design of pressure vessel 2

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Pressure VesselsReaction VesselsAgitator ShaftsHeat ExchangersProcess ColumnsStorage TankFloating RoofChimney

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

EXAMPLE NO. PV-02

DESIGN

OF

PRESSURE VESSEL

NOTE:

1) Link to youtube video of this design:https://www.youtube.com/watch?v=wTsjneCO96g&list=SPPL8SPZUxm-mFqQZceyhr13QYDEruelJx

2) As you can see in the video, the inbuilt intelligence in the software generates a lot of informationby itself.Eg:i. For a body flange, the software evaluates all the undefined parameters Flange OD, Flange ID,

PCD, Number and Size of bolts, Gasket OD & ID, etc. meeting the requirements of specifiedequipment design code.

ii. Please note that entire process from selection of saddle to checking its adequacy are doneautomatically, thus saving user’s valuable time.

3) In case of any changes to the interconnected shell geometry and / or design conditions (pressure /temperature) including material of constructions, these dimensions are automatically regenerated bythe software to meet the new requirements.

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

In this tutorial we will see how to design an LPG storage tank, a simple horizontal pressure vessel

with saddle supports.

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

Index

Licensee : Sunay Wagle, CADEM Services, Pune, India

Customer Sample Project

Project / Equipment Horizontal Presure Vessel with Saddle Supports / LPG Storage Tank

Designed By / Revision and Date / R00 , 31-03-2015 22:11:06

Sr. No. Description Page No

1 Title page & equipment info

2 Design data

3 Material of constructions

4 Effective Pressures

5 Weight summary report

6 Wind load calculations

7 Seismic load calculations

8 Design of Dished End (Front)

9 Design of Main Shell

10 Design of Dished End (Rear)

11 Design of Saddle Support



14 Design of N 01

15 Design of N 02

16 Design of N 03

17 Design of N 03

18 Design of Saddle Plate

19 Design of Bolted Cover [N 03]


21 Design of Lifting Lugs

22 Foundation load data

23 C.G. Data


EQUIPMENT INFORMATION :

DESIGN & REVIEWAL :

INSPECTION & APPROVAL :

EQUIPMENT DATA :

OTHER DATA :


Project Horizontal Presure Vessel with Saddle Supports

Location Sample SitePlant LPG Storage Tank

Design Code ASME VIII Div.1, 10 A11Equipment Name LPG Storage Tank Equipment Type Pressure VesselEquipment Class N.A.Equipment Category N.A.Reference Drawing No ---Service Explosive ServicesSupport Type Saddle Supports

Designed ByDesign Date 31-03-2015 22:11:06Checked ByApproved ByRevision R00

Inspection Agency ---

Reviewed By ---

Front end Dished EndFront end flanged FalseRear end Dished EndRear end flanged FalseShell ID 2350 mmShell OD 2382 mmLength, Shell (W.L. to W.L) / Overall 7980 / 10354 mm

Fabricated weight 9443.5 kgfEmpty weight + external weights 9443.5 kgfEstimated operating weight 51095.3 kgfEstimated hydrotest weight 52795.4 kgf


(1) PROCESS DETAILS :

(3) TEST PR. : kgf/mm² g

(4) TEMPERATURE : °C

(5) ALLOWANCES : mm

(6) RADIOGRAPHY & JOINT EFFICIENCY :





VESSEL DESIGN DATA

MEDIA DENSITYkg/m³

Operating LPG 470Design1 1000Design2StartupShutdownUpsetHydrotest Water 1000Pneumatic LPG 1.2

(2) PR. : kgf/mm² g INT. EXT.

