2003

No part of this document may be reproduced in any fo rm, inan electronic retrieveal system or any otherwise withou t the

prior written permission of the CORC/Designer.


4/136






C. Revision Description.

This page is a record of all revisions of the document, and the

following revision(s) has (have) been made to this document.

Sheet

Rev. Date No. Revision Description

0 4.7.2003 all Issued for comments

1 11.4.2004 all Issued for approval

2 16.1.2005 7 UG-22 : Abnormal pressures


5/136






D. Table of Contents.

Description Page

A. Ti tle. Page : 1 of 136B. Copyright. Page : 3 of 136

C. Revisions Descript ion. Page : 4 of 136

D. Table of Contents. Page : 5 of 136

E. Applicable Loading Considered in Design. Page : 7 of 136

F. Impact Test Requirements. Page : 8 of 136

G. Standarad ASME B16.5 Flange Rating Class. Page : 8 of 136

H. Cylindr ical Main Shell Thickness

1. Under Internal Pressureal (Pipe 20" NPS) Page : 9 of 136

2. Check of Main Shell Thickness for External Pressure (FV). Page : 10 of 136

I. Cylindrical Stationary Head-Channel.

1. Under Internal Pressure Page : 12 of 136

2. Check of Channel Thickness for External Pressure (Full Vacuum) Page : 13 of 136

J. Main Ellipsoidal Head Thickness

Under Internal Pressure. Page : 14 of 136

K. Max. Internal Working Pressure, MWP at New (cold) & Operating (corroded)

1. For Shell-Side : Page : 15 of 136

2. For Tube-Side : Page : 15 of 136

3. For Tubes : (Item 38) Page : 17 of 136

L. Check for External Pressure (Convex Side), (Tube Side Full Vacuum)

1. Ellipsoidal Head (Stationary Head-Bonnet NA) Page : 18 of 136

2. Channel Page : 19 of 136

3. Tubes Page : 20 of 136

M. Nozzle Neck Thicknesses & Nozzle Openings Compensation :

M1 S1 & S2 6" NPS 300# WNRF Sch. 80 10.9728 Page : 21 of 136

M2 T1 & T2 6" NPS 150# WNRF Sch. 80 10.9728 Page : 26 of 136N. Main Shell Flange (item no. 4). E514FLG 5 Page : 36 of 136

N1. Main Shell Flanges (item no. 3). E514FLG 6 Page : 46 of 136

N2. Main Shell Flanges (item no. 12). E514FLG 7 Page : 56 of 136

O. Main Channel Flanges (items no. 18). E514FLG 9 Page : 66 of 136

P. Channel Cover (bl ind flange) (item no. 22). E514FLG 14 Page : 76 of 136

Q. Stationary Tubesheet (item no. 36). TUBSH514 4 Page : 82 of 136

Q1. Floating Tubesheet (item no. 37). TUBSH514 6 Page : 84 of 136

Q2. TEMA Pass Partition Plate Thickness Calculation (item TUBSH514 7 Page : 86 of 136

Q3. Floating Head, Flange & Back ing Ring (items no. 29, 30 E514FLG 15 Page : 87 of 136

File Sheet


6/136






D. Table of Contents (cont.)

Description Page

R. Design of Saddle Supports . Page : 99 of 136

S. Lowest MDMT Without Impact Test. Page : 106 of 136

T. Radiography. Page : 116 of 136

U. Hydrostatic Test Pressure. [UG-99(b)] [ Refer to Page : 116 of 136

V. Post Weld Heat Treatment (PWHT). Page : 116 of 136

W. Calculation o f Exchanger Weight. Page : 117 of 136

X. Stresses in Vessel on Two Saddle Supports Using ZICK's Method. Page : 121 of 136

Y. Check for the Anchor Bolts Due to Seismic and Wind Loading. Page : 129 of 136

Check for the Existing Anchor Bolts Due to Seismic and Wind Loading. Page : 130 of 136

Z. Check for Bundle Pulling . Page : 131 of 136

Z1. Lifting Lugs Thickness Calculations. Page : 133 of 136

Z2. References. Page : 135 of 136

Z3. Notes. Page : 136 of 136

Figures Index.

Figure (1) Page : 36 of 136Figure (2) Page : 46 of 136

Figure (3) Page : 56 of 136











Figure (14) Page : 124 of 136Figure (15) Page : 128 of 136









7/136






E. Applicable Loading Considered in Design. [UG-22 & UG-98]

I. By considering UG-22 :

1. The loadings to be considered in design of exchanger shall include the following :

a. Internal & external design pressure (see item II below).

b. Weight of the vessel and contents under test conditions.

c. Attachment of vessel supports such as lifting lugs and saddles.

2. No expected effect for superimposed static reactions such as piping. There is no attached equipment such as motors, machinery, other vessels,

and lining. and insulation.

3. The effect of the following loadings is considered negligible and /or not applicable :

a. Cyclic and dynamic reactions due to pressure for thermal variations.

b. Snow reactions.

c. Impact reactions due to fluid chock.

d. Temperature gradients and differential thermal expansion.

e. Abnormal pressures, such as those caused by deflagration.

II. By considering UG-21 & UG-98 :

The max. allowable working pressure for a vessel part is the max.internal

pressure at the highest point of vessel (i.e. including the static head theron).

Since the exchanger is intended to be erected horizontaly, the static head

equals almost the ID of the exchanger (dimension units of water).

Max. Operating Pressure, Shell side 241.5 PSIG 17 Kg/cm2G

Tube side 42.6 PSIG 3 Kg/cm2G

Internal design pressure, P (MAWP) Shell side 284.0909 PSIG 20 Kg/cm2G

Tube side 71.02273 PSIG 5 Kg/cm2G

External design pressure, Pex (Tube side) 15 PSIG 1.056 Kg/cm2G

Exchanger shell ID (fabricated from Pipe 24" NPS, Sch. 30), ID 19 INCH 482.6 MM

Water sp. gr. 1

Fluid sp. gr. 0.8

Max. hydrostatic head at internal bottom of vessel* 0.685511 PSIG 0.04826 Kg/cm2G

Max. internal pressure : Shell side 284.7764 PSIG 20.0483 Kg/cm2G

Tube side 71.70824 PSIG 5.04826 Kg/cm2G

* p water 0.036127 lb/INCH 1000 Kg/M

Max. internal working pressure MAWP for calculation : Shell side 286 PSIG 20.0483 Kg/cm2G

Tube side 73 PSIG 5.04826 Kg/cm2G

External design pressure, Pe (at tube side) 15 PSIG 1.056 Kg/cm2G


8/136






F. Impact Test Requirements. [UG-22 & UG-98]

Impact test is not mandatory for the following pressure vessels materials at the specified MDMT :

