Updates for Current RCS Users
- This page is for current RCS customers only. It contains a listing of the latest updates and their features, and contains instructions on how to install updates. None of the links below are for a full installer of RCS. If you are a current user that needs a new complete installer, please contact RCS and we can get a new installer created for you. The appropriate Registration Code for each update should have been emailed to all RCS users. If you did not receive this code or can not locate it, contact us and we can assist further.
- Complete update instructions, as well as a full summary of changes and enhancements can be accessed within RCSWin by clicking Tools -> Administrative -> Edit / Print Updates from the main RCS menu.
- RCS recommends that you create a complete backup of your current RCSWin installation prior to installing any new updates. This can be done simply by making a copy of the entire RCSWin folder. If RCS is installed locally, the RCSWin folder will be on your local machine (usually C:\RCSWin). If you have a network installation, the RCSWin folder will reside somewhere on a network drive. Existing material files, gasket files, and default files will not be updated or overwritten when running updates.
- The updates below are not cumulative. Each update must be installed in sequence (unless otherwise noted for a specific update). If you have a version of RCS that predates the oldest available update on this site, you will need to contact RCS so we can issue you a new complete installer for the RCSWin software
- If you are running a network installation of RCSWin and your working directory resides on a local drive, you will need to download the corresponding RCSWin User Directory update as well. Users who have local installations do not need the separate User Directory update.
- The RCS software must be closed before you can run any of the updates. Make sure to close and save any jobs you have open before running the update installers.
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Available Updates
Click here to download the 01.01.23 RCSWin Update
This download is an installer for the 01.01.2023 update to RCS. This is an intermediate update year (it does not coincide with an ASME Update). Consequently, there are not a lot of significant changes that will impact designs within this update. Material files, gasket files, and default files will not be updated. If you are significantly behind on updates, or if you have need for other reasons, contact RCS and we can provide you with a fresh complete installer for the latest version of the software.
Click here to download the 01.01.23 User Directory (only needed for network installations)
This update is only needed if you are running a network installation of RCSWin and your working directory resides on a local drive. This update needs to be run and installed directly into the user directory (usually called rcs_user_001) on each machine that uses RCSWin, while the main 01.01.23 update needs to be run on the network path where RCSWin is installed.
Summary of Changes and Updates (01.01.23)
New RCS executable. This change should have minimal impact on the user, but represents a substantial change to the RCS software. The old primary executable is called rcs_master_menu.exe, and this is what the RCS shortcut points to. The new one is simply called RCS.exe, and a new shortcut will be made to this program when the update is installed. The look and feel of the new program should be very similar to the old one. The significant change is that the new version is compiled to the .NET framework, which is installed and updated automatically on Windows machines. This new version of the RCS executable is considered a test version, as it has not gone through a complete set of testing. As such, it is installed in parallel with the old RCS executable. Note that the calculations should not be impacted in any way with this new program, only the user interface has changed. We would love for folks to use the new version and provide any feedback on it, but if you encounter any problems or difficulties, the old version is still available, and you can simply switch to it and run RCS as normal.
Appendix O Calculations: There were a couple of different changes to Appendix O, the first was to correct a bug, and the second was to expand the Appendix O calculations to cover more scenarios.
- The bolt ambient yield stress is used to come up with a range of acceptable stresses. The min and max stresses are editable, but are intended to default to 40% and 70% of the bolt ambient yield stress. Instead, they were inadvertently defaulting to 40% and 70% of the ambient yield for SA-193-B7 studs every time. This has been corrected.
- In WRC-538, there is wording that states “In some cases (e.g. high temperature stainless steel flanges) the yield strength of the flange may reduce significantly during operation.” There is a process to perform this additional check, which RCS did not previously include in our calculations. In short, if the ratio of the flange yield at design temperature to the flange yield at ambient is less than 1.25 * Ψg, then a second check for an acceptable allowable flange stress should be made. Ψg is defined as the “fraction of gasket load remaining after relaxation”. RCS now looks up the yield at design temperature, which it previously did not do, and performs this additional check, and calculates Syo’. Ultimately, WRC-538 goes on to say that Sy (the allowable used) is the smaller of Sya or Syo’, and RCS is now complying with this.
Estimating program: Minor changes to the amount of machining allowance added for flanges, tubesheets, and covers for ordering purposes.
In the previous update (01.01.2022), the method to round stresses, specifically, the number of significant digits, was modified to exactly comply with ASME Code. We received a few complaints about the change and requests to go back to the old version. Consequently, on Page 6 of the RCS settings, we added an option that allows the user to toggle between the new and old methods of stress rounding. Caution should be exercised when overwriting this option. The modified rounding logic is exactly per ASME Code.
Click here to download the 01.01.22 RCSWin Update
This download is an installer for the 01.01.2022 update to RCS. This update is considered a major one, as it coincides with an ASME Code update year, and it will update RCS from each of the past two versions (01.01.2020 and 01.01.2021). If you did not run the previous update, it is not necessary, as the changes from that update are included in this one as well. Material files, gasket files, and default files will not be updated. If you are significantly behind on updates, or if you have need for other reasons, contact RCS and we can provide you with a fresh complete installer for the latest version of the software.
Click here to download the 01.01.22 User Directory (only needed for network installations)
This update is only needed if you are running a network installation of RCSWin and your working directory resides on a local drive. This update needs to be run and installed directly into the user directory (usually called rcs_user_001) on each machine that uses RCSWin, while the main 01.01.22 update needs to be run on the network path where RCSWin is installed.
Summary of Changes and Updates (01.01.22)
UW-20 Tube-to-Tubesheet Welds: There were some changes in this section that affect the tube to tubesheet joint load calculations in UHX. Figure UW-20.1 previously contained 4 different sketches for tube to tubesheet welding options. In the 2021 edition, they added two additional figures for “inset” tube to tubesheet welds, where the tube does not project to or past the face of the tubesheet, but is instead inset back from the face of the tubesheet. Within the UHX tubesheet section of RCS, these new options were added to the drop down list of possible types to select, and logic was added to handle the new equations introduced to calculate these joint types, and display the results in the UHX printout. Note that type “e” from Figure UW-20.1 can only be considered a partial strength weld per UW-20.6(e)(1), where type “f” can be either a partial or full strength weld.
Appendix A: There were some changes within Appendix A that affect UHX calculations as well. The welds are now classified as “af” for fillet welds, and “ag” for groove welds, where they were previously just all called “a”. This makes the naming convention consistent with UW-20. These updated selections are now available in the drop down, and the updated descriptions are shown on the printouts as well. There are two weld types that are no longer permitted: Weld joint types a and b for the “No Test” column. Note that, within RCS, these options are still available so that older job files will still be able to run. In the drop down, the text states that they are no longer allowed, and that a value for fr will no longer be defaulted based on this selection. If one of these two types is selected anyway, a pop up will appear with a more detailed explanation and caution, but it will allow for the user to provide their own fr value. This should only be done if trying to duplicate a design done prior to this update.
Previously, the screening criteria to determine if shear stress needed to be checked were based only on the allowable stress. ASME revised the screening criteria to be consistent with actual shear stress calculations. The screening criteria in UHX 12.5.9 (u-tube exchangers), UHX 13.5.8 (fixed tubesheet exchangers), and UHX 14.5.8 (floating head exchangers) now considers the yield stress. This change has been incorporated into RCS.
Appendix 1 changes for cone calculations: ASME changed the logic for cone reinforcement calculations in the 2021 edition in a few ways. The changes are in Appendix 1-5 and 1-8. Appendix 1-5 is for internal pressure calculations for cones, and 1-8 is for external pressure calculations for cones. Both sections are used to determine if additional reinforcement is necessary for the cone to cylinder joint at either end of the cone. Three tables in Appendix 1 have all been removed: 1-5.1, 1-5.2, and 1-8.1. References to these tables have been removed in RCS printouts and calculations as well. The tables were used to arrive at a Delta value, and all three tables have been replaced with formulas instead. Previously, Delta was limited to a maximum value of 30 degrees, but with the new formulas, that is no longer the case. In addition, the formulas for calculating the effective area of reinforcement (Aes for the small end, and AeL for the large end) have changed. There are two different formulas, depending on whether the attaching cylinder meets the minimum length requirements. All formula changes have been made within RCS, and all calculations and printouts will reflect the new requirements.
