01 Ma
01 Ma
01 Ma
P.O. Box 20678, Plot No. 105 & 95, New Industrial Area, Ajman, U.A.E.
Tel: 00971-6-7482504. Fax: 00971-6-7482506.
Email: dolheat@emirates.net.ae. Web: www.dolphinht.com
CONTENTS
SHEET NO. DESCRIPTION REV.A REV.B REV.C REV.D REV.E REV.F
1 COVER PAGE X X
2 CONTENTS X X
3 APPLICABLE CODES/STANDARD, UNIT OF MEASURMENT X X
4 MECHANICAL DESIGN DATA X X
5 APPLICABLE LOADS FOR DESIGN CALCULATION, EVALUATION OF MATERIALS X
6 EVALUATION OF INTERNAL DESIGN PRESSURE, CALCULATION OF TUBE BUNDLE HYDROTEST PRESSURE X
7 RADIOGRAPHY REQUIREMENT, JOINT EFFICIENCY FACTOR "E" X
8 POST FORMING / POST WELD HEAT TREATMENT REQUIREMENTS X
8-9 IMPACT TEST EXEMPTIONS/REQUIREMENTS, CALCULATION OF MDMT. X
10 REQUIREMENT OF INSPECTION OPENING, OVER PRESSURE PROTECTION CHECK, REQUIREMENT OF DRAIN X X
10 CALCULATION OF TUBE THICKNESS DUE TO INTERNAL DESIGN PRESSURE X
11 CALCULATIONS OF N1 NOZZLE NECK THICKNESS DUE TO INTERNAL DESIGN PRESSURE X
12 CALCULATIONS OF N2 NOZZLE NECK THICKNESS DUE TO INTERNAL DESIGN PRESSURE X
13 CALCULATIONS OF N3, N4 NOZZLE NECK THICKNESS DUE TO INTERNAL DESIGN PRESSURE X
14 NOZZLE REINFORCEMENT VERIFICATION (N3, N4) X
15 CALCULATIONS OF END PLATE THICKNESS DUE TO INTERNAL DESIGN PRESSURE X
16 FLANGE RATING, PLUGSHEET THREAD ENGAGEMENT LENGTH, HEX. HEADER PLUG TIGHTENING TORQUE X
17 PLUG AND PLUG SHEET THREAD STRENGTH CALCULATION BASED ON INTERNAL DESIGN PRESSURE X
18 TUBE TO TUBESHEET JOINT VERIFICATION X
19 WELD SIZE FOR TUBE SHEET/PLUG SHEET TO TOP/BOTTOM PLATE & END PLATE TO TOP&BOTTOM PLATE / TUBE&PLUG SHEET X
20 HYDRO TEST CHECK OF TUBES, NOZZLE NECK, END PLATE X X
21-40 HEADER BOX PLATE THICKNESS CALCULATION DUE TO INTERNAL DESIGN PRESSURE X
41-59 WELD DESIGN SUPPORTING CALCULATION FOR HEADER BOX X
60-78 HYDRO TEST CHECK OF HEADER BOX X X
79-138 FEA OF STATIONARY HEADER BOX FOR INTERNAL DESIGN PRESSURE, HYDRO TEST CHECK, VALIDATION REPORT X X
139-141 WEIGHT SUMMARY OF TUBE BUNDLE, TUBE BUNDLE INTERNAL VOLUME, LIFTING LUG CALCULATION X
DOLPHIN HEAT TRANSFER L. L. C.
P.O. Box 20678, Plot No. 105 & 95, New Industrial Area, Ajman, U.A.E.
Tel: 00971-6-7482504. Fax: 00971-6-7482506.
Email: dolheat@emirates.net.ae. Web: www.dolphinht.com
UNITS OF MEASUREMENT
SI UNITS AS PER ASME SECTION VIII-1, TABLE U-4-1 USED FOR CALCULATIONS.
WHERE,
CONCLUSION: - DESIGN PRESSURE SHALL BE THE HIGHEST PRESSURE “P” CALCULATED FOR THE ABOVE PART, LOCATED ON
TOP OF THE VESSEL. AS THERE IS CHANGE IN THE INTERNAL DESIGN PRESSURE DURING THE OPERATING CONDITION,
INCLUDING STATIC HEAD. THE “INTERNAL DESIGN PRESSURE- P’ (GIVEN BY CLIENT) + PRESSURE DUE TO STATIC HEAD” IS
CONSIDERED AS INTERNAL DESIGN PRESSURE- P.
