11 HEATING COIL Reff.

Pressure Vessel Manual,procedure 6-8 & ASME

Heater Sketch as per Data sheet

Coil Development Length 436 m

4 group coils each group 109 m
Average Pipe Length 12 m
Total pipes 36 pipe
Heater w,t 15,816 kg
Pipe supportes approx. 7000 kg
Total w,t 22,816 kg
 ` Product
Product in

1.0
Stem in

Condensate
Steam Coil Data
1.1 Operating Pressure 4 ata
1.2 Pressure at inlet of Coil heater 4 ata
1.3 Steam temp.at design pressure of coil 168 0
C

1.4 Design Pressure 4 ata

1.5 Latent heat at inlet pressure,hfg 509.43 Kcal/kg ( Note-1)
2 Asphalt Data
2.1 type FUEL OIL
2.2 Density at low temp. ,D1 950 kg/m3
2.3 Specific Heat ,Cp1H 0.48 K cal/Kg 0C ( Note-2)
2.4 initial Temp., (Minim.Ambient Air Temp.),,T1 5 0
C
2.5 Final Temp.(Fuell Temp.to be maintained) ,T2H 110 0
C
2.6 Average Temp. ...,Tav = (T1+T2H) / 2 57.5 0
C
3 Tank insulation Material
3.1 Type LRB Mineral Wool (IS8183)
3.2 Density of the material 100 kg/m3
3.3 Cladding Material Aluminium ,22 SWG
4 Process Requirment Data
4.1 Volume of Liquid to be Heated ,V 2219.65 m3
4.2 Heating time ,Ht 72 hr ( Note-3)
4.3 Mass of Liquid to be Heated ,M1H =V*D1 2,108,668 m3
5 Heat Thermal Load Calculations
5.1 Temp. difference during intial heating of Fuel ,Dt =T2H- T1 105 0
C
5.2 Heat Load For intial Heating of Product,Q1=M1H*Cp1H*D 1476067.25 Kcal/hr
6 Heat Loss through Tank Shell ,Bottom, Roof During Intial Stage
6.1 Heat Loss through Tank Shell for Product if Tank Fully insulated
a Tank , D(Tank inner Dia.) 16 m
b Tank , h(Tank height ) 12 m
c Average thickness of tank shell without insulation t s 7 mm
d Average thickness insulation , t in 40 mm
e Outer Dia.of Tank shell without Insulation, Ds 16.0140 m
f Outer Diameter Of Insulation ,Din 16.0940 m
g Thermal conductivity of insulation ,Ki 0.043 W/cm 0C ( Note-4)
H Thermal conductivity of insulation ,Ki 0.0369800 kcal/hr m 0C
I Film Co-efficient, (Refer calc. at end),f 6.1774 kcal/hr m2 0C
J Average Temp.difference during intial heating of Fuel
K ∆Tav.= T2H-Tav. 52.5 0
C
L Rate of heat Loss through Tank Shell,QL
M qL =∆Tav./ [ ( Ds /2ki) * ln (Din/Ds) + (Ds/ f * Din) ] 42.3370870445144 kcal/hr m2 ( Note-5)
N Shell surface area ,As 603.713577055043 m2
S Heat Loss through Tank Shell ,Q2 =(qL*As) 25559.4742617345 kcal/hr
6.2 Heat Loss through Roof of Tank (insulated)
a Insulation Thickness Considered ,tr 40 mm
b Thermal Conductivity of the insulation,Ki 0.0369800 kcal/hr m 0C
c Film Co-efficient,(Refer
f calc. at end) 6.1774 kcal/hr m2 0C
d Average Temp.for heat loss during intial heating , Tav. 57.5 0C
e Average Temp.difference during intial heating of Fuel
f ∆Tav.= T2H-Tav. 52.5 0C
 g Rate of heat loss through Roof ,q r=∆Tav/[ (tr/ki)+(1/f)] 42.2180128201183 kcal/hr m2
g Roof Diameter ,RD ( Development) 16.08 m
h Surface area of Roof ,Ar 203.07757567629 m2
i Heat Loss through roof QLr =qr*Ar 8573.53169338015 Kcal/hr
7 Heat Loss through Bottom of Tank
a Surface area of Bottom of Tank,Ab 201.061929829747 m2
b Theraml Conductivity of Sand ,Ks 1 W/Mk
c Theraml Conductivity of Sand ,Ks 0.85999999828 kcal/hr m 0C
d Average temp.difference during initial heating of Fuel ,
e ∆Tav.= T2H-Tav. 52.5 0C
f Depth of sand bed ,X 1m
j Heat Loss Through Bottom Plates ,QB=(Ab*Ks* ∆Tav.) / X 9077.94611365718 kcal/hr
8 Heat Loss through Tank shell&Bottom&Roof During Shutt down /Manintenance (insulated)
a Tank inner Diameter ,Di 16 m
b Tank outer Diameter without insulation,Do 16.014 m
c Tank outer Diameter with insulation ,Doi 16.094 m
d Height of Tank shell ,h 12 m
e Thermal Conductivity of insualtion ,Ki 0.0369800 kcal/hr m 0C ( Note-6)
f Film Co-efficient .f (Refer calc.at end) 6.1774 kcal/hr m2 0C
g Temp.diff. During Maintenance /Shutt down , ∆T=T2H -T1 105 0C
h Rate of heat loss through Tank shell
j q m = ∆T /[ ( Do/2* Ki) * ln (Doi/Do) + (Do/Doi*f) ] 84.6741740890288 kcal/hr m2 ( Note-7)
k Shell surface Area ,As 603.449683272142 m2
l Heat Loss Through Tank Shell ,Qsm=As*qm 51096.6035353546 kcal/hr
9 Heat Loss through Roof of Tank (insulated)
a Insulation thickness Considered ,tir 40 mm
b Theraml Conductivity of the insulation ,Ki 0.0369800 kcal/hr m 0C
c Film Co-efficient .f (Refer calc.at end) 6.1774 kcal/hr m2 0C
d Temp.diff. During Maintenance /Shutt down , ∆T=T2H -T1 105 0C
e Rate of heat Loss through Roof during Main./shutdown,q r
f q r=∆T / [ ( tir / ki) + ( 1 / f) ] 84.4360256402365 kcal/hr m2
g Roof Diameter,Dr 16.08 m
h Surface area of Roof ,Ar 203.07757567629 m2
j Heat Loss through roof /Main./shutt down ,Q rfm =Ar *qr 17147.0633867603 kcal/hr
10 Heat Loss through Bottom Plates during Maintenance/Shutdown
a Surface area of Bottom Plates,Abm 201.061929829747 m2
b Theraml Conductivity of Sand ,Ks 0.85999999828 kcal/hr m 0C
c Temp.diff. During Maintenance /Shutt down , ∆T=T2H -T1 105 0
C
d Depth of sand bed ,X 1 m
e Heat Loss Through Btm Plates ,QBm=(Abm*Ks* ∆Tav.) / X 18155.8922273143 kcal/hr

