2. test separator v-005 rev.1

8/11/2019 2. Test Separator v-005 Rev.1

1/79

PT. TUBAN STEEL WORKS

Jl RAYA TUBAN SEMARANG KM 19 DESA PURWEROJO

KECAMATAN JENU KABUPATEN TUBAN 62352

JAWA TIMUR

Phone +62 356 491260 dan Fax +62 356 491155

COMPRESS Pressure Vessel Design Calculations

Item: HORIZONTAL TEST SEPARATORVessel No: V-005

Customer: PT. DWIPA CITRA PERKASA

Contract:

Designer: my

Date:


2/79

Table of ContentsSettings Summary............... .....................................................................................................................................................................................1/76

Thickness Summary................................................................................................................................................................................................2/76

Pressure Summary..................... .............................................................................................................................................................................3/76

Hydrostatic Test.......................................................................................................................................................................................................5/76

Nozzle Summary......................... .............................................................................................................................................................................6/76

Nozzle Schedule.......................................................................................................................................................................................................7/76

Weight Summary................................................................ ......................................................................................................................................8/76

Ellipsoidal Head Left................................................................................................................................................................................................9/76

Straight Flange on Ellipsoidal Head Left.............................................................................................................................................................11/76

Course #1.............................................. ..................................................................................................................................................................12/76

Course #2.............................................................................. ..................................................................................................................................13/76

Ellipsoidal Head Right...........................................................................................................................................................................................14/76

Straight Flange on Ellipsoidal Head Right............... ............... ................ ............... ............... ................ ............... ................ ............... ............... ..16/76

Inlet Nozzle (N1).......................... ...........................................................................................................................................................................17/76

Gas Outlet Nozzle (N2)...........................................................................................................................................................................................19/76

Water Outlet (N3)....................................................................................................................................................................................................21/76

Burst Disk (N4).......................................... .............................................................................................................................................................23/76

Oil Outlet (N5)............................................ .............................................................................................................................................................25/76

Water Level Gauge (N6A)......................................................................................................................................................................................27/76

Water Level Gauge (N6B)......................................................................................................................................................................................30/76

WAter Level Control (N7A).............. ......................................................................................................................................................................33/76

WAter Level Control (N7B).............. ......................................................................................................................................................................35/76

Oil Level Gauge (N8A)...........................................................................................................................................................................................38/76

Oil Level Gauge (N8B)...........................................................................................................................................................................................41/76

Oil Level Control (N9A)..........................................................................................................................................................................................44/76

Oil Level Control (N9B)..........................................................................................................................................................................................47/76

Pressure Relieve Valve (N10)................................................................................................................................................................................50/76

Themowell (N11)................ .....................................................................................................................................................................................52/76

Pressure Gauge (N12).............. ................ ..............................................................................................................................................................54/76

Spare (N13)................................................. ............................................................................................................................................................56/76

Shringkage Tester (N14B).....................................................................................................................................................................................58/76

Shringkage Tester (N14A).....................................................................................................................................................................................61/76

Manway (M1).............. ............... ................ ............... ................ ............... ............... ................ ............... ................ ............... ............... ................ ....64/76

Saddle.....................................................................................................................................................................................................................66/76


3/79

Table of ContentsLifting Lug #1.................... ......................................................................................................................................................................................71/76

Lifting Lug #2......................... .................................................................................................................................................................................73/76

Wind Code..............................................................................................................................................................................................................75/76

Seismic Code............... ................ ............... ................ ............... ................ ............... ............... ................ ............... ................ ............... ............... ..76/76


4/79

Settings Summary

COMPRESS 2014 Build 7400

Units: MKS

Datum Line Location: -50.00 mm from right seam

Design

ASME Section VIII Division 1, 2013 Edition Metric

Design or Rating: Get Thickness from Pressure

Minimum thickness: 2.5 mm per UG-16(b)

Design for cold shut down only: No

Design for lethal service (full radiography required): No

Design nozzles for: Design P, find nozzle MAWP and MAP

Corrosion weight loss: 100% of theoretical loss

UG-23 Stress Increase: 1.20

Skirt/legs stress increase: 1.0

Minimum nozzle projection: 100 mm

Juncture calculations for > 30 only: Yes

Preheat P-No 1 Materials > 1.25" and


5/79

Thickness Summary

Component

IdentifierMaterial Diameter

(mm)

Length

(mm)

Nominal t

(mm)

Design t

(mm)

Total Corrosion

(mm)

Joint

ELoad

Ellipsoidal Head Left SA-516 70 1,157 OD 311.75 45* 41.98 3.18 1.00 Internal

Straight Flange on Ellipsoidal Head Left SA-516 70 1,157 OD 50 50 43.63 3.18 1.00 Internal

Course #1 SA-516 70 1,157 OD 1,524 45 43.63 3.18 1.00 Internal

Course #2 SA-516 70 1,157 OD 1,524 45 43.63 3.18 1.00 Internal

Straight Flange on Ellipsoidal Head Right SA-516 70 1,157 OD 50 50 43.63 3.18 1.00 Internal

