GETABEC Public Company Limited

609 Moo 17, Bangplee Industrial Estate, Bangsaotong,

Bangsaotong, Samutprakarn 10540, THAILAND

COMPRESS Pressure Vessel Design Calculations

Item: Heat exchanger

Customer: -
Revision:
Designer: Getabec
Date: Thursday, Jun 14, 2019
Project:
 Table of Contents
Nozzle Schedule........................................................................................................................................................1/12

Nozzle Summary.......................................................................................................................................................2/12

Thickness Summary.................................................................................................................................................3/12

Weight Summary.......................................................................................................................................................4/12

Tube Bundle Design.................................................................................................................................................5/12

Pressure Summary...................................................................................................................................................7/12

Hydrostatic Test........................................................................................................................................................9/12

Bill of Materials........................................................................................................................................................11/12

i
 Nozzle Schedule

Specifications

Nozzle Impact
Identifier Size Materials Normalized Fine Grain Flange Blind
mark Tested

NPS 2 Class 150

N1 Water Inlet NPS 2 Sch 40S (Std) DN 50 Nozzle SA-312 TP304 Wld pipe No No No No
WN A182 F304

NPS 2 Class 150

N2 Water Outlet NPS 2 Sch 40S (Std) DN 50 Nozzle SA-312 TP304 Wld pipe No No No No
WN A182 F304

NPS 2 Class 150

N3 Steam Inlet NPS 2 Sch 40S (Std) DN 50 Nozzle SA-312 TP304 Wld pipe No No No No
WN A182 F304

NPS 2 Class 150

N4 Steam Outlet NPS 2 Sch 40S (Std) DN 50 Nozzle SA-312 TP304 Wld pipe No No No No
WN A182 F304

NPS 2 Class 150

N5 Spare NPS 2 Sch 40S (Std) DN 50 Nozzle SA-312 TP304 Wld pipe No No No No
WN A182 F304

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 Nozzle Summary

Dimensions

Reinforcement
Shell
Nozzle OD tn Req tn Pad Corr Aa/Ar
A1? A2?
mark (mm) (mm) (mm) (mm) (%)
Nom t Design t User t Width tpad
(mm) (mm) (mm) (mm) (mm)

N1 60.33 3.91 3.13 Yes Yes 8 N/A N/A N/A 0 Exempt

N2 60.33 3.91 3.13 Yes Yes 8 N/A N/A N/A 0 Exempt

N3 60.33 3.91 3.13 Yes Yes 8 N/A N/A N/A 0 Exempt

N4 60.33 3.91 3.13 Yes Yes 8 N/A N/A N/A 0 Exempt

N5 60.33 3.91 3.13 Yes Yes 8 N/A N/A N/A 0 Exempt

Definitions

tn Nozzle thickness

Nozzle thickness required per UG-45/UG-16

Req tn
Increased for pipe to account for 12.5% pipe thickness tolerance

Nom t Vessel wall thickness

Design t Required vessel wall thickness due to pressure + corrosion allowance per UG-37

User t Local vessel wall thickness (near opening)

Aa Area available per UG-37, governing condition

Ar Area required per UG-37, governing condition

Corr Corrosion allowance on nozzle wall

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 Thickness Summary

Component Data

Component Material Diameter Length Nominal t Design t Total Corrosion Joint Load
Identifier (mm) (mm) (mm) (mm) (mm) E

