Calculation 40 VF 3540AB

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Vendor Rev. Page

A0 PAGE 1 OF 382

FPSO LEASE CONTRACT FOR MADURA STRAIT BD FIELD

DEVELOPMENT

CONTRACT/P.O NO: AP1429-0006

MECHANICAL DESIGN CALCULATION - CBA REACTOR

(40-VF-3540A/B)

A0 15-JULY-15 ISSUED FOR REVIEW

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A0 PAGE 2 OF 382

REVISION CHANGE NOTICES

Revision

Location of Changes

Brief Description of Change

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A0 PAGE 3 OF 382

INDEX SHEET

Sheet No.

Description

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DESIGN CALCULATION

CBA REACTOR (40-VF-3540A/B)

CLIENT

: VME PROCESS ASIA PACIFIC PTE. LTD.

CLIENT REF. NO

: 1429-M-CA-0001-8

PROJECT NAME

: HUSKY CNOOC MADURA LIMITED

PROJECT NO.

: T28/15

DOC.NO. : ET-T28-15-40-VF-3540AB-CALC

ET SERIAL NO. : ET/PV/053(40-VF-3540A),

ET/PV/051(40-VF-3540B)

A0 14/07/2015 ISSUED FOR REVIEW FAIZAL FAREZ IRWAN

REVISION DATE DESCRIPTION PREPARED

BY

CHECKED BY

APPROVED BY

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CHANGE RECORD

Revision Responsible

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Cover Sheet

... 2

Title Page

... 3

Input Echo :

... 5

Internal Pressure Calculations :

... 20

External Pressure Calculations :

... 29

Element and Detail Weights :

... 34

Nozzle Flange MAWP :

... 38

Wind Load Calculation :

... 40

Center of Gravity Calculation :

... 42

Horizontal Vessel Analysis (Ope.) :

... 43

Horizontal Vessel Analysis (Test) :

... 64

Nozzle Calcs. : A

... 85

Nozzle Calcs. : C

... 99

Nozzle Calcs. : L1

... 118

Nozzle Calcs. : L2

... 126

Nozzle Calcs. : L3

... 132

Nozzle Calcs. : L4

... 140

Nozzle Calcs. : L5

... 148

Nozzle Calcs. : L6

... 154

Nozzle Calcs. : L7

... 162

Nozzle Calcs. : L8

... 170

Nozzle Calcs. : L9

... 176

Nozzle Calcs. : P

... 184

Nozzle Calcs. : G1

... 197

Nozzle Calcs. : G2

... 206

Nozzle Calcs. : G3

... 215

Nozzle Schedule :

... 224

Nozzle Summary :

... 227

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ATTACHMENT 1 : TRANSPORTATION CASE ATTACHMENT 2 : WIND LOAD CALCULATION ATTACHMENT 3 : BLAST CONDITION

ATTACHMENT 4 : SHIP MOTION CALCULATION (OPERATING CONDITION) ATTACHMENT 5 : LIFTING LUG CALCULATION

ATTACHMENT 6 : LOCAL STRESS ANALYSIS (LIFTING LUG) ATTACHMENT 7 : FINITE ELEMENT ANALYSIS (NOZZLE C)

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DESIGN CALCULATION

In Accordance with ASME Section VIII Division 1

ASME Code Version : 2013

Analysis Performed by : HEX ENGINEERING SDN BHD

Date of Analysis : Jul 15,2015 6:16am

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Note: PV Elite performs all calculations internally in Imperial Units

to remain compliant with the ASME Code and any built in assumptions in the ASME Code formulas. The finalized results are reflected to show the users set of selected units.

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PV Elite Vessel Analysis Program: Input Data

Design Internal Pressure (for Hydrotest) 5.0000 bar Design Internal Temperature 400 °C Type of Hydrotest UG-99(c) Hydrotest Position Horizontal Projection of Nozzle from Vessel Top 400.00 mm Projection of Nozzle from Vessel Bottom 350.00 mm Minimum Design Metal Temperature 10 °C Type of Construction Welded Special Service None Degree of Radiography RT 1 Use Higher Longitudinal Stresses (Flag) Y Select t for Internal Pressure (Flag) N Select t for External Pressure (Flag) N Select t for Axial Stress (Flag) N Select Location for Stiff. Rings (Flag) N Consider Vortex Shedding N Perform a Corroded Hydrotest N Is this a Heat Exchanger No User Defined Hydro. Press. (Used if > 0) 0.0000 bar User defined MAWP 0.0000 bar User defined MAPnc 0.0000 bar

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

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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 User Defined

Wind Profile Height mm Pressure bars 3700.0000 0.0094 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 Damping Factor (Beta) for Wind (Ope) 0.0100 Damping Factor (Beta) for Wind (Empty) 0.0000 Damping Factor (Beta) for Wind (Filled) 0.0000

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Consider MAP New and Cold in Noz. Design N Consider External Loads for Nozzle Des. Y Use ASME VIII-1 Appendix 1-9 N

Material Database Year Current w/Addenda or Code Year

Configuration Directives:

Do not use Nozzle MDMT Interpretation VIII-1 01-37 No Use Table G instead of exact equation for "A" Yes Shell Head Joints are Tapered Yes Compute "K" in corroded condition Yes Use Code Case 2286 No Use the MAWP to compute the MDMT Yes Using Metric Material Databases, ASME II D No

Complete Listing of Vessel Elements and Details:

Element From Node 10 Element To Node 20 Element Type Elliptical Description Left head Distance "FROM" to "TO" 50.000 mm Inside Diameter 3000.0 mm Element Thickness 16.000 mm Internal Corrosion Allowance 6.0000 mm Nominal Thickness 19.000 mm External Corrosion Allowance 0.0000 mm Design Internal Pressure 5.0000 bar Design Temperature Internal Pressure 400 °C Design External Pressure 1.0340 bar

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Design Temperature External Pressure 400 °C Effective Diameter Multiplier 0.80000001 Material Name [Normalized] SA-516 70 Allowable Stress, Ambient 137.90 MPa Allowable Stress, Operating 101.30 MPa Allowable Stress, Hydrotest 235.81 MPa Material Density 7750.4 kg/m³ P Number Thickness 30.988 mm Yield Stress, Operating 181.12 MPa UCS-66 Chart Curve Designation D External Pressure Chart Name CS-2 UNS Number K02700 Product Form Plate Efficiency, Longitudinal Seam 1.0 Efficiency, Circumferential Seam 1.0 Elliptical Head Factor 2.0

Element From Node 10 Detail Type Insulation Detail ID INSULATION Dist. from "FROM" Node / Offset dist -750.00 mm Height/Length of Insulation 800.00 mm Thickness of Insulation 100.00 mm Density 120.00 kg/m³

---

Element From Node 20 Element To Node 30 Element Type Cylinder Description Shell

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Distance "FROM" to "TO" 2400.0 mm Inside Diameter 3000.0 mm Element Thickness 30.000 mm Internal Corrosion Allowance 6.0000 mm Nominal Thickness 30.000 mm External Corrosion Allowance 0.0000 mm Design Internal Pressure 5.0000 bar Design Temperature Internal Pressure 400 °C Design External Pressure 1.0340 bar Design Temperature External Pressure 400 °C Effective Diameter Multiplier 0.80000001 Material Name [Normalized] SA-516 70 Efficiency, Longitudinal Seam 1.0 Efficiency, Circumferential Seam 1.0

Element From Node 20 Detail Type Saddle Detail ID Sliding saddle Dist. from "FROM" Node / Offset dist 450.00 mm Width of Saddle 300.00 mm Height of Saddle at Bottom 1800.0 mm Saddle Contact Angle 120.0 Height of Composite Ring Stiffener 0.0000 mm Width of Wear Plate 400.00 mm Thickness of Wear Plate 10.000 mm Contact Angle, Wear Plate (degrees) 132.0

Element From Node 20 Detail Type Saddle Detail ID Fixed saddle Dist. from "FROM" Node / Offset dist 1950.0 mm