4 NOZZLE NECK (SWAGE FITTING) SA106M Gr.B 0.345 118 118 1.0
LOWEST STRESS RATIO = 1.0
AS PER UG-99(b) (END NOTE.35)
HYDROSTATIC TEST (SHOP/ FIELD) PRESSURE = 1.3 x P x (Sa/S) = 1.3 x 0.345 x 1.0 = 0.4485 MPa ROUNDED TO 0.45 MPa
AS PER UG-99(h) BODY METAL TEMPERATURE DURING HYDRO TEST (RECOMMENDED) = 17 DEG C MINIMUM, AND 48 DEG C
MAXIMUM
AS PER UG-99 END NOTE.35, “THE MAXIMUM ALLOWABLE WORKING PRESSURE MAY BE ASSUMED TO BE THE SAME AS THE
DESIGN PRESSURE WHEN CALCULATIONS ARE NOT MADE TO DETERMINE THE MAXIMUM ALLOWABLE WORKING PRESSURE”.
HENCE, HERE IN THIS CASE DESIGN PRESSURE AND MAWP ARE TAKEN SAME.
DOLPHIN HEAT TRANSFER L. L. C.
P.O. Box 20678, Plot No. 105 & 95, New Industrial Area, Ajman, U.A.E.
Tel: 00971-6-7482504. Fax: 00971-6-7482506.
Email: dolheat@emirates.net.ae. Web: www.dolphinht.com
** AS PER TABLE UW-12 NOTE-5, THERE IS NO JOINT EFFICIENCY E IN THE DESIGN EQUATIONS OF THIS DIVISION FOR CATEGORY
C AND D CORNER JOINTS. WHEN NEEDED, A VALUE OF E NOT GREATER THAN 1.0 MAY BE USED.
# AS PER CODE RADIOGRAPHY NOT MANDATORY, HOWEVER IN ACCORDANCE WITH CLIENT REQUIREMENT, 100%
RADIOGRAPHY APPLICABLE FOR NOZZLE NECK TO NOZZLE FLANGE.
DOLPHIN HEAT TRANSFER L. L. C.
P.O. Box 20678, Plot No. 105 & 95, New Industrial Area, Ajman, U.A.E.
Tel: 00971-6-7482504. Fax: 00971-6-7482506.
Email: dolheat@emirates.net.ae. Web: www.dolphinht.com
POST FORMING / POST WELD HEAT TREATMENT REQUIREMENTS AS PER UW-2, UCS-56
POST WELD HEAT TREATMENT IS REQUIRED WHEN ANY OF THE FOLLOWING CONDITION APPLICABLE:
SR. APPLICABLE APPLICABLE
DESCRIPTION REMARKS
No. CODE CLAUSE YES / NO
1 UW-2(a) LETHAL SERVICE NO
UNFIRED STEAM BOILER WITH DESIGN
2 UW-2(c) NO
PRESSURE EXCEED 345 KPa
IF MDMT IS COOLER THAN -48 DEG C AND OUR VESSEL MDMT IS 0 DEG C &
3 UCS-68(b) THE COINCIDENT RATIO DEFINED IN FIG. NO MAXIMUM DESIGN
UCS-66.1M IS 0.35 OR GREATER TEMPERATURE IS 148.89 DEG C
MATERIAL OVER 38mm NORMAL
4 UCS-56 NO SEE TABLE BELOW
THICKNESS AS DEFINED IN UW-40(f)
FOR FIN FAN COOLER TUBE BUNDLE
WELDED JOINT MAX. EXEM.
DESCRIPTION MATERIAL APPLICABLE CLAUSE P.NO. / G.NO.
THICKNESS mm THK. mm
TUBESHEET TO TABLE UCS -56-1
SA 516 Gr 70N 1/2 12 38
TOP/BOTTOM/END PLATE NOTE (b)(2)
PLUGSHEET TO TABLE UCS -56-1
SA 516 Gr 70N 1/2 12 38
TOP/BOTTOM/END PLATE NOTE (b)(2)
FORGINGS (STANDARD TABLE UCS -56-1
SA 105M 1/2 15.09 38
FLANGES) NOTE (b)(2)
CONCLUSION:
a) SINCE WELDED JOINT THICKNESS IS < 38 mm, PWHT NOT REQUIRED AS PER CODE.
b) POST WELD HEAT TREATMENT IS ADOPTED FOR THE HEADER BOX ASSEMBLY OF THE VESSELS AS PER PARA 9.2.1 OF
API-661 7th Ed.2013 WHICH IS ALSO THE APPLICABLE STANDARD FOR THE PRESSURE VESSEL.
c) THERE IS A FORMED SWAGE NOZZLE NECK (i.e. NOZZLE MARK N1, N2). HOWEVER, THERE IS NO PROVISION IN THE
UG-79 TO CALCULATE THE POST FORMING FIBER ELONGATION. HENCE, NORMALIZING PERFORMED FOR THE SWAGE
NOZZLE NECK TO RELIEVE THE POST FORMING STRESS.
