INDEX:

SR.
Descriptions SHEETS
NO.
PART A – GENERAL DESIGN REQUIREMENT AND CONSIDERATION

1 Design Notes

2 Equipment Loading

3 Material Of Construction

4 Units Conversion

5 Inspection Opening

6 Drain Requirement

7 Service Requirement

8 Radiography Requirement

PART B – DESIGN DATA

Annexure 1: PV-Elite Report for Mechanical calculation as per ASME Sec VIII Div. 1
10
for Heater Treater Vessel
Annexure 2: PV-Elite Report for Mechanical calculation as per ASME Sec VIII Div. 1
11
for Heater Treater Fire Tube
12 Annexure 3: Calculation of Circular Nozzle as per ASME Sec VIII Div. 1

13 Annexure 4: Calculation of Blind Flange with Fire Tube / Burner Nozzle

Annexure 5: Calculation of Fire Tube / Burner Nozzle flange (Non – Standard) 24
14
inch
Annexure 6: Lifting Lug Calculations Considering Impact Factor 2.0 Of Maximum
15
Weight. Local Load Analysis For Lifting Lug.
Annexure 7: Calculations of Chimney stack (24" X 8 mm THK) as per
16
IS – 6533 Part –1 and Part – 2
17

18
PART A – GENERAL DESIGN REQUIREMENT AND CONSIDERATION
1. DESIGN NOTES

SR.
DESIGN NOTES
NO.
1 Heater Treater designed as per ASME Sec VIII Div. 1 2015 Edition

2 Anchor bolt material is ASTM A 36 or equivalent.

Saddle analysis is performed as per (per ASME Sec. VIII Div. 2 based on the Zick method.
Below weights considered while designing supports.
Fire Tube Weight is 3200 Kg.
Other Internals 2000 Kg.
3
Weight of Transformer 1588 Kg.
Weight of Hood Baffle is 1000 Kg.
Chimney stack and burner box is 3000 Kg,
Also Platform 3m x 4m considered for weight.

4 Corrosion Allowance considered as 3 mm (internal) for main vessel, 3 mm (external) for fire tube

5 Wind load considered as per IS 875 with Basic Wind Speed 47 m/sec

6 Seismic Design considered as per IS 1893; Seismic Zone 2;

Obround nozzle design performed considering design of Rectangular Vessel as per Appendix 3 -
7 Fig. 13.2(b) (2) of ASME Sec VIII Div. 1. Obround body flange and Dish End considered as stiffeners
on the obround nozzle.

Obround Nozzle Blind Flange with 24 inch nozzle opening (for Fire tube and Burner) not satisfying
UG-39 requirement (Refer page 39 of Annexure 4 of this calculation). Special analysis will be
8
performed (Finite Element Analysis) for checking suitability of provided configuration for all applicable
loading conditions and satisfying stress limits as defined in ASME codes.

Instead of Obround Nozzle, we propose to provide round hole of diameter equal to major axis of obround
9
nozzle (OD = 1572 mm). Client to confirm the same.

Fire tube and Burner Nozzles are provided with Non-standard body flange made from plate of 20 mm
10
thickness and gasket used is CAF with full face gasket.

11 Process Internal design not included in design. Appropriate weight added in calculation.
 2. EQUIPMENT LOADING AS PER UG- 22 :

SR. APPLICABILITY
CLAUSE DESCRIPTION OF LOADINGS REMARKS
NO. (YES/NO)

1 UG-22(a) MAWP due to internal / external pressure

Weight of equipment, static head of operating

2 UG-22(b)
fluid

Super imposed loadings from attachment weight

3 UG-22(c) like motors, machinery, other vessels, nozzle
loadings, linings and insulations

Super imposed loading due to attachment and

4 UG-22(d)
vessel supports

Cyclic and dynamic reactions due to pressure or

5 UG-22(e) thermal variations, or from equipment mounted on
a vessel, and mechanical loadings

6 UG-22(f) Wind, snow, and seismic reactions

7 UG-22(g) Impact reactions due to fluid shock

Temperature gradients and differential thermal

8 UG-22(h)
expansion

Abnormal pressures, such as those caused by

9 UG-22(i)
deflagration;

Test pressure and coincident static head acting

10 UG-22(j)
during the test

CONCLUSION : Applicable loadings as per UG-22 are

 3. MATERIAL OF CONSTRUCTION:

ASME SEC II, PART D &

(Mpa) AT HYDRO TEST

REFERENCE IN ASME

UCS-66 OF ASME SEC-

ALLOWABLE STRESS
ALLOWABLE STRESS

AT DESIGN TEMP. OF

STRESS RATIO (St/Sd)

