Vessel Design Calculation

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1. DESIGN DATA

1.1 SUMMARY OF DESIGN DATA

CODE ASME SECTION VIII DIV.1 2010 ED ADD 2011 _{CODE CASE 2714}

SPECIFICATIONS -

DESIGN PRESSURE 15 MPA

DESIGN TEMPERATURE 115 °C

MAXIMUM ALLOW. WORKING PRESSURE 15 MPA

HYDROSTATIC TEST PRESSURE 19.5 MPA

RADIOGRAPHY FULL JOINT EFFICIENCY 1.0 CORROSION ALLOWANCE 3 MM PWHT NO MDMT -29 °C @ 15 MPA IMPACT TEST NO

ASME CODE STAMP YES

LOADINGS (AS PER UG-22):

(a) INTERNAL OR EXTERNAL DESIGN

PRESSURE YES

(b) WEIGHT OF VESSEL AND NORMAL CONTENTS UNDER OPERATING OR TEST CONDITIONS YES (c) SUPERIMPOSED STATIC REACTIONS YES (d) ATTACHMENT OF: (1) INTERNALS (2) VESSEL SUPPORTS YES (e) CYCLIC AND DYNAMIC

REACTIONS NONE

(f) WIND, SNOW, AND SEISMIC

REACTIONS NONE

(g) IMPACT REACTIONS NONE

(h) TEMPERATURE GRADIENTS AND

DIFFERENTIAL THERMAL EXPANSION NONE

(i) ABNORMAL PRESSURE NONE

(j) TEST PRESSURE AND

COINCIDENT STATIC HEAD ACTING DURING THE TEST

YES

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1.2 PVELITE INPUT DATA

PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 2 Input Echo : Step: 1 4:19p Sep 18,2012 PV Elite Vessel Analysis Program: Input Data Design Internal Pressure (for Hydrotest) 15.000 MPa Design Internal Temperature 115 C Type of Hydrotest UG99-b Hydrotest Position Horizontal Projection of Nozzle from Vessel Top 0.0000 mm Projection of Nozzle from Vessel Bottom 0.0000 mm Minimum Design Metal Temperature -29 C Type of Construction Welded Special Service Air/Water/Steam Degree of Radiography RT 1 Miscellaneous Weight Percent 5.0 Use Higher Longitudinal Stresses (Flag) Y Select t for Internal Pressure (Flag) N Select t for External Pressure (Flag) N Select t for Axial Stress (Flag) N Select Location for Stiff. Rings (Flag) N Consider Vortex Shedding N Perform a Corroded Hydrotest N Is this a Heat Exchanger No User Defined Hydro. Press. (Used if > 0) 0.0000 MPa User defined MAWP 0.0000 MPa User defined MAPnc 0.0000 MPa Load Case 1 NP+EW+WI+FW+BW Load Case 2 NP+EW+EE+FS+BS Load Case 3 NP+OW+WI+FW+BW Load Case 4 NP+OW+EQ+FS+BS Load Case 5 NP+HW+HI Load Case 6 NP+HW+HE

Load Case 7 IP+OW+WI+FW+BW Load Case 8 IP+OW+EQ+FS+BS Load Case 9 EP+OW+WI+FW+BW Load Case 10 EP+OW+EQ+FS+BS Load Case 11 HP+HW+HI Load Case 12 HP+HW+HE Load Case 13 IP+WE+EW Load Case 14 IP+WF+CW Load Case 15 IP+VO+OW Load Case 16 IP+VE+EW Load Case 17 NP+VO+OW Load Case 18 FS+BS+IP+OW Load Case 19 FS+BS+EP+OW Wind Design Code ASCE-7 2010 Basic Wind Speed [V] 158.40 km/hr Surface Roughness Category C: Open Terrain Importance Factor 1.0 Type of Surface Rough (D`/D = 0.02) Base Elevation 0.0000 mm

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PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 3 Input Echo : Step: 1 4:19p Sep 18,2012 Percent Wind for Hydrotest 33.0 Using User defined Wind Press. Vs Elev. N Height of Hill or Escarpment H or Hh 0.0000 mm Distance Upwind of Crest Lh 0.0000 mm Distance from Crest to the Vessel x 0.0000 mm Type of Terrain ( Hill, Escarpment ) Flat Damping Factor (Beta) for Wind (Ope) 0.0100

Damping Factor (Beta) for Wind (Empty) 0.0000 Damping Factor (Beta) for Wind (Filled) 0.0000 Seismic Design Code No Seismic Design Nozzle for Des. Press. + St. Head Y Consider MAP New and Cold in Noz. Design N Consider External Loads for Nozzle Des. Y Use ASME VIII-1 Appendix 1-9 N Material Database Year Current w/Addenda or Code Year Configuration Directives: Do not use Nozzle MDMT Interpretation VIII-1 01-37 No Use Table G instead of exact equation for "A" Yes Shell Head Joints are Tapered Yes Compute "K" in corroded condition Yes Use Code Case 2286 No Use the MAWP to compute the MDMT Yes Using Metric Material Databases, ASME II D No Complete Listing of Vessel Elements and Details: Element From Node 10 Element To Node 20 Element Type Elliptical Description Distance "FROM" to "TO" 39.868 mm Inside Diameter 131.80 mm Element Thickness 15.958 mm Internal Corrosion Allowance 3.0000 mm Nominal Thickness 18.237 mm External Corrosion Allowance 0.0000 mm Design Internal Pressure 15.000 MPa Design Temperature Internal Pressure 115 C Design External Pressure 0.0000 MPa Design Temperature External Pressure 34 C Effective Diameter Multiplier 1.2 Material Name SA-234 WPB Allowable Stress, Ambient 117.90 MPa Allowable Stress, Operating 117.90 MPa Allowable Stress, Hydrotest 153.28 MPa Material Density 0.007750 kg/cm³ P Number Thickness 31.750 mm Yield Stress, Operating 218.10 MPa

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PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 4 Input Echo : Step: 1 4:19p Sep 18,2012 UCS-66 Chart Curve Designation B External Pressure Chart Name CS-2 UNS Number K03006 Product Form Smls. & wld. fittings Efficiency, Longitudinal Seam 1.0 Efficiency, Circumferential Seam 1.0 Elliptical Head Factor 2.0 Element From Node 10 Detail Type Insulation Detail ID Ins: 10 Dist. from "FROM" Node / Offset dist -34.925 mm Height/Length of Insulation 74.793 mm Thickness of Insulation 50.800 mm Density 0.0002300 kg/cm³ --- Element From Node 20 Element To Node 30 Element Type Cylinder Description Distance "FROM" to "TO" 1104.9 mm Inside Diameter 139.73 mm Element Thickness 14.275 mm

Internal Corrosion Allowance 3.0000 mm Nominal Thickness 14.275 mm External Corrosion Allowance 0.0000 mm Design Internal Pressure 15.000 MPa Design Temperature Internal Pressure 115 C Design External Pressure 0.0000 MPa Design Temperature External Pressure 34 C Effective Diameter Multiplier 1.2 Material Name SA-106 B Allowable Stress, Ambient 117.90 MPa Allowable Stress, Operating 117.90 MPa Allowable Stress, Hydrotest 153.28 MPa Material Density 0.007750 kg/cm³ P Number Thickness 31.750 mm Yield Stress, Operating 218.10 MPa UCS-66 Chart Curve Designation B External Pressure Chart Name CS-2 UNS Number K03006 Product Form Smls. pipe Efficiency, Longitudinal Seam 1.0 Efficiency, Circumferential Seam 1.0 Element From Node 20 Detail Type Insulation Detail ID INS Dist. from "FROM" Node / Offset dist 0.0000 mm Height/Length of Insulation 1104.9 mm Thickness of Insulation 50.800 mm

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PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 5 Input Echo : Step: 1 4:19p Sep 18,2012