Front Head SA-240 304 394.4 ID 105 6.4* 0.49 0 1.00 Internal

Straight Flange on Front Head SA-240 304 394.4 ID 50 8 0.49 0 1.00 Internal

Front Channel SA-240 304 394.4 ID 400 8 0.49 0 1.00 Internal

Tubesheet SA-240 304 580 OD 30 30 29.89 0 1.00 Unknown

Tubes SA-213 TP304 Smls tube 19.05 OD 2,000 2.11 0.4 0 1.00 External

Shell #1 SA-240 304 394.4 ID 2,300 8 1.63 0 1.00 Internal

Straight Flange on Rear Shell Head SA-240 304 394.4 ID 50 8 1.63 0 1.00 Internal

Rear Shell Head SA-240 304 394.4 ID 105 6.4* 1.62 0 1.00 Internal

*Head minimum thickness after forming

Definitions

Nominal t Vessel wall nominal thickness

Design t Required vessel thickness due to governing loading + corrosion

Joint E Longitudinal seam joint efficiency

Load

Internal Circumferential stress due to internal pressure governs

External External pressure governs

Combined longitudinal stress of pressure + weight + wind

Wind
governs

Combined longitudinal stress of pressure + weight + seismic

Seismic
governs

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 Weight Summary

Weight (kg) Contributed by Vessel Elements

Operating
Metal Metal Insulation Piping Test Liquid Surface Area
Component Insulation Lining Liquid
New* Corroded Supports + Liquid m2
New Corroded New Corroded
Front Head 13.6 13.6 0 0 0 0 0 0 14.1 14.1 0.26
Front Channel 32.1 32.1 0 0 0 0 0 0 67 67 0.51
Tubesheet 38.3 38.3 0 0 0 0 0 0 0 0 0.05
Shell #1 186.2 186.2 0 0 0 0 0 0 260.9 260.9 2.96
Tubes 122.5 122.5 0 0 0 0 0 0 23.5 23.5 N/A
Rear Shell Head 13.6 13.6 0 0 0 0 0 0 14.1 14.1 0.26
Saddle 37.2 37.2 0 0 0 0 0 0 0 0 1.13
TOTAL: 443.6 443.6 0 0 0 0 0 0 379.6 379.6 5.18
*Shells with attached nozzles have weight reduced by material cut out for opening.

Weight (kg) Contributed by Attachments

Nozzles & Trays
Body Flanges Packed Tray Rings & Vertical Surface Area
Component Flanges Baffles
Beds Supports Clips Loads m2
Pass Partitions
New Corroded New Corroded
Front Head 0 0 0 0 0 0 0 0 0 0
Front Channel 54.8 54.8 6.5 6.5 0 0 0 0 0 0.35
Tubesheet 0 0 0 0 0 22.2 0 0 0 0
Shell #1 54.8 54.8 9.8 9.8 0 20.5¹ 0 0 0 0.41
Rear Shell Head 0 0 0 0 0 0 0 0 0 0
TOTAL: 109.5 109.5 16.3 16.3 0 42.7 0 0 0 0.77
¹Baffle weights are approximated.

Vessel Totals

New Corroded

Operating Weight (kg) 612 612

Empty Weight (kg) 612 612
Test Weight (kg) 992 992
Surface Area (m 2) 5.95 -
Shell side capacity** (liters) 275 275
Tube side capacity** (liters) 104 104
**The shell and tube capacity does not include
volume of nozzle, piping or other attachments.

Vessel Lift Condition

Vessel Lift Weight, New (kg) 612
Center of Gravity from Datum (mm) 1,717.58

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Tube Bundle Design

U-Tube Layout
Horizontal ribbon

Layout
First pass: top

Tube OD 19.05 mm
Pitch 30.48 mm
Pattern Triangular (30°)
X = 30.48 mm

Pattern Dimensions
Y = 52.79 mm

5/12
 Outer Tube Limit
Shell ID 394.4 mm
Design OTL 320 mm
Actual OTL 311 mm (+9 mm)

Tubes Per Pass - 64 Tubes Total

Pass # Tube Count Mean Tube Count % Deviation from Mean
1 32 32 0.00%
2 32 32 0.00%

Shell and Tube Areas

Total Shell Area 0.12 m2
Each Tube Area 285.0230 mm2
Total Tubes 64
Total Tubes Area 0.02 m2
Total Shell Area - Total Tubes Area - Total Tie Rods Area - Total Dummy Tubes Area
Net Free Area
0.12 - 0.02 - 0.00 - 0.00
0.1 m2

Baffle Window Areas

Baffle Cut 24.24% of Shell ID
Baffle Cut Distance from Center 101.6 mm
Baffle Window Area 0.02 m2
Number of Tubes in Baffle Window top = 5, bottom = 5
Baffle Window Tubes Area top = 0 m2, bottom = 0 m2
Window Area - Tubes Area
Baffle Free Area
top = 0.02 m2, bottom = 0.02 m2
Baffle Free Area / Net Free Area
% of Net Free Area
top = 20.63%, bottom = 20.63%

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 Pressure Summary

Component Summary for Tube side chamber

P T T
MAWP MAP MAEP e MDMT MDMT Impact
Identifier Design Design external
(bar) (bar) (bar) (°C) Exemption Tested
(bar) (°C) (°C)

