Annex C

(normative)

Thermal-stress Limitations (Elastic Range)

C.1 General

In heater tubes, the thermal stress of greatest concern is the one developed by the radial distribution of
temperature through the thickness. This stress can become particularly significant in thick stainless steel
tubes exposed to high heat fluxes.

There are two limits for thermal stress; both are described in Section 5.5.6 of ASME Section VIII, Division 2
Code. These limits apply only in the elastic range; in the rupture range, an appropriate limit for thermal stress
has not been established.

In addition to the above limitations, it should be noted that the applicability of the following thermal stress
methodologies are limited to “thin wall” tubes (e.g. tubes with a thickness-to-outside diameter ratio of less
than 0.15).

C.2 Equation for Thermal Stress

The following equation gives the maximum thermal stress, σTmax, in a tube:

 2 y 2  
 T max  X  2  ln y  1 (C.1)
 y  1 

where

  E   T    E   qo Do 
X       (C.2)
 2 1      ln y   4 1      s 

 is the coefficient of thermal expansion;

E is the modulus of elasticity;

 is Poisson's ratio;

T is the temperature difference across the tube wall;

y is Do /Di, ratio of outside diameter to actual inside diameter;

qo is the heat flux on the outside surface of the tube;

s is the thermal conductivity of the steel.

The material properties  , E, v, and s shall be evaluated at the mean temperature of the tube wall. The
average wall thickness shall also be used in this equation (see 5.7). Poisson’s ratio at elevated temperature
is not readily available. However, E and G (modulus of rigidity) at high temperature can be found in
numerous references and used to calculate with the equation: = (E/2G) – 1.

C-1
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C.3 Limits on Thermal Stress

The limitation, T,lim1, on primary plus secondary stress intensity of Mandatory Appendix 4 of ASME Section
VIII, Division 2 Code (2004 Edition), Paragraph 4-134, can be approximated for thermal stress as given in
Equations (C.3) and (C.4) (see Section C.4 for the derivation).

For ferritic steels:

T,lim1  (2.0  0.67y)y (C.3)

For austenitic steels:

 T,lim1  (2.7  0.90y)y (C.4)

where y is the yield strength.

The thermal-stress ratchet limit, T,lim2, of Mandatory Appendix 5 of ASME Section VIII, Division 2 Code
(2004 Edition), Paragraph 5-130, can be approximated for thermal stress as given in Equations (C.5) and
(C.6) (see Section C.5 for derivation).

For ferritic steels:

T,lim2  1.33y (C.5)

For austenitic steels:

 T,lim2  1.8y (C.6)

Both the primary plus secondary stress limit (T,lim1) and the thermal-stress ratchet limit (T,lim2) shall be met
if the tube is designed for the elastic range.

C.4 Derivation of Limits on Primary Plus Secondary Stress Intensity

The limit on primary plus secondary stress intensity can be expressed symbolically as given by the inequality
in Equation (C.7):

 pl   pb   cir,max  3  m (C.7)

where

 cir,max is the maximum circumferential thermal stress which, for this application, is the maximum
thermal stress given by equation (C.1);

 pl is the local primary membrane stress;

 pb is the primary bending stress.

From ASME BPVC Section VIII, Division 2, for tubes with an internal pressure:

 2 y2 
 pl   pb  pel  
 y 2  1
(C.8)
where

pel is the elastic design pressure;

y is the ratio of outside to actual inside diameter, equal to Do /Di.

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 CALCULATION OF HEATER-TUBE THICKNESS IN PETROLEUM REFINERIES C-3

If the primary membrane stress intensity, pm, is given by Equation (C.9),

pel  Do  p  y  1
 pm    1  el  (C.9)
2    2  y  1

it can, then, be easily shown that Equation (C.10) gives a first approximation and provides an upper bound:

 pl   pb  ypm (C.10)

In ASME Section VIII, Division 2 Pressure Vessel Code (2004 Edition)], m is the allowable membrane stress
intensity. For ferritic steels above about 340 °C (650 °F), m is equal to two-thirds of the yield strength, y, as
given in Equation (C.11):

3 m  2 y (C.11)

For austenitic steels above about 260 °C (500 °F), m is 90 % of y, as given in Equation (C.12):

3 m  2.7 y (C.12)

Heater tubes usually operate above these temperatures.

Combining all of this, the primary plus secondary stress intensity limit on thermal stress can be expressed as
given in Equations (C.13) and (C.14):

For ferritic steels:

 T,lim1  2y  ypm (C.13)

For austenitic steels:

 T,lim1  2.7y  ypm (C.14)

where  T,lim1 is the maximum value permitted for the thermal stress, T.

For ferritic-steel and austenitic-steel heater tubes designed according to this standard, the inequalities in
Equations (C.15) and (C.16), respectively, hold:

pm  0.67y (C.15)

pm  0.90y (C.16)

The thermal-stress limit,  T,lim1, can therefore be approximated as given in Equations (C.17) and (C.18):

For ferritic steels:

 T,lim1  (2.0 – 0.67y)y (C.17)

For austenitic steels:

 T,lim1  (2.7 – 0.90y)y (C.18)

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 C-4 API STANDARD 530

The limits expressed by these equations are simple and appropriate. If the thermal stress is less than this
limit, the design is appropriate. If the thermal stress exceeds the limit given by these equations, then, the
more exact form of Equation (C.13) or (C.14) shall be used with the primary membrane stress intensity given
by Equation (C.9). Also, if the tube thickness is arbitrarily increased over the thickness calculated in 5.3, then
the primary membrane stress intensity shall be calculated using the actual average thickness, and
Equation (C.13) or Equation (C.14) shall be used to calculate the thermal-stress limit.

C.5 Derivation of Limits on Thermal-stress Ratchet

The limit,  T,lim2, set to avoid thermal-stress ratchet can be expressed as given in Equation (C.19):

 T,lim2  4(  pm) (C.19)

For ferritic steels:

  y (C.20)

For austenitic steels above about 260 °C (500 °F):

  1.5 (0.9 y)  1.35 y (C.21)

As before, pm is derived from Equation (C.9). Using the inequalities in Equation (C.15) or Equation (C.16),
this limit can be approximated as given in Equations (C.22) and (C.23):

For ferritic steels:

T,lim2  1.33 y (C.22)

For austenitic steels:

T,lim2  1.8 y (C.23)

As with the limits developed in Section C.4, these limits are approximate. If the thermal stress exceeds this
limit or if the tube thickness is arbitrarily increased, the exact limit expressed by Equation (C.19) shall be
used with the primary membrane stress intensity given by Equation (C.9).

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