DESIGN CALCULATION ACCORDING TO
ASME CODE SECTION VIII Division 1Edit. 2007
FOR THE1ST STAGE OF THE CHARGE AIR COOLER
TYPE:208 / 48 / 2 / 6 - ESf - FE213 REFERENCE DRAWING: 13 10 2507 WH
ENGINE:RT-flex96C
Prep.:11-07-11Appr.:11-07-11 Page 1 of 6
208 / 48 / 2 / 6 - ESf - FE213 1. HEAT EXCHANGER TUBE
DESIGN CALCULATION FOR THE ELLIPTICAL FINED TUBE ACCORDING TO
TüV REPORT 2.5.1-59/89 unter consideration of an additional longitudinal weld efficiency of 0.6 ASME CODE SECTION VIII Division 1Edit. 2007UW-12
Design Pressure:348psi≈24.0bar
Design Temperature:426.8°F≈220.0°C
Min. Design Metal Temp.:41°F≈ 5.0°C
Hydrostatic Test Pressure:522psi≈37.0bar
Ref. Drawing:13 10 2507 WH
Material: SA-53 (welded tube)
R m≥370.0N/mm2R mDT≥N/mm2
R p0.2≥235.0N/mm2R p0.2DT≥153.0N/mm2
S DT =11700psi
S TT =11700psi
c =0.0394in≈ 1.0mm
GEA Calculation Programm OVALNEU:
Elliptical Tube:36.00x14.00x 1.00mm
Fin:55.00x26.00x0.23mm
Tipclearance: 2.10mm
s Fin153.00N/mm2
s Tube91.80N/mm2← for weld efficiency factor E=0,6: 0,6 x 153 N/mm2
s ROHmaxP68.56N/mm2
Allowable Internal Pressure ACC. TO TüV- REPORT 2.5.1-59/89
P Max25.82bar
Actual tube stress:s ROH =s ROHmaxP/ P Max· P N/mm2psi
s ROH =68.5625.8224.0=63.79243OK Actual wall thickness:t = 1.0+ 1.0= 2.00.0787OK
mm in
Required minimum hydrostatic test pressure by UG-99:
P′ =1,3·P·S TT/S DT
453psi≈31.3bar
1900-1-00-1-0011-07-11 Page 2 of 6
208 / 48 / 2 / 6 - ESf - FE213
2. TUBEPLATE
DESIGN OF FLAT SURFACES ACCORDING TO
ASME CODE SECTION VIII Division 1Edit. 2007UG-34/UG-39
Design Pressure:348psi≈24.0bar
Design Temperature:427°F≈220.0°C
Min. Design Metal Temp.:41°F≈ 5.0°C
Hydrostatic Test Pressure:522psi≈37.0bar
Ref. Drawing: 13 10 2507 WH
Material: Tubeplate:P355N EN 10028-3 9.03
R m≥490.0N/mm2R mDT≥366.4N/mm2
R p0.2≥345.0N/mm2R p0.2DT≥258.0N/mm2
S DT =16703psi [MIN R m/3,5 or 1,1/3,5·R mDT or 2/3R p0,2 or 2/3·R p0.2DT]
S TT =20305psi [MIN[R m/3,5 or 2/3R p0,2]
Tubes:SA-53 (welded tube)
S DT =11700psi
Required minimum wall thickness by UG-34:
t =d·√[Z·C·P/(S·E)]
D =262.7mm≈ 10.343in
d =114.0mm≈ 4.488in
C =0.33
MUT =0.0079in≈0.2mm
c =0.0394in≈ 1.0mm
E =0.60
Z =3,4 - (2,4·d/D)= 2.36
t =0.739in≈18.8mm
t r = t + MUT + c=0.786in≈20.0mm
Area of reinforcement at the tube holes required by UG-39:
A =0,5·d·t+t·t n·(1-f r1)
p thld =26.7mm≈ 1.051in
d thld =14.8mm≈0.583in
p thcd =55.4mm≈ 2.181in
d thcd =36.8mm≈ 1.449in
t =d·√[Z·C·P/(S·E)]
E = 1.0
t =0.572in≈14.6mm
t n =0.0787in
f r1 =S n/S v=0.70
A ld =0.1351in2
A cd =0.3829in2
Minimum wall thickness to provide adequate reinforcement:
t min =28.0mm≈ 1.102in
Resulting area of27
A1ld =(p thld-d thld)·(t min-t)=0.2485in2OK(sufficient reinforcement). Resulting area of reinforcement at the tube holes in cross direction:
A1cd =(p thcd-d thcd)·(t min-t)=0.3884in2OK(sufficient reinforcement).
