Mechanical design calculations for air cooler header box

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COVER PAGE
MECHANICAL DESIGN CALCULATIONS

HEADER BOX
Jord Job No
: C5437
Project
: COMPRESSOR GAS STATION CC3
Client
: SNGPL
Equipment
: GAS COMPRESSOR AIR COOLER
Tag No
: HE1
Total No Pages
: 50
2
1
0
KM
KM
AR
RS
RS
RS
KS
KS
KS
04.06.14
16.05.14
25.03.14
18 mm PLATE REVISED TO 20 mm & TI /PI REMOVED

25 mm PLATE REVISED TO 28 mm
ISSUED FOR APPROVAL
Revision
Created
Checked
Approved
Date
Description
JORD INTERNATIONAL PTY LTD
ABN 42 102 636 215
Main Office: 38 Oxley Street, St Leonards, NSW, Australia 2065

Tel: [612] 8425 1500 Fax: [612] 8425 1555
JORD INTERNATIONAL PTE LTD
REG 200106859W
Regional Office: 190 MacPherson Road #09-02 Wisma Gulab, Singapore, 348548
Tel: [65 ] 6879 4088 Fax: [65 ] 6879 4099
E-mail: info@jord.com.au
Web: www.jord.com.au
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NO.
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DESCRIPTION
COVER PAGE
SHEET
NO.
LATEST REV. STATUS

1
2
DATE
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2
3
4
5
6
7
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INDEX
3
4
5
6
7
LATEST APPLICABLE REVISION STATUS OF ENTIRE DOCUMENT

LATEST APPLICABLE DRAWINGS / DOCUMENTS
APPLICABLE STANDARDS & REFERENCES
DESIGN DATA
APPLICABLE LOADINGS AS PER UG-22
EVALUATION OF DESIGN PRESSURE AS PER UG-21, UG-98 AND

APPENDIX 3-2
25.03.14
EVALUATION OF MATERIALS AS PER APPENDIX 13-3, UCS-23 & UHA23
10
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EVALUATION OF JOINT & LIGAMENT EFFICIENCY AS PER APPENDIX

13
11
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VESSEL SKETCH FOR NOZZLE HEADER AS PER FIG. 13-2 (a) (10)
13
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INPUT DATA FOR NOZZLE HEADER AS PER APPENDIX 13-9 (c) & 135
14
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THICKNESS EVALUATION OF TOP & BOTTOM PLATE OF NOZZLE

HEADER AS PER APPENDIX 13-9 (c)
15
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THK. EVALUATION OF TUBE SHEET OF NOZZLE HEADER AS PER

APPENDIX 13-9 (c)
16
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THK. EVALUATION OF PLUG SHEET OF NOZZLE HEADER AS PER

APPENDIX 13-9 (c)
17
25.03.14
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THICKNESS EVALUATION OF STAY PLATE & END PLATE OF NOZZLE

HEADER AS PER APPENDIX 13-9 (c) & UG-34
18
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VESSEL SKETCH FOR RETURN HEADER AS PER FIG. 13-2 (a) (10)
19
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INPUT DATA FOR RETURN HEADER AS PER APPENDIX 13-9 (c) & 135
20
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THICKNESS EVALUATION OF TOP & BOTTOM PLATE OF RETURN

HEADER AS PER APPENDIX 13-9 (c)
21
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THK. EVALUATION OF TUBE SHEET OF RETURN HEADER AS PER

APPENDIX 13-9 (c)
22
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THK. EVALUATION OF PLUG SHEET OF RETURN HEADER AS PER

APPENDIX 13-9 (c)
23
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THICKNESS EVALUATION OF STAY PLATE & END PLATE OF RETURN

HEADER AS PER APPENDIX 13-9 (c) & UG-34
24
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THICKNESS EVALUATION OF TUBE AS PER UG-31 AND UG-27
25
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NOZZLE THICKNESS CALCULATION AS PER UG-45
26
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REINFORCEMENT REQUIREMENT FOR NOZZLE AS PER

APPENDIX 13-4
27
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REINFORCEMENT REQUIREMENT IN Z-DIRECTION AS PER UG-39 &

UG-37
28
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REINFORCEMENT REQUIREMENT FOR NOZZLE AS PER U-2 (g)
29
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FLANGE RATING CHECK AS PER ASME B16.5-2013
30
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INSPECTION OPENING AS PER UG-46.
31
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31
32
WELD DESIGN AS PER FIG. UW-16.1 (a)

WELD DESIGN AS PER FIG. 28-1 (b)
WELD DESIGN AS PER FIG. UG-34 (g)
32
33
34
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GOVERNING THICKNESS AS PER UCS-66 & UW-40 (f)
35
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34
IMPACT TEST REQUIREMENT AS PER UG-20 (f), UCS-66
36
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35
POST FORMING HEAT TREATMENT REQUIREMENT AS PER UG-79,

UCS-79 & POST WELD HEAT TREATMENT REQUIREMENT AS PER
UW-2, UCS-56
37
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FULL RADIOGRAPHY REQUIREMENT AS PER UW-11
37
38
38
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MAWP (HOT & CORRODED) CALCULATION FOR NOZZLE HEADER ,

RETURN HEADER,TUBES, NOZZLE & FLANGES
39
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MAP (NEW & COLD) CALCULATION FOR NOZZLE HEADER, RETURN

HEADER, TUBES, NOZZLE & FLANGES
42
43
44
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SHEET
NO.
LATEST REV. STATUS

0
DATE
39
HYDROSTATIC TEST PRESSURE CALCULATION AS PER UG-99 (b)
45
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NOZZLE HEADER, RETURN HEADER - STRESS DURING

HYDROSTATIC TEST CONDITION AS PER U-2 (g)
46
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TUBE,NOZZLE & FLANGES - STRESS DURING HYDROSTATIC TEST

CONDITION AS PER U-2 (g)
48
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NOZZLE LOAD CALCULATION U-2(g)
49
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LATEST APPLICABLE REVISION STATUS OF ENTIRE DOCUMENT
REV.
NO
REVISION
DATE
REVISED SHEET NO.
REVISION REMARKS
CHECKED
BY
APPROVED
BY
16.05.14
1-5, 7, 14, 15,21 ,24, 28,

29, 32-35, 39, 40, 42, 43,
46
25 mm PLATE REVISED TO 28 mm
RS
KS
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1-5,7,14,18,20,24,2627,35-36, 39-48
18 mm PLATE REVISED TO 20 mm &

TI /PI REMOVED
RS
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LATEST APPLICABLE DRAWINGS / DOCUMENTS
SR. NO.
DESCRIPTION
DRAWING NO.
Rev.
HEADER DETAILS
C5437-HD-002
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APPLICABLE STANDARDS & REFERENCES
SR. NO.
1
2
3
4
DESCRIPTION
ASME BOILER AND PRESSURE VESSEL CODE
SECTION VIII DIVISION 1 - 2013 EDITION
ASME BOILER AND PRESSURE VESSEL CODE
SECTION II PART D (METRIC) - 2013 EDITION
PIPE FLANGES AND FLANGED FITTINGS
ASME B 16.5 - EDITION 2013
API STANDARD 661, 7TH EDITION JULY 2013,
PETROLEUM, PETROCHEMICAL & NATURAL GAS INDUSTRIES
AIR COOLED HEAT EXCHANGERS
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DESIGN DATA
SR. NO
DESCRIPTION
UNIT
VALUE
CODE
REFERENCE
DESIGN & MANUFACTURING CODE
ASME BOILER & PRESSURE VESSEL

CODE SECTION VIII DIVISION - 1
EDITION 2013 & API STANDARD 661,
7TH EDITION JULY 2013
2
3
4
CODE STAMP
SERVICE (LETHAL / NON-LETHAL)
TYPE OF VESSEL
YES
NON LETHAL
HORIZONTAL
DESIGN PRESSURE INCLUDING STATIC HEIGHT INTERNAL / EXTERNAL
MPa (g)
10.205 / NIL
UG-21, UG-98
121.11
UG-20
MPa (g)
11.8 / NIL
-1.11 @ 11.8MPa (g)
MPa (g)
15.16 / NIL
MPa (a)
8.616
6
7
8
9
DESIGN TEMPERATURE
MAXIMUM ALLOWABLE WORKING PRESSURE
( MAWP - HOT & CORRODED ) INTERNAL / EXTERNAL
MINIMUM DESIGN METAL TEMPERATURE
MAXIMUM ALLOWABLE PRESSURE
( MAP - NEW & COLD ) INTERNAL / EXTERNAL
UG-20
10
OPERATING PRESSURE - INTERNAL
11
OPERATING TEMPERATURE - INLET / OUTLET
65.56 / 51.672
12
13
14
15
16
HYDROSTATIC TEST PRESSURE AT TOP

PNEUMATIC TEST PRESSURE
CORROSION ALLOWANCE
JOINT EFFICIENCY
RADIOGRAPHY / ULTRASONIC EXAMINATION
MPa (g)
MPa (g)
mm
-
15.340
NOT REQUIRED
3.175 (EXCEPT TUBE)
1 ii
REFER NDT TABLE OF C5437-HD-002
17
POST WELD HEAT TREATMENT (PWHT)
YES
18
19
20
21
22
IMPACT TEST
PRODUCTION TEST COUPONS
WIND DESIGN CODE / WIND SPEED
SEISMIC DESIGN CODE / ZONE
OTHER APPLICABLE LOADING AS PER UG-22
TYPE
FLUID
CONDITION
DENSITY
EMPTY
WEIGHT
HYDROSTATIC
OPERATING
CAPACITY
INSPECTION BY
NOT REQUIRED
NOT REQUIRED
UG-20(f), UG-84
NOT APPLICABLE ii
NOT APPLICABLE ii
REFER SHEET NO. 8
PROCESS GAS
SWEET NATURAL GAS
64.875
9212.00
10661.00
9306.00
1455.00
AI
UG-22
UG-22
UG-22
23
24
25
26
kg / m3
kg
kg
kg
L
-
UG-99
UG-100
UG-25
APPENDIX 13
UW-11, API-661
UW-2, UCS-56,
UCS-79 API 661
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 OF
WIND & SEISMIC REACTION.
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APPLICABLE LOADINGS AS PER UG - 22
SR. NO.
UG - 22
SUBCLAUSE
10
DESCRIPTION
INTERNAL DESIGN PRESSURE AS PER UG-21
EXTERNAL DESIGN PRESSURE AS PER UG-21
WEIGHT OF VESSEL AND NORMAL CONTENTS
UNDER OPERATING OR TEST CONDITIONS,
INCLUDING ADDITIONAL HEAD DUE TO STATIC
HEAD OF MEDIUM / WATER
SUPERIMPOSED STATIC REACTIONS FROM
WEIGHT OF ATTACHED EQUIPMENTS SUCH AS
MOTORS, 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 AND
MECHANICAL LOADINGS
WIND REACTIONS
SNOW REACTIONS
SEISMIC REACTIONS
IMPACT REACTIONS SUCH AS THOSE DUE TO
FLUID SHOCKS
TEMPERATURE GRADIENTS AND DIFFERENTIAL
THERMAL EXPANSION
ABNORMAL PRESSURES SUCH AS THOSE CAUSED
BY DEFLAGRATION
TEST PRESSURE & COINCIDENT STATIC HEAD ACTING
DURING THE TEST
APPLICABILITY
APPLICABLE
NOT APPLICABLE
APPLICABLE
APPLICABLE
NOT APPLICABLE
NOT APPLICABLE
NOT APPLICABLE i
NOT APPLICABLE i
NOT APPLICABLE i
NOT APPLICABLE ii
APPLICABLE iii
NOT APPLICABLE
APPLICABLE
SINCE HEADER BOX IS BEING SUPPORTED IN STRUCTURE, STRUCTURE SHALL TAKE

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

EVALUATION OF STATIC PRESSURE IN OPERATING / HYDROSTATIC TEST CONDITION :
PART
DESCRIPTION
INLET
NOZZLE
HEADER
BOX
OUTLET
NOZZLE
INTERNAL
DESIGN
PRESSURE
MPa (g)
DIFF. PRESS.
CORRECTION
MPa (g)
(IF ANY)
STATIC
HEIGHT
FLUID
mm
STATIC PR. OF
FLUID FOR
OPERATING
MPa (g)
10.204
NIL
322
0.000
322
0.003
10.204
NIL
710
0.000
710
0.007
10.204
NIL
1032
0.001
1032
0.010
1032
0.001
1032
0.01
MAXIMUM STATIC HEIGHT / PRESSURE
STATIC STATIC PR. OF

HEIGHT WATER FOR
HYDRO. HYDRO. TEST
MPa (g)
mm
EVALUATION OF DESIGN PRESSURE :

A) INTERNAL DESIGN PRESSURE
10.204 MPa (g)
B) EXTERNAL PRESSURE
NIL MPa (g)
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
FOR EVALUATION OF COMPONENT THICKNESS
CONVERSION :
1 mm OF WATER =
DENSITY =
9.80665E-06 MPa
64.875 kg / m3
(AS PER CLIENT)
10.205 MPa (g)
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EVALUATION OF MATERIALS AS PER APPENDIX 13-3,UCS-23 & UHA-23
MAXIMUM ALLOWABLE STRESS VALUES AS PER UCS-23 & UHA-23 :