CONSIDERING ALL ABOVE, IT CAN BE CONCLUDED THAT WPQ (WELDING PROCEDURE QUALIFICATION) NEED NOT INCLUDE IMPACT TEST OF WELD AND HEAT AFFECTED ZONE (HAZ)
MADE IN ACCORDANCE WITH UG-84. ACCORDINGLY, PRODUCTION TEST COUPONS (PTC) FOR IMPACT TESTING ARE NOT REQUIRED.
DOLPHIN HEAT TRANSFER L. L. C.
P.O. Box 20678, Plot No. 105 & 95, New Industrial Area, Ajman, U.A.E.
Tel: 00971-6-7482504. Fax: 00971-6-7482506.
Email: dolheat@emirates.net.ae. Web: www.dolphinht.com
DOLPHIN HEAT TRANSFER L. L. C.
P.O. Box 20678, Plot No. 105 & 95, New Industrial Area, Ajman, U.A.E.
Tel: 00971-6-7482504. Fax: 00971-6-7482506.
Email: dolheat@emirates.net.ae. Web: www.dolphinht.com
NOZZLE “N4 (DN50 x SCH160 x 150# WITH BLIND FLANGE)” IS PROVIDED FOR THIS PURPOSE.
o
DESIGN TEMPERATURE (INTERNAL/EXTERNAL) T C 148.89/N.A
ALLOWABLE STRESS AT DESIGN TEMP. (AS PER ASME SEC II PART D) S MPa 118.0
ALLOWABLE STRESS AT TEST TEMP. (AS PER ASME SEC II PART D) S MPa 118.0
OUTSIDE DIAMETER OF PIPE Do mm 60.3
OUTSIDE RADIUS OF PIPE = Do / 2 = 60.3 / 2 Ro mm 30.15
NOMINAL PIPE SIZE / SCHEDULE - - DN50 / SCH 160
PROVIDED THICKNESS - mm 8.74
CORROSION ALLOWANCE CA mm 3.175
LONGITUDINAL JOINT TYPE SEAMLESS
JOINT EFFICIENCY FOR NECK PIPE E 1.00
UG-45 AS PER APPENDIX 1-1
APPENDIX 1 - 1 t = P * Ro / (S * E + 0.4 * P) + CA = 0.355 x 30.15 / (118.0 x 1.00 + 0.4 x 0.355) + 3.175 ta mm 3.26
MINIMUM NOZZLE NECK THICKNESS REQUIRED (tb)
MAN.APP-13
REQUIRED TOP & BOTTOM PLATE THICKNESS FROM PAGE NO 51 tb1a mm 8.175
REQUIRED MINIMUM THICKNESS OF TOP & BOTTOM PLATE
UG-16(b) tb1b mm 4.675
= 1.5 + CA = 1.5 + 3.175
UG-45 tb1 = LARGER OF (tb1a, tb1b) = LARGER OF (8.175, 4.675) tb1 mm 8.175
MINIMUM THICKNESS REQUIRED (tb3)
TABLE UG-45 NOZZLE MINIMUM THICKNESS REQUIREMENTS AS PER TABLE UG-45 tb3 mm 3.42
MINIMUM THICKNESS REQUIRED (tb3) = t3+CA = 3.42 + 3.175 tb3 mm 6.595
MINIMUM THICKNESS REQUIRED (tb)
= MINIMUM OF [tb3, MAXIMUM OF (tb1, tb2)]
= MIN.OF [6.595, MAXIMUM OF (8.175, N.A)] = MIN. OF [6.595, 8.175] tb mm 6.595
UG-45 MINIMUM THICKNESS REQUIRED (tug-45)
= MAXIMUM OF (ta, tb) = MAXIMUM (3.26, 6.595) t UG-45 mm 6.595
PROVIDED MINIMUM THICKNESS INCLUSIVE OF 12.5% PIPE TOLERANCE tn mm 7.647
PROVIDED MINIMUM THICKNESS EXCLUSIVE OF 12.5% PIPE TOLERANCE tn mm 8.74
AS REQUIRED THK. (6.595 mm) <= PROVIDED MINIMUM THK. (7.647 mm), PROVIDED THICKNESS IS ADEQUATE.