Density 0.0002300 kg/cm³ Element From Node 20 Detail Type Nozzle Detail ID N4 Dist. from "FROM" Node / Offset dist 82.700 mm Nozzle Diameter 2.0 in. Nozzle Schedule XXS Nozzle Class 1500 Layout Angle 0.0 Blind Flange (Y/N) N Weight of Nozzle ( Used if > 0 ) 132.83 N Grade of Attached Flange GR 1.1 Nozzle Matl SA-106 B Element From Node 20 Detail Type Nozzle Detail ID PG Dist. from "FROM" Node / Offset dist 381.90 mm Nozzle Diameter 2.0 in. Nozzle Schedule XXS Nozzle Class 1500 Layout Angle 0.0 Blind Flange (Y/N) N Weight of Nozzle ( Used if > 0 ) 244.14 N Grade of Attached Flange GR 1.1 Nozzle Matl SA-106 B Element From Node 20 Detail Type Nozzle Detail ID N6 Dist. from "FROM" Node / Offset dist 932.70 mm Nozzle Diameter 2.0 in. Nozzle Schedule XXS Nozzle Class 1500 Layout Angle 0.0 Blind Flange (Y/N) N Weight of Nozzle ( Used if > 0 ) 132.83 N Grade of Attached Flange GR 1.1 Nozzle Matl SA-106 B Element From Node 20 Detail Type Nozzle Detail ID N3 Dist. from "FROM" Node / Offset dist 82.700 mm Nozzle Diameter 1.0 in. Nozzle Schedule XXS Nozzle Class 1500 Layout Angle 180.0 Blind Flange (Y/N) Y Weight of Nozzle ( Used if > 0 ) 63.417 N Grade of Attached Flange GR 1.1 Nozzle Matl SA-106 B

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PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 6 Input Echo : Step: 1 4:19p Sep 18,2012 Element From Node 20 Detail Type Nozzle Detail ID N2 Dist. from "FROM" Node / Offset dist 507.70 mm Nozzle Diameter 1.0 in. Nozzle Schedule XXS Nozzle Class 1500 Layout Angle 180.0 Blind Flange (Y/N) N Weight of Nozzle ( Used if > 0 ) 36.493 N Grade of Attached Flange GR 1.1 Nozzle Matl SA-106 B Element From Node 20 Detail Type Nozzle Detail ID N1

Dist. from "FROM" Node / Offset dist 932.70 mm Nozzle Diameter 2.0 in. Nozzle Schedule XXS Nozzle Class 1500 Layout Angle 180.0 Blind Flange (Y/N) N Weight of Nozzle ( Used if > 0 ) 132.83 N Grade of Attached Flange GR 1.1 Nozzle Matl SA-106 B Element From Node 20 Detail Type Nozzle Detail ID N5 Dist. from "FROM" Node / Offset dist 657.70 mm Nozzle Diameter 1.0 in. Nozzle Schedule XXS Nozzle Class 1500 Layout Angle 0.0 Blind Flange (Y/N) Y Weight of Nozzle ( Used if > 0 ) 36.493 N Grade of Attached Flange GR 1.1 Nozzle Matl SA-106 B Element From Node 20 Detail Type Weight Detail ID BUNDLE Dist. from "FROM" Node / Offset dist 938.69 mm Miscellaneous Weight 1382.7 N Offset from Element Centerline 0.0000 mm ---

Element From Node 30 Element To Node 40 Element Type Flange Description

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PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 7 Input Echo : Step: 1 4:19p Sep 18,2012 Distance "FROM" to "TO" 171.45 mm Flange Inside Diameter 154.18 mm Element Thickness 82.550 mm Internal Corrosion Allowance 3.0000 mm Nominal Thickness 14.275 mm External Corrosion Allowance 0.0000 mm Design Internal Pressure 15.000 MPa Design Temperature Internal Pressure 115 C Design External Pressure 0.0000 MPa Design Temperature External Pressure 34 C Effective Diameter Multiplier 1.2 Material Name SA-105 Allowable Stress, Ambient 137.90 MPa Allowable Stress, Operating 137.90 MPa Allowable Stress, Hydrotest 179.27 MPa Material Density 0.007750 kg/cm³ P Number Thickness 31.750 mm Yield Stress, Operating 224.31 MPa UCS-66 Chart Curve Designation B External Pressure Chart Name CS-2 UNS Number K03504 Product Form Forgings Perform Flange Stress Calculation (Y/N) Y Weight of ANSI B16.5/B16.47 Flange 0.0000 N Class of ANSI B16.5/B16.47 Flange Grade of ANSI B16.5/B16.47 Flange Element From Node 30 Detail Type Insulation Detail ID Ins: 30 Dist. from "FROM" Node / Offset dist 0.0000 mm Height/Length of Insulation 171.45 mm Thickness of Insulation 50.800 mm Density 0.0002300 kg/cm³ PV Elite is a trademark of Intergraph CADWorx & Analysis Solutions, Inc. 2012

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1.3 SKETCH OF FUEL GAS SCRUBBER 01H-5310

PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 8 XY Coordinate Calculations : Step: 2 4:19p Sep 18,2012 XY Coordinate Calculations | | | | | | From| To | X (Horiz.)| Y (Vert.) |DX (Horiz.)| DY (Vert.) | | | mm | mm | mm | mm | --- 10| 20| 39.8678 | ... | 39.8678 | ... | 20| 30| 1144.77 | ... | 1104.90 | ... | 30| 40| 1316.22 | ... | 171.450 | ... | PV Elite is a trademark of Intergraph CADWorx & Analysis Solutions, Inc. 2012 Node 10 Node 20 Node 30 Node 40

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2. INTERNAL PRESSURE AND HYDROSTATIC PRESSURE CALCULATIONS

PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 9 Internal Pressure Calculations : Step: 4 4:19p Sep 18,2012 Element Thickness, Pressure, Diameter and Allowable Stress : | | Int. Press | Nominal | Total Corr| Element | Allowable | From| To | + Liq. Hd | Thickness | Allowance | Diameter | Stress(SE)| | | MPa | mm | mm | mm | MPa | --- 10| 20| 15.000 | 18.237 | 3.0000 | 131.80 | 117.90 | 20| 30| 15.000 | 14.275 | 3.0000 | 139.73 | 117.90 | 30| 40| 15.000 | 14.275 | 3.0000 | 154.18 | 137.90 | Element Required Thickness and MAWP : | | Design | M.A.W.P. | M.A.P. | Minimum | Required | From| To | Pressure | Corroded | New & Cold | Thickness | Thickness | | | MPa | MPa | MPa | mm | mm | --- 10| 20| 15.0000 | 22.9935 | 27.8752 | 15.9575 | 11.3949 | 20| 30| 15.0000 | 16.6946 | 21.4601 | 14.2748 | 13.0358 | 30| 40| 15.0000 | 23.0733 | 25.5315 | 82.5500 | No Calc | Minimum 16.695 21.460 MAWP: 13.139 MPa, limited by: Nozzle Reinforcement. Internal Pressure Calculation Results : ASME Code, Section VIII, Division 1, 2010, 2011a Elliptical Head From 10 To 20 SA-234 WPB , UCS-66 Crv. B at 115 C Material UNS Number: K03006 Required Thickness due to Internal Pressure [tr]: = (P*D*Kcor)/(2*S*E-0.2*P) Appendix 1-4(c) = (15.000*137.8006*0.946)/(2*117.90*1.00-0.2*15.000) = 8.3949 + 3.0000 = 11.3949 mm Max. Allowable Working Pressure at given Thickness, corroded [MAWP]: = (2*S*E*t)/(Kcor*D+0.2*t) per Appendix 1-4 (c) = (2*117.90*1.00*12.9575)/(0.946*137.8006+0.2*12.9575) = 22.993 MPa Maximum Allowable Pressure, New and Cold [MAPNC]: = (2*S*E*t)/(K*D+0.2*t) per Appendix 1-4 (c) = (2*117.90*1.00*15.9575)/(1.000*131.8006+0.2*15.9575) = 27.875 MPa Actual stress at given pressure and thickness, corroded [Sact]: = (P*(Kcor*D+0.2*t))/(2*E*t) = (15.000*(0.946*137.8006+0.2*12.9575))/(2*1.00*12.9575) = 76.916 MPa Straight Flange Required Thickness:

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PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 10 Internal Pressure Calculations : Step: 4 4:19p Sep 18,2012 = (P*R)/(S*E-0.6*P) + c per UG-27 (c)(1) = (15.000*68.9003)/(117.90*1.00-0.6*15.000)+3.000 = 12.490 mm Straight Flange Maximum Allowable Working Pressure: = (S*E*t)/(R+0.6*t) per UG-27 (c)(1) = (117.90 * 1.00 * 15.2372 )/(68.9003 + 0.6 * 15.2372 ) = 23.020 MPa Factor K, corroded condition [Kcor]: = ( 2 + ( Inside Diameter/( 2 * Inside Head Depth ))^(2))/6 = ( 2 + ( 137.801/( 2 * 35.950 ))^(2))/6 = 0.945528 MDMT Calculations in the Knuckle Portion: Govrn. thk, tg = 15.958 , tr = 8.395 , c = 3.0000 mm , E* = 1.00 Stress Ratio = tr * (E*)/(tg - c) = 0.648 , Temp. Reduction = 20 C Min Metal Temp. w/o impact per UCS-66 -14 C Min Metal Temp. at Required thickness (UCS 66.1) -34 C Min Metal Temp. w/o impact per UG-20(f) -29 C MDMT Calculations in the Head Straight Flange: Govrn. thk, tg = 18.237 , tr = 9.490 , c = 3.0000 mm , E* = 1.00 Stress Ratio = tr * (E*)/(tg - c) = 0.623 , Temp. Reduction = 21 C Min Metal Temp. w/o impact per UCS-66 -10 C Min Metal Temp. at Required thickness (UCS 66.1) -31 C Min Metal Temp. w/o impact per UG-20(f) -29 C Cylindrical Shell From 20 To 30 SA-106 B , UCS-66 Crv. B at 115 C Material UNS Number: K03006 Required Thickness due to Internal Pressure [tr]: = (P*R)/(S*E-0.6*P) per UG-27 (c)(1) = (15.000*72.8627)/(117.90*1.00-0.6*15.000)

= 10.0358 + 3.0000 = 13.0358 mm Max. Allowable Working Pressure at given Thickness, corroded [MAWP]: = (S*E*t)/(R+0.6*t) per UG-27 (c)(1) = (117.90*1.00*11.2748)/(72.8627+0.6*11.2748) = 16.695 MPa Maximum Allowable Pressure, New and Cold [MAPNC]: = (S*E*t)/(R+0.6*t) per UG-27 (c)(1) = (117.90*1.00*14.2748)/(69.8627+0.6*14.2748) = 21.460 MPa Actual stress at given pressure and thickness, corroded [Sact]: = (P*(R+0.6*t))/(E*t)

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PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 11 Internal Pressure Calculations : Step: 4 4:19p Sep 18,2012 = (15.000*(72.8627+0.6*11.2748))/(1.00*11.2748) = 105.937 MPa Minimum Design Metal Temperature Results: Govrn. thk, tg = 14.275 , tr = 10.036 , c = 3.0000 mm , E* = 1.00 Stress Ratio = tr * (E*)/(tg - c) = 0.890 , Temp. Reduction = 6 C Min Metal Temp. w/o impact per UCS-66 -18 C Min Metal Temp. at Required thickness (UCS 66.1) -24 C Min Metal Temp. w/o impact per UG-20(f) -29 C Note: Heads and Shells Exempted to -20F (-29C) by paragraph UG-20F

Hydrostatic Test Pressure Results: Pressure per UG99b = 1.3 * M.A.W.P. * Sa/S 17.081 MPa Pressure per UG99b[34] = 1.3 * Design Pres * Sa/S 19.500 MPa Pressure per UG99c = 1.3 * M.A.P. - Head(Hyd) 27.897 MPa Pressure per UG100 = 1.1 * M.A.W.P. * Sa/S 14.453 MPa Pressure per PED = 1.43 * MAWP 18.789 MPa UG-99(b), Test Pressure Calculation: = Test Factor * MAWP * Stress Ratio = 1.3 * 13.139 * 1.000 = 17.081 MPa Horizontal Test performed per: UG-99b Please note that Nozzle, Shell, Head, Flange, etc MAWPs are all considered when determining the hydrotest pressure for those test types that are based on the MAWP of the vessel. Stresses on Elements due to Hydrostatic Test Pressure: From To Stress Allowable Ratio Pressure 10 20 72.3 153.3 0.471 17.08 20 30 93.9 153.3 0.612 17.08 Elements Suitable for Internal Pressure. PV Elite is a trademark of Intergraph CADWorx & Analysis Solutions, Inc. 2012

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3. ANSI FLANGE MAWP

PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 14 Nozzle Flange MAWP : Step: 7 4:19p Sep 18,2012

Nozzle Flange MAWP Results : Nozzle --- Flange Rating Description Operating Ambient Temperature Class Grade|Group MPa MPa C --- N4 23.1 25.5 115 1500 GR 1.1 PG 23.1 25.5 115 1500 GR 1.1 N6 23.1 25.5 115 1500 GR 1.1 N3 23.1 25.5 115 1500 GR 1.1 N2 23.1 25.5 115 1500 GR 1.1 N1 23.1 25.5 115 1500 GR 1.1 N5 23.1 25.5 115 1500 GR 1.1 --- Minimum Rating 23.1 25.5 MPa Note: ANSI Ratings are per ANSI/ASME B16.5 2009 Metric Edition PV Elite is a trademark of Intergraph CADWorx & Analysis Solutions, Inc. 2012

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4. WEIGHT CALCULATION

From| To | Metal Wgt. | ID Volume |Metal Wgt. | ID Volume | Misc % | | | kgm | ltr | kgm | ltr | kgm | --- 10| 20| 6.46449 | 0.84379 | 5.40109 | 0.93728 | 0.32322 | 20| 30| 59.1417 | 16.9450 | 47.6225 | 18.4315 | 2.95709 | 30| 40| 77.5906 | 3.32378 | 75.6221 | 3.45550 | 3.87953 | --- Total 143 21.11 128 22.82 7 Weight of Details | | Weight of | X Offset, | Y Offset, | From|Type| Detail | Dtl. Cent. |Dtl. Cent. | Description | | kgm | mm | mm | --- 10|Insl| 0.88772 | 2.47142 | ... | Ins: 10 20|Insl| 8.89602 | 552.450 | ... | INS 20|Nozl| 14.2231 | 82.7000 | 90.3351 | N4 20|Nozl| 26.1417 | 381.900 | 90.3351 | PG 20|Nozl| 14.2231 | 932.700 | 90.3351 | N6 20|Nozl| 6.79054 | 82.7000 | 78.6067 | N3 20|Nozl| 3.90757 | 507.700 | 78.6067 | N2 20|Nozl| 14.2231 | 932.700 | 90.3351 | N1 20|Nozl| 3.90757 | 657.700 | 78.6067 | N5 20|Wght| 141.002 | 938.693 | ... | BUNDLE 30|Insl| 2.32876 | 85.7250 | ... | Ins: 30 Total Weight of Each Detail Type Total Weight of Insulation 12.1 Total Weight of Nozzles 83.4 Total Weight of Weights 141.0 --- Sum of the Detail Weights 236.5 kgm Weight Summation Fabricated Shop Test Shipping Erected Empty Operating --- 150.4 233.8 150.4 233.8 150.4 386.9 ... 21.1 ... ... ... ... 83.4 141.0 83.4 ... ... ... ... ... ... 12.1 ... ... ... ... ... ... 12.1 ... ... ... ... ... ... 141.0 ... ... ... ... ... -141.0 ... ... ... ... 83.4 ... ... ... ... ... 141.0 ...

