Pressure Vessel Design

CademPVD by CADEM Softwares

Most value for money software for the mechanical design of process equipment

Trial version available on our website www.cadem.in

28 years of equipment design experience captured, polished, compacted and is now ready for transfer to

designers, fabricators and plant engineers

Intelligent, works with minimum inputs

For instance, in case of say a body flange, the software automatically evaluates optimum configuration of

all undefined parameters: Flange OD, Flange ID, PCD, Number and Size of bolts, Gasket OD & ID, etc.

meeting the requirements of the specified equipment design code.

Generates final design at estimation stage, saves more than 80% of your design & estimation time

Earn more as you save on costing and quotation making time

High quality documentation with all formulae and relevant code clauses

Most importantly, the user need not be a hard core designer

CADEM Softwares

Enhancing your business strengths and design capabilities.

Website: www.cadem.in

Email: [email protected]

Phone: +91 9370211312

Address: Office No. 19, SC-1 Building,

Kohinoor Estate, Wakdewadi,

Pune-Mumbai Road, Pune 411003,

Maharashtra, India

Follow Us:

@facebook: www.facebook.com/cademindia OR www.cadem.in/facebook

@youtube: www.youtube.com/cademchannel OR www.cadem.in/youtube

@linkedin: www.linkedin.com/company/cadem OR www.cadem.in/linkedin

@google+: http://plus.google.com/116314947079178385899 OR www.cadem.in/googleplus

@twitter: www.twitter.com/cademindia OR www.cadem.in/twitter

YOU CAN DOWNLOAD THIS DOCUMENT AND OTHERS AT www.cadem.in/links

Pressure VesselsReaction VesselsAgitator ShaftsHeat ExchangersProcess ColumnsStorage TankFloating RoofChimney

ASME Sec. VIII Div. 1TEMAEEUAIS 2825EN 13445API 650API 620IS 6533

EXAMPLE NO. PV-01

DESIGN

OF

PRESSURE VESSEL (GAS FILTER)

NOTE:

1) Link to youtube video of this design:

http://www.youtube.com/watch?v=3Y0yrt1Z6fI&list=PLPL8SPZUxm-

mFqQZceyhr13QYDEruelJx

2) As you can see in the video, the inbuilt intelligence in the software generates all

information by itself. Eg: For a body flange, the software evaluates all the undefined

parameters Flange OD, Flange ID, PCD, Number and Size of bolts, Gasket OD & ID, etc.

meeting the requirements of specified equipment design code.

3) In case of any changes to the interconnected shell geometry and / or design conditions

(pressure / temperature) including material of constructions, these dimensions

automatically regenerated by the software to meet the new requirements.

4) The software can generate cost estimation and BOM in Excel.

This example covers design of a simple pressure vessel. This pressure vessel has a top

flat cover and a bottom dished end. The top cover is of bolted type and is connected to

the shell through top body flange. The pressure vessel is provided with lugs support and

lifting lug.

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in

Index

Licensee : Sunay Wagle, CADEM Services, Pune, IndiaCustomer ABC Company Ltd.Project / Equipment Soap Plant / Gas FilterDesigned By / Revision and Date / R00 , 30-03-2015 23:35:19

Sr. No. Description Page No

1 Title page & equipment info

2 Design data

3 Material of constructions

4 Effective Pressures

5 Weight summary report

6 Test pressure calculations (shell side)

7 Wind load calculations

8 Seismic load calculations

9 Design of Cover (Front)


11 Design of Shell Flng (Front)


13 Design of Main Shell

14 Design of Dished End (Rear)

15 Design of Lug Support


17 Design of N 01

18 Design of N 01

19 Design of N 01

20 Design of N 02

21 Design of N 02

22 Design of N 02

23 Design of N 03

24 Design of N 03

25 Design of Lifting Lugs

26 Foundation load data

27 C.G. Data


EQUIPMENT INFORMATION :

DESIGN & REVIEWAL :

INSPECTION & APPROVAL :

EQUIPMENT DATA :

OTHER DATA :

Customer ABC Company Ltd.Project Soap PlantLocation Vapi SitePlant Refrigeration Plant

Design Code ASME VIII Div.1, 10 A11Equipment Name Gas FilterEquipment Type Pressure VesselEquipment Class N.A.Equipment Category N.A.Reference Drawing No ---Service Compressed Gas ServicesSupport Type Lug Supports

Designed ByDesign Date 30-03-2015 23:35:19Checked ByApproved ByRevision R00

Inspection Agency ---

Reviewed By ---

Front end Flat EndFront end flanged TrueRear end Dished EndRear end flanged FalseShell ID 1250 mmShell OD 1270 mmLength, Shell (W.L. to W.L) / Overall 1650 / 2254.6 mm

Fabricated weight 1898.3 kgfEmpty weight + external weights 1898.3 kgfEstimated operating weight 1926.8 kgfEstimated hydrotest weight 4439.8 kgf


(1) PROCESS DETAILS :

(3) TEST PR. : kgf/mm g

(4) TEMPERATURE : C

(5) ALLOWANCES : mm

(6) RADIOGRAPHY & JOINT EFFICIENCY :


VESSEL DESIGN DATA

MEDIA DENSITYkg/m

Operating Process Gas 10Design1 Process Gas 12Design2StartupShutdownUpsetHydrotest Water 1000Pneumatic Process Gas 1.2

(2) PR. : kgf/mm g INT. EXT.

Operating 0.1 0.12 0.01055Design1 0.12 0.12 0.01055Design2StartupShutdownUpset

Based onInput Pr MAWP MAP

Hydrotest 0.156 0.156 0.169Pneumatic 0.132 0.132 0.143

MIN. MAX.Input MDMT

Operating 20 -14.28 100Design1 20 -11.75 150Design2StartupShutdownUpsetHydrotest 21.67 -11.57 50Pneumatic 21.67 -11.75 50

INT. EXT.Corrosion 3 0Polishing 0 0

RADIOGRAPHY JOINT EFFICIENCYShell Spot + T Joints 0.85Head Full 1.00


VESSEL DESIGN DATA1. MATERIAL OF CONSTRUCTION :

2. NOZZLE CONNECTIONS :

3. INSULATION & CLADDING:


Shell sideShell SA-516 GR. 70 Plt. [UNS:K02700]

Head SA-516 GR. 70 Plt. [UNS:K02700]

Body flange SA-105 Frg. [UNS:K03504]Body flange cover SA-516 GR. 70 Plt. [UNS:K02700]Liner

Shell side

Nozzle neck 40 & < 200 SA-106 GR. B Smls. Pipe [UNS:K03006]Flange SA-105 Frg. [UNS:K03504]Cover flange SA-105 Frg. [UNS:K03504]

Nozzle neck >= NPS 200 SA-516 GR. 70 Plt. [UNS:K02700]Flange SA-516 GR. 70 Plt. [UNS:K02700]Cover flange SA-516 GR. 70 Plt. [UNS:K02700]

Pad flange SA-516 GR. 70 Plt. [UNS:K02700]Pad flange cover SA-516 GR. 70 Plt. [UNS:K02700]Manhole flange SA-516 GR. 70 Plt. [UNS:K02700]Manhole cover SA-516 GR. 70 Plt. [UNS:K02700]Reinforcement pad SA-516 GR. 70 Plt. [UNS:K02700]External bolt SA-193 GR. B7 Bolt [UNS:G41400]External gasket Spiral metal wound CAF filled (S.S.)Stiffener SA-516 GR. 70 Plt. [UNS:K02700]Lifting lug IS-2062 GR. A Plt.Support IS-2062 GR. A Plt.Anchor bolt Commercial CS Bolt

Mat. / Density / Thk. Rockwool (Mineral Fibre) / 136.2 kg/m / 25 mmMat. / Thk. Al. sheet / 1.191 mm


SUMMARY OF EFFECTIVE DESIGN PRESSURES IN kgf/mm g VS TEMPERATURE IN C


Sr. Item name Temp. Inside pr. Liquid pr. Effective pr.No. +ve -ve +ve -ve1 Cover (Front) 150 0.12 0.01055 0 0.12 0.010552 Shell Flng (Front) 150 0.12 0.01055 0 0.12 0.010553 Main Shell 150 0.12 0.01055 0 0.12 0.010554 Dished End (Rear) 150 0.12 0.01055 0 0.12 0.010555


ITEM WISE WEIGHT SUMMARY


Sr.No. Item name Item size Empty wt Volume Filled wt

kgf m kgf

1 Cover (Front)Blind Flange - 1420 OD x 73.411 Thk, RF, 1363 PCD, Tgrv = 1.588

900.5 0 900.5

2 Shell Flng (Front)

Fabricated WN - 1420 OD x 1250 ID x 1363 PCD, RF, 128.692 Thk, Trgv = 1.588, G1 = 20, G0 = 10, hf = 30

312.3 0 312.3

3 Gasket Flng (Front) 1313.5 OD x 1250 ID, 4.763 Thk 0.1 0 0.1

4 Bolt Flng (Front) Hex Head Bolt M24 x 243.128 Lg, 56 Nos. 48.76 0 48.76

5 Main Shell 1270 OD x 10 Thk, 1650 Lg 517.1 2.025 541.4

6 Dished End (Rear)Elliptical D/2H = 2.0, 1270 OD x 10 Nom / 9 Min Thk, SF = 50

181.7 0.317 185.5

7 Gusset Plate 200 Long x 190 Wide x 16 Thk, 8 Nos. 38.51 0 38.51

8 Anchor Bolt Anchor M20 x 200 Lg, 4 Nos. 1.99 0 1.99

9 Support Pad 270 Long x 292 Wide x 10 Thk, 4 Nos. 24.97 0 24.97

10 N 01 ANSIB36.10, 150 NPS Sch.80, 156 Lg 6.697 0.00262 6.728

11 Flange [N 01] Weld Neck, ANSI B16.5, RF, 150# for 150 NPS Sch 80 Pipe 8.08 0 8.08

12 Gasket [N 01] 166.329 OD x 146.329 ID, 4.763 Thk 0.1 0 0.1

13 Bolt [N 01] Hex Head Bolt M20 x 86.125 Lg, 8 Nos. 1.714 0 1.714

14 Counter Flng [N 01] Weld Neck, ANSI B16.5, RF, 150# for 150 NPS Sch 80 Pipe 8.08 0 8.08

15 Reinf [N 01] 292.659 OD x 171.275 ID x 10Thk 3.501 0 3.501

16 N 02 ANSIB36.10, 150 NPS Sch.80, 156 Lg 6.697 0.00262 6.728


18 Gasket [N 02] 166.329 OD x 146.329 ID, 4.763 Thk 0.1 0 0.1


20 Counter Flng [N 02] Weld Neck, ANSI B16.5, RF, 150# for 150 NPS Sch 80 Pipe 8.08 0 8.08

21 Reinf [N 02] 292.659 OD x 171.275 ID x 10Thk 3.501 0 3.501

22 N 03 ANSIB36.10, 50 NPS Sch.160, 150 Lg 1.682 0.00022 1.684


24 Gasket [N 03] 62.85 OD x 42.85 ID, 4.763Thk 0.1 0 0.1


26 Bolted Cover [N 03] Weld Neck, ANSI B16.5, RF, 150# for 50 160 NPS Pipe 2.522 0 2.522

120 Long x 70 Wide x 12 Thk,

27 Lifting Lugs 2 Nos. 1.596 0 1.596

28 Pad (Lifting Lugs) 70 Long x 170 Wide x 8 Thk, 2Nos. 1.507 0 1.507

29 Insulation 4084.07 W x 3754.584 L, 25 Thk 52.2 0 52.2

30 Cladding 4087.811 W x 3754.584 L, 1.191 Thk 5.058 0 5.058

31

32

33

34

35

2149.7 4439.8


TEST PRESSURES CALCULATION AS PER UG-99 / UG-100 : Vessel Inside

Legend :

Test Pressure CalculationsPressure due to hydro liquid column, [ Plh ]= Lh x rh x 1E-09= 0.00225 kgf/mm gHydrotest pressure, [ Ph ]= 1.3 x Pt - Plh= 1.3 x 0.12 - 0.00225= 0.154 kgf/mm gPneumatic test pressure, [ Pn ]= 1.1 x Pt= 1.1 x 0.12= 0.132 kgf/mm g


Design Temperature T 150 COperating Liquid Density r 12 kg/m

Hydrotest Liquid Density rh 1000 kg/mHydrotest Liquid Column Lh 2254.6 mm

Sr.No. Item Name

Pressure ( kgf/mm g ) Stress Correction ( kgf/mm )Pt

Pi Pl Pc Pe Peff Sfo Sfa SfaSfo1 Cover (Front) 0.12 0 0 0.01055 0.12 14.06 14.06 1 0.122 Shell Flng (Front) 0.12 0 0 0.01055 0.12 14.06 14.06 1 0.123 Main Shell 0.12 0 0 0.01055 0.12 14.06 14.06 1 0.124 Dished End (Rear) 0.12 0 0 0.01055 0.12 14.06 14.06 1 0.125

Min. Pr., Pt 0.12

Pi = Internal positive pressurePl = Pressure due to design liquid columnPe = Internal vacuum pressurePc = External negative pressurePeff = Pi + Pl + PcSfo = Allowabe stress at design temperatureSfa = Allowable stress at ambient temperaturePt = MAX [ Peff + Pc, Pe ] x ( Sfa / Sfo )


Vessel Inside

Legend :


CALC. OF MIN. DESIGN METAL TEMPERATURE Design Mode 1 , Corroded ConditionCODE ASME VIII Div.1, 10 A11

Design Pressure Pi 0.12 kgf/mm gDesign Temperature T 150 C

Sr.No.

