PV Elite and CodeCalc
Verification and Quality Assurance Manual
Version 2014 (16.0)
November 2013
2
PV Elite and CodeCalc Verification and Quality Assurance Manual
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PV Elite and CodeCalc Verification and Quality Assurance Manual
3
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PV Elite and CodeCalc Verification and Quality Assurance Manual
5
Contents
Introduction ... 7
Intergraph CAS Quality Assurance ... 9
Software Purpose... 9
Intellectual Property Statement ... 9
Management/Organization ... 10
PV Elite Development ... 10
User Documentation ... 10
Product Support ... 11
Software Issue Tracking/Resolution ... 11
Software Verification ... 13
Test Control ... 13
Beta Tests ... 14
Additional Manual Checks for Staff and Beta Users ... 15
PV Elite Test Jobs ... 19
Corrective Action Standard ... 20
Post-Development Procedures ... 20
Distribution Control ... 21
Pre-Shipping Procedures ... 21
CodeCalc QA Checks ... 23
Introduction ... 23
Shell and Head Checks ... 24
Nozzle Checks ... 26
Flange Checks ... 28
Cone Checks ... 31
Floating Heads Checks ... 32
Horizontal Vessel Checks ... 34
Leg and Lug ... 34
ASME Tubesheets Checks ... 36
TEMA Tubesheets Checks ... 37
WRC 107 Checks ... 38
Pipe and Pad Checks ... 39
Base Ring Checks ... 39
Half-Pipe Check ... 40
Large Opening Checks ... 41
Rectangular Vessel Checks ... 42
PV Elite Sample Benchmark Problem Sets ... 45
Problem 1 - Natural Frequency Calculation ... 45
Problem 2 - Example of Stiffening Ring Calculation ... 49
Problem 3 - Nozzle Reinforcement, Weld Strength, Weld Size ... 52
Problem 4 - Vessel under Internal and External Pressure on Legs ... 65
Problem 5 - Vertical Vessel with Wind and Seismic Loads ... 74
Problem 6 - Comparison against CAESAR II ... 83
Problem 7 - ASME Section VIII Division 2 Sample Comparisons ... 86
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PV Elite and CodeCalc Verification and Quality Assurance Manual
Index ... 101
PV Elite and CodeCalc Verification and Quality Assurance Manual
7
S
E C T I O N
1
The PV Elite
®/CodeCalc
®Verification and Quality Assurance Manual provides a standard set of
PV Elite/CodeCalc jobs that are used in verifying both the operation of the software and the
accuracy of the result for each release of the PV Elite/CodeCalc package. The examples
presented in this manual are a representative cross-section of the jobs run by Intergraph CAS.
The jobs selected for this manual compare the PV Elite/CodeCalc output with results published
in industry journals and with results from other software products. The PV Elite/CodeCalc output
is (also) verified with hand and/or MathCad™ calculations.
The component-analysis part of PV Elite, when sold separately, is called CodeCalc.
CodeCalc-specific results can be found in the Software Verification section of this manual. In all
other sections, the software is referred to simply as PV Elite.
This manual consists of two major sections: Intergraph CAS Quality Assurance and Software
Verification.
Intergraph CAS Quality Assurance describes the quality assurance procedures employed by
Intergraph CAS to ensure that PV Elite is producing correct results.
Software Verification explains a series of benchmark jobs that you can use to confirm
software accuracy. These jobs compare PV Elite output to published results, to output from
similar software, or to hand calculations. For each job in this section, a brief description of
the job and any special considerations are discussed. Following the discussion is a graphical
representation of the system with selected result comparisons. Because of the volume of
output, important results like required thickness, maximum allowable working pressure
(MAWP), and stress are listed in tables. Users interested in the entire output can re-analyze
the jobs as necessary.
The PV Elite development team is constantly testing and adding new test jobs to the QA
benchmark problem set. Currently, there are more than 250 test jobs run which test thousands
of different calculations. It is impractical to include all of these tests in this manual. As new
Quality Assurance procedures are published, they will be incorporated into the QA methods
employed by Intergraph CAS. Users with questions, comments, or suggestions are encouraged
to contact Intergraph CAS to discuss future revisions to this document. User requests for new
features are always welcome. By working with the user, the PV Elite development staff will
continue to develop a product that best meets the demands of pressure-vessel design and
analysis users.