Ellipsoidal Head Right SA-516 70 1,157 OD 311.75 45* 41.98 3.18 1.00 Internal

Nominal t: Vessel wall nominal thickness

Design t: Required vessel thickness due to governing loading + corrosion

Joint E: Longitudinal seam joint efficiency

* Head minimum thickness after forming

Load

internal: Circumferential stress due to internal pressure governs

external: External pressure governs

Wind: Combined longitudinal stress of pressure + weight + wind governs

Seismic: Combined longitudinal stress of pressure + weight + seismic governs

PT. TUBAN STEEL WORK V-005 2/76


6/79

Pressure Summary

Pressure Summary for Chamber bounded by Ellipsoidal Head Right and Ellipsoidal Head Left

Identifier

P

Design

( kg/cm2)

T

Design

( C)

MAWP

( kg/cm2)

MAP

( kg/cm2)

MDMT

( C)

MDMT

Exemption

Impact

Tested

Ellipsoidal Head Left 101.24 100 109.67 117.7 14.33 Note 1 No

Straight Flange on Ellipsoidal Head Left 101.24 100 117.71 125.98 14.33 Note 2 No

Course #1 101.24 100 104.77 112.98 14.33 Note 2 No

Course #2 101.24 100 104.77 112.98 14.33 Note 2 No

Straight Flange on Ellipsoidal HeadRight 101.24 100 117.71 125.98 14.33 Note 2 No

Ellipsoidal Head Right 101.24 100 109.67 117.7 14.33 Note 3 No

Saddle 101.24 100 101.33 N/A N/A N/A N/A

Manway (M1) 101.24 100 101.33 117.48 14.33 Note 4 No

Inlet Nozzle (N1) 101.24 100 117.51 125.98 2.97 Note 5 No

Pressure Relieve Valve (N10) 101.24 100 101.84 112.98 -1 Note 6 No

Themowell (N11) 101.24 100 104.77 112.98 0.91 Note 7 No

Pressure Gauge (N12) 101.24 100 104.77 112.98 -29 Note 8 No

Spare (N13) 101.24 100 104.77 112.98 0.91 Note 7 No

Shringkage Tester (N14A) 101.24 100 104.77 112.98 -29 Note 8 No

Shringkage Tester (N14B) 101.24 100 104.77 112.98 -29 Note 8 No

Gas Outlet Nozzle (N2) 101.24 100 104.77 112.98 12.98 Note 9 No

Water Outlet (N3) 101.24 100 104.77 112.98 0.91 Note 7 No

Burst Disk (N4) 101.24 100 104.77 112.98 0.91 Note 7 No

Oil Outlet (N5) 101.24 100 101.84 112.98 -1 Note 6 No

Water Level Gauge (N6A) 101.24 100 104.77 112.98 -29 Note 8 No

Water Level Gauge (N6B) 101.24 100 104.77 112.98 -29 Note 8 No

WAter Level Control (N7A) 101.24 100 104.77 112.98 0.91 Note 7 No

WAter Level Control (N7B) 101.24 100 104.77 112.98 0.91 Note 7 No

Oil Level Gauge (N8A) 101.24 100 104.77 112.98 -29 Note 8 No

Oil Level Gauge (N8B) 101.24 100 104.77 112.98 -29 Note 8 No

Oil Level Control (N9A) 101.24 100 104.77 112.98 -29 Note 8 No

Oil Level Control (N9B) 101.24 100 104.77 112.98 -29 Note 8 No

Chamber design MDMT is 15 CChamber rated MDMT is 14.33 C @ 101.33 kg/cm2

Chamber MAWP hot & corroded is 101.33 kg/cm2@ 100 C

Chamber MAP cold & new is 112.98 kg/cm2@ 25 C

This pressure chamber is not designed for external pressure.



7/79

Notes for MDMT Rating:

Note # Exemption Details

1. Straight Flangegoverns MDMT

2. Material impact test exemption temperature from Fig UCS-66M Curve B = 14.33 C UCS-66 governing thickness = 45 mm

3. Straight Flangegoverns MDMT

4. Nozzle impact test exemption temperature from Fig UCS-66M Curve B = 14.33 C UCS-66 governing thickness = 45 mm.

5. Nozzle impact test exemption temperature from Fig UCS-66M Curve B = 2.97 C UCS-66 governing thickness = 28.58 mm.

6. Nozzle impact test exemption temperature f rom Fig UCS-66M Curve B = -1 C UCS-66 governing thickness = 25.4 mm.


8. Nozzle is impact test exempt per UG-20(f) UCS-66 governing thickness = 14.22 mm.


Design notes are available on the Settings Summarypage.



8/79

Hydrostatic Test

Shop test pressure determination for Chamber bounded by Ellipsoidal Head Right and Ellipsoidal Head Left based on MAWP perUG-99(b)

Shop hydrostatic test gauge pressure is 131.72 kgf/cm2at 25 C (the chamber MAWP = 101.33 kgf/cm

2)

The shop test is performed with the vessel in the horizontal position.

Identifier Local testpressurekgf/cm

2

Test liquidstatic headkgf/cm

2

UG-99(b)stressratio

UG-99(b)pressurefactor

Stressduring testkgf/cm

2

Allowabletest stresskgf/cm

2

Stressexcessive?