Item Name / Material /Group

Stress (kgf/mm) Thickness (mm) MDMT (C)Smt Sdt tn tg tr Tm Tc MDMT

1

Cover (Front)SA-516 GR. 70 Plt. [UNS:K02700]Curve : B

14.06 14.06 70.41 17.6 17.6 -11.98 40.56 -52.53

2Shell Flng (Front)SA-105 Frg. [UNS:K03504]Curve : B

14.06 14.06 125.7 7 6.343 -28.89 -17.14 -11.75

3

Main ShellSA-516 GR. 70 Plt. [UNS:K02700]Curve : B

14.06 14.06 7 7 6.343 -28.89 -14.73 -14.16

4

Dished End (Rear)SA-516 GR. 70 Plt. [UNS:K02700]Curve : B

14.06 14.06 7 7 5.364 -28.89 -14.61 -14.28

5Max, MDMT -11.75

Smt = Stress at minimum design metal temperature.Sdt = Pressure due to design liquid columntn = Stress at design metal temperature.tg = Nominal item thickness excluding corrosion and thinning.tr = Governing metal thickness for the item.Tg = Required minimum thickness of the item.Tm = Minimum metal temperature for the the item.Tc = MDMT CorrectionMDMT = Final MDMT for the item = Tm - Tc.


EXTREME FIBRE ELONGATION CALCULATION

Legend :


Sr.No.

Item Name MOC Rf t Eqn.No.

e HTmm mm %

1 Main Shell SA-516 GR. 70 Plt. [UNS:K02700] 625 10 1 0.8 False2 Dished End (Rear) SA-516 GR. 70 Plt. [UNS:K02700] 1130 10 2 0.664 False345

Rf = Mean radius after formingRo = Infinityt = Nominal thickness of the plate before formingEqn. 1 = 50 x t / Rf x [ 1 - Rf / Ro ]Eqn. 2 = 75 x t / Rf x [ 1 - Rf / Ro ]


1. DESIGN CONDITIONS ( Design Mode 1 , Corroded Condition ) :

3. CALCULATION OF FORCES AND MOMENTS:


WIND LOAD CALCULATIONCODE Wind [IS:875, 87]

Basic wind speed ( Section 5.2 ) Vb 50 m/sExpected life of equipment ( Section 5.3.1 ) 25 YearsProbability factor (Risk coeff) ( Section 5.3.1 ) K1 0.902Terrain category ( Section 5.3.2 ) Category 2Structure class ( Section 5.3.2.2 ) Class BTopography factor ( Section 5.3.3 ) K3 1.3Force coefficient (Shape factor) Cf 0.8

Equivalent diameter De 1820 mmOverall length of equipment L 2254.6 mmHeight of C.G. of equipment Hcg 1807.5 mmSize and height factor ( Section 5.3.2 ) K2 0.98Effective transverse cross sectional area

= De x L A 4103343.3 mmEffective wind speed

= K1 x K2 x K3 x Vb Vz 57.44 m/sWind pressure

= 6E-08 x Vz 2 Pz 0.0002 kgf/mm

Longitudinal force= Cf x A x Pz F 649.9 kgf

Support elevation H 372.5 mmTurning moment

= F x ( Hcg - H ) M 932661.5 kgf-mm



2. CALCULATION OF FORCES AND MOMENTS:


SEISMIC LOAD CALCULATIONCODE Seismic [IS:1893, 02]

Weight of equipment Wo 1926.8 kgfImportance factor ( Table-6 , 2002 ) I 1.5Soil profile type Stiff Soil Profile (SD)Foundation type RCC footings + Tie BeamsDamping factor 5Seismic zone Zone IIISeismic zone factor ( Table-2 , 2002 ) Z 0.16Response reduction factor ( Table-7 , 2002 ) R 2.9Spectral accelerations coeff. ( Fig. 2 , 2002 ) Sa / g 2.5, Use max valueDamping correction factor ( Table-3 , 2002 ) Cf 1Seismic coefficient ( Clause-6.4.2 , 2002 )

= 0.5 x Z x I x Cf x ( Sa / g ) x ( 1 / R )= 0.5 x 0.16 x 1.5 x 1 x

2.5 x ( 1 / 2.9 ) Ah 0.103

Elevation of support H 372.5 mmHeight of C.G. of equipment Hcg 1807.5 mmSeismic base shear force

= Ah x Wo= 0.103 x 1926.8 Vb 199.3 kgf

Seismic moment of support= Vb x ( Hcg - H )= 199.3 x ( 1807.5 - 372.5 ) M 286034.2 kgf-mm



2. COVER DATA :

3. BOLTING DATA :

4. LINER DATA :

5. GASKET DATA :

6. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b1) :Total joint - contact surface compression load [Hp]= 2 x ( x b x G + b' x Lp ) x m x P= 2 x ( x 9.554 x 1294.4 + 0 x 0 ) x 3 x 0.12= 27973 kgfTotal hydrostatic end force [H]= 0.25 x x G 2 x P= 0.25 x x 1294.4 2 x 0.12= 157907.4 kgfMinimum required bolt load for operating condition [Wm1]= Hp + H


DESIGN OF FLAT BOLTED HEAD ( INTERNAL ) Cover (Front)CODE ASME VIII Div.1, 10 A11

Design pressure P 0.12 kgf/mm gDesign temperature T 150 CAllowance CA 3 mmGroove allowance Tg 0 mmRadiography Spot + T JointsJoint efficiency E 1

M.O.C. SA-516 GR. 70 Plt. [UNS:K02700]Code allw. stress @ design temp. Sfo 14.06 kgf/mmCode allw. stress @ atm. temp. Sfa 14.06 kgf/mmYoungs modulus Ey 19888.4 kgf/mmSelf reinforced FalseFlange OD A 1420 mmThickness provided 73.41 mmThickness available 70.41 mm

M.O.C. SA-193 GR. B7 Bolt [UNS:G41400]Code allw. stress @ design temp. Sb 17.58 kgf/mmCode allw. stress @ atm. temp. Sa 17.58 kgf/mmBolt PCD PCD 1363 mmBolt dia. db 24 mmNo. of bolts nb 56

M.O.C.Liner ID mmLiner OD mmLiner thk. mm

M.O.C. Spiral metal wound CAF filled (S.S.)Gasket seating stress y 7.031 kgf/mmGasket factor m 3Inside diameter Gi 1256 mmOutside diameter Go 1313.5 mmWidth of gasket N 28.75 mmWidth of gasket ( as per Table 2-5.2 ) 31.75 mmBasic gasket seating width ( as per Table 2-5.2 ) b0 14.38 mmEffective gasket width ( as per Table 2-5.2 ) b 9.554 mmDia. at load reaction ( see Table 2-5.2 ) G 1294.4 mmPass partition gasket width Wp 0 mmPass partition gasket length Lp 0 mmEffective pass partition gasket width b' 0 mm

= 27973 + 157907.4= 185880.4 kgf7. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b2) :Minimum required bolt load for gasket seating [Wm2]= ( x b x G + b' x Lp ) x y= ( x 9.554 x 1294.4 + 0 x 0 ) x 7.031= 273152.4 kgf8. BOLT AREAS AS PER APPENDIX 2-5 (d) :Total required cross-sectional area of bolts [Am]= MAX [ Wm2 / Sa , Wm1 / Sb ] ........ For Internal '+' Pr Design= Wm2 / Sa ..................................... For External Pr & Self Sealing Design = 15540.6 mmActual bolt area using root diameter [Ab]= 17513.9 mmFlange design bolt load for the gasket seating [W]= 0.5 x ( Am + Ab ) x Sa x 1 .................... average bolt area= Ab x Sa x 1 ..........................................full bolt area= 307837.2 kgf ( Full bolt area and margin factor of 1 ) 9. CHECK FOR GASKET CRUSHING :Minimum gasket width required [Nmin]= Ab x Sb / ( 2 x x y x G )= 17513.9 x 17.58 / ( 2 x x 7.031 x 1294.4 )= 5.384 mm10. DESIGN CALCULATION AS PER UG 34, BOLTING CONDITION :Required thickness for bolting condition [t]= G x SQRT [ 1.9 x W x 0.5 x ( PCD - G ) / ( Sfa x E x G 3 ) ]= 1294.4 x SQRT [ 1.9 x 307837.2 x 0.5 x ( 1363 - 1294.4 ) / ( 14.06 x 1 x 1294.4 3 ) ]= 33.2 mm11. DESIGN CALCULATION AS PER UG 34, OPERATING CONDITION :

Required thickness for operating condition [t] = G x SQRT { [ C x P / ( Sfo x E ) ] + 1.9 x Wm1 x 0.5 x ( PCD - G ) / ( Sfo x E x G 3 ) }= 1294.4 x SQRT { [ 0.3 x 0.12 / ( 14.06 x 1 ) ] + 1.9 x 185880.4 x 0.5 x ( 1363 - 1294.4 ) /

( 14.06 x 1 x 1294.4 3 ) } = 70.65 mm

Self reinforced FalseFactor C is user input FalseFactor C taken from fig. UG 34 or user input 0.3Maximum factor C value C 0.75Factor C (effective) 0.3

C = Min ( 2 x 0.3, 0.75 ) for self reinf.C = 0.3 in other cases



2. COVER DATA :

3. BOLTING DATA :

4. LINER DATA :

5. GASKET DATA :

6. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b1) :Total joint - contact surface compression load [Hp]= 2 x ( x b x G + b' x Lp ) x m x P= 2 x ( x 9.554 x 1294.4 + 0 x 0 ) x 3 x 0.01055= 2458.4 kgfTotal hydrostatic end force [H]= 0.25 x x G 2 x P= 0.25 x x 1294.4 2 x 0.01055= 13877.8 kgfMinimum required bolt load for operating condition [Wm1]= Hp + H


DESIGN OF FLAT BOLTED HEAD ( EXTERNAL ) Cover (Front)CODE ASME VIII Div.1, 10 A11

Design pressure P 0.01055 kgf/mm gDesign temperature T 150 CAllowance CA 3 mmGroove allowance Tg 0 mmRadiography Spot + T JointsJoint efficiency E 1

M.O.C. SA-516 GR. 70 Plt. [UNS:K02700]Code allw. stress @ design temp. Sfo 14.06 kgf/mmCode allw. stress @ atm. temp. Sfa 14.06 kgf/mmYoungs modulus Ey 19888.4 kgf/mmSelf reinforced FalseFlange OD A 1420 mmThickness provided 73.41 mmThickness available 70.41 mm

M.O.C. SA-193 GR. B7 Bolt [UNS:G41400]Code allw. stress @ design temp. Sb 17.58 kgf/mmCode allw. stress @ atm. temp. Sa 17.58 kgf/mmBolt PCD PCD 1363 mmBolt dia. db 24 mmNo. of bolts nb 56


