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GP-QM-7.3-2 R1
GRAND PRIX DESIGN CALCULATIONGP-839
SHT. 1 OF 12
Client : M/s. Bharat Pumps & Compressors Ltd.
Project : MSQU / IOCL
P.O. No. : 461-16430421-1533 Dtd. 14.02.2005
Item : Discharge Volume Bottles - D2A( 6510418/D )
Drg. No. : 2-GP839-1324
Inspection : BPCL/ EIL
G.P. Job No. : GP-839
1 Revised as per clients comment. 1.04.04 A.S.0 Issued for Approval 02.03.05 N.J.
Rev. No. Description Date Prepared By Checked By Approved ByDATE
GRAND PRIX FARIDABADDoc. No. Rev.
GP-QM-7.3-2 R1
GRAND PRIX FARIDABAD02.03.05 GP839-DC-01 1
GRAND PRIX DESIGN CALCULATIONGP-839
SHT. 2 OF 12
DESIGN DATA
Design Code : ASME SEC VIII, DIV. 1 - 2004
Design Pressure : 56.2 Kg/Cm2g
Design Temp. : 204
Flange Rating. : 600 #
Radiography : 100 %
Joint Efficiency : 1.0
Corrosion Allowance : 3.2 mm
Vessel OD, D : 450.0 mm
Vessel Outer Radius, R : 225.0 mm
Name of Part Material of Construction Stress Value at Design Temp.
Shell : SA 516 Gr. 60 1202.47
Dish End : SA 516 Gr. 60 1202.47
Nozzle : SA 106 Gr. B 1202.47
oC
Kg/Cm2
Kg/Cm2
Kg/Cm2
GP-QM-7.3-2 R1
DATE
GRAND PRIX FARIDABADDoc. No. Rev.
02.03.05 GP839-DC-01 1
GRAND PRIX DESIGN CALCULATIONGP-839
SHT. 3 OF 12
DESIGN SUMMARY
S. No. Description Size
1 Shell OD 450 x 14 Thk. 13.52 mm 14.0 mm
2 Dish End OD 450x13.3 Thk(min). 13.29 mm 16.0 mm(nom)
3 S3 6" NB x Sch. 80 7.06 mm 10.972 mm
4 S1,S2 4"NB x Sch. 120 5.82 mm 11.12 mm
5 S4,S5,S8,S9 1½"NB x Sch. XX 4.31 mm 10.16 mm
Calculated Minimum Thickness
Actual Thickness Provided
GP-QM-7.3-2 R1
DATE
GRAND PRIX FARIDABADDoc. No. Rev.
02.03.05 GP839-DC-01 1
GRAND PRIX DESIGN CALCULATIONGP-839
SHT. 4 OF 12
Shell Thickness :-
t = P.R (SE + 0.4P)
= 10.32 mm
= 10.32 + 3.2 Adding 3.2 mm Corrosion Allownace
= 13.52
Used Plate 14 mm Thick
Dish End Tickness :-
Type of D/End, Semi-Elliptical , 2 : 1 K =1.0
t = P.D.K2SE + 2P(K - 0.1)
= 10.09 mm
= 10.09 + 3.2 Adding 3.2 mm Corrosion Allownace
= 13.29 mm
Used Plate 16 mm Thick
GP-QM-7.3-2 R1
DATE
GRAND PRIX FARIDABADDoc. No. Rev.