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PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 13 Element and Detail Weights : Step: 6 4:19p Sep 18,2012 --- 233.8 395.9 245.9 386.9 386.9 386.9 kgm Miscellaneous Weight Percent: 5.0 % Note that the above value for the miscellaneous weight percent has been applied to the shells/heads/flange/tubesheets/tubes etc. in the weight calculations for metallic components. Note: The shipping total has been modified because some items have been specified as being installed in the shop. Weight Summary Fabricated Wt. - Bare Weight W/O Removable Internals 233.8 kgm Shop Test Wt. - Fabricated Weight + Water ( Full ) 395.9 kgm Shipping Wt. - Fab. Wt + Rem. Intls.+ Shipping App. 245.9 kgm Erected Wt. - Fab. Wt + Rem. Intls.+ Insul. (etc) 386.9 kgm Ope. Wt. no Liq - Fab. Wt + Intls. + Details + Wghts. 386.9 kgm Operating Wt. - Empty Wt + Operating Liq. Uncorroded 386.9 kgm Oper. Wt. + CA - Corr Wt. + Operating Liquid 371.6 kgm

Field Test Wt. - Empty Weight + Water (Full) 408.0 kgm Note: The Corroded Weight and thickness are used in the Horizontal Vessel Analysis (Ope Case) and Earthquake Load Calculations. Outside Surface Areas of Elements | | Surface | From| To | Area | | | mm² | --- 10| 20| 51770.8 | 20| 30| 584107. | 30| 40| 273015. | --- Total 908892.438 mm² PV Elite is a trademark of Intergraph CADWorx & Analysis Solutions, Inc. 2012

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5. CENTRE OF GRAVITY

PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 15

Center of Gravity Calculation : Step: 8 4:19p Sep 18,2012 Shop/Field Installation Options : Insulation is installed in the Shop. Note : The CG is computed from the first Element From Node Center of Gravity of Insulation 671.784 mm Center of Gravity of Nozzles 553.039 mm Center of Gravity of Added Weights (Operating) 978.560 mm Center of Gravity of Added Weights (Empty) 978.560 mm Center of Gravity of Bare Shell New and Cold 911.579 mm Center of Gravity of Bare Shell Corroded 942.784 mm Vessel CG in the Operating Condition 860.038 mm Vessel CG in the Fabricated (Shop/Empty) Condition 851.178 mm PV Elite is a trademark of Intergraph CADWorx & Analysis Solutions, Inc. 2012

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6. NOZZLE THICKNESS AND REINFORCEMENT CALCULATIONS

6.1. NOZZLES N1, N4, N6 & PG: DN 50 – CLASS 1500 RTJWN

PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 29 Nozzle Calcs. : N1 Nozl: 13 4:19p Sep 18,2012 INPUT VALUES, Nozzle Description: N1 From : 20 Pressure for Reinforcement Calculations P 15.0000 MPa Temperature for Internal Pressure Temp 115 C Shell Material SA-106 B Shell Allowable Stress at Temperature S 117.90 MPa Shell Allowable Stress At Ambient Sa 117.90 MPa Inside Diameter of Cylindrical Shell D 139.73 mm Shell Finished (Minimum) Thickness t 14.2748 mm Shell Internal Corrosion Allowance c 3.0000 mm Shell External Corrosion Allowance co 0.0000 mm Physical Maximum for Diameter Limit Dmax 93.8886 mm Physical Maximum for Thickness Limit Tmax 0.0000 mm Distance from Bottom/Left Tangent 972.5679 mm User Entered Minimum Design Metal Temperature -29.00 C Type of Element Connected to the Shell : Nozzle

Material SA-106 B Material UNS Number K03006 Material Specification/Type Smls. pipe Allowable Stress at Temperature Sn 117.90 MPa Allowable Stress At Ambient Sna 117.90 MPa Diameter Basis (for tr calc only) ID Layout Angle 180.00 deg Diameter 2.0000 in. Size and Thickness Basis Minimum Nominal Thickness tn XXS Flange Material SA-105 Flange Type RTJWn Corrosion Allowance can 3.0000 mm Joint Efficiency of Shell Seam at Nozzle E1 1.00 Joint Efficiency of Nozzle Neck En 1.00 Outside Projection ho 215.0000 mm Weld leg size between Nozzle and Pad/Shell Wo 7.0000 mm Groove weld depth between Nozzle and Vessel Wgnv 14.2748 mm Inside Projection h 0.0000 mm Weld leg size, Inside Element to Shell Wi 0.0000 mm ASME Code Weld Type per UW-16 None Class of attached Flange 1500 Grade of attached Flange GR 1.1 2

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PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD

FileName : 01H5310 R1--- Page 30 Nozzle Calcs. : N1 Nozl: 13 4:19p Sep 18,2012 The Pressure Design option was Design Pressure + static head. Nozzle Sketch (may not represent actual weld type/configuration) | | | | | | | | ____________/| | | \ | | | \ | | |____________\|__| Insert Nozzle No Pad, no Inside projection Reinforcement CALCULATION, Description: N1 ASME Code, Section VIII, Division 1, 2010, 2011a, UG-37 to UG-45 Actual Inside Diameter Used in Calculation 1.612 in. Actual Thickness Used in Calculation 0.382 in. Nozzle input data check completed without errors. Reqd thk per UG-37(a)of Cylindrical Shell, Tr [Int. Press] = (P*R)/(S*E-0.6*P) per UG-27 (c)(1) = (15.00*72.8627)/(117*1.00-0.6*15.00) = 10.0358 mm Reqd thk per UG-37(a)of Nozzle Wall, Trn [Int. Press] = (P*R)/(S*E-0.6*P) per UG-27 (c)(1) = (15.00*23.47)/(117*1.00-0.6*15.00) = 3.2330 mm UG-45 Minimum Nozzle Neck Thickness Requirement: [Int. Press.] Wall Thickness for Internal/External pressures ta = 6.2330 mm Wall Thickness per UG16(b), tr16b = 5.5000 mm Wall Thickness, shell/head, internal pressure trb1 = 13.0358 mm Wall Thickness tb1 = max(trb1, tr16b) = 13.0358 mm Wall Thickness tb2 = max(trb2, tr16b) = 5.5000 mm Wall Thickness per table UG-45 tb3 = 6.4200 mm Determine Nozzle Thickness candidate [tb]: = min[ tb3, max( tb1,tb2) ] = min[ 6.420 , max( 13.036 , 5.500 ) ] = 6.4200 mm Minimum Wall Thickness of Nozzle Necks [tUG-45]: = max( ta, tb ) = max( 6.2330 , 6.4200 ) = 6.4200 mm

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PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 31 Nozzle Calcs. : N1 Nozl: 13 4:19p Sep 18,2012 Available Nozzle Neck Thickness = 9.6901 mm --> OK Stresses on Nozzle due to External and Pressure Loads per the ASME B31.3 Piping Code (see 319.4.4 and 302.3.5): Sustained : 49.8, Allowable : 117.9 MPa Passed Expansion : 0.0, Allowable : 244.9 MPa Passed Occasional : 23.0, Allowable : 156.8 MPa Passed Shear : 18.6, Allowable : 82.5 MPa Passed Note : The number of cycles on this nozzle was assumed to be 7000 or less for the determination of the expansion stress allowable. Nozzle Junction Minimum Design Metal Temperature (MDMT) Calculations: MDMT of the Nozzle Neck to Flange Weld,

Curve: B

--- Govrn. thk, tg = 9.690 , tr = 3.233 , c = 3.0000 mm , E* = 1.00 Stress Ratio = tr * (E*)/(tg - c) = 0.483 , Temp. Reduction = 36 C Min Metal Temp. w/o impact per UCS-66 -29 C Min Metal Temp. at Required thickness (UCS 66.1) -48 C