- 1. (YES/NO)
CONSTRUCTION

PERMITTED BY
TEMP. OF 45 ° C

SEC II, PART D

MATERIAL OF

CAUTIONARY
APPLICABLE
WHETHER

NOGTES
(Sd-Mpa)

(St-Mpa)
SR. NO.

CODE
ITEM

(Mpa)

95 ° C

VIII,
DIV.
1 Shell

2 Head

Nozzle
3
R.F Pad

Forged
4 Nozzle
Neck

5 Elbows

Nozzle
6
Neck

Nozzle
7
Flange

1. Bolting material (SA – 193 Gr.B7 allowable stress at hydrostatic test temperature and design
temperature = 172Mpa (Refer table 3, Page 352-354 of ASME Sec II Part D)
Hence Lowest stress ratio (LSR) for bolting material = 1
Yield stress at hydrostatic temp. = 725 Mpa (Refer table Y-1; Page 595 of ASME Sec II Part D)
1.3 times LSR × Allowable stress = 1.3 × 172 = 223.6 Mpa < 0.9 × 725 (652.5Mpa) as per UG-99(b),
Since 1.3 × LSR × Allowable stress of bolt is less than the 90% of yield stress of bolt at hydrostatic
test temperature, the LSR of bolt shall not be included in the hydrostatic pressure calculation.

Notes:
1. G10, S1, T1, T2 : These cautionary notes do not have impact on design calculation conditions
stipulated for this equipment
4. UNITS CONVERSION :

Units Conversion as per Appendix GG

Conversion From Multiplying Factor

psi to Mpa 0.0068948
Psi to kpa 6.8948
Pound to kg 0.4535924
Inch to mm 25.4

1 Mpa = 1/0.0068948 145.036839 Psi

1 Mpa 1000 Kpa
0.10197099 Kg/mm2
10.1970996 Kg/cm2

Conversion From Multiplying Factor

Mpa to psi 145.036839
Psi to Kg/cm2 0.070306963
Mpa to Kg/cm2 10.1970996
Psi to bar 0.06894757
Kg/cm2 to bar 0.980664888
 5. INSPECTION OPENING :

Requirement as per UG – 46(f)

SR. APPLICABILITY
CLAUSE REQUIREMENTS
NO. (YES/NO)
All vessels less than 18 in. (450 mm) and over 12 in. (300 mm)
1 UG-46(f)(1) I.D. shall have at least two hand-holes or two plugged, threaded
inspection openings of not less than NPS 11/2 (DN 40).

All vessels 18 in. (450 mm) to 36 in. (900 mm), inclusive, I.D.
2 UG-46(f)(2) shall have a manhole or at least two hand-holes or two plugged,
threaded inspection openings of not less than NPS 2 (DN 50).
All vessels over 36 in. (900 mm) I.D. shall have a manhole, except
UG-46(f)(3) that those whose shape or use makes one impracticable shall have
3
at least two hand-holes 4 in. × 6 in. (100 mm × 150 mm) or two
equal openings of equivalent area.
When hand-holes or pipe plug openings are permitted for
UG-46(f)(4) inspection openings in place of a manhole, one hand-hole or one
4
pipe plug opening shall be in each head or in the shell near each
head.
Openings with removable heads or cover plates intended for other
UG-46(f)(5) purposes may be used in place of the required inspection openings
5
provided they are equal at least to the size of the required
inspection openings.
A single opening with removable head or cover plate may be used
6 UG-46(f)(6) in place of all the smaller inspection openings provided it is of such
size and location as to afford at least an equal view of the interior.

