Header Box Stress Calculations

Based On ASMEVIII Stayed Vessels of Rectangular Cross Section

Material Strengths as per ASME II Part D Materials Always Check Notes & Use Worst Case



INPUT

PRIMARY DATA
MAWP Estimate 1.3*Design pressure to begin with
Design Temperature From data sheet
Allowable Stress From ASME II Part D Materials (Lowest / worse case value)
Corrosion Allowance (0mm for St.St / Duplex etc., 3mm M.S)
No. Stays / Partitions See fig 1
Full Span End Plate Full Span is usual, split if partition plates run through end plate

HEADER BOX DETAILS
Top/Bottom Plates Min 12mm (M.S), Min 10mm (St.St / Duplex etc.) API 661 6
th
Ed 7.1.6.1.6
Tube Sheet Min 19mm (M.S), Min 16mm (St.St / Duplex etc.) - API 661 6
th
Ed 7.1.6.1.6 (Must be
25mm to have double groove which is preferred over single groove)
Plug Sheet Min 19mm (M.S) Min 16mm (St.St / Duplex etc.) API 661 6
th
Ed 7.1.6.1.6
Partition Min 12mm (M.S), Min 6mm (St.St / Duplex etc.) API 661 6
th
Ed 7.1.6.1.6
End Plate - Min 12mm (M.S), Min 10mm (St.St / Duplex etc.) API 661 6
th
Ed 7.1.6.1.6

Note: Start with thinnest materials & work up until acceptable

Internal Box Height No. of rows * Vertical pitch (Vertical pitch = sin (60)*Horizontal pitch)
Internal Box Depth Keep as close to 100mm as possible
Maximum Span See Fig 1
PLUG DETAILS
Plug Type Nearly always standard
Plug Dia 1/8 bigger than tube
Equiv. Plug Dia Same as plug if standard plug
Tube Hole Dia Special close fit (19.25mm , 25.65mm 1, 32.03mm 1 , 38.46mm 1 ,
51.26mm 2) API 661 6
th
Ed 9.3.1.3
Tube Pitch From Data Sheet

NOZZLE DETAILS
Box Type Use stress calc sheet info to fill in
Nozzle Type Use stress calc sheet info to fill in
Nozzle OD From data sheet (If squashed nozzle, treat as normal nozzle)
Wall Thickness Standard Schd (80, 120, 160) Start with smallest WT
Wall Tolerance Always 12.5% unless a forging 0% (Long weld neck)
Nozzle Length Rough Estimate
Allowable Pipe Stress From ASME II Part D - Materials (Lowest / worse case value
Weld Cap Size of weld round nozzle (Usually 6mm or 10mm)

MISCELANEOUS DATA
Weld Factor Main Seams Usually spot or full radiography (0.85 for Spot, 1 for Full)
C Factor for End Plates Always 0.2
Ligament / Weld Factor Ties Always 0.7 (Cannot radiograph internal plates)


RESULTS

Check that maximum value of stresses is less than 100% of allowable & check all outcomes

Required to Resist Pressure

Change top / bottom plate thickness until 100% of max allowable stress and put this thickness into
required to resist pressure Change top / bottom plate thickness to previous value

MAWP Maximum allowable working pressure

Increase MAWP until something breaks (end plates unacceptable or stress 100%)

When calculating maximum allowable working pressure ensure that all flanges are capable of
withstanding this pressure if not then the maximum allowable working pressure is determined by
flange maximum allowable working pressure.

Minimum Test Pressure Cover Sheet

Minimum test pressure if not stated by customer spec will be in accordance with UG99
(1.3 * MAWP * (Samb/Sdesign)) ASME VIII UG-99

Where: MAWP is Maximum allowable working pressure
Samb is Maximum allowable stress at ambient temperature - ASME II Part D - Materials
Sdesign is Maximum allowable stress at design temperature - ASME II Part D - Materials