I. Pressure Parts.

a. Main Exchanger Components : P-No. Group No. Curve

a. Shell, Main Shell : ASME SA 106 Grade B 1 1 B

Shell Cover Course

Channel : ASME SA516 Grade 70 1 1 D

b. Faormed Heads (cap) : ASME SA234 WPB 1 1 B

Floating Head (Spherical Sector) :c. Nozzle Necks : ASMESA 106 Grade B 1 1 B

d. Standard Flanges : ASME SA105 1 2 B

Non Standard Shell Flanges : ASME SA266 Class 2 1 2 B

Non Standard Channel Flanges : ASME SA266 Class 2 1 2

Channel Cover (blind flange) : ASME SA266 Class 2 1 2

Floating Head Flange : ASME SA266 Class 2 1 2

Backing Ring Flange : ASME SA266 Class 2 1 2

e. Stationary Tubesheet : ASME SB171 C63000 1 1 B

Floatng Tubesheet : ASME SB171 C63000 1 1 B

f. Tubes : ASME SB111 C68700 1 2 B

g. Fittings : Half Couplings : ASME SA105

90 0 Elbows : ASME SA234 WPB

b. Stud Bolts & Nuts :

i. Stud Bolts : ASME SA193 Grade B7 UNS No. G41400 [Size < 2-1/2"]

j. Nuts : ASME SA194 Grade 2H

II. Non-Pressure Parts.

a. Saddle plate : ASME SA106 Grade B 1 1 B

b. Lifting lugs & Pads : ASME SA 516 Grade 70 1 2 D

Thickness of exchanger components :

- Shell & Heads ASME SA106 Grade B 0.5 INCH 12.7 MM

- Max. Nozzle Necks Thk. ASME SA106 Grade B 0.432 INCH 10.9728 MM

Min. Design Metal Temperature, MDMT 28oF -2

oC

Where the MDMT is in accordance with UG-20(f), UCS-66and FIG. UCS-66, no impact test is required. Please refer to : Page : 106 of 136

Impct Test is not required as per ASME Code for MDMT of 28 oF -2 oC but is required as a client request.

G. Standard ASME Flange Rating Class .

1. Standard ASME B16.5 welded neck flanges shall be used.

2. For standard flange, Carbon Steel material in accordance with ASME SA105,

P-No. 1, Group No. 2 :

a. Shell side flanges, S1 & S2, 6" NPS : MAWP 186 PSIG & Design temp. 302oF : Raing 300#

b. Tube side flanges, T1 & T2, 6" NPS : MAWP 72 PSIG & Design temp. 140oF : Raing 150#


9/136






H. Cylindrical Main Shell Thickness [UG-27(C)]

1. Under Internal Pressureal (Pipe 20" NPS)

Shell material, Killed carbon steel ASME SA 106 Grade B

Operating Temperature : Shell Side 230oF 110

oC

Tube Side 104oF 40

oC

Design Temperature : Shell Side 302oF 150

oC

Tube Side 140oF 60

oC

Min. Design Metal Temperature, MDMT 28 oF -2 oCOperating Pressure: Shell Side 241.477 PSIG 17 Kg/CM

2G

Tube Side 42.6136 PSIG 3 Kg/CM2G

Internal Design Pressure: Shell Side 284.091 PSIG 20 Kg/CM2G


Shell Inside Diameter, D (by using pipe 20" NPS, Sch.30) 19 INCH 482.6 MM

Shell Inside Radius, R 9.5 INCH 241.3 MM

Stationary Shell Inside Diameter, Ds 19 INCH 482.6 MM

Static Head = Inside Diameter (D) 0.4826 M

Static Head Pressure: Shell & Tube Side 0.68551 PSIG 0.04826 Kg/CM2G

Floating Head Side 0.68551 PSIG 0.04826 Kg/CM2G

Internal Design Pressure, P (MAWP): Shell Side 284.776 PSIG 20.04826 Kg/CM2G

Tube Side 71.7082 PSIG 5.04826 Kg/CM2

GMax. Allowable Stress @ Design Temp., S 17100 PSIG 1203.84 Kg/CM

2G

Max. Allowable Stress @ Test Temp., St 17100 PSIG 1203.84 Kg/CM2G

[ Table 1A , SubPart 1 , ASME Sec. II , Part D]

Hydrostatic Test Pressure, Ph = 1.3*MAWP(St/S) [UG-99(b)] 370.2093347 PSIG 26.062738Kg/CM2G

Ph = 1.5*MAWP(St/S) [shell side] [Owner request] 427.164617 PSIG 30.07239Kg/CM

2G

Corrosion Allowance, C [UG-25] 0.19685 INCH 5 MM

Joint Efficiency, E [Table UW-12] 0.85

[Spot Radiography], [Table UCS-57]

Value of 0.385 SE [UG-27C(1)] 5595.98 PSIG 393.9567 Kg/CM2G

Since P does not exceed 0.385 SE , Use Thin Wall Equation:

[1] Min. Wall Thickness for Longitudinal Joints,

t1 = PR/(SE - 0.6 P) [UG-27C(1)] 0.18834 INCH 4.783898 MM

[2] Min. Wall Thickness for Circumferential Joints,

t2 = PR/(2SE + 0.4 P) [UG-27C(2)] 0.0927 INCH 2.354604 MM

The Min. Thickness shall be the Greater of t1 or t2 0.18834 INCH 4.783898 MM

By Adding Corrosion Allowance to Wall Tickness, t 0.38519 INCH 9.783898 MM

Use 20" Pipe with thickness of Construction, t (Sch. 30, 12.7 MM) 0.5 INCH 12.7 MM

20" Pipe wall thickness without tolerance 12.5% 0.4375 INCH 11.1125 MM

20" Pipe wall thickness without corrosion allowance 0.24065 INCH 6.1125 MM

Min. Pipe Shell Thickness according to TEMA Table R-3.13 0.375 INCH 9.525 MM


10/136

DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 10 of 136

According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 3





2. Check of Main Shell Thickness for External Pressure (FV).

a. Check of Shell Thickness (NA)

For external pressure on cylinder, use UG-28 and Subpart 3.

Determine the effective length of shell without stiffening rings, L

Height of shell flange-stationary head end (flange 7), L73.70079

INCH94 MMHeight of shell flange-rear head end (flange 6), L6 3.74016 INCH 95 MM

Total shell length (flange-to-flange), L' 228.346 INCH 5800 MM

Effective shell length without stiffening, L = L' - (L6 + L7) 228.346 INCH 5800 MM

In case of shell with heads, L = 1/3 each head depth + straight 234.68 INCH 5960.867 MM

Assume t for internal pressure (corroded) 0.24065 INCH 6.1125 MM

Do = ID + 2 t 19.4813 INCH 494.825 MM

L / Do 12.0464 For L/Do > 50, use it = 50

Do / t 80.953

a. Enter Fig. G with L / Do and read across to sloping line of Do/t

Read factor A 0.00038

b. Enter Fig. CS-2 with A (to find factor B), 5600 PSIG 394.24 Kg/CM2G

Follow step (6) of UG-28(c), P A = 4B / 3 (Do / t) 92.2346 PSIG 6.493318 Kg/CM2G

Change t untill P A > 15 PSI (full vacuum) 15 PSIG 1.056 Kg/CM2G

OK

For A falling to the left of the applicable material/temp. line,

Pa can be calculated from formula, Pa = 2 A E / 3(Do/t) 86.4329 PSIG 6.084877 Kg/CM2G

E = Modulus of elasticity at design temp. 2.8E+07 PSIG 1970355 Kg/CM2G

at amp. temp. 2.9E+07 PSIG 2055680 Kg/CM2G

The uncorroded shell wall thickness must not lrss thanUse the uncorroded shell wall thickness

Use Thickness of Construction, t (Adopted thickness)

Corroded Thickness = Adopted thickness + Corrosion allowance

Insulation Yes

Post Weld Heat Treatment, PWHT N.A.