THE MAXIMUM ALLOWABLE STRESS VALUES AT THE TEMPERATURE INDICATED FOR MATERIALS CONFORMING
TO THE SPECIFICATION LISTED IN ASME SECTION II, PART D. ( METRIC )
SR.
NO.
PART
DESCRIPTION
MATERIAL
SPECIFICATION
PAGE / P NO / ACTUAL
LINE GROUP DESIGN
NO.
NO
TEMP.
o
SEC II D
C
PERMISSIBLE
DESIGN
TEMP
o
STRESS
VALUE
AT
DESIGN
TEMP.
STRESS
VALUE
AT
ROOM
TEMP.
MPa
MPa
APPLICABLE
CAUTIONARY
NOTE
HEADER
PLATES
SA-516 Gr.70 N
22 / 6
1/2
121.11
538
138.00
138.00
NIL
FLANGES
SA-105N
18 / 32
1/2
121.11
538
138.00
138.00
NIL
HEADER
PLUGS
SA-105N
18 / 32
1/2
121.11
538
138.00
138.00
NIL
TUBES
SA-179
6 / 11
1/1
121.11
482
92.40
92.40
NIL
TRANSITION
NOZZLE
SA-234 Gr.WPB
14 / 21
1/1
121.11
538
118.00
118.00
NIL
COUPLING
SA-105N
18 / 32
1/2
121.11
538
138.00
138.00
NIL
ROUND PLUG
SA-182 Gr.F316
78 / 1
8/1
121.11
816
138.00
138.00
NIL
YIELD STRENGTH OF MATERIALS

SR.
NO.
PART
DESCRIPTION
MATERIAL
SPECIFICATION
YIELD
PAGE /
STRENGTH
LINE
NO.
AT
AT
SEC II D DESIGN ROOM
TEMP. TEMP.
MPa
MPa
578 / 30
235.62
262.00
SA-105N
578 / 17
223.62
248.00
HEADER
PLUGS
SA-105N
578 / 17
223.62
248.00
TUBES
SA-179
566 / 10
161.31
179.00
TRANSITION
NOZZLE
SA-234 Gr.WPB
574 / 5
217.47
241.00
COUPLING
SA-105N
578 / 17
ROUND PLUG
SA-182 Gr.F316
638 / 12
169.24
207.00
HEADER
PLATES
SA-516 Gr.70 N
FLANGES
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EVALUATION OF JOINT & LIGAMENT EFFICIENCY AS PER APPENDIX 13

LIGAMENT EFFICIENCY OF MULTIDIAMETER HOLES ON PLUG SHEET AS PER APPENDIX 13-6 :
=
=
=
=
=
=
=
=
=
VALUE
63.500
39.000
0.800
28.700
1.800
28.575
27.400
30.000
3.175
UNITS
mm
mm
mm
mm
mm
mm
mm
mm
mm
=
=
=
=
=
26.825
24.500
34.800
34.925
24.225
28.894 mm
A) CALCULATION :
t2
b0
b1
b2
T2
= ( t2' - C )
= ( p - d0 )
= ( p - d1 )
= ( p - d2 )
= ( T2' - C )
mm
mm
mm
mm
mm
B) LIGAMENT EFFICIENCY OF PLATE SUBJECTED TO MEMBRANE STRESS :

DE =
=
em =
=
EQUIVALENT UNIFORM DIAMETER OF MULTIDIAMETER HOLE.
( 1 / t2 ) * ( d0 * T0 + d1 * T1 + d2 * T2 )
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
[ {(b0*T0) * ({T0/2} + T1 + T2)} + {(b1*T1) * ({T1/ 2} + T2)} +
=
{(b2*T2) * (T2/ 2)} ] * [ (b0*T0) + (b1*T1) + (b2*T2) ] - 1
I = MOMENT OF INERTIA.
13.293 mm
= [ (1/12) * {(b0*T03) + (b1*T13) + (b2 * T23)} ] + [ (b0*T0) * {(T0/2) + T1 + T2 - X }2 ]

c2i =
=
c2O =
=
c=
DE =
=
eb =
=
50
Revision:
INPUT DATA :
p = PITCH DISTANCE BETWEEN TWO PLUG HOLE
do = DIAMETER OF HOLE OF LENGTH T0
T0 = LENGTH OF HOLE OF DIAMETER do
d1 = DIAMETER OF HOLE OF LENGTH T1
T1 = LENGTH OF HOLE OF DIAMETER d1
d2 = DIAMETER OF HOLE OF LENGTH T2
T2' = LENGTH OF HOLE OF DIAMETER d2
t2' = THICKNESS OF PLUG SHEET
C = CORROSION ALLOWANCE
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=
+ [ (b1*T1) * {(T1/2) + T2- X }2 ] + [ (b2*T2) * {(T2/2) - X }2 ]
DISTANCE FROM NEUTRAL AXIS OF CROSS SECTION OF PLATE
WITH MULITIDIAMETER HOLES TO THE INSIDE SURFACE.
X
=
DISTANCE FROM NEUTRAL AXIS OF CROSS SECTION OF PLATE
WITH MULITIDIAMETER HOLES TO THE EXTREME OUTSIDE SURFACE.
- ( t2 - X )
=
THE LARGER OF c2i OR c2o
=
EQUIVALENT UNIFORM DIAMETER OF MULTIDIAMETER HOLE.
=
p - ( 6 * I / t22 * c)
BENDING LIGAMENT EFFICIENCY.
( p - DE ) / p
=
54722.192 mm4
13.293 mm
-13.532 mm
13.532 mm
29.781 mm
0.531
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EVALUATION OF JOINT & LIGAMENT EFFICIENCY AS PER APPENDIX 13

LIGAMENT EFFICIENCY OF TUBE SHEET AS PER APPENDIX 13-4 (g) AND UG - 53 (b) (1) :
INPUT DATA :
LONGITUDINAL PITCH OF TUBE HOLES, p
DIAMETER OF TUBE HOLES, d
VALUE
=
=
UNITS
63.500 mm
25.750 mm
CALCULATION :
LIGAMENT EFFICIENCY OF TUBE SHEET , e = [ p - d ] / p
0.594
LIGAMENT EFFICIENCY OF STAY PLATE OF NOZZLE HEADER AS PER APPENDIX 13-4 (g) AND UG - 53 (b) (1) :
INPUT DATA :
LONGITUDINAL PITCH OF HOLES, p
DIAMETER OF HOLES, d
VALUE
=
=
UNITS
255.000 mm
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) :
INPUT DATA :
LONGITUDINAL PITCH OF HOLES, p
DIAMETER OF HOLES, d
VALUE
=
=
UNITS
248.000 mm
75.000 mm
CALCULATION :
LIGAMENT EFFICIENCY OF STAY PLATE , U = ( p - ( d + 2 * C ) ) / p
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04.06.14
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 APPLICABLE
TO 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.
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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 COMPARTMENT
OF 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).
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INPUT DATA FOR NOZZLE HEADER AS PER APPENDIX 13-9 (c) & 13-5
VALUE
INPUT DATA :
C
t4'
U
E
Ew
TP
RT
DP
DH
D'
CF
t5
= DESIGN PRESSURE
= DESIGN TEMPERATURE
= ALLOWABLE STRESS - PLATE
= INSIDE LENGTH OF SHORT SIDE
= INSIDE LENGTH OF LONG SIDE
= THICKNESS OF TOP/BOTTOM PLATE (SHORT SIDE)
= THICKNESS OF TUBE/PLUG PLATE (LONG SIDE)
= CORROSION ALLOWANCE OF PLATE / SHEET
= THICKNESS OF STAY PLATE
= STAY PLATE LIGAMENT EFFICIENCY
= JOINT EFFICIENCY FACTOR
= NOZZLE WELD EFFICIENCY
= TUBE PITCH
= TUBE INSIDE RADIUS
= TUBE PLUG DIAMETER
= TUBE HOLE INSIDE DIAMETER
= LARGE SPAN MEASURED PERPENDICULAR TO SHORT SPAN
= END PLATE ATTACHMENT FACTOR AS PER APP. - 13.4 (f)
= THICKNESS OF END PLATE
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
10.205
121.110
138.000
110.000
97.000
28.000
30.000
3.175
20.000
0.720
1.000
1.000
63.500
10.590
28.575
25.750
332.000
0.200
30.000
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
103.350
116.350
1.126
24.825
26.825
13.650
338.350
1274.931
1608.563
1.421
0.594
0.545
0.531
2.500
12.413
13.413
13.293
-13.532
UNITS
MPa
O
C
MPa
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
CALCULATIONS :
h = h' + ( 2 * C )
H = H' + ( 2 * C )
= RECTANGULAR VESSEL PARAMETER = H / h
t1 = ( t1' - C )
t2 = ( t2' - C )
t4 = ( t4' - 2 * C )
D = ( D' + 2 * C )
l1 = ( t1 )3 / 12
l2 = ( t2 )3 / 12
K = VESSEL PARAMETER = ( l2 / l1 ) *
e = TUBE SHEET LIGAMENT EFFICIENCY
em = MEMBRANE LIGAMENT EFFI. FOR PLUG SHEET
eb = BENDING LIGAMENT EFFI. FOR PLUG SHEET
Z = MIN ( 2.5, {3.4 - ( 2.4 * H ) / D } AS PER UG-34 (c) (3)
c1 = DIST. FROM NEUTRAL AXIS OF C/S TO EXTREME FIBERS = t1 / 2
c2i = DIST. FROM NEUTRAL AXIS OF C/S TO EXTREME FIBERS
c2o = DIST. FROM NEUTRAL AXIS OF C/S TO EXTREME FIBERS
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mm
mm
mm
mm
mm
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mm3
mm
mm
mm
mm
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HE1
THICKNESS EVALUATION OF TOP & BOTTOM PLATE OF NOZZLE HEADER AS PER APPENDIX 13-9 (c)
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
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
% ALLOWABLE = ( Sm / Sa ) * 100
[ 13.4 (b) ]
[ 13.9 (c) (1) (13) ]
15.97%
SAFE
184.957 MPa
[ 13.4 (b) ]
-63.032 MPa
[ 13.9 (c) (2) (16) ]
34.08%
SAFE
105.092 MPa
[ 13.9 (c) (2) (17) ]
56.82%
SAFE
207.000 MPa
[ 13.4 (b) ]
-40.989 MPa
[ 13.9 (c) (3) (20) ]
19.80%
SAFE
127.135 MPa
[ 13.9 (c) (3) (21) ]
61.42%
SAFE
B) BENDING STRESS ON SHORT SIDE, Sb :

Sa = ALLOWABLE STRESS = ( 1.5 * S ) - Sm
(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)} ]
% ALLOWABLE = [ (Sb)N / Sa ] * 100
(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 ) ]
% ALLOWABLE = [ (Sb)Q / Sa ] * 100
C) TOTAL STRESS ON SHORT SIDE, ST :
Sa = ALLOWABLE STRESS = ( 1.5* S )
(ST)N = Sm + (Sb)N
% ALLOWABLE = [ (ST)N / Sa ] * 100
(ST)Q = Sm + (Sb)Q
% ALLOWABLE = [ (ST)Q / Sa ] * 100
D) MINIMUM THICKNESS OF TOP & BOTTOM PLATE :
FOR MIN. THICKNESS, CONSIDERING t1' =
DATA REMAINING SAME THEN,
Sm =
28.448 MPa
(Sb)N =
-100.495 MPa
(ST)N =
-72.047 MPa
(ST)Q =
205.392 MPa
HENCE, t1 =
22.500 mm, t2' =
27.700 mm & t4' =
(Sb)Q = 176.944 MPa

% ALLOWABLE = [ (ST)N / Sa ] * 100 =
% ALLOWABLE = [(ST)Q / Sa ] * 100 =
16.800 mm & OTHER INPUT
34.81%
99.22%
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:
SR. NO.
DESCRIPTION
TOP / BOTTOM PLATE
UG-16
mm
1.5 + C
MINIMUM THICKNESS
CALCULATED
mm
4.675
22.500
API 661
mm
PROVIDED
THK.
mm
REMARK
12.000
28.00
SAFE
NOTE: THICKNESS MENTIONED ABOVE INCLUDES CORROSION ALLOWANCE
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HE1
THICKNESS EVALUATION OF TUBE SHEET OF NOZZLE HEADER AS PER APPENDIX 13-9 (c)
A) MEMBRANE STRESS ON LONG SIDE, Sm :
VALUE
UNITS
138.000 MPa
Sm = ( P * H ) / ( 2 * t2 )
= ( P * H ) / ( 2 * t2 * e )
37.258 MPa
[ 13.4 (b) ]
[ 13.9 (c) (1) (14) ]
27.00%
SAFE
169.742 MPa
[ 13.4 (b) ]
122.705 MPa
[ 13.9 (c) (2) (18) ]
72.29%
SAFE
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 ) ]
% ALLOWABLE = [ (Sb)M / Sa ] * 100
(Sb)Q = [ P * h2 * c2 / 12 * I2 ] * [ ( 3 + 5 *
* K) / ( 3 + 5 * K ) ]
90.005 MPa
[ 13.9 (c) (2) (19) ]
53.02%
SAFE
207.000 MPa
[ 13.4 (b) ]
159.963 MPa
[ 13.9 (c) (3) (22) ]
77.28%
SAFE
127.263 MPa
[ 13.9 (c) (3) (23) ]
61.48%
SAFE
C) TOTAL STRESS ON LONG SIDE, ST :