When designing a three pass exchanger and using the “Fast Input” method for entering nozzles, RCS would sometimes locate the channel nozzles incorrectly. This has been corrected. This also involved forcing the reach channel to have a cylinder (BEM1 for example) if the Fast Input located one channel nozzle at the front and the other channel nozzle at the rear.
In previous updates, RCS had added UG-44(b) calculations (formerly Code Case 2901) for nozzles. However, these calculations were not available from the print menu (File -> Print from the main menu, or the Print icon on the main toolbar). Now, these calculations are available for selection from the print menu, and the calculations are properly saved within the print file for each nozzle.
Similarly, RCS had previously added Appendix O calculations for flanges, but they were not properly being saved for each flange, or available from the print menu. This has been corrected, and now Appendix O calculations can be run and saved for each flange, and all calculations properly printed.
The CNC Program has been cleaned up a bit and added to the help system, providing some additional information on functionality, as well as a couple of bug fixes within the program. The “Change Formats” button now works correctly, and the “Edit” button does as well, where these both generated errors previously.
All aspects of nozzle calculations are now included in the help system. This includes the initial nozzle input and Fast Input screens, as well as the Menu Mode nozzle calculations (Run -> Menus -> Nozzle Reinforcement or Nozzle Reinforcement Edit). The process of altering a nozzle after it has been added to a job file is somewhat convoluted, and this process is now described in greater detail within the help system.
In the previous “intermediate” update to RCS (01.01.2021), we added the ability to handle a few new TEMA types (N-U, N-S, and N-T). This was a very extensive change in that it affected virtually every aspect of the design process. After some feedback from customers, we discovered some problems with the new TEMA types. Specifically, problems with handling the dimensions on the drawings for the new types. Tail dimensions and center to center dimensions were handled in different locations within RCS, as well as different sections of logic for batch mode and menu mode. After further changes and extensive additional testing, we believe the new TEMA types are now being handled correctly in all aspects – from the initial data input, through all aspects of the designing and customizing, to the drawings and sketches, to the BOM and estimating programs.
After receiving some questions from a customer regarding values pulled from HTRI, it was discovered that the shell and tube mean metal temperatures being imported from HTRI did not match the actual mean metal temperatures that HTRI shows within their printout. In short, this has been corrected. The more detailed explanation is that, in the older version of the DBO file, the actual mean metal temperatures were not available. Instead, RCS pulled a different value from HTRI and then made some assumptions. If you are using the HTRI Automation Server and importing directly from an HTRI file, this problem is automatically corrected. If you are exporting to a DBO file from within HTRI, make sure to choose the “Extended DBO” option – as this is the only version of the DBO file that contains the mean metal temperatures. RCS has added logic to read this extended version of the DBO file and pull the correct fields. If you use the older version of the DBO file that does not contain the mean metal temps, RCS will now generate a warning indicating that the previous logic and assumptions that RCS made will be used.
In the RCS UHX program, there was a problem with the button labeled “Calc AL”. AL is the variable in Code for the total pass lane area. There is a subroutine within the RCS calculations that did an excellent job of this part of the time, but other times simply gave an error message. There were multiple scenarios that could cause this error message. The program has been corrected so that the subroutine is called appropriately for all scenarios, and internally, an intermediate file containing results from this subroutine has been appropriately cleared so that no results from a previous run are left in the file.
Fixed a rarely encountered problem with the RCS nameplate drawing. When creating the nameplate drawing, RCS calculated the dimensions for the bracket to attach the nameplate. In the event of a very small pipe sized exchanger, it was possible for the bracket calculation to actually arrive at a dimension that was larger than the diameter of the exchanger, which caused the program to crash. This has been corrected.
For many years, RCS has simply used 0.3 for the Poisson’s Ratio for all materials. Within UHX calculations, the Poisson’s Ratio field was editable, so users could override this value, but it always defaulted to 0.3 and most users simply used this. With this update, RCS is now using values from Table PRD in ASME Section II Part D. The only thing necessary to make this work is to run the RCS Material Update utility, which is required with a new release of ASME anyway. When the update is run, it will automatically populate your entire material database with the appropriate Poisson’s Ratio values from Table PRD. In addition, any new materials that are added will automatically look up the correct value for Poisson’s Ratio.
The allowable stress rounding logic within RCS has changed to match the requirements set forth in the General Notes of the stress tables in Section II Part D. This rounding logic is used when interpolating between points within the tables. In short, the requirements specify that the number of significant digits used in interpolation must not exceed the number of significant digits of the actual table values, and then requirements are given on when to round up or down. RCS was retaining more significant digits in order to get a more accurate result, but per Code, this additional level of accuracy is not allowed. The end result is that looked up allowable stresses within RCS may vary slightly from previous versions, but will now be based on the proper rounding rules.
All applicable data from ASME Code charts and tables, such as heat treat data, radiograph data, x-ray data, impact test exemption data, external pressure charts, paragraph references for UHX, UCS, UHA, UNF, etc. have been updated to the 2021 edition of ASME Code.
We have continued the expansion and improvement of the RCS help system, with more topics available and more areas of the software integrated into the help system.
2021 ASME Material Update
All material properties from the 2021 edition of ASME Section II Part D are now included within this update. This includes stress table values, yield table values, moduli of elasticity values, coefficient of thermal expansion values, and now Poisson’s ratio values for all materials in ASME Section II Part D, as well as updates to the notes for those tables. As with all previous updates, it is required that each user update their material database in order to migrate their specific material list to the new 2021 material properties. One other noteworthy change with this update is a considerable expansion of ASME’s yield stress table. There are more materials included in the table, but more significantly, the yield stress table was expanded to higher temperatures for many materials. Previously, many materials within ASME had maximum allowable stress values at temperatures above the highest temperature at which yield stress values were present. With this update, ASME has corrected this discrepancy for many materials. Running the material update program will automatically update RCS to use these new expanded tables. Below is a summary of the material update process:
- Before reading through the entire material update explanation, it is worth noting that the RCS material update program is sent out with the most likely defaults already selected. The vast majority of customers will not need to make changes to the default selections. If you are unsure what options to use after reading the info below, your best bet is to just use the default selections and run through the steps as described below. It is also worth noting that far more extensive help is available within the software under the Materials heading of the RCS help system. If you are unsure what material database version you are currently using, the answer is located in the bottom right-hand corner of the main RCS window. 19 indicates the 2019 edition, 21 indicates the 2021 edition (the latest version, not previously available before this update.)
- Click Tools -> Setup -> Material Update from the main RCS screen. This opens the RCS material update program. The first field is the “source” material file, and this should be set to your current material database (19 for most people). The second field is the “destination” material database, and should always be set to 21, since the goal is to create a version of your material database that uses values out of the 2021 ASME Section II Part D tables.
- Search Settings: In almost all scenarios, you want to leave the first option set to “Yes” and all others set to “No”. This will search based on a unique material ID, which is the safest way to locate each material from one version of ASME to the next.
- Save Settings: The default is to clear out any data that is not found in the destination material files. What this means is that if you have added any materials to your material database that RCS cannot successfully locate in the 2021 edition of the tables, RCS will remove this material entirely from the new version of your database. This is the absolute safest way to ensure that all material data you use will be from the latest edition of ASME, but it is also the way that is most likely to result in lost materials. However, after testing on the standard RCS material database, we can confirm that ALL materials are successfully brought over to the 2021 tables, so hopefully other people will see similar results with their unique material databases. If the “Clear data in destination if no match found” option is set to “NO”, then materials that are not found in one or more of the 2021 tables during the update process will be kept and brought over from the previous material database. The remaining Save Settings are used to determine which portions of the previous material properties are retained.
- When you are satisfied with the settings, click the "OK/Build" button. This will pop up a window that is a summary of all materials in your database, and you can even edit on a material by material basis, any of the settings that were shown on the previous screen in this text file and save the changes. Most users will just glance through this file without changing anything. Close the file, and RCS will then begin the process of updating each material in the database sequentially. This process can take a few minutes to complete.
- When the process is complete, a final summary of the results will be displayed. The summary shows a listing of all materials from the previous database, and a warning will appear next to any material that was not brought over.