Front Head 3 250 39.47 44.64 N/A 250 -196 Note 1 No

Straight Flange on Front Head 3 250 48.32 54.65 N/A 250 -196 Note 2 No

Front Channel 3 250 48.32 54.65 N/A 250 -196 Note 2 No

Tubesheet 3 250 10.09 11.41 10.09 250 -196 Note 3 No

Tubes 3 250 256.11 289.7 88.01 250 -196 Note 4 No

Tube Side Flange (front) 3 250 28.97 10.34 N/A 250 -48 Note 5 No

Tube Side Flange (front) - Flange Hub 3 250 72.7 82.24 N/A 250 -196 Note 6 No

Water Inlet (N1) 3 250 12.1 19 N/A 250 -196 Note 7 No

Water Outlet (N2) 3 250 12.1 19 N/A 250 -196 Note 7 No

Chamber Summary for Tube side chamber

Design MDMT 0 °C

Rated MDMT -48 °C @ 10.09 bar

MAWP hot & corroded 10.09 bar @ 250 °C

MAP cold & new 10.34 bar @ 21.11 °C

(1) This pressure chamber is not designed for

external pressure.

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 Component Summary for Shell side chamber

P T T
MAWP MAP MAEP e MDMT MDMT Impact
Identifier Design Design external
(bar) (bar) (bar) (°C) Exemption Tested
(bar) (°C) (°C)

Tubesheet 10 250 10.09 11.41 10.09 250 -196 Note 3 No

Shell #1 10 250 48.32 54.65 N/A 250 -196 Note 2 No

Straight Flange on Rear Shell Head 10 250 48.32 54.65 N/A 250 -196 Note 2 No

Rear Shell Head 10 250 39.47 44.64 N/A 250 -196 Note 8 No

Tubes 10 250 88.01 88.01 256.11 250 N/A N/A No

Saddle 10 250 10.09 N/A N/A N/A N/A N/A N/A

Shell Side Flange (front) 10 250 28.97 10.34 N/A 250 -48 Note 5 No

Shell Side Flange (front) - Flange Hub 10 250 72.7 82.24 N/A 250 -196 Note 6 No

Steam Inlet (N3) 10 250 12.1 19 N/A 250 -196 Note 7 No

Steam Outlet (N4) 10 250 12.1 19 N/A 250 -196 Note 7 No

Spare (N5) 10 250 12.1 19 N/A 250 -196 Note 7 No

Chamber Summary for Shell side chamber

Design MDMT 0 °C

Rated MDMT -48 °C @ 10.09 bar

MAWP hot & corroded 10.09 bar @ 250 °C

MAP cold & new 10.34 bar @ 21.11 °C

(1) This pressure chamber is not designed for

external pressure.

Notes for MDMT Rating

Note # Exemption Details

1. Straight Flange governs MDMT

2. Impact test exempt per UHA-51(g) (coincident ratio = 0.181)

3. Rated MDMT per UHA-51(d)(1)(a), (carbon content does not exceed 0.10%) = -196°C

4. Impact test exempt per UHA-51(g) (coincident ratio = 0.0376)

5. Flange Rated MDMT per UHA-51(d)(1)(a), (carbon content does not exceed 0.10%) = -196°C Bolts rated MDMT per Fig UCS-66 note (c) = -48°C

6. Impact test exempt per UHA-51(g) (coincident ratio = 0.1188)

7. Impact test exempt per UHA-51(g) (coincident ratio = 0.0665)

8. Straight Flange governs MDMT

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 Hydrostatic Test

Horizontal shop hydrostatic test based on MAWP per UG-99(b) for Tube side chamber

Gauge pressure at 21.11°C = 1.3*MAWP*LSR

= 1.3*10.09*1.1311
= 14.83 bar

Horizontal shop hydrostatic test

Local test Test liquid UG-99(b) UG-99(b)
Identifier pressure static head stress pressure
(bar) (bar) ratio factor
Front Head (1) 14.89 0.05 1.1311 1.30

Straight Flange on Front Head 14.89 0.05 1.1311 1.30

Front Channel 14.89 0.05 1.1311 1.30

Tubes 14.88 0.05 1.1311 1.30

Tube Side Flange (front) - Flange Hub 14.89 0.05 1.1311 1.30

Tube Side Flange (front) 14.89 0.05 1.1311 1.30

Tubesheet 14.89 0.05 1.1311 1.30

Water Inlet (N1) 14.85 0.01 1.1359 1.30

Water Outlet (N2) 14.9 0.07 1.1359 1.30

(1) Front Head limits the UG-99(b) stress ratio.