02.03.05 GP839-DC-01 1
GRAND PRIX DESIGN CALCULATIONGP-839
SHT. 5 OF 12
Nozzle Thickness :- (6"NB Size)
Do = 168.27 mm
t = Ro = 84.135 mm (SE + 0.4P) E = 1.0
= 3.86 mm
= 3.86 + 3.2 Adding 3.2 mm Corrosion Allownace
= 7.06 mm
Used 6" NB x Sch. 80 Pipe (10.972 mm)
Nozzle Thickness :- (4" NB Size)
Do = 114.3 mm
t = Ro = 57.15 mm
(SE + 0.4P) E = 1.0
= 2.62 mm
= 2.62 + 3.2 Adding 3.2 mm Corrosion Allownace
= 5.82 mm
Used 4" NB x Sch. 120 Pipe (11.12 mm)
Nozzle Thickness :-
Do = 48.26 mm
t = Ro = 24.13 mm
(SE + 0.4P) E = 1.0
= 1.11 mm
= 1.11 + 3.2 Adding 3.2 mm Corrosion Allownace
P.Ro
P.Ro
(1½" NB Size)
P.Ro
GP-QM-7.3-2 R1
= 4.31 mm
Used 1½" NB x Sch. XX Pipe (10.16 mm)
DATE
GRAND PRIX FARIDABADDoc. No. Rev.
02.03.05 GP839-DC-01 1
GRAND PRIX DESIGN CALCULATIONGP-839
SHT. 6 OF 12
Table 1
Nozzle Size (NB)
S3 150 13.29 9.42 7.06 9.42 10.77
S1 100 13.52 8.46 5.82 8.46 9.67
S2 100 13.29 8.46 5.82 8.46 9.67
40 13.52 6.42 4.31 6.42 7.34
Shell/ D.End Thk.+C.A. (T1)
Std. Wall Thk. Less 12.5% + C.A. (T2)
Cal. Nozzle Thk.+C.A.
(T3)
Smaller of T1 & T2 (T4)
Greater of T3 & T4 / 0.875 for (Pipes)
Provided Thk. / Sch.
10.972 Sch. 80
11.12 Sch. 120
11.12 Sch. 120
S4,S5,S8, S9
10.16 Sch. XX
GP-QM-7.3-2 R1
DATE
GRAND PRIX FARIDABADDoc. No. Rev.
02.03.05 GP839-DC-01 1
GRAND PRIX DESIGN CALCULATIONGP-839
SHT. 7 OF 12
Nozzle Reinforcement 1.0 Nozzle No.2.0 Size (NB) 150 100
3.0 10.09 10.094.0 t = Provied Shell Thk. - C.A. 10.8 10.8
5.0 3.86 2.62
6.0 7.772 7.927.0 d = Inside Dia of Nozzle + C.A. 149.52 95.24
8.0 1202.47 1202.47
9.0 1202.47 1202.47
10.0 1202.47 1202.47
11.0 1.0 1.0
12.0 1.0 1.0
13.0 1.0 1.014.0 F = Correction Factor 1.0 1.0
15.0 14.0 14.0
16.0299.04 190.48
250.0 200.0
17.0 1508.86 961.10
18.0 1.0 1.0
19.0 105.95 67.49
20.0 152.02 209.88
21.0 100.0 100.0
22.0 1189.104 1244.88
tr = Required Shell Thk.
tm= Required Nozzle Thk.
tn = Provied Nozzle Thk. - C.A.
Sn = Allowable Stress in Nozzle (Kg/Cm2)
Sv = Allowable Stress in Vessel (Kg/Cm2)
Sp = Allowable Stress in RF. Pad (Kg/Cm2)
fr1 = Sn/Sv (1.0 Max.)
fr2 = Sn/Sv (1.0 Max.)
fr3 , fr4= Sp/Sv (1.0 Max.)
te = Thickness of RF. Pad
Dr = Dia. of RF. Pad (Available)
Dp = Dia. of RF. Pad (Provided)
Area Required, A = dtrF+2tntrF(1-fr1)
Value , E1
Area Available in Shell, A1 = Larger of d(E1t-Ftr)-2tn(E1t-Ftr)(1-fr1) OR 2(t+tn)(E1t-Ftr)-2tn(E1t-Ftr)(1-fr1)
Area Available in Nozzle, A2 = Smaller of 5(tn-tm)t.fr2 OR 5(tn-tm)tn.fr2
Welding Area, A41 = (LEG)2.fr2
Area in RF. Pad, A5 = (Dp-d-2tn)te.fr3
GP-QM-7.3-2 R1
23.0 100.0 100.0
24.0 1647.08 1722.25
Remarks :- 1. Reinforcement Provided is OK 2. No Reinforcement Required.