MDMT of Nozzle-Shell/Head Weld for the Nozzle (UCS-66(a)1(b)), Curve: B

--- Govrn. thk, tg = 9.690 , tr = 3.233 , c = 3.0000 mm , E* = 1.00 Stress Ratio = tr * (E*)/(tg - c) = 0.483 , Temp. Reduction = 36 C Min Metal Temp. w/o impact per UCS-66 -29 C Min Metal Temp. at Required thickness (UCS 66.1) -48 C Governing MDMT of all the sub-joints of this Junction : -48 C ANSI Flange MDMT including Temperature reduction per UCS-66.1: Unadjusted MDMT of ANSI B16.5/47 flanges per UCS-66(c) -29 C Flange MDMT with Temp reduction per UCS-66(b)(1)(b) -48 C Flange MDMT with Temp reduction per UCS-66(b)(1)(c) -48 C Where the Stress Reduction Ratio per UCS-66(b)(1)(b) is : Design Pressure/Ambient Rating = 15.00/25.53 = 0.588 Note: Using the minimum value from (b)(1)(b) and (b)(1)(c) above as the calculated nozzle flange MDMT. Nozzle Calculations per App. 1-10: Internal Pressure Case:

Thickness of Nozzle [tn]: = thickness - corrosion allowance = 9.690 - 3.000 = 6.690 mm Effective Pressure Radius [Reff]:

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PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 32 Nozzle Calcs. : N1 Nozl: 13 4:19p Sep 18,2012 = Di/2 + corrosion allowance = 139.725/2 + 3.000 = 72.863 mm Effective Length of Vessel Wall [LR]: = 8 * t = 8 * 11.275 = 19.782 mm Note: LR is governed by the user entered diameter limit. Thickness Limit Candidate [LH1]: = t + 0.78 * sqrt( Rn * tn ) = 11.275 + 0.78 * sqrt( 23.472 * 6.690 ) = 21.049 mm Thickness Limit Candidate [LH2]: = Lpr1 + T = 215.000 + 11.275 = 226.275 mm Thickness Limit Candidate [LH3]: = 8( t + te ) = 8( 11.275 + 0.000 ) = 90.198 mm Effective Nozzle Wall Length Outside the Vessel [LH]: = min[ LH1, LH2, LH3 ] = min[ 21.049 , 226.275 , 90.198 ) = 21.049 mm Effective Vessel Thickness [teff]: = t = 11.275 mm Determine Parameter [Lamda]: = min( 10, ( Dn + Tn )/( sqrt( ( Di + teff ) * teff )) ) = min( 10, (46.94 + 6.690 )/( sqrt((145.73 + 11.275 ) * 11.275 )) ) = 1.275 Compute Areas A1-A43 (No Pad) or A1-A5 (With Pad) : Area Contributed by the Vessel Wall [A1]: = t * LR * max( Lamda/4, 1 ) = 11.275 * 19.782 * max( 1.275/4, 1 ) = 223.036 mm² Area Contributed by the Nozzle Outside the Vessel Wall [A2]: = tn * LH = 6.690 * 21.049 = 140.821 mm² Area Contributed by the Outside Fillet Weld [A41]:

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PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 33 Nozzle Calcs. : N1 Nozl: 13 4:19p Sep 18,2012 = 0.5 * Leg41^(2) = 0.5 * 7.000^(2) = 24.500 mm² The total area contributed by A1 through A43 [AT]: = A1 + frn( A2 + A3 ) + A41 + A42 + A43 = 223.036+1.000(140.821+0.000)+24.500+0.000+0.000

= 388.357 mm² Allowable Local Primary Membrane Stress [Sallow]: = 1.5 * S * E = 1.5 * 117.905 * 1.000 = 176.9 MPa Determine Force acting on the Nozzle [fN]: = P * Rn( LH - t ) = 15.000 * 23.472 ( 21.049 - 11.275 ) = 3441.1 N Determine Force acting on the Shell [fS]: = P * Reff * ( LR + tn ) = 15.000 * 72.863 * ( 19.782 + 6.690 ) = 28929.8 N Discontinuity Force from Internal Pressure [fY]: = P * Reff * Rnc = 15.000 * 72.863 * 23.472 = 25651.8 N Area Resisting Internal Pressure [Ap]: = Rn( LH - t ) + Reff( LR + tn + Rnc ) = 23.472 ( 21.049 - 11.275 ) + 72.863 ( 19.782 + 6.690 + 23.472 ) = 3868.5 mm² Maximum Allowable Working Pressure Candidate [Pmax1]: = Sallow /( 2 * Ap/AT - Rxs/teff ) = 176.857/( 2 * 3868.505/388.357 - 72.863/11.275 ) = 13.1 MPa

Maximum Allowable Working Pressure Candidate [Pmax2]: = S[t/Reff] = 117.905 [11.275/72.863 ] = 18.2 MPa Maximum Allowable Working Pressure [Pmax]: = min( Pmax1, Pmax2 ) = min( 13.139 , 18.245 ) = 13.139 MPa Average Primary Membrane Stress [SigmaAvg]: = ( fN + fS + fY ) / AT = ( 3441.133 + 28929.758 + 25651.758 )/388.357 = 149.418 MPa

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PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 34 Nozzle Calcs. : N1 Nozl: 13 4:19p Sep 18,2012 General Primary Membrane Stress [SigmaCirc]: = P * Reff / teff = 15.000 * 72.863/11.275 = 96.9 MPa Maximum Local Primary Membrane Stress [PL]: = max( 2 * SigmaAvg - SigmaCirc, SigmaCirc ) = max( 2 * 149.418 - 96.937 , 96.937 ) = 201.9 MPa Summary of Nozzle Pressure/Stress Results: Allowed Local Primary Membrane Stress Sallow 176.86 MPa Local Primary Membrane Stress PL 201.90 MPa Maximum Allowable Working Pressure Pmax 13.14 MPa Strength of Nozzle Attachment Welds per 1-10 and U-2(g) Discontinuity Force Factor [ky]: = ( Rnc + tn ) / Rnc = ( 23.472 + 6.690 )/23.472 = 1.285 For set-in Nozzles Weld Length of Nozzle to Shell Weld [Ltau]: = pi/2 * ( Rn + tn ) = pi/2 * ( 23.472 + 6.690 ) = 47.379 mm Weld Throat Dimensions, (0.7071*Leg Dimensions) [L41T, L42T, L43T]: = 4.950, 0.000, 0.000, mm Weld Load Value [fwelds]: = min( fy * ky, 1.5 * Sn( A2 + A3 ), pi/4*P*Rn^2*ky^2 ) = min(25651*1.29,1.5*117.9(140.821+0.000),pi/4*15.0*23.47^2*1.29^2) = 10717.140 N Weld Stress Value [tau]: = fwelds/(Ltau(0.49*L41T + 0.6*tw1 + 0.49*L43T ) ) = 10717.140/(47.379 (0.49*4.950 + 0.6*11.275 + 0.49*0.000 ) ) = 24.615 < or = to 117.905 Weld Size is OK Weld Size Calculations, Description: N1 Intermediate Calc. for nozzle/shell Welds Tmin 6.6901 mm Results Per UW-16.1: Required Thickness Actual Thickness Nozzle Weld 4.6831 = 0.7 * tmin. 4.9490 = 0.7 * Wo mm Maximum Allowable Pressure for this Nozzle at this Location: Converged Max. Allow. Pressure in Operating case 13.1394 MPa The Drop for this Nozzle is : 6.8467 mm

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PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 35 Nozzle Calcs. : N1 Nozl: 13 4:19p Sep 18,2012

The Cut Length for this Nozzle is, Drop + Ho + H + T : 236.1215 mm

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Tabular Results

Results were generated with the finite element program FE/Pipe®. Stress results are post-processed in accordance with the rules specified in ASME Section III and ASME Section VIII, Division 2.

Analysis Time Stamp: Tue Sep 18 13:19:57 2012.

