PT. PERTAMINA
GEOTHERMAL ENERGY
KONSORSIUM
JFEEI-JFE-NK (LAHEDONG)
MECHANICAL CALCULATION
INTER CONDENSOR
DOC. NO. : -
A 08-01-16 Issued for Review FD MW HS
REV. DATE DESCRIPTION
PREP’D CHK’D APP’D APP’D
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 2 of 183
REVISION CONTROL SHEET
REV. DATE DESCRIPTION OF REVISION
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 3 of 183
Table of Contents
Cover Sheet ... Error! Bookmark not defined. Title Page ... Error! Bookmark not defined. Warnings and Errors : ... Error! Bookmark not defined. Input Echo : ... Error! Bookmark not defined.
XY Coordinate Calculations : ... 14
Internal Pressure Calculations : ... 15
External Pressure Calculations : ... 23
Element and Detail Weights : ... 28
Nozzle Flange MAWP : ... 32
Natural Frequency Calculation :... 33
Wind Load Calculation : ... 34
Earthquake Load Calculation : ... 39
Wind/Earthquake Shear, Bending : ... 40
Wind Deflection : ... 41
Longitudinal Stress Constants : ... 42
Longitudinal Allowable Stresses : ... 43
Longitudinal Stresses Due to . . . : ... 44
Stress due to Combined Loads :... 47
Center of Gravity Calculation : ... 54
Sup. Lug Calcs: Ope :... 55
Sup. Lug Calcs: Test : ... 59
Nozzle Calcs. : N8 ... 63 Nozzle Calcs. : MH ... 74 Nozzle Calcs. : N1 ... 88 Nozzle Calcs. : N2 ... 103 Nozzle Calcs. : N3 ... 118 Nozzle Calcs. : N4 ... 133 Nozzle Calcs. : N5 ... 148 Nozzle Calcs. : N6 ... 163 Nozzle Calcs. : N7 ... 180 Nozzle Schedule : ... 196 Nozzle Summary : ... 198 MDMT Summary : ... 200
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 4 of 183
PV Elite Vessel Analysis Program: Input Data
Design Internal Pressure (for Hydrotest) 145.00 psig Design Internal Temperature 180 °F Type of Hydrotest UG-99(b) Hydrotest Position Vertical
Projection of Nozzle from Vessel Top 0.0000 in. Projection of Nozzle from Vessel Bottom 0.0000 in. Minimum Design Metal Temperature -20 °F Type of Construction Welded
Special Service None Degree of Radiography RT-1 Use Higher Longitudinal Stresses (Flag) Y Select t for Internal Pressure (Flag) Y Select t for External Pressure (Flag) Y Select t for Axial Stress (Flag) Y Select Location for Stiff. Rings (Flag) N Consider Vortex Shedding N Perform a Corroded Hydrotest N Is this a Heat Exchanger No
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 5 of 183
User Defined Hydro. Press. (Used if > 0) 0.0000 psig User defined MAWP 0.0000 psig User defined MAPnc 0.0000 psig
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 93 Basic Wind Speed [V] 70.000 mile/hr Surface Roughness Category C: Open Terrain Importance Factor 1.0
Type of Surface Moderately Smooth Base Elevation 0.0000 ft. Percent Wind for Hydrotest 33.0 Using User defined Wind Press. Vs Elev. N
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 6 of 183
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 G Loading Seismic Importance Factor 1.000 G Loading Coefficient Gx 0.400 G Loading Coefficient Gz 0.400 G Loading Coefficient Gy 0.260 Percent Seismic for Hydrotest 0.000
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
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 7 of 183
Element Type Elliptical Description
Distance "FROM" to "TO" 0.1667 ft. Inside Diameter 35.433 in. Element Thickness 0.2953 in. Internal Corrosion Allowance 0.1250 in. Nominal Thickness 0.3937 in. External Corrosion Allowance 0.0000 in. Design Internal Pressure 145.00 psig Design Temperature Internal Pressure 180 °F Design External Pressure 0.1450 psig Design Temperature External Pressure 95 °F Effective Diameter Multiplier 1.2
Material Name SA-516 70 Allowable Stress, Ambient 20000. psi Allowable Stress, Operating 20000. psi Allowable Stress, Hydrotest 26000. psi Material Density 0.2800 lb./in³ P Number Thickness 1.2500 in. Yield Stress, Operating 35160. psi UCS-66 Chart Curve Designation B External Pressure Chart Name CS-2 UNS Number K02700 Product Form Plate Efficiency, Longitudinal Seam 0.85 Efficiency, Circumferential Seam 0.85 Elliptical Head Factor 2.0
Element From Node 10 Detail Type Nozzle Detail ID N8
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 8 of 183
Nozzle Diameter 4.0 in. Nozzle Schedule 80 Nozzle Class 150 Layout Angle 0.0 Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 0.0000 lb. Grade of Attached Flange GR 1.1 Nozzle Matl SA-106 B
---
Element From Node 20 Element To Node 30 Element Type Cylinder Description
Distance "FROM" to "TO" 9.8425 ft. Inside Diameter 35.433 in. Element Thickness 0.3150 in. Internal Corrosion Allowance 0.1250 in. Nominal Thickness 0.3150 in. External Corrosion Allowance 0.0000 in. Design Internal Pressure 145.00 psig Design Temperature Internal Pressure 180 °F Design External Pressure 0.1450 psig Design Temperature External Pressure 95 °F Effective Diameter Multiplier 1.2
Material Name SA-516 70 Efficiency, Longitudinal Seam 1.0 Efficiency, Circumferential Seam 1.0
Element From Node 20 Detail Type Nozzle
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 9 of 183
Detail ID MH
Dist. from "FROM" Node / Offset dist 3.5302 ft. Nozzle Diameter 20.0 in.
Nozzle Schedule 40 Nozzle Class 150 Layout Angle 0.0 Blind Flange (Y/N) Y
Weight of Nozzle ( Used if > 0 ) 0.0000 lb. 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 1.3123 ft. Nozzle Diameter 8.0 in.
Nozzle Schedule 40 Nozzle Class 150 Layout Angle 135.0 Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 0.0000 lb. Grade of Attached Flange GR 1.1 Nozzle Matl SA-106 B
Element From Node 20 Detail Type Nozzle Detail ID N2
Dist. from "FROM" Node / Offset dist 4.4160 ft. Nozzle Diameter 4.0 in.
Nozzle Schedule 80 Nozzle Class 150 Layout Angle 180.0
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 10 of 183
Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 0.0000 lb. 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 8.3924 ft. Nozzle Diameter 2.0 in.
Nozzle Schedule 160 Nozzle Class 150 Layout Angle 225.0 Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 0.0000 lb. Grade of Attached Flange GR 1.1 Nozzle Matl SA-106 B
Element From Node 20 Detail Type Nozzle Detail ID N4
Dist. from "FROM" Node / Offset dist 8.2480 ft. Nozzle Diameter 4.0 in.
Nozzle Schedule 80 Nozzle Class 150 Layout Angle 135.0 Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 0.0000 lb. Grade of Attached Flange GR 1.1 Nozzle Matl SA-106 B
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 11 of 183
Detail Type Nozzle Detail ID N5
Dist. from "FROM" Node / Offset dist 8.3924 ft. Nozzle Diameter 2.0 in.
Nozzle Schedule 160 Nozzle Class 150 Layout Angle 315.0 Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 0.0000 lb. Grade of Attached Flange GR 1.1 Nozzle Matl SA-106 B
Element From Node 20 Detail Type Lug Detail ID SUPPPORT
Dist. from "FROM" Node / Offset dist 5.9055 ft. Number of Lugs 4
Dist. from OD to Lug Cntrline(dlug) 5.1181 in. Height of Gusset Plates (hgp) 5.0000 in. Force Bearing Width (wfb) 0.7500 in. Weight of Lug 9.0000 lb. Lug Start Angle (degrees) 0.0
---
Element From Node 30 Element To Node 40 Element Type Elliptical Description
Distance "FROM" to "TO" 0.1667 ft. Inside Diameter 35.433 in. Element Thickness 0.2953 in.