Ellipsoidal Head Left (1) 131.86 0.13 1 1.30 1,406.899 2,404.489 No

Straight Flange on Ellipsoidal Head Left 131.86 0.13 1 1.30 1,458.642 2,404.489 No

Course #1 131.86 0.13 1 1.30 1,628.259 2,404.489 No

Course #2 131.86 0.13 1 1.30 1,628.259 2,404.489 No

Straight Flange on Ellipsoidal Head Right 131.86 0.13 1 1.30 1,458.642 2,404.489 No

Ellipsoidal Head Right 131.86 0.13 1 1.30 1,406.899 2,404.489 No

Burst Disk (N4) 131.74 0.02 1 1.30 1,872.723 3,579.201 No

Gas Outlet Nozzle (N2) 131.74 0.02 1 1.30 2,080.773 3,579.201 No

Inlet Nozzle (N1) 131.78 0.06 1 1.30 1,438.555 3,579.201 No

Manway (M1) 131.83 0.1 1 1.30 1,760.641 3,579.201 No

Oil Level Control (N9A) 131.82 0.09 1 1.30 2,115.221 3,579.201 No

Oil Level Control (N9B) 131.78 0.06 1 1.30 2,114.652 3,579.201 No

Oil Level Gauge (N8A) 131.83 0.1 1 1.30 2,115.399 3,579.201 No

Oil Level Gauge (N8B) 131.78 0.05 1 1.30 2,114.565 3,579.201 No

Oil Outlet (N5) 131.88 0.16 1 1.30 2,007.741 3,579.201 No

Pressure Gauge (N12) 131.74 0.02 1 1.30 2,114.07 3,579.201 No

Pressure Relieve Valve (N10) 131.74 0.02 1 1.30 2,005.664 3,579.201 No

Shringkage Tester (N14A) 131.84 0.11 1 1.30 1,948.26 3,579.201 No

Shringkage Tester (N14B) 131.77 0.05 1 1.30 1,947.286 3,579.201 No

Spare (N13) 131.88 0.16 1 1.30 2,037.069 3,579.201 No

Themowell (N11) 131.74 0.02 1 1.30 1,872.723 3,579.201 No

WAter Level Control (N7A) 131.8 0.08 1 1.30 1,873.581 3,579.201 No

WAter Level Control (N7B) 131.77 0.05 1 1.30 1,873.075 3,579.201 No

Water Level Gauge (N6A) 131.81 0.09 1 1.30 2,115.191 3,579.201 No

Water Level Gauge (N6B) 131.76 0.04 1 1.30 2,114.357 3,579.201 No

Water Outlet (N3) 131.88 0.16 1 1.30 2,037.069 3,579.201 No

Notes:(1) Ellipsoidal Head Left limits the UG-99(b) stress ratio.(2) PLstresses at nozzle openings have been estimated using the method described in Division 2 Part 4.5.(3) 1.5*0.9*Syused as the basis for the maximum local primary membrane stress at the nozzle intersection PL.(4) The zero degree angular position is assumed to be up, and the test liquid height is assumed to the top-most flange.

The field test condition has not been investigated for the Chamber bounded by Ellipsoidal Head Right and Ellipsoidal Head Left .

Warning! UG-99(h): The test temperature of 25C is colder than the minimum recommended temperature of 31.33C for the shop test.



9/79

Nozzle Summary

Nozzle

mark

OD

(mm)

tn

(mm)

Req tn

(mm)A1? A2?

ShellReinforcement

Pad Corr

(mm)

Aa/A

r(%)

Nom t

(mm)

Design t

(mm)

User t

(mm)

Width

(mm)

tpad

(mm)

M1 657.75 96 20.94 Yes Yes 45* 42.06 N/A N/A 3.18 100.0

N1 158.75 28.58 9.4 Yes Yes 45* 45 N/A N/A 3.18 132.3

N10 127 25.4 8.91 Yes Yes 45 43.86 N/A N/A 3.18 100.0

N11 104.65 26.92 8.44 Yes Yes 45 N/A N/A N/A 3.18 Exempt



N14A 53.85 14.22 6.6 Yes Yes 45 N/A N/A N/A 3.18 Exempt

N14B 53.85 14.22 6.6 Yes Yes 45 N/A N/A N/A 3.18 Exempt

N2 234.95 41.28 11.29 Yes Yes 45 45 N/A N/A 3.18 101.0



N5 127 25.4 8.91 Yes Yes 45 43.86 N/A N/A 3.18 100.0




N7B 104.65 26.92 8.44 Yes Yes 45 45 N/A N/A 3.18 380.5





tn: Nozzle thickness

Req tn: Nozzle thickness required per UG-45/UG-16

Nom t: Vessel wall thickness

Design t: Required vessel wall thickness due to pressure + corrosion allowance per UG-37

User t: Local vessel wall thickness (near opening)

Aa: Area available per UG-37, governing condition

Ar: Area required per UG-37, governing condition

Corr: Corrosion allowance on nozzle wall

* Head minimum thickness after forming



10/79

Nozzle Schedule

Nozzlemark

Service Size MaterialsImpactTested

Normalized Fine Grain Flange Blind

M1 Manway 657.75 OD x 96 Nozzle SA-105 No No NoNPS 18 Class 900Custom Integral Forging A105

NPS 18 Class 900A105

N1 Inlet Nozzle 158.75 OD x 28.58 Nozzle SA-105 No No NoNPS 4 Class 900LWN A105

No

N10 Pressure Relieve Valve 127 OD x 25.4 Nozzle SA-105 No No NoNPS 3 Class 900LWN A105