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Width of Saddle 300.00 mm Height of Saddle at Bottom 1800.0 mm Saddle Contact Angle 120.0 Height of Composite Ring Stiffener 0.0000 mm Width of Wear Plate 400.00 mm Thickness of Wear Plate 10.000 mm Contact Angle, Wear Plate (degrees) 132.0

Element From Node 20 Detail Type Insulation Detail ID INSULATION Dist. from "FROM" Node / Offset dist 0.0000 mm Height/Length of Insulation 2400.0 mm Thickness of Insulation 100.00 mm Density 120.00 kg/m³

Element From Node 20 Detail Type Nozzle Detail ID A Dist. from "FROM" Node / Offset dist 1200.0 mm Nozzle Diameter 30.0 in. Nozzle Schedule None Nozzle Class 150 Layout Angle 0.0 Blind Flange (Y/N) N Weight of Nozzle ( Used if > 0 ) 2866.6 N Grade of Attached Flange GR 1.1 Nozzle Matl [Normalized] SA-516 70

Element From Node 20 Detail Type Nozzle

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Detail ID C Dist. from "FROM" Node / Offset dist 1200.0 mm Nozzle Diameter 30.0 in. Nozzle Schedule None Nozzle Class 150 Layout Angle 222.61301 Blind Flange (Y/N) N Weight of Nozzle ( Used if > 0 ) 3625.4 N Grade of Attached Flange GR 1.1 Nozzle Matl [Normalized] SA-516 70

Element From Node 20 Detail Type Nozzle Detail ID L1 Dist. from "FROM" Node / Offset dist 250.00 mm Nozzle Diameter 2.0 in. Nozzle Schedule XXS Nozzle Class 150 Layout Angle 285.155 Blind Flange (Y/N) N Weight of Nozzle ( Used if > 0 ) 68.208 N Grade of Attached Flange GR 1.1 Nozzle Matl SA-106 B

Element From Node 20 Detail Type Nozzle Detail ID L2 Dist. from "FROM" Node / Offset dist 250.00 mm Nozzle Diameter 2.0 in. Nozzle Schedule XXS Nozzle Class 150

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Layout Angle 270.0 Blind Flange (Y/N) N Weight of Nozzle ( Used if > 0 ) 68.208 N Grade of Attached Flange GR 1.1 Nozzle Matl SA-106 B

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Element From Node 20 Detail Type Nozzle Detail ID L7 Dist. from "FROM" Node / Offset dist 2150.0 mm

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Nozzle Diameter 2.0 in. Nozzle Schedule XXS Nozzle Class 150 Layout Angle 285.155 Blind Flange (Y/N) N Weight of Nozzle ( Used if > 0 ) 68.208 N Grade of Attached Flange GR 1.1 Nozzle Matl SA-106 B

Element From Node 20 Detail Type Nozzle Detail ID L9 Dist. from "FROM" Node / Offset dist 2150.0 mm Nozzle Diameter 2.0 in. Nozzle Schedule XXS Nozzle Class 150 Layout Angle 254.845 Blind Flange (Y/N) N

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Weight of Nozzle ( Used if > 0 ) 68.208 N Grade of Attached Flange GR 1.1 Nozzle Matl SA-106 B

Element From Node 20 Detail Type Nozzle Detail ID P Dist. from "FROM" Node / Offset dist 1750.0 mm Nozzle Diameter 16.0 in. Nozzle Schedule None Nozzle Class 150 Layout Angle 101.308 Blind Flange (Y/N) Y Weight of Nozzle ( Used if > 0 ) 1928.3 N Grade of Attached Flange GR 1.1 Nozzle Matl [Normalized] SA-516 70

Element From Node 20 Detail Type Nozzle Detail ID G1 Dist. from "FROM" Node / Offset dist 450.00 mm Nozzle Diameter 30.0 in. Nozzle Schedule None Nozzle Class 150 Layout Angle 45.0 Blind Flange (Y/N) Y Weight of Nozzle ( Used if > 0 ) 7432.6 N Grade of Attached Flange GR 1.1 Nozzle Matl [Normalized] SA-516 70

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Detail Type Nozzle Detail ID G2 Dist. from "FROM" Node / Offset dist 1950.0 mm Nozzle Diameter 30.0 in. Nozzle Schedule None Nozzle Class 150 Layout Angle 45.0 Blind Flange (Y/N) Y Weight of Nozzle ( Used if > 0 ) 7432.6 N Grade of Attached Flange GR 1.1 Nozzle Matl [Normalized] SA-516 70

Element From Node 20 Detail Type Nozzle Detail ID G3 Dist. from "FROM" Node / Offset dist 1200.0 mm Nozzle Diameter 30.0 in. Nozzle Schedule None Nozzle Class 150 Layout Angle 135.0 Blind Flange (Y/N) Y Weight of Nozzle ( Used if > 0 ) 7432.6 N Grade of Attached Flange GR 1.1 Nozzle Matl [Normalized] SA-516 70

Element From Node 20 Detail Type Weight Detail ID BED SUPPORT Dist. from "FROM" Node / Offset dist 1200.0 mm Miscellaneous Weight 24515. N Offset from Element Centerline 0.0000 mm

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Element From Node 20 Detail Type Weight Detail ID CATALYST Dist. from "FROM" Node / Offset dist 1200.0 mm Miscellaneous Weight 78448. N Offset from Element Centerline 0.0000 mm

Element From Node 20 Detail Type Weight Detail ID REFRACTORY LINE Dist. from "FROM" Node / Offset dist 1200.0 mm Miscellaneous Weight 68642. N Offset from Element Centerline 0.0000 mm

Element From Node 20 Detail Type Weight Detail ID MISC.0 Dist. from "FROM" Node / Offset dist 2000.0 mm Miscellaneous Weight 10963. N Offset from Element Centerline 0.0000 mm

Element From Node 20 Detail Type Weight Detail ID BAFFLES Dist. from "FROM" Node / Offset dist 1200.0 mm Miscellaneous Weight 5383.5 N Offset from Element Centerline 0.0000 mm

Element From Node 20 Detail Type For./Mom.

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Detail ID Moment forces Dist. from "FROM" Node / Offset dist 1233.0 mm Force in X Direction 30228. N Force in Y Direction -18613. N Force in Z Direction 53142. N Moment about X Axis 0.0000 N-m Moment about Y Axis 0.0000 N-m Moment about Z Axis 0.0000 N-m Force/Moment Combination Method SRSS

---

Element From Node 30 Element To Node 40 Element Type Elliptical Description Right head Distance "FROM" to "TO" 50.000 mm Inside Diameter 3000.0 mm Element Thickness 16.000 mm Internal Corrosion Allowance 6.0000 mm Nominal Thickness 19.000 mm External Corrosion Allowance 0.0000 mm Design Internal Pressure 5.0000 bar Design Temperature Internal Pressure 400 °C Design External Pressure 1.0340 bar Design Temperature External Pressure 400 °C Effective Diameter Multiplier 0.80000001 Material Name [Normalized] SA-516 70 Efficiency, Longitudinal Seam 1.0 Efficiency, Circumferential Seam 1.0 Elliptical Head Factor 2.0

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Element From Node 30 Detail Type Insulation Detail ID INSULATION Dist. from "FROM" Node / Offset dist 0.0000 mm Height/Length of Insulation 800.00 mm Thickness of Insulation 100.00 mm Density 120.00 kg/m³

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Element Thickness, Pressure, Diameter and Allowable Stress :

| | Int. Press | Nominal | Total Corr| Element | Allowable | From| To | + Liq. Hd | Thickness | Allowance | Diameter | Stress(SE)| | | bar | mm | mm | mm | MPa | --- Left head| 5.0000 | 19.000 | 6.0000 | 3000.0 | 101.30 | Shell| 5.0000 | 30.000 | 6.0000 | 3000.0 | 101.30 | Right head| 5.0000 | 19.000 | 6.0000 | 3000.0 | 101.30 |

Element Required Thickness and MAWP :

| | Design | M.A.W.P. | M.A.P. | Minimum | Required | From| To | Pressure | Corroded | New & Cold | Thickness | Thickness | | | bar | bar | bar | mm | mm | --- Left head| 5.00000 | 6.75644 | 14.6915 | 16.0000 | 13.3991 | Shell| 5.00000 | 15.9877 | 27.2490 | 30.0000 | 13.4568 | Right head| 5.00000 | 6.75644 | 14.6915 | 16.0000 | 13.3991 | Minimum 6.499 14.691

Note : The M.A.W.P is Governed by a Standard Flange !