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 12 of 183
Internal Corrosion Allowance 0.1250 in. Nominal Thickness 0.3937 in. External Corrosion Allowance 0.0000 in. Design Internal Pressure 145.00 psig Design Temperature Internal Pressure 180 °F Design External Pressure 0.1450 psig Design Temperature External Pressure 95 °F Effective Diameter Multiplier 1.2
Material Name SA-516 70 Efficiency, Longitudinal Seam 0.85 Efficiency, Circumferential Seam 0.85 Elliptical Head Factor 2.0
Element From Node 30 Detail Type Nozzle Detail ID N6
Dist. from "FROM" Node / Offset dist 3.9370 in. Nozzle Diameter 8.0 in.
Nozzle Schedule 40 Nozzle Class 150 Layout Angle 180.0 Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 0.0000 lb. Grade of Attached Flange GR 1.1 Nozzle Matl SA-106 B
Element From Node 30 Detail Type Nozzle Detail ID N7
Dist. from "FROM" Node / Offset dist 11.811 in. Nozzle Diameter 2.0 in.
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 13 of 183
Nozzle Class 150 Layout Angle 0.0 Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 0.0000 lb. Grade of Attached Flange GR 1.1 Nozzle Matl SA-106 B
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 14 of 183
XY Coordinate Calculations
| | | | | |
From| To | X (Horiz.)| Y (Vert.) |DX (Horiz.)| DY (Vert.) | | | ft. | ft. | ft. | ft. |
--- 10| 20| ... | 0.16667 | ... | 0.16667 | 20| 30| ... | 10.0092 | ... | 9.84252 | 30| 40| ... | 10.1759 | ... | 0.16667 |
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 15 of 183
Element Thickness, Pressure, Diameter and Allowable Stress :
| | Int. Press | Nominal | Total Corr| Element | Allowable | From| To | + Liq. Hd | Thickness | Allowance | Diameter | Stress(SE)| | | psig | in. | in. | in. | psi |
---
10| 20| 145.000 | 0.39370 | 0.12500 | 35.4331 | 17000.0 | 20| 30| 145.000 | 0.31496 | 0.12500 | 35.4331 | 20000.0 | 30| 40| 145.000 | 0.39370 | 0.12500 | 35.4331 | 17000.0 |
Element Required Thickness and MAWP :
| | Design | M.A.W.P. | M.A.P. | Minimum | Required | From| To | Pressure | Corroded | New & Cold | Thickness | Thickness | | | psig | psig | psig | in. | in. |
---
10| 20| 145.000 | 163.600 | 282.862 | 0.29528 | 0.27590 | 20| 30| 145.000 | 211.590 | 351.803 | 0.31496 | 0.25492 | 30| 40| 145.000 | 163.600 | 282.862 | 0.29528 | 0.27590 | Minimum 163.600 282.861
MAWP: 163.600 psig, limited by: Elliptical Head.
Internal Pressure Calculation Results :
ASME Code, Section VIII, Division 1, 2013
Elliptical Head From 10 To 20 SA-516 70 , UCS-66 Crv. B at 180 °F
Longitudinal Joint: Spot Radiography per UW-11(b) Type 1 Circumferential Joint: Spot Radiography per UW-11(b) Type 1
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 16 of 183
Material UNS Number: K02700
Required Thickness due to Internal Pressure [tr]: = (P*D*Kcor)/(2*S*E-0.2*P) Appendix 1-4(c)
= (145.000*35.6831*0.991)/(2*20000.00*0.85-0.2*145.000) = 0.1509 + 0.1250 = 0.2759 in.
Max. Allowable Working Pressure at given Thickness, corroded [MAWP]: = (2*S*E*t)/(Kcor*D+0.2*t) per Appendix 1-4 (c)
= (2*20000.00*0.85*0.1703)/(0.991*35.6831+0.2*0.1703) = 163.600 psig
Maximum Allowable Pressure, New and Cold [MAPNC]: = (2*S*E*t)/(K*D+0.2*t) per Appendix 1-4 (c)
= (2*20000.00*0.85*0.2953)/(1.000*35.4331+0.2*0.2953) = 282.862 psig
Actual stress at given pressure and thickness, corroded [Sact]: = (P*(Kcor*D+0.2*t))/(2*E*t)
= (145.000*(0.991*35.6831+0.2*0.1703))/(2*0.85*0.1703) = 17726.119 psi
Straight Flange Required Thickness: = (P*R)/(S*E-0.6*P) + c per UG-27 (c)(1)
= (145.000*17.8415)/(20000.00*0.85-0.6*145.000)+0.125 = 0.278 in.
Straight Flange Maximum Allowable Working Pressure: = (S*E*t)/(R+0.6*t) per UG-27 (c)(1)
= (20000.00 * 0.85 * 0.2687 )/(17.8415 + 0.6 * 0.2687 ) = 253.734 psig
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 17 of 183
Factor K, corroded condition [Kcor]:
= ( 2 + ( Inside Diameter/( 2 * Inside Head Depth ))2)/6
= ( 2 + ( 35.683/( 2 * 8.983 ))2)/6
= 0.990756
Percent Elong. per UCS-79, VIII-1-01-57 (75*tnom/Rf)*(1-Rf/Ro) 4.747 %
MDMT Calculations in the Knuckle Portion:
Govrn. thk, tg = 0.295 , tr = 0.170 , c = 0.1250 in. , E* = 0.85 Stress Ratio = tr * (E*)/(tg - c) = 0.850 , Temp. Reduction = 15 °F
Min Metal Temp. w/o impact per UCS-66, Curve B -20 °F Min Metal Temp. at Required thickness (UCS 66.1) -35 °F
MDMT Calculations in the Head Straight Flange:
Govrn. thk, tg = 0.394 , tr = 0.173 , c = 0.1250 in. , E* = 0.85 Stress Ratio = tr * (E*)/(tg - c) = 0.546 , Temp. Reduction = 51 °F
Min Metal Temp. w/o impact per UCS-66, Curve B -20 °F Min Metal Temp. at Required thickness (UCS 66.1) -55 °F
Cylindrical Shell From 20 To 30 SA-516 70 , UCS-66 Crv. B at 180 °F
Longitudinal Joint: Full Radiography per UW-11(a) Type 1 Circumferential Joint: Full Radiography per UW-11(a) Type 1
Material UNS Number: K02700
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 18 of 183
= (P*R)/(S*E-0.6*P) per UG-27 (c)(1)
= (145.000*17.8415)/(20000.00*1.00-0.6*145.000) = 0.1299 + 0.1250 = 0.2549 in.
Max. Allowable Working Pressure at given Thickness, corroded [MAWP]: = (S*E*t)/(R+0.6*t) per UG-27 (c)(1)
= (20000.00*1.00*0.1900)/(17.8415+0.6*0.1900) = 211.590 psig
Maximum Allowable Pressure, New and Cold [MAPNC]: = (S*E*t)/(R+0.6*t) per UG-27 (c)(1)
= (20000.00*1.00*0.3150)/(17.7165+0.6*0.3150) = 351.803 psig
Actual stress at given pressure and thickness, corroded [Sact]: = (P*(R+0.6*t))/(E*t)
= (145.000*(17.8415+0.6*0.1900))/(1.00*0.1900) = 13705.729 psi
Percent Elongation per UCS-79 (50*tnom/Rf)*(1-Rf/Ro) 0.881 %
Minimum Design Metal Temperature Results:
Govrn. thk, tg = 0.315 , tr = 0.147 , c = 0.1250 in. , E* = 1.00 Stress Ratio = tr * (E*)/(tg - c) = 0.772 , Temp. Reduction = 23 °F
Min Metal Temp. w/o impact per UCS-66, Curve B -20 °F Min Metal Temp. at Required thickness (UCS 66.1) -43 °F
Elliptical Head From 30 To 40 SA-516 70 , UCS-66 Crv. B at 180 °F
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 19 of 183
Circumferential Joint: Spot Radiography per UW-11(b) Type 1
Material UNS Number: K02700
Required Thickness due to Internal Pressure [tr]: = (P*D*Kcor)/(2*S*E-0.2*P) Appendix 1-4(c)
= (145.000*35.6831*0.991)/(2*20000.00*0.85-0.2*145.000) = 0.1509 + 0.1250 = 0.2759 in.