- The final (and most important) step is to actually change to using this material database! Running the update creates the 2021 material database, but it does not automatically switch you to immediately start using it. Click Tools -> Setup -> Materials from the main RCS menu to run the material editor. This utility lets the user add new materials, or switch between the different material databases. The top line reads "Current RCS Material File", and you will need to select the 21 option, which was not in the list until after the above steps were executed. After doing this, you will be using the 2021 ASME material properties for all jobs so long as you do not ever change back to a different database from this same screen.
- Lastly, if anyone has questions or problems with their material update, feel free to contact RCS via phone or email for further assistance.
Click here to download the 01.01.21 RCSWin Update.
This download is an installer for the 01.01.21 update to RCS. This installer will update RCS from 01.01.20. Material files, gasket files, and default files will not be updated. This is NOT a comprehensive update. If you have not previously updated RCS to the 01.01.20 version, this update will not work! If you are behind on updates, feel free to contact RCS and we can provide you a fresh complete installer for the latest version of the RCS software.
Click here to download the 01.01.21 User Directory (only needed for network installations)
This update is only needed if you are running a network installation of RCSWin and your working directory resides on a local drive. This update needs to be run and installed directly into the user directory (usually called rcs_user_001) on each machine that uses RCSWin, while the main 01.01.21 update needs to be run on the network path where RCSWin is installed.
Summary of Changes and Updates (01.01.21)
Note: To get a printout of all instructions, and a summary of updates from within RCS, go to Tools -> Administrative and double click Edit / Print Updates.
- Updated the RCS Help system in a couple of ways. First, the RCS help system now uses a newer version of the .NET framework. The old one used Microsoft .NET 3.5, and the new one uses Microsoft .NET 4.6.1. This version of .NET should be preinstalled on most Windows machines, but if you have problems accessing the help content within RCS, it should prompt you to download the proper version of the .NET framework. We strongly recommend you do this in order to have access to the help content. The .NET framework is a free download from Microsoft. In addition to this, we have continued to gradually expand the help system to include more topics and cover more aspects of the entire RCSWin system.
- Corrected an issue with certain external pressure charts that could potentially generate an error when attempting to look up values that exceeded the chart. All external pressure charts have been corrected and published with this update.
- Corrected a couple of minor bugs within the RCS material update program
- Added the ability to handle new TEMA types within RCS: N-U, N-S, and N-T. All shell types are handled (NEU, NFU, NJS, etc.). These were previously not handled within RCS at all. This change starts at the data input stage, with the new TEMA types being available, and propagates through to many different programs in order to ensure dimensions, calculations, drawings, 3D model, the BOM, estimates, etc. are all properly handled. Note that this change will not affect any existing designs or change anything on any other TEMA types.
- Fixed an issue with losing the impingement plate when drawing a tube layout. This was a text comparison mistake that was searching for the wording “Yes on Bundle” and comparing it to “Yes On Bundle” when determining if an impingement plate was specified. The one extra capital letter caused the comparison to flunk, and consequently eliminated the impingement plate. This issue is now resolved.
- Completely redid the RCS website, updating and improving the content and modernizing the look and feel. In addition, the new website is friendlier on multiple platforms, including tables and phones instead of just PCs. The Updates section where this update is located is also improved, and is easier to navigate and find the latest updates to RCS.
- Fixed a bug within the RCS Inquiry / Purchase Order program that causes problems when adding multiline items to an inquiry or PO (weld pads, for example). The issue causes items that were present on the inquiry or PO to be omitted from the printout, and is now corrected.
- Added MAWP calculations for UG-44(b) - nozzle flange reduced equivalent pressure. The MAWP values have been added to the display within the program, and to the printout.
- Changed a few items within the WERCO nozzle load calculation program. First, MAWP values have been added to this program, which are shown on the printout of the calculations. In addition to adding MAWP calculations, a couple of changes have been made to the input fields. The “Yield Stress” input has been changed to “Allowable Primary Stress”, and the “Yield Stress Multiplier” field has been changed to be “Allowable Primary Plus Secondary Stress”. Calculated stresses that do not include pressure are compared against the allowable primary stress, and calculated stresses that do include pressure are compared against the allowable primary plus secondary stress.
- RCS’s UHX calculations for fixed tubesheet exchangers with expansion joints have been modified. It was discovered that the verbiage that had always been (and still is) in TEMA regarding bellows expansion joints was actually not in UHX. However, the program acted as if it was. The wording in TEMA stated that if your bellows expansion joint spring rate was below a certain value (there is a simple formula to arrive at this value) then you could use a “J” value of 0. That essentially implies that the expansion joint is infinitely flexible and does not require any force to expand or compress it. It also eliminates any “help” that the shell cylinder itself might provide in resisting the differential expansion loads. RCS was still set up in this fashion. In the drop-down list where you indicate whether or not you have an expansion joint, the options were: None, bellows, FSE, or procedure in UHX-17 (the last is probably rarely if ever used). If you picked “bellows” then the program defaulted the value of J to 0 and ignored the spring rates. Since this “safe” limit for assuming J = 0 is nowhere within UHX, this is not strictly correct. While several test cases indicate that the normally low spring rates of bellows expansion joints actually result in a J value of very close to 0 (like 0.000036), it is not technically zero. The following modifications were made:
1. The wording for the dropdown was changed to accommodate this change in behavior, and the help topics associated with this were modified accordingly.
2. Inadvertently, it was discovered that the units associated with the spring rate on the screen were in “in-lb”, which is wrong, and were corrected to show “lb/in”.
3. The program properly enables and disables the correct fields, and warns the user if no spring rate is input. The logic now works the same for a bellows expansion joint as for a FSE type expansion joint.
4. It was also discovered that the units within the UHX printout for the spring rate were simply in pounds, which is incorrect. This was changed to lb/in. - Calculation and selection of f1 and f2 for fixed tubesheet kettles, used in conjunction with cone reinforcement at large and small ends due to internal pressure (App. 1-5) & external pressure (App. 1-8):
ASME added a calculation method to UHX-13.10.2(g) for fixed tubesheet kettles only, to calculate values for f1 and f2 to be used with App. 1-5 and 1-8 calculations. The formulas for f1 and f2 contain the calculated axial membrane stress for the large end and small end of the cone as determined in UHX-13.10.4((d)(2) & (3). This stress varies for each case that UHX requires you to run. There is no direction given as far as which values of f1 and f2 are the appropriate ones to pull out and use in the App. 1-5 and 1-8 calculations.
Within RCS, we have shown the various values of f1 and f2 on the summary section of the UHX calcs, as additional columns for the sections showing the calculated axial membrane stresses for the large end and small end of the kettle, since they are determined from these calculated values. In addition, the program will issue an informational message to make certain the user is aware of these new variables and the need to select the appropriate one to use in their cone reinforcement calculations. The message is shown during the first UHX calculation.
UHX-13.10.2(g) & (h) state that f1 and f2 do not need to be considered for UHX operating cases (cases that include differential thermal expansion), so those cases are simply labeled as “N/A” within the output tables. That eliminates about half of the possible cases.
We have also eliminated UHX cases that do not involve shell side pressure, for use with Appendix 1-5. These cases will generate a value for f1 and f2, but then be used in App. 1-5 and utilized in a calculation that does not involve shell side internal pressure. Since these values for f1 and f2 were generated for a case where there was no shell side pressure, then these values cannot possibly exist for the case being analyzed by App. 1-5 which does include pressure. These cases are also labeled “N/A”.
Similarly, but in reverse, we rule out any cases for use with App. 1-8 that would contain f1 or f2 values derived from cases that do not have external shell pressure. Since App. 1-8 is a calculation method solely based on external pressure, these values for f1 and f2 could not possibly exists for the case being analyzed in App. 1-8. These cases are also labeled “N/A”. - Vacuum Conditions on cylinder calculations:
RCS has not ever had a check for vacuum conditions, as it is so rare that this would control the thickness of a cylinder. RCS will calculate and show the external pressure that a cylinder is good for, but it has never used this as a design criteria or even shown a flag or warning if the cylinder is not good for vacuum conditions. The most it would previously do is show a calculated external pressure that is less than full vacuum. A new check has been added to the cylinder calculations to bring attention to this issue. If the user specified full vacuum during the data input, RCS will now issue a warning on the cylinder calculation screen if the cylinder is not good for full vacuum external pressure. - Minimum cylinder lengths for attachment to small end of cones:
In UHX-13.5.11, there is a requirement that a cylinder must be a certain thickness for a certain minimum length of 1.8 * Sqrt (Ds * ts). For typical exchangers, this is not an issue, but for fixed tubesheet kettles where the cylinder adjacent to the tubesheet is a stub cylinder, this is essentially a more stringent minimum length requirement than those found in Appendix 1-5 (internal pressure) and 1-8 (external pressure). Previous versions of RCS were not taking this into account when setting the default minimum length for a stub cylinder, but it is now being calculated. Note that this length does not apply for Simply Supported Calculations.
