Unit Conversion

UNIT CONVERSION AS PER NON MANDATORY APPENDIX GG

1 in 25.4 mm . . . Appendix GG

1 m = 1000 mm . . . Appendix GG

1 ft = 0.3048 m . . . Appendix GG
= 0.3048 x 1000 mm
= 304.8 mm

1 psi = 0.0068948 MPa . . . Appendix GG

1 psi = 0.06894757 bar . . . Appendix GG

1 bar = 0.0068948 / 0.06894757 MPa

= 0.1 MPa

1 lbs = 0.4535924 kg . . . Appendix GG

1 ft-lbs = 0.4535924 x 0.3048 kg-m

0.13825 kg-m

1 cm = 10 mm

1 in^2 = 25.4 x 25.4 mm^2

= 645.16 mm^2
= 6.4516 cm^2

1 lbm/in2 = 0.4535924 / 645.16

1 psi = 0.070307 kg/cm2

1 MPa = 0.070307 / 0.0068948 kg/cm2

10.1971 kg/cm2
 Design data

Shell Side Tube Side

DESIGN PRESSURE ( INTERNAL ) : 26.00 kg/cm² g 2.55 MPa 27.00 kg/cm² g 2.65 MPa
DESIGN PRESSURE ( EXTERNAL ) : 0.52 kg/cm² g 0.05 MPa 0.52 kg/cm² g 0.05 MPa

MAWP. ( INTERNAL ) : 26.00 kg/cm² g 2.55 MPa 27.00 kg/cm² g 2.65 MPa
MAX. ALL. WORKING PRESS. ( EXTERNAL ) : 0.52 kg/cm² g 0.05 MPa 0.52 kg/cm² g 0.05 MPa

MAP. ( INTERNAL ) : 2.7 MPa 2.88 MPa

GOV. ELEMENT FOR MAP ( INTERNAL ): Shell Flange Right Channel Flange Left

DESIGN TEMPERATURE (INTERNAL) : 235 ⁰C 250 ⁰C

DESIGN TEMPERATURE (EXTERNAL) : 235 ⁰C --- ⁰C

MIN.DESIGN METAL TEMPERATURE : 5 ⁰C 5 ⁰C

HYDRO TEST PRESS. AT SHOP (At Top) : 35.69 kg/cm² g 3.50 MPa 37.19 kg/cm² g 3.65 MPa

MAX. HYDRO TEST PRESS. AT SHOP (At Top) : 37.00 kg/cm² g 3.63 MPa 216.00 kg/cm² g 21.18 MPa
Position: Horizontal
HYDRO TEST PRESS. AT SITE (At Top) : 30.59 kg/cm² g 3.00 MPa 203.94 kg/cm² g 20.00 MPa
Position: Horizontal
MINIMUM HYDROTEST TEMPERATURE > 17 / < 40 ⁰C > 17 / < 40 ⁰C

CORROSION ALLOWANCE (INT/EXT) 3 / -- mm 3 / -- mm

RADIOGRAPHY SPOT (RT 3) SPOT (RT 3)

JOINT EFFICIENCY (Shell / Head) 0.85 0.85

 Vessel Loads Requirements to ASME Section VIII Division 1 (UG-22)

APPLIES
YES NO ITEM

INTERNAL PRESSURE

EXTERNAL PRESSURE

WEIGHT OF VESSEL AND FLUID CONTENTS

WEIGHT OF NORMAL CONTENTS UNDER OPERATING CONDITIONS (STATIC HEAD)

WEIGHT OF NORMAL CONTENTS UNDER HYDROTEST CONDITIONS (STATIC HEAD)

SUPERIMPOSED STATIC REACTIONS FROM WEIGHT PIPING OF ATTACHED EQUIPMENT

ATTACHMENTS OF INTERNALS (APPENDIX D)

ATTACHMENTS OF VESSEL SUPPORT (SKIRTS,LEGS,LUGS,SADDLES,DAVIT – APPENDIX G)

ATTACHMENTS OF LIFTING LUGS (APPENDIX G)

CYCLIC AND DYNAMIC REACTIONS DUE TO PRESSURE

CYCLIC AND DYNAMIC REACTIONS DUE TO THERMAL VARIATIONS

CYCLIC AND DYNAMIC REACTIONS DUE TO EQUIPMENT INSTALLED ON THE VESSEL

CYCLIC AND DYNAMIC REACTIONS DUE TO MECHANICAL LOADING

WIND REACTIONS

SNOW REACTIONS

SEISMIC REACTIONS

IMPACT REACTIONS (E.G. DUE TO FLUID SHOCK)

TEMPERATURE GRADIENT

DIFFERENTIAL THERMAL EXPANSION

ABNORMAL OVERPRESSURE (E.G. DUE TO DEFLAGRATION)

TEST PRESSURE AND COINCIDENT STATIC HEAD ACTING DURING THE TEST (SEE UG-99)
 Check for service requirement (As per UW-2)

Shell side
(a) Does the vessel contain lethal fluid No

(b) Does the vessel operate below certain temperature designated by UCS-68, UHA-51(d)1 & UHA-51(e) No

(c) Is the vessel unfired steam boiler with design pressure exceeding 50 ksi No

(d) Is the vessel subjected to direct firing No

Since answer to points (a) to (d) are 'No', there are NO additional requirements on account of service restrictions.