PV Elite and CodeCalc Verification and Quality Assurance Manual
9
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E C T I O N
2
Software quality assurance is generally a speculative pursuit because, no matter how much
testing is performed, the next test may reveal an error in the software. The goal of any quality
assurance standard is to perform enough testing to achieve such a level of confidence in the
software that errors are rare and unlikely. With this objective in mind, several organizations have
published guidelines for use in software quality assurance.
In This Section
Software Purpose ... 9
Intellectual Property Statement... 9
Management/Organization ... 10
PV Elite Development ... 10
User Documentation ... 10
Product Support ... 11
Software Issue Tracking/Resolution ... 11
Software Purpose
PV Elite is a package of nineteen applications that work together to design and analyze
pressure vessels and heat exchangers. The purpose of the software is to provide the
mechanical engineer with easy-to-use, technically sound, well-documented calculations that will
expedite and simplify vessel-design and re-rating tasks. The software also provides recent,
industry-accepted analyses of the designs.
Calculations in PV Elite are based on the latest editions of national codes such as the ASME
Boiler and Pressure Vessel Code, or other relevant industry standards that are not covered
directly by ASME VIII-1, VIII-2 or other codes.
Intellectual Property Statement
This manual and its contents should be considered proprietary. This material should not be
copied or distributed to other parties without the expressed written consent of Intergraph CAS.
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PV Elite and CodeCalc Verification and Quality Assurance Manual
Management/Organization
At Intergraph CAS, the Chief Architect, Software Engineering Manager, and Product Manager
oversee the development and testing of the software product. Software development team
members include: engineers, software developers, and a technical writer. All members of the
development team support customers and test the software prior to each release. Specialized
technical support representatives work closely with the development team. In addition, an
on-staff, certified Nuclear Quality Assurance (NQA) lead auditor oversees the quality assurance
program followed by the team.
PV Elite Development
Intergraph CAS is wholly responsible for all software made available to the public that bears the
Intergraph label on the distribution media.
Changes to PV Elite are made by or with the consent of the Product Manager. Additional
members of the software team include engineers, who interact at the same level and
communicate directly with the product manager. Therefore, all software issues can be brought to
the attention of Product Manager quickly and easily.
Software engineers each bring a different kind of expertise to the team and write routines for
specialized functions in the software. For example, the source code to perform structural steel
checks may be written by an engineer at Intergraph CAS whose educational background
permits him to do this efficiently.
All members of the development staff provide customer support for PV Elite, directly or
indirectly. One member of the team is tasked with quality assurance procedures for each
release.
User Documentation
The PV Elite user has online access to documentation spanning all facets of the software,
including all of the ancillary processors and interfaces. The standard PV Elite documentation set
consists of the following documents:
PV Elite User's Guide
CodeCalc User's Guide
Quick Start Guide
All of these documents can be accessed online, from the Help tab in PV Elite. The PV Elite
documentation accompanies each new version of the program and is supplied in both PDF and
CHM (online help) formats.
Contact information for Intergraph CAS is included in these documents, as well as displayed in
the help system, and in a variety of other locations in the software. We encourage users
experiencing problems or confusion with the software to reference the documentation first, and
then contact us for further resolution and suggestions.
PV Elite and CodeCalc Verification and Quality Assurance Manual
11
Product Support
Intergraph CAS welcomes input/suggestions from our users. Users having problems with our
software may freely contact Intergraph CAS through our eCustomer support system, which is
found on our company website.
Our Technical Support staff may ask users with a numerical/computational issue in PV Elite to
submit the job to Intergraph CAS. This allows our support staff to identify the problem and locate
the cause, and then contact the user for resolution.
Software Issue Tracking/Resolution
PV Elite supports standard practices for tracking released software issues, including:
Incorporating user feedback directly back into the development process.
Notifying users regarding hot fix or service pack updates issued throughout development
Following software release criteria based on issue review and prioritization.
PV Elite and CodeCalc Verification and Quality Assurance Manual
13
S
E C T I O N
3
This section describes the test methods through which PV Elite software team performs Quality
Assurance testing on PV Elite. In addition, the section describes test methods that you can
implement to validate your PV Elite program data against industry-standard benchmarks.