= 1.150in≈29.3mm
≈ 1.181in
P′ =1,3·P·S TT/S DT
453psi≈31.3bar
1900-1-00-1-0011-07-11 Page 3 of 6
208 / 48 / 2 / 6 - ESf - FE213
3. WATER HEADER. SHELL
DESIGN OF CYLINDRICAL SHELLS FOR INTERNAL PRESSURE ACCORDING TO
ASME CODE SECTION VIII Division 1Edit. 2007UG-27
Design Pressure:348psi≈24.0bar
Design Temperature:427°F≈220.0°C
Min. Design Metal Temp.:41°F≈ 5.0°C
Hydrostatic Test Pressure:522psi≈36.0bar
Ref. Drawing:13 10 2507 WH
Material: P265GH_EN 10028
R m≥410.0N/mm2R mDT≥306.6N/mm2
R p0.2≥265.0N/mm2R p0.2DT≥198.2N/mm2
S DT =13978psi [MIN R m/3,5 or 1,1/3,5·R mDT or 2/3R p0,2 or 2/3·R p0.2DT]
S TT =16990psi [MIN[R m/3,5 or 2/3R p0,2]
Required minimum wall thickness by UG-27:
The greater of t = P·R/(S·E LJ-0,6·P)or t = P·R/(2·S·E CJ+0,4·P)
P =348psi
R =57.0mm≈ 2.244in
d =43.1mm≈ 1.697in
E LJ =0.60
E CJ =0.60
MUT =0.0039in≈0.1mm
c =0.0394in≈ 1.0mm
t =0.0955in≈ 2.430mm
t r = t + MUT + c=0.1388in≈ 3.6mm
Required minimum wall thickness by UG-16(b):
t =0.1124in≈ 2.86mm
t r = t + MUT + c=0.1557in≈ 4.0mm
≈0.2362in
AS PER UG-36(c)(3)(a): NO ADDITIONAL REINFORCEMENT REQUIRED
Required minimum hydrostatic test pressure by UG-99:
P′ =1,3·P·S TT/S DT
453psi≈31.3bar
1900-1-00-1-0011-07-11 Page 4 of 6
GEA INDUSTRIAL HEA
SYSTEMS (CHINA) CO. Heat Exchangers
208 / 48 / 2 / 6 - ESf - FE213
4. WATER HEADER. NOZZLE
DESIGN OF CYLINDRICAL SHELLS FOR INTERNAL PRESSURE ACCORDING TO
ASME CODE SECTION VIII Division 1Edit. 2007UG-27
Design Pressure:348psi≈24.0bar
Design Temperature:427°F≈220.0°C
Min. Design Metal Temp.:41°F≈ 5.0°C
Hydrostatic Test Pressure:522psi≈36.0bar
Ref. Drawing:13 10 2507 WH0
Material: St35.8I _DIN17175
R m≥360.0N/mm2R mDT≥274.2N/mm2
R p0.2≥235.0N/mm2R p0.2DT≥179.0N/mm2
S DT =12500psi [MIN R m/3,5 or 1,1/3,5·R mDT or 2/3R p0,2 or 2/3·R p0.2DT]
S TT =14918psi [MIN[R m/3,5 or 2/3R p0,2]
Required minimum wall thickness by UG-27:
The greater of t = P·R/(S·E LJ-0,6·P)or t = P·R/(2·S·E CJ+0,4·P)
P =348psi
R =21.55mm≈0.848in
E LJ = 1.00
E CJ =0.60
MUT =0.0120in≈0.31mm
c =0.0394in≈ 1.0mm
t =0.0241in≈0.620mm
t r = t + MUT + c=0.0756in≈ 2.0mm
Required minimum wall thickness by UG-16(b):
t =0.0288in≈0.74mm
t r = t + MUT + c=0.0803in≈ 2.1mm
≈0.1023in
Required minimum hydrostatic test pressure by UG-99:
P′ =1,3·P·S TT/S DT
453.00psi≈31.3bar
1900-1-00-1-0011-07-11 Page 5 of 6
GEA INDUSTRIAL HEA
SYSTEMS (CHINA) CO. Heat Exchangers
208 / 48 / 2 / 6 - ESf - FE213
5. WATER HEADER. ENDPLATE
DESIGN OF CYLINDRICAL SHELLS FOR INTERNAL PRESSURE ACCORDING TO
ASME CODE SECTION VIII Division 1Edit. 2007UG-34
Design Pressure:348psi≈24.0bar
Design Temperature:427°F≈220.0°C
Min. Design Metal Temp.:41°F≈ 5.0°C
Hydrostatic Test Pressure:522psi≈36.0bar
Ref. Drawing:13 10 2507 WH0
Material: P265GH_EN 10028
R m≥410.0N/mm2R mDT≥306.6N/mm2
R p0.2≥265.0N/mm2R p0.2DT≥198.2N/mm2
S DT =13978psi [MIN R m/3,5 or 1,1/3,5·R mDT or 2/3R p0,2 or 2/3·R p0.2DT]
S TT =16990psi [MIN[R m/3,5 or 2/3R p0,2]
Required minimum wall thickness by UG-34:
t =d·√[Z·C·P/(S·E)]
D =114.0mm≈ 4.488in
d =57.0mm≈ 2.244in
m =t r/t s=0.660
C =0,33·m=0.218
C =0.218
MUT =0.0079in=0.2mm
c =0.0394in= 1.0mm
E =0.6
Z =3.4 - (2.4·d/D)= 2.20
t =0.317in≈8.1mm
t r = t + MUT + c=0.364in≈9.3mm
≈0.3937in
Required minimum hydrostatic test pressure by UG-99:
P′ =1,3·P·S TT/S DT
453psi≈31.3bar
1900-1-00-1-0011-07-11 Page 6 of 6
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