11/136






A. CYLINDRICAL SHELL THICKNESSES [UG-27(C)]

a.2. Floating Shell

Shell material, Killed carbon steel (Pipe 26" Sch. 20) ASME SA 516 Grade 70


oC

Tube Side 104oF 40

oC


oC

Tube Side 140oF 60

oC

Min. Design Metal Temperature, MDMT 28.4 oF -2 oCOperating Pressure: Shell Side 241.477 PSIG 17 Kg/CM

2G



Tube Side 71.0227 INCH 5 MM

Shell Inside Diameter, D 24.9843 INCH 634.6 MM


Stationary Shell Inside Diameter, Ds 19 INCH 482.6 MM



Floating Head Side 0.0009 PSIG 6.35E-05 Kg/CM2G




2G


[ TABLE 1A , SUBPART 1 , ASME SEC. II , PART D]

Hydrostatic Test Pressure, Ph = 1.3*MAWP(St/S) 369.319 PSIG 26.00008 Kg/CM2G

[ UG-99(b) ]


Joint Efficiency, E [TABLE UW-12] 0.85

[Full Radiography], [Table UCS-57]




t1 = PR/(SE-0.6P) [UG-27C(1)] 0.24706 INCH 6.275335 MM


t2 = PR/(2SE+0.4P) [UG-27C(2)] 0.12161 INCH 3.088797 MM



Use Plate with thickness of Construction, t 0.5 INCH 12.7 MM

Min. Plate Shell Thickness according to TEMA Table R-3.13 0.4375 INCH 11.1125 MM

Insulation Yes



12/136






I. Cylindrical Stationary Head-Channel. [UG-27(C)]

1. Under Internal Pressure

Shell material, Killed carbon steel ASME SA 106 Grade B


oC

Tube Side 104oF 40

oC


oC

Tube Side 140oF 60

oC

Min. Design Metal Temperature, MDMT 28.4 oF -2 oCOperating Pressure: Shell Side 241.477 PSIG 17 Kg/CM

2G




Shell Inside Diameter, D 19 INCH 482.6 MM


Stationary Shell Inside Diameter, Ds 19.0157 INCH 483 MM



Floating Head Side 0.68608 PSIG 0.0483 Kg/CM2G




2G


[ TABLE 1A , SUBPART 1 , ASME SEC. II , PART D]

Hydrostatic Test Pressure, Ph = 1.3*MAWP(St/S) [UG-99(b)] 370.2093347 PSIG 26.062738Kg/CM

2G

Ph = 1.5*MAWP(St/S) [tubel side] [Owner request] 427.164617 PSIG 30.07239Kg/CM

2G


Joint Efficiency, E [TABLE UW-12] 0.85

[Full Radiography], [Table UCS-57]




t1 = PR/(SE-0.6P) [UG-27C(1)] 0.04743 INCH 1.204611 MM


t2 = PR/(2SE+0.4P) [UG-27C(2)] 0.0927 INCH 2.354604 MM



Use plate thickness, Use 20" Pipe with thickness of Construction, t (Sch. 30, 12.7 MM) 0.51181 INCH 13 MM20" Pipe wall thickness without tolerance 12.5%

0.511811024 INCH 13 MM

Plate Thickness less corrosion allowance 20" Pipe wall thickness without corrosion allowance 0.51181 INCH 13 MM

Min. Plate thickness Min. Pipe Shell Thickness according to TEMA Table R-3.13 0.375 INCH 9.525 MM


13/136






I. Cylindrical Stationary Head-Channel. [UG-27(C)]

2. Check of Channel Thickness for External Pressure (Full Vacuum)


Determine the effective length of shell without stiffening rings, L

Height of shell flange-stationary head end (flange 5), L7 4.72441 INCH 120 MM

Height of shell flange-rear head end (flange 6), L6 5.11811 INCH 130 MM

Total shell length (flange-to-flange), L' 23.622 INCH 600 MM

Effective shell length without stiffening, L = L' - (L6 + L7) 23.622 INCH 600 MM

In case of shell with heads, L = 1/3 each head depth + straight 29.96062992 INCH 761 MM

Assume t for internal pressure (corroded) 0.51181 INCH 13 MM

Do = ID + 2 t 20.0236 INCH 508.6 MM

L / Do 1.49626 For L/Do > 50, use it = 50

Do / t 39.1231

a. Enter Fig. G with L / Do and read across to sloping line of Do/t


b. Enter Fig. CS-2 with A (to find factor B), which is off to the left side and can 4750 PSIG 334.4 Kg/CM2G

Follow step (6) of UG-28(c), P A = 4B / 3 (Do / t) 161.882 PSIG 11.39651 Kg/CM2G


OK

For A falling to the left of the applicable material/temp. line,

Pa can be calculated from formula, Pa = 2 A E / 3(Do/t) 201.032 PSIG 14.15267 Kg/CM2G



The uncorroded shell wall thickness must not lrss thanUse the uncorroded shell wall thickness

Use Thickness of Construction, t (Adopted thickness)

Corroded Thickness = Adopted thickness + Corrosion allowance

Insulation Yes



14/136






J. Main Ellipsoidal Head Thickness [UG-32(d)]

Under Internal Pressure. [Semi-ellipsoidal form 2:1 ]

Head Material, Carbon Steel ASME SA 234 WPB

Design Temperature (shell side) 302oF 150

oC

MIN. Design Metal Temperature, MDMT 28oF -2

oC

Operating Pressure (shell side) 156.25 PSIG 11 Kg/CM2G

Internal Design Pressure (shell side) 284.091 PSIG 20 Kg/CM2

G

Internal Design Pressure, P (MAWP) 284.992 PSIG 20.06346 Kg/CM2G

Head Skirt Inside Diameter, Di 24.9843 INCH 634.6 MM

Head Inside Radius, L ( ri ) 12.4921 INCH 317.3 MM

Static Head 0.90142 PSIG 0.06346 Kg/CM2G

Max. Allowable Stress @ Design Temp., S 17100 PSIG 1203.84 Kg/CM2G


[TABLE 1A , SUBPART 1 , ASME SEC. II , PART D]


Joint Efficiency, E (Spot Radiography) [Table UW-12] 0.85

Assume Outside Diameter of Head, DO 25.4751 INCH 647.0672 MM

Outside Radius of Head, RO 12.7375 INCH 323.5336 MM

Value of 0.665 SE 9665.78 PSIG 680.4706 Kg/CM2G

Since the value of 0.66SE > P, Use Thin Wall Equation for

Calculating the Min. required Thickness of Head, t:

t1 = PD /(2SE-0.2P) [UG-32(d)] (1) 0.24542 INCH 6.233623 MM

Compare to Thickness of Seamless Spherical Shell :