Internal Pressure Calculation Results :

ASME Code, Section VIII, Division 1, 2013

Elliptical Head From 10 To 20 SA-516 70 , UCS-66 Crv. D at 400 °C

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Longitudinal Joint: Full Radiography per UW-11(a) Type 1 Circumferential Joint: Full Radiography per UW-11(a) 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)

= (5.000*3012.0000*0.995)/(2*101.30*1.00-0.2*5.000) = 7.3991 + 6.0000 = 13.3991 mm

Max. Allowable Working Pressure at given Thickness, corroded [MAWP]: = (2*S*E*t)/(Kcor*D+0.2*t) per Appendix 1-4 (c)

= (2*101.30*1.00*10.0000)/(0.995*3012.0000+0.2*10.0000) = 6.756 bar

Maximum Allowable Pressure, New and Cold [MAPNC]: = (2*S*E*t)/(K*D+0.2*t) per Appendix 1-4 (c)

= (2*137.90*1.00*16.0000)/(1.000*3000.0000+0.2*16.0000) = 14.692 bar

Actual stress at given pressure and thickness, corroded [Sact]: = (P*(Kcor*D+0.2*t))/(2*E*t)

= (5.000*(0.995*3012.0000+0.2*10.0000))/(2*1.00*10.0000) = 74.963 MPa

Straight Flange Required Thickness:

= (P*R)/(S*E-0.6*P) + c per UG-27 (c)(1) = (5.000*1506.0000)/(101.30*1.00-0.6*5.000)+6.000 = 13.457 mm

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= (S*E*t)/(R+0.6*t) per UG-27 (c)(1)

= (101.30 * 1.00 * 13.0000 )/(1506.0000 + 0.6 * 13.0000 ) = 8.698 bar

Factor K, corroded condition [Kcor]:

= ( 2 + ( Inside Diameter/( 2 * Inside Head Depth ))2)/6

= ( 2 + ( 3012.000/( 2 * 756.000 ))2)/6

= 0.994719

Percent Elong. per UCS-79, VIII-1-01-57 (75*tnom/Rf)*(1-Rf/Ro) 2.743 %

MDMT Calculations in the Knuckle Portion:

Govrn. thk, tg = 16.000 , tr = 7.065 , c = 6.0000 mm , E* = 1.00 Stress Ratio = tr * (E*)/(tg - c) = 0.706 , Temp. Reduction = 16 °C

Min Metal Temp. w/o impact per UCS-66, Curve D -46 °C Min Metal Temp per UCS-66 and UCS-68(c),PWHT credit -62 °C Min Metal Temp. at Required thickness (UCS 66.1) -65 °C

MDMT Calculations in the Head Straight Flange:

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Shell

Required Thickness due to Internal Pressure [tr]: = (P*R)/(S*E-0.6*P) per UG-27 (c)(1)

= (5.000*1506.0000)/(101.30*1.00-0.6*5.000) = 7.4568 + 6.0000 = 13.4568 mm

Max. Allowable Working Pressure at given Thickness, corroded [MAWP]: = (S*E*t)/(R+0.6*t) per UG-27 (c)(1)

= (101.30*1.00*24.0000)/(1506.0000+0.6*24.0000) = 15.988 bar

Maximum Allowable Pressure, New and Cold [MAPNC]: = (S*E*t)/(R+0.6*t) per UG-27 (c)(1)

= (137.90*1.00*30.0000)/(1500.0000+0.6*30.0000) = 27.249 bar

Actual stress at given pressure and thickness, corroded [Sact]: = (P*(R+0.6*t))/(E*t)

= (5.000*(1506.0000+0.6*24.0000))/(1.00*24.0000) = 31.680 MPa

Percent Elongation per UCS-79 (50*tnom/Rf)*(1-Rf/Ro) 0.990 %

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Elliptical Head From 30 To 40 SA-516 70 , UCS-66 Crv. D at 400 °C

Right head

= (5.000*3012.0000*0.995)/(2*101.30*1.00-0.2*5.000) = 7.3991 + 6.0000 = 13.3991 mm

Max. Allowable Working Pressure at given Thickness, corroded [MAWP]: = (2*S*E*t)/(Kcor*D+0.2*t) per Appendix 1-4 (c)

= (2*101.30*1.00*10.0000)/(0.995*3012.0000+0.2*10.0000) = 6.756 bar

Maximum Allowable Pressure, New and Cold [MAPNC]: = (2*S*E*t)/(K*D+0.2*t) per Appendix 1-4 (c)

= (2*137.90*1.00*16.0000)/(1.000*3000.0000+0.2*16.0000) = 14.692 bar

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Actual stress at given pressure and thickness, corroded [Sact]: = (P*(Kcor*D+0.2*t))/(2*E*t)

= (5.000*(0.995*3012.0000+0.2*10.0000))/(2*1.00*10.0000) = 74.963 MPa

Straight Flange Required Thickness:

= (P*R)/(S*E-0.6*P) + c per UG-27 (c)(1) = (5.000*1506.0000)/(101.30*1.00-0.6*5.000)+6.000 = 13.457 mm

Straight Flange Maximum Allowable Working Pressure: = (S*E*t)/(R+0.6*t) per UG-27 (c)(1)

= (101.30 * 1.00 * 13.0000 )/(1506.0000 + 0.6 * 13.0000 ) = 8.698 bar

Factor K, corroded condition [Kcor]:

= ( 2 + ( Inside Diameter/( 2 * Inside Head Depth ))2)/6

= ( 2 + ( 3012.000/( 2 * 756.000 ))2)/6

= 0.994719

Percent Elong. per UCS-79, VIII-1-01-57 (75*tnom/Rf)*(1-Rf/Ro) 2.743 %

MDMT Calculations in the Knuckle Portion:

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MDMT Calculations in the Head Straight Flange:

Hydrostatic Test Pressure Results:

Pressure per UG99b = 1.3 * M.A.W.P. * Sa/S 11.187 bar Pressure per UG99b[36] = 1.3 * Design Pres * Sa/S 8.607 bar Pressure per UG99c = 1.3 * M.A.P. - Head(Hyd) 18.731 bar Pressure per UG100 = 1.1 * M.A.W.P. * Sa/S 9.466 bar Pressure per PED = 1.43 * MAWP 9.294 bar

Horizontal Test performed per: UG-99c

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 --- Left head 178.6 235.8 0.757 19.03 Shell 96.3 235.8 0.408 19.03 Right head 178.6 235.8 0.757 19.03 ---

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Stress ratios for Nozzle and Pad Materials:

Description Pad/Nozzle Ambient Operating ratio --- A Nozzle 137.90 101.30 1.361 C Nozzle 137.90 101.30 1.361 L1 Nozzle 117.90 89.05 1.324 L2 Nozzle 117.90 89.05 1.324 L3 Nozzle 117.90 89.05 1.324 L4 Nozzle 117.90 89.05 1.324 L5 Nozzle 117.90 89.05 1.324 L6 Nozzle 117.90 89.05 1.324 L7 Nozzle 117.90 89.05 1.324 L8 Nozzle 117.90 89.05 1.324 L9 Nozzle 117.90 89.05 1.324 P Nozzle 137.90 101.30 1.361 G1 Nozzle 137.90 101.30 1.361 G2 Nozzle 137.90 101.30 1.361 G3 Nozzle 137.90 101.30 1.361 --- Minimum 1.324

Stress ratios for Vessel Elements:

Description Ambient Operating ratio --- Left head 137.90 101.30 1.361 Shell 137.90 101.30 1.361 Right head 137.90 101.30 1.361 ---

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Minimum 1.361

Elements Suitable for Internal Pressure.

