Pressure Vessel Design

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CademPVD

by CADEM Softwares

Most value for money software for the mechanical design of process equipment Trial version available on our website www.cadem.in

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For instance, in case of say a body flange, the software automatically evaluates optimum configuration of all undefined parameters: Flange OD, Flange ID, PCD, Number and Size of bolts, Gasket OD & ID, etc. meeting the requirements of the specified equipment design code.

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

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EXAMPLE NO. PV-01

DESIGN

OF

PRESSURE VESSEL (GAS FILTER)

NOTE:

1) Link to youtube video of this design:

http://www.youtube.com/watch?v=3Y0yrt1Z6fI&list=PLPL8SPZUxm-mFqQZceyhr13QYDEruelJx

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

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

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

meeting the requirements of specified equipment design code.

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

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

automatically regenerated by the software to meet the new requirements.

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

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

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

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

lifting lug.

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

Index

Licensee : Sunay Wagle, CADEM Services, _{Pune, India}

Customer ABC Company Ltd.

Project / Equipment Soap Plant / Gas Filter

Designed By / Revision and Date / R00 , 30-03-2015 23:35:19

Sr. No. Description Page No

1 Title page & equipment info 2 Design data

3 Material of constructions 4 Effective Pressures 5 Weight summary report

6 Test pressure calculations (shell side) 7 Wind load calculations

8 Seismic load calculations 9 Design of Cover (Front) 10 Design of Cover (Front) 11 Design of Shell Flng (Front) 12 Design of Shell Flng (Front) 13 Design of Main Shell 14 Design of Dished End (Rear) 15 Design of Lug Support 16 Design of Lug Support 17 Design of N 01 18 Design of N 01 19 Design of N 01 20 Design of N 02 21 Design of N 02 22 Design of N 02 23 Design of N 03 24 Design of N 03 25 Design of Lifting Lugs 26 Foundation load data 27 C.G. Data

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EQUIPMENT INFORMATION :

DESIGN & REVIEWAL :

INSPECTION & APPROVAL :

EQUIPMENT DATA :

OTHER DATA :

Project Soap Plant

Location Vapi Site

Plant Refrigeration Plant

Design Code ASME VIII Div.1, 10 A11

Equipment Name Gas Filter

Equipment Type Pressure Vessel

Equipment Class N.A.

Equipment Category N.A.

Reference Drawing No

---Service Compressed Gas Services

Support Type Lug Supports

Designed By Design Date 30-03-2015 23:35:19 Checked By Approved By Revision R00 Inspection Agency ---Reviewed By

---Front end Flat End

Front end flanged True

Rear end Dished End

Rear end flanged False

Shell ID 1250 mm

Shell OD 1270 mm

Length, Shell (W.L. to W.L) / Overall 1650 / 2254.6 mm

Fabricated weight 1898.3 kgf

Empty weight + external weights 1898.3 kgf

Estimated operating weight 1926.8 kgf

(5)

(1) PROCESS DETAILS :

(3) TEST PR. : kgf/mm² g

(4) TEMPERATURE : °C

(5) ALLOWANCES : mm

(6) RADIOGRAPHY & JOINT EFFICIENCY :

VESSEL DESIGN DATA

MEDIA DENSITY

kg/m³ Operating Process Gas 10

Design1 Process Gas 12

Design2 Startup Shutdown Upset

Hydrotest Water 1000

Pneumatic Process Gas 1.2

(2) PR. : kgf/mm² g INT. EXT. Operating 0.1 0.12 0.01055 Design1 0.12 0.12 0.01055 Design2 Startup Shutdown Upset Based on

Input Pr MAWP MAP Hydrotest 0.156 0.156 0.169 Pneumatic 0.132 0.132 0.143 MIN. MAX. Input MDMT Operating 20 -14.28 100 Design1 20 -11.75 150 Design2 Startup Shutdown Upset Hydrotest 21.67 -11.57 50 Pneumatic 21.67 -11.75 50 INT. EXT. Corrosion 3 0 Polishing 0 0

RADIOGRAPHY JOINT _EFFICIENCY Shell Spot + T Joints 0.85

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VESSEL DESIGN DATA

1. MATERIAL OF CONSTRUCTION :

2. NOZZLE CONNECTIONS :

3. INSULATION & CLADDING:

Shell side

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

Shell side

Nozzle neck <= NPS 40 SA-106 GR. B Smls. Pipe_[UNS:K03006] Flange SA-105 Frg. [UNS:K03504] Cover flange SA-105 Frg. [UNS:K03504] Nozzle NPS > 40 & < 200 SA-106 GR. B Smls. Pipe _[UNS:K03006] Flange SA-105 Frg. [UNS:K03504] Cover flange SA-105 Frg. [UNS:K03504] Nozzle neck >= NPS 200 SA-516 GR. 70 Plt. [UNS:K02700] Flange SA-516 GR. 70 Plt. [UNS:K02700] Cover flange SA-516 GR. 70 Plt. [UNS:K02700] Pad flange SA-516 GR. 70 Plt. [UNS:K02700] Pad flange cover SA-516 GR. 70 Plt. [UNS:K02700] Manhole flange SA-516 GR. 70 Plt. [UNS:K02700] Manhole cover SA-516 GR. 70 Plt. [UNS:K02700] Reinforcement pad SA-516 GR. 70 Plt. [UNS:K02700] External bolt SA-193 GR. B7 Bolt [UNS:G41400] External gasket Spiral metal wound CAF filled (S.S.) Stiffener SA-516 GR. 70 Plt. [UNS:K02700] Lifting lug IS-2062 GR. A Plt.

Support IS-2062 GR. A Plt. Anchor bolt Commercial CS Bolt

Mat. / Density / Thk. Rockwool (Mineral Fibre) / 136.2 kg/m³ / 25 mm Mat. / Thk. Al. sheet / 1.191 mm

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SUMMARY OF EFFECTIVE DESIGN PRESSURES IN kgf/mm² g VS TEMPERATURE IN °C

Sr. Item name Temp. Inside pr. Liquid pr. Effective pr.

No. +ve -ve +ve -ve

1 Cover (Front) 150 0.12 0.01055 0 0.12 0.01055

2 Shell Flng (Front) 150 0.12 0.01055 0 0.12 0.01055

3 Main Shell 150 0.12 0.01055 0 0.12 0.01055

4 Dished End (Rear) 150 0.12 0.01055 0 0.12 0.01055

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ITEM WISE WEIGHT SUMMARY

Designed By / Revision and Date / R00 , 30-03-2015 23:35:19 Sr.No. Item name Item size Empty _wt Volume Filled wt

kgf m³ kgf 1 Cover (Front) Blind Flange - 1420 OD x 73.411 Thk, RF, 1363 PCD,

Tgrv = 1.588 900.5 0 900.5 2 Shell Flng (Front) Fabricated WN - 1420 OD x 1250 ID x 1363 PCD, RF, 128.692 Thk, Trgv = 1.588, G1 = 20, G0 = 10, hf = 30 312.3 0 312.3

3 Gasket Flng (Front) 1313.5 OD x 1250 ID, 4.763 _Thk 0.1 0 0.1 4 Bolt Flng (Front) Hex Head Bolt M24 x 243.128 _{Lg, 56 Nos.} 48.76 0 48.76 5 Main Shell 1270 OD x 10 Thk, 1650 Lg 517.1 2.025 541.4 6 Dished End (Rear)

Elliptical D/2H = 2.0, 1270 OD x 10 Nom / 9 Min Thk, SF =

50 181.7 0.317 185.5

7 Gusset Plate 200 Long x 190 Wide x 16 _{Thk, 8 Nos.} 38.51 0 38.51 8 Anchor Bolt Anchor M20 x 200 Lg, 4 Nos. 1.99 0 1.99 9 Support Pad 270 Long x 292 Wide x 10 _{Thk, 4 Nos.} 24.97 0 24.97 10 N 01 ANSIB36.10, 150 NPS Sch.80, _{156 Lg} 6.697 0.00262 6.728 11 Flange [N 01] Weld Neck, ANSI B16.5, RF, _{150# for 150 NPS Sch 80 Pipe} 8.08 0 8.08 12 Gasket [N 01] 166.329 OD x 146.329 ID, _{4.763 Thk} 0.1 0 0.1 13 Bolt [N 01] Hex Head Bolt M20 x 86.125 _{Lg, 8 Nos.} 1.714 0 1.714 14 Counter Flng [N 01] Weld Neck, ANSI B16.5, RF, _{150# for 150 NPS Sch 80 Pipe} 8.08 0 8.08 15 Reinf [N 01] 292.659 OD x 171.275 ID x 10_Thk 3.501 0 3.501 16 N 02 ANSIB36.10, 150 NPS Sch.80, _{156 Lg} 6.697 0.00262 6.728 17 Flange [N 02] Weld Neck, ANSI B16.5, RF, _{150# for 150 NPS Sch 80 Pipe} 8.08 0 8.08 18 Gasket [N 02] 166.329 OD x 146.329 ID, _{4.763 Thk} 0.1 0 0.1 19 Bolt [N 02] Hex Head Bolt M20 x 86.125 _{Lg, 8 Nos.} 1.714 0 1.714 20 Counter Flng [N 02] Weld Neck, ANSI B16.5, RF, _{150# for 150 NPS Sch 80 Pipe} 8.08 0 8.08 21 Reinf [N 02] 292.659 OD x 171.275 ID x 10_Thk 3.501 0 3.501 22 N 03 ANSIB36.10, 50 NPS Sch.160, _{150 Lg} 1.682 0.00022 1.684 23 Flange [N 03] Weld Neck, ANSI B16.5, RF, _{150# for 50 NPS Sch 160 Pipe} 2.428 0 2.428 24 Gasket [N 03] 62.85 OD x 42.85 ID, 4.763_Thk 0.1 0 0.1 25 Bolt [N 03] Hex Head Bolt M16 x 67.725 _{Lg, 4 Nos.} 0.431 0 0.431 26 Bolted Cover [N 03] Weld Neck, ANSI B16.5, RF, _{150# for 50 160 NPS Pipe} 2.522 0 2.522