Ps = 0.665 SE 9665.78 PSIG 680.4706 Kg/CM2G

Since P < Ps, Calculate Thickness for thin Wall Spherical Shell:

t2 = PR/(2SE-0.2P) [UG-27(d)] (2) 0.12271 INCH 3.116812 MM

Head Thickness due to Internal Pressure: t = MAX ( t1 , t2 ) 0.24542 INCH 6.233623 MM

By adding Corrosion Allowance to Wall Thickness, 0.44227 INCH 11.23362 MM

Use 26" Cap with thickness of Construction, t (Thk. 14.27 MM) 0.56181 INCH 14.27 MM

[ t Represents the Min. Thickness after Forming ]

Head required thickness, tr = P K1 D / (2SE - 0.2P) 0.22088 INCH 5.610261 MM

NB. The required head thickness for reinforcement calculation are to be determined by the

hemispherical head formula using an equivalent radius of K1 D where,

Spherical Radius Factor, K1 (for ellipsoidal head 2:1) 0.9 [Table UG-37]


15/136






K. Max. Internal Working Pressure, MWP at New (cold) & Operating (corroded)

[MWP is differ from MAP or MAWP]

1. For Shell-Side : 302oF 150

oC

Main shell (Item 1) :

MWP, New & cold (12.7 MM-12.5%) P = SE t /(R + 0.6 t) [UG-27(c)(1)] 608.569 PSIG 42.843 Kg/CM2G

MWP, Operating & corroded (9.286 MM) P = SE t /(R + 0.6 t) 455.517 PSIG 32.068 Kg/CM2G

Head (cap) (Item 13) :MWP, New & cold (12.7-12.5% MM) P = 2SE t /(D + 0.2 t) [UG-32(d)(1)] 621.582 PSIG 43.75937 Kg/CM

2G

MWP, Operating & corroded (9.286 MM), P = 2SE t /(D + 0.2 t) 462.789 PSIG 32.58034 Kg/CM2G

Nozzle Neck 6" NPS, Sch. 80 for N3 & N4 (item 6) :

MWP, New & cold (7.489 MM-12.5%) neck 740 PSIG 52.096 Kg/CM2G

MWP, Operating & corroded (4.289 MM) neck N3 & N4 664.4 PSIG 46.774 Kg/CM2G

Standard Flange 6" NPS, ANSI 300#, Sch. 80 for N3 & N4 (items 5) :

MWP, New & cold [TEMA Table D-6.1] 740 PSIG 52.096 Kg/CM2G

MWP, Operating & corroded [TEMA Table D-6.1] 655 PSIG 46.112 Kg/CM2G

Non Standard Flange (Item 4) : MWP, New & cold 425.258 PSIG 29.938 Kg/CM2G

MWP, Operating & corroded 335.398 PSIG 23.612 Kg/CM2G






16/136






K. Max. Internal Working Pressure, MWP at New (cold) & Operating (corroded) (cont.)

[MWP is differ from MAP or MAWP]

2. For Tube-Side : 608oF 320

oC

Channel (Item 17) :

MWP, New & cold (13 MM-12.5%.) P = SE t /(R + 0.6 t) [UG-27(c)(1)] 608.569 PSIG 42.843 Kg/CM2G

MWP, Operating & corroded (8 MM) P = SE t /(R + 0.6 t) 455.537 PSIG 32.07 Kg/CM2G

Nozzle Neck 6" NPS, Sch. 80 for N1& N2 (item 20) :

MWP, New & cold (7.489 MM-12.5%) neck 285 PSIG 20.064 Kg/CM2G

MWP, Operating & corroded (4.289 MM) neck 275 PSIG 19.36 Kg/CM2G

Standard Flange 6" NPS, ANSI 150#, Sch. 80 for N1& N2 (item 19) :

MWP, New & cold [TEMA Table D-6.1] 285 PSIG 20.064 Kg/CM2G

MWP, Operating & corroded [TEMA Table D-6.1] 260 PSIG 18.304 Kg/CM2G

Non Standard Flanges (Item 18) : MWP, New & cold 425.258 PSIG 29.938 Kg/CM2G


Blind Flange (Item 22) : [see page 47 of 80]MWP, New & cold 289.381 PSIG 20.372 Kg/CM2G


Stationary Tubesheet (Item 36) : [see page 49 of 80]MWP, New & cold 431.681 PSIG 30.39 Kg/CM2G


Floating Tubesheet (Item 37) : [see page 49 of 80]MWP, New & cold 431.681 PSIG 30.39 Kg/CM2G


Floating Head Spherical Sector (Item 30) : [see page 49 of 80]MWP, New & c 431.681 PSIG 30.39 Kg/CM2G


Floating Head Elange (Item 29) : [see page 49 of 80]MWP, New & cold 431.681 PSIG 30.39 Kg/CM2G


Floating Head Backing Ring (Item 31) : [see page 49 of 80]MWP, New & cold 431.681 PSIG 30.39 Kg/CM2G



17/136






K. Max. Internal Working Pressure, MWP at New (cold) & Operating (corroded) (cont.)

3. For Tubes : (Item 38)

Tube Material ASME SB111 UNS No. C68700-061

P-Number

Group Number

Max. Temp. Limit 450oF 232.2222

oC


oC

Tube Side 140o

F 60o

C Test Pressure Temp. (ambient temp.) 104

oF 40

oC

Max. Allowable Stress @ Design Temp.302oF (150

oC), S 11492 PSIG 809.0368 Kg/CM

2G

Max. Allowable Stress @ Test Temp. 104oF (40

oC), St 11992 PSIG 844.2368 Kg/CM

2G

[Table 1A, SubPart 1, ASME Sec. II, Part D]

No of tubes, n 146

Tube OD 1 INCH 25.4 MM

Tube length, L 236.22 INCH 6000 MM

Tube pitch, p 1.45472 INCH 36.95 MM

Tube BWG [TEMA Table D-7] 13

Tube wall thickness, tt [TEMA Table D-7] 0.09843 INCH 2.500122 MM

Tube pattern (Triangle, equal angles 60o

) (square rotated) 30o

MWP (internal), New & cold [TEMA Table D-9] 4132.3 PSIG 290.9139 Kg/CM2G

MWP (internal), Operating & corroded [TEMA Table D-9] 3963.55 PSIG 279.0339 Kg/CM2G

Design pressure (tube-side), P 71.0227 PSI 5 Kg/CM2G

Design temperature (tube-side) 140oF 60

oC

Max. Allowable Stress @ Design Temp.302oF (150

oC), S 11492 PSIG 809.0368 Kg/CM

2G

Corrosion Allowance, C [UG-25] 0 INCH 0 MM

Joint Efficiency, E [TABLE UW-12] 1

Tube required thickness , trn = PRn /(SnEn - 0.6 P) [UG-27] 0.0062 INCH 0.157561 MM