Operating 0.1 0.1 0.01055Design1 0.145 0.145 0.01055Design2StartupShutdownUpset

Based onInput Pr MAWP MAP

Hydrotest 0.189 0.189 0.189Pneumatic 0.16 0.16 0.16

MIN. MAX.Input MDMT

Operating 20 55Design1 -10 75Design2StartupShutdownUpsetHydrotest 21.67 50Pneumatic 21.67 50

INT. EXT.Corrosion 3 0Polishing 0 0

RADIOGRAPHY JOINT EFFICIENCY

Shell Full 1.00Head Full 1.00


VESSEL DESIGN DATA1. MATERIAL OF CONSTRUCTION :

2. NOZZLE CONNECTIONS :

3. INSULATION & CLADDING:





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

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

Body flange SA-516 GR. 70 Plt. [UNS:K02700]Body flange cover SA-516 GR. 70 Plt. [UNS:K02700]Liner

Shell side

Nozzle neck <= NPS 40 SA-106 GR. B Smls. Pipe[UNS:K03006]

Flange SA-105 Frg. [UNS:K03504]Cover flange SA-105 Frg. [UNS:K03504]

Nozzle NPS > 40 & < 200 SA-106 GR. B Smls. Pipe [UNS:K03006]


Nozzle neck >= NPS 200 SA-516 GR. 70 Plt. [UNS:K02700]Flange SA-516 GR. 70 Plt. [UNS:K02700]Cover flange SA-516 GR. 70 Plt. [UNS:K02700]

Pad flange SA-516 GR. 70 Plt. [UNS:K02700]Pad flange cover SA-516 GR. 70 Plt. [UNS:K02700]Manhole flange SA-516 GR. 70 Plt. [UNS:K02700]Manhole cover SA-516 GR. 70 Plt. [UNS:K02700]Reinforcement pad SA-516 GR. 70 Plt. [UNS:K02700]External bolt SA-193 GR. B7 Bolt [UNS:G41400]External gasket CAF with suitable binder (3 mm.)Stiffener SA-516 GR. 70 Plt. [UNS:K02700]Lifting lug IS-2062 GR. A Plt.Support IS-2062 GR. A Plt.Anchor bolt Commercial CS Bolt

Mat. / Density / Thk. N.A. / kg/m³ / mmMat. / Thk. N.A. / mm


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





Sr. Item name Temp. Inside pr. Liquid pr. Effective pr.No. +ve -ve +ve -ve1 Dished End (Front) 75 0.145 0.01055 0 0.145 0.010552 Main Shell 75 0.145 0.01055 0 0.145 0.010553 Dished End (Rear) 75 0.145 0.01055 0 0.145 0.0105545