(ST)M = Sm + (Sb)M
% ALLOWABLE = [ (ST)M / Sa ] * 100
(ST)Q = Sm + (Sb)Q
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.
SR.
NO.
DESCRIPTION
TUBE SHEET
MINIMUM THICKNESS
CALCULATED
UW-13.2 (d)
mm
mm
UG-16
mm
1.5 + C
4.675
27.700
NAi
API 661
mm
PROVIDED
THK.
19.000

i
RULES OF APPENDIX 28 IS APPLICABLE FOR CORNER WELD JOINT
REMARK
mm
30.00
SAFE
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HE1
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THICKNESS EVALUATION OF PLUG SHEET OF NOZZLE HEADER AS PER APPENDIX 13-9 (c)
VALUE
UNITS
138.000 MPa
[ 13.4 (b) ]
= ( P * H ) / ( 2 * t2 * em )
Sm = ( P * H ) / ( 2 * t 2 )
=
=
40.608 MPa
29.43%
[ 13.9 (c) (1) (14) ]

SAFE
166.392 MPa
[ 13.4 (b) ]
(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 ) ]
% ALLOWABLE = [ (Sb)Mi / Sa ] * 100
=
=
136.040 MPa
81.76%
[ 13.9 (c) (2) (18) ]

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 ) ]
% ALLOWABLE = [ (Sb)Mo / Sa ] * 100
=
=
-138.486 MPa
83.23%
[ 13.9 (c) (2) (18) ]

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

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

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

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

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

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

SAFE

D) MINIMUM THICKNESS OF PLUG SHEET :

Sm =
44.416 MPa
(Sb)Mi =
162.412 MPa
(Sb)Qi =
108.794 MPa
(ST)Mi =
206.828 MPa
(ST)Mo =
-121.193 MPa
(ST)Qi =
153.210 MPa
(ST)Qo =
-66.519 MPa
22.500 mm, t2' =
27.700 mm & t4' =
(Sb)Mo = -165.609 MPa

(Sb)Qo = -110.935 MPa
% ALLOWABLE = [ (ST)Mi / Sa ] * 100 =
% ALLOWABLE = [ (ST)Mo / Sa ] * 100 =
% ALLOWABLE = [(ST)Qi / Sa ] * 100 =
% ALLOWABLE = [(ST)Qo / Sa ] * 100 =
99.92%
58.55%
74.01%
32.13%
HENCE, t2 =
i) WELD DESIGN AS PER FIG. APPENDIX-28.
ii) WELD DESIGN AS PER FIG.UG-34 (g).
SR.
NO.
DESCRIPTION
PLUG SHEET
MINIMUM THICKNESS
CALCULATED
UW-13.2 (d)
mm
mm
UG-16
mm
1.5 + C
4.675
27.700
NAi
API 661
mm
PROVIDED
THK.
mm
REMARK
19.000
30.00
SAFE

i
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HE1
THK. EVALUATION OF STAY & END PLATE OF NOZZLE HEADER AS PER APPENDIX 13-9 (c) & UG-34
1) THICKNESS EVALUATION - STAY PLATE AS PER APPENDIX 13-9 (c) :
A) MEMBRANE STRESS ON STAY PLATE, Sm :
VALUE
UNITS
138.000 MPa
[ 13.4 (b) ]
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) ]
76.28%
SAFE
138.000 MPa
[ 13.4 (b) ]
105.265 MPa
[ 13.9 (c) (3) (24) ]
76.28%
SAFE
B) TOTAL STRESS ON STAY PLATE , ST :
(ST) = Sm
% ALLOWABLE = [ (ST) / Sa ] * 100
C) MINIMUM THICKNESS OF STAY PLATE :
22.500 mm, t2' =

Sm =
137.161 MPa
(ST) =
137.161 MPa
27.700 mm & t4' =
% 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:
SR. NO.
DESCRIPTION
MINIMUM THICKNESS
CALCULATED
mm
UG-16 (b)
mm
API 661
mm
PROVIDED
THK.
REMARK
mm
STAY PLATE
1.5 + 2 * C
7.850
16.800
12.000
20.000
SAFE
END PLATE
1.5 + C
4.675
25.548
12.000
30.000
SAFE
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C5437-HC
HE1
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 COMPARTMENT
OF 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
Page No:
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C5437-HC
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INPUT DATA FOR RETURN HEADER AS PER APPENDIX 13-9 (c) & 13-5
VALUE
INPUT DATA :
C
t4'
U
E
Ew
TP
RT
DP
DH
D'
CF
t5
= DESIGN PRESSURE
= ALLOWABLE STRESS - PLATE
= NOZZLE WELD EFFICIENCY
= TUBE PITCH
= TUBE INSIDE RADIUS
= TUBE PLUG DIAMETER
= TUBE HOLE INSIDE DIAMETER
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
10.205
121.110
138.000
100.000
97.000
28.000
30.000
3.175
20.000
0.672
1.000
1.000
63.500
10.590
28.575
25.750
332.000
0.200
28.000
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
103.350
106.350
1.029
24.825
26.825
13.650
338.350
1274.931
1608.563
1.298
0.594
0.545
0.531
2.500
12.413
13.413
13.293
-13.532
UNITS
MPa
O
C
MPa
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
CALCULATIONS :
h = h' + ( 2 * C )
H = H' + ( 2 * C )
= RECTANGULAR VESSEL PARAMETER = H / h
t1 = ( t1' - C )
t2 = ( t2' - C )
t4 = ( t4' - 2 * C )
D = ( D' + 2 * C )
l1 = ( t1 )3 / 12
l2 = ( t2 )3 / 12
Z = MIN ( 2.5, {3.4 - ( 2.4 * H ) / D } AS PER UG-34 (c) (3)
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t2'
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mm
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HE1
Document No:
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THICKNESS EVALUATION OF TOP & BOTTOM PLATE OF RETURN HEADER AS PER APPENDIX 13-9 (c)
A) MEMBRANE STRESS ON SHORT SIDE PLATE, Sm :
VALUE
UNITS
138.000 MPa
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
[ 13.4 (b) ]
[ 13.9 (c) (1) (13) ]
15.52%
SAFE
185.587 MPa
[ 13.4 (b) ]
-48.472 MPa
[ 13.9 (c) (2) (16) ]
26.12%
SAFE
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)} ]
% ALLOWABLE = [ (Sb)N / Sa ] * 100
(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) ]
49.57%
SAFE
207.000 MPa
[ 13.4 (b) ]
-27.059 MPa
[ 13.9 (c) (3) (20) ]
13.07%
SAFE
113.407 MPa
[ 13.9 (c) (3) (21) ]
54.79%
SAFE
C) TOTAL STRESS ON SHORT SIDE, ST :

(ST)N = Sm + (Sb)N
% ALLOWABLE = [ (ST)N / Sa ] * 100
(ST)Q = Sm + (Sb)Q
D) MINIMUM THICKNESS OF TOP & BOTTOM PLATE :
Sm =
29.537 MPa
(Sb)N =
-90.642 MPa
(ST)N =
-61.105 MPa
(ST)Q =
205.335 MPa
HENCE, t1 =
21.200 mm, t2' =
27.900 mm & t4' =
(Sb)Q = 175.798 MPa

% ALLOWABLE = [ (ST)N / Sa ] * 100 =
% ALLOWABLE = [(ST)Q / Sa ] * 100 =
29.52%
99.20%
i) COMPENSATION CALCULATION AS PER UG-37 & UG-39.

ii) WELD DESIGN AS PER FIG. UG-34 (g)
SR. NO.
DESCRIPTION
TOP / BOTTOM PLATE
UG-16
mm
1.5 + C
MINIMUM THICKNESS
CALCULATED
mm
4.675
21.200
API 661
mm
PROVIDED
THK.
mm
REMARK
12.000
28.00
SAFE
Page No:
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Document No:
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50
C5437-HC
HE1
THICKNESS EVALUATION OF TUBE SHEET OF RETURN HEADER AS PER APPENDIX 13-9 (c)
VALUE
UNITS
138.000 MPa
Sm = ( P * H ) / ( 2 * t2 )
= ( P * H ) / ( 2 * t2 * e )
34.056 MPa
[ 13.4 (b) ]
[ 13.9 (c) (1) (14) ]
24.68%
SAFE
172.944 MPa
[ 13.4 (b) ]
126.482 MPa
[ 13.9 (c) (2) (18) ]
73.13%
SAFE

(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 ) ]
% ALLOWABLE = [ (Sb)M / Sa ] * 100
(Sb)Q = [ P * h2 * c2 / 12 * I2 ] * [ ( 3 + 5 *
* K) / ( 3 + 5 * K ) ]
78.788 MPa
[ 13.9 (c) (2) (19) ]
45.56%
SAFE
207.000 MPa
[ 13.4 (b) ]
160.538 MPa
[ 13.9 (c) (3) (22) ]
77.55%
SAFE
112.844 MPa
[ 13.9 (c) (3) (23) ]
54.51%
SAFE

(ST)M = Sm + (Sb)M
% ALLOWABLE = [ (ST)M / Sa ] * 100
(ST)Q = Sm + (Sb)Q
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.
SR.
NO.
DESCRIPTION
TUBE SHEET
MINIMUM THICKNESS
CALCULATED
UW-13.2 (d)
mm
mm
UG-16
mm
1.5 + C
4.675
27.900
NAi
API 661
mm
PROVIDED
THK.
19.000

i
REMARK
mm
30.00
SAFE
Page No:
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Revision:
23
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50
C5437-HC
Document No:
HE1
Tag No:
THICKNESS EVALUATION OF PLUG SHEET OF RETURN HEADER AS PER APPENDIX 13-9 (c)
VALUE
UNITS
138.000 MPa
[ 13.4 (b) ]
= ( P * H ) / ( 2 * t2 * em )
Sm = ( P * H ) / ( 2 * t 2 )
=
=
37.118 MPa
26.90%
[ 13.9 (c) (1) (14) ]

SAFE
169.882 MPa
[ 13.4 (b) ]
(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 ) ]
% ALLOWABLE = [ (Sb)Mi / Sa ] * 100
=
=
140.228 MPa
82.54%
[ 13.9 (c) (2) (18) ]

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 ) ]
% ALLOWABLE = [ (Sb)Mo / Sa ] * 100
=
=
-142.749 MPa
84.03%
[ 13.9 (c) (2) (18) ]

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

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

SAFE
207.000 MPa
[ 13.4 (b) ]
% ALLOWABLE = [ (ST)Mi / Sa ] * 100
=
=
177.346 MPa
85.67%
[ 13.9 (c) (3) (22) ]

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

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

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

SAFE

D) MINIMUM THICKNESS OF PLUG SHEET :

Sm =
40.271 MPa
(Sb)Mi =
165.298 MPa
(Sb)Qi =
92.528 MPa
(ST)Mi =
205.569 MPa
(ST)Mo =
-128.254 MPa
(ST)Qi =
132.799 MPa
(ST)Qo =
-54.063 MPa
21.200 mm, t2' =
27.900 mm & t4' =
(Sb)Mo = -168.525 MPa

(Sb)Qo =
-94.334 MPa
% ALLOWABLE = [ (ST)Mi / Sa ] * 100 =
% ALLOWABLE = [ (ST)Mo / Sa ] * 100 =
% ALLOWABLE = [(ST)Qi / Sa ] * 100 =
% ALLOWABLE = [(ST)Qo / Sa ] * 100 =
99.31%
61.96%
64.15%
26.12%
HENCE, t2 =
i) WELD DESIGN AS PER FIG. APPENDIX-28.
ii) WELD DESIGN AS PER FIG.UG-34 (g).
SR.
NO.
DESCRIPTION
PLUG SHEET
MINIMUM THICKNESS
CALCULATED
UW-13.2 (d)
mm
mm
UG-16
mm
1.5 + C
4.675
27.900
NAi
API 661
mm
PROVIDED
THK.
mm
REMARK
19.000
30.00
SAFE

i
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THK. EVALUATION OF STAY & END PLATE OF RETURN HEADER AS PER APPENDIX 13-9 (c) & UG-34
1) THICKNESS EVALUATION - STAY PLATE AS PER APPENDIX 13-9 (c) :
A) MEMBRANE STRESS ON STAY PLATE, Sm :
VALUE
UNITS
138.000 MPa
[ 13.4 (b) ]
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) ]
82.99%
SAFE
138.000 MPa
[ 13.4 (b) ]
114.521 MPa
[ 13.9 (c) (3) (24) ]
82.99%
SAFE
B) TOTAL STRESS ON STAY PLATE , ST :
(ST) = Sm
% ALLOWABLE = [ (ST) / Sa ] * 100
C) MINIMUM THICKNESS OF STAY PLATE :
21.200 mm, t2' =