Max. Internal Working pressure MWP for whole Exchanger :

Shell side : MWP, New & cold 425.258 PSIG 29.938 Kg/CM2G


Tube side : MWP, New & cold 285 PSIG 20.064 Kg/CM2G

MWP, Operating & corroded 260 PSIG 18.304 Kg/CM G


18/136






L. Check for External Pressure (Convex Side), (Tube Side Full Vacuum)

1. Ellipsoidal Head (Stationary Head-Bonnet NA)

[UG-33(d)]

Assumed corroded thickness of head, t 0.43583 INCH 11.07 MM

Outside diameter of the head skirt, Do 23.7638 INCH 603.6 MM

The equivalent outside spherical, Ro = Ko Do [UG-33(b)] 20.2171 INCH 513.5147 MM

Outside height of the ellipsoidal head (measured from head-bend line), ho 6.28484 INCH 159.635 MM

Ratio of the major to the minor axis of ellipsoidal head, Do/2ho 1.89056

Factor depending on the ellipsoidal head proportions Do/2ho, Ko 0.85075

(use interpolation) [See Table UG-33.1]

The required thickness of an ellipsoidal head having pressure on the

convex side, either seamless or of built-up construction with butt joints,

shall not be less than that determined by the following procedure :

Step 1. Assume a value for t and calculate the value of factor A

using the following formula : A = 0.125 / (Ro / t) 0.00269

Step 2. Using the value of A calculate in Step 1, follow the same

procedure as that given for sphericalshells in UG-28(d), Step 2 through 6 :

a. Enter Fig. CS-2 with A (to find factor B), which is under the curve, B 9900 PSIG 696.96 Kg/CM2G

Follow step (4) of UG-28(d), and calculate the value of max. allowable

external working pressure, P A = B / (Ro / t) 213.417 PSIG 15.02459 Kg/CM2G


OK

Notes.

1. For value of A falling to the left of the material-temp. line, the value

of Pa can be calculated in accordance with Step 5 of UG-28(d), as

follows : Pa = 0.0625 E / (Ro /t)2



19/136






L. Check of External Pressure (Convex Side), (Tube Side Full Vacuum) (cont.)

2. Channel

Channel Material ASME SA106 Grade B

Design Temperature 140oF 60

oC

Corrosion allowance 0.19685INCH

5 MMChannel Diameter, 20" NPS 20 INCH 508 MM

Channel Thickness (20" Sch. 30) 0.562 INCH 14.2748 MM

Channel Thickness (20" Sch. 30) - 12.5% 0.49175 INCH 12.49045 MM


Determine the effective length of shell without stiffening rings, L : 23.622 INCH 600 MM

Assume t for internal pressure (at corroded condition) 0.2949 INCH 7.49045 MM

Do = ID + 2 t 20 INCH 508 MM

L / Do 1.1811

Do / t 67.8197 > 10 UG-28(c)(1)

Since Do/t > 10, use UG-28(c)(1)a. Enter Fig. G with L / Do and read across to sloping line of Do/t


b. Enter Fig. CS-2 with A (to find factor B), which falls under the curve. 11500 PSIG 809.6 Kg/CM2G

Follow step (6) of UG-28(c)(1), and calculate the value of max. allowable

external working pressure, P A = 4B / 3 (Do / t) 226.09 PSIG 15.91672 Kg/CM2G


OK



Notes 1. For value of A falling to the left of the material-temp. line, the value

of Pa can be calculated as follows : Pa = 2 A E / 3 (Do /t)

2. For L/Do > 50, use L/Do = 50

For L/Do < 0.05, use L/Do = 0.05

3. For Do/t > 10, use UG-28(c)(1)

For Do/t < 10, use UG-28(c)(2)


20/136






L. Check of External Pressure (Convex Side), (Tube Side Full Vacuum) (cont.)

3. Tubes

Tube Material ASME SB111 UNS No. C68700-061


oC

Corrosion allowance 0 INCH 0 MM

Tube OD 1 INCH 25.4 MM

Tube BWG 13Tube Wall Thickness 0.09843 INCH 2.500122 MM


Determine the effective length of tube without stiffening rings, L : 236.22 INCH 6000 MM

Assume t for internal pressure (at corroded condition) 0.09843 INCH 2.500122 MM

Do 1 INCH 25.4 MM

L / Do 236.22 > 50

Use L / Do 50

Do / t 10.1595 > 10 UG-28(c)(1)

Since Do/t > 10, use UG-28(c)(1)

Step 1. Enter Fig. G in Subpart 3 of Sec. II, Part D with L / Do and read across to sloping line of Do/t Read factor A 0.012

Step 2. Enter Fig. NFC-2 with A (to find factor B), which falls under the curve. 6150 PSIG 432.96 Kg/CM2G

Follow step (2) of UG-28(c)(1), and calculate the value of max. allowable

external working pressure.

Step 3. Calculate a value of Pa = 4 B / 3 (Do/t) 807.126 PSIG 56.82167 Kg/CM2G

Step 4. Compare the calculated value of Pa with Pe 807.126 PSIG 56.82167 Kg/CM2G

Change t untill Pa > 15 PSI (full vacuum) 15 PSIG 1.056 Kg/CM2G

OK

Change t untill Pa > 186 PSI (full vacuum with respect to shell-side) 186 PSIG 13.0944 Kg/CM2G

OK

Change t untill Pa > 30.7Kg/cm2 (436 PSI) (hydrostatic test of tube sid436 PSIG 30.6944 Kg/CM2G

OK

Notes 1. For value of A falling to the left of the material-temp. line, the value

of Pa can be calculated as follows : Pa = 2 A E / 3 (Do /t)

2. For L/Do > 50, use L/Do = 50

For L/Do < 0.05, use L/Do = 0.05

3. For Do/t > 10, use UG-28(c)(1)

For Do/t < 10, use UG-28(c)(2) :

- for Do/t < 4, A = 1.1 / (Do/t)2

- for A > 0.10, use a value of 0.10


21/136






M1. Nozzle Mark : N3 & N4 6" 300# WNRF (Located at Shell) with Reinforcement

Nozzle Neck Thickness Calculation [UG-27(c) & Appendix 1-1]

Nozzle Size, NPS 6 INCH 150 DN

Nozzle Material ASME SA 106 Grade B

Design Pressure, P 284.776 PSIG 20.04826 Kg/CM2G


oC

For nominated Design Pressure & Temperature, Flange Rating 300#

[ASME B16.5-1996]

Max. Allowable Stress of Nozzle Material @ Design Temp.(150oC), Sn 17100 PSIG 1203.84 Kg/CM

2G

Max. Allowable Stress of Nozzle Materiall @ Test Temp.(40oC), Snt 17100 PSIG 1203.84 Kg/CM

2G


Outside Radius of Nozzle, Ron 3.3125 INCH 84.1375 MM

Joint Efficiency of Nozzle, En (Seamless Pipe) 1

Nozzle Corrosion Allowance, Can 0.19685 INCH 5 MM

Nozzle Thickness Calculation :