M.O.C. Spiral metal wound CAF filled (S.S.)Gasket seating stress y 7.031 kgf/mmGasket factor m 3Inside diameter Gi 1256 mmOutside diameter Go 1313.5 mmWidth of gasket N 28.75 mmWidth of gasket ( as per Table 2-5.2 ) 31.75 mmBasic gasket seating width ( as per Table 2-5.2 ) b0 14.38 mmEffective gasket width ( as per Table 2-5.2 ) b 9.554 mmDia. at load reaction ( see Table 2-5.2 ) G 1294.4 mmPass partition gasket width Wp 0 mmPass partition gasket length Lp 0 mmEffective pass partition gasket width b' 0 mm

= 2458.4 + 13877.8= 16336.3 kgf7. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b2) :Minimum required bolt load for gasket seating [Wm2]= ( p x b x G + b' x Lp ) x y= ( p x 9.554 x 1294.4 + 0 x 0 ) x 7.031= 273152.4 kgf8. BOLT AREAS AS PER APPENDIX 2-5 (d) :Total required cross-sectional area of bolts [Am]= MAX [ Wm2 / Sa , Wm1 / Sb ] ........ For Internal '+' Pr Design= Wm2 / Sa ..................................... For External Pr & Self Sealing Design = 15540.6 mmActual bolt area using root diameter [Ab]= 17513.9 mmFlange design bolt load for the gasket seating [W]= 0.5 x ( Am + Ab ) x Sa x 1 .................... average bolt area= Ab x Sa x 1 ..........................................full bolt area= 307837.2 kgf ( Full bolt area and margin factor of 1 ) 9. CHECK FOR GASKET CRUSHING :Minimum gasket width required [Nmin]= Ab x Sb / ( 2 x p x y x G )= 17513.9 x 17.58 / ( 2 x p x 7.031 x 1294.4 )= 5.384 mm10. DESIGN CALCULATION AS PER UG 34, BOLTING CONDITION :Required thickness for bolting condition [t]= G x SQRT [ 1.9 x W x 0.5 x ( PCD - G ) / ( Sfa x E x G 3 ) ]= 1294.4 x SQRT [ 1.9 x 307837.2 x 0.5 x ( 1363 - 1294.4 ) / ( 14.06 x 1 x 1294.4 3 ) ]= 33.2 mm11. DESIGN CALCULATION AS PER UG 34, OPERATING CONDITION :

Required thickness for operating condition [t] = G x SQRT { [ C x P / ( Sfo x E ) ] + 1.9 x Wm1 x 0.5 x ( PCD - G ) / ( Sfo x E x G 3 ) }= 1294.4 x SQRT { [ 0.3 x 0.01055 / ( 14.06 x 1 ) ] + 1.9 x 16336.3 x 0.5 x ( 1363 - 1294.4 ) /

( 14.06 x 1 x 1294.4 3 ) }= 32.29 mm

Self reinforced FalseFactor C is user input FalseFactor C taken from fig. UG 34 or user input 0.3Maximum factor C value C 0.75Factor C (effective) 0.3

C = Min ( 2 x 0.3, 0.75 ) for self reinf.C = 0.3 in other cases



2. FLANGE DATA :

3. BOLTING DATA :

4. LINER DATA :

5. GASKET DATA :5a. Flange gasket data :

5b. Partition groove gasket data (For H.E. body flange) :


FLANGE DESIGN ( INTERNAL ) Shell Flng (Front)CODE ASME VIII Div.1, 10 A11

Design pressure P 0.12 kgf/mm gDesign temperature T 150 CAllowance CA 3 mmGroove allowance Tg 0 mm

M.O.C. SA-105 Frg. [UNS:K03504]Code allw. stress @ design temp. Sfo 14.06 kgf/mmCode allw. stress @ atm. temp. Sfa 14.06 kgf/mmInside diameter B 1256 mmOutside diameter A 1420 mmHub length h 30 mmThickness ( hub end ) g1 17 mmThickness ( pipe end ) g0 7 mmThickness provided 128.7 mmThickness available 125.7 mm

M.O.C. SA-193 GR. B7 Bolt [UNS:G41400]Code allw. stress @ design temp. Sb 17.58 kgf/mmCode allw. stress @ atm. temp. Sa 17.58 kgf/mmBolt PCD C 1363 mmBolt dia. db 24 mmNo. of bolts nb 56


M.O.C. Spiral metal wound CAF filled (S.S.)Gasket type Ring GasketGasket confinement type UnconfinedFlange face type Raised FaceFlange gakset surface finish Serrated (Normal)Counter flange face type Raised FaceCounter gakset surface finish Serrated (Normal)Applicalbe gasket sketch in Table 2-5.2 Type 1BApplicable gasket column in Table 2-5.2 1Gasket seating stress ( refer to Note 1, Table 2-5.1 ) y 7.031 kgf/mmGasket factor ( from Table 2-5.1 ) m 3Inside diameter Gi 1256 mmOutside diameter Go 1313.5 mmWidth of gasket ( as per Table 2-5.2 ) N 28.75 mmWidth of gasket ( as per Table 2-5.2 ) w 28.75 mmWidth of raised face or gasket contact width 31.75 mm

( as per Table 2-5.2 )Basic gasket seating width ( as per Table 2-5.2 ) b0 14.38 mmEffective gasket width ( as per Table 2-5.2 ) b 9.554 mmDia. at load reaction ( see Table 2-5.2 ) G 1294.4 mm

M.O.C. --

6. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b1)Total joint - contact surface compression load [Hp]= 2 x ( p x b x G x m + b' x Lp x m' ) x P= 2 x ( p x 9.554 x 1294.4 x 3 + 0 x 0 x 0 ) x 0.12= 27973 kgfTotal hydrostatic end force [H]= 0.25 x p x G x P= 0.25 x p x 1294.4 x 0.12= 157907.4 kgfMinimum required bolt load for operating condition [Wm1a]= Hp + H= 27973 + 157907.4= 185880.4 kgfMinimum required bolt load for operating condition [Wm1b]( from mating flange )= 185880.4 kgfGoverning bolt load for operating condition [Wm1]= MAX [ Wm1a , Wm1b ]= MAX [ 185880.4 , 185880.4 ]= 185880.4 kgf7. BOLT LOAD CALCULATION AS PER APPENDIX 2-5 (b2)Minimum required bolt load for gasket seating [Wm2]= ( p x b x G x y + b' x Lp x y' )= ( p x 9.554 x 1294.4 x 7.031 + 0 x 0 x 0 )= 273152.4 kgf8. BOLT AREAS AS PER APPENDIX 2-5 (d)Total required cross-sectional area of bolts [Am]= MAX [ Wm2 / Sa , Wm1 / Sb ] ........ For Internal '+' Pr Design = Wm2 / Sa ..................................... For External Pr & Self Sealing Design= 15540.6 mmActual bolt area using root diameter [Ab]= 17513.9 mmFlange design bolt load for the gasket seating [W]= 0.5 x ( Am + Ab ) x Sa x 1 .................... average bolt area= Ab x Sa x 1 ..........................................full bolt area= 307837.2 kgf ( Full bolt area and margin factor of 1 ) 9. CHECK FOR GASKET CRUSHINGMinimum gasket width required [Nmin]= Ab x Sb / ( 2 x p x y x G )= 17513.9 x 17.58 / ( 2 x p x 7.031 x 1294.4 )= 5.384 mm10. BOLT SPACING CORRECTION FACTORAs per Brownell & Young or IS 2825, = SQRT [ Bolt spacing / ( 2 x db + t ) ]As per TEMA or BS 5500,= SQRT [ Bolt spacing / Bmax ] ................... where,

Bmax = maximum recommended bolt spacing = 2 x db + 6 x t / ( m + 0.5 )Brownell & Young, Cf = 1 ( min. equal to 1 )

11. LOADS AND FORCES DURING OPERATING CONDITION AS PER APPENDIX 2-3Hydrostatic end force on area inside of flange [HD]= 0.25 x p x B 2 x P= 0.25 x p x 1256 2 x 0.12= 148679.3 kgfGasket load (difference between flange design bolt load and total hydrostatic end force) [HG]= Wm1 - H= 185880.4 - 157907.4= 27973 kgfDifference between total hydrostatic end force and hydrostatic end force on area inside of flange [HT]= H - HD= 157907.4 - 148679.3= 9228.2 kgf12. MOMENT ARMS FOR FLANGE LOADS AS PER TABLE 2-6Radial distance from the bolt circle to intersection of hub and back of flange, as per Appendix 2-3 [R]= 0.5 x ( C - B ) - g1= 0.5 x ( 1363 - 1256 ) - 17

Gasket seating stress ( refer to Note 1, Table 2-5.1 ) y' 0 kgf/mmGasket factor ( from Table 2-5.1 ) m' 0Pass partition gasket width Wp 0 mmPass partition gasket length Lp 0 mmEffective pass partition gasket width b' 0 mm

INTEGRAL FLANGE DESIGN Shell Flng (Front)

= 36.5 mmRadial distance from the bolt circle to the circle on which HD acts [hD]= R + 0.5 x g1= 36.5 + 0.5 x 17= 45 mmRadial distance from gasket load reaction to the bolt circle [hG]= 0.5 x ( C - G )= 0.5 x ( 1363 - 1294.4 )= 34.3 mmRadial distance from the bolt circle to the circle on which HT acts [hT]= 0.5 x ( R + g1 + hG )= 0.5 x ( 36.5 + 17 + 34.3 )= 43.9 mm13. FLANGE MOMENTS UNDER OPERATING CONDITION AS PER APPENDIX 2-6Component of moment due to HD [MD]= HD x hD= 148679.3 x 45= 6690566.9 kgf-mmComponent of moment due to HG [MG]= HG x hG= 27973 x 34.3 = 959588.9 kgf-mmComponent of moment due to HT [MT]= HT x hT= 9228.2 x 43.9= 405136.1 kgf-mmTotal moment acting on the flange for operating condition [MO]= MD + MG + MT= 6690566.9 + 959588.9 + 405136.1 = 8055291.9 kgf-mm14. LOADS AND FORCES DURING GASKET SEATING AS PER APPENDIX 2-3Gasket load for seating condition [HG]= W= 307837.2 kgf15. MOMENT UNDER GASKET SEATING AS PER APPENDIX 2-6Total moment acting on the flange for gasket seating [MO']= W x hG= 307837.2 x 34.3= 10560086 kgf-mm16. SHAPE CONSTANTS

17. STRESS FORMULA FACTORSAssumed thickness [t]= 108.7 mmFactor [a]= t x e + 1= 108.7 x 0.00922 + 1= 2.002Factor [b]= 1.333 x t x e + 1= 1.333 x 108.7 x 0.00922 + 1= 2.336Factor [g]= a / T = 2.002 / 1.866= 1.073Factor [d]= t 3 / d

A / B K 1.131Flange factors from Fig. 2-7.1 T 1.866

Z 8.189Y 15.84U 17.41

h0 93.77F / h0 e 0.00922Factor from Fig. 2-7.2 F 0.864Factor from Fig. 2-7.3 V 0.261g1 / g0 2.429h / h0 0.32

( U / V ) x h0 x g0 2 d 306079.1

Factor from Fig. 2-7.6 f 2.935

= 108.7 3 / 306079.1= 4.195Factor [l]= g + d= 1.073 + 4.195= 5.26818. FLANGE STRESSES AS PER APPENDIX 2-7 & 2-8Equivalent moment [Mmax]= MAX [ MO , MO' x Sfo / Sfa ]= MAX [ 8055291.9 , 10560086 x 14.06 / 14.06 ] = 10560086 kgf-mmCorrected equivalent moment per unit length [M]= Mmax x ( Cf / B )= 10560086 x ( 1 / 1256 )= 8407.7 kgfLongitudinal hub stress [SH]= f x M / ( l x g1 2 )= 2.935 x 8407.7 / ( 5.268 x 17 2 )

Radial flange stress [SR] = b x M / ( l x t 2 )= 2.336 x 8407.7 / ( 5.268 x 108.7 2 )

Tangential flange stress [ST]= ( M x Y / t 2 ) - Z x SR= ( 8407.7 x 15.84 / 108.7 2 ) - 8.189 x 0.316

Average stress= MAX [ 0.5 x ( SH + SR ) , 0.5 x ( SH + ST ) ]= MAX [ 0.5 x ( 16.21 + 0.316 ) , 0.5 x ( 16.21 + 8.69 ) ]