ITEM WISE WEIGHT SUMMARY





Sr.No. Item name Item size Empty wt Volume Filled wt

kgf m³ kgf

1 Dished End (Front) Hemispherical End 2374 OD x 12 Nom / 10.8 Min Thk 1037.5 3.398 4435.2

2 Main Shell 2382 OD x 16 Thk, 7980 Lg 7513.1 34.61 42125.2

3 Dished End (Rear) Hemispherical End 2374 OD x 12 Nom / 10.8 Min Thk 1037.5 3.398 4435.2

4 Saddle Plate 892.5 Long x 2055.16 Wide x 14 Thk, 2 Nos. 406.6 0 406.6

5 Gusset Plate [01] 250 Long x 345.662 Wide x 14 Thk, 8 Nos. 76.62 0 76.62


7 Bolting Plate 2055.16 Long x 514 Wide x 22 Thk, 2 Nos. 368 0 368

8 Anchor Bolt Anchor M24 x 600 Lg, 8 Nos. 17.19 0 17.19

9 Support Pad 674 Long x 2695.914 Wide x 20 Thk, 2 Nos. 575.4 0 575.4

10 N 01 ANSIB36.10, 150 NPS Sch.80, 153 Lg 6.568 0.00257 9.141

11 Flange [N 01] Weld Neck, ANSI B16.5, RF, 300# for 150 NPS Sch 80 Pipe 17.34 0 17.34

12 Gasket [N 01] 166.329 OD x 146.329 ID, 3.175 Thk 0.1 0 0.1

13 Bolt [N 01] Hex Head Bolt M20 x 108.477 Lg, 12 Nos. 3.237 0 3.237

14 Reinf [N 01] 292.659 OD x 171.275 ID x 16Thk 5.602 0 5.602

15 N 02 ANSIB36.10, 100 NPS Sch.160, 151 Lg 5.106 0.0009 6.011

16 Flange [N 02]Weld Neck, ANSI B16.5, RF, 300# for 100 NPS Sch 160 Pipe

11.02 0 11.02




20 N 03 581 OD x 450 ID, 70 Thk 58.78 0.01113 69.92

21 Bolted Cover [N 03]Blind Flange - 581 OD x 34.073 Thk, RF, 534 PCD, Tgrv = 1.588

68.18 0 68.18

22 Cover Gasket [N 03] 504.188 OD x 450 ID, 3.175Thk 0.1 0 0.1

23 Cover Bolts [N 03] Hex Head Bolt M20 x 73.485 Lg, 16 Nos. 2.924 0 2.924

24 Lifting Lugs 120 Long x 67 Wide x 60 Thk, 2 Nos. 7.638 0 7.638

25 Pad (Lifting Lugs) 70 Long x 210 Wide x 8 Thk, 2Nos. 1.862 0 1.862

26

27

28

29

30

∑ 11373.4 ∑ 52795.4


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

2. CALCULATION OF FORCES AND MOMENTS:





WIND LOAD CALCULATIONCODE Wind [IS:875, 87]

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

Equivalent diameter De 3290 mmOverall length of equipment L 10354 mmHeight of C.G. of equipment Hcg 1500 mmHeight and size factor ( Section 5.3.2 ) K2 0.98Effective longitudinal cross sectional area

= 0.25 x x De 2 Al 8501228.3 mm²

Effective transverse cross sectional area= De x L At 34064660 mm²

Effective wind speed= K1 x K2 x K3 x Vb Vz 57.44 m/s

Wind pressure

= 6E-08 x Vz 2 Pz 0.0002 kgf/mm²

Longitudinal force= Al x Pz Fl 1683.1 kgf

Transverse force= Cf x At x Pz Ft 5395.5 kgf

Longitudinal turning moment= Fl x ( Hcg - H ) M 2524711.2 kgf-mm

Transverse turning moment= Ft x ( Hcg - H ) M 8093271 kgf-mm








SEISMIC LOAD CALCULATIONCODE Seismic [IS:1893, 02]

Weight of equipment Wo 51095.3 kgfImportance factor ( Table-6 , 2002 ) I 1.5Soil profile type Stiff Soil Profile (SD)Foundation type RCC footings + Tie BeamsDamping factor 5Seismic zone Zone IIISeismic zone factor ( Table-2 , 2002 ) Z 0.16Response reduction factor ( Table-7 , 2002 ) R 2.9Spectral accelerations coeff. ( Fig. 2 , 2002 ) Sa / g 2.5, Use max valueDamping correction factor ( Table-3 , 2002 ) Cf 1Seismic coefficient ( Clause-6.4.2 , 2002 )

= 0.5 x Z x I x Cf x ( Sa / g ) x ( 1 / R )= 0.5 x 0.16 x 1.5 x 1 x

2.5 x ( 1 / 2.9 ) Ah 0.103

Elevation of support H 0 mmHeight of C.G. of equipment Hcg 1500 mmSeismic base shear force

= Ah x Wo= 0.103 x 51095.3 Vb 5285.7 kgf

Seismic moment of support= Vb x ( Hcg - H )= 5285.7 x ( 1500 - 0 ) M 7928582.9 kgf-mm



2. DESIGN CALCULATION AS PER UG 32 f :Factor [K]= 0.5Thickness for internal pressure [t]= K x Pi x ID / ( 2 x S x E - 0.2 x Pi )= 0.5 x 0.145 x 2356 / ( 2 x 14.06 x 1 - 0.2 x 0.145 )= 6.08 mm3. DESIGN CALCULATION AS PER UG 33 c :Assumed head thickness, [te]= 3.375 mmFactor [A]= 0.125 x te / ( K x OD ) = 0.125 x 3.375 / ( 0.5 x 2374 )= 0.00035Factor with reference to chart (CS-2) [B] = 3.743 kgf/mm²Allowable external pressure [Pa]= B x te / ( K x OD ) = 3.743 x 3.375 / ( 0.5 x 2374 )= 0.01061 kgf/mm²Since Pa > Pe, design is safeSince available thickness is more than design thickness, design is safe.