Max. Allowable Working Pressure at given Thickness, corroded [MAWP]: = (2*S*E*t)/(Kcor*D+0.2*t) per Appendix 1-4 (c)
= (2*20000.00*0.85*0.1703)/(0.991*35.6831+0.2*0.1703) = 163.600 psig
Maximum Allowable Pressure, New and Cold [MAPNC]: = (2*S*E*t)/(K*D+0.2*t) per Appendix 1-4 (c)
= (2*20000.00*0.85*0.2953)/(1.000*35.4331+0.2*0.2953) = 282.862 psig
Actual stress at given pressure and thickness, corroded [Sact]: = (P*(Kcor*D+0.2*t))/(2*E*t)
= (145.000*(0.991*35.6831+0.2*0.1703))/(2*0.85*0.1703) = 17726.119 psi
Straight Flange Required Thickness: = (P*R)/(S*E-0.6*P) + c per UG-27 (c)(1)
= (145.000*17.8415)/(20000.00*0.85-0.6*145.000)+0.125 = 0.278 in.
Straight Flange Maximum Allowable Working Pressure: = (S*E*t)/(R+0.6*t) per UG-27 (c)(1)
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 20 of 183
= 253.734 psig
Factor K, corroded condition [Kcor]:
= ( 2 + ( Inside Diameter/( 2 * Inside Head Depth ))2)/6
= ( 2 + ( 35.683/( 2 * 8.983 ))2)/6
= 0.990756
Percent Elong. per UCS-79, VIII-1-01-57 (75*tnom/Rf)*(1-Rf/Ro) 4.747 %
MDMT Calculations in the Knuckle Portion:
Govrn. thk, tg = 0.295 , tr = 0.170 , c = 0.1250 in. , E* = 0.85 Stress Ratio = tr * (E*)/(tg - c) = 0.850 , Temp. Reduction = 15 °F
Min Metal Temp. w/o impact per UCS-66, Curve B -20 °F Min Metal Temp. at Required thickness (UCS 66.1) -35 °F
MDMT Calculations in the Head Straight Flange:
Govrn. thk, tg = 0.394 , tr = 0.173 , c = 0.1250 in. , E* = 0.85 Stress Ratio = tr * (E*)/(tg - c) = 0.546 , Temp. Reduction = 51 °F
Min Metal Temp. w/o impact per UCS-66, Curve B -20 °F Min Metal Temp. at Required thickness (UCS 66.1) -55 °F
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 212.680 psig Pressure per UG99b[36] = 1.3 * Design Pres * Sa/S 188.500 psig
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 21 of 183
Pressure per UG99c = 1.3 * M.A.P. - Head(Hyd) 362.670 psig Pressure per UG100 = 1.1 * M.A.W.P. * Sa/S 179.960 psig Pressure per PED = 1.43 * MAWP 233.949 psig
UG-99(b), Test Pressure Calculation: = Test Factor * MAWP * Stress Ratio = 1.3 * 163.600 * 1.000
= 212.680 psig
Vertical 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 Test Pressure:
From To Stress Allowable Ratio Pressure --- 10 20 15394.8 26000.0 0.592 217.73 20 30 12355.6 26000.0 0.475 217.34 30 40 15065.5 26000.0 0.579 213.07 ---
Stress ratios for Nozzle and Pad Materials:
Description Pad/Nozzle Ambient Operating ratio ---
N8 Nozzle 17100.00 17100.00 1.000 N8 Pad 20000.00 20000.00 1.000 MH Nozzle 17100.00 17100.00 1.000 MH Pad 20000.00 20000.00 1.000
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR Rev : A Page : 22 of 183 N1 Nozzle 17100.00 17100.00 1.000 N1 Pad 20000.00 20000.00 1.000 N2 Nozzle 17100.00 17100.00 1.000 N2 Pad 20000.00 20000.00 1.000 N3 Nozzle 17100.00 17100.00 1.000 N3 Pad 20000.00 20000.00 1.000 N4 Nozzle 17100.00 17100.00 1.000 N4 Pad 20000.00 20000.00 1.000 N5 Nozzle 17100.00 17100.00 1.000 N5 Pad 20000.00 20000.00 1.000 N6 Nozzle 17100.00 17100.00 1.000 N6 Pad 20000.00 20000.00 1.000 N7 Nozzle 17100.00 17100.00 1.000 N7 Pad 20000.00 20000.00 1.000 --- Minimum 1.000
Stress ratios for Vessel Elements:
Description Ambient Operating ratio --- 20000.00 20000.00 1.000 20000.00 20000.00 1.000 20000.00 20000.00 1.000 --- Minimum 1.000
Elements Suitable for Internal Pressure.
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 23 of 183
External Pressure Calculation Results :
ASME Code, Section VIII, Division 1, 2013
Elliptical Head From 10 to 20 Ext. Chart: CS-2 at 95 °F
Elastic Modulus from Chart: CS-2 at 95 °F : 0.290E+08 psi
Results for Maximum Allowable External Pressure (MAEP): Tca OD D/t Factor A B
0.170 36.02 211.56 0.0006565 9519.20
EMAP = B/(K0*D/t) = 9519.2021/(0.9000 *211.5607 ) = 49.9946 psig
Results for Required Thickness (Tca): Tca OD D/t Factor A B
0.009 36.02 3927.71 0.0000354 512.74
EMAP = B/(K0*D/t) = 512.7382/(0.9000 *3927.7144 ) = 0.1450 psig
Check the requirements of UG-33(a)(1) using P = 1.67 * External Design pressure for this head.
Material UNS Number: K02700
Required Thickness due to Internal Pressure [tr]: = (P*D*Kcor)/(2*S*E-0.2*P) Appendix 1-4(c)
= (0.242*35.6831*0.991)/(2*20000.00*1.00-0.2*0.242) = 0.0002 + 0.1250 = 0.1252 in.
Max. Allowable Working Pressure at given Thickness, corroded [MAWP]: = ((2*S*E*t)/(Kcor*D+0.2*t))/1.67 per Appendix 1-4 (c)
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 24 of 183
= 115.252 psig
Maximum Allowable External Pressure [MAEP]: = min( MAEP, MAWP )
= min( 49.99 , 115.2521 ) = 49.995 psig
Thickness requirements per UG-33(a)(1) govern the required thickness of this head.