No

N11 Themowell 104.65 OD x 26.92 Nozzle SA-105 No No NoNPS 2 Class 900LWN A105

No

N12 Pressure Gauge 53.85 OD x 14.22 Nozzle SA-105 No No NoNPS 1 Class 900LWN A105

No

N13 Spare 104.65 OD x 26.92 Nozzle SA-105 No No NoNPS 2 Class 900LWN A105

No

N14A ShringkageTester 53.85 OD x 14.22 Nozzle SA-105 No No NoNPS 1 Class 900LWN A105

No

N14B ShringkageTester 53.85 OD x 14.22 Nozzle SA-105 No No NoNPS 1 Class 900

LWN A105No

N2 Gas Outlet Nozzle 234.95 OD x 41.28 Nozzle SA-105 No No NoNPS 6 Class 900LWN A105

No

N3 Water Outlet 104.65 OD x 26.92 Nozzle SA-105 No No NoNPS 2 Class 900LWN A105

No

N4 Burst Disk 104.65 OD x 26.92 Nozzle SA-105 No No NoNPS 2 Class 900

LWN A105No

N5 Oil Outlet 127 OD x 25.4 Nozzle SA-105 No No No

NPS 3 Class 900

LWN A105 No

N6A Water Level Gauge 53.85 OD x 14.22 Nozzle SA-105 No No NoNPS 1 Class 900LWN A105

No

N6B Water Level Gauge 53.85 OD x 14.22 Nozzle SA-105 No No NoNPS 1 Class 900

LWN A105No

N7A WAter Level Control 104.65 OD x 26.92 Nozzle SA-105 No No NoNPS 2 Class 900LWN A105

No

N7B WAter Level Control 104.65 OD x 26.92 Nozzle SA-105 No No NoNPS 2 Class 900LWN A105

No

N8A Oil Level Gauge 53.85 OD x 14.22 Nozzle SA-105 No No NoNPS 1 Class 900LWN A105

No

N8B Oil Level Gauge 53.85 OD x 14.22 Nozzle SA-105 No No NoNPS 1 Class 900LWN A105

No

N9A Oil Level Control 53.85 OD x 14.22 Nozzle SA-105 No No NoNPS 1 Class 900LWN A105

No

N9B Oil Level Control 53.85 OD x 14.22 Nozzle SA-105 No No No NPS 1 Class 900LWN A105

No



11/79

Weight Summary

Component

Weight ( kg) Contributed by Vessel ElementsSurface Area

m2Metal

New*

Metal

Corroded*Insulation

InsulationSupports

LiningPiping

+ Liquid

OperatingLiquid

Test Liquid

New Corroded New Corroded

Ellipsoidal Head Left 461 432.4 0 0 0 0 0 0 225.9 230.9 1.46

Course #1 1,837.5 1,712.9 0 0 0 0 0 0 1,366.7 1,384 5.43

Course #2 1,866.1 1,739.4 0 0 0 0 0 0 1,362.6 1,379.1 5.51

Ellipsoidal Head Right 573.8 537.3 0 0 0 0 0 0 204.2 208.7 1.78

Saddle 268.5 268.5 0 0 0 0 0 0 0 0 4.51

TOTAL: 5,006.9 4,690.5 0 0 0 0 0 0 3,159.4 3,202.7 18.69

* Shells with attached nozzles have weight reduced by material cut out for opening.

Component

Weight ( kg) Contributed by AttachmentsSurface Area

m2BodyFlangesNozzles &Flanges

PackedBeds

TraysTray

SupportsRings &

ClipsVerticalLoads

New Corroded New Corroded

Ellipsoidal Head Left 0 0 1,084.1 1,071.3 0 0 0 0 0 1.51

Course #1 0 0 265.3 252.3 0 0 0 14.7 0 1.24

Course #2 0 0 65.5 62.5 0 0 0 14.7 0 0.37

Ellipsoidal Head Right 0 0 53.7 49.8 0 0 0 0 0 0.16

TOTAL: 0 0 1,468.5 1,435.9 0 0 0 29.3 0 3.28

Vessel operating weight, Corroded: 6,156 kgVessel operating weight, New: 6,505 kg

Vessel empty weight, Corroded: 6,156 kg

Vessel empty weight, New: 6,505 kg

Vessel test weight, New: 9,664 kg

Vessel test weight, Corroded: 9,358 kg

Vessel surface area: 21.98 m2

Vessel center of gravity location - from datum - lift condition

Vessel Lift Weight, New: 6,505 kg

Center of Gravity: 1,876.61 mm

Vessel Capacity

Vessel Capacity** (New): 3,131 li ters

Vessel Capacity** (Corroded): 3,172 liters

**The vessel capacity does not include volume of nozzle, piping or other attachments.



12/79

Ellipsoidal Head Left


Component: Ellipsoidal HeadMaterial Specification: SA-516 70 (II-D Metric p.22, ln. 6)Straight Flangegoverns MDMT

Internal design pressure: P = 101.24 kgf/cm2@ 100 C

Static liquid head:

Ps= 0 kgf/cm2(SG=1, Hs=0 mm Operating head)

Pth= 0.13 kgf/cm2(SG=1, Hs=1314.55 mm Horizontal test head)