Sm =
137.017 MPa
(ST) =
137.017 MPa
27.900 mm & t4' =
% 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:
SR. NO.
DESCRIPTION
MINIMUM THICKNESS
CALCULATED
mm
UG-16 (b)
mm
API 661
mm
PROVIDED
THK.
REMARK
mm
STAY PLATE
1.5 + 2 * C
7.850
17.750
12.000
20.000
SAFE
END PLATE
1.5 + C
4.675
23.625
12.000
28.000
SAFE
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THICKNESS EVALUATION OF TUBE AS PER UG-31 AND UG-27

UG-31 (a) :
THE REQUIRED WALL THICKNESS FOR TUBES UNDER INTERNAL PRESSURE SHALL BE DETERMINED IN ACCORDANCE
WITH THE RULES FOR SHELLS IN UG-27.
THICKNESS EVALUATION OF TUBE AS PER UG-27 (c) :
INPUT DATA :
P
T
Di
Ri
El
Ec
C
S
MOC
= INTERNAL DESIGN PRESSURE

= INSIDE DIAMETER OF TUBE (CORRODED)
= INSIDE RADIUS OF TUBE (CORRODED)
= LONGITUDINAL JOINT EFFICIENCY (SEAMLESS)
= CIRCUMFERENTIAL JOINT EFFICIENCY (SEAMLESS)
= CORROSION ALLOWANCE
= MAX. ALLOWABLE STRESS AT DESIGN TEMPERATURE
= MATERIAL OF CONSTRUCTION
=
=
=
=
=
=
=
=
=
VALUE
UNIT
10.205
121.110
21.180
10.590
1.000
1.000
0.000
92.400
SA-179
MPa (g)
C
mm
mm
mm
MPa
1) CIRCUMFERENTIAL STRESS ( LONGITUDINAL JOINTS ) :

() CONSIDERING JOINT EFFICIENCY El = 1
ts = [ ( P * Ri ) / ( S * E - 0.6 * P ) ] + C
CHECK WHETHER,
ts < (Ri/2 +c)
P < (0.385 x S x EI)
1.253 mm
0.572 mm
YES
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
CHECK WHETHER,
ts < (Ri/2 +c)
P < (1.25 x S x EC)
YES
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),
2) & 3) ABOVE
ts
1.253 mm
b) PROVIDED NOMINAL TUBE THICKNESS
ts
2.110 mm
c) PROVIDED THICKNESS IS LAGER THAN THE REQUIRED THICKNESS DUE TO PRESSURE, HENCE SAFE.
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NOZZLE THICKNESS CALCULATION AS PER UG-45

NOZZLE SIZE
NOZZLE MATERIAL
NOZZLE LOCATION
NOZZLE MARK NO.
INPUT DATA :
P = INTERNAL DESIGN PRESSURE
Pe = EXTERNAL DESIGN PRESSURE
Sn = ALLOWABLE STRESS - NOZZLE
Sv = ALLOWABLE STRESS - VESSEL
Do = OUT SIDE DIA. OF NOZZLE CONNECTION
Ro = OUT SIDE RADIUS OF NOZZLE CONNECTION
El = LONGITUDINAL JOINT EFFICIENCY
tstd = STD. WALL THK. OF PIPE (ASME B 36.10)
C = CORROSION ALLOWANCE.
(A) MINIMUM THICKNESS OF NOZZLE AS PER UG-45:

t= (P*Ro) / (Sn*El + 0.4P) ..[APPENDIX 1-1(a)]
ta = REQUIRED THICKNESS
= (ta + C )
(B) MINIMUM THICKNESS OF NOZZLE AS PER UG-45:

(i) FOR INTERNAL PRESSURE ONLY
- 1) TOP/ BOTTOM PLATE CALCULATED THK. WITH
JOINT EFFICIENCY AS 1.0
- 2) THE MINIMUM THICKNESS AS PER UG - 16 (b) :
= 1.5 + C
tb1 = MAXIMUM OF 1) & 2) ABOVE
(ii) FOR EXTERNAL PRESSURE ONLY
- 1) TOP/ BOTTOM PLATE CALCULATED THK. WITH
EFFICIENCY AS 1.0
- 2) THE MINIMUM THICKNESS AS PER UG - 16 (b) :
= 1.5 + C
tb2 = MAXIMUM OF 1) & 2) ABOVE
DN 200
DN 25 NPT
SA-234 Gr.WPB
SA-105N
NOZZLE HEADER RETURN HEADER
N1 - N4
V/D
MPa (g)
MPa (g)
MPa
MPa
mm
mm
mm
10.205
0.000
118.000
138.000
219.100
109.55
1
8.18
10.205
0.000
138.000
138.000
57.000
28.5
1
3.91
mm
3.175
3.175
mm
9.157
2.047
mm
12.332
5.222
mm
19.325
18.025
mm
mm
4.675
19.325
4.675
18.025
mm
mm
0.000
0.000
0.000
0.000
mm
(iii)
tb3 = THK AS PER TABLE UG-45
mm
10.335
6.135
(iv)
tb = MIN OF [tb3, MAX(tb1,tb2)]
mm
10.335
6.135
mm
12.332
6.135
mm
mm
20.134
23.01 SCH 160
(C) MIN.REQUIRED THK. IS tUG-45 =
MAX (ta, tb)
(D) MINIMUM NOZZLE THK. PROVIDED

(E) NOMINAL NOZZLE THK. PROVIDED
SUMMARY :
N1 - N4 DN 200
V / D DN 25 NPT
C1 - C2 DN 50
SCH 160
6000 #
SCH 160
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11.8
6000 #
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REINFORCEMENT REQUIREMENT FOR NOZZLE AS PER APPENDIX 13-4

APPENDIX 13-4 (j) (1) :
OPENINGS IN NONCIRCULAR VESSELS DO NOT REQUIRE REINFORCEMENT OTHER THAN THAT INHERENT IN THE
CONSTRUCTION, 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 :
Dn
Wt
C
tn
d
t1
= OUTER DIAMETER OF NOZZLE

= NOMINAL NOZZLE WALL THICKNESS
= NOZZLE WALL THICKNESS (CORRODED)
= FINISHED DIA. OF CIRCULAR OPENING = (Dn - 2*tn)
= REQUIRED MINIMUM THICKNESS SHELL
mm
mm
mm
mm
mm
mm
N1 - N4
V/D
219.100
23.010
3.175
19.835
179.430
19.325
57.000
11.800
3.175
8.625
39.750
18.025
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.
UG-36 (c) (3) (b) : THREADED, STUDDED, OR EXPANDED CONNECTIONS IN WHICH THE HOLE CUT IN THE SHELL
OR HEAD NOT GREATER THAN 60 mm DIAMETER.
UG-36 (c) (3) (c) : NO TWO ISOLATED UNREINFORCED OPENINGS IN ACCORDANCE WITH (a) OR (b) ABOVE, SHALL
HAVE 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 CLOSER
TO EACH OTHER THAN THE FOLLOWINGS :
FOR CYLINDRICAL OR CONICAL SHELLS
FOR DOUBLY CURVED SHELLS & FORMED OR FLAT HEAD :
: (1 + 1.5 COS ) (d1 + d2)

: 2.5 * (d1 + d2 )
WHERE,
= THE ANGLE BETWEEN THE LINE CONNECTING THE CENTER OF THE OPENINGS
AND THE LONGITUDINAL AXIS OF THE SHELL
d1, 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).
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REINFORCEMENT REQUIREMENT IN Z-DIRECTION AS PER UG-39 & UG-37

NOZZLE SIZE
NOZZLE MATERIAL
NOZZLE 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 = FACTOR
F = FACTOR
E1*t-F*tr = EXCESS THK IN SHELL OR HEAD
mm
MPa (g)
Sn = ALLOWABLE STRESS - NOZZLE
MPa
MPa
Dn = OUT SIDE DIA. OF NOZZLE CONNECTION
mm
Ro = OUTSIDE RADIUS OF NOZZLE CONNECTION
mm
Rn = INSIDE RADIUS OF NOZZLE CONNECTION (CORRODED)
mm
El = LONGITUDINAL JOINT EFFICIENCY
C = CORROSION ALLOWANCE.
mm
Tn, Ti = NOMINAL THICKNESS OF NOZZLE
mm
tn, 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/Sv
fr2 = Sn/Sv
d = I.D. OF FINISHED OPENING (CORRODED)
mm
h = DISTANCE NOZZLE PROJECTS BEYOND INNER
SURFACE OF VESSEL WALL
mm
leg1 = WELD FILLET SIZE FOR OUTWARD NOZZLE
mm
leg2 = WELD FILLET SIZE FOR INWARD NOZZLE
mm
tp = THICKNESS OF TOP/BTM PLATE STIFFNER (CORRODED)
mm
Lp = LENGTH OF TOP/BTM PLATE STIFFNER (CORRODED)
mm
Np = NOS. OF TOP/BTM PLATE STIFFNER
ts = THICKNESS OF NOZZLE STIFFNER (CORRODED)
mm
Ls = LENGTH OF NOZZLE STIFFNER (CORRODED)
mm
Ns = NOS. OF NOZZLE STIFFNER
(a)
(i)
(ii)
(iii)
(b)
(i)
(ii)
(iii)
(c)
(i)
(ii)
(iii)
(iv)
(d)
(i)
(e)
(i)
(f)
(g)
(i)
(h)
(i)
REINFORCEMENT CALCULATION :
A1 = AREA AVAILABLE IN SHELL OR HEAD
= (E1*t-F*tr)*d - 2*tn(E1*t-F*tr)(1-fr1) OR
= 2(E1*t-F*tr)*(t+tn) - 2*tn*(E1*t-F*tr)*(1-fr1)
A1 = GREATER VALUE OF (i) OR (ii) ABOVE
A2 = AREA AVAILABLE IN NOZZLE PROJECTING OUTWARD
= 5 * t * ( tn - trn ) * fr2 OR
= 5 * tn * ( tn - trn ) * fr2
A2 = SMALLER VALUE OF (i) OR (ii) ABOVE
A3 = AREA AVAILABLE IN INWARD NOZZLE
= 5 * t * ti * fr2
= 5 * ti * ti * fr2
= 2 * h * ti * fr2
A3 = SMALLER VALUE OF (i) OR (ii) OR (iii) ABOVE
A41 = AREA AVAILABLE IN OUTWARD NOZZLE WELD
= leg1 * leg1 * fr2
A43 = AREA AVAILABLE IN INWARD NOZZLE WELD
= leg2 * leg2 * fr2
A5 = AREA AVAILABLE IN STIFFNERS
= Np * Lp * tp + Ns * Ls * ts
A' = REINFORCEMENT AREA AVAILABLE WITHOUT PAD
= A1+A2+A3+A41+A43+A5
A = REINFORCEMENT AREA REQUIRED
= 0.5 * d * tr + 2 * tn * tr * ( 1 - fr1 )
CONCLUSION :1) CHECK WHETHER A' > A

2) CHECK WHETHER REINFORCEMENT IS REQUIRED
mm2
2
mm
2
mm
2
mm
mm2
mm2
mm
mm2
DN 200
SA-234 Gr.WPB
NOZZLE HEADER
N1 - N4
24.825
19.325
1
1
5.500
10.205
118.000
138.000
304.787
152.394
132.559
1
3.175
23.01
19.835
12.739
7.096
0.855
0.855
265.117
0.000
9.000
0.000
18.650
39.650
1.000
18.650
63.650
1.000
1426.522
459.639
1426.522
753.140
601.754
601.754
2105.205
1682.044
0.000
0.000
69.261
mm
0.000
mm
1926.545
mm2
4024.082
2672.798
mm
YES SATISFIED
NOT REQUIRED
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REINFORCEMENT REQUIREMENT AS PER U - 2(g)

REFERENCE : ASME SECTION VIII DIVISION 2 CL. 4.5.12
NOZZLE SIZE
NOZZLE MATERIAL
NOZZLE 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
DN 200
SA-234 Gr.WPB
NOZZLE HEADER
N1 - N4
DN 20
SA-312M Gr TP316L
HEADER
D1 - D2 / V1 - V2
24.825
11.800
mm
mm
19.325
0.000
4.246
0.000
mm
MPa (g)
MPa
MPa
mm
1
0.000
10.205
118.000
138.000
219.100
1
1
1.000
0.358
108.520
108.520
26.700
1
mm
mm
mm
mm
3.175
23.01
19.835
8.104
3
5.56
2.560
832.065
Din = NOZZLE INSIDE DIAMETER (CORRODED)

Rn = NOZZLE INSIDE RADIUS (CORRODED)
Lpr1 = NOZZLE PROJECTION FROM THE OUTSIDE OF THE
mm
179.430
89.715
21.580
10.790
VESSEL WALL
Lpr2 = NOZZLE PROJECTION FROM THE INSIDE OF THE
mm
322.000
21.580
VESSEL WALL
L41 = WELD LEG LENGTH OF THE OUTSIDE
mm
0.000
0.000
NOZZLE FILLET WELD