19. FLANGE RIGIDITY CHECKING AS PER APPENDIX 2-14

Rigidity index [J]= 52.14 x V x Mmax / ( l x Efo x g0 2 x KI x h0 )= 52.14 x 0.261 x 10560086 / ( 5.268 x 19888.4 x 7 2 x 0.3 x 93.77 )= 0.996Since J < 1.0, design is safe

= 16.21 kgf/mm .................................... < 1.5 x Sfo

= 0.316 kgf/mm .................................... < Sfo

= 8.69 kgf/mm .................................... < Sfo

= 12.45 kgf/mm .................................... < Sfo

Modulus of elasticity for flange Efo 19888.4 kgf/mmRigidity factor KI 0.3



2. FLANGE DATA :

3. BOLTING DATA :

4. LINER DATA :

5. GASKET DATA :5a. Flange gasket data :

5b. Partition groove gasket data (For H.E. body flange) :


FLANGE DESIGN ( EXTERNAL ) Shell Flng (Front)CODE ASME VIII Div.1, 10 A11

Design pressure P 0.01055 kgf/mm gDesign temperature T 150 CAllowance CA 3 mmGroove allowance Tg 0 mm

M.O.C. SA-105 Frg. [UNS:K03504]Code allw. stress @ design temp. Sfo 14.06 kgf/mmCode allw. stress @ atm. temp. Sfa 14.06 kgf/mmInside diameter B 1256 mmOutside diameter A 1420 mmHub length h 30 mmThickness ( hub end ) g1 17 mmThickness ( pipe end ) g0 7 mmThickness provided 128.7 mmThickness available 125.7 mm

M.O.C. SA-193 GR. B7 Bolt [UNS:G41400]Code allw. stress @ design temp. Sb 17.58 kgf/mmCode allw. stress @ atm. temp. Sa 17.58 kgf/mmBolt PCD C 1363 mmBolt dia. db 24 mmNo. of bolts nb 56


M.O.C. Spiral metal wound CAF filled (S.S.)Gasket type Ring GasketGasket confinement type UnconfinedFlange face type Raised FaceFlange gakset surface finish Serrated (Normal)Counter flange face type Raised FaceCounter gakset surface finish Serrated (Normal)Applicalbe gasket sketch in Table 2-5.2 Type 1BApplicable gasket column in Table 2-5.2 1Gasket seating stress ( refer to Note 1, Table 2-5.1 ) y 7.031 kgf/mmGasket factor ( from Table 2-5.1 ) m 3Inside diameter Gi 1256 mmOutside diameter Go 1313.5 mmWidth of gasket ( as per Table 2-5.2 ) N 28.75 mmWidth of gasket ( as per Table 2-5.2 ) w 28.75 mmWidth of raised face or gasket contact width 31.75 mm

( as per Table 2-5.2 )Basic gasket seating width ( as per Table 2-5.2 ) b0 14.38 mmEffective gasket width ( as per Table 2-5.2 ) b 9.554 mmDia. at load reaction ( see Table 2-5.2 ) G 1294.4 mm

M.O.C. --

6. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b1)Total joint - contact surface compression load [Hp]= 2 x ( p x b x G x m + b' x Lp x m' ) x P= 2 x ( p x 9.554 x 1294.4 x 3 + 0 x 0 x 0 ) x 0.01055= 2458.4 kgfTotal hydrostatic end force [H]= 0.25 x p x G x P= 0.25 x p x 1294.4 x 0.01055= 13877.8 kgfMinimum required bolt load for operating condition [Wm1a]= Hp + H= 2458.4 + 13877.8= 16336.3 kgfMinimum required bolt load for operating condition [Wm1b]( from mating flange )= 16336.3 kgfGoverning bolt load for operating condition [Wm1]= MAX [ Wm1a , Wm1b ]= MAX [ 16336.3 , 16336.3 ]= 16336.3 kgf7. BOLT LOAD CALCULATION AS PER APPENDIX 2-5 (b2)Minimum required bolt load for gasket seating [Wm2]= ( p x b x G x y + b' x Lp x y' )= ( p x 9.554 x 1294.4 x 7.031 + 0 x 0 x 0 )= 273152.4 kgf8. BOLT AREAS AS PER APPENDIX 2-5 (d)Total required cross-sectional area of bolts [Am]= MAX [ Wm2 / Sa , Wm1 / Sb ] ........ For Internal '+' Pr Design = Wm2 / Sa ..................................... For External Pr & Self Sealing Design= 15540.6 mmActual bolt area using root diameter [Ab]= 17513.9 mmFlange design bolt load for the gasket seating [W]= 0.5 x ( Am + Ab ) x Sa x 1 .................... average bolt area= Ab x Sa x 1 ..........................................full bolt area= 307837.2 kgf ( Full bolt area and margin factor of 1 ) 9. CHECK FOR GASKET CRUSHINGMinimum gasket width required [Nmin]= Ab x Sb / ( 2 x p x y x G )= 17513.9 x 17.58 / ( 2 x p x 7.031 x 1294.4 )= 5.384 mm10. BOLT SPACING CORRECTION FACTORAs per Brownell & Young or IS 2825, = SQRT [ Bolt spacing / ( 2 x db + t ) ]As per TEMA or BS 5500,= SQRT [ Bolt spacing / Bmax ] ................... where,

Bmax = maximum recommended bolt spacing = 2 x db + 6 x t / ( m + 0.5 )Brownell & Young, Cf = 1 ( min. equal to 1 )

11. LOADS AND FORCES DURING OPERATING CONDITION AS PER APPENDIX 2-3Hydrostatic end force on area inside of flange [HD]= 0.25 x p x B 2 x P= 0.25 x p x 1256 2 x 0.01055= 13066.8 kgfDifference between total hydrostatic end force and hydrostatic end force on area inside of flange [HT]= H - HD= 13877.8 - 13066.8= 811 kgf12. MOMENT ARMS FOR FLANGE LOADS AS PER APPENDIX TABLE 2-6Radial distance from the bolt circle to intersection of hub and back of flange, as per Appendix 2-3 [R]= 0.5 x ( C - B ) - g1= 0.5 x ( 1363 - 1256 ) - 17= 36.5 mmRadial distance from the bolt circle to the circle on which HD acts [hD]= R + 0.5 x g1= 36.5 + 0.5 x 17

Gasket seating stress ( refer to Note 1, Table 2-5.1 ) y' 0 kgf/mmGasket factor ( from Table 2-5.1 ) m' 0Pass partition gasket width Wp 0 mmPass partition gasket length Lp 0 mmEffective pass partition gasket width b' 0 mm

INTEGRAL FLANGE DESIGN Shell Flng (Front)

= 45 mmRadial distance from gasket load reaction to the bolt circle [hG]= 0.5 x ( C - G )= 0.5 x ( 1363 - 1294.4 )= 34.3 mmRadial distance from the bolt circle to the circle on which HT acts [hT]= 0.5 x ( R + g1 + hG )= 0.5 x ( 36.5 + 17 + 34.3 )= 43.9 mm13. FLANGE MOMENTS UNDER OPERATING CONDITION AS PER APPENDIX 2-6Component of moment due to HD [MD]= HD x ( hD - hG )= 13066.8 x ( 45 - 34.3 )= 139760.9 kgf-mmComponent of moment due to HT [MT]= HT x ( hT - hG )= 811 x ( 43.9 - 34.3 )= 7784.2 kgf-mmTotal moment acting on the flange for operating condition [MO]= MD + MT= 139760.9 + 7784.2= 147545.1 kgf-mm14. LOADS AND FORCES DURING GASKET SEATING AS PER APPENDIX 2-3Gasket load for seating condition [HG]= W= 307837.2 kgf15. MOMENT UNDER GASKET SEATING AS PER APPENDIX 2-6Total moment acting on the flange for gasket seating [MO']= W x hG= 307837.2 x 34.3= 10560086 kgf-mm16. SHAPE CONSTANTS

17. STRESS FORMULA FACTORSAssumed thickness [t]= 108.9 mmFactor [a]= t x e + 1= 108.9 x 0.00922 + 1= 2.004Factor [b]= 1.333 x t x e + 1= 1.333 x 108.9 x 0.00922 + 1= 2.338Factor [g]= a / T = 2.004 / 1.866= 1.074Factor [d]= t 3 / d= 108.9 3 / 306079.1= 4.217Factor [l]= g + d= 1.074 + 4.217= 5.2918. FLANGE STRESSES AS PER APPENDIX 2-7 & 2-8Equivalent moment [Mmax]

A / B K 1.131Flange factors from Fig. 2-7.1 T 1.866

Z 8.189Y 15.84U 17.41

h0 93.77F / h0 e 0.00922Factor from Fig. 2-7.2 F 0.864Factor from Fig. 2-7.3 V 0.261g1 / g0 2.429h / h0 0.32

( U / V ) x h0 x g0 2 d 306079.1

Factor from Fig. 2-7.6 f 2.935

= MAX [ MO , MO' x Sfo / Sfa ]= MAX [ 147545.1 , 10560086 x 14.06 / 14.06 ] = 10560086 kgf-mmCorrected equivalent moment per unit length [M]= Mmax x ( Cf / B )= 10560086 x ( 1 / 1256 )= 8407.7 kgfLongitudinal hub stress [SH]= f x M / ( l x g1 2 )= 2.935 x 8407.7 / ( 5.29 x 17 2 )

Radial flange stress [SR] = b x M / ( l x t 2 )= 2.004 x 8407.7 / ( 5.29 x 108.9 2 )

Tangential flange stress [ST]= ( M x Y / t 2 ) - Z x SR= ( 8407.7 x 15.84 / 108.9 2 ) - 8.189 x 0.313

Average stress= MAX [ 0.5 x ( SH + SR ) , 0.5 x ( SH + ST ) ]= MAX [ 0.5 x ( 16.14 + 0.313 ) , 0.5 x ( 16.14 + 8.669 ) ]

19. FLANGE RIGIDITY CHECKING AS PER APPENDIX AS PER 2-14

Rigidity index [J]= 52.14 x V x Mmax / ( l x Efo x g0 2 x KI x h0 )= 52.14 x 0.261 x 10560086 / ( 5.29 x 19888.4 x 7 2 x 0.3 x 93.77 )= 0.992Since J < 1.0, design is safe

= 16.14 kgf/mm .................................... < 1.5 x Sfo

= 0.313 kgf/mm .................................... < Sfo

= 8.669 kgf/mm .................................... < Sfo

= 12.4 kgf/mm .................................... < Sfo

Modulus of elasticity for flange Efo 19888.4 kgf/mmRigidity factor KI 0.3


1. DESIGN CONDITIONS ( Design Mode 1 , Corroded Condition )

2. DESIGN CALCULATION AS PER UG-27

Thickness of shell under internal pressure [ti]= Pi x R / ( S x E - 0.6 x Pi ) = 0.12 x 628 / ( 14.06 x 0.85 - 0.6 x 0.12 )= 6.343 mm

3. DESIGN CALCULATION OF SHELL THICKNESS UNDER EXTERNAL PRESSURE AS PER UG-28

Allowable external pressure [Pa]= 4 x B / ( 3 x ( OD / te ) )= 4 x 2.272 / ( 3 x 284.4 )= 0.01065 kgf/mm gSince Pa > Pe, design is safeSince available thickness is more than design thickness, design is safe.