DESIGN OF HEMISPHERICAL HEAD ( INT. & EXT.PRESSURE ) Dished End (Front)CODE ASME VIII Div.1, 10 A11

Design pressure ( internal ) Pi 0.145 kgf/mm² gDesign pressure ( external ) Pe 0.01055 kgf/mm² gDesign temperature T 75 °CMaterial of construction SA-516 GR. 70 Plt. [UNS:K02700]Max. allowable stress @ design temp. S 14.06 kgf/mm²Radiography FullJoint efficiency E 1Outside diameter of head OD 2374 mmInside diameter of shell ID 2356 mmHead shapeNominal thickness 12 mmNominal thickness required as per TEMA N.A mmInternal allowance, corrosion + polishing 3 mmExternal allowance, corrosion + polishing 0 mmThinning allowance / Under tolerance 1.2 mmAvailable thickness 7.8 mm


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

2. DESIGN CALCULATION AS PER UG-27

Thickness of shell under internal pressure [ti]= Pi x R / ( S x E - 0.6 x Pi ) = 0.145 x 1178 / ( 14.06 x 1 - 0.6 x 0.145 )= 12.22 mm

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

Allowable external pressure [Pa]= 4 x B / ( 3 x ( OD / te ) )= 4 x 1.531 / ( 3 x 192.5 )= 0.0106 kgf/mm² gSince Pa > Pe, design is safeSince available thickness is more than design thickness, design is safe.





DESIGN OF SHELL ( INTERNAL AND EXTERNAL PRESSURE ) Main ShellCODE ASME VIII Div.1, 10 A11

Design pressure ( internal ) Pi 0.145 kgf/mm² gDesign pressure ( external ) Pe 0.01055 kgf/mm² gDesign temperature T 75 °CMaterial of construction SA-516 GR. 70 Plt. [UNS:K02700]Max. allowable stress at design temp. S 14.06 kgf/mm²Radiography FullJoint efficiency long. seam Ec 1Outside diameter OD 2382 mmInside radius ( corroded ) R 1178 mmShell length L 7980 mmDesign length L1 7980 mmNominal thickness 16 mmNominal thickness required as per TEMA N.A. mmInternal allowance, corrosion + polishing 3 mmExternal allowance, corrosion + polishing 0 mmThickness undertolerance 0 mmAvailable thickness 13 mm

Assumed te 12.38 mmL1 / OD 3.35OD / te 192.5Factor A ( Refer to Fig. G in Subpart 3 of Sec. II, Part D ) 0.00014Factor B ( CS-2 ) 1.531 kgf/mm²



2. DESIGN CALCULATION AS PER UG 32 f :Factor [K]= 0.5Thickness for internal pressure [t]= K x Pi x ID / ( 2 x S x E - 0.2 x Pi )= 0.5 x 0.145 x 2356 / ( 2 x 14.06 x 1 - 0.2 x 0.145 )= 6.08 mm3. DESIGN CALCULATION AS PER UG 33 c :Assumed head thickness, [te]= 3.375 mmFactor [A]= 0.125 x te / ( K x OD ) = 0.125 x 3.375 / ( 0.5 x 2374 )= 0.00035Factor with reference to chart (CS-2) [B] = 3.743 kgf/mm²Allowable external pressure [Pa]= B x te / ( K x OD ) = 3.743 x 3.375 / ( 0.5 x 2374 )= 0.01061 kgf/mm²Since Pa > Pe, design is safeSince available thickness is more than design thickness, design is safe.





DESIGN OF HEMISPHERICAL HEAD ( INT. & EXT.PRESSURE ) Dished End (Rear)CODE ASME VIII Div.1, 10 A11

Design pressure ( internal ) Pi 0.145 kgf/mm² gDesign pressure ( external ) Pe 0.01055 kgf/mm² gDesign temperature T 75 °CMaterial of construction SA-516 GR. 70 Plt. [UNS:K02700]Max. allowable stress @ design temp. S 14.06 kgf/mm²Radiography FullJoint efficiency E 1Outside diameter of head OD 2374 mmInside diameter of shell ID 2356 mmHead shapeNominal thickness 12 mmNominal thickness required as per TEMA N.A mmInternal allowance, corrosion + polishing 3 mmExternal allowance, corrosion + polishing 0 mmThinning allowance / Under tolerance 1.2 mmAvailable thickness 7.8 mm