FINISHED OPENING SIZE
AS PER UG - = do -2 x tn (UNDER TOLERANCE) + 2 x C = (60.3 – 2 x 8.74) + (2 x 3.175) D mm 49.17
36(c)(3)(a) REQUIRED MINIMUM THICKNESS OF NOZZLE tn mm 3.26
HEADER BOX SHORT SPAN & ONE -FOURTH SHORT SPAN d mm 100 & 25
-AS PER UG -36(c)(3)(a), UG-39(a), FINISHED OPENING SIZE NOT LARGER THAN 89 mm DIAMETER – IN VESSEL SHELLS OR HEADS
WITH A REQUIRED MINIMUM THICKNESS 10mm OR LESS AND EXCEED ONE-FOURTH THE HEADER BOX SHORT SPAN. HENCE,
REINFORCEMENT CHECKING CALCULATION IS REQUIRED FOR THIS NOZZLE.
-AS PER UW-15(b)(1) STRENGTH CALCULATIONS FOR NOZZLE ATTACHMENT WELDS FOR PRESSURE LOADING ARE NOT REQUIRED
FOR FIGURE UW-16.1 SKETCHES (a).
WELD SIZE REQUIREMENT AT NOZZLE TO TOP/BOTTOM JUNCTION AS PER UW-16.1(a):
tn : NOMINAL THICKNESS OF NOZZLE NECK : 8.74 mm
t : NOMINAL THICKNESS OF TOP & BOTTOM PLATE : 12.00 mm
tmin : SMALLER OF 19 mm OR LESSER OF tn & t = SMALLER (19.00, LESSER [8.74, 12.00]) : 8.74 mm
tc : REQUIRED THROT NOT LESS THAN SMALLER OF 6 mm OR (0.7 x tmin ) = MIN.[6, 8.74x 0.7] : 6.00 mm
tc : PROVIDED FILLET WELD THROT SIZE (tleg x 0.7) = 9.00 x 0.7 : 6.30 mm
tleg : PROVIDED FILLET WELD LEG SIZE : 9.00 mm
DOLPHIN HEAT TRANSFER L. L. C.
P.O. Box 20678, Plot No. 105 & 95, New Industrial Area, Ajman, U.A.E.
Tel: 00971-6-7482504. Fax: 00971-6-7482506.
Email: dolheat@emirates.net.ae. Web: www.dolphinht.com
(FOR SA105M ULTIMATE TENSILE STRENGTH 485 MPa <689.476 MPa REF. P.NO 556/L.NO 29 OF ASME SEC II Part-D)
2) LOAD DUE TO INTERNAL PRESSURE
F = LOAD ON THE PLUG DUE TO INTERNAL PRESSURE
= P * [π / 4 * (D)2] = 333.5 N
3) MAXIMUM AXIAL FORCE THAT CAN BE APPLIED ON PLUG TO BREAK THREAD, P A : (Ref. Pg.1491)
PA = REQUIRED AXIAL FORCE TO BREAK PLUG THREAD
= σP * At = 114643.5 N
SINCE, LOAD ON PLUG DUE TO INTERNAL PRESSURE (F) IS LESS THAN MAXIMUM AXIAL FORCE (P A), HENCE SAFE.
4) SHEAR STRENGTH OF SCREW THREADS: (Ref. Pg.1490, 1491)
AS= SHEAR STRESS AREA OF EXTERNAL THREAD
= [π*n* Le * Kn max * {1 / (2 * n) + 0.57735 * (Es min - Kn max)}] = 2358.70 mm2
An= SHEAR STRESS AREA OF INTERNAL THREAD
= [π * n * Le * Ds min*{1 / (2 * n) + 0.57735 * (Ds min - En max)}] = 3153.90 mm2
J = FACTOR FOR ALTERNATIVE STRENGTH OF EXT. & INT. THREAD
= (AS * σP) / (An * σPS) THREAD ENGAGEMENT LG. IS OK = 0.74 <1.00
5) SHEAR STRENGTH FOR EXTERNAL THREAD:
PS = REQUIRED TENSILE LOAD TO BREAK THE EXTERNAL THREAD PORTION
= σp * AS = 325500.6 N
SINCE LOAD ON THE PLUG DUE TO INTERNAL PRESSURE (F) IS LESS THAN TENSILE LOAD (P S), HENCE SAFE.