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External Pressure Calculation Results :

ASME Code, Section VIII, Division 1, 2013

Elliptical Head From 10 to 20 Ext. Chart: CS-2 at 400 °C

Left head

Elastic Modulus from Chart: CS-2 at 400 °C : 0.163E+06 MPa

Results for Maximum Allowable External Pressure (MAEP):

Tca OD D/t Factor A B 10.000 3032.00 303.20 0.0004581 37.30

EMAP = B/(K0*D/t) = 37.2965/(0.9000 *303.2000 ) = 1.3666 bar

Results for Required Thickness (Tca):

EMAP = B/(K0*D/t) = 32.4433/(0.9000 *348.5552 ) = 1.0341 bar

Check the requirements of UG-33(a)(1) using P = 1.67 * External Design pressure for this head.

= (1.727*3012.0000*0.995)/(2*101.30*1.00-0.2*1.727) = 2.5545 + 6.0000 = 8.5545 mm

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= ((2*S*E*t)/(Kcor*D+0.2*t))/1.67 per Appendix 1-4 (c)

= ((2*101.30*1.00*10.0000)/(0.995*3012.0000+0.2*10.0000))/1.67 = 4.046 bar

Maximum Allowable External Pressure [MAEP]: = min( MAEP, MAWP )

= min( 1.37 , 4.0458 ) = 1.367 bar

Thickness requirements per UG-33(a)(1) do not govern the required thickness of this head.

Cylindrical Shell From 20 to 30 Ext. Chart: CS-2 at 400 °C

Shell

Tca OD SLEN D/t L/D Factor A B 24.000 3060.00 3000.00 127.50 0.9804 0.0009493 51.29 EMAP = (4*B)/(3*(D/t)) = (4*51.2925 )/(3*127.5000 ) = 5.3631 bar

Tca OD SLEN D/t L/D Factor A B 10.578 3060.00 3000.00 289.27 0.9804 0.0002756 22.44 EMAP = (4*B)/(3*(D/t)) = (4*22.4364 )/(3*289.2662 ) = 1.0340 bar

Results for Maximum Stiffened Length (Slen):

Tca OD SLEN D/t L/D Factor A B 24.000 3060.00 20528.64 127.50 6.7087 0.0001215 9.89

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EMAP = (4*B)/(3*(D/t)) = (4*9.8934 )/(3*127.5000 ) = 1.0345 bar

Elliptical Head From 30 to 40 Ext. Chart: CS-2 at 400 °C

Right head

EMAP = B/(K0*D/t) = 37.2965/(0.9000 *303.2000 ) = 1.3666 bar

EMAP = B/(K0*D/t) = 32.4433/(0.9000 *348.5552 ) = 1.0341 bar

Check the requirements of UG-33(a)(1) using P = 1.67 * External Design pressure for this head.

= (1.727*3012.0000*0.995)/(2*101.30*1.00-0.2*1.727) = 2.5545 + 6.0000 = 8.5545 mm

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)

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= 4.046 bar

Maximum Allowable External Pressure [MAEP]: = min( MAEP, MAWP )

= min( 1.37 , 4.0458 ) = 1.367 bar

Thickness requirements per UG-33(a)(1) do not govern the required thickness of this head.

External Pressure Calculations

| | Section | Outside | Corroded | Factor | Factor | From| To | Length | Diameter | Thickness | A | B | | | mm | mm | mm | | MPa | --- 10| 20| No Calc | 3032.00 | 10.0000 | 0.00045808 | 37.2965 | 20| 30| 3000.00 | 3060.00 | 24.0000 | 0.00094928 | 51.2925 | 30| 40| No Calc | 3032.00 | 10.0000 | 0.00045808 | 37.2965 |

| | External | External | External | External | From| To | Actual T. | Required T.|Des. Press. | M.A.W.P. | | | mm | mm | bar | bar | --- 10| 20| 16.0000 | 14.6988 | 1.03400 | 1.36657 | 20| 30| 30.0000 | 16.5785 | 1.03400 | 5.36315 | 30| 40| 16.0000 | 14.6988 | 1.03400 | 1.36657 | Minimum 1.367

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| | Actual Len.| Allow. Len.| Ring Inertia | Ring Inertia | From| To | Bet. Stiff.| Bet. Stiff.| Required | Available | | | mm | mm | mm**4 | mm**4 | --- 10| 20| No Calc | No Calc | No Calc | No Calc | 20| 30| 3000.00 | 20528.6 | No Calc | No Calc | 30| 40| No Calc | No Calc | No Calc | No Calc |

Elements Suitable for External Pressure.

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Element and Detail Weights

| | Element | Element | Corroded | Corroded | Extra due | From| To | Metal Wgt. | ID Volume |Metal Wgt. | ID Volume | Misc % | | | kgm | m³ | kgm | m³ | kgm | --- 10| 20| 1676.22 | 3.79589 | 1146.89 | 3.84023 | 83.8111 | 20| 30| 5311.96 | 16.5639 | 4257.98 | 16.6967 | 265.598 | 30| 40| 1676.22 | 3.79589 | 1146.89 | 3.84023 | 83.8111 | --- Total 8664 24.16 6551 24.38 433 Weight of Details

---

10|Insl| 168.448 | -350.000 | ... | INSULATION 20|Sadl| 496.912 | 450.000 | 1630.00 | Sliding saddle 20|Sadl| 496.912 | 1950.00 | 1630.00 | Fixed saddle 20|Insl| 285.918 | 1200.00 | ... | INSULATION 20|Nozl| 306.944 | 1200.00 | 1881.00 | A 20|Nozl| 388.194 | 1200.00 | 1881.00 | C 20|Nozl| 7.30357 | 250.000 | 1530.16 | L1 20|Nozl| 7.30357 | 250.000 | 1530.16 | L2 20|Nozl| 7.30357 | 250.000 | 1530.16 | L3 20|Nozl| 7.30357 | 1200.00 | 1530.16 | L4 20|Nozl| 7.30357 | 1200.00 | 1530.16 | L5 20|Nozl| 7.30357 | 1200.00 | 1530.16 | L6 20|Nozl| 7.30357 | 2150.00 | 1530.16 | L7

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20|Nozl| 7.30357 | 2150.00 | 1530.16 | L8 20|Nozl| 7.30357 | 2150.00 | 1530.16 | L9 20|Nozl| 206.481 | 1750.00 | 1703.20 | P 20|Nozl| 795.867 | 450.000 | 1881.00 | G1 20|Nozl| 795.867 | 1950.00 | 1881.00 | G2 20|Nozl| 795.867 | 1200.00 | 1881.00 | G3 20|Wght| 2500.00 | 1200.00 | ... | BED SUPPORT 20|Wght| 8000.00 | 1200.00 | ... | CATALYST 20|Wght| 7000.00 | 1200.00 | ... | REFRACTORY LINE 20|Wght| 1118.00 | 2000.00 | ... | MISC. 20|Wght| 549.000 | 1200.00 | ... | BAFFLES 20|Forc| ... | 1233.00 | ... | Moment forces 30|Insl| 168.448 | 400.000 | ... | INSULATION

Total Weight of Each Detail Type

Total Weight of Saddles 993.8 Total Weight of Insulation 622.8 Total Weight of Nozzles 3355.0 Total Weight of Weights 19167.0 --- Sum of the Detail Weights 24138.6 kgm

Weight Summation

Fabricated Shop Test Shipping Erected Empty Operating --- 9097.6 13446.4 9097.6 13446.4 9097.6 16569.2 993.8 24729.4 993.8 ... 993.8 ... 3355.0 ... 3355.0 ... ... ...