1. SHELL DESIGN DATA :

2. SADDLE DESIGN DATA :

3. PAD DESIGN DATA :

4. BOLTING DESIGN DATA :

5. AREAS :

6. LOADS :

7. SADDLE REACTION : Saddle reaction due to long. force [QL]





SADDLE SUPPORT DESIGN Saddle SupportCODE ASME VIII Div.1, 10 A11

Design Mode 1 , Corroded Condition

Outside diameter OD 2382 mmThickness ts 13 mm

M.O.C IS-2062 GR. A Plt.No. of supports N 2Distance between saddles L 4788 mmDistance of saddle from T.L. A 1596 mmHeight of vessel C.L. B 1500 mmBase plate length E 2055.2 mmBase plate width C 514 mmBase plate thickness tb 22 mmSaddle angle α 120 °Saddle / gusset thk. te 14 mmNo. of gussets n 8 mmGusset width ( bottom ) b1 250 mmGusset width ( top ) b2 250 mmDistance between gussets D1 570 mmYield stress Sy1 24.61 kgf/mm²Allowable stress for saddle ( 2 / 3 x Sy1 ) S1 16.41 kgf/mm²

M.O.C SA-516 GR. 70 Plt. [UNS:K02700]Thickness tp 20 mmWidth b 674 mmLength of pad Lp 2695.9 mmYield stress Sy2 24.88 kgf/mm²Allowable stress for pad ( 2 / 3 x Sy2 ) S2 16.59 kgf/mm²

M.O.C Commercial CS BoltDia. of bolt db 24 mmArea of bolt Ar 312.7 mm²No. of bolt / saddle Nb 4Bolt hole dia G 30 mmBolt slot length 65 mmDistance between bolts D2 1880 mmAllowable stress S3 20.88 kgf/mm²

Area in pad a1 13480 mm²Area in saddle a2 3738 mm²Area in base plate a3 11308 mm²Total area ( excl. shell ) As 28526 mm²

Design load WindDesign weight W 7741.4 kgfLong. load F1 1683.1 kgfTrans. load F2 5395.5 kgfFriction factor μ 0.3Friction load F3 1161.2 kgf

= F1 x B / L= 1683.1 x 1500 / 4788= 527.3 kgfSaddle reaction due to trans. force [QR]= 6 x F2 x B / E= 6 x 5395.5 x 1500 / 2055.2= 23628.2 kgfTotal reaction force on saddle [Q]= MAX [ QL , QR ] + 0.5 x W= MAX [ 527.3 , 23628.2 ] + 0.5 x 7741.4= 27498.9 kgf8. DESIGN OF PAD PLATE : Saddle angle [θ]= a x p / 360= 120 x p / 360= 1.047 radSaddle angle [β]= p - θ= p - 1.047= 2.094 radUnit load on pad plate [Fv]= [ Q / ( 0.5 x OD ) ] x [ ( 1 + cos b ) / ( p - b + sin b x cos b ) ]= [ 27498.9 / ( 0.5 x 2382 ) ] x [ ( 1 + cos 2.094 ) / ( p - 2.094 + sin 2.094 x cos 2.094 ) ]= 18.8 kgf/mmMoment on pad plate [Mp]= Fv x b’ / 8 ................................................................ where, b’ = 330 mm= 18.8 x 330 / 8= 775.4 kgf-mmThickness of pad plate [tp1]= SQRT [ 6 x Mp / S2 ]= SQRT [ 6 x 775.4 / 16.59 ]= 13.91 mm9. DESIGN OF SADDLE WEB AND GUSSET : Saddle coefficient [K1]= ( 1 + cos b - 0.5 x sin 2 b ) / ( p - b + sin b x cos b )= ( 1 + cos 2.094 - 0.5 x sin 2 2.094 ) / ( p - 2.094 + sin 2.094 x cos 2.094 )= 0.204Saddle splitting force [Fh]= Q x K1= 27498.9 x 0.204= 5596.6 kgfStress due to splitting force [σt]= Fh / As = 5596.6 / 28526