Cylindrical Shell From 20 to 30 Ext. Chart: CS-2 at 95 °F
Elastic Modulus from Chart: CS-2 at 95 °F : 0.290E+08 psi
Results for Maximum Allowable External Pressure (MAEP): Tca OD SLEN D/t L/D Factor A B
0.190 36.06 128.02 189.84 3.5498 0.0001363 1976.34 EMAP = (4*B)/(3*(D/t)) = (4*1976.3380 )/(3*189.8446 ) = 13.8804 psig
Results for Required Thickness (Tca):
Tca OD SLEN D/t L/D Factor A B
0.030 36.06 128.02 1191.38 3.5498 0.0000089 129.61 EMAP = (4*B)/(3*(D/t)) = (4*129.6081 )/(3*1191.3799 ) = 0.1451 psig
Results for Maximum Stiffened Length (Slen): Tca OD SLEN D/t L/D Factor A B
0.190 36.06 5875.59 189.84 50.0000 0.0000312 452.17 EMAP = (4*B)/(3*(D/t)) = (4*452.1724 )/(3*189.8446 ) = 3.1757 psig
Elliptical Head From 30 to 40 Ext. Chart: CS-2 at 95 °F
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 25 of 183
Results for Maximum Allowable External Pressure (MAEP): Tca OD D/t Factor A B
0.170 36.02 211.56 0.0006565 9519.20
EMAP = B/(K0*D/t) = 9519.2021/(0.9000 *211.5607 ) = 49.9946 psig
Results for Required Thickness (Tca): Tca OD D/t Factor A B
0.009 36.02 3927.71 0.0000354 512.74
EMAP = B/(K0*D/t) = 512.7382/(0.9000 *3927.7144 ) = 0.1450 psig
Check the requirements of UG-33(a)(1) using P = 1.67 * External Design pressure for this head.
Material UNS Number: K02700
Required Thickness due to Internal Pressure [tr]: = (P*D*Kcor)/(2*S*E-0.2*P) Appendix 1-4(c)
= (0.242*35.6831*0.991)/(2*20000.00*1.00-0.2*0.242) = 0.0002 + 0.1250 = 0.1252 in.
Max. Allowable Working Pressure at given Thickness, corroded [MAWP]: = ((2*S*E*t)/(Kcor*D+0.2*t))/1.67 per Appendix 1-4 (c)
= ((2*20000.00*1.00*0.1703)/(0.991*35.6831+0.2*0.1703))/1.67 = 115.252 psig
Maximum Allowable External Pressure [MAEP]: = min( MAEP, MAWP )
= min( 49.99 , 115.2521 ) = 49.995 psig
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 26 of 183
thickness of this head.
External Pressure Calculations
| | Section | Outside | Corroded | Factor | Factor | From| To | Length | Diameter | Thickness | A | B | | | ft. | in. | in. | | psi |
---
10| 20| No Calc | 36.0236 | 0.17028 | 0.00065650 | 9519.20 | 20| 30| 10.6680 | 36.0630 | 0.18996 | 0.00013630 | 1976.34 | 30| 40| No Calc | 36.0236 | 0.17028 | 0.00065650 | 9519.20 |
External Pressure Calculations
| | External | External | External | External | From| To | Actual T. | Required T.|Des. Press. | M.A.W.P. | | | in. | in. | psig | psig |
---
10| 20| 0.29528 | 0.18750 | 0.14504 | 49.9946 | 20| 30| 0.31496 | 0.15527 | 0.14504 | 13.8804 | 30| 40| 0.29528 | 0.18750 | 0.14504 | 49.9946 | Minimum 13.880
External Pressure Calculations
| | Actual Len.| Allow. Len.| Ring Inertia | Ring Inertia | From| To | Bet. Stiff.| Bet. Stiff.| Required | Available | | | ft. | ft. | in**4 | in**4 |
--- 10| 20| No Calc | No Calc | No Calc | No Calc | 20| 30| 10.6680 | 489.632 | No Calc | No Calc | 30| 40| No Calc | No Calc | No Calc | No Calc |
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 27 of 183
Elements Suitable for External Pressure.
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 28 of 183
Element and Detail Weights
| | Element | Element | Corroded | Corroded | Extra due | From| To | Metal Wgt. | ID Volume |Metal Wgt. | ID Volume | Misc % | | | lb. | in³ | lb. | in³ | lb. | --- 10| 20| 194.163 | 7795.38 | 132.516 | 7947.44 | ... | 20| 30| 1169.78 | 116465. | 707.989 | 118114. | ... | 30| 40| 194.163 | 7795.38 | 132.516 | 7947.44 | ... | --- Total 1558 132055 973 134009 0 Weight of Details
| | Weight of | X Offset, | Y Offset, |
From|Type| Detail | Dtl. Cent. |Dtl. Cent. | Description | | lb. | ft. | ft. | --- 10|Nozl| 24.7692 | ... | -0.73819 | N8 20|Nozl| 538.669 | 2.26029 | 3.53018 | MH 20|Nozl| 63.6504 | 1.80892 | 1.31234 | N1 20|Nozl| 26.4911 | 1.63579 | 4.41601 | N2 20|Nozl| 27.9179 | 1.54667 | 8.39239 | N3 20|Nozl| 31.4088 | 1.63579 | 8.24803 | N4 20|Nozl| 11.9451 | 1.54667 | 8.39239 | N5 20|Lugs| 36.0000 | ... | 6.11385 | SUPPPORT 30|Nozl| 64.2813 | ... | 1.71973 | N6 30|Nozl| 11.0243 | ... | 1.55021 | N7
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 29 of 183
Total Weight of Nozzles 800.2 Total Weight of Lugs 36.0 --- Sum of the Detail Weights 836.2 lb.
Weight Summation
Fabricated Shop Test Shipping Erected Empty Operating --- 1558.1 2394.3 1558.1 2394.3 1558.1 2394.3 ... 4768.7 ... ... ... ... 800.2 ... 800.2 ... ... ... 36.0 ... 36.0 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 800.2 ... ... ... ... ... 36.0 ... --- 2394.3 7162.9 2394.3 2394.3 2394.3 2394.3 lb.
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 2394.3 lb. Shop Test Wt. - Fabricated Weight + Water ( Full ) 7162.9 lb. Shipping Wt. - Fab. Wt + Rem. Intls.+ Shipping App. 2394.3 lb. Erected Wt. - Fab. Wt + Rem. Intls.+ Insul. (etc) 2394.3 lb. Ope. Wt. no Liq - Fab. Wt + Intls. + Details + Wghts. 2394.3 lb.
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 30 of 183
Operating Wt. - Empty Wt + Operating Liq. Uncorroded 2394.3 lb. Field Test Wt. - Empty Weight + Water (Full) 7162.9 lb. Mass of the Upper 1/3 of the Vertical Vessel 511.1 lb.
Outside Surface Areas of Elements
| | Surface | From| To | Area | | | in² | --- 10| 20| 1649.68 | 20| 30| 13381.3 | 30| 40| 1649.68 | --- Total 16680.697 in² [115.8 Square Feet ]
Element and Detail Weights
| To | Total Ele.| Total. Ele.|Total. Ele.| Total Dtl.| Oper. Wgt. |
From| To | Empty Wgt.| Oper. Wgt.|Hydro. Wgt.| Offset Mom.| No Liquid | | | lbm | lbm | lbm | ft.lb. | lbm | --- 10| 20| 218.932 | 218.932 | 500.432 | ... | 218.932 | 20|Lugs| 1121.92 | 1121.92 | 3645.32 | 893.434 | 1121.92 | Lugs| 30| 747.943 | 747.943 | 2430.21 | 595.622 | 747.943 | 30| 40| 269.469 | 269.469 | 550.969 | ... | 269.469 |
Cumulative Vessel Weight
| | Cumulative Ope | Cumulative | Cumulative | From| To | Wgt. No Liquid | Oper. Wgt. | Hydro. Wgt. | | | lbm | lbm | lbm |
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR Rev : A Page : 31 of 183 --- 10| 20| ... | ... | ... | 20|Lugs| -218.932 | -218.932 | -500.432 | Lugs| 30| 1017.41 | 1017.41 | 2981.18 | 30| 40| 269.469 | 269.469 | 550.969 |
Note: The cumulative operating weights no liquid in the column above are the cumulative operating weights minus the operating liquid weight minus any weights absent in the empty condition.