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... ... ... 622.8 ... ... ... ... ... ... 622.8 ... ... ... ... ... ... 19167.0 ... ... ... ... ... -2500.0 ... ... ... ... 3355.0 ... ... ... ... ... 2500.0 ... --- 13446.4 38175.8 13446.4 16569.2 16569.2 33236.2 kgm

Miscellaneous Weight Percent: 5.0 %

Note that the above value for the miscellaneous weight percent has been applied to the shells/heads/flange/tubesheets/tubes etc. in the weight calculations for metallic components.

Note: The shipping total has been modified because some items have been specified as being installed in the shop.

Weight Summary

Fabricated Wt. - Bare Weight W/O Removable Internals 13446.4 kgm Shop Test Wt. - Fabricated Weight + Water ( Full ) 38175.8 kgm Shipping Wt. - Fab. Wt + Rem. Intls.+ Shipping App. 13446.4 kgm Erected Wt. - Fab. Wt + Rem. Intls.+ Insul. (etc) 16569.2 kgm Ope. Wt. no Liq - Fab. Wt + Intls. + Details + Wghts. 16569.2 kgm Operating Wt. - Empty Wt + Operating Liq. Uncorroded 33236.2 kgm Oper. Wt. + CA - Corr Wt. + Operating Liquid 31017.9 kgm Field Test Wt. - Empty Weight + Water (Full) 38798.6 kgm

(43)

Vessel Analysis (Ope Case) and Earthquake Load Calculations.

Outside Surface Areas of Elements

| | Surface | From| To | Area | | | mm² | --- 10| 20| 10.48E+06 | 20| 30| 23.07E+06 | 30| 40| 10.48E+06 | --- Total 44035440.000 mm²

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Nozzle Flange MAWP Results :

Nozzle --- Flange Rating

Description Operating Ambient Temperature Class Grade|Group bar bar °C --- A 6.5 19.6 400 150 GR 1.1 C 6.5 19.6 400 150 GR 1.1 L1 6.5 19.6 400 150 GR 1.1 L2 6.5 19.6 400 150 GR 1.1 L3 6.5 19.6 400 150 GR 1.1 L4 6.5 19.6 400 150 GR 1.1 L5 6.5 19.6 400 150 GR 1.1 L6 6.5 19.6 400 150 GR 1.1 L7 6.5 19.6 400 150 GR 1.1 L8 6.5 19.6 400 150 GR 1.1 L9 6.5 19.6 400 150 GR 1.1 P 6.5 19.6 400 150 GR 1.1 G1 6.5 19.6 400 150 GR 1.1 G2 6.5 19.6 400 150 GR 1.1 G3 6.5 19.6 400 150 GR 1.1 --- Minimum Rating 6.5 19.6 bar (for Core Elements)

Note: ANSI Ratings are per ANSI/ASME B16.5 2009 Metric Edition

Note: Large Diameter Flange ratings per ANSI B16.47 2006 edition.

(45)

(46)

Note: Using the User Defined Wind Profile ...

Note: Due to a computed wind velocity of 0.0, vortex effects could not be computed for user defined wind pressure vs. elevation.

Platform Load Calculations

ID Wind Area Elevation Pressure Force Cf mm² mm bars N

---

Wind Loads on Masses/Equipment/Piping

ID Wind Area Elevation Pressure Force mm² mm bars N --- BED SUPPORT 0.00 1200.00 0.01 0.00 CATALYST 0.00 1200.00 0.01 0.00 REFRACTORY LI 0.00 1200.00 0.01 0.00 MISC. 0.00 2000.00 0.01 0.00 BAFFLES 0.00 1200.00 0.01 0.00

Wind Load Calculation

| | Wind | Wind | Wind | Wind | Element | From| To | Height | Diameter | Area | Pressure | Wind Load | | | mm | mm | mm² | bars | N | --- 10| 20| 1800.00 | 2585.60 | 2.328E+06 | 0.0093900 | 2184.55 |

(47)

20| 30| 1800.00 | 2608.00 | 6.259E+06 | 0.0093900 | 5874.67 | 30| 40| 1800.00 | 2585.60 | 2.328E+06 | 0.0093900 | 2184.55 |

(48)

Shop/Field Installation Options :

Insulation is installed in the Field.

Note : The CG is computed from the first Element From Node

Center of Gravity of Saddles 1250.000 mm Center of Gravity of Insulation 1250.000 mm Center of Gravity of Nozzles 1283.850 mm Center of Gravity of Added Weights (Operating) 1296.664 mm Center of Gravity of Added Weights (Empty) 1250.000 mm

Center of Gravity of Bare Shell New and Cold 1250.000 mm Center of Gravity of Bare Shell Corroded 1250.000 mm

Vessel CG in the Operating Condition 1282.496 mm Vessel CG in the Fabricated (Shop/Empty) Condition 1257.122 mm Vessel CG in the Test Condition 1252.792 mm

(49)

ASME Horizontal Vessel Analysis: Stresses for the Left Saddle (per ASME Sec. VIII Div. 2 based on the Zick method.)

Horizontal Vessel Stress Calculations : Operating Case

Note: Wear Pad Width (400.00) is less than 1.56*sqrt(rm*t) and less than 2a. The wear plate will be ignored.

Minimum Wear Plate Width to be considered in analysis [b1]: = min( b + 1.56*sqrt( Rm * t ), 2a )

= min( 300.000 + 1.56*sqrt( 1518.0000 * 24.0000 ), 2 * 500.000 ) = 597.7598 mm

Input and Calculated Values:

Vessel Mean Radius Rm 1518.00 mm Stiffened Vessel Length per 4.15.6 L 2500.00 mm Distance from Saddle to Vessel tangent a 500.00 mm

Saddle Width b 300.00 mm Saddle Bearing Angle theta 120.00 degrees

Inside Depth of Head h2 756.00 mm

Shell Allowable Stress used in Calculation 101.30 MPa Head Allowable Stress used in Calculation 101.30 MPa Circumferential Efficiency in Plane of Saddle 1.00 Circumferential Efficiency at Mid-Span 1.00

(50)

Horizontal Vessel Analysis Results: Actual Allowable

--- Long. Stress at Top of Midspan 15.58 101.30 MPa Long. Stress at Bottom of Midspan 16.05 101.30 MPa Long. Stress at Top of Saddles 15.78 101.30 MPa Long. Stress at Bottom of Saddles 15.85 101.30 MPa

Tangential Shear in Shell 5.13 81.04 MPa Tangential Shear in Head 12.30 81.04 MPa Circ. Stress at Horn of Saddle 39.17 126.62 MPa Addl. Stress in Head as Stiffener 80.62 126.62 MPa Circ. Compressive Stress in Shell 1.12 101.30 MPa

Intermediate Results: Saddle Reaction Q due to Wind or Seismic

Saddle Reaction Force due to Wind Ft [Fwt]:

= Ftr * ( Ft/Num of Saddles + Z Force Load ) * B / E = 3.00 * ( 10243.8/2 + 25401 ) * 1800.0000/2629.2532 = 62690.2 N

Saddle Reaction Force due to Wind Fl or Friction [Fwl]:

= max( Fl, Friction Load, Sum of X Forces) * B / Ls = max( 5521.89 , 0.00 , 30228 ) * 1800.0000/1500.0000 = 36273.6 N

Saddle Reaction Force due to Earthquake Fl or Friction [Fsl]:

= max( Fl, Friction Force, Sum of X Forces ) * B / Ls = max( 5521.89 , 0.00 , 30228 ) * 1800.0000/1500.0000 = 36273.6 N

(51)

= Ftr * ( Ft/Num of Saddles + Z Force Load ) * B / E = 3.00 * ( 10243/2 + 25401 ) * 1800.0000/2629.2532 = 62690.2 N

Load Combination Results for Q + Wind or Seismic [Q]: = Saddle Load + Max( Fwl, Fwt, Fsl, Fst ) = 149515 + Max( 36273 , 62690 , 36273 , 62690 ) = 212205.9 N

Note: The Wind and Seismic Forces in the horizontal directions have been added together by user request.