In This Section
Test Control ... 13
Beta Tests ... 14
Additional Manual Checks for Staff and Beta Users ... 15
PV Elite Test Jobs ... 19
Corrective Action Standard ... 20
Post-Development Procedures ... 20
Distribution Control ... 21
Pre-Shipping Procedures ... 21
CodeCalc QA Checks ... 23
PV Elite Sample Benchmark Problem Sets ... 45
Test Control
Currently in the United States there is no organization that formally establishes the credibility of
pressure-vessel analysis software. Therefore, software suppliers take on this responsibility.
Generally, there are two ways to establish that any software product is performing correctly:
Comparing product results to hand calculations.
Comparing results to previously verified results from an external source.
If these methods compare favorably to software-generated results, then the software is
assumed to be performing as expected. If the results do not compare favorably, the PV Elite
development team identifies the differences and corrects the problem.
Testing Process
Before a new version of PV Elite is released, the development personnel perform alpha-level
testing. This involves checking the Fortran/C++ or assembler code and running of basic test
problems designed to test the functionality of the feature addition, error and abort conditions,
and so forth. Next, the development staff generates a series of alpha jobs that:
Test new features against existing software.
Run tests against industry standard programs, such as Compress™ and BJAC™ teams.
Suggest to customers that they independently compare the results of PV Elite against their
own in-house program or spreadsheets.
Test new features against hand calculations.
Test new features against published literature, such as the ASME VIII-1, PTB-3, and other
codes.
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PV Elite and CodeCalc Verification and Quality Assurance Manual
Test the interaction between new features and features already existing in the software.
Once these selected alpha jobs are run and verified to the satisfaction of the lead developer,
beta series testing begins.
The new job results are compared to the previously verified results. Program errors that have
been identified are remedied and/or justified.
To summarize, at Intergraph CAS, we believe that thoroughly checking software results by hand
and comparing these results to those of other software and to benchmarks assures a quality
product. This method has worked very well in the past and we will check new versions using this
same methodology.
Beta Tests
Often before releasing the PV Elite software, we distribute the alpha-tested software to users to
perform beta testing. At the end of the test period, we ask that beta users send evaluations to
us, so that we can process the information, resolve any issues found, and archive feedback.
The following are the beta test files for the CodeCalc module available from within PV Elite.
Intergraph CAS ships some of these files with the PV Elite software.
Beta Test Files
Checks.cci
Shell.cci
Extra_qa.cci
Texample.cci
Fexample.cci
Texample2.cci
Fexample2.cci
Vesexmpl.cci
Lg_nozzl.cci
WRC107.cci
Lg_nozzl.cci
Rctexmpl.cci
Mm_wrc.cci
Appy.cci
ASME_Tubesheet.cci
The following section discusses manual checks that users can perform additional verification of
the software.
PV Elite and CodeCalc Verification and Quality Assurance Manual
15
Additional Manual Checks for Staff and Beta Users
The tables below display a list of items that should be verified for each release of PV Elite.
Different individuals should check each item multiple times.
Installation Checklist
Items to Check
Initials
Initials
Comments
A. Program Installation
B. File Extraction
C. File CRC Check
Database Access Checklist
Items to Check
Initials
Initials
Comments
A. Structural Steel - AISC89.BIN
B. ASME Materials *
1. Check some material properties
(selected randomly) with ASME
Code
2. Check yield stress vs.
temperature table.
* Specify different material ID in the input, and check the allowable stresses, density, TEMA
number, and external pressure chart.
Units Checklist
Items to Check
Initials
Initials
Comments
A. Creation of input files
B. Verify change of units
Check each input field of the following modules to verify that the help facilities function properly.
Help Checklist
Items to Check
Initials
Initials
Comments
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PV Elite and CodeCalc Verification and Quality Assurance Manual