Corrosion allowance: Inner C = 3.18 mm Outer C = 0 mm

Design MDMT = 15C No impact test performedRated MDMT = 14.33C Material is not normalized

Material is not produced to fine grain practicePWHT is performedDo not Optimize MDMT / Find MAWP

Radiography: Category A joints - Seamless No RTHead to shell seam - Full UW-11(a) Type 1

Estimated weight*: new = 461 kg corr = 432.4 kgCapacity*: new = 202.9 liters corr = 207.2 liters* includes straight flange

Outer diameter = 1157 mmMinimum head thickness = 45 mmHead ratio D/2h = 2 (new)Head ratio D/2h = 1.9882 (corroded)Straight flange length Lsf = 50 mmNominal straight flange thickness tsf = 50 mmResults Summary

The governing condition is internal pressure.Minimum thickness per UG-16 = 2.5 mm + 3.18 mm = 5.68 mmDesign thickness due to internal pressure (t) = 41.98mm

Maximum allowable working pressure (MAWP) = 109.67kgf/cm

2

Maximum allowable pressure (MAP) = 117.7kgf/cm2

K (Corroded)

K=(1/6)*[2 + (D / (2*h))2]=(1/6)*[2 + (1,073.35 / (2*269.93))2]=0.992181

K (New)

K=(1/6)*[2 + (D / (2*h))2]=(1/6)*[2 + (1,067 / (2*266.75))2]=1

Design thickness for internal pressure, (Corroded at 100 C) Appendix 1-4(c)

t = P*Do*K / (2*S*E + 2*P*(K - 0.1)) + Corrosion= 101.24*1,157*0.992181 / (2*1,407.21*1 + 2*101.24*(0.992181 - 0.1)) + 3.18

= 41.98 mm

The head internal pressure design thickness is 41.98mm.

Maximum allowable working pressure, (Corroded at 100 C) Appendix 1-4(c)

P = 2*S*E*t / (K*Do- 2*t*(K - 0.1)) - Ps= 2*1,407.21*1*41.83 / (0.992181*1,157 - 2*41.83*(0.992181 - 0.1)) - 0= 109.67 kgf/cm

2

The maximum allowable working pressure (MAWP) is 109.67kgf/cm2.



13/79

Maximum allowable pressure, (New at 25 C) Appendix 1-4(c)

P = 2*S*E*t / (K*Do- 2*t*(K - 0.1)) - Ps= 2*1,407.21*1*45 / (1*1,157 - 2*45*(1 - 0.1)) - 0= 117.7 kgf/cm

2

The maximum allowable pressure (MAP) is 117.7kgf/cm2.

% Extreme fiber elongation - UCS-79(d)

EFE = (75*t / Rf)*(1 - Rf/ Ro)

= (75*50 / 206.39)*(1 - 206.39 / )= 18.1695%



14/79

Straight Flange on Ellipsoidal Head Left


Component: Straight FlangeMaterial specification: SA-516 70 (II-D Metric p. 22, ln. 6)Material impact test exemption temperature from Fig UCS-66M Curve B = 14.33 CUCS-66 governing thickness = 45 mm

Internal design pressure: P = 101.24 kg/cm2@ 100 C

Static liquid head:

Pth = 0.13 kg/cm2 (SG = 1, Hs= 1,309.55 mm, Horizontal test

head)

Corrosion allowance Inner C = 3.18 mm Outer C = 0 mm

Design MDMT = 15 C No impact test performedRated MDMT = 14.33 C Material is not normalized

Material is not produced to Fine Grain PracticePWHT is performed

Radiography: Longitudinal joint - Seamless No RTCircumferential joint - Full UW-11(a) Type 1

Estimated weight New = 68.1 kg corr = 64 kg

Capacity New = 43.87 liters corr = 44.4 liters

OD = 1,157 mmLengthLc

= 50 mm

t = 50 mm

Design thickness, (at 100 C) Appendix 1-1

t = P*Ro/ (S*E + 0.40*P) + Corrosion= 101.24*578.5 / (1,407.21*1.00 + 0.40*101.24) + 3.18= 43.63 mm

Maximum allowable working pressure, (at 100 C) Appendix 1-1

P = S*E*t / (Ro- 0.40*t) - Ps= 1,407.21*1.00*46.83 / (578.5 - 0.40*46.83) - 0= 117.71 kg/cm2

Maximum allowable pressure, (at 25 C) Appendix 1-1

P = S*E*t / (Ro- 0.40*t)= 1,407.21*1.00*50 / (578.5 - 0.40*50)= 125.98 kg/cm2


EFE = (50*t / Rf)*(1 - Rf/ Ro)

= (50*50 / 553.5)*(1 - 553.5 /)

= 4.5167%

The extreme fiber elongation does not exceed 5%.