Flanged and/or threaded connections from which piping,

7 UG-46(f)(7) instruments, or similar attachments can be removed may be used
in place of the required inspection openings provided that:

UG-46(f)(7)(a) The connections are at least equal to the size of the required
8
openings

UG-46(f)(7)(b) The connections are sized and located to afford at least an equal
9
view of the interior as the required inspection openings.

As per UG-46(g),
When inspection or access openings are required, they shall comply at least with the following requirements:
1) An elliptical or obround manhole shall be not less than 12 in. × 16 in. (300 mm × 400 mm). A circular
manhole shall be not less than 16 in. (400 mm) I.D.
2) A hand-hole opening shall be not less than 2 in. × 3 in. (50 mm × 75 mm), but should be as large as is
consistent with the size of the vessel and the location of the opening.

CONCLUSION :
For the vessel, we have provided a manhole of DN600 (with ID591 and thickness is 10 mm), as per client
requirement which satisfies the above code requirement.
 6. DRAIN REQUIREMENT :

Requirement as per UG – 25(f)

As per UG-25(f),
Vessels subject to corrosion shall be supplied with a suitable drain opening at the lowest point practicable in the
vessel; or a pipe may be used extending inward from any other location to within 1/4 in. (6 mm) of the lowest point.
Conclusion :
For the vessel, we have provided a drain of DN50 (2’’ × Sch-XXS ASME Pipe), as per client requirement which
satisfies the above code requirement.

7. SERVICE REQUIREMENT :

Check for Service Requirement as per UW – 2

SR. APPLICABILITY
CLAUSE REQUIREMENTS
NO. (YES/NO)

1 UW – 2(a) Does the vessel contain lethal fluid

2 UW – 2(b) Does the vessel material or weld metal require impact testing

3 UW – 2(c) Is the Vessel unfired steam boiler with design pressure exceeding
50 psi

4 UW – 2(d) Is the vessel subjected to direct firing

Conclusion :
Since answer to point (1) to (4) are No, there are no additional requirements on account of service restrictions.
 8. RADIOGRAPHY REQUIREMENT :

Check for radiography requirement as per UW-11

SR. APPLICABILITY
CLAUSE REQUIREMENTS
NO. (YES/NO)

1 UW – 11(a)(1) Does the vessel used to contain the lethal substances (See UW-2(a))

All butt welds in the shell and heads of vessels in which the nominal
thickness at the welded joint exceeds 11/2 in. (38 mm), or exceeds
2 UW – 11(a)(2)
the lesser thicknesses prescribed in UCS-57 i.e. 32mm for the
materials (P. No. 1 and G. No. 1 or 2)

Is the Vessel unfired steam boilers having design pressure

3 UW – 11(a)(3)
exceeding 50 psi (350Kpa) [See UW-2(c)]

All butt welds in nozzles, communicating chambers, etc., with the

nominal thickness at the welded joint that exceeds the thickness in
(2) above or attached to the shell or heads of vessels under (1), (2),
or (3) above that are required to be fully radiographed; however,
4 UW – 11(a)(4)
except as required by UHT-57(a), Categories B and C butt welds in
nozzles and communicating chambers that neither exceed NPS 10
(DN 250) nor 11/8 in. (29 mm) wall thickness do not require any
radiographic examination.
All Category A and D butt welds in the shell and heads of vessels
where the design of the joint or part is based on a joint efficiency
permitted by UW-12(a), in which case:
(-a) Category A and B welds connecting the shell or heads of vessels
shall be of Type No. (1) Or Type No. (2) of Table UW-12;
(-b) Category B or C butt welds [but not including those in nozzles
UW – 11(a)(5)
and communicating chambers except as required in (4) above]
which intersect the Category A butt welds in the shell or heads of
vessels or connect seamless vessel shell or heads shall, as a
minimum, meet the requirements for spot radiography in
accordance with UW-52. Spot radiographs required by this
paragraph shall not be used to satisfy the spot radiography rules as
applied to any other weld increment.

Does all butt welds joined by electro-gas welding with any single
UW – 11(a)(6) pass greater than 11/2 in. (38 mm) and all butt welds joined by
electro-slag welding;

Conclusion :
Since answer to point (1) to (4) are No, there are no additional requirements on account of service restrictions.
PART B – DESIGN DATA