Items to Check
Initials
Initials
Comments
1. Shells and Heads
2. Nozzles
3. Flange
4. Conical Sections
5. Floating head
6. Horizontal Vessels
7. ASME Tubesheets
8. Tubesheets
9. WRC107/FEA
10. Leg and Lug
11. Pipe and Pad
12. Base Rings
13. Thin Bellows Exp. Joints
14. Thick Joints
15. Half-Pipe
16. Large Openings
17. Rectangular Vessels
18. WRC 297/Annex G
19. Appendix Y
B. Check HELP Index.
C. Search on a topic.
D. Print a HELP topic.
PV Elite and CodeCalc Verification and Quality Assurance Manual
17
New Input Generation/General Operation Checklist
Items to Check
Initials
Initials
Comments
A. Check each module with a random example.
1. Shells and Heads
2. Nozzles
3. Flange
4. Conical Sections
5. Floating head
6. Horizontal Vessel
7. ASME Tubesheets
8. TEMA Tubesheets
9. WRC 107
10. Leg and Lug
11. Pipe and Pad
12. Base Rings
13. Thin Joints
14. Thick Joints
15. Half Pipes
16. Large Openings
17. Rectangular Vessels
18. WRC 297
19. Appendix Y
B. Graphics
1. Onscreen
2. Printed
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PV Elite and CodeCalc Verification and Quality Assurance Manual
Items to Check
Initials
Initials
Comments
C. Window operation
1. Merge operation
2. Insert/Delete an item
3. Add an item
4. Browse items
Output Review Checklist
Items to Check
Initials
Initials
Comments
A. Review output data in
1. Terminal
2. Printer
3. Disk file
B. Output Processor
1. Results on screen
2. Print the selected chapters
Operating Environments Checklist
Items to Check
Initials
Initials
Comments
A. Dealer Version
B. Windows
C. Network
1. PV Elite and data on network
2. PV Elite on network, data local
3. PV Elite local, data on network
PV Elite and CodeCalc Verification and Quality Assurance Manual
19
Vessel Code Checklist
Items to Check
Initials
Initials
Comments
ASME Section VIII, Div. 1
ASME Section VIII, Div. 2
PD-5500
EN - 13445
Miscellaneous Checklist
Items to Check
Initials
Initials
Comments
A. ESL/SPLM
(a)B. Mouse Operations
C. Material Database Editor
1. Editing materials
2. Adding materials
(a)
Insures program does not run without the ESL.
PV Elite Test Jobs
The PV Elite QA benchmark problem set consists of over 250 different analysis jobs. Each of
these jobs is run prior to release time and compared with the results from previous versions. A
wide variety of jobs are checked, which includes tests of all wind and seismic codes, checks of
baserings, weights, stresses, liquid pressures, MAWP, weights, volumes, required thickness and
many others. By analyzing these jobs, the quality of the software is kept very high and
consistent. Again, these are just a few sample problems run every time we test the software.
Many of the jobs contained in this manual are listed in the table below.
Quality Assurance Test Form
Job Name
Perform Analysis
Analysis Date
104EX4
11436
ANDY1
APP1_7
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PV Elite and CodeCalc Verification and Quality Assurance Manual
Job Name
Perform Analysis
Analysis Date
APP1_7_2
APP1_7_3
APPLCHK
AS_450V2
BEDN237
+200 more jobs
Corrective Action Standard
PV Elite users have many channels through which they can reach the Intergraph CAS
development staff. The main way to contact us is through the eCustomer system. When a
problem or error is detected, the development staff reviews the problem and takes corrective
action. When a user problem is verified to be a defect, a TR (trouble report) is filled out using
internal Intergraph software. After the TR is completed, the problem is fixed, and the user is
notified by email through the eCustomer system. Updated PV Elite files are made available in a
product Hot Fix or Service Pack, which can be downloaded from the eCustomer website. In
many cases, software issues have workarounds. The Intergraph CAS technical support staff
notifies users of workarounds whenever possible.
Post-Development Procedures
After a new version of the software has been developed, Intergraph CAS uses the following
quality assurance procedures to ensure that the new CDs are correct in content, contain the
proper ESL protection schemes, and can be reproduced properly.
1. Scan the development machine for virus infection before producing any distribution set. Use
the latest version of Trend Micro Office Scan virus-scanning software.
2. Assemble in a "clean" directory all of the files that comprise the installation set. This includes
.EXE files, database files, and example files.
3. Run the CRCCHK program to build the CRC verification file.
4. Generate an installation program using Install Shield. Once the DVD is made, test it
according to the Distribution Control procedures outlined below.
PV Elite and CodeCalc Verification and Quality Assurance Manual
21
Distribution Control
To control the distribution and integrity of the program DVDs before sending them out for mass
production, Intergraph CAS adheres to the following procedures:
1. After the quality assurance procedures have been completed, use the lead developer's
computer to make a production copy of PV Elite.
2. Modify the installation program to load any new executables that may be released with the
new version.
3. Load PV Elite onto at least one PC in the production department to check the installation
program and DVD integrity.