When running a kettle through the “Run Job” sequence, the logic has been modified. The popup to select the kettle configuration has changed. Now, there is a new option. The following options appear:
1. Cone with Stub: This will add a stub cylinder that defaults to a length long enough to comply with App. 1-5 and 1-8 for cone reinforcement calculations.
2. FTS Kettle Cone with Stub: This will add a stub cylinder that defaults to a length long enough to comply with the more stringent UHX-13.5.11(a) minimum length requirement. Note that this method is not required if Simply Supported UHX calculations are performed. In that case, the “Cone with Stub” option would be appropriate.
3. Cone without Stub: This option is the same as it always was, it will add a cone but no stub cylinder.
4. Head with Stub: This option is the same as it always was, it will add a head with a stub cylinder.
After making a selection, the cylinder thickness calculation screen will appear. From this screen, the length of the stub cylinder can be changed as desired. If a length is entered that does not comply with either App. 1-5 and 1-8 or UHX-13.5.11(a) (depending on which option was chosen), the program will warn the user but proceed. Note that you can enter a 0 in the cylinder length field and it will automatically recalculate the minimum length based on which option was chosen for this stub cylinder, and set the length to this value. In addition, if the fixed tubesheet kettle option applies and the user chose a stub length that is too short, RCS will issue a warning during the UHX calculations to indicate this. - Nozzle flange facing in 3D model:
In the logic to calculate the geometry for the nozzles, 300# and below flanges were calculated the same as 400# and above. In the flange tables, however, the WN flange thickness includes the raised face thickness (1/16”) for flanges 300# and below. For 400# and above flanges, the same table has flange thicknesses that do not include the RF height (1/4”). For reasons unknown, this is how nozzle flange suppliers have always shown them. Consequently, when figuring the required length of the nozzle pipe when using a 400# or above nozzle flange, the program arrived at a pipe length that was actually ¼” too long (since it should have subtracted both the flange thickness AND the RF thickness from the overall projection). The end result was that the nozzle pipe was drawn a ¼” too long in the 3D model, and the flange was drawn a ¼” too short. This problem has been corrected, and the 3D model will now draw all nozzle flanges correctly. - Created a new Excel macro enabled template to assist in editing the estimating program tables. This template is located in the \RCSWin\stest subfolder, and is called RCS_Estimating_File_Editor.xltm. Note that VBA and macros must be enabled in Excel before this template will work properly. The purpose of this new file is to make modifications of the main estimating default file (stedata) simpler and cleaner. The stedata.ada file is quite large and difficult to manage, and is all a text based file. Making modifications to this file requires a high level of attention to detail and care to maintain the exact structure of each SUB within the file. The Excel macro greatly simplifies this process. Users can import any of the SUBs from the estimating file, modify them in an Excel table format, then export them back to the estimating file without having to worry about maintaining the proper file structure. As with any changes of this fashion, we recommend creating a backup of all estimating files prior to making changes so that you can revert back to the previous version if any problems arise. Lastly, it is worth pointing out that, after making changes using this macro, the modified STEData.ada file will need to be rebuilt as always.
Click here to download the 01.01.20 RCSWin Update.
This download is an installer for the 01.01.20 update to RCS. This installer will update RCS from each of the two previous versions: 01.01.18 and 03.25.19. If your company has not run the 03.25.19 update, it is not necessary to do so. Material files, gasket files, and default files will not be updated. This is NOT a comprehensive update. If you have not previously updated RCS to at least the 01.01.18 version, this update will not work! If you are behind on updates, feel free to contact RCS and we can provide you a fresh complete installer for the latest version of the RCS software.
Click here to download the 01.01.20 User Directory (only needed for network installations)
This update is only needed if you are running a network installation of RCSWin and your working directory resides on a local drive. This update needs to be run and installed directly into the user directory (usually called rcs_user_001) on each machine that uses RCSWin, while the main 01.01.20 update needs to be run on the network path where RCSWin is installed.
Summary of Changes and Updates (01.01.20)
Note: To get a printout of all instructions, and a summary of updates from within RCS, go to Tools -> Administrative and double click Edit / Print Updates.
- The entirety of Code Case 2901 was inserted in ASME Section VIII, in paragraph UG-44(b). The methodology and wording are identical to the Code Case, which had already been incorporated into the RCS software. It is noteworthy, that even though this method in now part of the official Code, it still states that it “may” be utilized. It is not mandatory at this time. Since the wording is identical to the Code Case, we simply changed all the references to “Code Case 2901” to “UG-44(b)”. It still is an optional calculation which is available either as a standalone utility, or via the “Nozzle Reinforcement Edit” menu option.
- UHX Changes:
a.) UHX-4(h) is a new paragraph. It has restrictions on how close a large diameter (> 30% of cylinder ID) can be located to a tubesheet that is welded to that cylinder, with or without a hub. There is a minimum distance, which is shown on the first page of the UHX printout. This restriction does not apply if you utilize the Simply Supported method. In that method, the attached cylinder is not counted as part of the strength of the tubesheet. However, in the Elastic-Plastic method, the strength of the attached cylinder is counted and can affect the tubesheet design. Since this section of the cylinder is already “counted” in the tubesheet design, the user is restricted from counting the same portion of the cylinder as available reinforcement for the nozzle located there. It states “no part of the nozzle ‘d’ may be within 1.8(Dt)**0.5 of the adjacent tubesheet face”. UG-4(h)(3) goes on to clarify that the nozzle reinforcement itself, may be in this area, simply the corroded nozzle ID itself cannot be. Figure UHX-4.1 was added to pictorially demonstrate this.
b.) UHX-10(d) and associated new figure UHX-10(c) were added with regard to attaching a hemi-head directly to a tubesheet (or its hub) without a connecting cylinder. It apparently resolves a dilemma that folks that use hemi-heads had, with regard to whether or not a straight flange on a hemi-head negated the special rules for hemi-head attachments and forced you back into the more common cylindrical attachment. This gives a “clever” way around this problem. Note that the hemi-head geometry can be selected in RCS under the Fixed Tubesheet Configuration drop down list. It is labeled “fts * configuration a”. The help topic associated with it gives further information.
c.) UHX-10(f) was reworded slightly to allow the use of either the operating pressure or the design pressure when evaluating the operating load cases. Previously an assumed “preference” was implied that the operating pressure should be used, but the design pressure could be used when operating pressure wasn’t known. There seems to be no preference now, although operating pressures would seem to be more appropriate when evaluating the operating load cases.
d.) The shear stress allowable value for all tubesheet types has been modified from simply 0.8S, to min.(0.8S,0.533Sy). This is now reflected in the calculations and the printout.
e.) Changed the wording of Figure UHX-13.4 to cover “thicker” cylinders welded to the tubesheet as well as cylinders that are a different material. The previous title seemed to imply that it only applied to thicker cylinders. However, the figure is referred to by UHX-13.6, which clearly covers cylinders that are thicker as well as cylinders that are a different material. The change makes them agree. RCS note: There are already input fields for the allowable stresses of the tubesheet, channel and shell (if either or both are integral). It appears to me that the procedure in UHX-13.6, when used due to “different materials”, rather than “different thicknesses” only applies when the “different materials” would have differing modulus of elasticity and / or coefficient of expansion. In other words, it is not necessary to consider a plate cylinder welded to a forged tubesheet as “different” materials, so long as they are both the same basic grade (i.e. both CS, both 1 ¼ Cr, etc.). The fact that plate and forging may have different allowable stresses is already accounted for in the existing input fields without applying this method.
