Engineers India Limited

FIRED HEATER PRESSURE PARTS

BY : PRAKHAR KUMAR

02.01.2020

1
 INDEX

1 Typical Pressure Part components in Heater coil

2 Heater Tube Material Specification

3 Pressure part inputs received in Fired heater datasheet

4 Pressure Part design governing codes

5 Design details as per the governing codes

6 Hydro test Calculation

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 TYPICAL PRESSURE PART COMPONENTS IN HEATER COIL

BARE TUBES

Tubes
STUDDED OR FINNED TUBES

FITTINGS
( WROUGHT / CAST)

Flanges

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 TYPICAL PRESSURE PART COMPONENTS IN HEATER COIL

Gaskets

Bolts and nuts

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 HEATER TUBE MATERIAL SPECIFICATION
Chromium Properties: Strength and high
resistance to corrosion.

Nickel Properties: Resistant to both heat

and corrosion.
- High strength and excellent toughness or
impact strength, at both low and high
temperatures.

Molybdenum Properties : Resistance to

crevice and pitting corrosion, particularly in
sulphur and chlorides-containing
environments.

Titanium: stabilizes carbide, particularly

when metal has to be welded.

Niobium: Similar to titanium. Also

strengthens alloys and steels for increased
temperature service.

Vanadium: high resistance to alkalis,

hydrochloric and sulfuric acids

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 PRESSURE PART INPUTS RECEIVED IN FIRED HEATER DATASHEET

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 PRESSURE PART INPUTS RECEIVED IN FIRED HEATER DATASHEET

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 PRESSURE PART DESIGN GOVERNING CODES

API 560 AND API 530 ASME ASME SECTION VIII

B16.5 DEV 1

DESIGN OF HEATER TUBES AND DESIGN OF COMPONENTS

FLANGE DESIGN
FITTINGS SUBJECTED TO EXTERNAL
PRESSURE

RETURN
ELASTIC / BEND
RUPTURE DESIGN VACUUM DESIGN
DESIGN OF (ELASTIC OF TUBES
TUBES AND
RUPTURE)

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 PRESSURE PART DESIGN GOVERNING CODES

IBR ASME B31.3 ASME section 1 and

B31.1

For Process Piping. Not

Indian code for design of power applicable for pipes of fired Design of power boilers,
boilers, steam coils and manifolds. heater which are internal to steam coils and manifolds
heater enclosure.

Coil design Coil design

Coil design

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ELASTIC and CREEP RUPTURE DESIGN OF HEATER TUBES

ELASTIC DESIGN RUPTURE DESIGN

Allowable stresses are based Allowable stress based on

on yield strength rupture strength. At higher
temperature, rupture can
occur well below the yield
strength.

Not time dependent. Dependent on service time.

The allowable stress decreases
with increase in design life.

Governing at lower TMT. Governing at higher TMT.

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ELASTIC and CREEP RUPTURE DESIGN OF HEATER TUBES

ALLOWABLE STRESS CURVE FOR SS304

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ELASTIC DESIGN OF HEATER TUBES

Min. wall thickness = Max. [δmin, API 530 table 1 min. thk.]

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ELASTIC DESIGN OF HEATER TUBES

SAMPLE CALCULATION FOR TUBE ELASTIC DESIGN

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RUPTURE DESIGN OF HEATER TUBES

Min. wall thickness = Max. [δmin, API 530 table 1 min. thk.]

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RUPTURE DESIGN OF HEATER TUBES

Corrosion Fraction (fcorr)

The rate of using life depends on temperature and stress.

At constant temperature, rate of using life increases as stress

increases

With time, tube thickness decreases due to corrosion and the

stress increases.

Initially, the stress is less than σr. After operating for design
life when the corrosion allowance is used up, then only the
rupture stress is σr.

As the stress has been less than σr, the tube still has
some time to operate before failure. This is an
uneconomical design.

Therefore a factor of corrosion fraction is introduced for economical

design of the tubes while ensuring the design adequacy.

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RUPTURE DESIGN OF HEATER TUBES

Corrosion Fraction (fcorr)

n is the rupture exponent

at the design metal
temperature (shown in
figures provided in
annexure E and F of API
530).

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RUPTURE DESIGN OF HEATER TUBES

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ELASTIC/ RUPTURE DESIGN OF HEATER TUBES

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RUPTURE DESIGN OF HEATER TUBES

SAMPLE CALCULATION FOR TUBE RUPTURE DESIGN

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MINIMUM ALLOWABLE THICKNESS OF NEW TUBES

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LIMITING DESIGN METAL TEMPERATURE

The limiting design

metal temperature is the upper
limit of the design allowed.

Higher temperatures, i.e. up to

30 °C below the lower critical
temperature, are permitted for
short-term operating conditions

Operation at higher
temperatures can result in
changes in the alloy’s
microstructure.

Austenitic steels do not have

lower critical temperatures

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DRY RUN CHECK FOR TUBES

The dry run requirement and the corresponding dry run TMT is provided in the Heater API datasheet.

This TMT is compared with the limiting design metal temperature.