Longitudinal Stress, t = PRon /(Sn*En + 0.4 P) [Appendix 1.1] 0.0548 INCH 1.391917 MM

By adding Corrosion Allowance, t [UG-25] 0.25165 INCH 6.391917 MM

By adding Pipe Tolerance 12.5% to the Thickness of Nozzle, t 0.28311 INCH 7.190907 MM

Use Nozzle 6" NPS with Selected Neck Sch. 80, 0.432 INCH 10.9728 MM

with Thickness 0.432" ( 10.97 MM ). [Table 2 of ASME B 36.10M-1985-(R-1994)]

Nozzle Neck Maximum Working Pressure, MWP (New & Operating)Nozzle wall thickness less tolerance 12.5% 0.378 INCH 9.6012 MM

Nozzle wall thickness less tolerance 12.5% - Corrosion allowance 0.18115 INCH 4.6012 MM

MWP, New & cold (10.97 MM) P = Snt E t /(Ron - 0.4 t) [App. 1.1] 2044.67 PSIG 143.944 Kg/CM2G

MWP, Operating & corroded (4.6 MM) P = Sn E t /(Ron - 0.4 t) 956.056 PSIG 67.306 Kg/CM2G

Nozzle Flange Maximum Working Pressure, MWP (New & Operating)

MWP, New & cold , 300# @ 100oF [ASME B.165, Table 2] 740 PSIG 52.096 Kg/CM

2G

MWP, Operating & corroded, 300# @ 302oF [ASME B16.5, Table 2] 664.4 PSIG 46.774 Kg/CM

2G


22/136






M1. Nozzle Mark : N3 & N4 6" 300# WNRF (Located at Shell) (cont.)

Nozzle Opening Calculation With Reinforc ing [UG-27(c) & Appendix 1-1]

Nozzle Pipe Size, NPS 6 INCH 150 DN

Nozzle Pipe Sch. 80


Design Temparture 302oF 150

oC

Shell Material ASME SA106 Grade B


Reinforcing Pad Material ASME SA 106 Grade B

Allowable Stress of Shell Material, Sv 17100 PSIG 1203.84 Kg/CM2G

Allowable Stress of Nozzle Material, Sn 17100 PSIG 1203.84 Kg/CM2G

Allowable Stress of Pad Material, Sp 17100 PSIG 1203.84 Kg/CM2G

Shell Thickness 0.5 INCH 12.7 MM

Shell Corrosion Allowance, Cas 0.19685 INCH 5 MM

Shell Thickness less Pipe Tolerance 12.5% (12.5% NA) 0.4375 INCH 11.1125 MM

Shell Thickness less Corrosion Allowance & 12.5%, t (12.5% NA) 0.24065 INCH 6.1125 MM

Nozzle Wall Nominal Thickness 0.432 INCH 10.9728 MMNozzle Wall Thickness less Pipe Tolerance 12.5% 0.378 INCH 9.6012 MM


Nozzle Wall Thick. less Corr. Allowance & 12.5% , tn 0.18115 INCH 4.6012 MM

Nozzle Wall Thick.of Internal Projection (less Corr. Allowance & 12.5%), ti 0.18115 INCH 4.6012 MM

Reinforced Pad Thickness, te 0.5 INCH 12.7 MM

Joint Efficiency of Shell, E 1

Joint Efficiency of Nozzle, En 1

Correction Factor, F [UG-37(a)] 1

E1 [Nozzle in solid plate] 1

Shell Outside Diameter, OD 20 INCH 508 MM

Shell Inside Diameter in Corroded Condition, 2R = OD - 2 t 19.5187 INCH 495.775 MM

Shell Inside Radius in Corroded Condition, R 9.75935 INCH 247.8875 MM

Nozzle Outside Diameter, OD 6.625 INCH 168.275 MM

Nozzle Inside Diameter, ID 5.761 INCH 146.3294 MM

Nozzle Projection beyond Inner Vessel Wall, h = min. (h1,h2) 0 INCH 0 MM

h1 = 2.5 t 0.60162 INCH 15.28125 MM

h2 = 2.5 ti 0.45287 INCH 11.503 MM

Nozzle ID Without Corrosion Allowance & 12.5% , d = OD - 2*tn 6.2627 INCH 159.0726 MM

Finished Radius of Circular Opening, Rn 3.13135 INCH 79.5363 MM


23/136







Nozzle Opening Calculation With Reinforc ing (cont.)

[UG-27(c) & Appendix 1-1]

* Outside Diameter of Reinforced Pad (if used) [UG-40(b)&FIG.UG-37.1]

Dp1 = 2 d 12.5254 INCH 318.1452 MM

Dp2 = 2 (Rn + nozzle wall thk. , tn + vessel wall thk. , t ) 7.1063 INCH 180.5 MM

OD of Reinf. Pad, Dp = the greater of Dp1 or Dp2 12.5254 INCH 318.1452 MM

Calculating Siz of Fillet Welds : [UW-16(c)(2)&Fig.UW-16.1]

* For Outward Nozzle Weld [UW-16(c)(2)&Fig.UW-16.1Sketch (c)]

Calculation of tmin. :

tmin.1 = 0.75 inch 0.75 INCH 19.05 MM

tmin.2 (nozzle wall nominal thickness) 0.432 INCH 10.9728 MM

tmin.3 (shell wall thickness) 0.56181 INCH 14.27 MM

tmin. = lesser of tmin.1, tmin. & tmin.3 0.432 INCH 10.9728 MM

Calculation of tc : tc1 = 0.25 inch 0.25 INCH 6.35 MM

tc2 = 0.7 t min. 0.3024 INCH 7.68096 MM

tc = lesser of tc1 & tc2 0.25 INCH 6.35 MM

By Considering Equal Legs Fillet Welds :

Leg of Outward Nozzle Weld = SQRT2 * tc 0.35355 INCH 8.980256 MM

Use Leg with Dimension E in Dwg. No. 7443-33-1A 0.35433 INCH 9 MM

* For Outer Reinforcing Pad Weld [Fig.UW-16 Sketch (c)]

tmin.1 = 0.75 inch 0.75 INCH 19.05 MM

tmin.2 ( te = thk. of reinforcing element) 0.5 INCH 12.7 MM

tmin.3 ( shell wall thickness) 0.5 INCH 12.7 MM

tmin. = lesser of tmin.1, tmin. 2 & tmin.3 0.5 INCH 12.7 MM

1/2 tmin. 0.25 INCH 6.35 MM


Leg of Outer Pad Weld = SQRT(2)*(tmin./2) 0.35355 INCH 9 MM

Use Leg with Dimension D in Dwg. No. 7443-33-1A 0.35433 INCH 9 MM

* Wall Thickness Required : [UG-27(c)(1)]

Shell tr = PR / (SE - 0.6 P) 0.1255 INCH 3.187732 MM Nozzle trn = PRn /(SnEn - 0.6 P) 0.03419 INCH 0.868379 MM