Cumulative Vessel Moment
| | Cumulative | Cumulative |Cumulative | From| To | Empty Mom. | Oper. Mom. |Hydro. Mom.| | | ft.lb. | ft.lb. | ft.lb. | --- 10| 20| ... | ... | ... | 20|Lugs| 893.434 | 893.434 | 893.434 | Lugs| 30| 595.622 | 595.622 | 595.622 | 30| 40| ... | ... | ... |
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 32 of 183
Nozzle Flange MAWP Results :
Nozzle --- Flange Rating
Description Operating Ambient Temperature Class Grade|Group psig psig °F --- N8 265.0 285.0 180 150 GR 1.1 MH 265.0 285.0 180 150 GR 1.1 N1 265.0 285.0 180 150 GR 1.1 N2 265.0 285.0 180 150 GR 1.1 N3 265.0 285.0 180 150 GR 1.1 N4 265.0 285.0 180 150 GR 1.1 N5 265.0 285.0 180 150 GR 1.1 N6 265.0 285.0 180 150 GR 1.1 N7 265.0 285.0 180 150 GR 1.1 --- Minimum Rating 265.000 285.000 psig (for Core Elements)
Note: ANSI Ratings are per ANSI/ASME B16.5 2009 Edition
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 33 of 183
The Natural Frequencies for the vessel have been computed iteratively by solving a system of matrices. These matrices describe the mass and the stiffness of the vessel. This is the generalized eigenvalue/ eigenvector problem and is referenced in some mathematical texts.
The Natural Frequency for the Vessel (Empty.) is 84.4571 Hz.
The Natural Frequency for the Vessel (Ope...) is 84.4571 Hz.
The Natural Frequency for the Vessel (Filled) is 62.7303 Hz.
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 34 of 183
Wind Analysis Results
User Entered Importance Factor is 1.000 Gust Factor (Gh, Gbar) Static 1.351 Shape Factor (Cf) for the Vessel is 0.545
User Entered Basic Wind Speed 70.0 mile/hr Exposure Category C
Table Lookup Value Alpha from Table C6 7.0000 Table Lookup Value Zg from Table C6 900.0000 Table Lookup Value Do from Table C6 0.0050
Wind Load Results per ASCE-7 93:
Sample Calculation for the First Element:
Rougness Factor = 1.000
Values [cf1] and [cf2]
Because RoughFact = 1 and DQZ > 2.5 and H/D < 7.0 Interpolating to find the final cf:
Because H / D < 7.0
CF = CF1 + (CF2-CF1)*( H/D - 1) / (7 - 1) = 0.500 + (0.600 -0.500 )*( 3.695 - 1)/(7 - 1) = 0.545
Value of Alpha, Zg is taken from Table C6-2 [Alpha, Zg] For Exposure Category C:
Alpha = 7.000 , Zg = 900.000 ft.
Height of Interest for First Element [z] = Centroid Hgt + Base Height
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 35 of 183
= 0.528 + 0.000 = 0.528 ft.
but: z = Max(15.000 , 0.528 ) = 15.000 ft.
Note: Because z < 15 feet, use 15 feet to compute kz.
Velocity Pressure Coefficient [kZ]:
= 2.58( z/zg )2/Alpha : z is Elevation of First Element
= 2.58( 15.000/900 )2/7.0
= 0.801
Determine if Static or Dynamic Gust Factor Applies
Height to Diameter ratio :
= Maximum Height(length)^2 / Sum of Area of the Elements = 10.939 (^2)/32.378
= 3.695
Vibration Frequency = 84.457 Hz
Because H/D < 5 And Frequency > 1.0: Static Analysis Implemented
The following two calculations allow for any user units
Compute [tz]
= 2.35 * Sqrt(DO / VesselHtg/30(feet)1/Alpha
= 2.35 * Sqrt(0.005/10.939 )1/30.000
= 0.192
Compute [Gh] = 0.65 + 3.65 * tz
= 0.65 + 3.65 * 0.192 = 1.351
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 36 of 183
Importance Factor: I = 1.000 Wind Speed = 70.000 mile/hr qz = 0.00256 * kZ * (I * Vr)²
= 0.00256 * 0.801 *(1.000 * 70.000 )² = 10.046 psf
Force on the First Element [Fz] = qz * Gh * CF * Wind Area = 10.046 * 1.351 * 0.545 * 397.233 = 20.396 lb.
Element z GH Area qz Force ft. in² psf lb.
--- Node 10 to 20 0.5 1.351 397.2 10.0 20.4 Node 20 to 30 5.8 1.351 5111.3 10.0 262.4 Node 30 to 40 11.1 1.351 397.2 10.0 20.4
Wind Vibration Calculations
This evaluation is based on work by Kanti Mahajan and Ed Zorilla
Nomenclature
Cf - Correction factor for natural frequency D - Average internal diameter of vessel ft.
Df - Damping Factor < 0.75 Unstable, > 0.95 Stable Dr - Average internal diameter of top half of vessel ft. f - Natural frequency of vibration (Hertz)
f1 - Natural frequency of bare vessel based on a unit value of (D/L²)(104)
L - Total height of structure ft.
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 37 of 183
tb - Uncorroded plate thickness at bottom of vessel in. V30 - Design Wind Speed provided by user mile/hr Vc - Critical wind velocity mile/hr
Vw - Maximum wind speed at top of structure mile/hr W - Total corroded weight of structure lb.
Ws - Cor. vessel weight excl. weight of parts which do not effect stiff. lb. Z - Maximum amplitude of vibration at top of vessel in.
Dl - Logarithmic decrement ( taken as 0.03 for Welded Structures ) Vp - Vib. Chance, <= 0.200E+02 (High); 0.200E+02 < 0.250E+02 (Probable) P30 - wind pressure 30 feet above the base
Check other Conditions and Basic Assumptions: #1 - Total Cone Length / Total Length < 0.5 0.000/10.176 = 0.000
#2 - ( D / L² ) * 104 < 8.0 (English Units)
- ( 3.01/10.18² ) * 104 = 290.217 [Geometry Violation]
Compute the vibration possibility. If Vp > 0.250E+02 no chance. [Vp]: = W / ( L * Dr²)
= 1809/( 10.18 * 2.974² ) = 0.20107E+02
Compute the damping factor Df which is a measure of instability [Df]: = W * Dl/ ( L * Dr² )
= 1809 * 0.03/( 10.18 * 2.974² ) = 0.603
Compute the critical wind velocity [Vc]: = 3.4 * f * Dr
= 3.4 * 84.457 * 2.974 = 853.878 mile/hr
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 38 of 183
Compute the velocity at the top of the tower [Vw]: = V30 * ( L / ( 30 + BaseHeight ))0.143
= 70.00 * ( 10.18/( 30 + 0.0 ))^0.143 = 59.973 mile/hr
Compute the maximum gust velocity using the gust response factor Gh [Vg]: = Vw * Gh
= 59.973 * 1.351 = 80.996 mile/hr
Since Vc is greater than Vg the dynamic deflection Z, does not need to be computed.
The Natural Frequency for the Vessel (Ope...) is 84.4571 Hz.
Wind Load Calculation
| | Wind | Wind | Wind | Wind | Element | From| To | Height | Diameter | Area | Pressure | Wind Load | | | ft. | ft. | in² | psf | lb. |
---
10| 20| 0.52765 | 3.60236 | 397.233 | 10.0464 | 20.3959 | 20| 30| 5.82612 | 3.60630 | 5111.29 | 10.0464 | 262.439 | 30| 40| 11.1492 | 3.60236 | 397.233 | 10.0464 | 20.3959 |
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 39 of 183
Input Values for G Loading:
Horizontal Acceleration factor (GX) 0.400 Horizontal Acceleration factor (GZ) 0.400 Vertical Acceleration factor (GY) 0.260
Computed Results:
Note: +Y Direction G loads should also be run in the negative direction. to insure maximum support loads are calculated.