Sample datasheet requirement

DRY RUN CHECK

DRY RUN TMT 300 Deg C

MATERIAL A213, A312 and A376 TP 347H

MAXIMUM LIMITING TEMPERATURE AS PER API - 530 (TABLE-5) 815 Deg C

RESULT:

SAFE IN DRYRUN

Sample dry run check

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RETURN BEND DESIGN

All standard wrought return bends shall be manufactured in accordance with ASME B16.9

All non standard wrought return bends thickness such as the bends with minimum wall thickness shall
be calculated as per the return bend design calculation.

The design temperature for the fittings inside the firebox shall be equal to the design TMT of the
connected tube.

The design temperature for the fittings outside the firebox, i.e in header box or crossovers shall be
equal to the fluid design temperature plus 30 degree Celsius.

The minimum thickness at 90 degree to

inner and outer bend radius shall be same
as that of connecting tube.

The wall thickness shall be gradually

increased from inner/outer radius to 90
degree from it.

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RETURN BEND DESIGN

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RETURN BEND DESIGN

Thickness at inner bend radius for elastic design

Min. wall thickness = Max. [{stress thickness + corrosion allowable}, API 530 table
1 min. thk.]
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RETURN BEND DESIGN

Thickness at outer bend radius for elastic design

Min. wall thickness = Max. [{stress thickness + corrosion allowable}, API 530 table
1 min. thk.]

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RETURN BEND DESIGN

ELASTIC DESIGN MAY NOT BE GOVERNING

ELASTIC DESIGN of BEND as per API 530 - 2015 Edition

Tube Outside Diameter, Do 219.1 mm Bend Radius, rcl 304.8 mm

Tube Material Austenitic A213, A312 and A376 TP 347H

Design Tube Metal Temperature 540 DegC

Elastic Design Pressure, Pe 10 Kg/cm2

Corrosion Allowance, CA 1.6 mm Casting Factor, cf 1

Elastic Allowable stress, Se 1230.38 Kg/cm2 All. Stress, Se' = Se*cf 1230.38 Kg/cm2

Thickness Calculation for Inner Radius

Ni = (4(rcl/Do)-2)/(4(rcl/Do)-1) , (Equation -12) 0.781

Required Stress thickness, tsi=Do*Pe/(2*Ni*Se'+Pe), (Equation -11) 1.135 mm

Minimum Wall Thickness, tmi = tsi + CA 2.735 mm

Thickness Calculation for Outer Radius

No = (4(rcl/Do)+2)/(4(rcl/Do)+1) , (Equation -14) 1.152

Required Stress thickness, tso=Do*Pe/(2*No*Se'+Pe), (Equation -13) 0.77 mm

Minimum Wall Thickness, tmo = tso + CA 2.37 mm

Required Minimum Tube thickness from Table-1 3.302 mm

Inner Radius Outer Radius

tmi' = Max (tmi, tm) tmo' = Max (tmo, tm)
Final Minimum Walls Thickness, mm
3.302 3.302

Adopted Thickness,mm PASS 3.302 3.302

Notes:

SAMPLE RETURN BEND ELASTIC DESIGN CALCULATION

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RETURN BEND RUPTURE DESIGN CALCULATION

Thickness at Inner/Outer bend radius for rupture design

-The formulae for stress thickness is similar to elastic design. Rupture pressure
and rupture allowable stress is considered.

-The corrosion fraction is calculated in similar way as that of tubes.

Min. wall thickness = Max. [{stress thickness + Fcorr*corrosion allowable}, API

530 table 1 min. thk.]

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RETURN BEND RUPTURE DESIGN CALCULATION
RUPTURE DESIGN MAY NOT BE GOVERNING
RUTURE DESIGN of BEND as per API 530 - 2015 Edition

Tube Outside Diameter, Do 219.1 mm Bend Radius, rcl 304.8 mm

Tube Material Austenitic A213, A312 and A376 TP 347H

Design Tube Metal Temperature 570 DegC Rupture Exponent, n 6.9

Rupture Design Pressure, Pr 10 Kg/cm2

Corrosion Allowance, CA 1.6 mm Casting Factor, cf 1

Rupture Allowable stress, Sr 1282.36 Kg/cm2 All. Stress, Sr' = Sr*cf 1282.36 Kg/cm2

Thickness Calculation for Inner Radius

Ni = (4(rcl/Do)-2)/(4(rcl/Do)-1) , (Equation -12) 0.781

Required Stress thickness, tsi=Do*Pr/(2*Ni*Sr'+Pr), (Equation -11) 1.09 mm

Bi = CA / tsi 1.47 Corrosion Fraction, fcri 0.79

Minimum Wall Thickness, tmi = tsi + CA 2.35 mm

Thickness Calculation for Outer Radius

No = (4(rcl/Do)+2)/(4(rcl/Do)+1) , (Equation -14) 1.152

Required Stress thickness, tso=Do*Pe/(2*No*Se'+Pe), (Equation -13) 0.74 mm

Bo = CA / tso 2.17 Corrosion Fraction, fcro 0.84

Minimum Wall Thickness, tmo = tso + CA 2.08 mm

Required Minimum Tube thickness from Table-1 3.302 mm

Inner Radius Outer Radius

tmi' = Max (tmi, tm) tmo' = Max (tmo, tm)
Final Minimum Walls Thickness, mm
3.3 3.3

Adopted Thickness,mm PASS 3.3 3.3

Notes:

SAMPLE RETURN BEND RUPTURE DESIGN CALCULATION

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FLANGE CHECK AS PER ASME B16.5

The pressure rating of the flange at design condition shall be taken from the table provided in ASME
B16.5.