* Strength Reduction Factors : Sp / Sv 1

fr1 = Sn / Sv 1

fr2 = Sn / Sv 1

fr3 = lesser of Sn/Sv or Sp/Sv 1

fr4 = Sp / Sv 1


24/136







Min. Nozzle Neck Wall Thickness Check Per UG-45

A. Wall Thickness per UG-45(a) : trna = trn + C.A. 0.23104 INCH 5.868379 MM

B. Wall Thickness per UG-45(b) : trnb = Min. (trnb1, trnb2, trnb3, trnb 0.245 INCH 6.223 MM

Wall Thickness per UG-45(b)(1), trnb1 = Min. (trnb11, trnb12) 0.2906 INCH 7.38125 MM

trnb11 = tr + C.A. (tr for shell or head at E=1) 0.32235 INCH 8.187732 MM

trnb12 = Min Wall Thickness per UG-16(b), see below 0.2906 INCH 7.38125 MM

Wall Thickness per UG-45(b)(2), trnb2 (apply to external pressure only), NA INCH #VALUE! MM

Wall Thickness per UG-45(b)(3), trnb3 (apply to internal & external pressure)

= Max. (trnb1, trnb2) NA INCH #VALUE! MM

Wall Thickness per UG-45(b)(4), trnb4

= Min. thickness of std. wall pipe - 12.5% Max. (including CA) 0.245 INCH 6.223 MM

(Under tolerance12.5% in accordance with ASME B36.10M )

Nominal thickness of std. pipe wall thickness, NPS 6", Sch. Std. 0.28 INCH 7.112 MM

Wall Thickness per UG-16(b), trnb12

I - Min. Wall Thickness 1/16" + C.A. 0.25935 INCH 6.5875 MM II - Min. Wall Thickness of Unfired Steam Boilers = 1/4" + C.A. 0.44685 INCH 11.35 MM

III - Min. Wall Thickness of Shell/Head in Compressed Air

Service, Steam Service, and Water Service = 3/32" + C.A. 0.2906 INCH 7.38125 MM

Selected Vessel Service in our case is : Case III (compressed air)

So, the Min. Wall Thickness per UG-16(b), trnb12 0.2906 INCH 7.38125 MM

The min. nozzle wall thk. = Max. thk. determined by UG-45(a) , or by UG-45(b 0.245 INCH 6.223 MM

The min. nozzle thk. provided = t (1-0.125) 0.378 INCH 9.6012 MM

So, the thickness provided meets the rules of UG-45. OK

Since there is no superimposed loads, the vessel doesn't require

a calculationon shear stresses caused by UG-22(c).


25/136







Nozzle Opening Calculation With Reinforc ing (cont.) [UG-27]

Area of Reinforcement (witht Reinforcing element) :

Required Area, A = d tr F + 2 tn tr F(1-fr1) 0.78598 INCH2

507.0808 MM2

Area Available in Shell, A1: A11 = d (E1 t - F tr) - 2tn (E1 t - F tr)(1-fr1) 0.72114 INCH2

465.2505 MM2

A12 = 2 (t + tn)(E1 t - F tr) - 2tn (E1 t - F tr)(1-f r1) 0.09714 INCH2

62.67018 MM2

A1 = The Greater of A11 or A12 0.72114 INCH2

465.2505 MM2

Area Available in Nozzle Projecting Outward, A2 :

A21 = 5 (tn - trn) fr2 t 0.17683 INCH2

114.0844 MM2

A22 = 2 (tn - trn)(2.5tn+te) fr2 0.28007 INCH2

180.691 MM2

A2 = The Lesser of A21 or A22 0.17683 INCH2

114.0844 MM2

Area Available in Inward Nozzle, A3 : (Not applicable)

A31 = 5 t ti fr2 0.21797 INCH2

140.6242 MM2

A32 = 5 ti ti fr2 0.16408 INCH2

105.8552 MM2

A33 = 2 h ti fr2 0 INCH2

0 MM2

A3 = The Greater of A31, A32 or A33 0 INCH2

0 MM2

Area Available in Outward Nozzle Weld, A41:

A41 = (LEG)2 fr2 0.12555 INCH

281 MM

2

Area Available in Outer Reinforcing Pad Weld, A42:

A42 = (LEG)2 fr4 0.12555 INCH

281 MM

2

Area Available in Inward Nozzle Weld, A43 :

A43 = (LEG)2 fr2 0 INCH

20 MM

2

Area Available in Reinforcing Pad, A5 :

A5 = (Dp - d - 2tn) te fr4 2.9502 INCH2

1903.352 MM2

Total Area Available, AT :

AT = A1 + A2 + A41 + A42 + A43 + A5 4.09927 INCH2

2644.686 MM2

AT is greater than A, therefore opening is adequately reinforced.

NOTE. No need for Strength Path Calculations.


26/136






M2. Nozzle Mark : N1 & N2 6" 150# WNRF (Located at Channel) with reinforcement

Nozzle Neck Thickness Calculation [UG-45, UG-27 & APPENDIX 1-1]





oC


[ASME B16.5-1996]

Max. Allowable Stress of Nozzle Material @ Design Temp.(60oC), Sn 17100 PSIG 1203.84 Kg/CM

2G


2G






Longitudinal Stress, t = PRon /(Sn*En + 0.4 P) [APPENDIX 1.1] 0.01387 INCH 0.352236 MM




with Thickness 0.432" ( 10.97 MM ). [Table 2 of ASME B 36.10M-1985-(R-1994)]







2G

MWP, Operating & corroded, 150# @ 140oF [ASME B16.5, Table 2] 275 PSIG 19.36 Kg/CM

2G


27/136






M2. Nozzle Mark : N1 & N2 6" 150# WNRF (located at channel) (cont .)

Nozzle Opening Calculation With Reinforc ing [UG-27(c) & Appendix 1-1]


Nozzle Pipe Sch. 80



oC



Reinforcing Pad Material ASME SA106 Grade B



Allowable Stress of Pad Material, Sp 17100 PSIG 1203.84 Kg/CM2G









Reinforced Pad Thickness, te 0.5 INCH 12.7 MM











h1 = 2.5 t 0.60162 INCH 15.28125 MM

h2 = 2.5 ti 0.45287 INCH 11.503 MM




28/136







Nozzle Opening Calculation With Reinforc ing (cont.) [UG-27(c) & Appendix 1-1]

* Outside Diameter of Reinforced Pad [UG-40(b) & Fig.UG-37.1]

Dp1 = 2 d 12.5254 INCH 318.1452 MM


OD of Reinf. Pad, Dp = the greater of Dp1 or Dp2 12.5254 INCH 318.1452 MM

Calculating Size of Fillet Welds : [UW-16(c)(2) & Fig.UW-16.1]