f.) Non-Mandatory Appendix A (used within UHX): In all previous versions of this appendix, there has been a factor, Ft. This is a multiplier to account for differences between the amount that the tube expands radially, versus the amount that the tube hole in the tubesheet expands, during operation. Theoretically, if the tube and tubesheet have differing coefficients of thermal expansion, then one could grow more than the other during operation. Following this logic, if the tube itself had the higher coefficient, then its growth would actually “enhance” the tube to tubesheet joint, and this factor, Ft, is allowed to be greater than 1.0 in order to allow for this. Conversely, if the tubesheet has the higher coefficient, then the hole might expand more than the tube and lessen its strength (Ft < 1.0). There has always been an equation to calculate this effect, which is: Ft=(Po+Pt)/Po. Basically, Po is the residual pressure resulting from the roller (or hydraulic) expansion process, and Pt is the interfacial pressure resulting from differential thermal expansion at design temperature. The differential expansion pressure, consequently, either adds to, or takes away from, the original tube expansion pressure. However, there was previously no methodology to calculate either Po or Pt and consequently the program simply defaulted to Ft=1.0, even though informing you of the “potential” calculation for a more precise value. Now, Code has added fairly complex equations to calculate Po & Pt and consequently arrive at a more precise value of Ft. In order to arrive at a value for Po, one must first calculate the value of a new variable introduced in appendix A, which is Pe (tube expanding pressure). All of these variables are now added to the RCS UHX analysis in order to arrive at the allowable tube to tubesheet joint load. For designs where the tube and tubesheet are of the same basic material (CS, Cr, SS, etc.) and will have the same coefficient of expansion, the variable Po has a calculated value of 0 (no difference between the amount the tube and tube hole are “growing”), which causes the equation for Ft to calculate to 1.0 (the historical default). However, for a case such as SS tubes in a CS tubesheet, Ft will be > 1.0. A copy of portions of two fixed tubesheet designs is attached. They are identical except that one has 304SS tubes and the other has CS tubes. The Appendix A calculations are shown by hand, to demonstrate typical values for the new variables, Pe, Po and Pt as well as the resulting value of Ft. This demonstrates how the value of Ft may be greater than 1.0 and how it may affect the allowable tube to tubesheet joint load differently than before. Note … in order to be able to duplicate existing designs that were done prior to this new method, the program allows the user to input a value for Ft. If any value other than 0.0 is input, then it will be respected and will override the potential value calculated per the new method. The program now defaults Ft to 0.0, rather than 1.0, and that is how one indicates that the new method is to be utilized.
g.) Also added in 2019, was the incorporation of this factor, Ft, in determination of the allowable tube to tubesheet joint load for welded type joints f,g & h (Table A-2) where previously Ft was only utilized for expanded only joint types i,j & k. Note that for typical strength welds, these would be calculated per UW-20, which exempts them from this Appendix A analysis. However, if one were to utilize a strength weld, but not comply with UW-20, then the value of Lmax would be determined by Appendix A and the factor Ft would be relevant in that case. Also, Appendix A-1(e)(3)(-a) states that, should you fall in the category of strength weld just described (i.e. done with Appendix A) then the temperature of the tube to tubesheet joint must be below the time-dependent temperature of Section II, Part D. The Appendix A analysis within RCS has been updated in accordance with the above.
h.) A note was added to address tube to tubesheet joints that are either hydraulically or explosive expanded into the tubesheet. The only difference here, is that if you are utilizing a tube to tubesheet joint attachment of a single groove, you are now allowed to use the Fr factor applicable to two or more grooves, when using this expansion method. An option has been added to the program for you to specify this attachment method. If you select the single groove attachment option as well as the hydraulic / explosive attachment method, then the program asks if you want to utilize the higher allowable Fr value allowed. In addition, there is a calculation to set the minimum groove width for this attachment method. This number is also calculated and shown on the output. Note that while the equation formulation looks different from the one typically used from the TEMA Standards, the resulting groove width is exactly the same.
i.) We have added the variable ∆s,M which is calculated per UHX-17(c)(1)(-b) or (c)(2)(-b). This variable is not utilized in the UHX calculations at all. It is a value that is intended to be utilized in the calculation of a non-bellows type flexible shell element in fixed tubesheet exchangers only. This variable is referred to in the latest (tenth) edition of the TEMA Standards in paragraphs RCB-8.5(2) & (3) and is intended to be used as an input value for the design of a flexible shell element as described in the general procedure of RCB-8. TEMA paragraph RCB-8.5(2) states that this value should be calculated for each loading condition required by the tubesheet analysis (UHX). Since the value is not needed in the tubesheet calculations themselves, RCS simply calculates this value for convenience of the user that is performing a TEMA RCB-8 analysis. The value is only printed for the case where the exchanger being analyzed is a fixed tubesheet type and also contains a non-bellows type expansion joint. For that situation only, the value of ∆s,M is shown at the end of the UHX printout, in the summary recap section in the table where the various cases are currently shown. It is simply an additional column in this table. This value depends on the shell design pressure, calculated shell stress and other values that may vary from case to case. Therefore the value is printed for each case in the summary section. We note that TEMA paragraph RCB-8.5(2) states that the “FEA model described in this section does not include shell thermal growth” and therefore the thermal growth of the shell shall not be included in the calculation of ∆s,M. This seems to correlate precisely with UHX-17(c)(1)(-b) which is the formulation of the value of ∆s,M “if the expansion joint analysis does not include thermal expansion effects”. If the option is selected, in the UHX run, to utilize the procedure in UHX-13.6 (Calculation Procedure for Effect of Different Shell Materials and Thicknesses Adjacent to the Tubesheet), then the program utilizes the formulation for ∆s,M shown in UHX-17(c)(2)(-b) along with the appropriate variables for that method. - ASME PCC-1 / Appendix O analysis:
a.) This calculation procedure to determine an appropriate assembly bolt stress, was added in 2018. There were a couple of factors that were assumed, based on recommendations from the publication. Users have asked for additional input fields to be able to utilize alternate values for some of these. One of these is the variable, K, which is the nut friction factor. It is used to convert the bolt stress value into a torque value. The built in default is 0.2. There is now an input field, which defaults to 0.2, where the user may specify an alternate value if desired. Another value which has been made available for modification, is the gasket relaxation factor, ᴪg, which is used to determine if the gasket operating stress is maintained (O-8). The suggested default was 0.7 (if industry test data was not available). This field is now available for an alternate entry if desired.
b.) We have added the ability to print Appendix O calculations in Metric units, where it previously was always printed in English, regardless of your unit conversion settings.
c.) There is now an informative warning that pops up if a valid bolt stress range could not be determined that offers some guidance on how to proceed. - 2019 ASME Material Update. All material properties from 2019 edition of ASME Section II Part D are included within this update. This includes stress table values, yield table values, moduli of elasticity values, and coefficient of thermal expansion values for all materials in ASME Section II Part D, as well as updates to the notes for these tables. One other noteworthy item is that we have eliminated many of the “No yield in source” messages that were prevalent for bolting materials. As with all previous updates, it is required that each user update their material database in order to migrate their specific material listing to the new 2019 material properties. Below is a summary of the material update process:
a.) Before reading the entire material update explanation, it is worth noting that the RCS material update program is sent out with the most likely defaults already selected. If you are unsure what the best course of action is, after reading the information below, your best bet is most likely to just use the defaults that are already selected in the program and run through the steps to update your database described below without worrying about making changes to the options and settings. It is also worth noting that far more extensive help is available within the software under the Materials heading of the new help system. If you are unsure what material database you are currently using, the answer is located in the bottom right hand corner of the main RCS window. 15 indicates the 2015 edition, 17 indicates the 2017 edition (which was the most recent one available prior to this update), and 19 indicates the latest edition (2019). While older versions than these are available within RCS, it is unlikely that anyone is still using these older versions on a regular basis.
b.) Click "Tools"->"Setup"->"Material Update" from the main RCS screen. This opens the RCS material update program. The first field is the "source" material file, and this should be set to your current material database (17 for most people). The second field is the "destination" material database, and should always be set to 19, since the goal is to create a version of your material database that uses values out of the 2019 ASME Section II Part D tables.
c.) Search Settings: In almost all scenarios, you want to leave the first option set to "Yes", and all others set to "No". This will search based on a unique material ID, which is the safest way to locate each material from one version of ASME to the next.