The Natural Frequency for the Vessel (Ope...) is 84.4571 Hz.
Earthquake Load Calculation
| | Earthquake | Earthquake | Element | Element | From| To | Height | Weight | Ope Load | Emp Load | | | ft. | lb. | lb. | lb. | --- 10| 20| 0.083333 | 218.932 | 123.847 | 123.847 | 20|Lugs| 6.07218 | 1121.92 | 634.651 | 634.651 | Lugs| 30| 8.04068 | 747.943 | 423.101 | 423.101 | 30| 40| 10.0925 | 269.469 | 152.434 | 152.434 |
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 40 of 183
The following table is for the Operating Case.
Wind/Earthquake Shear, Bending
| | Distance to| Cumulative |Earthquake | Wind | Earthquake | From| To | Support| Wind Shear | Shear | Bending | Bending | | | ft. | lb. | lb. | ft.lb. | ft.lb. | --- 10| 20| 6.30732 | ... | ... | ... | ... | 20|Lugs| 2.95276 | 20.3959 | 123.847 | 4.79593 | 29.1216 | Lugs| 30| 1.96850 | 145.767 | 699.382 | 298.455 | 1165.62 | 30| 40| 4.17215 | 20.3959 | 152.434 | 4.79593 | 35.8437 | Note:
The Wind Shears/Moments and the Earthquake Shears/Moments calculated and printed in the Wind/Earthquake Shear and Bending report have
been factored by the input Scalar/Load reductions factors of; Wind: 1.000; Earthquake: 1.000.
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 41 of 183
Wind Deflection Calculations:
The following table is for the Operating Case.
Wind Deflection
| | Cumulative | Centroid | Elem. End | Elem. Ang. | From| To | Wind Shear | Deflection |Deflection | Rotation | | | lb. | in. | in. | | --- 10| 20| ... | 0.00001 | 0.00001 | ... | 20|Lugs| 20.3959 |-0.00015104 | ... | ... | Lugs| 30| 145.767 | -0.00008 | 0.00006 | ... | 30| 40| 20.3959 | 0.00007 | 0.00007 | ... |
Critical Wind Velocity for Tower Vibration
| | 1st Crit. | 2nd Crit. |
From| To | Wind Speed | Wind Speed | | | mile/hr | mile/hr |
--- 10| 20| 1034.43 | 6465.21 | 20| 30| 1035.56 | 6472.27 | 30| 40| 1034.43 | 6465.21 |
Allowable deflection at the Tower Top (Ope)( 6.000"/100ft. Criteria) Allowable deflection : 0.611 Actual Deflection : 0.000 in.
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 42 of 183
Longitudinal Stress Constants
| | Metal Area | Metal Area |New & Cold | Corroded | From| To | New & Cold | Corroded |Sect. Mod. | Sect. Mod. | | | in² | in² | in.³ | in.³ |
---
10| 20| 33.1428 | 19.1792 | 293.628 | 171.100 | 20| 30| 35.3719 | 21.4082 | 313.382 | 190.989 | 30| 40| 33.1428 | 19.1792 | 293.628 | 171.100 |
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 43 of 183
Longitudinal Allowable Stresses
| | | Hydrotest | | Hydrotest |
From| To | Tensile | Tensile | Compressive | Compressive | | | psi | psi | psi | psi |
---
10| 20| 20400.0 | 26520.0 | -15710.0 | -18152.2 | 20|Lugs| 24000.0 | 31200.0 | -16240.0 | -18393.4 | Lugs| 30| 24000.0 | 31200.0 | -16240.0 | -18393.4 | 30| 40| 20400.0 | 26520.0 | -15710.0 | -18152.2 |
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 44 of 183
Longitudinal Stress Report
Note: Longitudinal Operating and Empty Stresses are computed in the corroded condition. Stresses due to loads in the hydrostatic test cases have been computed in the new and cold condition.
Longitudinal Stresses Due to . . .
| | Long. Str. | Long. Str. |Long. Str. | From| To | Int. Pres. | Ext. Pres. |Hyd. Pres. | | | psi | psi | psi |
---
10| 20| 7567.58 | -7.70772 | 6337.88 | 20| 30| 6780.37 | -6.92028 | 5939.10 | 30| 40| 7567.58 | -7.70772 | 6337.88 |
Longitudinal Stresses Due to . . .
| | Wght. Str. | Wght. Str. |Wght. Str. | Wght. Str. | Wght. Str. | From| To | Empty | Operating |Hydrotest | Emp. Mom. | Opr. Mom. | | | psi | psi | psi | psi | psi |
--- 10| 20| ... | ... | ... | ... | ... |
20|Lugs| 10.2265 | 10.2265 | 14.1477 | 56.1353 | 56.1353 | Lugs| 30| -47.5243 | -47.5243 | -28.7633 | 37.4235 | 37.4235 | 30| 40| -14.0501 | -14.0501 | -8.13053 | ... | ... |
Longitudinal Stresses Due to . . .
| | Wght. Str. | Bend. Str. |Bend. Str. | Bend. Str. | Bend. Str. |
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 45 of 183
| | psi | psi | psi | psi | psi | --- 10| 20| ... | ... | ... | ... | ... |
20|Lugs| 34.2113 | 0.30133 | 1.82974 | 0.060603 | ... | Lugs| 30| 22.8075 | 18.7522 | 73.2367 | 3.77138 | ... | 30| 40| ... | 0.33636 | 2.51387 | 0.064680 | ... |
Longitudinal Stresses Due to . . .
| | Long. Str. | Long. Str. |Long. Str. | EarthQuake | From| To | Vortex Ope.| Vortex Emp.|Vortex Tst.| Empty | | | psi | psi | psi | psi |
--- 10| 20| ... | ... | ... | ... | 20|Lugs| ... | ... | ... | 1.82974 | Lugs| 30| ... | ... | ... | 73.2367 | 30| 40| ... | ... | ... | 2.51387 |
Longitudinal Stresses Due to . . .
| | Long. Str. | Long. Str. | From| To | Y Forces W | Y ForceS S | | | psi | psi | --- 10| 20| ... | -2.96793 | 20|Lugs| ... | -16.2844 | Lugs| 30| ... | 12.3563 | 30| 40| ... | 3.65302 |
Long. Stresses due to User Forces and Moments
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 46 of 183
From| To | Corroded | Corroded | No Corr. | No Corr. | | | psi | psi | psi | psi |
--- 10| 20| ... | ... | ... | ... | 20|Lugs| ... | ... | ... | ... | Lugs| 30| ... | ... | ... | ... | 30| 40| ... | ... | ... | ... |
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 47 of 183
Stress Combination Load Cases for Vertical Vessels:
Load Case Definition Key
IP = Longitudinal Stress due to Internal Pressure EP = Longitudinal Stress due to External Pressure HP = Longitudinal Stress due to Hydrotest Pressure NP = No Pressure
EW = Longitudinal Stress due to Weight (No Liquid) OW = Longitudinal Stress due to Weight (Operating) HW = Longitudinal Stress due to Weight (Hydrotest) WI = Bending Stress due to Wind Moment (Operating) EQ = Bending Stress due to Earthquake Moment (Operating) EE = Bending Stress due to Earthquake Moment (Empty) HI = Bending Stress due to Wind Moment (Hydrotest) HE = Bending Stress due to Earthquake Moment (Hydrotest) WE = Bending Stress due to Wind Moment (Empty) (no CA) WF = Bending Stress due to Wind Moment (Filled) (no CA) CW = Longitudinal Stress due to Weight (Empty) (no CA) VO = Bending Stress due to Vortex Shedding Loads ( Ope ) VE = Bending Stress due to Vortex Shedding Loads ( Emp ) VF = Bending Stress due to Vortex Shedding Loads ( Test No CA. ) FW = Axial Stress due to Vertical Forces for the Wind Case FS = Axial Stress due to Vertical Forces for the Seismic Case
BW = Bending Stress due to Lat. Forces for the Wind Case, Corroded BS = Bending Stress due to Lat. Forces for the Seismic Case, Corroded BN = Bending Stress due to Lat. Forces for the Wind Case, UnCorroded BU = Bending Stress due to Lat. Forces for the Seismic Case, UnCorroded
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 48 of 183
Case types HI and HE are in the Un-Corroded condition.