4. Use Office Scan virus-scanning software to scan each original, all disk drives, and memory
for known viruses.
5. Using the appropriate ESL, install and test the masters on another computer. All EXE files
accessing the ESL must be tested.
6. Install the masters on a production computer for further use. ESL-specific files should be
copied into the appropriate subdirectories for organizational purposes.
7. Send the masters to the DVD duplicator.
8. Install the software from the DVD onto each of the PCs in the engineering and development
groups at Intergraph CAS.
9. Load the required set of PV Elite executables onto at least one computer in the production
department.
10. Using the DVD and installation checklists, perform periodic testing of the software as
necessary.
The following section provides the tasks that must be performed by the development and
production personnel to verify the quality of disk sets before shipment.
Pre-Shipping Procedures
The following procedures help to ensure that the disk sets shipped by Intergraph CAS contain
the correct product, are not infected with a virus, and are void of imperfections.
1. When DVDs are received from the duplicator, install and test a random selection from the
batch. These final tests will ensure that the DVDs were correctly assembled by the
duplicator, that they are not flawed, and that the ESL interaction routines are in order.
The tests are software-specific and are detailed elsewhere in this manual. None of
these tests should use the environment support available from the programs. Run the tests
from the installation directory. Ensure that the installation directory is empty before
beginning this procedure.
PV Elite and CodeCalc Verification and Quality Assurance Manual
23
S
E C T I O N
4
CodeCalc QA Checks
In This Section
Introduction ... 23
Shell and Head Checks ... 24
Nozzle Checks ... 26
Flange Checks ... 28
Cone Checks ... 31
Floating Heads Checks ... 32
Horizontal Vessel Checks ... 34
Leg and Lug ... 34
ASME Tubesheets Checks ... 36
TEMA Tubesheets Checks ... 37
WRC 107 Checks ... 38
Pipe and Pad Checks ... 39
Base Ring Checks ... 39
Half-Pipe Check ... 40
Large Opening Checks ... 41
Rectangular Vessel Checks ... 42
Introduction
This section provides the results of QA tests for CodeCalc, which is also the
component-analysis part of PV Elite. For simplicity, this part of PV Elite will be referred to as
CodeCalc in this chapter. The following CodeCalc modules have been subjected to Intergraph
CAS quality assurance procedures.
Shell/Head
Nozzle
Flange
Cone
Floating Head
Horizontal Vessel
Leg and Lug
ASME Tubesheets
TEMA Tubesheets
WRC 107/537
Pipe and Pad
Base Ring
Thin Joint
Thick Joint
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PV Elite and CodeCalc Verification and Quality Assurance Manual
Half-Pipe
Large Opening
Rectangular Vessel
Shell and Head Checks
As a part of its quality assurance procedures, Intergraph CAS completed the following shell and
head checks on CodeCalc:
ASME Appendix 1-4, 2 (CodeCalc job: Checks.cc2/ASME VIII-1 2011a, APP 1, 1-4, 2) -
Ellipsoidal head under internal pressure.
Parameters
CodeCalc
ASME
MAWP (psi)
338.87
339
ASME Appendix 1-4, D (CodeCalc job: Checks.cc2/ASME VIII-1 2011a, APP 1, 1-4, D)
-Torispherical head under internal pressure
Parameters
CodeCalc
ASME
Req. thickness (in.)
0.4488
0.45
ASME Appendix 1-4, D2 (CodeCalc job: Checks.cc2/ASME VIII-1 2011a, APP 1, 1-4, D2)
-Torispherical head under internal pressure
Parameters
CodeCalc
ASME
MAWP (psi)
167.16
167
ASME Appendix L-6.1 (CodeCalc job: Checks.cc2/ASME VIII-1 2011a, APP L, L-6.1) -
Ellipsoidal head under external pressure
Parameters
CodeCalc
ASME
A
0.0004623
0.000462
B
5662.91*
5100
EMAWP (psi)
20.9427*
18.9
ASME Appendix L-6.2 (CodeCalc job: Checks.cc2/ASME VIII-1 2011a, APP L, L-6.2)
-Torispherical head under external pressure
PV Elite and CodeCalc Verification and Quality Assurance Manual
25
Parameters
CodeCalc
ASME
A
0.0004157
0.00042
B
5092.85*
4700
EMAWP (psi)
16.9385*
15.6
ASME Appendix L-6.3 (CodeCalc job: Checks.cc2/APP L, L-6.3) -Hemispherical head under
external pressure
Parameters
CodeCalc
ASME
A
0.0004623
0.00046
B
5662.91*
5200
EMAWP (psi)
20.9427*
19.23
ASME Appendix L-6.4 (CodeCalc job: Checks.cc2/APP L, L-6.4) - Conical head under external
pressure
Parameters
CodeCalc
ASME
Design Len.