Summary of Loads at the base of this Saddle:

Vertical Load (including saddle weight) 217078.61 N Transverse Shear Load Saddle 30523.77 N Longitudinal Shear Load Saddle 30228.00 N

Formulas and Substitutions for Horizontal Vessel Analysis:

Note: Wear Plate is Welded to the Shell, k = 0.1

The Computed K values from Table 4.15.1:

K1 = 0.1066 K2 = 1.1707 K3 = 0.8799 K4 = 0.4011 K5 = 0.7603 K6 = 0.0529 K7 = 0.0132 K8 = 0.3405 K9 = 0.2711 K10 = 0.0581 K1* = 0.1923

Note: Dimension a is less than Rm/2.

Moment per Equation 4.15.3 [M1]:

= -Q*a [1 - (1- a/L + (R²-h2²)/(2a*L))/(1+(4h2)/3L)] = -212205*500.00[1-(1-500.00/2500.00+(1518.000²-756.000²)/

(52)

(2*500.00*2500.00))/(1+(4*756.00)/(3*2500.00))] = 6801.7 N-m

= Q*L/4(1+2(R²-h2²)/(L²))/(1+(4h2)/( 3L))-4a/L = 212205*2500/4(1+2(1517²-756²)/(2500²))/(1+(4*756)/ (3*2500))-4*499/2500

= 40842.2 N-m

Longitudinal Stress at Top of Shell (4.15.6) [Sigma1]: = P * Rm/(2t) - M2/(pi*Rm²t)

= 5.000 * 1518.000/(2*24.000 ) - 40842.2/(pi*1518.0²*24.000 ) = 15.58 MPa

Longitudinal Stress at Bottom of Shell (4.15.7) [Sigma2]: = P * Rm/(2t) + M2/(pi * Rm² * t)

= 5.000 * 1518.000/(2 * 24.000 ) + 40842.2/(pi * 1518.0² * 24.000 ) = 16.05 MPa

Longitudinal Stress at Top of Shell at Support (4.15.8) [Sigma3]: = P * Rm/(2t) - M1/(pi * Rm² * t)

= 5.000 * 1518.000/(2 * 24.000 ) - 6801.7/(pi * 1518.0² * 24.000 ) = 15.78 MPa

Longitudinal Stress at bottom of Shell at Support (4.15.9) [Sigma4]: = P * Rm/(2t) + M1/(pi*Rm²t)

= 5.000 * 1518.000/(2*24.000 ) + 6801.7/(pi*1518.0²*24.000 ) = 15.85 MPa

Maximum Shear Force in the Saddle (4.15.5) [T]: = Q(L-2a)/(L+(4*h2/3))

(53)

= 212205 ( 2500.00 - 2 * 500.00 )/(2500.00 + ( 4 * 756.00/3)) = 90738.0 N

Shear Stress in the shell no rings, stiffened (4.15.15) [tau3]: = K3 * Q / ( Rm * t )

= 0.8799 * 212205/( 1518.0000 * 24.0000 ) = 5.13 MPa

Shear Stress in the head, shell stiffened (4.15.16) [tau3*]: = K3 * Q / ( Rm * th )

= 0.8799 * 212205/( 1518.0000 * 10.0000 ) = 12.30 MPa

Membrane stress in the head as a stiffener (4.15.18) [sigma5]: = K4 * Q/(Rm*th) + ((P*Ri)/(2*th)) * (Ri/h2) = 0.4011 * 212205/(1518.00 * 10.000 ) + ((5.00 * 1506.00 )/(2 * 10.000 ))*(1506.00/756.00 ) = 80.62 MPa Decay Length (4.15.22) [x1,x2]: = 0.78 * sqrt( Rm * t ) = 0.78 * sqrt( 1518.000 * 24.000 ) = 148.880 mm

Circumferential Stress in shell, no rings (4.15.23) [sigma6]: = -K5 * Q * k / ( t * ( b + X1 + X2 ) )

= -0.7603 * 212205 * 0.1/( 24.000 * ( 300.00 + 148.88 + 148.88 ) ) = -1.12 MPa

Circ. Comp. Stress at Horn of Saddle, L<8Rm (4.15.25) [sigma7*]: = -Q/(4*t*(b+X1+X2)) - 12*K7*Q*Rm/(L*t²)

(54)

= -212205/(4*24.000 *(300.000 +148.880 +148.880 )) - 12 * 0.013 * 212205 * 1518.000/(2500.000 * 24.000²) = -39.17 MPa

Effective reinforcing plate width (4.15.1) [B1]:

= min( b + 1.56 * sqrt( Rm * t ), 2a )

= min( 300.00 + 1.56 * sqrt( 1518.000 * 24.000 ), 2 * 500.000 ) = 597.76 mm

Free Un-Restrained Thermal Expansion between the Saddles [Exp]:

= Alpha * Ls * ( Design Temperature - Ambient Temperature ) = 0.139E-04 * 1500.000 * ( 400.0 - 21.1 )

= 7.880 mm

Results for Vessel Ribs, Web and Base:

Baseplate Length Bplen 2619.9998 mm Baseplate Thickness Bpthk 22.0000 mm Baseplate Width Bpwid 300.0000 mm Number of Ribs ( inc. outside ribs ) Nribs 6 Rib Thickness Ribtk 10.0000 mm Web Thickness Webtk 10.0000 mm Web Location Webloc Center

Moment of Inertia of Saddle - Lateral Direction

Y A AY Io Shell 12. 16718. 200615. 3209840. Wearplate 29. 4000. 116000. 3397330. Web 156. 2440. 380640. 71485416. BasePlate 289. 6600. 1907400. 551504256. Totals 486. 29758. 2604655. 629596864.

(55)

Value C1 = Sumof(Ay)/Sumof(A) = 88. mm Value I = Sumof(Io) - C1*Sumof(Ay) = 401616576. mm**4 Value As = Sumof(A) - Ashell = 13040. mm²

K1 = (1+Cos(beta)-.5*Sin(beta)² )/(pi-beta+Sin(beta)*Cos(beta)) = 0.2035

Fh = K1 * Q = 0.2035 * 212205.891 = 43188.5078 N

Tension Stress, St = ( Fh/As ) = 3.3123 MPa Allowed Stress, Sa = 0.6 * Yield Str = 157.2060 MPa

d = B - R*Sin(theta) / theta = 560.5480 mm Bending Moment, M = Fh * d = 24219.0469 N-m

Bending Stress, Sb = ( M * C1 / I ) = 5.2766 MPa Allowed Stress, Sa = 2/3 * Yield Str = 174.6733 MPa

Minimum Thickness of Baseplate per Moss :

= ( 3 * ( Q + Saddle_Wt ) * BasePlateWidth / ( 4 * BasePlateLength * AllStress ))½

= ( 3 * (212205 + 4872 ) * 300.00/( 4 * 2620.000 * 174.673 ))½ = 10.331 mm

Calculation of Axial Load, Intermediate Values and Compressive Stress

Effective Baseplate Length [e]:

= ( Bplen - Clearance ) / ( Nribs - 1)

= ( 2619.9998 - 25.4 )/( 6 - 1 ) = 518.9200 mm

(56)

= e * Bpwid / 2

= 518.9200 * 300.0000/2 = 77837.9922 mm²

Axial Load [P]: = Ap * Bp

= 77838.0 * 0.27 = 21014.9 N

Area of the Rib and Web [Ar]:

= ( Bpwid - Clearance - Webtk ) * Ribtk + e/2 * Webtk

= ( 300.000 - 25.4 - 10.000 ) * 10.000 + 518.9200/2 * 10.000 = 5240.600 mm²

Compressive Stress [Sc]: = P/Ar

= 21014.9/5240.5996 = 4.0104 MPa

Check of Outside Ribs:

Inertia of Saddle, Outer Ribs - Longitudinal Direction

Y A AY Ay² Io Rib 150.0 2773.0 415950.0 0.0 19761742.0 Web 150.0 2594.6 389189.9 0.0 43243.3 Values 150.0 5367.6 805140.0 0.0 19804984.0 Bending Moment [Rm]: = Fl /( 2 * Bplen ) * e * rl / 2 = 30228.0/( 2 * 2620.00 ) * 518.920 * 1041.00/2 = 1558.746 N-m

KL/R < Cc ( 16.9338 < 122.7360 ) per AISC E2-1

Sca = (1-(Klr)²/(2*Cc²))*Fy/(5/3+3*(Klr)/(8*Cc)-(Klr³)/(8*Cc³) Sca = ( 1-( 16.93 )²/(2 * 122.74² )) * 262/

(57)

( 5/3+3*(16.93 )/(8* 122.74 )-( 16.93³)/(8*122.74³) Sca = 151.05 MPa

AISC Unity Check on Outside Ribs ( must be <= 1.0 ) Check = Sc/Sca + (Rm/Z)/Sba

Check = 4.01/151.05 + (1558.75/132033.219)/174.67 Check = 0.09

Check of Inside Ribs

Inertia of Saddle, Inner Ribs - Axial Direction

Y A AY Ay² Io Rib 137.3 2646.0 363295.8 0.0 17255196.0 Web 137.3 5189.2 712477.1 0.0 43243.3 Values 137.3 7835.2 1075772.8 0.0 17298440.0

KL/R < Cc ( 10.1559 < 122.7360 ) per AISC E2-1

( 5/3+3*(10.16 )/(8* 122.74 )-( 10.16³)/(8*122.74³) Sca = 153.81 MPa

AISC Unity Check on Inside Ribs ( must be <= 1.0 ) Check = Sc/Sca + (Rm/Z)/Sba

Check = 5.36/153.81 + ( 1429.06/125990.094)/174.67 Check = 0.10

Input Data for Base Plate Bolting Calculations:

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Total Number of Bolts in Tension/Baseplate Nbt 4 Bolt Material Specification SA-193 B7 Bolt Allowable Stress Stba 172.38 MPa Bolt Corrosion Allowance Bca 0.0000 mm Distance from Bolts to Edge Edgedis 50.8000 mm Nominal Bolt Diameter Bnd 22.0000 mm Thread Series Series TEMA Metric BasePlate Allowable Stress S 137.90 MPa Area Available in a Single Bolt BltArea 272.4190 mm² Saddle Load QO (Weight) QO 154388.4 N Saddle Load QL (Wind/Seismic contribution) QL 36273.6 N Maximum Transverse Force Ft 32862.0 N Maximum Longitudinal Force Fl 30228.0 N Saddle Bolted to Steel Foundation Yes

Bolt Area Calculation per Dennis R. Moss

Bolt Area Requirement Due to Longitudinal Load [Bltarearl]:

= 0.0 (QO > QL --> No Uplift in Longitudinal direction)

Bolt Area due to Shear Load [Bltarears]: = Fl / (Stba * Nbolts) = 30228.00/(172.38 * 8.00 ) = 21.9221 mm²

Bolt Area due to Transverse Load

Moment on Baseplate Due to Transverse Load [Rmom]: = B * Ft + Sum of X Moments

= 1800.00 * 32862.02 + 0.00 = 59175.61 N-m

(59)

Eccentricity (e): = Rmom / QO

= 59175.61/154388.44

= 383.14 mm < Bplen/6 --> No Uplift in Transverse direction

Bolt Area due to Transverse Load [Bltareart]: = 0 (No Uplift)

Required of a Single Bolt [Bltarear]

= max[Bltarearl, Bltarears, Bltareart] = max[0.0000 , 21.9221 , 0.0000 ] = 21.9221 mm²

ASME Horizontal Vessel Analysis: Stresses for the Right Saddle (per ASME Sec. VIII Div. 2 based on the Zick method.)

= min( 300.000 + 1.56*sqrt( 1518.0000 * 24.0000 ), 2 * 500.000 ) = 597.7598 mm

(60)

Saddle Force Q, Operating Case 231006.05 N

= Ftr * ( Ft/Num of Saddles + Z Force Load ) * B / E = 3.00 * ( 10243.8/2 + 27740 ) * 1800.0000/2629.2532

(61)

= 67492.5 N

Saddle Reaction Force due to Earthquake Fl or Friction [Fsl]:

= max( Fl, Friction Force, Sum of X Forces ) * B / Ls = max( 5521.89 , 0.00 , 30228 ) * 1800.0000/1500.0000 = 36273.6 N

Saddle Reaction Force due to Earthquake Ft [Fst]:

= Ftr * ( Ft/Num of Saddles + Z Force Load ) * B / E = 3.00 * ( 10243/2 + 27740 ) * 1800.0000/2629.2532 = 67492.5 N

Note: The Wind and Seismic Forces in the horizontal directions have been added together by user request.

Summary of Loads at the base of this Saddle:

Vertical Load (including saddle weight) 235878.77 N Transverse Shear Load Saddle 32862.02 N Longitudinal Shear Load Saddle 30228.00 N

(62)

Note: Wear Plate is Welded to the Shell, k = 0.1

The Computed K values from Table 4.15.1:

K1 = 0.1066 K2 = 1.1707 K3 = 0.8799 K4 = 0.4011 K5 = 0.7603 K6 = 0.0529 K7 = 0.0132 K8 = 0.3405 K9 = 0.2711 K10 = 0.0581 K1* = 0.1923

Note: Dimension a is less than Rm/2.

= -Q*a [1 - (1- a/L + (R²-h2²)/(2a*L))/(1+(4h2)/3L)] = -231006*500.00[1-(1-500.00/2500.00+(1518.000²-756.000²)/ (2*500.00*2500.00))/(1+(4*756.00)/(3*2500.00))]

= 7404.3 N-m

= Q*L/4(1+2(R²-h2²)/(L²))/(1+(4h2)/( 3L))-4a/L = 231006*2500/4(1+2(1517²-756²)/(2500²))/(1+(4*756)/ (3*2500))-4*499/2500

= 44460.6 N-m

Longitudinal Stress at Top of Shell (4.15.6) [Sigma1]: = P * Rm/(2t) - M2/(pi*Rm²t)

= 5.000 * 1518.000/(2*24.000 ) - 44460.6/(pi*1518.0²*24.000 ) = 15.56 MPa

Longitudinal Stress at Bottom of Shell (4.15.7) [Sigma2]: = P * Rm/(2t) + M2/(pi * Rm² * t)

= 5.000 * 1518.000/(2 * 24.000 ) + 44460.6/(pi * 1518.0² * 24.000 ) = 16.07 MPa

(63)

Longitudinal Stress at Top of Shell at Support (4.15.8) [Sigma3]: = P * Rm/(2t) - M1/(pi * Rm² * t)

= 5.000 * 1518.000/(2 * 24.000 ) - 7404.3/(pi * 1518.0² * 24.000 ) = 15.77 MPa

Longitudinal Stress at bottom of Shell at Support (4.15.9) [Sigma4]: = P * Rm/(2t) + M1/(pi*Rm²t)

= 5.000 * 1518.000/(2*24.000 ) + 7404.3/(pi*1518.0²*24.000 ) = 15.86 MPa

Maximum Shear Force in the Saddle (4.15.5) [T]: = Q(L-2a)/(L+(4*h2/3))

= 231006 ( 2500.00 - 2 * 500.00 )/(2500.00 + ( 4 * 756.00/3)) = 98776.8 N

Shear Stress in the shell no rings, stiffened (4.15.15) [tau3]: = K3 * Q / ( Rm * t )

= 0.8799 * 231006/( 1518.0000 * 24.0000 ) = 5.58 MPa

Shear Stress in the head, shell stiffened (4.15.16) [tau3*]: = K3 * Q / ( Rm * th )