L42 = WELD LEG LENGTH OF THE PAD TO
mm
9.000
9.000
VESSEL FILLET WELD

L43 = WELD LEG LENGTH OF THE INSIDE
mm
mm
AS PER 4.6.1 (USING E = 1)

te = THICKNESS OF THE REINFORCINGPAD
E1 =
W=
P=
Sn =
Sv =
Don =
El =
C=
Tn, Ti =
tn, ti =
trn =
FACTOR
WIDTH OF THE REINFORCING PAD
INTERNAL DESIGN PRESSURE
ALLOWABLE STRESS - NOZZLE
ALLOWABLE STRESS - VESSEL
OUT SIDE DIA. OF NOZZLE CONNECTION
LONGITUDINAL JOINT EFFICIENCY
CORROSION ALLOWANCE.
NOMINAL THICKNESS OF NOZZLE
NOZZLE THICKNESS IN CORRODED COND.
Din * [ EXP(P/SnEl) - 1] / 2
NOZZLE FILLET WELD

CALCULATIONS:
MAXIMUM UNIT MOMENT AT THE NOZZLE INTERSECTION :
Mo =Sv * trf4 / 6(t + Cp * te)2
5205.079
Cp = MIN [{(W + 0.5 * L42) * te / (Rn * t)}, 0.6]
0.00
NOZZLE PARAMETERS :
n
= 1.285 / (Rnm * tn) ^ 0.5

2
0.029
C1 = SINH [CL] + SIN [CL]
40688.27593
C2 = SINH2 [CL] - SIN2 [CL]

CL = MIN [ { n (Lpr1 + t + Lpr2)}, 6.0 ]
40688.11978
C3 = (Lpr1 + t) / [Lpr1 + t + MIN {(
-1
n)
6.000
, Lpr2)}]
Rnm = Rn + 0.5 * tn
1.000
99.633
Rxn = tn / ln [(Rn + tn) / Rn]

xt = 0.5 * n * (te + L41)
99.303
(for nozzle abutting vessel wall)
Ct = EXP [-xt]
0.131
0.877
DETERMINE MAXIMUM LOCAL PRIMARY MEMBRANE STRESS

IN THE NOZZLE INTERSECTION:
PL
= (2 * Mo *
* Rnm * Ct * C1 * C3 / tn C2) + (P * Rxn / tn)
89.659
CONCLUSION :PL <= 1.5 Sn

PL <= 1.5 S * E
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FLANGE RATING CHECK AS PER UG-44 & ASME B16.5-2013

AS PER UG - 44, THE FLANGE RATINGS SHALL BE IN ACCORDANCE WITH ASME B 16.5.
NOZZLE MARK NO.
N1 - N4
SIZE
DN 200
TYPE OF FLANGE
WNRTJ
MATERIAL
SA-105N
TABLE
2-1.1
MATERIAL GROUP
1.1
SELECTED RATING
900
PERMITTED MAWP
w.r.t DESIGN TEMP.,
MPa (g)
13.785
PERMITTED MAWP
w.r.t ROOM TEMP.,
MPa (g)
15.320
PROVIDED RATING
900
=
=
50
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10.205 MPa (g)

121.110 C
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INSPECTION OPENING AS PER UG-46.
INSPECTION OPENING AS PER UG-46 (d) :

FOR VESSELS 300 mm OR LESS IN INSIDE DIAMETER, OPENINGS FOR INSPECTION ONLY MAY BE OMITTED IF THERE
ARE AT LEAST TWO REMOVABLE PIPE CONNECTIONS NOT LESS THAN DN 20.
CONCLUSION :
A)
B)
C)
D)
E)
NOZZLE HEADER INSIDE DIMENSION (SHORT SPAN) IS 110 mm WHICH IS LESS THAN 300 mm.
RETURN HEADER INSIDE DIMENSION (SHORT SPAN) IS 100 mm WHICH IS LESS THAN 300 mm.
NOZZLE HEADER HAVING PIPE CONNECTION OF SIZE DN 200 WHICH IS LARGER THAN DN 20.
RETURN HEADER HAVING PIPE CONNECTION OF DN 25 WHICH IS LARGER THAN DN 20.
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.
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WELD DESIGN AS PER FIG. UW-16.1 (a)
50
FIG : UW 16.1 (a)

tmin = MIN(19,tn ,t) tc = MIN (6, 0.7 * tmin)
f = tc / 0.7
fp
tn
mm
mm
mm
mm
mm
mm
N1 - N4 - TOP/BTM PLATE NOZZLE HEADER
24.825
19.835
19.000
6.000
8.571
9.000
SAFE
V / D TOP/BTM PLATE RETURN HEADER
24.825
8.625
8.625
6.000
8.571
9.000
SAFE
COMPONENT
(min.)
RESULT
WHERE,
t
tn
f
fp
= NOMINAL THICKNESS OF TOP & BOTTOM PLATE / NOZZLE (CORRODED), mm

= NOMINAL THICKNESS OF NOZZLE (CORRODED), mm
= LEG SIZE OF FILLET WELD, mm
= 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).
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WELD DESIGN AS PER APPENDIX 28 FIG. 28-1 (b)
FIG : 28-1 (b)

COMPONENT
a(Ref.)
b(Ref.)
ts
a2
a2 / ts
t - b(Ref)
mm
mm
deg.
deg.
mm
mm
mm
mm
mm
TOP / BOTTOM PLATE - TUBE / PLUG

SHEET - NOZZLE HEADER
31.00
16.564
32.50
15.00
28.00
30.00
16.564
0.59
13.44
TOP / BOTTOM PLATE - TUBE / PLUG

SHEET - RETURN HEADER
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, mm

ts = NOMINAL THICKNESS OF TOP / BOTTOM PLATE, mm
FOLLOWING CONDITION ARE SATISFIED TO MEET THE REQUIREMENTS OF APPENDIX 28.

CLAUSE
CONDITION
APPENDIX 28-2 (f) (1) > 15O

APPENDIX 28-2 (f) (2) a2 SHALL BE MEASURED FROM PROJECTED SURFACE OF PLATE
APPENDIX 28-2 (f) (3) > 15O
APPENDIX 28-2 (f) (4) a2 / ts > K SHOWN IN THE TABLE IN FIG. 28-1 (b) :
a2 / ts =
CONSIDERING K =
0.6
AND
0.55
CONDITIONS
SATISFIED
YES
YES
YES
YES
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.
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WELD DESIGN AS PER UG-34 (g)
FIG : UG-34 (g)

t
ts
tr
2 * tr
1.25 * ts
tw = MIN (2 * tr , 1.25 * ts, t)
t / tw
mm
mm
mm
mm
mm
mm
mm
END PLATE - TOP /BOTTOM

PLATE - NOZZLE HEADER
22.373
24.825
19.325
38.650
31.031
22.373
26.825
SAFE
END PLATE - TUBE /PLUG

SHEET - NOZZLE HEADER
22.373
26.825
24.525
49.050
33.531
22.373
26.825
SAFE
END PLATE - TOP /BOTTOM

PLATE - RETURN HEADER
20.450
24.825
18.025
36.050
31.031
20.450
24.825
SAFE
END PLATE - TUBE /PLUG

SHEET - RETURN HEADER
20.450
26.825
24.725
49.450
33.531
20.450
24.825
SAFE
COMPONENT
WHERE,
t
ts
tr
tw
= MINIMUM REQUIRED THICKNESS OF END PLATE (CORRODED), mm

= NOMINAL THICKNESS OF TOP / BOTTOM PLATE OR TUBE / PLUG SHEET (CORRODED), mm
= REQUIRED THICKNESS OF TOP / BOTTOM PLATE OR TUBE / PLUG SHEET, mm
= 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.
RESULT
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GOVERNING THICKNESS AS PER UCS-66, UHA-51 & UW-40 (f)
GOVERNING
THK., UW-40 (f)
mm
30.00 i
-31.13
30.00 iii
28.00
28.00 i
-32.38
28.00 iii
30.00
30.00 i
-31.13
30.00 iii
1/2
20.00
20.00
-39.80
20.00
SA-234 Gr.WPB
1/1
23.01
23.01 i
-3.99
23.01 iii
SA-105N
1/2
UCS-66 (C)
(1)
23.01 i
-29.00
23.01 iii
DN 25 - NPT- PLUG SA-182 Gr.F316
8/1
UHA-51 ((d)
DN 25 - NPTCOUPLING
SA-105N
1/2
11.80
11.8 i
-23.69
11.8 iii
MISCELLANEOUS
PLUG
SA-105N
1/2
28.575
7.144 ii
-29.00
TUBES
SA-179
1/1
UCS-66 (d)
(4) (a)
2.110
-105.00
SR.
NO.
COMPONENT /
ITEM NO.
MATERIAL
SPEC.
P NO. / MATERIAL COMPONENT

GROUP CATEGORY THICKNESS
mm
NO.
CURVE
HEADER
TUBE / PLUG
SHEET - HEADER
SA-516 Gr.70 N
1/2
30.00
TOP / BOTTOM
PLATE - HEADER
SA-516 Gr.70 N
1/2
END PLATE
NOZZLE HEADER
SA-516 Gr.70 N
1/2
STAY PLATE HEADER
SA-516 Gr.70 N
TRANSITION
NOZZLE -200 DN
WNRF FLANGES 200 DN
GOVERNING
THK., UCS-66 (a)
mm
MDMT v
O
iii
-196 oC
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).
THE MDMT IS -3.99 C (WARMER TEMPERATURE) AS DEMONSTRATED ABOVE.
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IMPACT TEST REQUIREMENT AS PER UG-20 (f), UCS-66

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 CONDITION
ARE SATISFIED :
SR.
NO.
1
2
3
4
5
CONDITIONS
SATISFIED
CONDITION
MATERIAL IS LIMITED TO P1, GROUP 1 OR 2 & THICKNESS IS NOT EXCEEDING
13 mm FOR MATERIAL LISTED IN CURVE 'A' OR FIGURE UCS-66 AND 25 mm
FOR 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 DESIGN
REQUIREMENT ( REFER UG-22 )
CYCLIC LOADING IS NOT CONTROLLING DESIGN REQUIREMENT.
(REFER UG-22)
NO
YES
YES
YES
YES
CONCLUSION :
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 C. REFER SHEET "GOVERNING THICKNESS".
3) MDMT REQUIRED BY CUSTOMER
PROPOSED (CERTIFIED) MDMT
=
=
-1.11 OC
-1.11 C @ 11.8 MPa (g).
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POST FORMING HEAT TREATMENT REQUIREMENT AS PER UG-79, UCS-79, &

POST WELD HEAT TREATMENT REQUIREMENT AS PER UW-2, UCS-56
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
2
3
4
CONDITION
LETHAL SERVICE APPLICATION
UNFIRED STEAM BOILER SERVICE WITH DESIGN
PRESSURE GREATER THAN 345 kPa
MATERIALS OVER 32 mm NOMINAL THICKNESS
AS DEFINED IN UW- 40 (f)
FOR MATERIAL WITH MDMT COLDER THAN -48 C
AND COINCIDENT RATIO IS EQUAL TO OR GREATER
THAN 0.35
APPLICABILITY
REFERENCE
NO
UW -2(a)
NO
UW -2(c)
NO
TABLE UCS-56 FOR P1,GROUP 1,2,3
NO
UCS-68(b)
CONCLUSION:
1) POST WELD HEAT TREATMENT AS PER UCS 56 IS NOT MANDATORY.
2) POST WELD HEAT TREATMENT AS PER API-661 IS MANDATORY.
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FULL RADIOGRAPHY REQUIREMENT AS PER UW-11

FULL RADIOGRAPHY REQUIREMENT IS MANDATORY WHEN ANY OF THE FOLLOWING CONDITIONS EXIST :
SR.
NO.
1
2
3
4
5
6
DESCRIPTION
LETHAL SERVICE APPLICATION [ UW-2 (a) ]
ALL BUTT WELDS WITH MINIMUM NOMINAL THICKNESS EXCEEDING 38 mm
OR EXCEEDS THE LESSER THICKNESS SPECIFIED IN UCS-57 i.e. 32 mm
UNFIRED STEAM BOILER SERVICE WITH DESIGN PRESSURE GREATER THAN
345 kPa
CATEGORY B & C BUTT WELDS IN NOZZLES AND COMMUNICATING CHAMBERS
THAT 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-12
ALL BUTT WELDS JOINT BY ELECTRO GAS WELDING WITH ANY SINGLE PASS
GREATER THAN 38 mm & ALL BUTT WELDS JOINED BY ELECTRO SLAG WELDING
ULTRASONIC EXAMINATION IN ACCORDANCE WITH UW-53 MAY BE
SUBSTITUTED FOR RADIOGRAPHY FOR THE FINAL CLOSURE SEAM OF A
PRESSURE VESSEL IF THE CONSTRUCTION OF THE VESSEL DOES NOT
PERMIT INTERPRETABLE RADIOGRAPHS IN ACCORDANCE WITH CODE
REQUIREMENTS.
APPLICABILITY
NO
NO
NO
NO
NO
NO
NO
CONCLUSION :
1) FULL RADIOGRAPHY AS PER UW-11 IS NOT MANDATORY.
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 IN
ACCORDANCE 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) AND
THE 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
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NOZZLE HEADER - MAWP CALCULATION (HOT & CORRODED)