DATE
GRAND PRIX FARIDABADDoc. No. Rev.
02.03.05 GP839-DC-01 1
GRAND PRIX DESIGN CALCULATIONGP-839
SHT. 8 OF 12
Nozzle Reinforcement 1.0 Nozzle No.2.0 Size (NB) 100
3.0 10.324.0 t = Provied Shell Thk. - C.A. 10.8
5.0 2.62
6.0 7.927.0 d = Inside Dia of Nozzle + C.A. 95.24
8.0 1202.47
9.0 1202.47
10.0 1202.47
11.0 1.0
12.0 1.0
13.0 1.014.0 F = Correction Factor 1.0
15.0 10.8
16.0190.48
200.0
17.0 983.15
18.0 1.0
19.0 45.44
20.0 198
21.0 100.0
Welding Area, A42 = (LEG)2.fr4
Total Area Available = A1+A2+A41+A5+A42
tr = Required Shell Thk.
tm= Required Nozzle Thk.
tn = Provied Nozzle Thk. - C.A.
Sn = Allowable Stress in Nozzle (Kg/Cm2)
Sv = Allowable Stress in Vessel (Kg/Cm2)
Sp = Allowable Stress in RF. Pad (Kg/Cm2)
fr1 = Sn/Sv (1.0 Max.)
fr2 = Sn/Sv (1.0 Max.)
fr3 , fr4= Sp/Sv (1.0 Max.)
te = Thickness of RF. Pad
Dr = Dia. of RF. Pad (Available)
Dp = Dia. of RF. Pad (Provided)
Area Required, A = dtrF+2tntrF(1-fr1)
Value , E1
Area Available in Shell, A1 = Larger of d(E1t-Ftr)-2tn(E1t-Ftr)(1-fr1) OR 2(t+tn)(E1t-Ftr)-2tn(E1t-Ftr)(1-fr1)
Area Available in Nozzle, A2 = Smaller of 5(tn-tm)t.fr2 OR 5(tn-tm)tn.fr2
Welding Area, A41 = (LEG)2.fr2
GP-QM-7.3-2 R1
22.0 960.336
23.0 100.0
24.0 1403.78
Remarks :- 1. Reinforcement Provided is OK 2. No Reinforcement Required.
DATE
GRAND PRIX FARIDABADDoc. No. Rev.
02.03.05 GP839-DC-01 1
GRAND PRIX DESIGN CALCULATIONGP-839
SHT. 9 OF 12
Calculation for Nozzle Loads( Code used : BSI-PD 5500 :2000)
(a) Calculation for Nozzles S1 & S2 ( 4" NB ) :-
= 422.4 mm
= 200.15 mm
Corrosion Allowance , CA = 3.2 mm
= 14.0 mm
= 14.0 mm
= 11.12 mm
= 28 mm
=
= 12.0247
= 12.0247
Constant ,S = 1
Area in RF. Pad, A5 = (Dp-d-2tn)te.fr3
Welding Area, A42 = (LEG)2.fr4
Total Area Available = A1+A2+A41+A5+A42
Inside Diametre of Shell , Di
Nozzle Flange bolt ( PCD ) , do
Shell Thickness, ts
Reinforcing Pad Thickness, tp
Nozzle Thickness , tn
Shell, Calculation Thickness, tcs
AllowableStress of Shell Material,Sa Kg/mm2
AllowableStress of Pad Material ,Sp Kg/mm2
GP-QM-7.3-2 R1
(As per Table 1)
(As per PD 5500)
= 2.90760147956962
= 5.33964267969865
= 13.81
DATE
GRAND PRIX FARIDABADDoc. No. Rev.