Model Notes Input Echo: Model Type : Cylindrical Shell Parent Outside Diameter : 168.280 mm. Thickness : 14.270 mm. Fillet Along Shell : 9.000 mm. Parent Properties: Material DB # 1008218. (See Output Reports for Allowables.) Elastic Modulus (Amb) : 202700.0 MPa Poissons Ratio : 0.300 Expansion Coefficient : 0.1220E-04 mm./mm./deg. Weight Density : 0.0000E+00 N /cu.mm.(NOT USED) Nozzle Outside Diameter : 60.330 mm. Thickness : 6.690 mm. Length : 215.000 mm. Nozzle Weld Length : 9.000 mm. Nozzle Tilt Angle : 0.000 deg. Distance from Top : 552.500 mm. Distance from Bottom : 552.500 mm. Nozzle Properties Material DB # 1008218. (See Output Reports for Allowables.) Elastic Modulus (Amb) : 202700.0 MPa Poissons Ratio : 0.300 Expansion Coefficient : 0.1220E-04 mm./mm./deg. Weight Density : 0.0000E+00 N /cu.mm. (NOT USED) Design Operating Cycles : 7000. Ambient Temperature (Deg.) : 21.00 The following temperatures have been specified for the analysis: Nozzle Inside Temperature : 115.00 deg. Nozzle Outside Temperature : 115.00 deg. Vessel Inside Temperature : 115.00 deg. Vessel Outside Temperature : 115.00 deg. Nozzle Pressure : 15.000 MPa Vessel Pressure : 15.000 MPa User Defined Load Input Echo: Loads are given at the End of Nozzle Loads are defined in Global Coordinates Forces( N ) Moments (N-m) Load Case FX FY FZ MX MY MZ

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--- OPER: 2205.0 -1800.0 2205.0 375.0 530.0 375.0 FEA Model Loads: These are the actual loads applied to the FEA model. These are the User Defined Loads translated to the end of the nozzle and reported in global coordinates. Forces( N ) Moments (N-m) Load Case FX FY FZ MX MY MZ --- OPER: 2205.0 -1800.0 2205.0 375.0 530.0 375.0 The "top" or "positive" end of this model is "free" in the axial and translational directions. Stresses ARE nodally AVERAGED. Vessel Centerline Vector : 0.000 1.000 0.000 Nozzle Orientation Vector : 1.000 0.000 0.000

ASME Code Stress Output Plots 1) Pl < (1.5)(S) (SUS,Membrane) Case 1 2) Qb < SPS (SUS,Bending) Case 1 3) S1+S2+S3 < 4S (SUS,S1+S2+S3) Case 1 4) Pl+Pb+Q < SPS (OPE,Inside) Case 3 5) Pl+Pb+Q < SPS (OPE,Outside) Case 3

ASME Overstressed Areas

*** NO OVERSTRESSED NODES IN THIS MODEL ***

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Highest Primary Stress Ratios

Header Next to Nozzle Weld

Pl (1.5)(S) Primary Membrane Load Case 1 83 177 Plot Reference: MPa MPa 1) Pl < (1.5)(S) (SUS,Membrane) Case 1 46%

Branch Next to Header Weld

Pl (1.5)(S) Primary Membrane Load Case 1 52 177 Plot Reference: MPa MPa 1) Pl < (1.5)(S) (SUS,Membrane) Case 1 29% Branch Transition

Header away from Junction

Branch away from Junction

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Highest Secondary Stress Ratios

Pl+Pb+Q SPS Primary+Secondary (Inner) Load Case 3 98 459 Plot Reference: MPa MPa 4) Pl+Pb+Q < SPS (OPE,Inside) Case 3 21%

Pl+Pb+Q SPS Primary+Secondary (Inner) Load Case 3 86 459 Plot Reference: MPa MPa 4) Pl+Pb+Q < SPS (OPE,Inside) Case 3 18% Branch Transition

Pl+Pb+Q SPS Primary+Secondary (Outer) Load Case 3 93 459 Plot Reference: MPa MPa 5) Pl+Pb+Q < SPS (OPE,Outside) Case 3 20%

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6.2. NOZZLES N2, N3 & N5 : DN 25 – CLASS 1500 RTJWN

PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 16 Nozzle Calcs. : N2 Nozl: 12 4:19p Sep 18,2012

INPUT VALUES, Nozzle Description: N2 From : 20 Pressure for Reinforcement Calculations P 15.0000 MPa Temperature for Internal Pressure Temp 115 C Shell Material SA-106 B Shell Allowable Stress at Temperature S 117.90 MPa Shell Allowable Stress At Ambient Sa 117.90 MPa Inside Diameter of Cylindrical Shell D 139.73 mm Shell Finished (Minimum) Thickness t 14.2748 mm Shell Internal Corrosion Allowance c 3.0000 mm Shell External Corrosion Allowance co 0.0000 mm Physical Maximum for Diameter Limit Dmax 93.8886 mm Physical Maximum for Thickness Limit Tmax 0.0000 mm Distance from Bottom/Left Tangent 547.5679 mm User Entered Minimum Design Metal Temperature -29.00 C Type of Element Connected to the Shell : Nozzle Material SA-106 B Material UNS Number K03006 Material Specification/Type Smls. pipe Allowable Stress at Temperature Sn 117.90 MPa Allowable Stress At Ambient Sna 117.90 MPa Diameter Basis (for tr calc only) ID Layout Angle 180.00 deg Diameter 1.0000 in. Size and Thickness Basis Minimum Nominal Thickness tn XXS Flange Material SA-105 Flange Type RTJWn Corrosion Allowance can 3.0000 mm Joint Efficiency of Shell Seam at Nozzle E1 1.00 Joint Efficiency of Nozzle Neck En 1.00 Outside Projection ho 215.0000 mm Weld leg size between Nozzle and Pad/Shell Wo 7.0000 mm Groove weld depth between Nozzle and Vessel Wgnv 14.2748 mm Inside Projection h 0.0000 mm Weld leg size, Inside Element to Shell Wi 0.0000 mm ASME Code Weld Type per UW-16 None Class of attached Flange 1500 Grade of attached Flange GR 1.1

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PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 17 Nozzle Calcs. : N2 Nozl: 12 4:19p Sep 18,2012 The Pressure Design option was Design Pressure + static head. Nozzle Sketch (may not represent actual weld type/configuration) | | | | | | | | ____________/| | | \ | | | \ | | |____________\|__| Insert Nozzle No Pad, no Inside projection Reinforcement CALCULATION, Description: N2 ASME Code, Section VIII, Division 1, 2010, 2011a, UG-37 to UG-45

Actual Inside Diameter Used in Calculation 0.689 in. Actual Thickness Used in Calculation 0.313 in. Nozzle input data check completed without errors. Reqd thk per UG-37(a)of Cylindrical Shell, Tr [Int. Press] = (P*R)/(S*E-0.6*P) per UG-27 (c)(1) = (15.00*72.8627)/(117*1.00-0.6*15.00) = 10.0358 mm Reqd thk per UG-37(a)of Nozzle Wall, Trn [Int. Press] = (P*R)/(S*E-0.6*P) per UG-27 (c)(1) = (15.00*11.74)/(117*1.00-0.6*15.00) = 1.6176 mm UG-45 Minimum Nozzle Neck Thickness Requirement: [Int. Press.] Wall Thickness for Internal/External pressures ta = 4.6176 mm Wall Thickness per UG16(b), tr16b = 5.5000 mm Wall Thickness, shell/head, internal pressure trb1 = 13.0358 mm Wall Thickness tb1 = max(trb1, tr16b) = 13.0358 mm Wall Thickness tb2 = max(trb2, tr16b) = 5.5000 mm Wall Thickness per table UG-45 tb3 = 5.9464 mm Determine Nozzle Thickness candidate [tb]: = min[ tb3, max( tb1,tb2) ] = min[ 5.946 , max( 13.036 , 5.500 ) ] = 5.9464 mm Minimum Wall Thickness of Nozzle Necks [tUG-45]: = max( ta, tb )