INPUT DATA : (AS PER APPENDIX 13-9 (c) & 13-5)
MAWP
P
T
S
H'
h'
t1'
t2'
t4'
t5
C
U
E
D'
CF
= MAXIMUM ALLOWABLE WORKING PRESSURE

= MAWP WITH STATIC HEIGHT
= ALLOWABLE STRESS AT DESIGN TEMP.- PLATE
CALCULATIONS :
h = h' + ( 2 * C )
H = H' + ( 2 * C )
= RECTANGULAR VESSEL PARA METER = H / h
t1 = ( t1' - C )
t2 = ( t2' - C )
t4 = ( t4' - 2 * C )
D = ( D' + 2 * C )
l1 = ( t1 )3 / 12
l2 = ( t2 )3 / 12
Z = MIN ( 2.5, {3.4 - ( 2.4 * H ) / D } AS PER UG-34 (c) (3)
Sa (m) = ALLOWBALE STRESS FOR MEMBRANE STRESS = S
Sa (T) = ALLOWBALE STRESS FOR TOTAL STRESS = 1.5 * S
VALUE
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
11.800
11.801
121.110
138.000
110.000
97.000
28.000
30.000
20.000
30.000
3.175
0.720
1.000
332.000
0.200
MPa
MPa
O
C
MPa
mm
mm
mm
mm
mm
mm
mm
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
103.350
116.350
1.126
24.825
26.825
13.650
338.350
1274.931
1608.563
1.421
0.594
0.545
0.531
2.500
12.413
13.413
13.293
-13.532
138.00
207.00
mm
mm
PLUG SHEET :
Sm = ( P * H ) / ( 2 * t2 * em )
(Sb)Mi = [ P * h2 * c2i / 12 * I2 * eb ] * [ { 3 + K * ( 6 - 2 ) } / ( 3 + 5 * K ) ]
(Sb)Mo = [ P * h2 * c2o / 12 * I2 * eb ] * [ { 3 + K * ( 6 - 2 ) } / ( 3 + 5 * K ) ]
(Sb)Qi = [ P * h2 * c2i / 12 * I2 ] * [ ( 3 + 5 * 2 * K) / ( 3 + 5 * K ) ]
(Sb)Qo = [ P * h2 * c2o / 12 * I2 ] * [ ( 3 + 5 * 2 * K) / ( 3 + 5 * K ) ]
=
=
=
=
=
=
=
=
=
46.959
157.316
-160.145
103.154
-105.009
204.275
-113.186
150.113
-58.050
STAY PLATE :
Sm = [ P * h / 2 * t4 * U ] * [ ( 6 + K * ( 11 (ST) = Sm
=
=
END PLATE AS PER APPENDIX 13-4 ( f ) & UG-34 (c) (3) :

t5 = [ H * { ( CF * Z * P ) / S * E } 1/2 ] + C
S = [ ( H2 * CF * Z * P ) / { ( t5 - C )2 * E ) } ]
mm
mm
mm
mm
mm3
mm3
mm
mm
mm
mm
MPa
MPa
ALLOWABLE
% ALLOWABLE
STRESS,MPa
18.47%
25.490
138.00
-72.889
121.528
22.90%
-47.399
207.00
71.02%
147.018
207.00
=
=
=
=
=
)/(3+5*K)]
mm
MPa
TOP / BOTTOM PLATE

Sm = [ P * h / 2 * t1 * E ] * [ 3 - { ( 6 + K * ( 11 - 2 ) / ( 3 + 5 * K ) } ]
(Sb)N = [P * c1 / 24 * I1 * E] * [-3 * H2 + 2 * h2 * {(3 + 5 * 2 * K) / (3 + 5 *K)} ]
(Sb)Q = [ P * h2 * c1 / 12 * I1 * E ] * [ ( 3 + 5 * 2 * K ) / ( 3 + 5 * K ) ]
(ST)N = Sm + (Sb)N
(ST)Q = Sm + (Sb)Q
UNITS
138.00
34.03%
207.00
207.00
207.00
207.00
98.68%
54.68%
72.52%
28.04%
121.727
121.727
138.00
88.21%
111.005
138.00
80.44%
CONCLUSION : GOVERNING COMPONENT IS PLUG SHEET OF RETURN HEADER WITH MAWP OF 10.4 MPa
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RETURN HEADER - MAWP CALCULATION (HOT & CORRODED)

MAWP
P
T
S
H'
h'
t1'
t2'
t4'
t5
C
U
E
D'
CF

= ALLOWABLE STRESS AT DESIGN TEMP.- PLATE
CALCULATIONS :
h = h' + ( 2 * C )
H = H' + ( 2 * C )
t1 = ( t1' - C )
t2 = ( t2' - C )
t4 = ( t4' - 2 * C )
D = ( D' + 2 * C )
l1 = ( t1 )3 / 12
l2 = ( t2 )3 / 12
Z = MIN ( 2.5, {3.4 - ( 2.4 * H ) / D } AS PER UG-34 (c) (3)
VALUE
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
11.800
11.801
121.110
138.000
100.000
97.000
28.000
30.000
20.000
28.000
3.175
0.672
1.000
332.000
0.200
MPa
MPa
O
C
MPa
mm
mm
mm
mm
mm
mm
mm
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
103.350
106.350
1.029
24.825
26.825
13.650
338.350
1274.931
1608.563
1.298
0.594
0.545
0.531
2.500
12.413
13.413
13.293
-13.532
138.00
207.00
mm
mm
PLUG SHEET :
Sm = ( P * H ) / ( 2 * t2 * em )
(Sb)Mi = [ P * h2 * c2i / 12 * I2 * eb ] * [ { 3 + K * ( 6 - 2 ) } / ( 3 + 5 * K ) ]
(Sb)Mo = [ P * h2 * c2o / 12 * I2 * eb ] * [ { 3 + K * ( 6 - 2 ) } / ( 3 + 5 * K ) ]
(Sb)Qi = [ P * h2 * c2i / 12 * I2 ] * [ ( 3 + 5 * 2 * K) / ( 3 + 5 * K ) ]
(Sb)Qo = [ P * h2 * c2o / 12 * I2 ] * [ ( 3 + 5 * 2 * K) / ( 3 + 5 * K ) ]
=
=
=
=
=
=
=
=
=
42.923
162.158
-165.074
90.298
-91.921
205.081
-122.151
133.221
-48.998
STAY PLATE :
Sm = [ P * h / 2 * t4 * U ] * [ ( 6 + K * ( 11 (ST) = Sm
=
=

t5 = [ H * { ( CF * Z * P ) / S * E } 1/2 ] + C
S = [ ( H2 * CF * Z * P ) / { ( t5 - C )2 * E ) } ]
mm
mm
mm
mm
mm3
mm3
mm
mm
mm
mm
MPa
MPa
ALLOWABLE
% ALLOWABLE
STRESS,MPa
17.94%
24.762
138.00
-56.053
106.381
15.12%
-31.291
207.00
63.35%
131.143
207.00
=
=
=
=
=
)/(3+5*K)]
mm
MPa
TOP / BOTTOM PLATE

Sm = [ P * h / 2 * t1 * E ] * [ 3 - { ( 6 + K * ( 11 - 2 ) / ( 3 + 5 * K ) } ]
(Sb)N = [P * c1 / 24 * I1 * E] * [-3 * H2 + 2 * h2 * {(3 + 5 * 2 * K) / (3 + 5 *K)} ]
(Sb)Q = [ P * h2 * c1 / 12 * I1 * E ] * [ ( 3 + 5 * 2 * K ) / ( 3 + 5 * K ) ]
(ST)N = Sm + (Sb)N
(ST)Q = Sm + (Sb)Q
UNITS
138.00
31.10%
207.00
207.00
207.00
207.00
99.07%
59.01%
64.36%
23.67%
132.432
132.432
138.00
95.97%
108.289
138.00
78.47%
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TUBE ,NOZZLE & FLANGES - MAWP CALCULATION (HOT & CORRODED)
REFERENCE : APPENDIX-13 OF ASME SECTION VIII DIVISION 1.

= MATERIAL OF CONSTRUCTION FOR TUBE
= ALLOWABLE STRESS AT DESIGN TEMPERATURE- TUBE
= OUTSIDE RADIUS OF TUBE
= THICKNESS OF TUBE
= MATERIAL OF CONSTRUCTION FOR NOZZLE - N1 - N4
= ALLOWABLE STRESS AT DESIGN TEMPERATURE- NOZZLE
= OUTSIDE RADIUS OF NOZZLE - N1 - N4
= THICKNESS OF NOZZLE - N1 - N4
= MATERIAL OF CONSTRUCTION FOR NOZZLE - D - V
= OUTSIDE RADIUS OF NOZZLE - D - V
= THICKNESS OF NOZZLE - D - V
E = JOINT EFFICIENCY - NOZZLE & TUBE
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
MAWP
P
T
C
MOCt
St
Rot
tt
MOCn1
Stn1
Ron1
tn1
MOCn2
Stn2
Ron2
tn2
TUBE AS PER APPENDIX 1-1 (a) :
VALUE
UNIT
11.800 MPa
11.801 MPa (g)
121.110 C
3.175 mm
SA-179
92.400 MPa
12.700 mm
2.110 mm
SA-234 Gr.WPB
118.000 MPa
109.550 mm
20.134 mm
SA-182 Gr.F316
138.000 MPa
28.500 mm
11.800 mm
1.000
MPa
ALLOWABLE
STRESS,MPa
% ALLOWABLE
66.309
92.400
71.76%
A) NOZZLE N1 - N4
S = [ P * { Ron1 - 0.4 * ( tn1 - C ) } ] / [ E * ( tn1 - C ) ]
71.510
118.000
60.60%
A) NOZZLE V / D
S = [ P * { Ron2 - 0.4 * ( tn2 - C ) } ] / [ E * ( tn2 - C ) ]
34.274
138.000
24.84%
11.801
13.785
85.61%
t = ( P * Ro ) / ( S * E + 0.4 * P )
S = [ P * { Rot - 0.4 * ( tt ) } ] / [ E * ( tt ) ]
NOZZLE AS PER APPENDIX 1-1 (a) :
t = ( P * Ro ) / ( S * E + 0.4 * P )
FLANGE RATING AS PER ASME B16.5

FOR # 900 RATING
PERMITTED MAWP w.r.t DESIGN TEMP.
50
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50
HE1
NOZZLE HEADER - MAP CALCULATION (NEW & COLD)

MAP
P
T
S
H'
h'
t1'
t2'
t4'
t5
C
U
E
D'
CF
= MAXIMUM ALLOWABLE PRESSURE

= MAP WITH STATIC HEIGHT
= ROOM TEMPERATURE
= ALLOWABLE STRESS AT ROOM TEMP.- PLATE
= STAY / PARTITION PLATE LIGAMENT EFFICIENCY
CALCULATIONS :
h = h' + ( 2 * C )
H = H' + ( 2 * C )
t1 = ( t1' - C )
t2 = ( t2' - C )
t4 = ( t4' - 2 * C )
D = ( D' + 2 * C )
l1 = ( t1 )3 / 12
l2 = ( t2 )3 / 12
Z = MIN ( 2.5, {3.4 - ( 2.4 * H ) / D } AS PER UG-34 (c) (3)
VALUE
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
15.160
15.161
17.000
138.000
110.000
97.000
28.000
30.000
20.000
30.000
0.000
0.720
1.000
332.000
0.200
MPa
MPa
O
C
MPa
mm
mm
mm
mm
mm
mm
mm
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
97.000
110.000
1.134
28.000
30.000
20.000
332.000
1829.333
2250.000
1.395
0.594
0.545
0.533
2.500
14.000
15.000
14.880
-15.120
138.00
207.00
mm
mm
PLUG SHEET :
Sm = ( P * H ) / ( 2 * t2 * em )
(Sb)Mi = [ P * h2 * c2i / 12 * I2 * eb ] * [ { 3 + K * ( 6 - 2 ) } / ( 3 + 5 * K ) ]
(Sb)Mo = [ P * h2 * c2o / 12 * I2 * eb ] * [ { 3 + K * ( 6 - 2 ) } / ( 3 + 5 * K ) ]
(Sb)Qi = [ P * h2 * c2i / 12 * I2 ] * [ ( 3 + 5 * 2 * K) / ( 3 + 5 * K ) ]
(Sb)Qo = [ P * h2 * c2o / 12 * I2 ] * [ ( 3 + 5 * 2 * K) / ( 3 + 5 * K ) ]
=
=
=
=
=
=
=
=
=
51.000
141.598
-143.882
94.335
-95.857
192.598
-92.882
145.335
-44.857
STAY PLATE :
Sm = [ P * h / 2 * t4 * U ] * [ ( 6 + K * ( 11 (ST) = Sm
=
=

t5 = [ H * { ( CF * Z * P ) / S * E } 1/2 ] + C
S = [ ( H2 * CF * Z * P ) / { ( t5 - C )2 * E ) } ]
mm
mm
mm
mm
mm3
mm3
mm
mm
mm
mm
MPa
MPa
ALLOWABLE
% ALLOWABLE
STRESS,MPa
19.79%
27.311
138.00
-66.326
109.167
18.85%
-39.015
207.00
65.93%
136.478
207.00
=
=
=
=
=
)/(3+5*K)]
mm
MPa
TOP / BOTTOM PLATE