02.03.05 GP839-DC-01 1
GRAND PRIX DESIGN CALCULATIONGP-839
SHT. 10 OF 12
= 453.6 mm
= 192.23 mm
= 2.41226571099003
Maximum allowable Axial Force
= 27411.0198409225 Kg268902.10463945 N
Maximum allowable Circumferential
= 50338.7594431687 Kg493823.230137485 N
Maximum allowable Longitudinal Force
= 130167.342017879 Kg
1276941.62519539 N
Maximum allowable Axial Moment
= 1317318.79151505 Kg-mm
12922.8973447627 NmMaximum Allowable Circumferential
= 2419180.1013198 Kg-mm23732.1567939473 Nm
Maximum Allowable Longitudinal
Polynomial Coeffecients ,a0 to a4
Calculation Factors , C2 to C4
C2
C3
C4
Shell effective mean Diametre, De
Nozzle Mean Diametre, dm
Geometric Parametre for shells λ C
on the Nozzle ,FX Max
Forceon the Nozzle ,FY Max
on the Nozzle ,FZ Max
on the Nozzle ,M X Max
moment on the Nozzle , MY Max
GP-QM-7.3-2 R1
= 6255582.12269522 Kg-mm61367.2606236401 Nm
TABLE 1 Coefficients to define factore C2 , C3 or C4
FactorC2 0.60072181 0.95196257 0.00520 -0.0014064 0C3 4.526315 0.064021889 0.15888 -0.0214193 0.00104C4 with
4.8844124 -0.07138921 0.79991 -0.0241557 0C4 with
6.3178075 -3.6618209 4.51454 -0.8309484 0.0507
DATE
GRAND PRIX FARIDABADDoc. No. Rev.
02.03.05 GP839-DC-01 1
GRAND PRIX DESIGN CALCULATIONGP-839
SHT. 11 OF 12
CALCULATED
MAX ALLOWABLE 268902.1 493823.2 1276941.6 12922.90 23732.157 61367.26
LOAD N / Nm
ALLOWABLE2700.00 3350.00 3350.00 1250.00 850.00 850.00
LOAD N / Nm
The forces and Moments are on the safer Side.
moment on the Nozzle , MZ Max
a0 a1 a2 a3 a4
tp / ts ≤ 0.2
tp / ts ≥ 0.5
FX FY FZ MX MY MZ
GP-QM-7.3-2 R1
DATE
GRAND PRIX FARIDABADDoc. No. Rev.
02.03.05 GP839-DC-01 1
GRAND PRIX DESIGN CALCULATIONGP-839
SHT. 12 OF 12
Calculation for Saddle Support.( Code used : BS- PD 5500 )
Allowable Stress of Saddle Mat. = 9.80
Design Stress of the web section = 6.533
Outer Dia of Vessel , D = 450 mm
Outer radius of Vessel , R = 225 mm
Test Weight of the Vessel , W = 640.00 Kg.
The load on one Saddle , Q = 640.00 Kg.
0.204 ( From Table 1)
Web Plate Thickness , T = 10.00 mm
Horizontal Force F = 130.56 Kg.
Kg/mm2
Kg/mm2
( Considered 2/3rd of the allowable stress )
Numerical Constant , k9 =
GP-QM-7.3-2 R1
CONTACT ANGLE 120 130 140 150 160 170 180
0.222 0.241 0.259 0.279 0.298 0.318
R / 3 = 75 mm.
To Resist this Force The effective area of Web Plate = 750
Stress due to Horizontal Force, F = 0.17408
DATE
GRAND PRIX FARIDABADDoc. No. Rev.
02.03.05 GP839-DC-01 1
VALUE OF CONSTANT K9 (As per PD 5500:2000 Annex. G)
K9 0.204
mm2
kg/mm2
Since the allowable Stress is 6.533 Kg/mm2 , The Selected size is satisfactory
Prepared By Checked By Approved By