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27 Lifting Lugs 2 Nos. 1.596 0 1.596 28 Pad (Lifting Lugs) 70 Long x 170 Wide x 8 Thk, 2_Nos. 1.507 0 1.507 29 Insulation 4084.07 W x 3754.584 L, 25 _Thk 52.2 0 52.2 30 Cladding 4087.811 W x 3754.584 L, _{1.191 Thk} 5.058 0 5.058 31 32 33 34 35 ∑ 2149.7 ∑ 4439.8

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

Legend :

Test Pressure Calculations

Pressure due to hydro liquid column, [ Plh ] = Lh xrh x 1E-09 = 0.00225 kgf/mm² g Hydrotest pressure, [ Ph ] = 1.3 x Pt - Plh = 1.3 x 0.12 - 0.00225 = 0.154 kgf/mm² g

Pneumatic test pressure, [ Pn ] = 1.1 x Pt

= 1.1 x 0.12 = 0.132 kgf/mm² g

Design Temperature T 150 °C

Operating Liquid Density r 12 kg/m³

Hydrotest Liquid Density rh 1000 kg/m³

Hydrotest Liquid Column Lh 2254.6 mm

Sr.

No. Item Name

Pressure ( kgf/mm² g ) Stress Correction ( kgf/mm² ) Pt Pi Pl Pc Pe Peff Sfo Sfa Sfa_Sfo

1 Cover (Front) 0.12 0 0 0.01055 0.12 14.06 14.06 1 0.12 2 Shell Flng (Front) 0.12 0 0 0.01055 0.12 14.06 14.06 1 0.12

3 Main Shell 0.12 0 0 0.01055 0.12 14.06 14.06 1 0.12

4 Dished End (Rear) 0.12 0 0 0.01055 0.12 14.06 14.06 1 0.12 5

Min. Pr., Pt 0.12 Pi = Internal positive pressure

Pl = Pressure due to design liquid column Pe = Internal vacuum pressure

Pc = External negative pressure Peff = Pi + Pl + Pc

Sfo = Allowabe stress at design temperature Sfa = Allowable stress at ambient temperature Pt = MAX [ Peff + Pc, Pe ] x ( Sfa / Sfo )

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Vessel Inside

Legend :

CALC. OF MIN. DESIGN METAL TEMPERATURE Design Mode 1 , Corroded _Condition

CODE ASME VIII Div.1, 10 A11

Design Pressure Pi 0.12 kgf/mm² g

Design Temperature T 150 °C

Sr.

No. Item Name / Material /Group

Stress (kgf/mm²) Thickness (mm) MDMT (°C) Smt Sdt tn tg tr Tm Tc MDMT 1 Cover (Front) SA-516 GR. 70 Plt. [UNS:K02700] Curve : B 14.06 14.06 70.41 17.6 17.6 -11.98 40.56 -52.53

2 Shell Flng (Front)SA-105 Frg. [UNS:K03504] Curve : B 14.06 14.06 125.7 7 6.343 -28.89 -17.14 -11.75 3 Main Shell SA-516 GR. 70 Plt. [UNS:K02700] Curve : B 14.06 14.06 7 7 6.343 -28.89 -14.73 -14.16 4

Dished End (Rear) SA-516 GR. 70 Plt. [UNS:K02700] Curve : B 14.06 14.06 7 7 5.364 -28.89 -14.61 -14.28 5 Max, MDMT -11.75 Smt = Stress at minimum design metal temperature.

Sdt = Pressure due to design liquid column tn = Stress at design metal temperature.

tg = Nominal item thickness excluding corrosion and thinning. tr = Governing metal thickness for the item.

Tg = Required minimum thickness of the item. Tm = Minimum metal temperature for the the item. Tc = MDMT Correction

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EXTREME FIBRE ELONGATION CALCULATION

Legend :

Designed By / Revision and Date / R00 , 30-03-2015 23:35:19 Sr.

No.

Item Name MOC Rf t Eqn.

No.

e HT

mm mm %

1 Main Shell SA-516 GR. 70 Plt. [UNS:K02700] 625 10 1 0.8 False 2 Dished End (Rear) SA-516 GR. 70 Plt. [UNS:K02700] 1130 10 2 0.664 False 3

4 5

Rf = Mean radius after forming Ro = Infinity

t = Nominal thickness of the plate before forming Eqn. 1 = 50 x t / Rf x [ 1 - Rf / Ro ]

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

3. CALCULATION OF FORCES AND MOMENTS:

WIND LOAD CALCULATION

CODE Wind [IS:875, 87]

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

Equivalent diameter De 1820 mm

Overall length of equipment L 2254.6 mm

Height of C.G. of equipment Hcg 1807.5 mm

Size and height factor ( Section 5.3.2 ) K2 0.98 Effective transverse cross sectional area

= De x L A 4103343.3 mm²

Effective wind speed

= K1 x K2 x K3 x Vb Vz 57.44 m/s Wind pressure = 6E-08 x Vz 2 _Pz _{0.0002 kgf/mm²} Longitudinal force = Cf x A x Pz F 649.9 kgf Support elevation H 372.5 mm Turning moment = F x ( Hcg - H ) M 932661.5 kgf-mm

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2. CALCULATION OF FORCES AND MOMENTS:

SEISMIC LOAD CALCULATION

CODE Seismic [IS:1893, 02]

Weight of equipment Wo 1926.8 kgf

Importance factor ( Table-6 , 2002 ) I 1.5

Soil profile type Stiff Soil Profile (SD)

Foundation type RCC footings + Tie Beams

Damping factor 5

Seismic zone Zone III

Seismic zone factor ( Table-2 , 2002 ) Z 0.16 Response reduction factor ( Table-7 , 2002 ) R 2.9

Spectral accelerations coeff. ( Fig. 2 , 2002 ) Sa / g 2.5, Use max value Damping correction factor ( Table-3 , 2002 ) Cf 1

Seismic coefficient ( Clause-6.4.2 , 2002 ) = 0.5 x Z x I x Cf x ( Sa / g ) x ( 1 / R ) = 0.5 x 0.16 x 1.5 x 1 x

2.5 x ( 1 / 2.9 ) Ah 0.103

Elevation of support H 372.5 mm

Height of C.G. of equipment Hcg 1807.5 mm

Seismic base shear force = Ah x Wo

= 0.103 x 1926.8 Vb 199.3 kgf

Seismic moment of support = Vb x ( Hcg - H )

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2. COVER DATA :

3. BOLTING DATA :

4. LINER DATA :

5. GASKET DATA :

6. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b1) :

Total joint - contact surface compression load [Hp] = 2 x (  x b x G + b' x Lp ) x m x P

= 2 x (  x 9.554 x 1294.4 + 0 x 0 ) x 3 x 0.12 = 27973 kgf

Total hydrostatic end force [H] = 0.25 x  x G 2_{x P}

= 0.25 x  x 1294.4 2_{x 0.12}

= 157907.4 kgf

Minimum required bolt load for operating condition [Wm1] = Hp + H

DESIGN OF FLAT BOLTED HEAD ( INTERNAL ) Cover (Front)

Design pressure P 0.12 kgf/mm² g

Design temperature T 150 °C

Allowance CA 3 mm

Groove allowance Tg 0 mm

Radiography Spot + T Joints

Joint efficiency E 1

M.O.C. SA-516 GR. 70 Plt. [UNS:K02700]

Code allw. stress @ design temp. Sfo 14.06 kgf/mm² Code allw. stress @ atm. temp. Sfa 14.06 kgf/mm²

Young’s modulus Ey 19888.4 kgf/mm²

Self reinforced False

Flange OD A 1420 mm

Thickness provided 73.41 mm

Thickness available 70.41 mm

M.O.C. SA-193 GR. B7 Bolt [UNS:G41400]

Code allw. stress @ design temp. Sb 17.58 kgf/mm² Code allw. stress @ atm. temp. Sa 17.58 kgf/mm²

Bolt PCD PCD 1363 mm Bolt dia. db 24 mm No. of bolts nb 56 M.O.C. Liner ID mm Liner OD mm Liner thk. mm

M.O.C. Spiral metal wound CAF filled (S.S.)