DESIGN OF SHELL ( INTERNAL AND EXTERNAL PRESSURE ) Main ShellCODE ASME VIII Div.1, 10 A11

Design pressure ( internal ) Pi 0.12 kgf/mm gDesign pressure ( external ) Pe 0.01055 kgf/mm gDesign temperature T 150 CMaterial of construction SA-516 GR. 70 Plt. [UNS:K02700]Max. allowable stress at design temp. S 14.06 kgf/mmRadiography Spot + T JointsJoint efficiency long. seam Ec 0.85Outside diameter OD 1270 mmInside radius ( corroded ) R 628 mmShell length L 1650 mmDesign length L1 1650 mmNominal thickness 10 mmNominal thickness required as per TEMA N.A. mmInternal allowance, corrosion + polishing 3 mmExternal allowance, corrosion + polishing 0 mmThickness undertolerance 0 mmAvailable thickness 7 mm

Assumed te 4.466 mmL1 / OD 1.299OD / te 284.4Factor A ( Refer to Fig. G in Subpart 3 of Sec. II, Part D ) 0.00021Factor B ( CS-2 ) 2.272 kgf/mm



2. DESIGN CALCULATION AS PER UG 32 d / APPENDIX 1-4 ( c ) :Factor [K]= 1Thickness for internal pressure [t]= K x Pi x ID / ( 2 x S x E - 0.2 x Pi )= 1 x 0.12 x 1256 / ( 2 x 14.06 x 1 - 0.2 x 0.12 )= 5.364 mm3. DESIGN CALCULATION AS PER UG 33 d :Thickness for equivalent external pressure [t]= K x 1.67 x Pe x ID / ( 2 x S x 1.0 - 0.2 x 1.67 x Pe )= 1 x 1.67 x 0.01055 x 1256 / ( 2 x 14.06 x 1.0 - 0.2 x 1.67 x 0.01055 ) = 0.787 mmFactor [Ko]= 0.77Assumed head thickness, [te]= 2.779 mm Factor [A]= 0.125 x te / ( Ko x OD )= 0.125 x 2.779 / ( 0.77 x 1270 )= 0.00036Factor with reference to chart (CS-2) [B]= 3.743 kgf/mmAllowable external pressure [Pa]= B / ( Ko x OD / te )= 3.743 x 2.779 / ( 0.77 x 1270 )= 0.01064 kgf/mmSince Pa > Pe, design is safeSince available thickness is more than design thickness, design is safe.


DESIGN OF ELLIPSOIDAL HEAD ( INT. & EXT. PRESSURE ) Dished End (Rear)CODE ASME VIII Div.1, 10 A11

Design pressure ( internal ) Pi 0.12 kgf/mm gDesign pressure ( external ) Pe 0.01055 kgf/mm gDesign temperature T 150 CMaterial of construction SA-516 GR. 70 Plt. [UNS:K02700]Max. allowable stress @ design temp. S 14.06 kgf/mmRadiography FullJoint efficiency E 1Outside diameter of head OD 1270 mmInside diameter of shell ID 1256 mmHead shape Elliptical D/2H = 2.0Nominal thickness 10 mmNominal thickness required as per TEMA N.A mmInternal allowance, corrosion + polishing 3 mmExternal allowance, corrosion + polishing 0 mmThinning allowance / Under tolerance 1 mmAvailable thickness 6 mm

109


1. LUG DATA :

2. BOLT DATA :

3. GUSSET DATA :

4. SHELL DATA :

5. PAD DATA :

6. LOAD AND MOMENT ( Wind ) :

7. DESIGN OF ANCHOR BOLTS :Total uplift force on bolts [T]= [ 4 x M / ( D x N ) ] - Wt / N= [ 4 x 940925.4 / ( 1570 x 4 ) ] - 2388.5 / 4= 2.203 kgfRequired area of bolts [Am]= MAX [ ( T / Fs ) , 0 ]= MAX [ ( 2.203 / 20.88 ) , 0 ]= 0.106 mmAvailable area of bolts [Ab]= Ar x Nb ........................................................................................ where, Ar = 217.1 mm, is root area of bolt= 217.1 x 1= 217.1 mmSince Ab > Am, bolts provided are sufficient8. GUSSET DESIGN : Reaction force at each support [Q]= [ 4 x M / ( D x N ) ] + Wt / N


LUG SUPPORT DESIGN Lug SupportCODE P V Design Manual, D.R. Moss

Design Mode 1 , Corroded Condition

M.O.C IS-2062 GR. A Plt.No. of support N 4Base plate width b1 242 mmBase plate depth Lb 200 mmThickness of base plate tb 16 mmAllowable bending stress Sb 22.15 kgf/mm

M.O.C Commercial CS BoltNo. of bolt / lug Nb 1Bolt diameter db 20 mmPCD D 1570 mmDiameter of bolt hole 24 mmAllowable tensile stress Fs 20.88 kgf/mm

Thickness tg 16 mmHeight h 190 mmGusset angle 51.71Gusset depth at top Lc 50 mmNumber of gussets n 2Distance between gussets b 200 mm

Material SA-516 GR. 70 Plt. [UNS:K02700]OD diameter OD 1270 mmInside diameter ID 1256 mmThickness available ts 7 mm

Material SA-516 GR. 70 Plt. [UNS:K02700]Thickness tp 10 mmWidth W 270 mmLength L 292 mm

Max. overturning moment M 940925.4 kgf-mmDesign weight of vessel Wt 2388.5 kgf

= [ 4 x 940925.4 / ( 1570 x 4 ) ] + 2388.5 / 4= 1196.4 kgfMaximum axial force in gusset [P1]= Q / n = 1196.4 / 2= 598.2 kgfAllowable compr. stress in gusset [Sg]

= 1800 / [ ( 1 + 12 / 18000 ) x ( h / tg ) 2 ] ....................................... where, h = 242.1 mm= 1800 / [ ( 1 + 12 / 18000 ) x ( 242.1 / 16 ) 2 ]= 15616.8 psi= 10.98 kgf/mmRequired thickness of gusset [tg]

= 2 x P1 x ( 3 x a - Lb ) / [ Sg x Lb 2 x ( sin ) 2 ] = 2 x 598.2 x ( 3 x 150 - 200 ) / [ 10.98 x ( 200 ) 2 x ( sin 51.71 ) 2 ] = 1.106 mm9. BASE PLATE DESIGN : Bending moment [Mb]= Q x b1 / 6= 1196.4 x 242 / 6= 48255.9 kgf-mmBearing pressure [bp]= Q / ( w x b1 ) ............................................................................... where, w = 120 mm= 1196.4 / ( 120 x 242 )= 0.0412 kgf/mmBending moment due to bearing pressure [Mb]

= bp x b 2 / 10= 0.0412 x 200 2 / 10= 164.8 kgf-mmRequired thickness of base plate between chairs [tb]= SQRT { 6 x MAX [ Mb , Mb' ] / [ ( Lb - db ) x Sb ] }= SQRT { 6 x MAX [ 48255.9 , 164.8 ] / [ ( 200 - 20 ) x 22.15 ] }= 8.619 mm10. CHECK FOR COMPRESSION PLATE :Equivalent radial load [f]= Q x a / h= 1196.4 x 150 / 190= 472.3 kgfAngle between supports [b]= 2 x p / N= 2 x p / 4= 1.571 radInternal bending moment coefficient [Kr]= 0.5 x [ 1 / a - cot ( a ) ]= 0.5 x [ 1 / 1.571 - cot ( 1.571 ) ]= 0.318Internal bending moment [Mc]= 0.5 x Kr x f x OD= 0.5 x 0.318 x 472.3 x 1270= 95459.3 kgf-mmBending stress induced [fb]= Mo / Zc= 95459.3 / 7785.1= 12.26 kgf/mm ......................................................................... < Sb = 22.15 kgf/mmSince, induced stress fb < allow. stress Sb in shell material, design is safe.


1. LUG DATA :

2. BOLT DATA :

3. GUSSET DATA :

4. SHELL DATA :

5. PAD DATA :

6. LOAD AND MOMENT ( Seismic ) :

7. DESIGN OF ANCHOR BOLTS :Total uplift force on bolts [T]= [ 4 x M / ( D x N ) ] - Wt / N= [ 4 x 288590.5 / ( 1570 x 4 ) ] - 1841.2 / 4= -276.5 kgfRequired area of bolts [Am]= MAX [ ( T / Fs ) , 0 ]= MAX [ ( -276.5 / 20.88 ) , 0 ]= 0 mmAvailable area of bolts [Ab]= Ar x Nb ........................................................................................ where, Ar = 217.1 mm, is root area of bolt= 217.1 x 1= 217.1 mmSince Ab > Am, bolts provided are sufficient8. GUSSET DESIGN : Reaction force at each support [Q]= [ 4 x M / ( D x N ) ] + Wt / N


LUG SUPPORT DESIGN Lug SupportCODE P V Design Manual, D.R. Moss


M.O.C IS-2062 GR. A Plt.No. of support N 4Base plate width b1 242 mmBase plate depth Lb 200 mmThickness of base plate tb 16 mmAllowable bending stress Sb 22.15 kgf/mm

M.O.C Commercial CS BoltNo. of bolt / lug Nb 1Bolt diameter db 20 mmPCD D 1570 mmDiameter of bolt hole 24 mmAllowable tensile stress Fs 20.88 kgf/mm

Thickness tg 16 mmHeight h 190 mmGusset angle 51.71Gusset depth at top Lc 50 mmNumber of gussets n 2Distance between gussets b 200 mm

Material SA-516 GR. 70 Plt. [UNS:K02700]OD diameter OD 1270 mmInside diameter ID 1256 mmThickness available ts 7 mm

Material SA-516 GR. 70 Plt. [UNS:K02700]Thickness tp 10 mmWidth W 270 mmLength L 292 mm

Max. overturning moment M 288590.5 kgf-mmDesign weight of vessel Wt 1841.2 kgf

= [ 4 x 288590.5 / ( 1570 x 4 ) ] + 1841.2 / 4= 644.1 kgfMaximum axial force in gusset [P1]= Q / n = 644.1 / 2= 322.1 kgfAllowable compr. stress in gusset [Sg]

= 1800 / [ ( 1 + 12 / 18000 ) x ( h / tg ) 2 ] ....................................... where, h = 242.1 mm= 1800 / [ ( 1 + 12 / 18000 ) x ( 242.1 / 16 ) 2 ]= 15616.8 psi= 10.98 kgf/mmRequired thickness of gusset [tg]

= 2 x P1 x ( 3 x a - Lb ) / [ Sg x Lb 2 x ( sin ) 2 ] = 2 x 322.1 x ( 3 x 150 - 200 ) / [ 10.98 x ( 200 ) 2 x ( sin 51.71 ) 2 ] = 0.595 mm9. BASE PLATE DESIGN : Bending moment [Mb]= Q x b1 / 6= 644.1 x 242 / 6= 25979.7 kgf-mmBearing pressure [bp]= Q / ( w x b1 ) ............................................................................... where, w = 120 mm= 644.1 / ( 120 x 242 )= 0.02218 kgf/mmBending moment due to bearing pressure [Mb]

= bp x b 2 / 10= 0.02218 x 200 2 / 10= 88.72 kgf-mmRequired thickness of base plate between chairs [tb]= SQRT { 6 x MAX [ Mb , Mb' ] / [ ( Lb - db ) x Sb ] }= SQRT { 6 x MAX [ 25979.7 , 88.72 ] / [ ( 200 - 20 ) x 22.15 ] }= 6.324 mm10. CHECK FOR COMPRESSION PLATE :Equivalent radial load [f]= Q x a / h= 644.1 x 150 / 190= 254.3 kgfAngle between supports [b]= 2 x p / N= 2 x p / 4= 1.571 radInternal bending moment coefficient [Kr]= 0.5 x [ 1 / a - cot ( a ) ]= 0.5 x [ 1 / 1.571 - cot ( 1.571 ) ]= 0.318Internal bending moment [Mc]= 0.5 x Kr x f x OD= 0.5 x 0.318 x 254.3 x 1270= 51392.7 kgf-mmBending stress induced [fb]= Mo / Zc= 51392.7 / 7785.1= 6.601 kgf/mm ......................................................................... < Sb = 22.15 kgf/mmSince, induced stress fb < allow. stress Sb in shell material, design is safe.


