A finite element steady state heat transfer and stress analysis of a waste heat boiler was performed for Exchanger Industries, for the Suncor Voyageur Upgrader Waste Heat Boiler.  The boiler was analyzed and the results compared to the ASME Section VIII Division 1 allowable stress values, using the methodology of Division 2 (2004 Edition with 2006 Addenda).  The loads analyzed were design, operating, hydrotest and vacuum internal pressures, reaction load on the inlet channel, self-weight, contents weight and three steady state thermal loads (normal operation and two upset conditions).  Conservative outside air temperatures were used for all thermal analyses.

Results of the revised analyses predicted that the vessel conforms to the allowable limits for stress according to criteria set forth in Mandatory Appendix 4 of Section VIII, Division 2 of the Code, using allowable design tensile stress values from Division 1 of the Code.  A manual check also indicated that there is sufficient margin in the compressive stress in the tubes to prevent buckling.