Case types WE, WF, and CW are in the Un-Corroded condition.
A blank stress and stress ratio indicates that the corresponding stress comprising those components that did not contribute to that type of stress.
An asterisk (*) in the final column denotes overstress.
Analysis of Load Case 1 : NP+EW+WI+FW+BW
From Tensile All. Tens. Comp. All. Comp. Tens. Comp. Node Stress Stress Stress Stress Ratio Ratio 10 0.00 20400.00 0.00 15710.03 0.0000 0.0000 20 66.66 24000.00 -46.21 16240.04 0.0028 0.0028 20 8.65 24000.00 -103.70 16240.04 0.0004 0.0064 30 20400.00 -14.39 15710.03 0.0009
Analysis of Load Case 2 : NP+EW+EE+FS+BS
From Tensile All. Tens. Comp. All. Comp. Tens. Comp. Node Stress Stress Stress Stress Ratio Ratio 10 20400.00 -2.97 15710.03 0.0002 20 51.91 24000.00 -64.02 16240.04 0.0022 0.0039 20 75.49 24000.00 -145.83 16240.04 0.0031 0.0090 30 20400.00 -12.91 15710.03 0.0008
Analysis of Load Case 3 : NP+OW+WI+FW+BW
From Tensile All. Tens. Comp. All. Comp. Tens. Comp. Node Stress Stress Stress Stress Ratio Ratio 10 0.00 20400.00 0.00 15710.03 0.0000 0.0000
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR Rev : A Page : 49 of 183 20 66.66 24000.00 -46.21 16240.04 0.0028 0.0028 20 8.65 24000.00 -103.70 16240.04 0.0004 0.0064 30 20400.00 -14.39 15710.03 0.0009
Analysis of Load Case 4 : NP+OW+EQ+FS+BS
From Tensile All. Tens. Comp. All. Comp. Tens. Comp. Node Stress Stress Stress Stress Ratio Ratio 10 20400.00 -2.97 15710.03 0.0002 20 51.91 24000.00 -64.02 16240.04 0.0022 0.0039 20 75.49 24000.00 -145.83 16240.04 0.0031 0.0090 30 20400.00 -12.91 15710.03 0.0008
Analysis of Load Case 5 : NP+HW+HI
From Tensile All. Tens. Comp. All. Comp. Tens. Comp. Node Stress Stress Stress Stress Ratio Ratio 10 0.00 26520.00 0.00 18152.20 0.0000 0.0000 20 48.42 31200.00 -20.12 18393.39 0.0016 0.0011 20 31200.00 -55.34 18393.39 0.0030 30 26520.00 -8.20 18152.20 0.0005
Analysis of Load Case 6 : NP+HW+HE
From Tensile All. Tens. Comp. All. Comp. Tens. Comp. Node Stress Stress Stress Stress Ratio Ratio 10 0.00 26520.00 0.00 18152.20 0.0000 0.0000 20 48.36 31200.00 -20.06 18393.39 0.0015 0.0011 20 31200.00 -51.57 18393.39 0.0028 30 26520.00 -8.13 18152.20 0.0004
Analysis of Load Case 7 : IP+OW+WI+FW+BW
From Tensile All. Tens. Comp. All. Comp. Tens. Comp. Node Stress Stress Stress Stress Ratio Ratio 10 7567.58 20400.00 15710.03 0.3710
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR Rev : A Page : 50 of 183 20 6847.03 24000.00 16240.04 0.2853 20 6789.02 24000.00 16240.04 0.2829 30 7553.86 20400.00 15710.03 0.3703
Analysis of Load Case 8 : IP+OW+EQ+FS+BS
From Tensile All. Tens. Comp. All. Comp. Tens. Comp. Node Stress Stress Stress Stress Ratio Ratio 10 7564.61 20400.00 15710.03 0.3708 20 6832.27 24000.00 16240.04 0.2847 20 6855.86 24000.00 16240.04 0.2857 30 7559.69 20400.00 15710.03 0.3706
Analysis of Load Case 9 : EP+OW+WI+FW+BW
From Tensile All. Tens. Comp. All. Comp. Tens. Comp. Node Stress Stress Stress Stress Ratio Ratio 10 20400.00 -7.71 15710.03 0.0005 20 59.74 24000.00 -53.13 16240.04 0.0025 0.0033 20 1.73 24000.00 -110.62 16240.04 0.0001 0.0068 30 20400.00 -22.09 15710.03 0.0014
Analysis of Load Case 10 : EP+OW+EQ+FS+BS
From Tensile All. Tens. Comp. All. Comp. Tens. Comp. Node Stress Stress Stress Stress Ratio Ratio 10 20400.00 -10.68 15710.03 0.0007 20 44.99 24000.00 -70.94 16240.04 0.0019 0.0044 20 68.57 24000.00 -152.75 16240.04 0.0029 0.0094 30 20400.00 -20.62 15710.03 0.0013
Analysis of Load Case 11 : HP+HW+HI
From Tensile All. Tens. Comp. All. Comp. Tens. Comp. Node Stress Stress Stress Stress Ratio Ratio 10 6337.88 26520.00 18152.20 0.2390
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR Rev : A Page : 51 of 183 20 5987.52 31200.00 18393.39 0.1919 20 5936.92 31200.00 18393.39 0.1903 30 6329.81 26520.00 18152.20 0.2387
Analysis of Load Case 12 : HP+HW+HE
From Tensile All. Tens. Comp. All. Comp. Tens. Comp. Node Stress Stress Stress Stress Ratio Ratio 10 6337.88 26520.00 18152.20 0.2390 20 5987.46 31200.00 18393.39 0.1919 20 5933.15 31200.00 18393.39 0.1902 30 6329.75 26520.00 18152.20 0.2387
Analysis of Load Case 13 : IP+WE+EW
From Tensile All. Tens. Comp. All. Comp. Tens. Comp. Node Stress Stress Stress Stress Ratio Ratio 10 7567.58 20400.00 15710.03 0.3710 20 6846.73 24000.00 16240.04 0.2853 20 6770.26 24000.00 16240.04 0.2821 30 7553.52 20400.00 15710.03 0.3703
Analysis of Load Case 14 : IP+WF+CW
From Tensile All. Tens. Comp. All. Comp. Tens. Comp. Node Stress Stress Stress Stress Ratio Ratio 10 7567.58 20400.00 15710.03 0.3710 20 6786.55 24000.00 16240.04 0.2828 20 6751.60 24000.00 16240.04 0.2813 30 7559.44 20400.00 15710.03 0.3706
Analysis of Load Case 15 : IP+VO+OW
From Tensile All. Tens. Comp. All. Comp. Tens. Comp. Node Stress Stress Stress Stress Ratio Ratio 10 7567.58 20400.00 15710.03 0.3710
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR Rev : A Page : 52 of 183 20 6846.73 24000.00 16240.04 0.2853 20 6770.26 24000.00 16240.04 0.2821 30 7553.52 20400.00 15710.03 0.3703
Analysis of Load Case 16 : IP+VE+EW
From Tensile All. Tens. Comp. All. Comp. Tens. Comp. Node Stress Stress Stress Stress Ratio Ratio 10 7567.58 20400.00 15710.03 0.3710 20 6846.73 24000.00 16240.04 0.2853 20 6770.26 24000.00 16240.04 0.2821 30 7553.52 20400.00 15710.03 0.3703
Analysis of Load Case 17 : NP+VO+OW
From Tensile All. Tens. Comp. All. Comp. Tens. Comp. Node Stress Stress Stress Stress Ratio Ratio 10 0.00 20400.00 0.00 15710.03 0.0000 0.0000 20 66.36 24000.00 -45.91 16240.04 0.0028 0.0028 20 24000.00 -84.95 16240.04 0.0052 30 20400.00 -14.05 15710.03 0.0009
Analysis of Load Case 18 : FS+BS+IP+OW
From Tensile All. Tens. Comp. All. Comp. Tens. Comp. Node Stress Stress Stress Stress Ratio Ratio 10 7564.61 20400.00 15710.03 0.3708 20 6830.44 24000.00 16240.04 0.2846 20 6782.62 24000.00 16240.04 0.2826 30 7557.18 20400.00 15710.03 0.3704
Analysis of Load Case 19 : FS+BS+EP+OW
From Tensile All. Tens. Comp. All. Comp. Tens. Comp. Node Stress Stress Stress Stress Ratio Ratio 10 20400.00 -10.68 15710.03 0.0007
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR Rev : A Page : 53 of 183 20 43.16 24000.00 -69.11 16240.04 0.0018 0.0043 20 24000.00 -79.51 16240.04 0.0049 30 20400.00 -18.10 15710.03 0.0012
Absolute Maximum of the all of the Stress Ratio's 0.3710
Element From : 10 to : 20
Governing Load Case 7 : IP+OW+WI+FW+BW
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 54 of 183
Shop/Field Installation Options :
Note : The CG is computed from the first Element From Node
Center of Gravity of Nozzles 4.593 ft. Center of Gravity of Lugs 6.281 ft.