Sm = [ P * h / 2 * t1 * E ] * [ 3 - { ( 6 + K * ( 11 - 2 ) / ( 3 + 5 * K ) } ]
(Sb)N = [P * c1 / 24 * I1 * E] * [-3 * H2 + 2 * h2 * {(3 + 5 * 2 * K) / (3 + 5 *K)} ]
(Sb)Q = [ P * h2 * c1 / 12 * I1 * E ] * [ ( 3 + 5 * 2 * K ) / ( 3 + 5 * K ) ]
(ST)N = Sm + (Sb)N
(ST)Q = Sm + (Sb)Q
UNITS
CONCLUSION : GOVERNING COMPONENT IS NOZZLE FLANGE WITH MAP OF 15.160 MPa
138.00
36.96%
207.00
207.00
207.00
207.00
93.04%
44.87%
70.21%
21.67%
100.057
100.057
138.00
72.51%
101.916
138.00
73.85%
Page No:
Date:
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50
HE1
RETURN HEADER - MAP CALCULATION (NEW & COLD)

MAP
P
T
S
H'
h'
t1'
t2'
t4'
t5
C
U
E
D'
CF

= ROOM TEMPERATURE
= ALLOWABLE STRESS AT ROOM TEMP.- PLATE
= STAY / PARTITION PLATE LIGAMENT EFFICIENCY
CALCULATIONS :
h = h' + ( 2 * C )
H = H' + ( 2 * C )
t1 = ( t1' - C )
t2 = ( t2' - C )
t4 = ( t4' - 2 * C )
D = ( D' + 2 * C )
l1 = ( t1 )3 / 12
l2 = ( t2 )3 / 12
Z = MIN ( 2.5, {3.4 - ( 2.4 * H ) / D } AS PER UG-34 (c) (3)
VALUE
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
15.160
15.161
17.000
138.000
100.000
97.000
28.000
30.000
20.000
28.000
0.000
0.672
1.000
332.000
0.200
MPa
MPa
O
C
MPa
mm
mm
mm
mm
mm
mm
mm
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
97.000
100.000
1.031
28.000
30.000
20.000
332.000
1829.333
2250.000
1.268
0.594
0.545
0.533
2.500
14.000
15.000
14.880
-15.120
138.00
207.00
mm
mm
PLUG SHEET :
Sm = ( P * H ) / ( 2 * t2 * em )
(Sb)Mi = [ P * h2 * c2i / 12 * I2 * eb ] * [ { 3 + K * ( 6 - 2 ) } / ( 3 + 5 * K ) ]
(Sb)Mo = [ P * h2 * c2o / 12 * I2 * eb ] * [ { 3 + K * ( 6 - 2 ) } / ( 3 + 5 * K ) ]
(Sb)Qi = [ P * h2 * c2i / 12 * I2 ] * [ ( 3 + 5 * 2 * K) / ( 3 + 5 * K ) ]
(Sb)Qo = [ P * h2 * c2o / 12 * I2 ] * [ ( 3 + 5 * 2 * K) / ( 3 + 5 * K ) ]
=
=
=
=
=
=
=
=
=
46.364
146.236
-148.595
81.976
-83.298
192.600
-102.231
128.340
-36.934
STAY PLATE :
Sm = [ P * h / 2 * t4 * U ] * [ ( 6 + K * ( 11 (ST) = Sm
=
=

t5 = [ H * { ( CF * Z * P ) / S * E } 1/2 ] + C
S = [ ( H2 * CF * Z * P ) / { ( t5 - C )2 * E ) } ]
mm
mm
mm
mm
mm3
mm3
mm
mm
mm
mm
MPa
MPa
ALLOWABLE
% ALLOWABLE
STRESS,MPa
19.19%
26.485
138.00
-50.171
94.864
11.44%
-23.686
207.00
58.62%
121.349
207.00
=
=
=
=
=
)/(3+5*K)]
mm
MPa
TOP / BOTTOM PLATE

Sm = [ P * h / 2 * t1 * E ] * [ 3 - { ( 6 + K * ( 11 - 2 ) / ( 3 + 5 * K ) } ]
(Sb)N = [P * c1 / 24 * I1 * E] * [-3 * H2 + 2 * h2 * {(3 + 5 * 2 * K) / (3 + 5 *K)} ]
(Sb)Q = [ P * h2 * c1 / 12 * I1 * E ] * [ ( 3 + 5 * 2 * K ) / ( 3 + 5 * K ) ]
(ST)N = Sm + (Sb)N
(ST)Q = Sm + (Sb)Q
UNITS
138.00
33.60%
207.00
207.00
207.00
207.00
93.04%
49.39%
62.00%
17.84%
108.957
108.957
138.00
78.95%
96.69
138.00
70.07%
Page No:
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C5437-HC
HE1
TUBE ,NOZZLE & FLANGES - MAP CALCULATION (NEW & COLD)
REFERENCE : APPENDIX-13 OF ASME SECTION VIII DIVISION 1.

= ROOM TEMPERATURE
= ALLOWABLE STRESS AT ROOM TEMPERATURE- TUBE
= THICKNESS OF TUBE
= ALLOWABLE STRESS AT ROOM TEMPERATURE- NOZZLE
= MATERIAL OF CONSTRUCTION FOR NOZZLE - D - V
E = JOINT EFFICIENCY - NOZZLE & TUBE
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
MAP
P
T
C
MOCt
St
Rot
tt
MOCn1
Stn1
Ron1
tn1
MOCn2
Stn2
Ron2
tn2
VALUE
UNIT
15.160 MPa
15.170 MPa (g)
17.000 C
0.000 mm
SA-179
115.000 MPa
12.700 mm
2.110 mm
SA-234 Gr.WPB
118.000 MPa
109.550 mm
20.134 mm
SA-182 Gr.F316
138.000 MPa
28.500 mm
11.800 mm
1.000
MPa
ALLOWABLE
STRESS,MPa
% ALLOWABLE
85.24
115.000
74.12%
A) NOZZLE N1 - N4
S = [ P * { Ron1 - 0.4 * ( tn1 - C ) } ] / [ E * ( tn1 - C ) ]
76.473
118.000
64.81%
A) NOZZLE V / D
S = [ P * { Ron2 - 0.4 * ( tn2 - C ) } ] / [ E * ( tn2 - C ) ]
30.571
138.000
22.15%
15.170
15.320
99.02%
t = ( P * Ro ) / ( S * E + 0.4 * P )
S = [ P * { Rot - 0.4 * ( tt ) } ] / [ E * ( tt ) ]
t = ( P * Ro ) / ( S * E + 0.4 * P )

FOR # 900 RATING
PERMITTED MAP w.r.t ROOM TEMP.
50
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C5437-HC
HE1
Document No:
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HYDROSTATIC TEST PRESSURE CALCULATION AS PER UG-99 (b)

HYDROSTATIC TEST PRESSURE AS PER UG-99 (b) :
MAXIMUM ALLOWABLE WORKING PRESSURE
DESIGN TEMPERATURE
MIN. RECOMMENDED TEST TEMPERATURE
11.800 MPa (g)

121.11 C
17.000 C
=
=
=
PARTS
MATERIAL
ALLOWABLE STRESS
AT DESIGN TEMP.
SD (MPa)
ALLOWABLE STRESS
AT TEST TEMP.
ST (MPa)
RATIO
r = ST / SD
HEADER PLATES
SA-516 Gr.70 N
138.00
138.00
1.000
FLANGES
SA-105N
138.00
138.00
1.000
PLUG
SA-105N
138.00
138.00
1.000
NOZZLES
SA-234 Gr.WPB
118.00
118.00
1.000
TUBES
SA-179
92.40
92.40
1.000
TRANSITION
NOZZLE
SA-234 Gr.WPB
118.00
118.00
1.000
COUPLING
SA-105N
138.00
138.00
1.000
ROUND PLUG
SA-182 Gr.F316
138.00
138.00
1.000
MINIMUM HYDROSTATIC TEST PRESSURE = 1.3 x MAWP x LOWEST RATIO r

=
15.340 MPa (g)
50
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Date:
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50
HE1
NOZZLE HEADER - STRESS DURING HYDROTEST CONDITION AS PER U-2(g)

P
T
Sy
H'
h'
t1'
t2'
t4'
t5
C
U
E
D'
CF
= HYDROSTATIC TEST PRESSURE WITH STATIC HEIGHT

= HYDROSTATIC TEST TEMPERATURE
= ALLOWABLE YIELD STRESS AT ROOM TEMP.- PLATE
CALCULATIONS :
h = h' + ( 2 * C )
H = H' + ( 2 * C )
t1 = ( t1' - C )
t2 = ( t2' - C )
t4 = ( t4' - 2 * C )
D = ( D' + 2 * C )
l1 = ( t1 )3 / 12
l2 = ( t2 )3 / 12
Z = MIN ( 2.5, {3.4 - ( 2.4 * H ) / D } AS PER UG-34 (c) (3)
Sa (m) = ALLOWBALE STRESS FOR MEMBRANE STRESS = 0.9 * Sy
Sa (T) = ALLOWBALE STRESS FOR TOTAL STRESS = 1.5 * ( 0.9 * Sy )
VALUE
=
=
=
=
=
=
=
=
=
=
=
=
=
=
15.350
17.000
262.000
110.000
97.000
28.000
30.000
20.000
30.000
3.175
0.720
1.000
332.000
0.200
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
103.350
116.350
1.126
24.825
26.825
13.650
338.350
1274.931
1608.563
1.421
0.594
0.545
0.531
2.500
12.413
13.413
13.293
-13.532
235.80
353.70
PLUG SHEET :
Sm = ( P * H ) / ( 2 * t2 * em )
(Sb)Mi = [ P * h2 * c2i / 12 * I2 * eb ] * [ { 3 + K * ( 6 - 2 ) } / ( 3 + 5 * K ) ]
(Sb)Mo = [ P * h2 * c2o / 12 * I2 * eb ] * [ { 3 + K * ( 6 - 2 ) } / ( 3 + 5 * K ) ]
(Sb)Qi = [ P * h2 * c2i / 12 * I2 ] * [ ( 3 + 5 * 2 * K) / ( 3 + 5 * K ) ]
(Sb)Qo = [ P * h2 * c2o / 12 * I2 ] * [ ( 3 + 5 * 2 * K) / ( 3 + 5 * K ) ]
=
=
=
=
=
=
=
=
=
61.081
204.627
-208.306
134.177
-136.589
265.708
-147.225
195.258
-75.508
STAY PLATE :
Sm = [ P * h / 2 * t4 * U ] * [ ( 6 + K * ( 11 (ST) = Sm
=
=

t5 = [ H * { ( CF * Z * P ) / S * E } 1/2 ] + C
S = [ ( H2 * CF * Z * P ) / { ( t5 - C )2 * E ) } ]
mm
mm
mm
mm
mm
mm
mm
mm3
mm3
mm
mm
mm
mm
MPa
MPa
ALLOWABLE
STRESS,MPa
33.156
235.80
-94.810
158.075
-61.654
353.70
191.231
353.70
=
=
=
=
=
)/(3+5*K)]
MPa
C
MPa
mm
mm
mm
mm
mm
mm
mm
MPa
TOP / BOTTOM PLATE

Sm = [ P * h / 2 * t1 * E ] * [ 3 - { ( 6 + K * ( 11 - 2 ) / ( 3 + 5 * K ) } ]
(Sb)N = [P * c1 / 24 * I1 * E] * [-3 * H2 + 2 * h2 * {(3 + 5 * 2 * K) / (3 + 5 *K)} ]
(Sb)Q = [ P * h2 * c1 / 12 * I1 * E ] * [ ( 3 + 5 * 2 * K ) / ( 3 + 5 * K ) ]
(ST)N = Sm + (Sb)N
(ST)Q = Sm + (Sb)Q
UNITS
% ALLOWABLE
SO, SAFE
SO, SAFE
SO, SAFE
235.80
SO, SAFE
353.70
353.70
353.70
353.70
SO, SAFE
SO, SAFE
SO, SAFE
SO, SAFE
158.335
158.335
235.80
SO, SAFE
144.388
235.80
SO, SAFE
Page No:
Date:
Revision:
Document No:
47
of
04.06.14
3
C5437-HC
Tag No:
50
HE1
RETURN HEADER - STRESS DURING HYDROTEST CONDITION AS PER U-2(g)