Allowable compr. stress [Sa]= 18000 / [ 1 + ( 12 / 18000 ) x ( h / te ) 2 ] .................. where, h = 267 mm= 18000 / [ 1 + ( 12 / 18000 ) x ( 267 / 14 ) 2 ]= 14487.2 psi= 10.19 kgf/mm²Induced compr. stress [fa]= Fv / te = 18.8 / 14

10. DESIGN OF BASE PLATE : Required thickness of base plate [tb]= SQRT [ 3 x Q x C / ( 4 x E x S1 ) ]= SQRT [ 3 x 27498.9 x 514 / ( 4 x 2055.2 x 16.41 ) ]= 15.26 mm11. CHECK FOR BOLT ADEQUACY : Bolt tension [T]= MAX [ QL - Q , 0 ]= MAX [ 527.3 - 27498.9 , 0 ]

= 1.343 kgf/mm² ............................................. < St where, St = 0.6 x Sy1

= 0.196 kgf/mm² ............................................. < Sa

= 0 kgfBolt tensile stress [Stb]= T / ( S3 x Nb )= 0 / ( 20.88 x 4 )= 0 kgf/mm²Shear force on bolt [F]= MAX [ MAX ( F1 , F2 ) - F3 , 0 ] = MAX [ MAX ( 1683.1 , 5395.5 ) - 1161.2 , 0 ]= 4234.3 kgfBolt shear load [Sh]= F / ( Nb x Ar ) .......................................................... where, Ar = 312.7 mm²= 4234.3 / [ 4 x 312.7 ]

= 3.385 kgf/mm² ............................................. < 0.7 x S

101






5. AREAS :

6. LOADS :













Design load SeismicDesign weight W 51095.5 kgfLong. load F1 5285.7 kgfTrans. load F2 5285.7 kgfFriction factor μ 0.3Friction load F3 7664.3 kgf

= F1 x B / L= 5285.7 x 1500 / 4788= 1655.9 kgfSaddle reaction due to trans. force [QR]= 6 x F2 x B / E= 6 x 5285.7 x 1500 / 2055.2= 23147.4 kgfTotal reaction force on saddle [Q]= MAX [ QL , QR ] + 0.5 x W= MAX [ 1655.9 , 23147.4 ] + 0.5 x 51095.5= 48695.2 kgf8. DESIGN OF PAD PLATE : Saddle angle [θ]= a x p / 360= 120 x p / 360= 1.047 radSaddle angle [β]= p - θ= p - 1.047= 2.094 radUnit load on pad plate [Fv]= [ Q / ( 0.5 x OD ) ] x [ ( 1 + cos b ) / ( p - b + sin b x cos b ) ]= [ 48695.2 / ( 0.5 x 2382 ) ] x [ ( 1 + cos 2.094 ) / ( p - 2.094 + sin 2.094 x cos 2.094 ) ]= 33.28 kgf/mmMoment on pad plate [Mp]= Fv x b’ / 8 ................................................................ where, b’ = 330 mm= 33.28 x 330 / 8= 1373 kgf-mmThickness of pad plate [tp1]= SQRT [ 6 x Mp / S2 ]= SQRT [ 6 x 1373 / 16.59 ]= 18.51 mm9. DESIGN OF SADDLE WEB AND GUSSET : Saddle coefficient [K1]= ( 1 + cos b - 0.5 x sin 2 b ) / ( p - b + sin b x cos b )= ( 1 + cos 2.094 - 0.5 x sin 2 2.094 ) / ( p - 2.094 + sin 2.094 x cos 2.094 )= 0.204Saddle splitting force [Fh]= Q x K1= 48695.2 x 0.204= 9910.5 kgfStress due to splitting force [σt]= Fh / As = 9910.5 / 28526