= max( 4.6176 , 5.9464 ) = 5.9464 mm

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PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 18 Nozzle Calcs. : N2 Nozl: 12 4:19p Sep 18,2012 Available Nozzle Neck Thickness = 7.9566 mm --> OK Stresses on Nozzle due to External and Pressure Loads per the ASME B31.3 Piping Code (see 319.4.4 and 302.3.5): Sustained : 87.9, Allowable : 117.9 MPa Passed Expansion : 0.0, Allowable : 206.8 MPa Passed Occasional : 14.7, Allowable : 156.8 MPa Passed Shear : 53.4, Allowable : 82.5 MPa Passed Note : The number of cycles on this nozzle was assumed to be 7000 or less for the determination of the expansion stress allowable. Nozzle Junction Minimum Design Metal Temperature (MDMT) Calculations: MDMT of the Nozzle Neck to Flange Weld,

Curve: B

--- Govrn. thk, tg = 7.957 , tr = 1.618 , c = 3.0000 mm , E* = 1.00 Stress Ratio = tr * (E*)/(tg - c) = 0.326 , Temp. Reduction = 78 C Min Metal Temp. w/o impact per UCS-66 -29 C Min Metal Temp. at Required thickness (UCS 66.1) -104 C

MDMT of Nozzle-Shell/Head Weld for the Nozzle (UCS-66(a)1(b)), Curve: B

--- Govrn. thk, tg = 7.957 , tr = 1.618 , c = 3.0000 mm , E* = 1.00 Stress Ratio = tr * (E*)/(tg - c) = 0.326 , Temp. Reduction = 78 C Min Metal Temp. w/o impact per UCS-66 -29 C Min Metal Temp. at Required thickness (UCS 66.1) -104 C Governing MDMT of all the sub-joints of this Junction : -104 C ANSI Flange MDMT including Temperature reduction per UCS-66.1: Unadjusted MDMT of ANSI B16.5/47 flanges per UCS-66(c) -29 C Flange MDMT with Temp reduction per UCS-66(b)(1)(b) -48 C Flange MDMT with Temp reduction per UCS-66(b)(1)(c) -104 C Where the Stress Reduction Ratio per UCS-66(b)(1)(b) is : Design Pressure/Ambient Rating = 15.00/25.53 = 0.588 Note: Using the minimum value from (b)(1)(b) and (b)(1)(c) above as the calculated nozzle flange MDMT. Nozzle Calculations per App. 1-10: Internal Pressure Case: Thickness of Nozzle [tn]: = thickness - corrosion allowance = 7.957 - 3.000 = 4.957 mm Effective Pressure Radius [Reff]:

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PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 19 Nozzle Calcs. : N2 Nozl: 12 4:19p Sep 18,2012 = Di/2 + corrosion allowance = 139.725/2 + 3.000 = 72.863 mm Effective Length of Vessel Wall [LR]: = 8 * t = 8 * 11.275 = 33.244 mm Note: LR is governed by the user entered diameter limit.

Thickness Limit Candidate [LH1]: = t + 0.78 * sqrt( Rn * tn ) = 11.275 + 0.78 * sqrt( 11.744 * 4.957 ) = 17.226 mm Thickness Limit Candidate [LH2]: = Lpr1 + T = 215.000 + 11.275 = 226.275 mm Thickness Limit Candidate [LH3]: = 8( t + te ) = 8( 11.275 + 0.000 ) = 90.198 mm Effective Nozzle Wall Length Outside the Vessel [LH]: = min[ LH1, LH2, LH3 ] = min[ 17.226 , 226.275 , 90.198 ) = 17.226 mm Effective Vessel Thickness [teff]: = t = 11.275 mm Determine Parameter [Lamda]: = min( 10, ( Dn + Tn )/( sqrt( ( Di + teff ) * teff )) ) = min( 10, (23.49 + 4.957 )/( sqrt((145.73 + 11.275 ) * 11.275 )) ) = 0.676 Compute Areas A1-A43 (No Pad) or A1-A5 (With Pad) :

Area Contributed by the Vessel Wall [A1]: = t * LR * max( Lamda/4, 1 ) = 11.275 * 33.244 * max( 0.676/4, 1 ) = 374.817 mm² Area Contributed by the Nozzle Outside the Vessel Wall [A2]: = tn * LH = 4.957 * 17.226 = 85.381 mm² Area Contributed by the Outside Fillet Weld [A41]:

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PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 20 Nozzle Calcs. : N2 Nozl: 12 4:19p Sep 18,2012 = 0.5 * Leg41^(2) - Area cut by thickness limit = 0.5 * 7.000^(2) - 0.550 = 23.950 mm² The total area contributed by A1 through A43 [AT]: = A1 + frn( A2 + A3 ) + A41 + A42 + A43 = 374.817+1.000(85.381+0.000)+23.950+0.000+0.000 = 484.148 mm² Allowable Local Primary Membrane Stress [Sallow]: = 1.5 * S * E = 1.5 * 117.905 * 1.000 = 176.9 MPa Determine Force acting on the Nozzle [fN]: = P * Rn( LH - t ) = 15.000 * 11.744 ( 17.226 - 11.275 ) = 1048.2 N Determine Force acting on the Shell [fS]: = P * Reff * ( LR + tn ) = 15.000 * 72.863 * ( 33.244 + 4.957 ) = 41747.2 N Discontinuity Force from Internal Pressure [fY]: = P * Reff * Rnc = 15.000 * 72.863 * 11.744 = 12834.3 N Area Resisting Internal Pressure [Ap]: = Rn( LH - t ) + Reff( LR + tn + Rnc ) = 11.744 ( 17.226 - 11.275 ) + 72.863 ( 33.244 + 4.957 + 11.744 ) = 3709.0 mm² Maximum Allowable Working Pressure Candidate [Pmax1]: = Sallow /( 2 * Ap/AT - Rxs/teff ) = 176.857/( 2 * 3708.965/484.148 - 72.863/11.275 ) = 20.0 MPa Maximum Allowable Working Pressure Candidate [Pmax2]: = S[t/Reff] = 117.905 [11.275/72.863 ] = 18.2 MPa Maximum Allowable Working Pressure [Pmax]: = min( Pmax1, Pmax2 ) = min( 19.963 , 18.245 ) = 18.245 MPa Average Primary Membrane Stress [SigmaAvg]: = ( fN + fS + fY ) / AT = ( 1048.238 + 41747.168 + 12834.349 )/484.148 = 114.912 MPa

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PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 21 Nozzle Calcs. : N2 Nozl: 12 4:19p Sep 18,2012 General Primary Membrane Stress [SigmaCirc]: = P * Reff / teff

= 15.000 * 72.863/11.275 = 96.9 MPa Maximum Local Primary Membrane Stress [PL]: = max( 2 * SigmaAvg - SigmaCirc, SigmaCirc ) = max( 2 * 114.912 - 96.937 , 96.937 ) = 132.9 MPa Summary of Nozzle Pressure/Stress Results: Allowed Local Primary Membrane Stress Sallow 176.86 MPa Local Primary Membrane Stress PL 132.89 MPa Maximum Allowable Working Pressure Pmax 18.24 MPa Strength of Nozzle Attachment Welds per 1-10 and U-2(g) Discontinuity Force Factor [ky]: = ( Rnc + tn ) / Rnc = ( 11.744 + 4.957 )/11.744 = 1.422 For set-in Nozzles Weld Length of Nozzle to Shell Weld [Ltau]: = pi/2 * ( Rn + tn ) = pi/2 * ( 11.744 + 4.957 ) = 26.233 mm Weld Throat Dimensions, (0.7071*Leg Dimensions) [L41T, L42T, L43T]: = 4.950, 0.000, 0.000, mm Weld Load Value [fwelds]: = min( fy * ky, 1.5 * Sn( A2 + A3 ), pi/4*P*Rn^2*ky^2 ) = min(12834*1.42,1.5*117.9(85.381+0.000),pi/4*15.0*11.74^2*1.42^2)

= 3285.513 N Weld Stress Value [tau]: = fwelds/(Ltau(0.49*L41T + 0.6*tw1 + 0.49*L43T ) ) = 3285.513/(26.233 (0.49*4.950 + 0.6*11.275 + 0.49*0.000 ) ) = 13.629 < or = to 117.905 Weld Size is OK Weld Size Calculations, Description: N2 Intermediate Calc. for nozzle/shell Welds Tmin 4.9566 mm Results Per UW-16.1: Required Thickness Actual Thickness Nozzle Weld 3.4696 = 0.7 * tmin. 4.9490 = 0.7 * Wo mm Maximum Allowable Pressure for this Nozzle at this Location: Converged Max. Allow. Pressure in Operating case 16.6946 MPa Note: The MAWP of this junction was limited by the parent Shell/Head.