11 HEAT REQUIRED PER HOUR TO HEAT TANK MATERIAL UP TO 110 0

C
a Product weight to be Heated ,M2 73460 kg
b Specific Heat of Product ,Cp2 0.502 kj /(kg 0c)
c Specific Heat of Product ,Cp2 0.12 kcal/(kg 0c)
d Temp.difference during intial heating ,∆T=T2H -T1 105 0
C
e Heating Time ,Ht 72 hr
f Heat req. for pumping in/out of asphalt Mass(M2) Qp=M 2Cp2∆T / Ht 12855.5 kcal / hr
12 TOTAL HEAT LOAD / HOUR
Intermittent heat load / Tank (for intial heating of Fuel
a Qint =Heat rate required forintial heating+Heat rate req.for product pumping(in/out)+Heat Loss
Qint= ( intermittent) = Q1+Q2+QLr+Qrf+Qp = 1532134 kcal / hr
Continous heat load /Tank(Temp.Maintenance for fuel) , Q cont
b
Q cont. = Qsm +Qrm+QBm 86399.5591494293 kcal / hr
13 HEAT TRANSFER AREA OF FLOOR COIL
a Pressure at inlet of Floor Coil Heater 4 ata
b Steam Temp.at Operating pressure,Ts 168 0C
c intial Product Temp.T1 5.9 0C
d Product final Temp. T2 60 0C
e Average Mean Temperature Difference ,AMTD =Ts-(T2+T1)/2 135.05 0C
Heat Transfer Coefficient (Steam Coil to Product),K 97 kcal/hr m2 0C
f
(Refer Spirax sarco Data book(Table24)
Heat Transfer area required for Floor coil Heater ,a h=Max(Qint ,Qcont.)/(AMTD*K)
116.96 m2
g
Considering 10% Margin in the surface area required 12 m2
Area of Coil He ACOIL 128.65 m2
14 TOTAL HEAT LOAD / HOUR
a LENGTH OF FLOOR COIL PIPE REQUIRED
b Provided pipe Size of coil heater
c Carbon steel Pipe : 3 in SCH 40 / ASTM A-106 GR B
d Pipe ND 89 mm
e Pipe Thk. 5 mm
f Pipe average Diameter 94 mm
h Pipe Surface area / m 0.2953 m 2/m
Coil Length = Coil Heater Area/ Pipe surface area 436 m
15 STEAM REQUIRMENTS
a Intermittent Steam requirement,Si =Intermittent Heat Load per hour /Latent heat of steam(Qnit./hfg)
b Si ( stea 3008 kg/hr
c Continous Steam requirement,Sc=Continous Heat Load per hour/Latent heat of Steam (Qcont./h fg)
d Sc ( stea 170 kg/hr
16 Calculation of Film Co-efficient
f (Covection ) =1.957*(TO.S.I-Ta.)0.25 *(2.57 V +1)0.5 5.72 W/m2.k
f (Radiation ) =5.7557*10 * E * (T
-8
O.S.I
-T )/(TO.S.I -Ta.)
4
a.
4
1.50 W/m2.k
where :
Ta. = Ambient air temp. 306 K
TO.S.I=Outside surafce temp.of insu. (considering Max.outside temp. as 60 0C 333 K
V =Average Wind speed 0.25 m/sec
E =Emissivity of finished surface 0.2
Film Co-efficient,f = Film co-efficient due to radiation+Fil co-efficent due to convection
f ,Film Co-effic 7.22 W/m2.k
f 6.18 kcal/hr.m2.0C