d.) Save Settings: The default is to clear out any data that is not found in the destination material files. What this means is that if you have added any materials to your material database that RCS cannot successfully locate in the 2019 edition of the tables, RCS will remove this material entirely from the new version of your database. This is the absolute safest way to ensure that all material data you use will be from the latest edition of ASME, but it is also the way that is most likely to result in lost materials. However, after testing on the standard RCS material database, we can confirm that ALL materials are successfully brought over to the 2019 tables, so hopefully other people will see similar results with their unique material databases. If the “Clear data in destination if no match found” option is set to “NO”, then materials that are not found in one or more of the 2019 tables during the update process will be kept and brought over from the previous material database. The remaining Save Settings are used to determine which portions of the previous material properties are retained.
e.) When you are satisfied with the settings, click the "OK/Build" button. This will pop up a window that is a summary of all materials in your database, and you can even edit on a material by material basis, any of the settings that were shown on the previous screen in this text file and save the changes. Most users will just glance through this file without changing anything. Close the file, and RCS will then begin the process of updating each material in the database sequentially. This process can take a few minutes to complete.
f.) When the process is complete, a final summary of the results will be displayed. The summary shows a listing of all materials from the previous database, and a warning will appear next to any material that was not brought over.
g.) The final (and most important) step is to actually change to using this material database! Running the update creates the 2019 material database, but it does not automatically switch you to immediately start using it. Click "Tools"->"Setup"->"Materials" from the main RCS menu to run the material editor. This utility lets the user add new materials, or switch between the different material databases. The top line reads "Current RCS Material File", and you will need to select the 19 option, which was not in the list until after the above steps were executed. After doing this, you will be using the 2019 ASME material properties for all jobs so long as you do not ever change back to a different database from this same screen.
h.) Lastly, if anyone has questions or problems with their material update, feel free to contact RCS via phone or email for further assistance. - RCS has added the 2017 ASME B16.5 Pressure / Temperature rating tables, and made this be the default within the RCS system. Technically, Table U-3 in Section VIII Div. 1 still references the 2013 edition of ASME B16.5, but 2017 will be required eventually and we went ahead and added it. If you would prefer to continue using the 2013 edition of B16.5 (or any other previous version), you can click Tools -> Tables -> B16.5 from the main RCS menu and choose the edition of this table that is desired.
- All applicable data from ASME Code charts and tables, such as heat treat data, radiograph data, x-ray data, impact test exemption data, external pressure charts, paragraph references for UHX, UCS, UHA, UNF, etc. have been updated to the 2019 edition of ASME Code.
- Made numerous changes to wording and spelling in various locations, including in help topics, pop up warnings and messages, and on several of the screens in RCS. This is part of the ongoing goal of improving the functionality of the user interface, adding clarification to messages, and improving the user-friendliness of the RCS software.
- We have continued the expansion and improvement of the RCS help system. This is a similar goal to the previous item, but is specific to the help content provided within RCS. Several new help topics are available as more areas of the RCS software are integrated into the new help system. Specifically, many of the programs from within the RCS Menus system are now integrated into the new help.
- Removed the H-Type drawing from the list of available drawings to generate. This was apparently something that Don had intended to eventually provide, but it never actually existed. Removing this option prevents the “Select All” option for drawing generation from crashing.
Click here to download the 03.25.19 RCSWin Update
This downloader is an installer for the 03.25.19 update to RCS. This installer will update RCS from the 01.01.18 version of RCS. Material files, gasket files, and default files will not be updated. This is NOT a comprehensive update. If you have not previously updated RCS to the 01.01.18 version, this update will not work! Each update must be run in sequence. If you are behind on updates, feel free to contact RCS and we can provide you a fresh installer for the latest version of the RCS software. Note that there are two versions of this update! The email notification and the information in the update summary below give more specifics, but in general, the main installer should be used unless your company has made your own modifications to the estimating files. If your company has modified the estimating files, use the link below for the alternate version of this update.
Click here to download the Alternate 03.25.19 Update
This download is an installer for the alternate version of the 03.25.19 update that does not contain the modified estimating files. This installer is only necessary if your company has made their own internal modifications to the estimating program and does not want those changes overwritten!
Click here to download the 03.25.19 User Directory
This update is only needed if you are running a network installation of RCSWin and your working directory resides on a local drive. This update needs to be run and installed directly in the user directory (usually called rcs_user_001) on each machine that uses RCSWin, while the main 03.25.19 update needs to be run on the network path where RCSWin is installed.
Summary of Changes and Updates (03.25.19)
There are two different versions of this update! The reason for this is because we have made some significant changes to the estimating files that are intended to make the estimating program more usable and accurate "out of the box", but we recognize that companies who have been using the estimating program for years will likely not want our modified versions of these files. As such, we have created a version of the update that will apply all updates EXCEPT for the following files:
1.) Stedata.ada and stedata.bda
2.) Ste.dat
3.) Stesta.aop and Stesta.bop
The files mentioned above are all related to the estimating program, and if your company does not use the estimating module, then use the standard installer. If your company has been using the estimating program for years, we recommend that you keep your existing files and use the alternate installer that will ensure your modifications will not be lost. As always, we recommend creating a backup before installing either way.
Note: To get a printout of all instructions, program and file updates, enhancements, and corrections from within RCS, go to Tools -> Administrative and double click on Edit / Print Updates.
- General Updates:
(a) This is an "intermediate" update, meaning it does not coincide with a new release of ASME Code. As such, there is no need to update your material database.
(b) An ongoing process is to clarify and improve input field wording as well as the associated "general" help and "context sensitive" help. While the list is far too long to delineate, you will find the help system to be greatly improved and comprehensive, and work is continuing. Numerous screens have improved help, but specific areas of interest with this update are help topics for utility programs, the estimating program, nozzle reinforcement, and the interactive graphics editor. There are several other new topics as well, but these are the main ones.
(c) A handful of minor bug fixes and wording issues were resolved. - Code Case 2901:
(a) The most significant addition with this update to RCS is the ability to run Code Case 2901 calculations for nozzle flanges. There are three different ways that these calculations can be performed within RCS. The first is as a standalone utility, the second is in conjunction with WRC-107 nozzle load calculations, and the third is to run the calculations directly for any nozzle within a job. When run as a standalone utility, all data input must be done by the user. When run for a specific nozzle, the relevant nozzle geometry will be automatically populated, and when run in conjunction with WRC-107 nozzle loads, both the nozzle geometry and the applicable load and moments will be automatically populated. Note that Code Case 2901 is not an automatic calculation within RCS, meaning it will not automatically be performed. Instead, it is a supplemental calculation that can be added for each nozzle in a job file after that nozzle has been run. There is an extensive help topic within RCS that explains this process and everything related to Code Case 2901. We recommend users read that help topic first. Below is a partial summary of Code Case 2901 within RCS:
(b) The analysis defined in Code Case 2901 was developed to address the fact that external forces and moments, applied to nozzle flanges, need to be evaluated to determine the effect on the nozzle flange itself. The Code Case only considers the radial load on the nozzle flange and an unspecified moment. In comparing with other similar analysis methods, most of which calculate an “equivalent pressure” due to the nozzle loads, it seems consistent with other methods, to utilize the circumferential and longitudinal moments imposed on the flange. The resultant of these two moments is calculated and that is what is utilized in the input for the nozzle moment. This is the primary reason why Code Case 2901 calculations are accessed from within the WRC-107 nozzle loading program in RCS. The nozzle loads and moments, as well as all of the nozzle geometry and design conditions can be directly imported into the Code Case program. However, it is worth noting that WRC-107 calculations need not be run if they are not desired. The WRC-107 calculations can be skipped entirely, but any data that is input on the nozzle loading screen will be imported into the Code Case 2901 program.
The Code Case is presented in the form of an equation, which has several variables on the left side and several other variables on the right side. The check, to determine if the flange is adequate for the superimposed loads and moments, is to make certain that the resultant value on the left side of the equation is less than or equal to the resultant value of the right side. The program performs these calculations and shows the resultant respective values. If the right side value is greater than the left side value, the program will warn you that you either need to reduce the loadings or else bump up to the next flange rating classification.
Since these two resultant values tend to be quite large and do not have any apparent “real world” significance as to what they represent, we have dissected the method to one that seems more meaningful. You will find that both approaches reach the limiting loadings at precisely the same point. This method is simply a bit more intuitive in “real world” terms. In comparing with other methods that calculate an “equivalent pressure” due to the loadings, it is clear that this same methodology is utilized in this Code Case. We have rearranged the terms and isolated the variables that result in a similar equivalent pressure. You will see this value displayed or printed and labeled the “Equivalent Pressure”. This represents an additional pressure which is the equivalent of the superimposed loadings on the nozzle. We add this value to the actual design pressure in order to determine the new "Combined Equivalent Pressure" that the nozzle flange sees.