The rating obtained shall be compared with the design pressure.

If the rating is more than the design pressure, the flange is safe for that design condition.

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FLANGE CHECK AS PER ASME B16.5

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FLANGE CHECK AS PER ASME B16.5

FLANGE CHECK AS PER ASME B16.5

Elastic Design Pressure 10 Kg/cm2

Flange Material A182 F347H

Design Fluid Temperature 498 Deg C

Flange Class 300 #

Output:

Pressure rating of the Flange at design temperature (refer B16.5) 29.04 Kg/cm2

Pressure rating of the Flange at 100 DegF (38 DegC) (refer B16.5) 50.58 Kg/cm2

Conclusion:

Since, 10 <= 29.04 , FLANGE CLASS IS SAFE

SAMPLE FLANGE CHECK CALCULATION AS PER ASME B16.5

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VACUUM DESIGN OF TUBES
Applicable to tubes with external pressure and the inside tube at vacuum condition. Such as for VDU
heaters

The design is as per UG-28 of ASME Section VIII Division 1.

Step 1: Assume a value for t and determine the ratios L/Do and Do /t.

Step 2: Factor A is calculated from the figure G in Subpart 3 of Section II, Part D.

Step 3: Factor B is determined from the applicable material chart or table in Subpart 3 of Section II,
Part D for maximum design metal temperature.

Step 4: Calculate the value of the maximum

allowable external working pressure Pa using the
following equation:

Step 5: Compare this value with the actual external pressure. If the allowable external pressure is
more than the actual external pressure, the selection is safe.

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VACUUM DESIGN OF TUBES

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VACUUM DESIGN OF TUBES

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VACUUM DESIGN OF TUBES

SAMPLE VACUUM DESIGN OF TUBES

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TUBE CHECK AS PER IBR

The maximum allowable working pressure should not be less than the design pressure.

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TUBE CHECK AS PER IBR
Minimum thickness requirement of the tubes as per IBR

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TUBE CHECK AS PER IBR
For calculation of permissible stress, following temperature shall be considered:-

-This shall be compared with the design TMT, and the working temperature shall be the maximum of
the two.

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TUBE CHECK AS PER IBR
Allowable stress shall be taken minimum of :

Obtained from
ASME IID

Sr/1.5
corresponds to
the allowable
stress as per
ASME IID as
Sr/1.5 is one of
the factor for
deciding
allowable
stress.

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SAMPLE TUBE CHECK CALC. AS PER IBR

SAMPLE TUBES CHECK AS PER IBR

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TUBE CHECK AS PER ASME B31.3

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TUBE CHECK AS PER ASME B31.3

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TUBE CHECK AS PER ASME B31.3

SAMPLE TUBE CHECK AS PER ASME B31.3

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TUBE CHECK AS PER ASME B31.1

E = 1 for seamless or welded pipes.

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TUBE CHECK AS PER ASME B31.1

The allowable stress, S is taken as per ASME section II, Part D.

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TUBE CHECK AS PER ASME B31.1

SAMPLE TUBE CALCULATION AS PER ASME B31.1

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HYDROTEST CALCULATION
Required for both new as well as revamp jobs.

Test pressure shall be at least equal to 1.5 times the design pressure.

Minimum hydrotest pressure, Phmin = 1.5 x P x Sa / Sd

Sa = Stress value at test pressure, i.e. 38 deg C (100deg F).
Sd = Stress value at design temperature.
P = design pressure

Minimum HTP shall be calculated both for elastic as well as rupture design condition.

Higher of the two HTPs will be considered as the minimum HTP.

A minimum HTP of 35 Kg/cm^2 is specified for coil testing.

The maximum HTP shall be limited to the extent that the weakest component shall not be stressed
beyond 90% of the material’s yield strength at test temperature (100 deg F).

Minimum flange rating of 300# to be used.

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HYDROTEST CALCULATION
HTP shall be maintained for a minimum period of one hour to test for leaks.

If the minimum HTP is greater than maximum HTP, the adopted HTP shall be restricted to the
maximum HTP. However, the adopted HTP must be equal to at least P x Sa / Sd. The thickness of the
component can be increased to meet this criteria.

If the minimum HTP is greater than maximum HTP due to flange limitation, the flange rating to be
increased. In case it is not possible, coil is to be tested without flange.

The HTP to be reported should be minimum HTP and not the maximum HTP.

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HYDROTEST CALCULATION

SAMPLE
HYDROTEST
CALCULATION

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 Engineers India Limited

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