Tube side
(a) Does the vessel contain lethal fluid No

(b) Does the vessel operate below certain temperature designated by UCS-68, UHA-51(d)1 & UHA-51(e) No

(c) Is the vessel unfired steam boiler with design pressure exceeding 50 ksi No

(d) Is the vessel subjected to direct firing No

Since answer to points (a) to (d) are 'No', there are NO additional requirements on account of service restrictions.
 Check for Post Weld Heat Treatment Requirement

Shell side
Material Classification P. No. 1
G. No. 1, 2
Post Weld Heat Treatment is required when any of the following condition exists:
Applicable Applicable /
Sr. No. Description Remark
clause Not Applicable
1 UW-2(a) Lethal service Not Applicable

2 UW-2(b) Operate below certain temperatures designated by Part UCS Not Applicable
Unfired Steam Boiler with Design Pressure
3 UW-2(c) Not Applicable
exceeding 50 psi (343 kPa)
Postweld heat treatment is mandatory if welded joints over 38 mm nominal Refer below component
4 UCS-56-1 Not Applicable
thickness thickness.
Post weld heat treatment is not required As per CODE
Proposed PWHT on Shell Side - NO
Following are the thickness of the components:
Dishend (Nominal thickness) = 16 mm
Main shell = 14 mm
Cover shell = 14 mm
S1, S2 Nozzle on Main shell = 10.97 mm (Thinner of nozzle neck and shell)
V, D Nozzle on cover shell = 10.97 mm (Thinner of nozzle neck and shell)
Maximum thickness = 16 mm < 38 mm

Tube side
Material Classification P. No. 1
G. No. 1, 2
Post Weld Heat Treatment is required when any of the following condition exists:
Applicable Applicable /
Sr. No. Description Remark
clause Not Applicable
1 UW-2(a) Lethal service Not Applicable

2 UW-2(b) Operate below certain temperatures designated by Part UCS Not Applicable
Unfired Steam Boiler with Design Pressure
3 UW-2(c) Not Applicable
exceeding 50 psi (343 kPa)
Postweld heat treatment is mandatory if welded joints over 38 mm nominal Refer below component
4 UCS-56-1 Not Applicable
thickness thickness.
Post weld heat treatment is not required As per CODE
Proposed PWHT on Tube Side - NO
Following are the thickness of the components:

Channel = 14 mm
T1, T2 Nozzle on Channel = 11.13 mm (Thinner of nozzle neck and channel)
Maximum thickness = 14 mm < 38
 Check for Radiography Requirement (As per UW-11 , UCS 57)

Shell side
Material Classification P. No. 1
G. No. 1, 2

Since the fluid handled is non-lethal, the reference thickness above which full radiography is mandatory is calculated as below :

tref = Minimum ( tr1, tr2)

where tr1 = 38.0 mm As per UW-11 (a)(2)

tr2 = 32.0 mm As per UCS 57

so tref = 32.0 mm

t = Maximum nominal thickness of butt welded joint

= 14.00 mm
Since t < tref
Full radiography is not mandatary as per Code

Proposed Radiography = Spot (RT3)

Tube side
Material Classification P. No. 1
G. No. 1, 2

Since the fluid handled is non-lethal, the reference thickness above which full radiography is mandatory is calculated as below :

tref = Minimum ( tr1, tr2)

where tr1 = 38.0 mm As per UW-11 (a)(2)

tr2 = 32.0 mm As per UCS 57

so tref = 32.0 mm

t = Maximum nominal thickness of butt welded joint

= 14.00 mm
Since t < tref
Full radiography is not mandatary as per Code

Proposed Radiography = Spot (RT3)

 Check for Fiber Elongation as per UG-79

εf % Allow. Strain
Component Mark No. ID R tnom Rf r Ro Remarks
Strain %
900 - 16 458 - ∞ 1.750 5 PFHT Not
Cylinderical Shell Shell
50*t/Rf*(1-Rf/Ro) εf = 50*16/458*(1-458/∞) Required
157 - 10.97 83.985 - ∞ 6.530 5 PFHT
Cylinderical Shell S1, S2 Neck
50*t/Rf*(1-Rf/Ro) εf = 50*10.97/83.985*(1-83.985/∞) Required
900 - 16 458 - ∞ 1.750 5 PFHT Not
Cylinderical Shell Channel
50*t/Rf*(1-Rf/Ro) εf = 50*16/458*(1-458/∞) Required
1006 - 16 179.02 - ∞ 6.703 5 PFHT
2:1 Dished Head Dishend
75*t/Rf*(1-Rf/Ro) εf = 75*16/179.02*(1-179.02/-) Required