15/79

Course #1


Component: CylinderMaterial specification: SA-516 70 (II-D Metric p. 22, ln. 6)Material impact test exemption temperature from Fig UCS-66M Curve B = 14.33 CUCS-66 governing thickness = 45 mm


Static liquid head:


head)




Radiography: Longitudinal joint - Full UW-11(a) Type 1Left circumferential joint - Full UW-11(a) Type 1Right circumferential joint - Full UW-11(a) Type 1

Estimated weight New = 1,837.5 kg corr = 1,712.9 kgCapacity New = 1,362.71 liters corr = 1,378.98 liters


= 1,524 mm

t = 45 mm




P = S*E*t / (Ro- 0.40*t) - Ps= 1,407.21*1.00*41.83 / (578.5 - 0.40*41.83) - 0= 104.77 kg/cm2


P = S*E*t / (Ro- 0.40*t)= 1,407.21*1.00*45 / (578.5 - 0.40*45)= 112.98 kg/cm2


EFE = (50*t / Rf)*(1 - Rf/ Ro)

= (50*45 / 556)*(1 - 556 / )

= 4.0468%




16/79

Course #2


Component: CylinderMaterial specification: SA-516 70 (II-D Metric p. 22, ln. 6)Material impact test exemption temperature from Fig UCS-66M Curve B = 14.33 CUCS-66 governing thickness = 45 mm


Static liquid head:


head)




Radiography: Longitudinal joint - Full UW-11(a) Type 1Left circumferential joint - Full UW-11(a) Type 1Right circumferential joint - Full UW-11(a) Type 1

Estimated weight New = 1,866.1 kg corr = 1,739.4 kgCapacity New = 1,362.71 liters corr = 1,378.98 liters


= 1,524 mm

t = 45 mm




P = S*E*t / (Ro- 0.40*t) - Ps= 1,407.21*1.00*41.83 / (578.5 - 0.40*41.83) - 0= 104.77 kg/cm2


P = S*E*t / (Ro- 0.40*t)= 1,407.21*1.00*45 / (578.5 - 0.40*45)= 112.98 kg/cm2


EFE = (50*t / Rf)*(1 - Rf/ Ro)

= (50*45 / 556)*(1 - 556 / )

= 4.0468%




17/79

Ellipsoidal Head Right


Component: Ellipsoidal HeadMaterial Specification: SA-516 70 (II-D Metric p.22, ln. 6)Straight Flangegoverns MDMT

Internal design pressure: P = 101.24 kgf/cm2@ 100 C

Static liquid head:

Ps= 0 kgf/cm2(SG=1, Hs=0 mm Operating head)

Pth= 0.13 kgf/cm2(SG=1, Hs=1314.55 mm Horizontal test head)

Corrosion allowance: Inner C = 3.18 mm Outer C = 0 mm

Design MDMT = 15C No impact test performedRated MDMT = 14.33C Material is not normalized

Material is not produced to fine grain practicePWHT is performedDo not Optimize MDMT / Find MAWP

Radiography: Category A joints - Seamless No RTHead to shell seam - Full UW-11(a) Type 1

Estimated weight*: new = 573.8 kg corr = 537.3 kgCapacity*: new = 202.9 liters corr = 207.2 liters* includes straight flange

Outer diameter = 1157 mmMinimum head thickness = 45 mmHead ratio D/2h = 2 (new)Head ratio D/2h = 1.9882 (corroded)Straight flange length Lsf = 50 mmNominal straight flange thickness tsf = 50 mmResults Summary

The governing condition is internal pressure.Minimum thickness per UG-16 = 2.5 mm + 3.18 mm = 5.68 mmDesign thickness due to internal pressure (t) = 41.98mm

Maximum allowable working pressure (MAWP) = 109.67kgf/cm

2

Maximum allowable pressure (MAP) = 117.7kgf/cm2

K (Corroded)

K=(1/6)*[2 + (D / (2*h))2]=(1/6)*[2 + (1,073.35 / (2*269.93))2]=0.992181

K (New)

K=(1/6)*[2 + (D / (2*h))2]=(1/6)*[2 + (1,067 / (2*266.75))2]=1

Design thickness for internal pressure, (Corroded at 100 C) Appendix 1-4(c)

t = P*Do*K / (2*S*E + 2*P*(K - 0.1)) + Corrosion= 101.24*1,157*0.992181 / (2*1,407.21*1 + 2*101.24*(0.992181 - 0.1)) + 3.18

= 41.98 mm

The head internal pressure design thickness is 41.98mm.

Maximum allowable working pressure, (Corroded at 100 C) Appendix 1-4(c)

P = 2*S*E*t / (K*Do- 2*t*(K - 0.1)) - Ps= 2*1,407.21*1*41.83 / (0.992181*1,157 - 2*41.83*(0.992181 - 0.1)) - 0= 109.67 kgf/cm

2

The maximum allowable working pressure (MAWP) is 109.67kgf/cm2.



18/79

Maximum allowable pressure, (New at 25 C) Appendix 1-4(c)

P = 2*S*E*t / (K*Do- 2*t*(K - 0.1)) - Ps= 2*1,407.21*1*45 / (1*1,157 - 2*45*(1 - 0.1)) - 0= 117.7 kgf/cm

2

The maximum allowable pressure (MAP) is 117.7kgf/cm2.