DESIGN CONDITIONS

NOZZLE DATA

SHELL DATA ( Main Shell )

WELD DATA

CALCULATION OF NOZZLE NECK THICKNESS AS PER UG 45Neck thickness for internal pressure as per UG 45(a)Formula in Appendix 1-1 , [trn1]= ( 0.5 x Pi x OD ) / ( Sn x E + 0.4 x Pi )= ( 0.5 x 0.12 x 168.3 ) / ( 12.02 x 1.0 + 0.4 x 0.12 )= 0.983 mmNeck thickness for external pressure as per UG 45(a)Neck thickness for external pressure as per UG 28 Assumed neck thickness , [trn3] = 0.512 mmL / OD = 0.891OD / trn3 = 328.5Factor A = 0.00025Factor B = 2.679 kgf/mmAllowable external pressure , [Pa]= 4 x B / ( 3 x OD / trn3 )= 4 x 2.679 / ( 3 x 328.5 )= 0.01088 kgf/mm gThickness of shell as per UG 45(b)(1)Min. shell thickness reqd. as per UG 27 , [tr1 = trn2]= Pi x R / ( Sv x E - 0.6 x Pi )= 0.12 x 628 / ( 14.06 x 1.0 - 0.6 x 0.12 )= 5.387 mmThickness for equivalent pressure as per UG 45(b)(2) , [trn4]= Pe x R / ( Sv x E - 0.6 x Pe )


NOZZLE NECK THICKNESS AND REINFORCEMENT DESIGN N 01CODE ASME VIII Div.1, 10 A11


Design pressure ( internal ) Pi 0.12 kgf/mm gDesign pressure ( external ) Pe 0.01055 kgf/mm gDesign temperature T 150 C

M.O.C. SA-106 GR. B Smls. Pipe[UNS:K03006]Allowable stress @ design temperature Sn 12.02 kgf/mmOutside diameter OD 168.3 mmInside diameter ID 152.3 mmMaximum chord length D 152.3 mmNeck thickness ( provided ) tnp 10.97 mmInternal allowance , corrosion + polishing CAI 3 mmExternal allowance , corrosion + polishing CAE 0Neck thickness (tnp - CAI - CAE) tn 7.973 mmMax. under tolerance on thickness Alw 1.372 mmAvailable neck thickness ( tn - Alw ) ta 6.601 mmNozzle projection outward ( from vessel outer face ) Lo 150 mmTotal length of nozzle ( Lo + Addn for curvature) L 156 mm

Connection type Pipe NozzleApplication type Process OpeningReinforcement calculation method Isolated OpeningDesign as large opening False

M.O.C. SA-516 GR. 70 Plt. [UNS:K02700]Allowable stress @ design temperature Sv 14.06 kgf/mmInside radius R 628 mmThickness t 7 mmMin. thickness for external pressure tr2 4.466 mm

Nozzle outside weld W1 7 mm

= 0.01055 x 628 / ( 14.06 x 1.0 - 0.6 x 0.01055 )= 0.471 mmStandard wall thickness as per UG 45(b)(4) , [t3]= 7.112 mmNeck thk as per UG 45 , [trn]= MAX { MAX [ trn1, trn3 ] , MIN [ MAX ( trn2 , trn4 ) , 0.875 x t3 ] } ..... for Process Nozzle= MAX [ trn1, trn3 ] ............................................................................ for Access Opening= 5.387 mm .................................................................................... Process OpeningSince available neck thickness, ta >= trn, selected neck thickness is adequate.


1. DESIGN CONDITION :

2. ATTACHMENT DATA :

3. EXTERNAL LOADS :

4. SHELL DATA :

5. STRESS CONCENTRATION FACTORS :

6. COMPUTING STRESSES :


LOCAL STRESS ANALYSIS (EDGE OF ATTACHMENT) N 01

CODE D.R. MOSS (EXTRACT OF WRC 107)Design Mode 1, CorrodedCondition

Design pressure ( internal ) Pi 0.12 kgf/mm gDesign temperature T 150 C

M.O.C SA-106 GR. B Smls. Pipe [UNS:K03006]Outside diameter OD 168.3 mmWeld size w 7 mmPad diameter Dp 292.7 mmPad thickness tp 10 mm0.5 x OD C 84.14 mm

Radial force Fr 344.6 kgfLong. moment ML 254724.1 kgf-mmCirc. moment Mc 254724.1 kgf-mmTorsional moment Mt 254724.1 kgf-mmTotal eff. shear load Q 487.4 kgf

M.O.C SA-516 GR. 70 Plt. [UNS:K02700]Allowable stress Sv 14.06 kgf/mmInside radius R 628 mmThickness of shell tv 7 mm

Mean radius of shell , [ Rm ]= R + 0.5 x ( tv + tp ) = 628 + 0.5 x ( 7 + 10 )= 636.5 mm

Thickness , [t]= SQRT [ tv 2 + tp 2 ]= SQRT [ 7 2 + 10 2 ]= 12.21 mm

Calculate ratio , [ g ]= Rm / te= 636.5 / 12.21= 52.14

Calculate ratio , [ b ]= 0.875 x C / Rm= 0.875 x 84.14 / 636.5= 0.116

Factor , [ Kn ] = 1 Factor , [ Kb ] = 1

Shear stress due to Q , [ t1 ]= Q / ( p x Ro x t )= 487.4 / ( p x 84.14 x 12.21 )= 0.151 kgf/mm

Shear stress due to Mt , [ t2 ]

= Mt / ( 2 x p x Ro 2 x t )= 254724.1 / ( 2 x p x 84.14 2 x 12.21 )= 0.469 kgf/mm

Total shear stress , [ t ]= t1 + t2= 0.151 + 0.469= 0.62 kgf/mm

STRESSES FACT FIG. FORCES( kgf ) & MOMENTS( kgf-mm ) STRESS ( kgf/mm )

Radial load

Membrane5-17A 7.023 x FrRm Nf 3.803

Kn x Nft

f 0.312

5-17B 8.616 x FrRm Nx 4.665Kn x Nxt

x 0.382

Bending5-18A 0.117 x Fr Mf 40.25

6 x Kb x Mft 2

f 1.621

6 x Kb x Mx

7. COMBINING STRESSES :

** Only absolute values of quantities in bracket shall be used while combining stresses ( 1 ) : Fr sign is (+) for outward load, & (-) for inward load.Allowabe Stresses for various catergories:1. Membrane only, Sm = 1.5 x Sv2. Membrane + Bending, Sa = 3 x Sv3. Shear only, Sh = 0.5 x SvDESIGN IS ACCEPTABLE ? : YES

5-18B 0.0707 x Fr Mx 24.37 t 2 x 0.981

Long. moment

MembraneCL=1 5-19A

3.516 x CL x MLRm 2 x b

Nf 19.11 Kn x Nft

f 1.566

CL=1 5-19B1.697 x CL x MLRm 2 x b

Nx 9.222 Kn x Nxtx 0.756

Bending5-20A

0.03827 x MLRm x b Mf 132.4

6 x Kb x Mft 2

f 5.331

5-20B 0.06937 x MLRm x B Mx 2406 x Kb x Mxt 2

x 9.665

Circ. moment

MembraneCc=1 5-21A

1.893 x Cc x McRm 2 x b

Nf 10.29 Kn x Nft

f 0.843

Cc=1 5-21B2.973 x Cc x McRm 2 x b

Nx 16.16 Kn x Nxtx 1.324

Bending5-22A 0.09066 x McRm x b Mf 313.7

6 x Kb x Mft 2

f 12.63

5-22B0.04678 x McRm x b Mx 161.9

6 x Kb x Mxt 2

x 6.518

Stress due tox f

0 90 180 270 0 90 180 270

Radial load, Fr.(1)

MembraneNf 0.312 0.312 0.312 0.312Nx 0.382 0.382 0.382 0.382

BendingMf 1.621 1.621 1.621 1.621Mx 0.981 0.981 0.981 0.981

Long. moment,

ML.

MembraneNf +( 1.566 ) -( 1.566 )

Nx +( 0.756 ) -( 0.756 )

BendingMf +( 5.331 ) -( 5.331 )

Mx +( 9.665 ) -( 9.665 )

Circ moment,

Mc.

MembraneNf +( 0.843 ) -( 0.843 )

Nx +( 1.324 ) -( 1.324 )

BendingMf + ( 12.63 )

-( 12.63 )

Mx +( 6.518 ) -( 6.518 )

Int. pr., P.

Pi x Rmt

f +( 10.91 )+( 10.91)

+( 10.91 )

+( 10.91 )

Pi x Rm2 x t

x +( 5.456 )+( 5.456 )

+( 5.456 )

+( 5.456 )

Total,

Membrane 6.593 7.162 5.082 4.514 12.86 12.14 9.728 10.45Mem+Bend 17.24 14.66 -3.601 -1.023 19.74 26.32 5.946 -0.631




3. EXTERNAL LOADS :

4. SHELL DATA :




LOCAL STRESS ANALYSIS (EDGE OF PAD) N 01





M.O.C SA-516 GR. 70 Plt. [UNS:K02700]Allowable stress Sv 14.06 kgf/mmInside radius R 628 mmThickness of shell t 7 mm

Mean radius of shell , [ Rm ]= R + 0.5 x t= 628 + 0.5 x 7= 631.5 mm

Calculate ratio , [ g ]= Rm / t= 631.5 / 7= 90.21



Shear stress due to Q , [ t1 ]= Q / ( p x Ro x t )= 487.4 / ( p x 146.3 x 7 )= 0.151 kgf/mm


= Mt / ( 2 x p x Ro 2 x t )= 254724.1 / ( 2 x p x 146.3 2 x 7 )= 0.27 kgf/mm



Radial load


Kn x Nft

f 0.385


x 0.862

Bending5-18A 0.04175 x Fr Mf 14.39

6 x Kb x Mft 2

f 1.762

6 x Kb x Mx



5-18B 0.01857 x Fr Mx 6.398 t 2 x 0.783

Long. moment

MembraneCL=1 5-19A


Nf 19.63 Kn x Nft

f 2.804

CL=1 5-19B3.293 x CL x MLRm 2 x b

Nx 10.38 Kn x Nxtx 1.482

Bending5-20A

0.0128 x MLRm x b Mf 25.46

6 x Kb x Mft 2

f 3.117

5-20B 0.01693 x MLRm x B Mx 33.686 x Kb x Mxt 2

x 4.124

Circ. moment

MembraneCc=1 5-21A


Nf 12.19 Kn x Nft

f 1.741

Cc=1 5-21B7.986 x Cc x McRm 2 x b

Nx 25.16 Kn x Nxtx 3.594


6 x Kb x Mft 2

f 14.72

5-22B0.026 x McRm x b Mx 51.73

6 x Kb x Mxt 2

x 6.334

Stress due tox f

0 90 180 270 0 90 180 270

Radial load, Fr.(1)

MembraneNf ( 0.385 ) ( 0.385) ( 0.385 ) ( 0.385 )Nx ( 0.862 ) ( 0.862 ) ( 0.862 ) ( 0.862 )

BendingMf ( 1.762 ) ( 1.762 ) ( 1.762 ) ( 1.762 )Mx ( 0.783 ) ( 0.783 ) ( 0.783 ) ( 0.783 )

Long. moment,

ML.

MembraneNf +( 2.804 ) -( 2.804 )

Nx +( 1.482 ) -( 1.482 )

BendingMf +( 3.117 ) -( 3.117 )

Mx +( 4.124 ) -( 4.124 )

Circ moment,

Mc.

MembraneNf +( 1.741 ) -( 1.741 )

Nx +( 3.594 ) -( 3.594 )


-( 14.72 )

Mx +( 6.334 ) -( 6.334 )

Int. pr., P.

Pi x Rmt

f +( 10.83 )+( 10.83)

+( 10.83 )

+( 10.83 )

Pi x Rm2 x t

x +( 5.413 )+( 5.413 )

+( 5.413 )

+( 5.413 )

Total,

Membrane 7.757 9.869 4.793 2.681 14.49 13.43 8.884 9.947Mem+Bend 12.67 16.99 1.452 -2.87 18.89 29.44 7.051 -3.49


DESIGN CONDITIONS

NOZZLE DATA

SHELL DATA ( Main Shell )

WELD DATA

CALCULATION OF NOZZLE NECK THICKNESS AS PER UG 45Neck thickness for internal pressure as per UG 45(a)Formula in Appendix 1-1 , [trn1]= ( 0.5 x Pi x OD ) / ( Sn x E + 0.4 x Pi )= ( 0.5 x 0.12 x 168.3 ) / ( 12.02 x 1.0 + 0.4 x 0.12 )= 0.983 mmNeck thickness for external pressure as per UG 45(a)Neck thickness for external pressure as per UG 28 Assumed neck thickness , [trn3] = 0.512 mmL / OD = 0.891OD / trn3 = 328.5Factor A = 0.00025Factor B = 2.679 kgf/mmAllowable external pressure , [Pa]= 4 x B / ( 3 x OD / trn3 )= 4 x 2.679 / ( 3 x 328.5 )= 0.01088 kgf/mm gThickness of shell as per UG 45(b)(1)Min. shell thickness reqd. as per UG 27 , [tr1 = trn2]= Pi x R / ( Sv x E - 0.6 x Pi )= 0.12 x 628 / ( 14.06 x 1.0 - 0.6 x 0.12 )= 5.387 mmThickness for equivalent pressure as per UG 45(b)(2) , [trn4]= Pe x R / ( Sv x E - 0.6 x Pe )







M.O.C. SA-516 GR. 70 Plt. [UNS:K02700]Allowable stress @ design temperature Sv 14.06 kgf/mmInside radius R 628 mmThickness t 7 mmMin. thickness for external pressure tr2 4.466 mm

Nozzle outside weld W1 7 mm

= 0.01055 x 628 / ( 14.06 x 1.0 - 0.6 x 0.01055 )= 0.471 mmStandard wall thickness as per UG 45(b)(4) , [t3]= 7.112 mmNeck thk as per UG 45 , [trn]= MAX { MAX [ trn1, trn3 ] , MIN [ MAX ( trn2 , trn4 ) , 0.875 x t3 ] } ..... for Process Nozzle= MAX [ trn1, trn3 ] ............................................................................ for Access Opening= 5.387 mm .................................................................................... Process OpeningSince available neck thickness, ta >= trn, selected neck thickness is adequate.