P
T
Sy
H'
h'
t1'
t2'
t4'
t5
C
U
E
D'
CF

= ALLOWABLE YIELD STRESS AT ROOM TEMP.- PLATE
CALCULATIONS :
h = h' + ( 2 * C )
H = H' + ( 2 * C )
t1 = ( t1' - C )
t2 = ( t2' - C )
t4 = ( t4' - 2 * C )
D = ( D' + 2 * C )
l1 = ( t1 )3 / 12
l2 = ( t2 )3 / 12
Z = MIN ( 2.5, {3.4 - ( 2.4 * H ) / D } AS PER UG-34 (c) (3)
Sa (m) = ALLOWBALE STRESS FOR MEMBRANE STRESS = 0.9 * Sy
Sa (T) = ALLOWBALE STRESS FOR TOTAL STRESS = 1.5 * ( 0.9 * Sy )
VALUE
=
=
=
=
=
=
=
=
=
=
=
=
=
=
15.350
17.000
262.000
100.000
97.000
28.000
30.000
20.000
28.000
3.175
0.672
1.000
332.000
0.200
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
103.350
106.350
1.029
24.825
26.825
13.650
338.350
1274.931
1608.563
1.298
0.594
0.545
0.531
2.500
12.413
13.413
13.293
-13.532
235.80
353.70
PLUG SHEET :
Sm = ( P * H ) / ( 2 * t2 * em )
(Sb)Mi = [ P * h2 * c2i / 12 * I2 * eb ] * [ { 3 + K * ( 6 - 2 ) } / ( 3 + 5 * K ) ]
(Sb)Mo = [ P * h2 * c2o / 12 * I2 * eb ] * [ { 3 + K * ( 6 - 2 ) } / ( 3 + 5 * K ) ]
(Sb)Qi = [ P * h2 * c2i / 12 * I2 ] * [ ( 3 + 5 * 2 * K) / ( 3 + 5 * K ) ]
(Sb)Qo = [ P * h2 * c2o / 12 * I2 ] * [ ( 3 + 5 * 2 * K) / ( 3 + 5 * K ) ]
=
=
=
=
=
=
=
=
=
55.832
210.926
-214.718
117.454
-119.565
266.758
-158.886
173.286
-63.733
STAY PLATE :
Sm = [ P * h / 2 * t4 * U ] * [ ( 6 + K * ( 11 (ST) = Sm
=
=

t5 = [ H * { ( CF * Z * P ) / S * E } 1/2 ] + C
S = [ ( H2 * CF * Z * P ) / { ( t5 - C )2 * E ) } ]
mm
mm
mm
mm
mm
mm
mm
mm3
mm3
mm
mm
mm
mm
MPa
MPa
ALLOWABLE
% ALLOWABLE
STRESS,MPa
SO, SAFE
32.209
235.80
-72.910
138.374
SO, SAFE
-40.701
353.70
SO, SAFE
170.583
353.70
=
=
=
=
=
)/(3+5*K)]
MPa
C
MPa
mm
mm
mm
mm
mm
mm
mm
MPa
TOP / BOTTOM PLATE

Sm = [ P * h / 2 * t1 * E ] * [ 3 - { ( 6 + K * ( 11 - 2 ) / ( 3 + 5 * K ) } ]
(Sb)N = [P * c1 / 24 * I1 * E] * [-3 * H2 + 2 * h2 * {(3 + 5 * 2 * K) / (3 + 5 *K)} ]
(Sb)Q = [ P * h2 * c1 / 12 * I1 * E ] * [ ( 3 + 5 * 2 * K ) / ( 3 + 5 * K ) ]
(ST)N = Sm + (Sb)N
(ST)Q = Sm + (Sb)Q
UNITS
235.80
SO, SAFE
353.70
353.70
353.70
353.70
SO, SAFE
SO, SAFE
SO, SAFE
SO, SAFE
172.259
172.259
235.80
SO, SAFE
140.856
235.80
SO, SAFE
Page No:
48
Date:
of
Revision:
Document No:
Tag No:
C5437-HC
HE1
TUBE ,NOZZLE & FLANGES - STRESS DURING HYDROSTATIC TEST AS PER U-2(g)
VALUE
P
T
C
MOCt
Syt
Rot
tt
MOCn1
Sytn1
Ron1
tn1
MOCn2
Sytn2
Ron2
tn2
E
Syt
Syn1
Syn2

= ALLOWABLE YEILD STRESS AT ROOM TEMPERATURE- TUBE
= THICKNESS OF TUBE
= ALLOWABLE YEILD STRESS AT ROOM TEMPERATURE- NOZZLE
= MATERIAL OF CONSTRUCTION FOR NOZZLE -D - V
= ALLOWABLE YEILD STRESS AT ROOM TEMPERATURE- NOZZLE
= JOINT EFFICIENCY - NOZZLE & TUBE
= ALLOWABLE STRESS AT ROOM TEMPERATURE- TUBE = 0.9 * Syt
= ALLOWABLE STRESS AT ROOM TEMPERATURE- NOZZLE = 0.9 * Syn1
= ALLOWABLE STRESS AT ROOM TEMPERATURE- NOZZLE = 0.9 * Syn2
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
UNIT
15.350 MPa (g)

17.000 C
3.175 mm
SA-179
179.000 MPa
12.700 mm
2.110 mm
SA-234 Gr.WPB
241.000 MPa
109.550 mm
20.134 mm
SA-182 Gr.F316
207.000
28.500 mm
11.800 mm
1.000
161.100
216.900
186.300
MPa
ALLOWABLE
STRES,MPa
86.251
161.100
SO, SAFE
A) NOZZLE N1 - N4
S = [ P * { Ron1 - 0.4 * ( tn1 - C ) } ] / [ E * ( tn1 - C ) ]
93.016
216.900
SO, SAFE
B) NOZZLE D - V
S = [ P * { Ron2 - 0.4 * ( tn2 - C ) } ] / [ E * ( tn2 - C ) ]
44.582
186.300
SO, SAFE
15.350
t = ( P * Ro ) / ( S * E + 0.4 * P )
S = [ P * { Rot - 0.4 * ( tt ) } ] / [ E * ( tt ) ]
t = ( P * Ro ) / ( S * E + 0.4 * P )

FOR # 900 RATING
PERMITTED MAWP w.r.t ROOM TEMP.
(1.5 TIMES MAWP AT ROOM TEMP. AS PER CLAUSE 2.6)
50
04.06.14
22.980
SO, SAFE
Page No:
49
Revision:
NOZZLE LOAD CALCULATION INPUT DATA
CORROSION ALLOWANCE.
PIPE UNDER TOLERANCE
WELD FILLET SIZE
INSIDE WIDTH OF HEADER
DISTANCE FROM PLATE TO FORCE LINE OF ACTION
L = INSIDE WIDTH OF NOZZLE
Ta = THINNING ALLOWANCE
C=
Ut =
Dhalf weld =
DH =
Dh =
NOZZLE LOADING DATA :

N = SAFETY MULTIFICATION FACTOR
AS PER API
Mx =
My =
Mz =
Fx =
Fy =
Fz =
=
=
=
=
DN 200
SA-234 Gr.WPB
NOZZLE HEADER
N1 - N4
10.205 MPa (g)
138.000 MPa
219.100 mm
23.021 mm
=
=
3.175 mm
12.50%
=
=
=
=
=
9
110
322
173.058
0
=
=
=
=
=
=
3050
6100
2240
5690
13340
8010
mm
mm
mm
mm
mm
MANUAL ENTRY
3050
6100
2240
5690
13340
8010
STRESSES :
Sts = EXISTING STRESS IN TUBESHEET ( = (ST)Q , REFER PAGE : )
Sps = EXISTING STRESS IN PLUGSHEET ( = (ST)Q1 , REFER PAGE : )
=
=
50
C5437-HC
HE1
Document No:
Tag No:
INPUT DATA :
NOZZLE SIZE
NOZZLE MATERIAL
NOZZLE LOCATION
NOZZLE MARK NO.
Dod = OUT SIDE DIA. OF NOZZLE
Wt = WALL THK. OF PIPE
of
04.06.14
Date:
N.m
N.m
N.m
N
N
N
127.263 MPa
-50.199 MPa
Page No:
50
of
50
04.06.14
Date:
Revision:
3
C5437-HC
HE1
Document No:
Tag No:
NOZZLE LOAD CALCULATION

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 ACCURATELY
CALCULATE THE RESULTING STRESS IS BY FEA
CALCULATION :
Did = INSIDE DIA. OF NOZZLE
Dwld = WELD THICKNESS = D half weld + Wt - Ta- C - Ut * Wt
Rwld = WELD RADIUS = 0.5 * DH + W t + D half weld
=
=
=
185.16325 mm
25.97 mm
87.02 mm
Dcnt = DISTANCE FROM WELD CENTRE TO NOZZLE CENTRE

= Di + 0.5 * D wld
2
2 1/2
DI = WELD LENGTH = 2 * ( Rwld - Di ) * (Di / Rwld ) + L - DH
=
=
71.16 mm
149.59 mm
Di = DIASTANCE FORM NOZZLE CENTER TO WELD INTERNAL

= 0.5 * DH + C
Aeff = TOTAL EFFECTIVE WELD AREA = 2 * ( Dwld * DI)
=
=
58.18 mm
2
7769.07 mm
DESIGN LOADS
Mt = TENSILE MOMENT = My
Mb =
Ft =
Fh =
Mbt =
BENDING MOMENT (due to moments), Mb = ( Mx2 + Mz2 )1/2

TENSILE FORCE, = Fy
SHEAR FORCE = ( Fx2 + Fz2 ) 1/2
TOTAL BENDING MOMENT , Mbt = Mb+ Fh*Dh
=
=
=
=
=
6100 N.m
3784.1908
13340
9825.2837
6947.9322
N.m
N.m
N.m
N.m
EFFECTIVE SECTION PROPERTIES

=
4
3.98E+07 mm
3
4.73E+05 mm
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 )
3
2
Iyy = 2 *( ( Dwld * Dl ) / 12 + Dcnt * Aeff / 2)
Zyy = Iyy / (Dwld + Di)

STRESS CALCULATION
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

Mechanical design calculations for air cooler header box

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MECHANICAL DESIGN CALCULATIONS

: COMPRESSOR GAS STATION CC3

: GAS COMPRESSOR AIR COOLER

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

JORD INTERNATIONAL PTY LTD

ABN 42 102 636 215

Main Office: 38 Oxley Street, St Leonards, NSW, Australia 2065

JORD INTERNATIONAL PTE LTD

LATEST REV. STATUS

LATEST APPLICABLE REVISION STATUS OF ENTIRE DOCUMENT

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

EVALUATION OF MATERIALS AS PER APPENDIX 13-3, UCS-23 & UHA23

EVALUATION OF JOINT & LIGAMENT EFFICIENCY AS PER APPENDIX

THICKNESS EVALUATION OF TOP & BOTTOM PLATE OF NOZZLE

THK. EVALUATION OF TUBE SHEET OF NOZZLE HEADER AS PER

THK. EVALUATION OF PLUG SHEET OF NOZZLE HEADER AS PER

THICKNESS EVALUATION OF STAY PLATE & END PLATE OF NOZZLE

THICKNESS EVALUATION OF TOP & BOTTOM PLATE OF RETURN

THK. EVALUATION OF TUBE SHEET OF RETURN HEADER AS PER

THK. EVALUATION OF PLUG SHEET OF RETURN HEADER AS PER

THICKNESS EVALUATION OF STAY PLATE & END PLATE OF RETURN

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

NOZZLE THICKNESS CALCULATION AS PER UG-45

REINFORCEMENT REQUIREMENT FOR NOZZLE AS PER

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

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

FLANGE RATING CHECK AS PER ASME B16.5-2013

INSPECTION OPENING AS PER UG-46.

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

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

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

POST FORMING HEAT TREATMENT REQUIREMENT AS PER UG-79,

FULL RADIOGRAPHY REQUIREMENT AS PER UW-11

MAWP (HOT & CORRODED) CALCULATION FOR NOZZLE HEADER ,

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

LATEST REV. STATUS

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

NOZZLE HEADER, RETURN HEADER - STRESS DURING

TUBE,NOZZLE & FLANGES - STRESS DURING HYDROSTATIC TEST

NOZZLE LOAD CALCULATION U-2(g)

LATEST APPLICABLE REVISION STATUS OF ENTIRE DOCUMENT

REVISED SHEET NO.

1-5, 7, 14, 15,21 ,24, 28,

18 mm PLATE REVISED TO 20 mm &

LATEST APPLICABLE DRAWINGS / DOCUMENTS

APPLICABLE STANDARDS & REFERENCES

DESIGN & MANUFACTURING CODE

ASME BOILER & PRESSURE VESSEL

DESIGN PRESSURE INCLUDING STATIC HEIGHT INTERNAL / EXTERNAL

-1.11 @ 11.8MPa (g)

OPERATING PRESSURE - INTERNAL

OPERATING TEMPERATURE - INLET / OUTLET

HYDROSTATIC TEST PRESSURE AT TOP

POST WELD HEAT TREATMENT (PWHT)

REFER APPENDIX 13 FOOT NOTE-1 FOR JOINT EFFICIENCY

APPLICABLE LOADINGS AS PER UG - 22

SINCE HEADER BOX IS BEING SUPPORTED IN STRUCTURE, STRUCTURE SHALL TAKE

NO IMPACT REACTIONS ARE ANTICIPATED IN OPERATION.

DIFFERENTIAL THERMAL EXPANSION HAS BEEN TAKEN INTO ACCOUNT BY MEANS OF

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

MAXIMUM STATIC HEIGHT / PRESSURE

= [ (1/12) * {(b0T03) + (b1T13) + (b2 * T23)} ] + [ (b0T0) {(T0/2) + T1 + T2 - X }2 ]