Gasket seating stress y 7.031 kgf/mm²

Gasket factor m 3

Inside diameter Gi 1256 mm

Outside diameter Go 1313.5 mm

Width of gasket N 28.75 mm

Width of gasket ( as per Table 2-5.2 ) 31.75 mm Basic gasket seating width ( as per Table 2-5.2 ) b0 14.38 mm Effective gasket width ( as per Table 2-5.2 ) b 9.554 mm Dia. at load reaction ( see Table 2-5.2 ) G 1294.4 mm

Pass partition gasket width Wp 0 mm

Pass partition gasket length Lp 0 mm

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= 27973 + 157907.4 = 185880.4 kgf

Minimum required bolt load for gasket seating [Wm2] = (  x b x G + b' x Lp ) x y

= (  x 9.554 x 1294.4 + 0 x 0 ) x 7.031 = 273152.4 kgf

8. BOLT AREAS AS PER APPENDIX 2-5 (d) :

Total required cross-sectional area of bolts [Am]

= MAX [ Wm2 / Sa , Wm1 / Sb ] ... For Internal '+' Pr Design

= Wm2 / Sa ... For External Pr & Self Sealing Design = 15540.6 mm²

Actual bolt area using root diameter [Ab] = 17513.9 mm²

Flange design bolt load for the gasket seating [W]

= 0.5 x ( Am + Ab ) x Sa x 1 ... average bolt area = Ab x Sa x 1 ...full bolt area = 307837.2 kgf ( Full bolt area and margin factor of 1 )

9. CHECK FOR GASKET CRUSHING :

Minimum gasket width required [Nmin] = Ab x Sb / ( 2 x  x y x G )

= 17513.9 x 17.58 / ( 2 x x 7.031 x 1294.4 ) = 5.384 mm

10. DESIGN CALCULATION AS PER UG 34, BOLTING CONDITION :

Required thickness for bolting condition [t]

= G x SQRT [ 1.9 x W x 0.5 x ( PCD - G ) / ( Sfa x E x G 3_{) ]}

= 1294.4 x SQRT [ 1.9 x 307837.2 x 0.5 x ( 1363 - 1294.4 ) / ( 14.06 x 1 x 1294.4 3_{) ]}

= 33.2 mm

11. DESIGN CALCULATION AS PER UG 34, OPERATING CONDITION :

Required thickness for operating condition [t]

= G x SQRT { [ C x P / ( Sfo x E ) ] + 1.9 x Wm1 x 0.5 x ( PCD - G ) / ( Sfo x E x G 3_{) }}

= 1294.4 x SQRT { [ 0.3 x 0.12 / ( 14.06 x 1 ) ] + 1.9 x 185880.4 x 0.5 x ( 1363 - 1294.4 ) / ( 14.06 x 1 x 1294.4 3_{) }}

= 70.65 mm

Factor C is user input False

Factor C taken from fig. UG 34 or user input 0.3

Maximum factor C value C 0.75

Factor C (effective) 0.3

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

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2. COVER DATA :

4. LINER DATA :

5. GASKET DATA :

Total joint - contact surface compression load [Hp] = 2 x (  x b x G + b' x Lp ) x m x P

= 2 x (  x 9.554 x 1294.4 + 0 x 0 ) x 3 x 0.01055 = 2458.4 kgf

Total hydrostatic end force [H] = 0.25 x  x G 2_{x P}

= 0.25 x  x 1294.4 2_{x 0.01055}

= 13877.8 kgf

Minimum required bolt load for operating condition [Wm1] = Hp + H

DESIGN OF FLAT BOLTED HEAD ( EXTERNAL ) Cover (Front)

Allowance CA 3 mm

M.O.C. SA-516 GR. 70 Plt. [UNS:K02700]

Young’s modulus Ey 19888.4 kgf/mm²

Flange OD A 1420 mm

Bolt PCD PCD 1363 mm Bolt dia. db 24 mm No. of bolts nb 56 M.O.C. Liner ID mm Liner OD mm Liner thk. mm

Gasket seating stress y 7.031 kgf/mm²

Gasket factor m 3

Width of gasket N 28.75 mm

Width of gasket ( as per Table 2-5.2 ) 31.75 mm Basic gasket seating width ( as per Table 2-5.2 ) b0 14.38 mm Effective gasket width ( as per Table 2-5.2 ) b 9.554 mm Dia. at load reaction ( see Table 2-5.2 ) G 1294.4 mm

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= 2458.4 + 13877.8 = 16336.3 kgf

Minimum required bolt load for gasket seating [Wm2] = ( p x b x G + b' x Lp ) x y

= ( p x 9.554 x 1294.4 + 0 x 0 ) x 7.031 = 273152.4 kgf

8. BOLT AREAS AS PER APPENDIX 2-5 (d) :

9. CHECK FOR GASKET CRUSHING :

Minimum gasket width required [Nmin] = Ab x Sb / ( 2 x p x y x G )

= 17513.9 x 17.58 / ( 2 xp x 7.031 x 1294.4 ) = 5.384 mm

10. DESIGN CALCULATION AS PER UG 34, BOLTING CONDITION :

Required thickness for bolting condition [t]

= G x SQRT [ 1.9 x W x 0.5 x ( PCD - G ) / ( Sfa x E x G 3_{) ]}

= 1294.4 x SQRT [ 1.9 x 307837.2 x 0.5 x ( 1363 - 1294.4 ) / ( 14.06 x 1 x 1294.4 3_{) ]}

= 33.2 mm

11. DESIGN CALCULATION AS PER UG 34, OPERATING CONDITION :

Required thickness for operating condition [t]

= G x SQRT { [ C x P / ( Sfo x E ) ] + 1.9 x Wm1 x 0.5 x ( PCD - G ) / ( Sfo x E x G 3_{) }}

= 1294.4 x SQRT { [ 0.3 x 0.01055 / ( 14.06 x 1 ) ] + 1.9 x 16336.3 x 0.5 x ( 1363 - 1294.4 ) / ( 14.06 x 1 x 1294.4 3_{) }}

= 32.29 mm

Factor C is user input False

Factor C taken from fig. UG 34 or user input 0.3

Maximum factor C value C 0.75

Factor C (effective) 0.3

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

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2. FLANGE DATA :

4. LINER DATA :

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

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

FLANGE DESIGN ( INTERNAL ) Shell Flng (Front)

Allowance CA 3 mm

M.O.C. SA-105 Frg. [UNS:K03504]

Inside diameter B 1256 mm

Outside diameter A 1420 mm

Hub length h 30 mm

Thickness ( hub end ) g1 17 mm

Thickness ( pipe end ) g0 7 mm

Bolt PCD C 1363 mm Bolt dia. db 24 mm No. of bolts nb 56 M.O.C. Liner ID mm Liner OD mm Liner thk. mm

Gasket type Ring Gasket

Gasket confinement type Unconfined

Flange face type Raised Face

Flange gakset surface finish Serrated (Normal)

Counter flange face type Raised Face

Counter gakset surface finish Serrated (Normal) Applicalbe gasket sketch in Table 2-5.2 Type 1B

Applicable gasket column in Table 2-5.2 1

Gasket seating stress ( refer to Note 1, Table 2-5.1 ) y 7.031 kgf/mm² Gasket factor ( from Table 2-5.1 ) m 3

Width of gasket ( as per Table 2-5.2 ) N 28.75 mm Width of gasket ( as per Table 2-5.2 ) w 28.75 mm Width of raised face or gasket contact width 31.75 mm

( as per Table 2-5.2 )

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

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--6. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b1)

Total joint - contact surface compression load [Hp] = 2 x ( p x b x G x m + b' x Lp x m' ) x P

= 2 x ( p x 9.554 x 1294.4 x 3 + 0 x 0 x 0 ) x 0.12 = 27973 kgf

Total hydrostatic end force [H] = 0.25 x p x G ² x P

= 0.25 x p x 1294.4 ² x 0.12 = 157907.4 kgf

Minimum required bolt load for operating condition [Wm1a] = Hp + H

= 27973 + 157907.4 = 185880.4 kgf

Minimum required bolt load for operating condition [Wm1b] ( from mating flange )

= 185880.4 kgf

Governing bolt load for operating condition [Wm1] = MAX [ Wm1a , Wm1b ]

= MAX [ 185880.4 , 185880.4 ] = 185880.4 kgf

7. BOLT LOAD CALCULATION AS PER APPENDIX 2-5 (b2)

Minimum required bolt load for gasket seating [Wm2] = (p x b x G x y + b' x Lp x y' )