= 0.8799 * 231006/( 1518.0000 * 10.0000 ) = 13.39 MPa

Membrane stress in the head as a stiffener (4.15.18) [sigma5]: = K4 * Q/(Rm*th) + ((P*Ri)/(2*th)) * (Ri/h2) = 0.4011 * 231006/(1518.00 * 10.000 ) +

((5.00 * 1506.00 )/(2 * 10.000 ))*(1506.00/756.00 ) = 81.12 MPa

(64)

Decay Length (4.15.22) [x1,x2]: = 0.78 * sqrt( Rm * t )

= 0.78 * sqrt( 1518.000 * 24.000 ) = 148.880 mm

Circumferential Stress in shell, no rings (4.15.23) [sigma6]: = -K5 * Q * k / ( t * ( b + X1 + X2 ) )

= -0.7603 * 231006 * 0.1/( 24.000 * ( 300.00 + 148.88 + 148.88 ) ) = -1.22 MPa

Circ. Comp. Stress at Horn of Saddle, L<8Rm (4.15.25) [sigma7*]: = -Q/(4*t*(b+X1+X2)) - 12*K7*Q*Rm/(L*t²)

= -231006/(4*24.000 *(300.000 +148.880 +148.880 )) - 12 * 0.013 * 231006 * 1518.000/(2500.000 * 24.000²) = -42.64 MPa

Effective reinforcing plate width (4.15.1) [B1]:

= min( b + 1.56 * sqrt( Rm * t ), 2a )

= min( 300.00 + 1.56 * sqrt( 1518.000 * 24.000 ), 2 * 500.000 ) = 597.76 mm

Results for Vessel Ribs, Web and Base

Baseplate Length Bplen 2619.9998 mm Baseplate Thickness Bpthk 22.0000 mm Baseplate Width Bpwid 300.0000 mm Number of Ribs ( inc. outside ribs ) Nribs 6 Rib Thickness Ribtk 10.0000 mm Web Thickness Webtk 10.0000 mm Web Location Webloc Center

(65)

Moment of Inertia of Saddle - Lateral Direction Y A AY Io Shell 12. 16718. 200615. 3209840. Wearplate 29. 4000. 116000. 3397330. Web 156. 2440. 380640. 71485416. BasePlate 289. 6600. 1907400. 551504256. Totals 486. 29758. 2604655. 629596864. Value C1 = Sumof(Ay)/Sumof(A) = 88. mm Value I = Sumof(Io) - C1*Sumof(Ay) = 401616576. mm**4 Value As = Sumof(A) - Ashell = 13040. mm²

K1 = (1+Cos(beta)-.5*Sin(beta)² )/(pi-beta+Sin(beta)*Cos(beta)) = 0.2035

Fh = K1 * Q = 0.2035 * 231006.047 = 47014.7461 N

Tension Stress, St = ( Fh/As ) = 3.6057 MPa Allowed Stress, Sa = 0.6 * Yield Str = 157.2060 MPa

d = B - R*Sin(theta) / theta = 560.5480 mm Bending Moment, M = Fh * d = 26364.7051 N-m

Bending Stress, Sb = ( M * C1 / I ) = 5.7441 MPa Allowed Stress, Sa = 2/3 * Yield Str = 174.6733 MPa

Minimum Thickness of Baseplate per Moss :

= ( 3 * ( Q + Saddle_Wt ) * BasePlateWidth / ( 4 * BasePlateLength * AllStress ))½

(66)

= 10.769 mm

Calculation of Axial Load, Intermediate Values and Compressive Stress

Effective Baseplate Length [e]:

= ( Bplen - Clearance ) / ( Nribs - 1)

= ( 2619.9998 - 25.4 )/( 6 - 1 ) = 518.9200 mm

Baseplate Pressure Area [Ap]: = e * Bpwid / 2

= 518.9200 * 300.0000/2 = 77837.9922 mm²

Axial Load [P]: = Ap * Bp

= 77838.0 * 0.29 = 22876.7 N

Area of the Rib and Web [Ar]:

= ( Bpwid - Clearance - Webtk ) * Ribtk + e/2 * Webtk

= ( 300.000 - 25.4 - 10.000 ) * 10.000 + 518.9200/2 * 10.000 = 5240.600 mm²

Compressive Stress [Sc]: = P/Ar

= 22876.7/5240.5996 = 4.3656 MPa

Check of Outside Ribs:

Inertia of Saddle, Outer Ribs - Longitudinal Direction

(67)

Bending Moment [Rm]:

= Fl /( 2 * Bplen ) * e * rl / 2

= 30228.0/( 2 * 2620.00 ) * 518.920 * 1041.00/2 = 1558.746 N-m

KL/R < Cc ( 16.9338 < 122.7360 ) per AISC E2-1

( 5/3+3*(16.93 )/(8* 122.74 )-( 16.93³)/(8*122.74³) Sca = 151.05 MPa

AISC Unity Check on Outside Ribs ( must be <= 1.0 ) Check = Sc/Sca + (Rm/Z)/Sba

Check = 4.37/151.05 + (1558.75/132033.219)/174.67 Check = 0.10

Check of Inside Ribs

Inertia of Saddle, Inner Ribs - Axial Direction

KL/R < Cc ( 10.1559 < 122.7360 ) per AISC E2-1

( 5/3+3*(10.16 )/(8* 122.74 )-( 10.16³)/(8*122.74³) Sca = 153.81 MPa

(68)

AISC Unity Check on Inside Ribs ( must be <= 1.0 ) Check = Sc/Sca + (Rm/Z)/Sba

Check = 5.84/153.81 + ( 1429.06/125990.094)/174.67 Check = 0.10

Input Data for Base Plate Bolting Calculations:

Total Number of Bolts per BasePlate Nbolts 8 Total Number of Bolts in Tension/Baseplate Nbt 4 Bolt Material Specification SA-193 B7 Bolt Allowable Stress Stba 172.38 MPa Bolt Corrosion Allowance Bca 0.0000 mm Distance from Bolts to Edge Edgedis 50.8000 mm Nominal Bolt Diameter Bnd 22.0000 mm Thread Series Series TEMA Metric BasePlate Allowable Stress S 137.90 MPa Area Available in a Single Bolt BltArea 272.4190 mm² Saddle Load QO (Weight) QO 168386.3 N Saddle Load QL (Wind/Seismic contribution) QL 36273.6 N Maximum Transverse Force Ft 32862.0 N Maximum Longitudinal Force Fl 30228.0 N Saddle Bolted to Steel Foundation Yes

Bolt Area Calculation per Dennis R. Moss

Bolt Area Requirement Due to Longitudinal Load [Bltarearl]:

= 0.0 (QO > QL --> No Uplift in Longitudinal direction)

Bolt Area due to Shear Load [Bltarears]: = Fl / (Stba * Nbolts)

(69)

= 30228.00/(172.38 * 8.00 ) = 21.9221 mm²

Bolt Area due to Transverse Load

Moment on Baseplate Due to Transverse Load [Rmom]: = B * Ft + Sum of X Moments = 1800.00 * 32862.02 + 0.00 = 59175.61 N-m Eccentricity (e): = Rmom / QO = 59175.61/168386.27

= 351.29 mm < Bplen/6 --> No Uplift in Transverse direction

Bolt Area due to Transverse Load [Bltareart]: = 0 (No Uplift)

Required of a Single Bolt [Bltarear]

= max[Bltarearl, Bltarears, Bltareart] = max[0.0000 , 21.9221 , 0.0000 ] = 21.9221 mm²

(70)

ASME Horizontal Vessel Analysis: Stresses for the Left Saddle (per ASME Sec. VIII Div. 2 based on the Zick method.)

Horizontal Vessel Stress Calculations : Test Case

= min( 300.000 + 1.56*sqrt( 1515.0000 * 30.0000 ), 2 * 500.000 ) = 632.5765 mm

(71)

= Ftr * ( Ft/Num of Saddles + Z Force Load ) * B / E = 3.00 * ( 3380.4/2 + 0 ) * 1800.0000/2624.0571 = 3478.3 N