(2) The zero degree angular position is assumed to be up, and the test liquid
height is assumed to the top-most flange.

The field test condition has not been investigated for the Tube side chamber.

Horizontal shop hydrostatic test based on MAWP per UG-99(b) for Shell side chamber

Gauge pressure at 21.11°C = 1.3*MAWP*LSR

= 1.3*10.09*1.1311
= 14.83 bar

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 Horizontal shop hydrostatic test
Local test Test liquid UG-99(b) UG-99(b)
Identifier pressure static head stress pressure
(bar) (bar) ratio factor
Shell #1 (1) 14.89 0.05 1.1311 1.30

Straight Flange on Rear Shell Head 14.89 0.05 1.1311 1.30

Rear Shell Head 14.89 0.05 1.1311 1.30

Tubes 14.88 0.05 N/A 1.30

Shell Side Flange (front) - Flange Hub 14.89 0.05 1.1311 1.30

Tubesheet 14.89 0.05 1.1311 1.30

Shell Side Flange (front) 14.89 0.05 1.1311 1.30

Spare (N5) 14.85 0.01 1.1359 1.30

Steam Inlet (N3) 14.85 0.01 1.1359 1.30

Steam Outlet (N4) 14.9 0.07 1.1359 1.30

(1) Shell #1 limits the UG-99(b) stress ratio.

(2) The zero degree angular position is assumed to be up, and the test liquid
height is assumed to the top-most flange.

The field test condition has not been investigated for the Shell side chamber.

10/12
 Bill of Materials

Heads / Tubesheets

Item # Type Material Thk [mm] Dia. [mm] Wt. [kg] (ea.) Qty

H1 Ellipsoidal Head SA-240 304 6.4 (min.) 394.4 ID 13.6 2

H2 Tubesheet SA-240 304 (N, FGP) 30 580 OD 38.3 1

Shells / Tubes

Item # Type Material Thk [mm] Dia. [mm] Length [mm] Wt. [kg] (ea.) Qty

S1 Cylinder SA-240 304 8 394.4 ID 400 32.5 1

S2 Cylinder SA-240 304 8 394.4 ID 2,300 186.7 1

U-Tube1 Tube SA-213 TP304 Smls tube 2.11 19.05 4,251 3.8 32

U-Tube1 - Note: Tube length for U-Tube exchangers is approximated by using a mean bend radius. Quantity is the
complete number of "U"s.

Nozzles

Item # Type Material NPS Thk [mm] Dia. [mm] Length [mm] Wt. [kg]

Noz1 Nozzle SA-312 TP304 Wld pipe NPS 2 Sch 40S (Std) DN 50 3.91 60.33 OD 484 2.7

Flanges

Item # Type Material NPS Dia. [mm] Wt. [kg] (ea.) Qty

AF1 ASME B16.5 Welding Neck - Class 150 A182 F304 2.0 152.4 x 52.58 2.7 5

CF1 Weld neck integral SA-240 304 - 580 x 411 54.8 2

Gaskets

Item # Type Size [mm] Thk [mm] Qty

G1 Self-energizing (Flat Nonmetallic) 490 x 411 4.44 2

There are 5 flanges that do not include gasket information.

Fasteners

Item # Description Material Length [mm] Qty

FB1 1" series 8 bolt SA-193 B7 Bolt <= 64 171 16

FB2 5/8" coarse bolt SA-193 B8 1 Bolt 70 20

SB1 1" series 8 bolt SA-193 B8 - 8

All listed flange bolts require associated nuts and washers in accordance with Division 1, UCS-11.

11/12
 Plates

Item # Material Thk [mm] Wt. [kg] Qty [ m²]

Plate1 A36 8 17.3 0.28

Plate1 - Note: Applies to saddle wear plate, saddle base plate

Plate2 A36 6 12.2 0.26

Plate2 - Note: Applies to saddle web plate

Plate3 A36 6.35 7.2 0.1449

Plate3 - Note: Applies to saddle rib plate

Plate4 SA-204 304 8 20.5 0.33

Plate4 - Note: Applies to baffle plates

Plate5 SA-240 304 12.7 22.2 0.218

Plate5 - Note: Applies to pass partition plates

Notes

Note # Note

1. Tubesheet attachements including Tie Rods, Skid Bars, Seal Bars, and Dummy Tubes, are not included in the Bill of Materials.

12/12