= ( p x 9.554 x 1294.4 x 7.031 + 0 x 0 x 0 ) = 273152.4 kgf

8. BOLT AREAS AS PER APPENDIX 2-5 (d)

9. CHECK FOR GASKET CRUSHING

= 17513.9 x 17.58 / ( 2 xp x 7.031 x 1294.4 ) = 5.384 mm

10. BOLT SPACING CORRECTION FACTOR

As per Brownell & Young or IS 2825, = SQRT [ Bolt spacing / ( 2 x db + t ) ] As per TEMA or BS 5500,

= SQRT [ Bolt spacing / Bmax ] ... where,

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

11. LOADS AND FORCES DURING OPERATING CONDITION AS PER APPENDIX 2-3

Hydrostatic end force on area inside of flange [HD] = 0.25 x p x B2_{x P}

= 0.25 x p x 12562_{x 0.12}

= 148679.3 kgf

Gasket load (difference between flange design bolt load and total hydrostatic end force) [HG] = Wm1 - H

= 185880.4 - 157907.4 = 27973 kgf

Difference between total hydrostatic end force and hydrostatic end force on area inside of flange [HT] = H - HD

= 157907.4 - 148679.3 = 9228.2 kgf

12. MOMENT ARMS FOR FLANGE LOADS AS PER TABLE 2-6

Radial distance from the bolt circle to intersection of hub and back of flange, as per Appendix 2-3 [R] = 0.5 x ( C - B ) - g1

= 0.5 x ( 1363 - 1256 ) - 17

Gasket seating stress ( refer to Note 1, Table 2-5.1 ) y' 0 kgf/mm² Gasket factor ( from Table 2-5.1 ) m' 0

Effective pass partition gasket width b' 0 mm

(21)

= 36.5 mm

Radial distance from the bolt circle to the circle on which HD acts [hD] = R + 0.5 x g1

= 36.5 + 0.5 x 17 = 45 mm

Radial distance from gasket load reaction to the bolt circle [hG] = 0.5 x ( C - G )

= 0.5 x ( 1363 - 1294.4 ) = 34.3 mm

Radial distance from the bolt circle to the circle on which HT acts [hT] = 0.5 x ( R + g1 + hG )

= 0.5 x ( 36.5 + 17 + 34.3 ) = 43.9 mm

13. FLANGE MOMENTS UNDER OPERATING CONDITION AS PER APPENDIX 2-6

Component of moment due to HD [MD] = HD x hD

= 148679.3 x 45 = 6690566.9 kgf-mm

Component of moment due to HG [MG] = HG x hG

= 27973 x 34.3 = 959588.9 kgf-mm

Component of moment due to HT [MT] = HT x hT

= 9228.2 x 43.9 = 405136.1 kgf-mm

Total moment acting on the flange for operating condition [MO] = MD + MG + MT

= 6690566.9 + 959588.9 + 405136.1 = 8055291.9 kgf-mm

14. LOADS AND FORCES DURING GASKET SEATING AS PER APPENDIX 2-3

Gasket load for seating condition [HG] = W

= 307837.2 kgf

15. MOMENT UNDER GASKET SEATING AS PER APPENDIX 2-6

Total moment acting on the flange for gasket seating [MO'] = W x hG

= 307837.2 x 34.3 = 10560086 kgf-mm

16. SHAPE CONSTANTS

17. STRESS FORMULA FACTORS

Assumed thickness [t] = 108.7 mm Factor [a] = t x e + 1 = 108.7 x 0.00922 + 1 = 2.002 Factor [b] = 1.333 x t x e + 1 = 1.333 x 108.7 x 0.00922 + 1 = 2.336 Factor [g] = a / T = 2.002 / 1.866 = 1.073 Factor [d] = t 3_{/ d} A / B K 1.131

Flange factors from Fig. 2-7.1 T 1.866

Z 8.189 Y 15.84 U 17.41

h0 93.77

F / h0 e 0.00922

Factor from Fig. 2-7.2 F 0.864

Factor from Fig. 2-7.3 V 0.261

g1 / g0 2.429

h / h0 0.32

( U / V ) x h0 x g0 2 _d _306079.1

(22)

= 108.73_{/ 306079.1} = 4.195 Factor [l] = g + d = 1.073 + 4.195 = 5.268

18. FLANGE STRESSES AS PER APPENDIX 2-7 & 2-8

Equivalent moment [Mmax] = MAX [ MO , MO' x Sfo / Sfa ]

= MAX [ 8055291.9 , 10560086 x 14.06 / 14.06 ] = 10560086 kgf-mm

Corrected equivalent moment per unit length [M] = Mmax x ( Cf / B )

= 10560086 x ( 1 / 1256 ) = 8407.7 kgf

Longitudinal hub stress [SH] = f x M / ( l x g1 2₎

= 2.935 x 8407.7 / ( 5.268 x 172₎

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

= 2.336 x 8407.7 / ( 5.268 x 108.7 2₎

Tangential flange stress [ST] = ( M x Y / t 2_{) - Z x SR}

= ( 8407.7 x 15.84 / 108.7 2_{) - 8.189 x 0.316}

Average stress

= MAX [ 0.5 x ( SH + SR ) , 0.5 x ( SH + ST ) ]

= MAX [ 0.5 x ( 16.21 + 0.316 ) , 0.5 x ( 16.21 + 8.69 ) ]

19. FLANGE RIGIDITY CHECKING AS PER APPENDIX 2-14

Rigidity index [J]

= 52.14 x V x Mmax / ( l x Efo x g02_{x KI x h0 )}

= 52.14 x 0.261 x 10560086 / ( 5.268 x 19888.4 x 7 2_{x 0.3 x 93.77 )}

= 0.996

Since J < 1.0, design is safe

= 16.21 kgf/mm² ... < 1.5 x Sfo

= 0.316 kgf/mm² ... < Sfo

= 8.69 kgf/mm² ... < Sfo

= 12.45 kgf/mm² ... < Sfo

Modulus of elasticity for flange Efo 19888.4 kgf/mm²

(23)

2. FLANGE DATA :

4. LINER DATA :

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

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

FLANGE DESIGN ( EXTERNAL ) Shell Flng (Front)

Allowance CA 3 mm

M.O.C. SA-105 Frg. [UNS:K03504]

Inside diameter B 1256 mm

Outside diameter A 1420 mm

Hub length h 30 mm

Thickness ( hub end ) g1 17 mm

Thickness ( pipe end ) g0 7 mm

Bolt PCD C 1363 mm Bolt dia. db 24 mm No. of bolts nb 56 M.O.C. Liner ID mm Liner OD mm Liner thk. mm

Gasket type Ring Gasket

Gasket confinement type Unconfined

Flange face type Raised Face

Flange gakset surface finish Serrated (Normal)

Counter flange face type Raised Face

Counter gakset surface finish Serrated (Normal) Applicalbe gasket sketch in Table 2-5.2 Type 1B

Applicable gasket column in Table 2-5.2 1

Gasket seating stress ( refer to Note 1, Table 2-5.1 ) y 7.031 kgf/mm² Gasket factor ( from Table 2-5.1 ) m 3

Width of gasket ( as per Table 2-5.2 ) N 28.75 mm Width of gasket ( as per Table 2-5.2 ) w 28.75 mm Width of raised face or gasket contact width 31.75 mm

( as per Table 2-5.2 )

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

(24)

--6. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b1)

Total joint - contact surface compression load [Hp] = 2 x ( p x b x G x m + b' x Lp x m' ) x P

= 2 x ( p x 9.554 x 1294.4 x 3 + 0 x 0 x 0 ) x 0.01055 = 2458.4 kgf

Total hydrostatic end force [H] = 0.25 x p x G ² x P

= 0.25 x p x 1294.4 ² x 0.01055 = 13877.8 kgf

Minimum required bolt load for operating condition [Wm1a] = Hp + H

= 2458.4 + 13877.8 = 16336.3 kgf

Minimum required bolt load for operating condition [Wm1b] ( from mating flange )

= 16336.3 kgf

Governing bolt load for operating condition [Wm1] = MAX [ Wm1a , Wm1b ]

= MAX [ 16336.3 , 16336.3 ] = 16336.3 kgf

7. BOLT LOAD CALCULATION AS PER APPENDIX 2-5 (b2)

Minimum required bolt load for gasket seating [Wm2] = (p x b x G x y + b' x Lp x y' )

= ( p x 9.554 x 1294.4 x 7.031 + 0 x 0 x 0 ) = 273152.4 kgf

8. BOLT AREAS AS PER APPENDIX 2-5 (d)

9. CHECK FOR GASKET CRUSHING

= 17513.9 x 17.58 / ( 2 xp x 7.031 x 1294.4 ) = 5.384 mm

10. BOLT SPACING CORRECTION FACTOR

As per Brownell & Young or IS 2825, = SQRT [ Bolt spacing / ( 2 x db + t ) ] As per TEMA or BS 5500,