102.30
102.30
A
0.0005912
0.0006
B
7004.29
6900
EMAWP (psi)
38.1777
37.5
ASME Appendix L-9.2.1 (CodeCalc job: Checks.cc2/APP L, L-9.1, 2) - Minimum design metal
temperature (MDMT) of a cylinder
Parameters
CodeCalc
ASME
Unadjusted MDMT (°F)
31
31
Adjusted MDMT (°F)
12
12
ASME Appendix. L-5 (CodeCalc job: Checks.cc2/APP L, L-5): Selection of a circumferential
stiffening ring for a cylinder under external pressure. A bar type 2 in. x 3.75 in. stiffening ring
selected.
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PV Elite and CodeCalc Verification and Quality Assurance Manual
Parameters
CodeCalc
ASME
Moment of Inertia (in.
4)
16.541
16.57
Required Moment of
Inertia (in.
4)
16.1933
16.25
Weld load
643.78
644
Weld Allowable load
1828.75
1830
Minimum Weld Thickness
0.25
0.25
* As of this printing the ASME Appendix L6.1, 6.2, 6.3 appear to be in error in determining the B
value from the External Pressure chart CS-2 for SA-285C, with E = 24.5 x 106 psi. When points
lie in the linear portion of the chart CS-2 (as in cases 4, 5, 60, CodeCalc uses the formula B =
A*E/2.
Nozzle Checks
Nozzle checks involve the area of reinforcement and failure path calculations. Intergraph CAS
performed the following nozzle checks using CodeCalc:
ASME Appendix L-7.3b (CodeCalc Job: Checks.cc2/APP L, L-7.3B): Insert-type Nozzle lying on
a longitudinal weld of a cylindrical shell. A 19-in. Diameter and 0.5-in. thick reinforcement pad is
selected.
Parameters
CodeCalc
ASME
Req. Thk. Shell (in.)
0.5300
0.530
Req. Thk. Noz (in.)
0.0893
0.0893
Reinforcement Area Req. (in.
2) 6.228
6.23
Total Area available (in.
2)
6.267
6.27
Total weld load, W (lb)
72539.17
72600
Weld load for path 1-1, W
1-1(lb)
71556.86
71600
Weld load for path 2-2, W
2-2(lb)
34856.25
34900
Weld load for path 3-3, W
3-3(lb)
82280.86
82300
Strength of failure path 1-1 (lb)
203289
203000
Strength of failure path 2-2 (lb)
229116
229000
PV Elite and CodeCalc Verification and Quality Assurance Manual
27
ASME Appendix L-7.4 (CodeCalc Job Checks.cc2/APP L, L-7.4): Abutting-type Nozzle on a
cylindrical shell. A 26-in. Diameter and 2.75-in. (average value) thick reinforcement pad is
selected.
Parameters
CodeCalc
ASME
Req. Thk. Shell (in.)
1.8593
1.83
Req. Thk. Noz (in.)
0.3542
0.292
Reinforcement Area Req. (in.
2)
29.554
29.6
Total Area available (in.
2)
33.647
33.7
Total weld load, W (lb)
317668.22
318000
Weld load for path 1-1, W
1-1(lb)
364331.03
364000
Strength of failure path 1-1 (lb)
319507
318000
ASME Appendix L-7.6 (CodeCalc Job Checks.cc2/APP L, L-7.6): Insert-type Nozzle without pad
on a 2:1 ellipsoidal head.
Parameters
CodeCalc
ASME
Req. Thk. Head (in.)
0.0912
0.091
Req. Thk. Noz (in.)
0.0512
0.051
Reinforcement Area Req. (in.
2)
0.755
0.754
Total Area available (in.
2)
1.146
1.15
Total weld load, W (lb)
302.43*
250
Weld load for path 1-1, W
1-1(lb)
2992.86
2990
Weld load for path 2-2, W
2-2(lb)
7691.86
7690
Strength of failure path 1-1 (lb)
47542
47500
Strength of failure path 2-2 (lb)
39831
39800
*The differences in dimensions, of the order of 1E-3, are magnified after being multiplied by the
allowable stress.