= 0.347 kgf/mm² ............................................. < Sa

= 0 kgfBolt tensile stress [Stb]= T / ( S3 x Nb )= 0 / ( 20.88 x 4 )= 0 kgf/mm²Shear force on bolt [F]= MAX [ MAX ( F1 , F2 ) - F3 , 0 ] = MAX [ MAX ( 5285.7 , 5285.7 ) - 7664.3 , 0 ]= 0 kgfBolt shear load [Sh]= F / ( Nb x Ar ) .......................................................... where, Ar = 312.7 mm²= 0 / [ 4 x 312.7 ]

= 0 kgf/mm² ............................................. < 0.7 x S

101


1. DESIGN CONDITION :


3. HEAD DESIGN DATA :



6. LOAD :

7. FACTORS :

8. BENDING MOMENT AT SADDLE : Bending moment at saddle [M1]= ( Q / 2 ) x [ ( 6 x A 2 + 8 x A x H - 3 x R 2 + 3 x H 2 ) / ( 3 x L + 4 x H ) ]= ( 48695.2 / 2 ) x [ ( 6 x 1596 2 + 8 x 1596 x 1187 - 3 x 1191 2 + 3 x 1187 2 )





SADDLE SUPPORT - ZICK ANALYSIS Saddle SupportCODE BS 5500


Design pressure ( internal ) Pi 0.145 kgf/mm² gDesign pressure ( external ) Pe 0.01055 kgf/mm² gDesign temperature T 75 °C

M.O.C IS-2062 GR. A Plt.Outside diameter OD 2382 mmMean radius R 1191 mmThickness ( provided ) t 16 mmThickness ts 13 mmAllowance internal / external CA 0 / 0 mmJoint efficiency ( circ.) Ec 1Yield strength Sy 26.72 kgf/mm²Allowable stress Sa 14.06 kgf/mm²Young’s modulus Ey 20373.3 kgf/mm²Allowable tensile stress S 14.06 kgf/mm²Factor A 0.00136Chart for factor B CS-2Factor B 9.452 kgf/mm²Allowable compr. stress Sc 9.452 kgf/mm²

Height of head H 1187 mmThickness of head th 9 mm

M.O.C IS-2062 GR. A Plt.No. of supports N 2Equivalent equipment length L 7980 mmDistance between saddles Ls 4788 mmDistance of saddle from T.L. A 1596 mmEquivalent equipment length L 7980 mmSaddle angle a 120 °Gusset width ( top ) b2 250 mm

M.O.C SA-516 GR. 70 Plt. [UNS:K02700]Thickness tp 20 mmWidth b 674 mmLength L1 2695.9 mm

Max. reaction at support Q 48695.2 kgf

K1 0.107K2 0.192K3 1.171K4 -K5 0.76K6 0.053

/ ( 3 x 7980 + 4 x 1187 ) ]= 25809394 kgf-mm9. BENDING MOMENT AT MIDSPAN : Bending moment at midspan [M2]= ( Q / 4 ) x [ ( 3 x L 2 - 12 x A x L - 16 x A x H + 6 x R 2 - 6 x H 2 ) / ( 3 x L + 4 x H ) ]= ( 48695.2 / 4 ) x [ ( 3 x 7980 2 - 12 x 1596 x 7980 - 16 x 1596 x 1187 + 6 x 1191 2 - 6 x 1187 2 )

/ ( 3 x 7980 + 4 x 1187 ) ]= 3375328 kgf-mm10. STRESS CALCULATION :As per G.3.3.2.2 ( G.9 )Longitudinal bending compr. stress in shell at midspan [S1]= [ M2 / ( p x R 2 x ts ) ] + [ Pe x R / ( 2 x ts ) ]= [ 3375328 / ( p x 1191 2 x 13 ) ] + [ ( 0.01055 x 1191 ) / ( 2 x 13 ) ]

As per G.3.3.2.2 ( G.10 )Longitudinal bending tensile stress in shell at midspan [S2]= [ M2 / ( p x R 2 x ts ) ] + [ Pi x R / ( 2 x ts ) ]= [ 3375328 / ( p x 1191 2 x 13 ) ] + [ ( 0.145 x 1191 ) / ( 2 x 13 ) ]