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PV Elite 2012 R1 Licensee: APPLIED ENGINEERING PTE LTD FileName : 01H5310 R1--- Page 22 Nozzle Calcs. : N2 Nozl: 12 4:19p Sep 18,2012 The Drop for this Nozzle is : 2.0255 mm The Cut Length for this Nozzle is, Drop + Ho + H + T : 231.3003 mm

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Tabular Results

Analysis Time Stamp: Tue Sep 18 16:36:01 2012.

Model Notes Input Echo: Model Type : Cylindrical Shell Parent Outside Diameter : 168.280 mm. Thickness : 14.280 mm. Fillet Along Shell : 9.525 mm. Parent Properties: Material DB # 1008218. (See Output Reports for Allowables.) Elastic Modulus (Amb) : 202700.0 MPa Poissons Ratio : 0.300 Expansion Coefficient : 0.1220E-04 mm./mm./deg. Weight Density : 0.0000E+00 N /cu.mm.(NOT USED) Nozzle Outside Diameter : 33.400 mm. Thickness : 4.957 mm. Length : 186.567 mm. Nozzle Weld Length : 9.525 mm. Nozzle Tilt Angle : 0.000 deg. Distance from Top : 552.500 mm. Distance from Bottom : 552.500 mm. Nozzle Properties Material DB # 1008218. (See Output Reports for Allowables.) Elastic Modulus (Amb) : 202700.0 MPa Poissons Ratio : 0.300 Expansion Coefficient : 0.1220E-04 mm./mm./deg. Weight Density : 0.0000E+00 N /cu.mm. (NOT USED) Design Operating Cycles : 7000. Ambient Temperature (Deg.) : 21.00 The following temperatures have been specified for the analysis: Nozzle Inside Temperature : 115.00 deg. Nozzle Outside Temperature : 115.00 deg. Vessel Inside Temperature : 115.00 deg. Vessel Outside Temperature : 115.00 deg. Nozzle Pressure : 15.000 MPa Vessel Pressure : 15.000 MPa User Defined Load Input Echo: Loads are given at the End of Nozzle Loads are defined in Global Coordinates Forces( N ) Moments (N-m) Load Case FX FY FZ MX MY MZ ---

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OPER: 1565.0 -1280.0 1565.0 200.0 290.0 200.0 FEA Model Loads: These are the actual loads applied to the FEA model. These are the User Defined Loads translated to the end of the nozzle and reported in global coordinates. Forces( N ) Moments (N-m) Load Case FX FY FZ MX MY MZ --- OPER: 1565.0 -1280.0 1565.0 200.0 290.0 200.0 The "top" or "positive" end of this model is "free" in the axial and translational directions. Stresses ARE nodally AVERAGED. Vessel Centerline Vector : 0.000 1.000 0.000 Nozzle Orientation Vector : 1.000 0.000 0.000

ASME Code Stress Output Plots 1) Pl < (1.5)(S) (SUS,Membrane) Case 1 2) Qb < SPS (SUS,Bending) Case 1 3) S1+S2+S3 < 4S (SUS,S1+S2+S3) Case 1 4) Pl+Pb+Q < SPS (OPE,Inside) Case 3 5) Pl+Pb+Q < SPS (OPE,Outside) Case 3

ASME Overstressed Areas

*** NO OVERSTRESSED NODES IN THIS MODEL ***

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Highest Primary Stress Ratios

Pl (1.5)(S) Primary Membrane Load Case 1 38 177 Plot Reference: MPa MPa 1) Pl < (1.5)(S) (SUS,Membrane) Case 1 21% Branch Transition

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Highest Secondary Stress Ratios

Pl+Pb+Q SPS Primary+Secondary (Inner) Load Case 3 134 459 Plot Reference: MPa MPa 4) Pl+Pb+Q < SPS (OPE,Inside) Case 3 29% Branch Transition

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8. LIFTING LUG CALCULATIONS

8.1. LONG LIFTING LUG

8. LIFTING LUG CALCULATIONS

8.1. LONG LIFTING LUG

2 1

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8.2. SHORT LIFTING LUG

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9. SUPPORT ATTACHMENT CALCULATIONS

Tabular Results

Model Notes Input Echo: Model Type : Cylindrical Shell Parent Outside Diameter : 168.280 mm. Thickness : 14.275 mm. Fillet Along Shell : 19.050 mm. Parent Properties: Material DB # 1014518. (See Output Reports for Allowables.) Elastic Modulus (Amb) : 202700.0 MPa Poissons Ratio : 0.300 Expansion Coefficient : 0.1220E-04 mm./mm./deg. Weight Density : 0.0000E+00 N /cu.mm.(NOT USED) Structural Attachment Type : Longitudinal Lug Thickness : 12.700 mm. Height : 100.000 mm. Length : 128.400 mm. Rectangular Pad Width : 41.900 mm. Rectangular Pad Height : 150.000 mm. Rectangular Pad Thick : 12.700 mm. Nozzle Tilt Angle : 0.000 deg. Distance from Top : 0.000 mm. Distance from Bottom : 1281.000 mm. Nozzle Properties Material DB # 1008218. (See Output Reports for Allowables.) Elastic Modulus (Amb) : 202700.0 MPa Poissons Ratio : 0.300 Expansion Coefficient : 0.1220E-04 mm./mm./deg. Weight Density : 0.0000E+00 N /cu.mm. (NOT USED) Design Operating Cycles : 7000. Ambient Temperature (Deg.) : 21.00 The following temperatures have been specified for the analysis: Nozzle Inside Temperature : 115.00 deg. Nozzle Outside Temperature : 115.00 deg. Vessel Inside Temperature : 115.00 deg. Vessel Outside Temperature : 115.00 deg. Nozzle Pressure : 0.000 MPa Vessel Pressure : 15.000 MPa

Vessel Design Calculation

TABLE OF CONTENTS

1. DESIGN DATA

1.1 SUMMARY OF DESIGN DATA

1.2 PVELITE INPUT DATA

1.3 SKETCH OF FUEL GAS SCRUBBER 01H-5310

2. INTERNAL PRESSURE AND HYDROSTATIC PRESSURE CALCULATIONS

3. ANSI FLANGE MAWP

4. WEIGHT CALCULATION

5. CENTRE OF GRAVITY

6. NOZZLE THICKNESS AND REINFORCEMENT CALCULATIONS

6.1. NOZZLES N1, N4, N6 & PG: DN 50 – CLASS 1500 RTJWN

6.2. NOZZLES N2, N3 & N5 : DN 25 – CLASS 1500 RTJWN

8. LIFTING LUG CALCULATIONS

8.1. LONG LIFTING LUG

8. LIFTING LUG CALCULATIONS

8.1. LONG LIFTING LUG

8.2. SHORT LIFTING LUG

8.2. SHORT LIFTING LUG

9. SUPPORT ATTACHMENT CALCULATIONS