17 DESIGN CODE ASME B31.1 (PROCESS PIPING)

a PARA 304.1.2 STRAIGHT PIPE UNDER INTERNAL PRESSURE
Internal Pressure Design thickness Formula (3a) per ANSI B31.3 1999 Section304.1.2
Internal Design Pressure P 405.3 Kpag
Design Metal Temp. MDMT 295 °C
Outside Diameter of Pipe D 89 mm
Co-efficient From Table (3Y 0.4
Corrosion allowance Ca 1.5 mm
Joint Effeciency E 1
Pipe Material SA106 GR B 136823.3615 Kpag
Allowable Stress of Pipe S
Provided Thickness 5 mm
 Thickness as per Purchase Specification-12.5% Mill tolerance
12.5% oMr 0.1 " for rolled T 4.38 mm

t = PD / 2(SE + PY) 0.132 mm

tm= t + c 1.632 mm
Safe Design
DESIGN CODE ASME B31.3-ED. 1999- ADD.2000
PARA 304.2.3 MITER BENDS
Internal Pressure P 405.3 Kpag
Design Metal Temp.MDMT 295 °C
Outside Diameter of Pipe D 89 mm
Mean Radius r2 42 mm
Measured Miter Pipe WallTthk. 5.000 mm
Angle of Miter Cut q 18 °
Angle of Change in Directia 36 °
Corrodion Allowance Ca 1.5 mm
Joint Effeciency E 1
Miter Piece SA-516 GR 70
Allowable stress of Mite S 129680 Kpag
Effective Radius of Miter Bend
R1 =(A/Tan Ɵ )+(d/2) R1 121.44 mm
Where A=25
Procided bend Radius R1 200 MM
Radius of bend is grater than calculated
Design as per Para 304.2.3 (a) Multiple Miter Bends
The Maximum allowable internal pressure shall be the lesser value calculated
from equation (4a) and (4 q is < 22.5 °
Equation (4a)
Pm = SE (T-c) /r2 ( (T-c)/(T-c) + 0.643 tan q (r2(T-c))^0.5) Pm1 = 6269.3435754 kpag
Equation (4b)
Pm = SE (T-c) /r2 (R1-r2/R1-0.5r2) Pm2 = 21613.333333 kpag
Lesser of Equation (4a) & (4b) Pm = 6269.3435754 kpag

Pm>int.Pressure then Safe

18 STEAM HEATER COIL SPEC,S

COIL LENGTH 436 m

COIL PIPE ND 89 mm
PIPE SCH 40
FLG,S 150#WN#R.F
BEND RADIUS MI 200 mm
START UP STEA 3008 kg/hr
OPERATING STE 170 kg/hr
PIPE W,T/M 7.47 Kg
Coil w,t 3254 Kg
1) ROOF DESIGN
2) WIND LOAD
Wind Speed 180 kph V = 50 m/s
Height of Tank H = 16 m
Tank Diameter D = 18 m
H/D 0.87
Roof Structure Data:-
Roof structure is Rafter supported and consist of
conical Roof consist of first order rafter, . Roof connection for rafters are lateral
braces . Constraints and releases are
given at rafter ends and columns subjected to application. Design is checked based on allowable stress
design criteria (AISC-ASD).
Major design parameters for roof Structure are:
1. Deflection ratio
2. Bending stress
3. Utility ratio