This Code Case recognizes that we are now dealing with a combination of primary and secondary stresses and consequently allows the combined pressure to be higher than the value derived directly from the ANSI B16.5 tables. Table 1 in the Code Case determines the multiplier to use on the B16.5 tabulated value, in order to determine a higher allowable pressure than just the value in the tables for primary only stresses. There are only a few different values in the table, so the multiplier to the B16.5 P/T rating ends up being between 1.1 to 2.2. We apply this multiplier to the value obtained from the B16.5 tables and arrive at an "Allowable Pressure", based on this Code Case, which the "Combined Equivalent Pressure" needs to be within. If the calculated Combined Equivalent Pressure exceeds the calculated Allowable Pressure, then the program warns you in a similar fashion to what is described above. This methodology produces the exact same end result, but presents the numbers in a way that would seem to have a more meaningful representation. - Estimating Program Changes:
(a) A number of modifications have been made to the estimating program. We recognized that the "default" setup for the estimating program was functional to the point that it would run and generate numbers, but it was not terribly accurate or realistic in a number of ways. As such, we have made an effort to "clean up" the estimating files in order to get the estimating program closer to being able to run "out of the box" and provide decent estimates without quite the same degree of customization as was previously required. It is important to note that the estimating program will still need to be customized on a company by company basis, as there is simply no way to generate an estimate that can accurately reflect the shop processes, hour estimates, and pricing for ALL companies. The intent of this update was not to eliminate the need for customization, but instead to clean up and modify the operations file and data file so that customization for each company is less daunting than before.
(b) In addition to significant modifications to the estimating files, we have also cleaned up and changed wording on screens, and made the entirety of the estimating program work with the new help system. Within the new help system is a vastly expanded and improved set of instructions and explanations of how each aspect of the estimating program works. We believe that the RCS estimating program is an incredibly powerful tool, but many users have shied away from it in the past due to the rather substantial learning curve and amount of time required to get it set up. We hope that this update will help alleviate these reservations. We recommend all users who are interested in the estimating program pull up the estimating help topic in the help system and spend some time getting familiar with it's capabilities. There is also a general tutorial or sequence of events to follow within the help, which can assist new users in getting familiar with the RCS estimating program. - Appendix O Calculations:
(a) The ability to run ASME PCC-1 Appendix O calculations for body flanges was added to RCS with the last update (01.01.18). However, the logic to perform these calculations was incomplete. The calculations were run correctly, but for a pair of flanges, the calculations were only run for the first flange, and not the second. This error has been corrected. Now, when Appendix O calculations are added for a pair of flanges, the calculations will be performed for both flanges, and the results for each will be displayed and added to your print file. Below is a summary of the Appendix O update that was included in the previous version of RCS.
(b) A method to calculate the Gasket Stress / Bolting Stress analysis in API-660 7.8.1 is now included in the RCS software. API-660 states that it is not “mandatory”, but is to be used “when specified by the purchaser”. None-the-less, we have gotten an increasing number of inquiries with regard to this calculation, so it is now included in the software. The calculation method utilizes the ASME PCC-1 Appendix O method, which is referenced in API-660 as the “joint component approach” and is recommended. The Appendix O paper references WRC Bulletin 538 as a method to determine the maximum bolt stress that will not damage the flange. The method can be accessed via the flange screen. In short, the calculations arrive at two maximum allowable bolt stresses and two minimum bolt stresses. The two maximum bolt stresses are the stress in the bolts that would overstress the flange (determined by WRC-538), and the bolt stress, above which, you would “crush” the gasket. The two minimum bolt stresses are the bolt stress required to seat the gasket at test conditions as well as the bolt stress required to maintain a seal on the gasket during operation. Ideally the calculations will yield a range of bolt stresses that can be utilized that falls between the smaller of the two maximums and the larger of the two minimums. This is not always the case. There is a lengthy explanation of this whole procedure that is available in RCS on the flange menu.
(c) Sometimes a “range” can be obtained by thickening up the flange, if that is the limiting component. Sometimes adding bolting helps so that less stress has to be applied, per bolt, to seat or keep seated, the gasket. Consideration may be given to increasing the gasket width if the gasket is controlling. Sometimes it is impossible to achieve a range and the paper suggests that consideration be given to all aspects and good engineering judgement used to determine the proper bolting stress to be used.
Click here to download the 01.01.18 RCSWin Update
This download is an installer for the 01.01.18 update to RCS. This installer will update RCS from the 01.01.16 version. Material files, gasket files, and default files will not be updated or overwritten. If you are behind on updates, feel free to contact RCS and we can provide you a fresh complete installer for the latest version of the RCS software.
Click here to download the 01.01.18 User Directory (only needed for network installations)
This update is only needed if you are running a network installation of RCSWin and your working directory resides on a local drive. This update needs to be run and installed directly into the user directory (usually called rcs_user_001) on each machine that uses RCSWin, while the main 01.01.18 update needs to be run on the network path where RCSWin is installed.
Summary of Changes and Updates (01.01.18)
Note: To get a printout of all instructions, program and file updates, enhancements, and corrections from within RCS, go to Tools -> Administrative and double click on Edit / Print Updates.
- Summary of Changes in this Update:
(a) The help system within RCS is completely overhauled. While there are still portions of RCS that use the older help, a large percentage of screens, programs, and utilities within RCS are all now using a single, comprehensive help system. This new help system is intended to replace the somewhat disjointed and non-integrated help that existed previously in a variety of different formats. See item (2) below for more info.
(b) Changes were made to Part UHX of the Code. There were two main changes. The first is relatively simple: UHX has added a provision that allows for the use of a different temperature and subsequent allowable stress for the flanged extension portion of the tubesheet. The second change is the addition of a subsection that pertains only to fixed tubesheet kettle type exchangers. See (3) below for additional information.
(c) A new utility has been added to run Appendix O calculations. More specifically, this is for API-660 / ASME PCC-1 Appendix O / WRC Bulletin 538 - Gasket Stress / Bolting Stress Analysis. This new utility is an optional calculation that can be performed on any body flange, and can be accessed from the main flange screen (Run -> Menus -> Flange, then select the desired flange, and click the "App O" button. See ( 4) below for additional information.
(d) In the previous update, new bolting tables were added to accommodate the use of bolt tensioners, as the standard bolt tables do not allow for sufficient clearance. However, we inadvertently left out the ability to use these new tables when running floating head calculations. A similar change code (Code 94) has been added at the top of the list of change codes to allow the use of these new tables when making bolting selections. Note that this also allows for the use of other modified bolting tables (such as a table for metric bolts).
(e) All applicable data from ASME Code charts and tables, such as heat treat data, radiograph data, x-ray data, impact test exemption data, external pressure charts, paragraph references for UHX, UCS, UHA, UNF, etc. have all been updated to the 2017 edition of ASME Code.
(f) All of the materials' allowable stresses, yield stresses and physical properties in Section II part D of the 2017 ASME Code are available and included in this update. Instructions on how to update your current materials database to the new values are given below in (5).
(g) Fixed a few random bugs, errors, and print formatting issues that users had encountered. - New Comprehensive Help System for RCS
(a) Firstly, the new help system is the first aspect of the RCS software to be compiled to the .NET framework. What this means is that the Microsoft .NET framework must be installed (specifically, version 3.5 or higher) on each machine that runs RCS. The .NET framework is NOT packaged with RCS, but is available as a free download from Microsoft. However, the .NET framework is included on all new Windows machines, and is updated in the same fashion as all other Microsoft updates, so in the vast majority of cases, there should not be any further requirements after running the RCS update.
(b) The new help system is intended to replace a variety of other help options. The old help system that was loaded when you clicked Help -> Contents has all been built into the new help system. All of the sketches and help topics from that help system are now included in the new help menu.
(c) Similarly, the "online help" option is no longer necessary. It is still available by clicking Help -> Online, but will eventually be removed entirely. The vast majority of the online help topics are all built into the new system, and once the migration is 100% complete, the online help will be removed.
(d) Similarly, the RCS procedure notes that can be enabled and disabled from the RCS settings are really no longer necessary. The option to enable the procedure notes is still there, at least for the time being, but they will ultimately eventually be phased out, as the info contained in these notes is all contained in the new help system.