= SQRT [ Bolt spacing / Bmax ] ... where,

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

11. LOADS AND FORCES DURING OPERATING CONDITION AS PER APPENDIX 2-3

Hydrostatic end force on area inside of flange [HD] = 0.25 x p x B2_{x P}

= 0.25 x p x 1256 2_{x 0.01055}

= 13066.8 kgf

Difference between total hydrostatic end force and hydrostatic end force on area inside of flange [HT] = H - HD

= 13877.8 - 13066.8 = 811 kgf

12. MOMENT ARMS FOR FLANGE LOADS AS PER APPENDIX TABLE 2-6

Radial distance from the bolt circle to intersection of hub and back of flange, as per Appendix 2-3 [R] = 0.5 x ( C - B ) - g1

= 0.5 x ( 1363 - 1256 ) - 17 = 36.5 mm

Radial distance from the bolt circle to the circle on which HD acts [hD] = R + 0.5 x g1

= 36.5 + 0.5 x 17

Gasket seating stress ( refer to Note 1, Table 2-5.1 ) y' 0 kgf/mm² Gasket factor ( from Table 2-5.1 ) m' 0

Effective pass partition gasket width b' 0 mm

(25)

= 45 mm

Radial distance from gasket load reaction to the bolt circle [hG] = 0.5 x ( C - G )

= 0.5 x ( 1363 - 1294.4 ) = 34.3 mm

Radial distance from the bolt circle to the circle on which HT acts [hT] = 0.5 x ( R + g1 + hG )

= 0.5 x ( 36.5 + 17 + 34.3 ) = 43.9 mm

13. FLANGE MOMENTS UNDER OPERATING CONDITION AS PER APPENDIX 2-6

Component of moment due to HD [MD] = HD x ( hD - hG )

= 13066.8 x ( 45 - 34.3 ) = 139760.9 kgf-mm

Component of moment due to HT [MT] = HT x ( hT - hG )

= 811 x ( 43.9 - 34.3 ) = 7784.2 kgf-mm

Total moment acting on the flange for operating condition [MO] = MD + MT

= 139760.9 + 7784.2 = 147545.1 kgf-mm

14. LOADS AND FORCES DURING GASKET SEATING AS PER APPENDIX 2-3

Gasket load for seating condition [HG] = W

= 307837.2 kgf

15. MOMENT UNDER GASKET SEATING AS PER APPENDIX 2-6

Total moment acting on the flange for gasket seating [MO'] = W x hG

= 307837.2 x 34.3 = 10560086 kgf-mm

16. SHAPE CONSTANTS

17. STRESS FORMULA FACTORS

Assumed thickness [t] = 108.9 mm Factor [a] = t x e + 1 = 108.9 x 0.00922 + 1 = 2.004 Factor [b] = 1.333 x t x e + 1 = 1.333 x 108.9 x 0.00922 + 1 = 2.338 Factor [g] = a / T = 2.004 / 1.866 = 1.074 Factor [d] = t 3_{/ d} = 108.93_{/ 306079.1} = 4.217 Factor [l] = g + d = 1.074 + 4.217 = 5.29

18. FLANGE STRESSES AS PER APPENDIX 2-7 & 2-8

Equivalent moment [Mmax]

A / B K 1.131

Flange factors from Fig. 2-7.1 T 1.866

Z 8.189 Y 15.84 U 17.41

h0 93.77

F / h0 e 0.00922

Factor from Fig. 2-7.2 F 0.864

Factor from Fig. 2-7.3 V 0.261

g1 / g0 2.429

h / h0 0.32

( U / V ) x h0 x g0 2 _d _306079.1

(26)

= MAX [ MO , MO' x Sfo / Sfa ]

= MAX [ 147545.1 , 10560086 x 14.06 / 14.06 ] = 10560086 kgf-mm

Corrected equivalent moment per unit length [M] = Mmax x ( Cf / B )

= 10560086 x ( 1 / 1256 ) = 8407.7 kgf

Longitudinal hub stress [SH] = f x M / ( l x g1 2₎

= 2.935 x 8407.7 / ( 5.29 x 172₎

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

= 2.004 x 8407.7 / ( 5.29 x 108.9 2₎

Tangential flange stress [ST] = ( M x Y / t 2_{) - Z x SR}

= ( 8407.7 x 15.84 / 108.9 2_{) - 8.189 x 0.313}

Average stress

= MAX [ 0.5 x ( SH + SR ) , 0.5 x ( SH + ST ) ]

= MAX [ 0.5 x ( 16.14 + 0.313 ) , 0.5 x ( 16.14 + 8.669 ) ]

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

Rigidity index [J]

= 52.14 x V x Mmax / ( l x Efo x g02_{x KI x h0 )}

= 52.14 x 0.261 x 10560086 / ( 5.29 x 19888.4 x 72_{x 0.3 x 93.77 )}

= 0.992

Since J < 1.0, design is safe

= 16.14 kgf/mm² ... < 1.5 x Sfo

= 0.313 kgf/mm² ... < Sfo

= 8.669 kgf/mm² ... < Sfo

= 12.4 kgf/mm² ... < Sfo

Modulus of elasticity for flange Efo 19888.4 kgf/mm²

(27)

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

2. DESIGN CALCULATION AS PER UG-27

Thickness of shell under internal pressure [ti] = Pi x R / ( S x E - 0.6 x Pi )

= 0.12 x 628 / ( 14.06 x 0.85 - 0.6 x 0.12 ) = 6.343 mm

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

Allowable external pressure [Pa] = 4 x B / ( 3 x ( OD / te ) ) = 4 x 2.272 / ( 3 x 284.4 ) = 0.01065 kgf/mm² g Since Pa > Pe, design is safe

Since available thickness is more than design thickness, design is safe.

DESIGN OF SHELL ( INTERNAL AND EXTERNAL PRESSURE ) Main Shell

Design pressure ( internal ) Pi 0.12 kgf/mm² g Design pressure ( external ) Pe 0.01055 kgf/mm² g

Material of construction SA-516 GR. 70 Plt. [UNS:K02700] Max. allowable stress at design temp. S 14.06 kgf/mm²

Joint efficiency long. seam Ec 0.85

Outside diameter OD 1270 mm

Inside radius ( corroded ) R 628 mm

Shell length L 1650 mm

Design length L1 1650 mm

Nominal thickness 10 mm

Nominal thickness required as per TEMA N.A. mm Internal allowance, corrosion + polishing 3 mm External allowance, corrosion + polishing 0 mm

Thickness undertolerance 0 mm

Available thickness 7 mm

Assumed te 4.466 mm

L1 / OD 1.299

OD / te 284.4

Factor A ( Refer to Fig. G in Subpart 3 of Sec. II, Part D ) 0.00021

(28)

2. DESIGN CALCULATION AS PER UG 32 d / APPENDIX 1-4 ( c ) :

Factor [K] = 1

Thickness for internal pressure [t] = K x Pi x ID / ( 2 x S x E - 0.2 x Pi )

= 1 x 0.12 x 1256 / ( 2 x 14.06 x 1 - 0.2 x 0.12 ) = 5.364 mm

3. DESIGN CALCULATION AS PER UG 33 d :

Thickness for equivalent external pressure [t] = K x 1.67 x Pe x ID / ( 2 x S x 1.0 - 0.2 x 1.67 x Pe )

= 1 x 1.67 x 0.01055 x 1256 / ( 2 x 14.06 x 1.0 - 0.2 x 1.67 x 0.01055 ) = 0.787 mm

Factor [Ko] = 0.77

Assumed head thickness, [te] = 2.779 mm

Factor [A]

= 0.125 x te / ( Ko x OD ) = 0.125 x 2.779 / ( 0.77 x 1270 ) = 0.00036

Factor with reference to chart (CS-2) [B] = 3.743 kgf/mm²

Allowable external pressure [Pa] = B / ( Ko x OD / te )

= 3.743 x 2.779 / ( 0.77 x 1270 ) = 0.01064 kgf/mm²

Since Pa > Pe, design is safe

Since available thickness is more than design thickness, design is safe.

DESIGN OF ELLIPSOIDAL HEAD ( INT. & EXT. PRESSURE ) Dished End (Rear)

Material of construction SA-516 GR. 70 Plt. [UNS:K02700] Max. allowable stress @ design temp. S 14.06 kgf/mm²

Radiography Full

Outside diameter of head OD 1270 mm

Inside diameter of shell ID 1256 mm

Head shape Elliptical D/2H = 2.0

Nominal thickness 10 mm

Nominal thickness required as per TEMA N.A mm Internal allowance, corrosion + polishing 3 mm External allowance, corrosion + polishing 0 mm Thinning allowance / Under tolerance 1 mm

Available thickness 6 mm

(29)

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in 1. LUG DATA : 2. BOLT DATA : 3. GUSSET DATA : 4. SHELL DATA : 5. PAD DATA :

6. LOAD AND MOMENT ( Wind ) :

7. DESIGN OF ANCHOR BOLTS :

Total uplift force on bolts [T] = [ 4 x M / ( D x N ) ] - Wt / N

= [ 4 x 940925.4 / ( 1570 x 4 ) ] - 2388.5 / 4 = 2.203 kgf

Required area of bolts [Am] = MAX [ ( T / Fs ) , 0 ] = MAX [ ( 2.203 / 20.88 ) , 0 ] = 0.106 mm²

Available area of bolts [Ab]

= Ar x Nb ... where, Ar = 217.1 mm², is root area of bolt = 217.1 x 1

= 217.1 mm²

Since Ab > Am, bolts provided are sufficient

8. GUSSET DESIGN :

Reaction force at each support [Q] = [ 4 x M / ( D x N ) ] + Wt / N

LUG SUPPORT DESIGN Lug Support

CODE P V Design Manual, D.R. Moss

Design Mode 1 , Corroded Condition

M.O.C IS-2062 GR. A Plt.