6) SHEAR STRENGTH FOR INTERNAL THREAD:
Pn = REQUIRED TENSILE LOAD TO BREAK THE INTERNAL THREAD PORTION
= σps * An = 435238.20 N
SINCE LOAD ON THE PLUG DUE TO INTERNAL DESIGN PRESSURE (F) IS LESS THAN TENSILE LOAD (P n),
HENCE, SAFE. (THREADS OF PLUG & PLUG SHEET ARE SAFE AS DEMONSTRATED ABOVE.)
DOLPHIN HEAT TRANSFER L. L. C.
P.O. Box 20678, Plot No. 105 & 95, New Industrial Area, Ajman, U.A.E.
Tel: 00971-6-7482504. Fax: 00971-6-7482506.
Email: dolheat@emirates.net.ae. Web: www.dolphinht.com
TUBE TO TUBESHEET JOINT CONFIGURATION: EXPANDED, ENHANCED WITH TWO GROOVES [TYPE "i" OF TABLE A-2 IN
NONMANDATORY APP.-A]
APPLICABLE
CODE CLAUSE
NONMANDATOR TUBE OUTSIDE DIAMETER do = 31.75 mm
Y APP.A-2 PROVIDED MINIMUM TUBE WALL THICKNESS t = 2.80 mm
ALLOWABLE STRESS OF TUBE AT DESIGN TEMPERATURE
Sa = 92.4 MPa
(AS PER ASME SEC II PART D)
ALLOWABLE STRESS OF TUBESHEET AT DESIGN TEMPERATURE
St = 138 MPa
(AS PER ASME SEC II PART D)
TUBE CROSS SECTIONAL AREA = π x (do - t) x t At = 254.65 mm2
INTERNAL DESIGN PRESSURE WITH STATIC HEAD P = 0.355 MPa
FACTOR FOR THE LENGTH OF THE EXPANDED PORTION OF THE TUBE fe = 1.0 -
TUBE JOINT EFFICIENCY (NO TEST CASE AS PER TABLE A-2) fr = 0.7 -
YIELD STRENGTH OF TUBESHEET MATERIAL AT DESIGN MPa
Sy = 232.1
TEMPERATURE (AS PER ASME SEC II PART D)
YIELD STRENGTH OF TUBE MATERIAL AT DESIGN TEMPERATURE (AS MPa
Sy,t = 158.1
PER ASME SEC II PART D)
FACTOR FOR DIFFERENCES IN MECHANICAL PROPERTIES OF
fy = 1.468 -
TUBESHEET AND THE TUBE MATERIALS = Sy / Sy,t = 232.1 / 158.1
FACTOR TO ACCOUNT FOR THE INCREASE OR DECREASE OF TUBE
JOINT STRENGTH DUE TO RADIAL DIFFERENTIAL THERMAL fT = 1.0 -
EXPANSION AT THE TUBE-TO-TUBESHEET JOINT
NONMANDATOR MAX. ALLOW. TUBE-TUBESHEET JOINT LOAD, Lmax
Y APP. A-2 (3) Lmax = At x Sa x fe x fr x fy x fT
= 254.65 x 92.4 x 1 x 0.7 x 1.468x 1
Lmax = 24179.07 N
LOAD ON TUBE DUE TO INTERNAL DESIGN PRESSURE
AXIAL FORCE ON TUBE DUE TO INTERNAL DESIGN PRESSURE L(INT)
L(INT)= At x INTERNAL DESIGN PRESSURE
L(INT)= 254.65 x 0.355
L(INT)= 90.4 N
L(INT) < Lmax, SINCE THE LOAD ON THE TUBE DUE TO INTERNAL DESIGN PRESSURE IS LESS THAN THE MAXIMUM
DOLPHIN HEAT TRANSFER L. L. C.
P.O. Box 20678, Plot No. 105 & 95, New Industrial Area, Ajman, U.A.E.
Tel: 00971-6-7482504. Fax: 00971-6-7482506.
Email: dolheat@emirates.net.ae. Web: www.dolphinht.com
tw=MIN
t ts tr 2 x tr 1.25 x ts Actual
COMPONENT (2xtr,1.25xts, t) RESULT
mm mm mm mm mm tw
mm
2) 100% NDT REQUIRED ON WELD SEAM BETWEEN TOP/BOTTOM OR TUBE/PLUG SHEET PLATE TO END PLATE.
NO. OF LIFTING LUG PER FIN FAN COOLER SIDE FRAME: 4 No’s
TUBE BUNDLE WITH SIDE FRAME EMPTY WEIGHT: 6025 kg (59105.25 N)
EMPTY WEIGHT OF THE TUBE BUNDLE WITH SIDE FRAME PER LIFTING LUG: 14777 N