Proposed PFHT : - No (To be done along with job)

Loading temperature : - ºC
Rate of heating (max) : - ºC/hr
Soaking time (min) : - minutes
Soaking temperature : - ºC
Rate of cooling (max) : - ºC/hr
Unloading temperature : - ºC

Nomenclature
εf = Calculated forming strain or extreme fiber elongation
R = Nominal bending radius to centerline of pipe or tube
r = Nominal outside radius of pipe or tube
ID = Inside diameter of cylinderical shell / head
Rf = Mean radius after forming
Ro = Original mean radius
tnom = Nominal thickness of the plate before forming
PFHT = Post forming heat treatment

Since the fiber elongation is almost 5% but less than post forming
heat treatment requirement to be further verified as per UCS-79 (d)
clauses a to e
UCS-79 d (2-a) --> Equipment is not in lethal service hence heat treatment is exempted
UCS-79 d (2-b) -->Impact testing is neither required by ASME Sec. VIII Div 1 nor the Material specification Sec. II Part A, hence heat treatment is exempted
UCS-79 d (2-c) --> Thickness of Head is 14 mm which is less than 16 mm. Hence Heat treatment is not required after forming.
UCS-79 d (2-d) --> Since the reduction in head thickness is more than 10%, post forming heat treatment is mandatory
UCS-79 d (2-e) --> Since the temperature of the material during forming is less than 480°C hence post forming heat treatment is mandatory.

As evident from the above, post forming heat treatment is mandatory for dishend as per para UCS-79 d (2-d & e).
 Check for Impact Test Requirement

Shell side Minimum design metal temperature = 5 °C

Heat Nominal / Yield Energy J / Simulation

Min. allowed Is impact req
Description treatment Material governing Clause strength Test Temp. heat
temp. °C ?
condition Thick. mm MPa °C treatment
90 Fig. UG-
Tubesheet Normalized SA 266 GR2 84.1M Note c
-49 NO --- --- ---
22.5
2.77 UCS-66
Tube Normalized SA 179 -48 NO --- --- ---
2.77 Curve C
16 UCS-66
Main Shell, Cover Shell Normalized SA-516 Gr.70 -44 NO --- --- ---
14 Curve D
16 UCS-66
Ellipsoidal Head Normalized SA-516 Gr.70 -44 NO --- --- ---
14 Curve D
10.97 Fig. UG-
Nozzle neck Normalized SA 106 Gr B 84.1M Note c
-48 NO --- --- ---
10.97
Fig. UG-
Bolting As per spec. SA 193 GR B7 30 84.1M Note c
-104 NO --- --- ---
Fig. UCS-66
Nuts As per spec. SA 193 GR B7 30 -48 NO --- --- ---
Note c
Tube side Minimum design metal temperature = 5 °C

Heat Nominal / Yield Energy J / Simulation

Min. allowed Is impact req
Description treatment Material governing Clause strength Test Temp. heat
temp. °C ?
condition Thick. mm MPa °C treatment
Fig. UG-
90
Tubesheet Normalized SA 266 GR2 84.1M Note -49 NO --- --- ---
22.5
c
2.77 UCS-66
Tube Normalized SA 179 -48 NO --- --- ---
2.77 Curve C
16 UCS-66
Channel Normalized SA-516 Gr.70 -44 NO --- --- ---
14 Curve D
32 UCS-66
Floating Head Normalized SA-516 Gr.70 -27 NO --- --- ---
28.2 Curve D
119 Fig. UG-
Floating Flange Normalized SA 266 GR2 84.1M Note c
-49 NO --- --- ---
111
Fig. UG-
Bolting As per spec. SA 193 GR B7 27 84.1M Note c
-104 NO --- --- ---
Fig. UCS-66
Nuts As per spec. SA 193 GR B7 27 -48 NO --- --- ---
Note c
 Permissible out-of-roundness as per UG-80

Ellipsoidal dishend
Outside diameter Do = 1022 mm
Provided thickness minus corrosion allowance t = 13 mm
Do / t = 78.62
L / Do = 0.5

Maximum Permissible Deviation e = 0.39 x t

e = 5.07 mm
Maximum Permissible Deviation (Rounddown value) e = 5.00 mm

Arc arc = 0.12 x Do

arc = 122.6 mm

Chord length Le = 245 mm

Chord length (Roundup value) Le = 250 mm

Main shell / Bonnet Shell Main Shell Bonnet Shell

Outside diameter Do = 928 mm = 1038 mm
Provided thickness minus corrosion allowance t = 11 mm = 13 mm
Design length L = 5722 mm = 670 mm
Do / t = 84.36 = 79.85
L / Do = 6.17 = 0.65