No. of support N 4

Base plate width b1 242 mm

Base plate depth Lb 200 mm

Thickness of base plate tb 16 mm

Allowable bending stress Sb 22.15 kgf/mm²

M.O.C Commercial CS Bolt

No. of bolt / lug Nb 1

Bolt diameter db 20 mm

PCD D 1570 mm

Diameter of bolt hole 24 mm

Allowable tensile stress Fs 20.88 kgf/mm²

Thickness tg 16 mm

Height h 190 mm

Gusset angle θ 51.71

Gusset depth at top Lc 50 mm

Number of gussets n 2

Distance between gussets b 200 mm

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

OD diameter OD 1270 mm

Inside diameter ID 1256 mm

Thickness available ts 7 mm

Thickness tp 10 mm

Width W 270 mm

Length L 292 mm

Max. overturning moment M 940925.4 kgf-mm

(30)

= [ 4 x 940925.4 / ( 1570 x 4 ) ] + 2388.5 / 4 = 1196.4 kgf

Maximum axial force in gusset [P1] = Q / n

= 1196.4 / 2 = 598.2 kgf

Allowable compr. stress in gusset [Sg]

= 1800 / [ ( 1 + 12 / 18000 ) x ( h’ / tg )2_{] ... where, h’ = 242.1 mm}

= 1800 / [ ( 1 + 12 / 18000 ) x ( 242.1 / 16 ) 2_]

= 15616.8 psi = 10.98 kgf/mm²

Required thickness of gusset [tg’]

= 2 x P1 x ( 3 x a - Lb ) / [ Sg x Lb 2_{x ( sin θ )}2_]

= 2 x 598.2 x ( 3 x 150 - 200 ) / [ 10.98 x ( 200 ) 2_{x ( sin 51.71 )}2_]

= 1.106 mm

9. BASE PLATE DESIGN :

Bending moment [Mb] = Q x b1 / 6 = 1196.4 x 242 / 6 = 48255.9 kgf-mm Bearing pressure [bp] = Q / ( w x b1 ) ... where, w = 120 mm = 1196.4 / ( 120 x 242 ) = 0.0412 kgf/mm²

Bending moment due to bearing pressure [Mb’] = bp x b 2_{/ 10}

= 0.0412 x 200 2_{/ 10}

= 164.8 kgf-mm

Required thickness of base plate between chairs [tb’] = SQRT { 6 x MAX [ Mb , Mb' ] / [ ( Lb - db ) x Sb ] }

= SQRT { 6 x MAX [ 48255.9 , 164.8 ] / [ ( 200 - 20 ) x 22.15 ] } = 8.619 mm

10. CHECK FOR COMPRESSION PLATE :

Equivalent radial load [f] = Q x a / h

= 1196.4 x 150 / 190 = 472.3 kgf

Angle between supports [b] = 2 x p / N

= 2 x p / 4 = 1.571 rad

Internal bending moment coefficient [Kr] = 0.5 x [ 1 / a - cot ( a ) ]

= 0.5 x [ 1 / 1.571 - cot ( 1.571 ) ] = 0.318

Internal bending moment [Mc] = 0.5 x Kr x f x OD

= 0.5 x 0.318 x 472.3 x 1270 = 95459.3 kgf-mm

Bending stress induced [fb] = Mo / Zc

= 95459.3 / 7785.1

= 12.26 kgf/mm² ... < Sb = 22.15 kgf/mm² Since, induced stress fb < allow. stress Sb in shell material, design is safe.

(31)

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in 1. LUG DATA : 2. BOLT DATA : 3. GUSSET DATA : 4. SHELL DATA : 5. PAD DATA :

6. LOAD AND MOMENT ( Seismic ) :

7. DESIGN OF ANCHOR BOLTS :

Total uplift force on bolts [T] = [ 4 x M / ( D x N ) ] - Wt / N

= [ 4 x 288590.5 / ( 1570 x 4 ) ] - 1841.2 / 4 = -276.5 kgf

Required area of bolts [Am] = MAX [ ( T / Fs ) , 0 ]

= MAX [ ( -276.5 / 20.88 ) , 0 ] = 0 mm²

Available area of bolts [Ab]

= Ar x Nb ... where, Ar = 217.1 mm², is root area of bolt = 217.1 x 1

= 217.1 mm²

Since Ab > Am, bolts provided are sufficient

8. GUSSET DESIGN :

Reaction force at each support [Q] = [ 4 x M / ( D x N ) ] + Wt / N

LUG SUPPORT DESIGN Lug Support

CODE P V Design Manual, D.R. Moss

M.O.C IS-2062 GR. A Plt.

No. of support N 4

Base plate width b1 242 mm

Base plate depth Lb 200 mm

Thickness of base plate tb 16 mm

Allowable bending stress Sb 22.15 kgf/mm²

M.O.C Commercial CS Bolt

No. of bolt / lug Nb 1

Bolt diameter db 20 mm

PCD D 1570 mm

Diameter of bolt hole 24 mm

Allowable tensile stress Fs 20.88 kgf/mm²

Thickness tg 16 mm

Height h 190 mm

Gusset angle θ 51.71

Gusset depth at top Lc 50 mm

Number of gussets n 2

Distance between gussets b 200 mm

OD diameter OD 1270 mm

Inside diameter ID 1256 mm

Thickness available ts 7 mm

Thickness tp 10 mm

Width W 270 mm

Length L 292 mm

Max. overturning moment M 288590.5 kgf-mm

(32)

= [ 4 x 288590.5 / ( 1570 x 4 ) ] + 1841.2 / 4 = 644.1 kgf

Maximum axial force in gusset [P1] = Q / n

= 644.1 / 2 = 322.1 kgf

Allowable compr. stress in gusset [Sg]

= 1800 / [ ( 1 + 12 / 18000 ) x ( h’ / tg )2_{] ... where, h’ = 242.1 mm}

= 1800 / [ ( 1 + 12 / 18000 ) x ( 242.1 / 16 ) 2_]

= 15616.8 psi = 10.98 kgf/mm²

Required thickness of gusset [tg’]

= 2 x P1 x ( 3 x a - Lb ) / [ Sg x Lb 2_{x ( sin θ )}2_]

= 2 x 322.1 x ( 3 x 150 - 200 ) / [ 10.98 x ( 200 ) 2_{x ( sin 51.71 )}2_]

= 0.595 mm

9. BASE PLATE DESIGN :

Bending moment [Mb] = Q x b1 / 6 = 644.1 x 242 / 6 = 25979.7 kgf-mm Bearing pressure [bp] = Q / ( w x b1 ) ... where, w = 120 mm = 644.1 / ( 120 x 242 ) = 0.02218 kgf/mm²

Bending moment due to bearing pressure [Mb’] = bp x b 2_{/ 10}

= 0.02218 x 200 2_{/ 10}

= 88.72 kgf-mm

Required thickness of base plate between chairs [tb’] = SQRT { 6 x MAX [ Mb , Mb' ] / [ ( Lb - db ) x Sb ] }

= SQRT { 6 x MAX [ 25979.7 , 88.72 ] / [ ( 200 - 20 ) x 22.15 ] } = 6.324 mm

10. CHECK FOR COMPRESSION PLATE :

Equivalent radial load [f] = Q x a / h

= 644.1 x 150 / 190 = 254.3 kgf

Angle between supports [b] = 2 x p / N

= 2 x p / 4 = 1.571 rad

Internal bending moment coefficient [Kr] = 0.5 x [ 1 / a - cot ( a ) ]

= 0.5 x [ 1 / 1.571 - cot ( 1.571 ) ] = 0.318

Internal bending moment [Mc] = 0.5 x Kr x f x OD

= 0.5 x 0.318 x 254.3 x 1270 = 51392.7 kgf-mm

Bending stress induced [fb] = Mo / Zc

= 51392.7 / 7785.1

= 6.601 kgf/mm² ... < Sb = 22.15 kgf/mm² Since, induced stress fb < allow. stress Sb in shell material, design is safe.