3. EXTERNAL LOADS :

4. SHELL DATA :




LOCAL STRESS ANALYSIS (EDGE OF ATTACHMENT) N 02





M.O.C SA-516 GR. 70 Plt. [UNS:K02700]Allowable stress Sv 14.06 kgf/mmInside radius R 628 mmThickness of shell tv 7 mm

Mean radius of shell , [ Rm ]= R + 0.5 x ( tv + tp ) = 628 + 0.5 x ( 7 + 10 )= 636.5 mm

Thickness , [t]= SQRT [ tv 2 + tp 2 ]= SQRT [ 7 2 + 10 2 ]= 12.21 mm

Calculate ratio , [ g ]= Rm / te= 636.5 / 12.21= 52.14



Shear stress due to Q , [ t1 ]= Q / ( p x Ro x t )= 487.4 / ( p x 84.14 x 12.21 )= 0.151 kgf/mm


= Mt / ( 2 x p x Ro 2 x t )= 254724.1 / ( 2 x p x 84.14 2 x 12.21 )= 0.469 kgf/mm



Radial load


Kn x Nft

f 0.312


x 0.382

Bending5-18A 0.117 x Fr Mf 40.25

6 x Kb x Mft 2

f 1.621

6 x Kb x Mx



5-18B 0.0707 x Fr Mx 24.37 t 2 x 0.981

Long. moment

MembraneCL=1 5-19A


Nf 19.11 Kn x Nft

f 1.566

CL=1 5-19B1.697 x CL x MLRm 2 x b

Nx 9.222 Kn x Nxtx 0.756

Bending5-20A

0.03827 x MLRm x b Mf 132.4

6 x Kb x Mft 2

f 5.331

5-20B 0.06937 x MLRm x B Mx 2406 x Kb x Mxt 2

x 9.665

Circ. moment

MembraneCc=1 5-21A


Nf 10.29 Kn x Nft

f 0.843

Cc=1 5-21B2.973 x Cc x McRm 2 x b

Nx 16.16 Kn x Nxtx 1.324


6 x Kb x Mft 2

f 12.63

5-22B0.04678 x McRm x b Mx 161.9

6 x Kb x Mxt 2

x 6.518

Stress due tox f

0 90 180 270 0 90 180 270

Radial load, Fr.(1)

MembraneNf 0.312 0.312 0.312 0.312Nx 0.382 0.382 0.382 0.382

BendingMf 1.621 1.621 1.621 1.621Mx 0.981 0.981 0.981 0.981

Long. moment,

ML.

MembraneNf +( 1.566 ) -( 1.566 )

Nx +( 0.756 ) -( 0.756 )

BendingMf +( 5.331 ) -( 5.331 )

Mx +( 9.665 ) -( 9.665 )

Circ moment,

Mc.

MembraneNf +( 0.843 ) -( 0.843 )

Nx +( 1.324 ) -( 1.324 )


-( 12.63 )

Mx +( 6.518 ) -( 6.518 )

Int. pr., P.

Pi x Rmt

f +( 10.91 )+( 10.91)

+( 10.91 )

+( 10.91 )

Pi x Rm2 x t

x +( 5.456 )+( 5.456 )

+( 5.456 )

+( 5.456 )

Total,

Membrane 6.593 7.162 5.082 4.514 12.86 12.14 9.728 10.45Mem+Bend 17.24 14.66 -3.601 -1.023 19.74 26.32 5.946 -0.631




3. EXTERNAL LOADS :

4. SHELL DATA :




LOCAL STRESS ANALYSIS (EDGE OF PAD) N 02





M.O.C SA-516 GR. 70 Plt. [UNS:K02700]Allowable stress Sv 14.06 kgf/mmInside radius R 628 mmThickness of shell t 7 mm

Mean radius of shell , [ Rm ]= R + 0.5 x t= 628 + 0.5 x 7= 631.5 mm

Calculate ratio , [ g ]= Rm / t= 631.5 / 7= 90.21



Shear stress due to Q , [ t1 ]= Q / ( p x Ro x t )= 487.4 / ( p x 146.3 x 7 )= 0.151 kgf/mm





Radial load


Kn x Nft

f 0.385


x 0.862

Bending5-18A 0.04175 x Fr Mf 14.39

6 x Kb x Mft 2

f 1.762

6 x Kb x Mx



5-18B 0.01857 x Fr Mx 6.398 t 2 x 0.783

Long. moment

MembraneCL=1 5-19A


Nf 19.63 Kn x Nft

f 2.804

CL=1 5-19B3.293 x CL x MLRm 2 x b

Nx 10.38 Kn x Nxtx 1.482

Bending5-20A

0.0128 x MLRm x b Mf 25.46

6 x Kb x Mft 2

f 3.117

5-20B 0.01693 x MLRm x B Mx 33.686 x Kb x Mxt 2

x 4.124

Circ. moment

MembraneCc=1 5-21A


Nf 12.19 Kn x Nft

f 1.741

Cc=1 5-21B7.986 x Cc x McRm 2 x b

Nx 25.16 Kn x Nxtx 3.594


6 x Kb x Mft 2

f 14.72

5-22B0.026 x McRm x b Mx 51.73

6 x Kb x Mxt 2

x 6.334

Stress due tox f

0 90 180 270 0 90 180 270

Radial load, Fr.(1)

MembraneNf ( 0.385 ) ( 0.385) ( 0.385 ) ( 0.385 )Nx ( 0.862 ) ( 0.862 ) ( 0.862 ) ( 0.862 )

BendingMf ( 1.762 ) ( 1.762 ) ( 1.762 ) ( 1.762 )Mx ( 0.783 ) ( 0.783 ) ( 0.783 ) ( 0.783 )

Long. moment,

ML.

MembraneNf +( 2.804 ) -( 2.804 )

Nx +( 1.482 ) -( 1.482 )

BendingMf +( 3.117 ) -( 3.117 )

Mx +( 4.124 ) -( 4.124 )

Circ moment,

Mc.

MembraneNf +( 1.741 ) -( 1.741 )

Nx +( 3.594 ) -( 3.594 )


-( 14.72 )

Mx +( 6.334 ) -( 6.334 )

Int. pr., P.

Pi x Rmt

f +( 10.83 )+( 10.83)

+( 10.83 )

+( 10.83 )

Pi x Rm2 x t

x +( 5.413 )+( 5.413 )

+( 5.413 )

+( 5.413 )

Total,

Membrane 7.757 9.869 4.793 2.681 14.49 13.43 8.884 9.947Mem+Bend 12.67 16.99 1.452 -2.87 18.89 29.44 7.051 -3.49


DESIGN CONDITIONS

NOZZLE DATA

HEAD DATA ( Dished End (Rear) )

WELD DATA

CALCULATION OF NOZZLE NECK THICKNESS AS PER UG 45Thickness of head as per UG 37Min. head thickness reqd. as per UG 27(d) , [tr1]= 0.5 x Pi x ID1 / ( 2 x Sv x E - 0.2 x Pi )= 0.5 x 0.12 x 2260.8 / ( 2 x 14.06 x 1.0 - 0.2 x 0.12 )= 4.828 mmNeck thickness for internal pressure as per UG 45(a)Formula in Appendix 1-1 , [trn1]= ( 0.5 x Pi x OD ) / ( Sn x E + 0.4 x Pi )= ( 0.5 x 0.12 x 60.33 ) / ( 12.02 x 1.0 + 0.4 x 0.12 )= 0.353 mmNeck thickness for external pressure as per UG 45(a)Neck thickness for external pressure as per UG 28 Assumed neck thickness , [trn3] = 0.279 mmL / OD = 2.487OD / trn3 = 216.3Factor A = 0.00016Factor B = 1.763 kgf/mmAllowable external pressure , [Pa]= 4 x B / ( 3 x OD / trn3 )= 4 x 1.763 / ( 3 x 216.3 )







Allowable stress @ design temperature Sv 14.06 kgf/mmInside diameter of head @ head skirt Dsf 1256 mmD / 2 H for Ellispoidal head 2Factor from Table UG-37 K1 0.9Inside diameter of equivalent sphere, K1 x Dsk x 2 ID1 2260.8 mmThickness t 7 mmMin. thickness for external pressure tr2 2.779 mm

Nozzle outside weld W1 6.35 mm

= 0.01087 kgf/mm gThickness of head as per UG 45(b)(1)Min. head thickness reqd. as per UG 27(d) , [trn2 = tr1]= 4.828 mmThickness for equivalent pressure as per UG 45(b)(2) , [trn4]= 0.5 x Pe x ID1 / ( 2 x Sv x E - 0.2 x Pe )= 0.5 x 0.01055 x 2260.8 / ( 2 x 14.06 x 1.0 - 0.2 x 0.01055 )= 0.424 mmStandard wall thickness as per UG 45(b)(4) , [t3]= 3.912 mmNeck thk as per UG 45 , [trn]= MAX { MAX [ trn1, trn3 ] , MIN [ MAX ( trn2 , trn4 ) , 0.875 x t3 ] } ..... for Process Nozzle= MAX [ trn1, trn3 ] ............................................................................ for Access Opening= 3.423 mm .................................................................................... Process OpeningSince available neck thickness, ta >= trn, selected neck thickness is adequate.




3. EXTERNAL LOADS :

4. HEAD DATA :




LOCAL STRESS ANALYSIS ( ROUND ATTACHMENT ) N 03



M.O.C SA-106 GR. B Smls. Pipe [UNS:K03006]Outside diameter OD 60.33 mmWeld size w 7 mm

0.5 x OD Ro = C 30.16 mm

Radial force Fr 74.92 kgfLatitudinal moment ML 29967.5 kgf-mmMeridional moment Mc 29967.5 kgf-mm

Total eff. moment, [ ML 2 + Mc 2 ] 0.5 M 42380.5 kgf-mm

Shear load Q 106 kgfTorsional moment Mt 29967.5 kgf-mm

M.O.C SA-516 GR. 70 Plt. [UNS:K02700]Allowable stress Sv 14.06 kgf/mmInside radius R 1130.4 mmThickness ( corroded ) t 7 mm

Mean radius of shell , [ Rm ]= R + 0.5 x t= 1130.4 + 0.5 x 7= 1133.9 mm

Calculate factor , [ U ]= 1.82 x 30.16 / SQRT [ 1133.9 x 7 ]]= 0.616

Calculate factor , [ S ]= 1.82 x 0.5 x Dp / SQRT [ Rm x t ]= 1.82 x 0.5 x / SQRT [ 1133.9 x 7 ]= 0.616


Shear stress due to Q , [ t1 ]= Q / ( p x Ro x t )= 106 / ( p x 30.16 x 7 )= 0.16 kgf/mm




STRESS FIGURE VALUE FROM FIGURE STRESS ( kgf/mm )

Radial load

Membrane5-25A Nx x tFr

-0.06044

Kn x Fr t 2

x -0.09241

5-25B Nf x tFr

-0.179Kn x Frt 2

f -0.274

Bending 5-26AMxFr 0.0621

6 x Kb x Frt 2

x 0.57



5-26B MfFr

0.1316 x Kb x Frt 2

f 1.203

Moment , M

Membrane5-27A Nx x t x SQRT [ Rm x t ]M

-0.05621

Kn x M t 2 x SQRT [ Rm x t ]

x -0.546

5-27B Nf x t x SQRT [ Rm x t ]M

-0.159Kn x Mt 2x SQRT [ Rm x t ]

f -1.541

Bending5-28A Mx x SQRT [ Rm x t ] M 0.117

6 x Kb x Mt 2 x SQRT [ Rm x t ]

x 6.794

5-28B Mf x SQRT [ Rm x t ]M 0.436 x Kb x M t 2x SQRT [ Rm x t ]

f 25.07

Stress due tox f

0 90 180 270 0 90 180 270

Radial load, Fr.(1)

MemberaneNx +( -0.274 )

+( -0.274 )

+( -0.274 )

+( -0.274 )

Nf +( -0.09241 )+( -0.09241 )

+( -0.09241 )

+( -0.09241 )

BendingMx +( 1.203 )

+( 1.203 )

+( 1.203 )

+( 1.203 )

Mf +( 0.57 ) +( 0.57 ) +( 0.57 ) +( 0.57 )

Moment, M.