Maximum Permissible Deviation e = 0.72 x t = 0.38 x t

e = 7.92 mm = 4.94 mm
Maximum Permissible Deviation (Rounddown value) e = 6.00 mm = 3.00 mm

Arc arc = 0.35 x Do = 0.145 x Do

arc = 324.8 mm = 150.5 mm

Chord length Le = 650 mm = 301 mm

Chord length (Roundup value) Le = 650 mm = 325 mm

Channel
Outside diameter Do = 928 mm
Provided thickness minus corrosion allowance t = 11 mm
Design length L = 645 mm
Do / t = 84.36
L / Do = 0.70

Maximum Permissible Deviation e = 0.37 x t

e = 4.07 mm
Maximum Permissible Deviation (Rounddown value) e = 3.00 mm

Arc arc = 0.15 x Do

arc = 139.2 mm

Chord length Le = 278 mm

Chord length (Roundup value) Le = 300 mm
 Requirement of inspection opening as per UG-46

For TEMA type: AJU, BEU

The channel can be accessed by removing the channel cover bolting.
The main shell can be accessed by removing the channel to shell flange bolting.

For TEMA type: AJS, AES

The channel can be accessed by removing the channel cover bolting.
The main shell can be accessed by removing the channel to shell flange bolting.

For TEMA type: AEL, BEL, BEM, BKM, BJM

As per UG-46(a) inspection openings are omitted in fixed tubesheet heat exchangers.
The channel can be accessed by removing the channel cover bolting.

Requirement of drain as per UG-25 (f)

Nozzle mark S3 & D is located at the lowest portion of the shell side which can be used for draining purpose as per clause UG-25(f) of
ASME Sec. VIII Div.1.

Nozzle mark T1 is located at the lowest portion of the channel side which can be used for draining purpose as per clause UG-25(f) of
ASME Sec. VIII Div.1.

Requirement of overpressure protection devices (as per UG-125)

The installation of pressure relief devices is not in M/s TEMA's scope. The same shall be done by the user at site.
Title Pulling Eye Bolt Thread calculation

PULLING EYE BOLT MATERIAL SA 266 Gr 2

PULLING EYE BOLT SIZE M24 x 3p
TUBESHEET MATERIAL SA 266 Gr 2
YIELD STRESS OF EYE BOLT AT AMBIENT Ybolt = 2549.2 kgf/cm2
YIELD STRESS OF TUBESHEET AT AMBIENT YINS = 2549.2 kgf/cm2
BUNDLE WEIGHT WEIGHT Wb = 8500 kgf
IMPACT FACTOR I.F. = 1.5
TOTAL BUNDLE PULLING LOAD Wp = Wb x I.F. 12750 kgf
NO OF PULLING EYE BOLT N = 4 Nos.
ROOT AREA OF EYE BOLT Ab = 312.748 mm2
AXIAL STRESS PER EYE BOLT σs = Wp / (Ab x N) 1019.191 kgf/cm2
ALLOWABLE SHEAR STRESS OF EYE BOLT σsallow = 0.4X Min(YINS , Ybolt ) 1019.68 kgf/cm2
ALLOWABLE TENSILE STRESS OF EYE BOLT σTallow = 0.66X Min(YINS , Ybolt ) 1682.472 kgf/cm2

SINCE σs IS LESS THEN σsallow AS WELL AS σTallow DESIGN IS SAFE

Calculation for Required thread length in Tubesheet(As per UG -43(g))

Tubesheet Allowable at Ambient Temp σINS 1407.1 kgf/cm2

Eye bolt Allowable stress at ambient Temp σbolt 1407.1 kgf/cm2
Nominal diameter of eye bolt ds 24 mm

Min. Allowable stress of eye bolt at

ambient temp.
Min. Tapped hole engagement length = MAX ds , 0.75 x ds x
Min. Allowable stress of Insertion
piece at ambient temp.
= 24 mm
Provided Threaded Tapped hole length = 36 mm

PROVIDED THREADED LENGTH IS GREATER THAN REQUIRED, HENCE IT IS SAFE.

Calculation for Required thread length At Allowable Shear Strees

Core Diameter of eye bolt dc 20.704 mm

Allowable Shear Stress Yallow = 0.4 x Min(YINS , Ybolt ) 1019.68 kgf/cm2
Total load per eye bolt P = Wp / N 3187.50 kgf

Min. Tapped hole engagement length = 2P / (π x dc x Yallow) 9.61 mm

PROVIDED THREADED LENGTH IS GREATER THAN REQUIRED. HENCE, IT IS SAFE.