EFE = (75*t / Rf)*(1 - Rf/ Ro)

= (75*50 / 206.39)*(1 - 206.39 / )= 18.1695%



19/79

Straight Flange on Ellipsoidal Head Right


Component: Straight FlangeMaterial specification: SA-516 70 (II-D Metric p. 22, ln. 6)Material impact test exemption temperature from Fig UCS-66M Curve B = 14.33 CUCS-66 governing thickness = 45 mm


Static liquid head:


head)




Radiography: Longitudinal joint - Seamless No RTCircumferential joint - Full UW-11(a) Type 1

Estimated weight New = 68.1 kg corr = 64 kg

Capacity New = 43.87 liters corr = 44.4 liters


= 50 mm

t = 50 mm




P = S*E*t / (Ro- 0.40*t) - Ps= 1,407.21*1.00*46.83 / (578.5 - 0.40*46.83) - 0= 117.71 kg/cm2


P = S*E*t / (Ro- 0.40*t)= 1,407.21*1.00*50 / (578.5 - 0.40*50)= 125.98 kg/cm2


EFE = (50*t / Rf)*(1 - Rf/ Ro)

= (50*50 / 553.5)*(1 - 553.5 /)

= 4.5167%




20/79

Inlet Nozzle (N1)


tw(lower)= 45 mm

Leg41= 25 mm

Leg43= 25 mm

hnew= 78.86 mm

Note: round inside edges per UG-76(c)

Location and Orientation

Located on: Ellipsoidal Head RightOrientation: 0

End of nozzle to datum line: -515 mm

Calculated as hillside: Yes

Distance to head center, R: 227 mm

Passes through a Category A joint: No

Nozzle

Access opening: No

Material specification: SA-105 (II-D Metric p. 18, ln. 32)

Inside diameter, new: 101.6 mm

Nominal wall thickness: 28.58 mm

Corrosion allowance: 3.18 mm

Opening chord length: 110.88 mm

Projection available outside vessel, Lpr: 162.77 mm

Internal projection, hnew: 78.86 mm

Projection available outside vessel to flange face, Lf: 213.57 mm

Local vessel minimum thickness: 45 mm

Liquid static head included: 0 kgf/cm2

Longitudinal joint efficiency: 1

ASME B16.5-2009 Flange

Description: NPS 4 Class 900 LWN A105

Bolt Material: SA-193 B7 Bolt


21/79

UG-37 Area Calculation Summary (cm2)For P = 117.51 kg

f/cm

2@ 100 C

The opening is adequately reinforced

UG-45Nozzle WallThicknessSummary

(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin

46.377 61.3678 -- 26.2322 24.6975 -- 10.438 9.4 28.58

UG-41 Weld Failure Path Analysis Summary

The nozzle is exempt from weld strength calculationsper UW-15(b)(1)

UW-16 Weld Sizing Summary

Weld descriptionRequired weld

throat size (mm)Actual weld

throat size (mm)Status

Nozzle to shell fillet (Leg41) 6 17.5 weld size is adequate

Reinforcement Calculations for MAP

The vessel wall thickness governs the MAP of this nozzle.


f/cm

2@ 25 C



(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin

46.9646 87.2877 -- 33.9606 40.8265 -- 12.5006 6.22 28.58


The nozzle is exempt from weld strength calculations

per UW-15(b)(1)








22/79

Gas Outlet Nozzle (N2)


tw(lower)= 45 mm

Leg41= 25 mm



Located on: Course #1Orientation: 0

Nozzle center line offset to datum line: 2,743 mm

End of nozzle to shell center: 781.05 mm


Nozzle

Access opening: No














23/79


24/79

Water Outlet (N3)


tw(lower)= 45 mm

Leg41= 15 mm




Nozzle center line offset to datum line: 2,082.8 mm



Nozzle

Access opening: No














25/79

UG-37 Area Calculation Summary(cm2)

For P = 104.77 kgf/cm2@ 100 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin

This nozzle is exempt from areacalculations per UG-36(c)(3)(a)

8.44 26.92








This opening does not require reinforcement per UG-36(c)(3)(a)




For P = 112.98 kgf/cm2@ 25 C


(mm)The nozzle

passes UG-45

A

required

A

availableA1 A2 A3 A5

A

weldstreq tmin

This nozzle is exempt from areacalculations per UG-36(c)(3)(a) 5.27 26.92











26/79

Burst Disk (N4)


tw(lower)= 45 mm

Leg41= 25 mm




Nozzle center line offset to datum line: 180 mm



Nozzle

Access opening: No














27/79


For P = 104.77 kgf/cm2@ 100 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin


8.44 26.92












For P = 112.98 kgf/cm2@ 25 C


(mm)The nozzle

passes UG-45

A

required

A


A

weldstreq tmin












28/79

Oil Outlet (N5)


tw(lower)= 45 mm

Leg41= 33.02 mm







Nozzle

Access opening: No














29/79


f/cm

2@ 100 C



(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin

33.5879 33.5883 1.4568 21.2283 -- -- 10.9032 8.91 25.4











f/cm

2@ 25 C



(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin

34.2899 39.0806 -- 28.1774 -- -- 10.9032 5.73 25.4



per UW-15(b)(1)








30/79

Water Level Gauge (N6A)


tw(lower)= 45 mm

Leg41= 18 mm





End of nozzle to shell center: 700 mm

Offset from center, Lo: 108 mm


Nozzle

Access opening: No















31/79


For P = 104.77 kgf/cm2@ 100 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin


6.6 14.22









Reinforcement check in the plane parallel to the longitudinal axis

Reinforcement Calculations for MAWP

The vessel wall thickness governs the MAWP of this nozzle.