MemberaneNx +( -1.541 )

-( -1.541 )

Nf +( -0.546 )-( -0.546 )

BendingMx +( 25.07 )

-( 25.07 )

Mf +( 6.794 ) -( 6.794 )

Int. pr., P.

Pi x Rmt

f +( 9.719 )+( 9.719)

+( 9.719 )

+( 9.719 )

+( 9.719 ) +( 9.719)

+( 9.719 )

+( 9.719 )

Total,

Membrane 1.815 0.274 -1.267 0.274 0.82 0.274 -0.272 0.274Mem+Bend 28.09 1.477 -25.14 1.477 8.002 0.662 -6.678 0.662


1. LIFTING LUG DATA :

2. DESIGN LOADS :

3. CALCULATION OF REFERENCE DIMENSIONS :

4. DESIGN OF LUG PLATE :

5. CALCULATION OF STRESSES IN LUG PLATE WELDS :


DESIGN OF LIFTING LUG Lifting LugsCODE P V Design Manual, D.R. Moss

Design Mode 1 , Uncorroded Condition

Material IS-2062 GR. A Plt.Length of lug LL 70 mmWidth of lug A 120 mmThickness of lug plate TL 12 mmStraight length B1 10 mmRadius at tip R3 35 mmPin Hole diameter D1 40 mmLug to vessel weld size W1 8 mmMin yield stress Sy 24.61 kgf/mmAllowable tensile stress ( 2 / 3 x Sy ) St 16.4 kgf/mmAllowable bending stress ( 1.5 x St ) Sb 22.15 kgf/mmAllowable shear stress (0.6 x St ) Ss 9.843 kgf/mm

Empty weight of equipment Wt 2149.7 kgfNumber of lifting lugs N 2Jirk load factor j 1.5

Dimension [ L1 ]= LL - B1 - R3= 70 - 10 - 35= 25 mm

Dimension [ L2 ]= L1 / SIN ( q1 ) = 25 / SIN ( 0.395 ) = 65 mm

Dimension [ LT ]= LL - R3= 70 - 35 = 35 mm

Angle [ q2 ]= ASIN ( R3 / L2 ) = ASIN ( 35 / 65 ) = 0.569 radians

Angle [ q1 ]= ATAN ( 2 x L1 / A ) = ATAN ( 2 x 25 / 120 ) = 0.395 radians

Angle [ q3 ]= q1 + q2 = 0.395 + 0.569 = 0.963 radians

Dimension [ L3 ]= R3 / SIN ( q3 ) = 35 / SIN ( 0.963 ) = 42.62 mm

Effective design load on each lug [ P ]= j x Wt / N= 1.5 x 2149.7 / 2= 1633 kgf

Required min. thickness of lug plate for shear [ t2 ]= P / [ ( R3 - 0.5 x D1) x ss ] = 1633 / [ ( 35 - 0.5 x 40 ) x 9.843 ]= 11.06 mm

Required min. thickness of lug plate for bending [ t1 ]= 6 x P x LT / ( A 2 x Sb ) = 6 x 1633 x 35 / ( 120 2 x 22.15 )= 1.075 mm

Required min. thickness of lug plate for shear [ t3 ]= P / [ ( 2 x L3 - D1 ) x ss ] = 1633 / [ ( 2 x 42.62 - 40 ) x 9.843 ]= 2.2 mm

Bending stress in weld [ f1 ]= 6 x P x LT / [ 2 x LL2 ]= 6 x 1633 x 35 / ( 2 x 70 2 )= 34.99 kgf/mm

Max. shear stress in weld [ f2 ]= P / [ 2 x A ]= 1633 / ( 2 x 120 )= 6.804 kgf/mm

Min. Size of lug plate weld [ w1 ]= MAX ( f1 , 2 x f2 ) / ( 0.707 x Ss )= MAX ( 34.99 , 2 x 6.804 ) / ( 0.707 x 9.843 )

= 5.028 mm


FOUNDATION LOAD DATA


Sr.No. Mode Condition

Weight ( kgf ) Wind Seismic

Empty FilledShear ( kgf ) Moment ( kgf-m ) Shear Moment

Tran. Long. Tran. Long. ( kgf ) ( kgf-m )

1 Operating Corroded 1898.3 1922.1 649.9 649.9 940.9 940.9 198.8 285.7

2 Design1 Corroded 1898.3 1926.8 649.9 649.9 940.9 940.9 199.3 286

3 Hydro Corroded 1841.1 4212.7 649.9 649.9 940.9 940.9 435.8 436.7

4 Pneumatic Corroded 1841.1 1843.9 649.9 649.9 940.9 940.9 190.8 275.9

5 Operating Uncorroded 2149.7 2173.2 649.9 649.9 882.1 882.1 224.8 303.3

6 Design1 Uncorroded 2149.7 2177.9 649.9 649.9 882.1 882.1 225.3 303.6

7 Hydro Uncorroded 2092.5 4439.8 649.9 649.9 882.1 882.1 459.3 454.2

8 Pneumatic Uncorroded 2092.5 2095.3 649.9 649.9 882.1 882.1 216.8 294


CENTER OF GRAVITY DATA


Sr.No. Mode Condition

Empty Operating / FilledWt ( kgf ) C.G. ( mm ) Wt ( kgf ) C.G. ( mm )

1 Operating Corroded 1898.3 1820.2 1922.1 1809.62 Design1 Corroded 1898.3 1820.2 1926.8 1807.53 Hydro Corroded 1841.1 1820.2 4212.7 1374.54 Pneumatic Corroded 1841.1 1820.2 1843.9 1818.95 Operating Uncorroded 2149.7 1729.8 2173.2 1721.76 Design1 Uncorroded 2149.7 1729.8 2177.9 1720.17 Hydro Uncorroded 2092.5 1729.8 4439.8 1361.38 Pneumatic Uncorroded 2092.5 1729.8 2095.3 1728.8


Index


Sr. No. Description Page No

1 Title page & equipment info

2 Design data

3 Material of constructions

4 Effective Pressures

5 Weight summary report

6 Test pressure calculations (shell side)

7 Wind load calculations

8 Seismic load calculations



11 Design of Main Shell

12 Design of Dished End (Rear)



15 Design of N 01

16 Design of N 01

17 Design of N 01

18 Design of N 02

19 Design of N 02

20 Design of N 02

21 Design of N 03

22 Design of N 03

23 Design of Lifting Lugs

24 Foundation load data

25 C.G. Data


EQUIPMENT INFORMATION :

DESIGN & REVIEWAL :

INSPECTION & APPROVAL :

EQUIPMENT DATA :

OTHER DATA :

Customer ABC Company Ltd.Project Soap PlantLocation Vapi SitePlant Refrigeration Plant

Design Code ASME VIII Div.1, 10 A11Equipment Name Gas FilterEquipment Type Pressure VesselEquipment Class N.A.Equipment Category N.A.Reference Drawing No ---Service Compressed Gas ServicesSupport Type Lug Supports

Designed ByDesign Date 30-03-2015 23:35:19Checked ByApproved ByRevision R00

Inspection Agency ---

Reviewed By ---

Front end Flat EndFront end flanged TrueRear end Dished EndRear end flanged FalseShell ID 1250 mmShell OD 1270 mmLength, Shell (W.L. to W.L) / Overall 1650 / 2254.6 mm

Fabricated weight 1841.1 kgfEmpty weight + external weights 1841.1 kgfEstimated operating weight 4212.7 kgfEstimated hydrotest weight 4439.8 kgf


(1) PROCESS DETAILS :

(3) TEST PR. : kgf/mm g

(4) TEMPERATURE : C

(5) ALLOWANCES : mm

(6) RADIOGRAPHY & JOINT EFFICIENCY :


VESSEL DESIGN DATA

MEDIA DENSITYkg/m

Operating Process Gas 10Design1 Process Gas 12Design2StartupShutdownUpsetHydrotest Water 1000Pneumatic Process Gas 1.2

(2) PR. : kgf/mm g INT. EXT.

Operating 0.1 0.12 0.01055Design1 0.12 0.12 0.01055Design2StartupShutdownUpset

Based onInput Pr MAWP MAP

Hydrotest 0.156 0.156 0.169Pneumatic 0.132 0.132 0.143

MIN. MAX.Input MDMT

Operating 20 -14.28 100Design1 20 -11.75 150Design2StartupShutdownUpsetHydrotest 21.67 -11.57 50Pneumatic 21.67 -11.75 50

INT. EXT.Corrosion 3 0Polishing 0 0

RADIOGRAPHY JOINT EFFICIENCYShell Spot + T Joints 0.85Head Full 1.00


VESSEL DESIGN DATA1. MATERIAL OF CONSTRUCTION :

2. NOZZLE CONNECTIONS :

3. INSULATION & CLADDING:


Shell sideShell SA-516 GR. 70 Plt. [UNS:K02700]

Head SA-516 GR. 70 Plt. [UNS:K02700]

Body flange SA-105 Frg. [UNS:K03504]Body flange cover SA-516 GR. 70 Plt. [UNS:K02700]Liner

Shell side

Nozzle neck 40 & < 200 SA-106 GR. B Smls. Pipe [UNS:K03006]Flange SA-105 Frg. [UNS:K03504]Cover flange SA-105 Frg. [UNS:K03504]

Nozzle neck >= NPS 200 SA-516 GR. 70 Plt. [UNS:K02700]Flange SA-516 GR. 70 Plt. [UNS:K02700]Cover flange SA-516 GR. 70 Plt. [UNS:K02700]

Pad flange SA-516 GR. 70 Plt. [UNS:K02700]Pad flange cover SA-516 GR. 70 Plt. [UNS:K02700]Manhole flange SA-516 GR. 70 Plt. [UNS:K02700]Manhole cover SA-516 GR. 70 Plt. [UNS:K02700]Reinforcement pad SA-516 GR. 70 Plt. [UNS:K02700]External bolt SA-193 GR. B7 Bolt [UNS:G41400]External gasket Spiral metal wound CAF filled (S.S.)Stiffener SA-516 GR. 70 Plt. [UNS:K02700]Lifting lug IS-2062 GR. A Plt.Support IS-2062 GR. A Plt.Anchor bolt Commercial CS Bolt

Mat. / Density / Thk. Rockwool (Mineral Fibre) / 136.2 kg/m / 25 mmMat. / Thk. Al. sheet / 1.191 mm


SUMMARY OF EFFECTIVE DESIGN PRESSURES IN kgf/mm g VS TEMPERATURE IN C


Sr. Item name Temp. Inside pr. Liquid pr. Effective pr.No. +ve -ve +ve -ve1 Cover (Front) 50 0.12 0 0.00007 0.12 02 Shell Flng (Front) 50 0.12 0 0.00023 0.12 03 Main Shell 50 0.12 0 0.00188 0.122 04 Dished End (Rear) 50 0.12 0 0.00225 0.122 05


ITEM WISE WEIGHT SUMMARY

Licensee : Sunay Wagle, CADEM Services, Pune, IndiaCustomer ABC Company Ltd.Project / Equipment

Date post:	17-Oct-2015
Category:	Documents
Upload:	cadem-softwares-and-services
View:	179 times
Download:	15 times

Pressure Vessel Design

Documents