* For Outward Nozzle Weld [UW-16(c)(2)&Fig.UW-16.1 Sketch (c)]


tmin.1 = 0.75 inch 0.75 INCH 19.05 MM





tc2 = 0.7 t min. 0.3024 INCH 7.68096 MM





* For Outer Reinforcing Pad Weld [Fig.UW-16 Sketch (c)]

tmin.1 = 0.75 inch 0.75 INCH 19.05 MM

tmin.2 ( te = thk. of reinforcing element) 0.5 INCH 12.7 MM


tmin. = lesser of tmin.1, tmin. 2 & tmin.3 0.5 INCH 12.7 MM

1/2 t min. 0.25 INCH 6.35 MM


Leg of Outer Pad Weld = SQRT(2)*(tmin./2) 0.35355 INCH 9 MM

Use Leg with Dimension D in Dwg. No. 7443-33-1A 0.35433 INCH 9 MM




fr1 = Sn / Sv 1

fr2 = Sn / Sv 1


fr4 = Sp / Sv 1


29/136







Min. Nozzle Neck Wall Thickness Check Per UG-45










= Min. thickness of std. wall pipe - 12.5% Max. (including CA) 0.245 INCH 6.223 MM


Nominal thickness of std. pipe wall thickness, NPS 6", Sch. Std0.28 INCH 7.112 MM













30/136







Nozzle Opening Calculation With Reinforc ing (cont.) [UG-37]

Area of Reinforcement (with reinforcing Element) :

Required Area, A = d tr F + 2 tn tr F(1-fr1) 0.30243 INCH2

195.1147 MM2

Area Available in Shell, A1: A11 = d (E1 t - F tr) - 2tn (E1 t - F tr)(1-fr1) 1.20469 INCH2

777.2165 MM2

A12 = 2 (t + tn)(E1 t - F tr) - 2tn (E1 t - F tr)(1-f r1) 0.16227 INCH2

104.6926 MM2

A1 = The Greater of A11 or A12 1.20469 INCH2

777.2165 MM2

Area Available in Nozzle Projecting Outward, A2 :

A21 = 5 (tn - trn) fr2 t 0.17683 INCH2

114.0844 MM2

A22 = 2 (tn - trn)(2.5tn+te) fr2 0.28007 INCH2

180.691 MM2

A2 = The Lesser of A21 or A22 0.17683 INCH2

114.0844 MM2

Area Available in Inward Nozzle, A3 :

A31 = 5 t ti fr2 0.21797 INCH2

140.6242 MM2

A32 = 5 ti ti fr2 0.16408 INCH2

105.8552 MM2

A33 = 2 h ti fr2 0 INCH2

0 MM2

A3 = The Greater of A31, A32 or A33 0 INCH2

0 MM2

Area Available in Outward Nozzle Weld, A41:

A41 = (LEG)2 fr2 0.12555 INCH

281 MM

2

Area Available in Outer Reinforcing Pad Weld, A42:

A42 = (LEG)2 fr4 0.12555 INCH

281 MM

2

Area Available in Inward Nozzle Weld, A43 :

A43 = (LEG)2 fr2 0 INCH

20 MM

2

Area Available in Reinforcing Pad, A5 :

A5 = (Dp - d - 2tn) te fr4 2.9502 INCH2

1903.352 MM2

Total Area Available, AT :

AT = A1 + A2 + A41 + A42 + A43 + A5 4.58282 INCH2

2956.652 MM2

AT is greater than A, therefore opening is adequately reinforced.

NOTE. No need for Strength Path Calculations.


31/136






M4a. Nozzle Mark : N1 & N2 6" 150# WNRF (Located at Shell) without reinforcement

Nozzle Neck Thickness Calculation [UG-45 , UG-27 & APPENDIX 1-1]





oC


[ANSI/ASME B16.5-1996]

Allowable Stress of Nozzle Material @ Design Temp. (60oC), Sn 17100 PSIG 1203.84 Kg/CM

2G


2G






Longitudinal Stress, t = PRon /(Sn*En + 0.4 P) [APPENDIX 1.1] 0.01387 INCH 0.352236 MM




with Thickness 0.432" ( 10.97 MM ). [Table 2 of ANSI B 36.10M-1985-(R-1994)]







2G

MWP, Operating & corroded, 150# @ 140oF [ASME B16.5, Table 2] 275 PSIG 19.36 Kg/CM

2G


32/136


Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Date : 11.4.2004

Project : Design & Fabrication of Heat Exchanger for APRC Refinery Client : APRCJob No. : 7443-33 Location : Alex.



M4. Nozzle Mark : N1 & N2 6" 150# WNRF (Located at Channel) without reinforcement (cont.)

Nozzle Opening Calculation Without Reinforcing [UG-27(c) & Appendix 1-1]


Nozzle Pipe Sch. 80



oC



Reinforcing Pad Material N.A.



Allowable Stress of Pad Material, Sp 0 PSIG 0 Kg/CM2G









Reinforced Pad Thickness, te 0 INCH 0 MM











h1 = 2.5 t 0.60162 INCH 15.28125 MM

h2 = 2.5 ti 0.45287 INCH 11.503 MM




33/136






M4. Nozzle Mark : N1 & N2 6" 150# WNRF (Located at Channel) without reinfo rcement (cont.)

Nozzle Opening Calculation With Reinforc ing (cont.) [UG-27(c) & Appendix 1-1]

* Outside Diameter of Reinforced Pad (if used) [UG-40(b)&FIG.UG-37.1]

Dp1 = 2 d 12.5254 INCH 318.1452 MM


OD of Reinf. Pad, Dp = the greater of Dp1 or Dp2 0 INCH 0 MM

Calculating Size of Fillet Welds : [UW-16(c)(2)&FIG.UW-16.1]

* For Outward Nozzle Weld [UW-16(c)(2)&FIG.UW-16.1SKETCH (c)]


tmin.1 = 0.75 inch 0.75 INCH 19.05 MM





tc2 = 0.7 t min. 0.3024 INCH 7.68096 MM





* For Outer Reinforcing Pad Weld (NA) [FIG.UW-16 SKETCH (c)]

tmin.1 = 0.75 inch 0.75 INCH 19.05 MM

tmin.2 ( te = thk. of reinforcing element) 0 INCH 0 MM


tmin. = lesser of tmin.1, tmin. 2 & tmin.3 0 INCH 0 MM

1/2 t min. 0 INCH 0 MM


Leg of Outer Pad Weld = SQRT(2)*(tmin./2) 0 INCH 0 MM

Use Leg with Dimension D in Dwg. No. 7443-33-1A 0 INCH 0 MM




fr1 = Sn / Sv 1

fr2 = Sn / Sv 1


fr4 = Sp / Sv 0


34/136






M4. Nozzle Mark : N1 & N2 6" 150# WNRF (Located at Channel) without reinfo rcement (cont.)

MIN. NOZZLE NECK WALL THICKNESS CHECK PER UG-45










= Min. thickness of std. wall pipe - 12.5% Max. (icluding CA) 0.245 INCH 6.223 MM


Nominal thickness of std. pipe wall thickness, NPS 6", Sch. Std. 0.28 INCH 7.112 MM













35/136





Exchanger : Residue Coole

8. Heat Exchanger Mechanical Design Calculations Per ASME & TEMA - By Abdel Halim Galala

Documents

Transcript of 8. Heat Exchanger Mechanical Design Calculations Per ASME & TEMA - By Abdel Halim Galala