Center of Gravity of Bare Shell New and Cold 5.088 ft. Center of Gravity of Bare Shell Corroded 5.088 ft.
Vessel CG in the Operating Condition 4.893 ft. Vessel CG in the Fabricated (Shop/Empty) Condition 4.941 ft. Vessel CG in the Test Condition 5.039 ft.
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 55 of 183
Support Lug Calculations: Operating Case
INPUT ECHO OF SUPPORT LUG INPUT
Type of Geometry : Gussets with Top Plate Number of Support Lugs Nlug 4
Distance from Vessel OD to Lug Contact Point Dlug 5.1181 in. Lug Support Force Bearing Width Wfb 0.7500 in. Lug Material SA-516 70
Lug Yield Stress 35160.00 psi
Radial Width of bottom Support Lug Plate Wpl 5.9055 in. Effective Force Bearing Length Lpl 4.7244 in. Thickness of bottom Support Lug Plate Tpl 0.3937 in. Distance between Gussets Dgp 2.5000 in. Mean Width of Gusset Plate Wgp 5.5000 in. Height of Gusset Plate Hgp 5.0000 in. Thickness of Gusset Plate Tgp 0.3937 in. Radial Width of Top Bar Plate Wtp 3.5433 in. Thickness of Top Plate Ttp 0.3937 in.
Bolt Material SA-193 B7
Bolt Allowable Stress at Design Temperature 25000.00 psi Thread Series TEMA
Bolt Diameter 0.00 in.
Results for Support Lugs: Description: SUPPPORT
Overturning Moment at Support Lug 1166. ft.lb. Weight Load at the top of one Lug 743. lb.
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 56 of 183
= ( W/Nlug + Mlug/( Rlug * Nlug/2 ) ) = ( 2971/4 + 1166/( 1.93 * 4/2 )) = 1044.96 lb.
Top Bar Plate Stress per Bednar p.154 [Stpl]: = 0.75*( Flug*Dlug*Lpl )/( Ttp*Wtp²*Hgp )
= 0.75*( 1045 *5.118 *4.724 )/( 0.3937 *3.543²*5.000 ) = 766.77 psi
Required Thickness of Top Plate 0.0625 in.
Bearing Area [Ba]: = Lpl * Wfb = 4.724 * 0.750 = 3.54 in²
Bending Stress in bottom Plate (Unif. Load) Per Bednar p.156 [Spl2]: = Beta1 * Flug/Ba * Wfb² / Tpl² per Roark & Young 5th Ed.
= 2.105 * 1045.0/3.543 * 0.750²/0.394² = 2252.85 psi
Bottom Plate Required Thickness (Uniform Load) 0.1221 in.
Bottom Plate Required Thickness based on ADM S 3/4 [trAD]: = 0.71 * Dgp * (( Flug / ( Lpl * Wfb ))/Spa )½
= 0.71*2.50*((1045/(4.72*0.75))/23440.000)½ = 0.199 in.
Note: If using the AD Code recommendations, the force bearing width (Wfb) must be greater than or equal to 1/3 of the bottom plate radial width (Wpl)
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 57 of 183
Bottom Support Plate Allowable Stress [Spa]: = 2/3 * Ylug
= 2/3 * 35160 = 23440.00 psi
Gusset Plate Axial Stress ( Force / Gusset Plate Area ) [Sgp]: = ( Flug/2 )/( Wgp * Tgp )
= ( 1045/2 )/( 5.500 *0.3937 ) = 241.29 psi
Required Thickness of Gussets per AISC 0.0644 in.
Gusset Plate Allowable Stress [Sga]:
= ( 1-(Klr)²/(2*Cc²))*Fy /( 5/3+3*(Klr)/(8*Cc)-(Klr³)/(8*Cc³) = ( 1-( 50.80 )²/(2 * 127.36² )) * 35160/
( 5/3+3*(50.80 )/(8* 127.36 )-( 50.80³)/(8*127.36³) = 17896.85 psi
Maximum Compressive Gusset Plate Stress per Bednar [SgpB]: = Flug*( 3*Dlug-Wpl )/( Tgp* Wpl² * (Sin(Alph_G))² )
= 1045 *( 3*5.118 -5.906 )/( 0.3937 *5.906²*(Sin(80.79 ))² ) = 738.03 psi
Gusset Plate Allowable Compressive Stress [SgaB]: = 18000/(1+(1/18000)*( Hgp/Sin(Alph_G)/(0.289*Tgp))² ) = 18000/(1+(1/18000)* (5.000/Sin(80.79 )/(0.289*0.3937 ))² ) = 16214.64 psi
Note :
There was no uplift. Please choose an appropriate bolt size for this support design.
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 58 of 183
Date : Jan 08, 2016 Mechanical Calculation INTER CONDENSOR
Rev : A Page : 59 of 183
Support Lug Calculations: Test Case
INPUT ECHO OF SUPPORT LUG INPUT
Type of Geometry : Gussets with Top Plate Number of Support Lugs Nlug 4
Distance from Vessel OD to Lug Contact Point Dlug 5.1181 in. Lug Support Force Bearing Width Wfb 0.7500 in. Lug Material SA-516 70
Lug Yield Stress 38000.00 psi
Radial Width of bottom Support Lug Plate Wpl 5.9055 in. Effective Force Bearing Length Lpl 4.7244 in. Thickness of bottom Support Lug Plate Tpl 0.3937 in. Distance between Gussets Dgp 2.5000 in. Mean Width of Gusset Plate Wgp 5.5000 in. Height of Gusset Plate Hgp 5.0000 in. Thickness of Gusset Plate Tgp 0.3937 in. Radial Width of Top Bar Plate Wtp 3.5433 in. Thickness of Top Plate Ttp 0.3937 in.
Bolt Material SA-193 B7
Bolt Allowable Stress at Design Temperature 25000.00 psi Thread Series TEMA
Bolt Diameter 0.00 in.
Results for Support Lugs: Description: SUPPPORT
Overturning Moment at Support Lug 98. ft.lb. Weight Load at the top of one Lug 1782. lb.