(33)

DESIGN CONDITIONS

NOZZLE DATA

SHELL DATA ( Main Shell )

WELD DATA

CALCULATION OF NOZZLE NECK THICKNESS AS PER UG 45

Neck thickness for internal pressure as per UG 45(a) Formula in Appendix 1-1 , [trn1]

= ( 0.5 x Pi x OD ) / ( Sn x E + 0.4 x Pi )

= ( 0.5 x 0.12 x 168.3 ) / ( 12.02 x 1.0 + 0.4 x 0.12 ) = 0.983 mm

Neck thickness for external pressure as per UG 45(a) Neck thickness for external pressure as per UG 28 Assumed neck thickness , [trn3] = 0.512 mm L / OD = 0.891

OD / trn3 = 328.5 Factor A = 0.00025 Factor B = 2.679 kgf/mm² Allowable external pressure , [Pa] = 4 x B / ( 3 x OD / trn3 ) = 4 x 2.679 / ( 3 x 328.5 ) = 0.01088 kgf/mm² g

Thickness of shell as per UG 45(b)(1)

Min. shell thickness reqd. as per UG 27 , [tr1 = trn2] = Pi x R / ( Sv x E - 0.6 x Pi )

= 0.12 x 628 / ( 14.06 x 1.0 - 0.6 x 0.12 ) = 5.387 mm

Thickness for equivalent pressure as per UG 45(b)(2) , [trn4] = Pe x R / ( Sv x E - 0.6 x Pe )

NOZZLE NECK THICKNESS AND REINFORCEMENT DESIGN N 01

M.O.C. SA-106 GR. B Smls. Pipe_[UNS:K03006]

Allowable stress @ design temperature Sn 12.02 kgf/mm²

Outside diameter OD 168.3 mm

Inside diameter ID 152.3 mm

Maximum chord length D 152.3 mm

Neck thickness ( provided ) tnp 10.97 mm

Internal allowance , corrosion + polishing CAI 3 mm External allowance , corrosion + polishing CAE 0 Neck thickness (tnp - CAI - CAE) tn 7.973 mm Max. under tolerance on thickness Alw 1.372 mm Available neck thickness ( tn - Alw ) ta 6.601 mm Nozzle projection outward ( from vessel outer face ) Lo 150 mm Total length of nozzle ( Lo + Addn for curvature) L 156 mm

Connection type Pipe Nozzle

Application type Process Opening

Reinforcement calculation method Isolated Opening

Design as large opening False

M.O.C. SA-516 GR. 70 Plt. [UNS:K02700]

Allowable stress @ design temperature Sv 14.06 kgf/mm²

Inside radius R 628 mm

Thickness t 7 mm

Min. thickness for external pressure tr2 4.466 mm

(34)

= 0.01055 x 628 / ( 14.06 x 1.0 - 0.6 x 0.01055 ) = 0.471 mm

Standard wall thickness as per UG 45(b)(4) , [t3] = 7.112 mm

Neck thk as per UG 45 , [trn]

= MAX { MAX [ trn1, trn3 ] , MIN [ MAX ( trn2 , trn4 ) , 0.875 x t3 ] } ... for Process Nozzle = MAX [ trn1, trn3 ] ... for Access Opening = 5.387 mm ... Process Opening Since available neck thickness, ta >= trn, selected neck thickness is adequate.

(35)

1. DESIGN CONDITION :

2. ATTACHMENT DATA :

3. EXTERNAL LOADS :

4. SHELL DATA :

5. STRESS CONCENTRATION FACTORS :

6. COMPUTING STRESSES :

LOCAL STRESS ANALYSIS (EDGE OF ATTACHMENT) N 01

CODE D.R. MOSS (EXTRACT OF WRC ₁₀₇₎

Design Mode 1, Corroded Condition

Design pressure ( internal ) Pi 0.12 kgf/mm² g

M.O.C SA-106 GR. B Smls. Pipe _[UNS:K03006]

Outside diameter OD 168.3 mm Weld size w 7 mm Pad diameter Dp 292.7 mm Pad thickness tp 10 mm 0.5 x OD C 84.14 mm Radial force Fr 344.6 kgf Long. moment ML 254724.1 kgf-mm Circ. moment Mc 254724.1 kgf-mm Torsional moment Mt 254724.1 kgf-mm

Total eff. shear load Q 487.4 kgf

M.O.C SA-516 GR. 70 Plt. [UNS:K02700]

Allowable stress Sv 14.06 kgf/mm²

Thickness of shell tv 7 mm

Mean radius of shell , [ Rm ] = R + 0.5 x ( tv + tp ) = 628 + 0.5 x ( 7 + 10 ) = 636.5 mm Thickness , [t] = SQRT [ tv 2_{+ tp}2_] = SQRT [ 7 2_{+ 10}2_] = 12.21 mm Calculate ratio , [ g ] = Rm / te = 636.5 / 12.21 = 52.14 Calculate ratio , [ b ] = 0.875 x C / Rm = 0.875 x 84.14 / 636.5 = 0.116 Factor , [ Kn ] = 1 Factor , [ Kb ] = 1 Shear stress due to Q , [ t₁ ]

= Q / ( p x Ro x t )

= 487.4 / ( p x 84.14 x 12.21 ) = 0.151 kgf/mm²

Shear stress due to Mt , [ t₂ ] = Mt / ( 2 xp x Ro 2_{x t )}

= 254724.1 / ( 2 x p x 84.14 2_{x 12.21 )}

= 0.469 kgf/mm² Total shear stress , [ t ]

= t₁ + t₂ = 0.151 + 0.469 = 0.62 kgf/mm²

STRESSES FACT FIG. FORCES( kgf ) & MOMENTS( kgf-mm ) STRESS ( kgf/mm² )

Radial load Membrane 5-17A 7.023 x Fr_Rm Nf 3.803 Kn x Nf_t σf 0.312 5-17B 8.616 x Fr_Rm Nx 4.665 Kn x Nx_t σx 0.382 Bending 5-18A 0.117 x Fr Mf 40.25 6 x Kb x Mf t 2 σf 1.621 6 x Kb x Mx

(36)

7. COMBINING STRESSES :

** Only absolute values of quantities in bracket shall be used while combining stresses ( 1 ) : Fr sign is (+) for outward load, & (-) for inward load.

Allowabe Stresses for various catergories: 1. Membrane only, Sm = 1.5 x Sv 2. Membrane + Bending, Sa = 3 x Sv 3. Shear only, Sh = 0.5 x Sv

DESIGN IS ACCEPTABLE ? : YES

5-18B 0.0707 x Fr Mx 24.37 t2 _σx _0.981 Long. moment Membrane CL=1 5-19A 3.516 x CL x ML_Rm₂ x b Nf 19.11 Kn x Nft σf 1.566 CL=1 5-19B 1.697 x CL x ML Rm 2_{x b} Nx 9.222 Kn x Nx_t σx 0.756 Bending 5-20A 0.03827 x ML_{Rm x b} Mf 132.4 6 x Kb x Mf t 2 σf 5.331 5-20B 0.06937 x ML_{Rm x B} Mx 240 6 x Kb x Mx t2 σx 9.665 Circ. moment Membrane Cc=1 5-21A 1.893 x Cc x Mc Rm 2_{x b} Nf 10.29 Kn x Nf_t σf 0.843 Cc=1 5-21B 2.973 x Cc x Mc_Rm₂ x b Nx 16.16 Kn x Nx t σx 1.324 Bending 5-22A 0.09066 x Mc Rm x b Mf 313.7 6 x Kb x Mf t 2 σf 12.63 5-22B 0.04678 x Mc Rm x b Mx 161.9 6 x Kb x Mx t2 σx 6.518 Stress due to σx σf 0° 90° 180° 270° 0° 90° 180° 270° Radial load, Fr.(1) Membrane Nf 0.312 0.312 0.312 0.312 Nx 0.382 0.382 0.382 0.382 Bending Mf 1.621 1.621 1.621 1.621 Mx 0.981 0.981 0.981 0.981 Long. moment, ML. Membrane Nf + ( 1.566 ) -( 1.566 ) Nx +_{( 0.756 )} -( 0.756 ) Bending Mf +_{( 5.331 )} -( 5.331 ) Mx +_{( 9.665 )} -( 9.665 ) Circ moment, Mc. Membrane Nf + ( 0.843 ) -( 0.843 ) Nx +_{( 1.324 )} -( 1.324 ) Bending Mf + ( 12.63 ) -( 12.63 ) Mx +_{( 6.518 )} -( 6.518 ) Int. pr., P. Pi x Rm t σf + ( 10.91 ) +( 10.91) +( 10.91 ) +( 10.91 ) Pi x Rm 2 x t σx +_{( 5.456 )} +_{( 5.456 )} +_{( 5.456 )} +_{( 5.456 )} Total, ∑ Membrane 6.593 7.162 5.082 4.514 12.86 12.14 9.728 10.45 Mem+Bend 17.24 14.66 -3.601 -1.023 19.74 26.32 5.946 -0.631

(37)