For P = 104.77 kgf/cm2@ 100 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin


6.6 14.22





throat size (mm)

Actual weld








32/79


For P = 112.98 kgf/cm2@ 25 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin


3.42 14.22













For P = 112.98 kgf/cm2@ 25 C


(mm)The nozzle

passes UG-45

A

required

A

available A1 A2 A3 A5

A

welds treq tmin


3.42 14.22











33/79

Water Level Gauge (N6B)


tw(lower)= 45 mm

Leg41= 18 mm






Offset from center, Lo: -412 mm


Nozzle

Access opening: No















34/79


For P = 104.77 kgf/cm2@ 100 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin


6.6 14.22













For P = 104.77 kgf/cm2@ 100 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin


6.6 14.22





throat size (mm)

Actual weld








35/79


For P = 112.98 kgf/cm2@ 25 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin


3.42 14.22













For P = 112.98 kgf/cm2@ 25 C


(mm)The nozzle

passes UG-45

A

required

A


A

welds treq tmin


3.42 14.22











36/79

WAter Level Control (N7A)


tw(lower)= 45 mm

Leg41= 25 mm







Nozzle

Access opening: No














37/79


For P = 104.77 kgf/cm2@ 100 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin


8.44 26.92












For P = 112.98 kgf/cm2@ 25 C


(mm)The nozzle

passes UG-45

A

required

A


A

weldstreq tmin












38/79

WAter Level Control (N7B)


tw(lower)= 45 mm

Leg41= 25 mm








Nozzle

Access opening: No















39/79


f/cm

2@ 100 C



(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin

15.5656 59.2321 27.4264 25.5554 -- -- 6.2503 8.44 26.92












For P = 104.77 kgf/cm2@ 100 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin


8.44 26.92













40/79


f/cm

2@ 25 C



(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin

14.9418 71.9786 32.3657 33.3625 -- -- 6.2503 5.27 26.92












For P = 112.98 kgf/cm2@ 25 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin


5.27 26.92











41/79

Oil Level Gauge (N8A)


tw(lower)= 45 mm

Leg41= 18 mm








Nozzle

Access opening: No















42/79


For P = 104.77 kgf/cm2@ 100 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin


6.6 14.22













For P = 104.77 kgf/cm2@ 100 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin


6.6 14.22





throat size (mm)

Actual weld








43/79


For P = 112.98 kgf/cm2@ 25 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin


3.42 14.22













For P = 112.98 kgf/cm2@ 25 C


(mm)The nozzle

passes UG-45

A

required

A


A

welds treq tmin


3.42 14.22











44/79

Oil Level Gauge (N8B)


tw(lower)= 45 mm

Leg41= 18 mm








Nozzle

Access opening: No















45/79


For P = 104.77 kgf/cm2@ 100 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin


6.6 14.22













For P = 104.77 kgf/cm2@ 100 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin


6.6 14.22





throat size (mm)

Actual weld








46/79


For P = 112.98 kgf/cm2@ 25 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin


3.42 14.22













For P = 112.98 kgf/cm2@ 25 C


(mm)The nozzle

passes UG-45

A

required

A


A

welds treq tmin


3.42 14.22











47/79

Oil Level Control (N9A)


tw(lower)= 45 mm

Leg41= 18 mm








Nozzle

Access opening: No















48/79


For P = 104.77 kgf/cm2@ 100 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin


6.6 14.22













For P = 104.77 kgf/cm2@ 100 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin


6.6 14.22





throat size (mm)

Actual weld








49/79


For P = 112.98 kgf/cm2@ 25 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin


3.42 14.22













For P = 112.98 kgf/cm2@ 25 C


(mm)The nozzle

passes UG-45

A

required

A


A

welds treq tmin


3.42 14.22











50/79

Oil Level Control (N9B)


tw(lower)= 45 mm

Leg41= 18 mm








Nozzle

Access opening: No















51/79


For P = 104.77 kgf/cm2@ 100 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin


6.6 14.22













For P = 104.77 kgf/cm2@ 100 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin


6.6 14.22





throat size (mm)

Actual weld








52/79


For P = 112.98 kgf/cm2@ 25 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin


3.42 14.22













For P = 112.98 kgf/cm2@ 25 C


(mm)The nozzle

passes UG-45

A

required

A


A

welds treq tmin


3.42 14.22











53/79

Pressure Relieve Valve (N10)


tw(lower)= 45 mm

Leg41= 33.02 mm




Nozzle center line offset to datum line: 485.3 mm



Nozzle

Access opening: No














54/79


f/cm

2@ 100 C



(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin

33.5879 33.5883 1.4568 21.2283 -- -- 10.9032 8.91 25.4











f/cm

2@ 25 C



(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin

34.2899 39.0806 -- 28.1774 -- -- 10.9032 5.73 25.4



per UW-15(b)(1)








55/79

Themowell (N11)


tw(lower)= 45 mm

Leg41= 25 mm







Nozzle

Access opening: No














56/79


For P = 104.77 kgf/cm2@ 100 C


(mm)The nozzle

passes UG-45

Arequired

Aavailable

A1 A2 A3 A5A

weldstreq tmin


8.44 26.92












For P = 112.98 kgf/cm2@ 25 C


(mm)The nozzle

passes UG-45

A

required

A


A

weldstreq tmin












57/79

Pressure Gauge (N12)


tw(lower)= 45 mm

Leg41= 18 mm







No

2. test separator v-005 rev.1

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