ASME Appendix L-7.7 (CodeCalc Job Checks.cc2/APP L, L-7.71): Abutting-type Hillside Nozzle
on a cylindrical shell.
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PV Elite and CodeCalc Verification and Quality Assurance Manual
Parameters
CodeCalc
ASME
Req. Thk. Shell (in.)
1.1364
1.14
Req. Thk. Noz (in.)
0.1389
0.139
Area Req. in circumferential dir.
(in.
2)
3.720
3.68
Area available in circumferential
dir. (in.
2)
7.486
7.16
Area Req. in longitudinal dir.
(in.
2)
4.545
4.56
Area available in longitudinal dir.
(in.
2)
2.607
2.59
The area available in the longitudinal direction is insufficient. The new area values after
increasing the nozzle thickness from 0.5 in. to 0.875 in.
Parameters
CodeCalc
ASME
Area Req. in longitudinal dir. in.
2) 4.545
4.56
Area available in longitudinal dir.
(in.
2)
5.198
5.18
Minimum Weld throat. (in.
2)
0.25
0.25
Actual Weld throat. (in.
2)
0.3535
0.35
Flange Checks
Intergraph CAS completed the following flange checks on CodeCalc:
Taylor Forge, Bulletin 502 (CodeCalc Job: Checks.cc2/TAYLOR FORGE)- Integral weld neck
flange.
Parameters
CodeCalc
Taylor Forge
Gasket Reaction Diameter, G (in.)
33.888
33.88
Operating
Bolt Load W
M1(lb)
432484.688
432484
Gasket Seating Force, H
G(lb)
71713.25
71713
PV Elite and CodeCalc Verification and Quality Assurance Manual
29
Parameters
CodeCalc
Taylor Forge
Face Pressure, M
T(in. lb)
79248
79242
Gasket Load, M
G(in. lb)
111600
111599
Total Moment, M
o(in. lb)
814128
814133
Longitudinal Hub Stress (psi)
22865.0
22865
Radial Flange Stress (psi)
10981.8
10982
Tangential Stress Flange (psi)
6799.5
6800
Seating
Bolt Load, W
M2(lb)
120608.648
120609
Flange Design Bolt Load, W (lb)
464192.38
464192
Total Moment, M
G(in. lb) *
722364
722371
Longitudinal Hub Stress (psi)
20287.8
20288
Radial Flange Stress (psi)
9744.0
9744
Tangential Stress Flange (psi)
6033.1
6033
*Total Moment is M
Gin the Taylor Forge bulletin 502 and M
Ain CodeCalc output.
Taylor Forge, Bulletin 502 (CodeCalc Job: Checks.cc2/ FULL FACE SLIP)- Loose, Slip on
Flange with a full face gasket.
Parameters
CodeCalc
Taylor Forge
Dist. to Gasket Load Reaction hg, (in.) 1.328
1.325
Gasket Reaction Diameter, G (in.)
26.844
26.85
Full Face ID Pressure Load, H’GY (lb) 48614.715
48555
Operating
Bolt Load, WM1 (lb)
96302.469
96286
Gasket Seating Force, HG (lb)
68003.63
67994
End Pressure, MD (in. lb)
93300
93305
Face Pressure, MT (in. lb)
17364
17390
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PV Elite and CodeCalc Verification and Quality Assurance Manual
Parameters
CodeCalc
Taylor Forge
Longitudinal Hub Stress (psi)
1951.8
1995
Radial Flange Stress (psi)
5141.6
5236
Tangential Flange Stress (psi)
13470.3
13176
Bolt Circle Stress (psi)
2585.7
2679
Seating
Bolt Load, WM2 (lb)
71806.469
23196
Flange Design Bolt Load, W (lb)
110451.23
110460
Reverse Moment MG (in. lb) *
29160
29101
*Reverse Moment is MG in Taylor Forge bulletin 502 and MR in CodeCalc output. See "Notes"
below.
a. The value of hg, in the Taylor Forge Bulletin is off by 0.0029, using
With C = 29.5 in. and B =24 in. this comes out to be 1.3279 and not 1.325. This error is
magnified resulting in error in the calculations of G, W
M1, W, H
G