(e) Lastly, the content from many of the Word help documents located in the \RCSWin\RCSOverview folder is now built into the new help system, and the remaining help documents will also be integrated in when the system is 100% complete.
(f) From any screen within RCS, clicking F1 will bring up the overall help topic associated with that screen, and scroll you to the help item that is specific to the field that the cursor was on. Similarly, clicking F2 will load the overall help topic for the current screen. Note that all screens that have not yet been integrated into the new system will continue to function as before, bringing up the old help as in previous versions of RCS.
(g) There is also a search option within the new help system. Click the magnifying glass icon and type in search words, and a list of all help topics related to the search words will be revealed. - Modifications required by changes in Part UHX
There are two main changes that were made in the 2017 UHX section for tubesheet design:
(a) The first is fairly simple. UHX-9.3 has added a new allowable stress for the extended portion of the tubesheet, whether flanged or not. This allows the extended portion of the tubesheet to be designed at a different (presumably lower) design temperature than the main central portion of the tubesheet. TEMA had a similar capability in years past. By default, RCS assumes that the temperature of the central portion of the tubesheet and the extension are the same. There are two types of tubesheet extensions:
(1) Flanged extensions that have bolt loads applied to them as defined by UHX-9.5(a). This calculation is based solely on the bolting moments passed to it from the mating flanges. RCS actually already had this capability built in. The input allows for a different allowable stress to be used in this calculation. The calculation is done only once and is included as hr on the first page of the UHX printout.
(2) Unflanged tubesheet extensions are addressed in UHX-9.5(c). The RCS variable that defines this calculation is hrDE. The Code states that this calculation should be done for each design loading case and consequently it is shown on each individual case printout. In the "Auto Set Cases" form, we have added a temperature field for the user to input the desired temperature at which the allowable stress is determined. The stress is determined for you, for each case accordingly. As with all allowable stresses, RCS allows for setting these values on a case by case basis, if so desired
(b) The major change is the addition of section UHX-13.10, which applies only to fixed tubesheet kettle type exchangers. The new method uses the same basic methodology of the standard UHX-13 section which applies to fixed tubesheet exchangers. However, UHX-13.10 contains new variables that are used "in place of" existing variables for steps 2, 5, 6, and 10. These new variables help reflect the additional pressure head associated with the larger kettle section of the exchanger. Section UHX-13.10.2 contains the "Conditions of Applicability" for utilizing this new method. Basically both cones must be identical and there must be identical stub cylinders at each end to attach the cones to the tubesheets. There are also restrictions with regard to the relative length of the cone, and to the ratio of the large end and small end of the cones. RCS will warn you if you do not meet one of these criteria. UHX-13.10.4(d) requires calculation of axial membrane stresses for the small stub cylinder, the kettle cylinder, the small end of the cone and the large end of the cone. Each of these must be within defined limits. Again, RCS will do it's best to accommodate all these, but at some point the program will quit trying and simply warn you that all cases did not pass, just as before. Generally a solution can be obtained by thickening one of the cylinders, the cone, or perhaps changing the cone geometry. The easiest way to determine which component is failing is to view the stress summary at the end of the UHX printout.
In general it appears that this new method often results in a tubesheet that is slightly thicker than the previous method, since it is accounting for the larger kettle diameter which is subject to pressure. - Appendix O Calculations
(a) A method to calculate the Gasket Stress / Bolting Stress analysis in API-660 7.8.1 is now included in the RCS software. API-660 states that it is not “mandatory”, but is to be used “when specified by the purchaser”. None-the-less, we have gotten an increasing number of inquiries with regard to this calculation, so it is now included in the software. The calculation method utilizes the ASME PCC-1 Appendix O method, which is referenced in API-660 as the “joint component approach” and is recommended. The Appendix O paper references WRC Bulletin 538 as a method to determine the maximum bolt stress that will not damage the flange. The method can be accessed via the flange screen. In short, the calculations arrive at two maximum allowable bolt stresses and two minimum bolt stresses. The two maximum bolt stresses are the stress in the bolts that would overstress the flange (determined by WRC-538), and the bolt stress, above which, you would “crush” the gasket. The two minimum bolt stresses are the bolt stress required to seat the gasket at test conditions as well as the bolt stress required to maintain a seal on the gasket during operation. Ideally the calculations will yield a range of bolt stresses that can be utilized that falls between the smaller of the two maximums and the larger of the two minimums. This is not always the case. There is a lengthy explanation of this whole procedure that is available in RCS on the flange menu.
(b) Sometimes a “range” can be obtained by thickening up the flange, if that is the limiting component. Sometimes adding bolting helps so that less stress has to be applied, per bolt, to seat or keep seated, the gasket. Consideration may be given to increasing the gasket width if the gasket is controlling. Sometimes it is impossible to achieve a range and the paper suggests that consideration be given to all aspects and good engineering judgement used to determine the proper bolting stress to be used. - Updating your materials database to the 2017 values.
(a) Before reading the entire material update explanation, it is worth noting that the RCS material update program is sent out with the most likely defaults already selected. If you are unsure what the best course of action is, after reading the information below, your best bet is most likely to just use the defaults that are already selected in the program and run through the steps to update your database described below without worrying about making changes to the options and settings. It is also worth noting that far more extensive help is available within the software under the Materials heading of the new help system.
(b) If you are unsure what material database you are currently using, the answer is located in the bottom right hand corner of the main RCS window. 13 indicates the 2013 edition, 15 indicates the 2015 edition (which was the most recent one available prior to this update), and 17 indicates the latest edition (2017). While older versions than these are available within RCS, it is unlikely that anyone is still using these older versions on a regular basis.
(c) Click "Tools"->"Setup"->"Material Update" from the main RCS screen. This opens the RCS material update program. The first field is the "source" material file, and this should be set to your current material database (15 for most people). The second field is the "destination" material database, and should always be set to 17, since the goal is to create a version of your material database that uses values out of the 2017 ASME Section II Part D tables.
(d) Search Settings:
In almost all scenarios, you want to leave the first option set to "Yes", and all others set to "No". This will search based on a unique material ID, which is the safest way to locate each material from one version of ASME to the next.
(e) Save Settings:
The default is to clear out any data that is not found in the destination material files. What this means is that if you have added any materials to your material database that RCS can not successfully locate in the 2017 edition of the tables, RCS will remove this material entirely from the new version of your database. This is the absolute safest way to ensure that all material data you use will be from the latest edition of ASME, but it is also the way that is most likely to result in lost materials. However, after testing on the standard RCS material database, we can confirm that ALL materials are successfully brought over to the 2017 tables, so hopefully other people will see similar results with their unique material databases.
(f) When you are satisfied with the settings, click the "OK/Build" button. This will pop up a window that is a summary of all materails in your database, and you can even edit on a material by material basis, any of the settings that were shown on the previous screen in this text file and save the changes. Most users will just glance through this file without changing anything. Close the file, and RCS will then begin the process of updating each material in the database sequentially. This process can take a few minutes to complete.
(g) When the process is complete, a final summary of the results will be displayed. The summary shows a listing of all materials from the previous database, and a warning will appear next to any material that was not brought over. Note that several materials may have a note that reads "No yield in source". ASME has a number of materials that do not have values in their yield stress table. However, almost all of these materials are bolting, and yield values are not required for bolting calculations anyway. This note would only be a cause for concern if the material in question needed yield stress values for ASME calculations.
(h) The final (and most important) step is to actually change to using this material database! Running the update creates the 2017 material database, but it does not automatically switch you to immediately start using it. Click "Tools"->"Setup"->"Materials" from the main RCS menu to run the material editor. This utility lets the user add new materials, or switch between the different material databases. The top line reads "Current RCS Material File", and you will need to select the 17 option, which was not in the list until after the above steps were executed. After doing this, you will be using the 2017 ASME material properties for all jobs so long as you do not ever change back to a different database from this same screen.
(i) Lastly, if anyone has questions or problems with their material update, feel free to contact RCS via phone or email using the contact info shown at the top of this help summary.
Contact Information:
Mailing Address:
RCS, Inc.
PO Box 417
Jenks, OK 74037
Phone:
918-299-7262
Email:
For technical support, software related questions, updates, etc.: support@rcs-system.com
For billing, pricing, and other sales related questions: sales@rcs-system.com