1. DESIGN CONDITION :

2. ATTACHMENT DATA :

3. EXTERNAL LOADS :

4. SHELL DATA :

5. STRESS CONCENTRATION FACTORS :

6. COMPUTING STRESSES :

LOCAL STRESS ANALYSIS (EDGE OF PAD) N 01

CODE D.R. MOSS (EXTRACT OF WRC ₁₀₇₎

Design Mode 1, Corroded Condition

Design pressure ( internal ) Pi 0.12 kgf/mm² g

M.O.C SA-106 GR. B Smls. Pipe _[UNS:K03006]

Outside diameter OD 168.3 mm Weld size w 7 mm Pad diameter Dp 292.7 mm Pad thickness tp 0 mm 0.5 x OD C 146.3 mm Radial force Fr 344.6 kgf Long. moment ML 254724.1 kgf-mm Circ. moment Mc 254724.1 kgf-mm Torsional moment Mt 254724.1 kgf-mm

Total eff. shear load Q 487.4 kgf

M.O.C SA-516 GR. 70 Plt. [UNS:K02700]

Allowable stress Sv 14.06 kgf/mm²

Thickness of shell t 7 mm

Mean radius of shell , [ Rm ] = R + 0.5 x t = 628 + 0.5 x 7 = 631.5 mm Calculate ratio , [ g ] = Rm / t = 631.5 / 7 = 90.21 Calculate ratio , [ b ] = 0.875 x C / Rm = 0.875 x 146.3 / 631.5 = 0.203 Factor , [ Kn ] = 1 Factor , [ Kb ] = 1 Shear stress due to Q , [ t₁ ]

= Q / ( p x Ro x t ) = 487.4 / ( p x 146.3 x 7 ) = 0.151 kgf/mm²

Shear stress due to Mt , [ t₂ ] = Mt / ( 2 xp x Ro 2_{x t )}

= 254724.1 / ( 2 x p x 146.3 2_{x 7 )}

= 0.27 kgf/mm² Total shear stress , [ t ]

= t₁ + t₂ = 0.151 + 0.27 = 0.422 kgf/mm²

STRESSES FACT FIG. FORCES( kgf ) & MOMENTS( kgf-mm ) STRESS ( kgf/mm² )

Radial load Membrane 5-17A 4.941 x Fr_Rm Nf 2.696 Kn x Nf_t σf 0.385 5-17B 11.06 x Fr_Rm Nx 6.037 Kn x Nx_t σx 0.862 Bending 5-18A 0.04175 x Fr Mf 14.39 6 x Kb x Mf t 2 σf 1.762 6 x Kb x Mx

(38)

7. COMBINING STRESSES :

** Only absolute values of quantities in bracket shall be used while combining stresses ( 1 ) : Fr sign is (+) for outward load, & (-) for inward load.

Allowabe Stresses for various catergories: 1. Membrane only, Sm = 1.5 x Sv 2. Membrane + Bending, Sa = 3 x Sv 3. Shear only, Sh = 0.5 x Sv

DESIGN IS ACCEPTABLE ? : YES

5-18B 0.01857 x Fr Mx 6.398 t2 _σx _0.783 Long. moment Membrane CL=1 5-19A 6.231 x CL x ML_Rm₂ x b Nf 19.63 Kn x Nft σf 2.804 CL=1 5-19B 3.293 x CL x ML Rm 2_{x b} Nx 10.38 Kn x Nx_t σx 1.482 Bending 5-20A 0.0128 x ML_{Rm x b} Mf 25.46 6 x Kb x Mf t 2 σf 3.117 5-20B 0.01693 x ML_{Rm x B} Mx 33.68 6 x Kb x Mx t2 σx 4.124 Circ. moment Membrane Cc=1 5-21A 3.869 x Cc x Mc Rm 2_{x b} Nf 12.19 Kn x Nf_t σf 1.741 Cc=1 5-21B 7.986 x Cc x Mc_Rm₂ x b Nx 25.16 Kn x Nx t σx 3.594 Bending 5-22A 0.06043 x Mc Rm x b Mf 120.2 6 x Kb x Mf t 2 σf 14.72 5-22B 0.026 x Mc Rm x b Mx 51.73 6 x Kb x Mx t2 σx 6.334 Stress due to σx σf 0° 90° 180° 270° 0° 90° 180° 270° Radial load, Fr.(1) Membrane Nf ( 0.385 ) ( 0.385) ( 0.385 ) ( 0.385 ) Nx ( 0.862 ) ( 0.862 ) ( 0.862 ) ( 0.862 ) Bending Mf ( 1.762 ) ( 1.762 ) ( 1.762 ) ( 1.762 ) Mx ( 0.783 ) ( 0.783 ) ( 0.783 ) ( 0.783 ) Long. moment, ML. Membrane Nf + ( 2.804 ) -( 2.804 ) Nx +_{( 1.482 )} -( 1.482 ) Bending Mf +_{( 3.117 )} -( 3.117 ) Mx +_{( 4.124 )} -( 4.124 ) Circ moment, Mc. Membrane Nf + ( 1.741 ) -( 1.741 ) Nx +_{( 3.594 )} -( 3.594 ) Bending Mf + ( 14.72 ) -( 14.72 ) Mx +_{( 6.334 )} -( 6.334 ) Int. pr., P. Pi x Rm t σf + ( 10.83 ) +( 10.83) +( 10.83 ) +( 10.83 ) Pi x Rm 2 x t σx +_{( 5.413 )} +_{( 5.413 )} +_{( 5.413 )} +_{( 5.413 )} Total, ∑ Membrane 7.757 9.869 4.793 2.681 14.49 13.43 8.884 9.947 Mem+Bend 12.67 16.99 1.452 -2.87 18.89 29.44 7.051 -3.49

(39)

DESIGN CONDITIONS

NOZZLE DATA

SHELL DATA ( Main Shell )

WELD DATA

CALCULATION OF NOZZLE NECK THICKNESS AS PER UG 45

Neck thickness for internal pressure as per UG 45(a) Formula in Appendix 1-1 , [trn1]

= ( 0.5 x Pi x OD ) / ( Sn x E + 0.4 x Pi )

= ( 0.5 x 0.12 x 168.3 ) / ( 12.02 x 1.0 + 0.4 x 0.12 ) = 0.983 mm

Neck thickness for external pressure as per UG 45(a) Neck thickness for external pressure as per UG 28 Assumed neck thickness , [trn3] = 0.512 mm L / OD = 0.891

OD / trn3 = 328.5 Factor A = 0.00025 Factor B = 2.679 kgf/mm² Allowable external pressure , [Pa] = 4 x B / ( 3 x OD / trn3 ) = 4 x 2.679 / ( 3 x 328.5 ) = 0.01088 kgf/mm² g

Thickness of shell as per UG 45(b)(1)

Min. shell thickness reqd. as per UG 27 , [tr1 = trn2] = Pi x R / ( Sv x E - 0.6 x Pi )

= 0.12 x 628 / ( 14.06 x 1.0 - 0.6 x 0.12 ) = 5.387 mm

Thickness for equivalent pressure as per UG 45(b)(2) , [trn4] = Pe x R / ( Sv x E - 0.6 x Pe )

NOZZLE NECK THICKNESS AND REINFORCEMENT DESIGN N 02

M.O.C. SA-106 GR. B Smls. Pipe_[UNS:K03006]

Allowable stress @ design temperature Sn 12.02 kgf/mm²

Outside diameter OD 168.3 mm

Inside diameter ID 152.3 mm

Maximum chord length D 152.3 mm

Neck thickness ( provided ) tnp 10.97 mm

Internal allowance , corrosion + polishing CAI 3 mm External allowance , corrosion + polishing CAE 0 Neck thickness (tnp - CAI - CAE) tn 7.973 mm Max. under tolerance on thickness Alw 1.372 mm Available neck thickness ( tn - Alw ) ta 6.601 mm Nozzle projection outward ( from vessel outer face ) Lo 150 mm Total length of nozzle ( Lo + Addn for curvature) L 156 mm

Connection type Pipe Nozzle

Application type Process Opening

Reinforcement calculation method Isolated Opening

Design as large opening False

M.O.C. SA-516 GR. 70 Plt. [UNS:K02700]

Allowable stress @ design temperature Sv 14.06 kgf/mm²

Thickness t 7 mm

Min. thickness for external pressure tr2 4.466 mm

(40)

= 0.01055 x 628 / ( 14.06 x 1.0 - 0.6 x 0.01055 ) = 0.471 mm

Standard wall thickness as per UG 45(b)(4) , [t3] = 7.112 mm

Neck thk as per UG 45 , [trn]

= MAX { MAX [ trn1, trn3 ] , MIN [ MAX ( trn2 , trn4 ) , 0.875 x t3 ] } ... for Process Nozzle = MAX [ trn1, trn3 ] ... for Access Opening = 5.387 mm ... Process Opening Since available neck thickness, ta >= trn, selected neck thickness is adequate.