As per G.3.3.2.3 ( G.11 )Longitudinal tensile stress in shell at saddle [S3]= [ M1 / ( p x K1 x R 2 x ts ) ] + [ Pi x R / ( 2 x ts ) ]= [ 25809394 / p x 0.107 x 1191 2 x 13 ] + [ ( 0.145 x 1191 ) / ( 2 x 13 ) ]

As per G.3.3.2.3 ( G.12 )Longitudinal compr. stress in shell at saddle [S4]= [ M1 / ( p x K2 x R 2 x ts ) ] + [ Pe x R / ( 2 x ts ) ]= [ 25809394 / ( p x 0.192 x 1191 2 x 13 ) ] + [ ( 0.01055 x 1191 ) / ( 2 x 13 ) ]

As per G.3.3.2.4 ( G.13 )Tangential shear stress in shell for A > 0.5 R [S6]= [ K3 x Q / ( R x ts ) ] x [ ( L - 2 x A ) / ( L + ( 4 / 3 ) x H ) ]= [ 1.171 x 48695.2 / ( 1191 x 13 ) ] x [ ( 7980 - 2 x 1596 ) / ( 7980 + ( 4 / 3 ) x 1187 ) ]

Θ Refer noteAs per G.3.3.2.5.1 ( G.16 )Circumferential compr. stress [S8]= K5 x Q / ( ts x b )= 0.76 x 48695.2 / ( 33 x 674 )

Θ Refer noteAs per G.3.3.2.5.1 ( G.17 )Circum. bending stress compr. at horn of saddle for L < 8 x R [S10]= [ Q / ( 4 x ts x b ) ] + [ 12 x K6 x Q x R / ( L x ts 2 ) ]= [ 48695.2 / ( 4 x 33 x 674 ) ] + [ 12 x 0.053 x 48695.2 x 1191 / ( 7980 x 33 2 ) ]

Θ If b > b2 + 10 x t and pad plate extends by more than 6° above saddle plate then, use b = b + 10 x t and ts = ts + tp. Since, induced stresses are less than allowable, design is safe.

= 0.541 kgf/mm² ......................................... < [ MIN ( S , Sc ) = 9.452 kgf/mm² ]

= 6.7 kgf/mm² ......................................... < [ S x Ec = 14.06 kgf/mm² ]

= 10.81 kgf/mm² ......................................... < [ S x Ec = 14.06 kgf/mm² ]


= 3.683 kgf/mm² ......................................... < [ MIN ( 0.8 x S , 0.5 x Sy ) = 11.25 kgf/mm² ]



202


DESIGN CONDITIONS

NOZZLE DATA

SHELL DATA ( Main Shell )

WELD DATA

CALCULATION OF NOZZLE NECK THICKNESS AS PER UG 45Neck thickness for internal pressure as per UG 45(a)Formula in Appendix 1-1 , [trn1]= ( 0.5 x Pi x OD ) / ( Sn x E + 0.4 x Pi )= ( 0.5 x 0.145 x 168.3 ) / ( 12.02 x 1.0 + 0.4 x 0.145 )= 1.01 mmNeck thickness for external pressure as per UG 45(a)Neck thickness for external pressure as per UG 28 Assumed neck thickness , [trn3] = 0.512 mmL / OD = 0.891OD / trn3 = 328.5Factor A = 0.00025Factor B = 2.684 kgf/mm²Allowable external pressure , [Pa]= 4 x B / ( 3 x OD / trn3 )= 4 x 2.684 / ( 3 x 328.5 )= 0.0109 kgf/mm² gThickness of shell as per UG 45(b)(1)Min. shell thickness reqd. as per UG 27 , [tr1 = trn2]= Pi x R / ( Sv x E - 0.6 x Pi )= 0.145 x 1178 / ( 14.06 x 1.0 - 0.6 x 0.145 )= 12.22 mmThickness for equivalent pressure as per UG 45(b)(2) , [trn4]





NOZZLE NECK THICKNESS AND REINFORCEMENT DESIGN N 01CODE ASME VIII Div.1, 10 A11



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

Allowable stress @ design temperature Sn 12.02 kgf/mm²Outside diameter OD 168.3 mmInside diameter ID 152.3 mmMaximum chord length D 152.3 mmNeck thickness ( provided ) tnp 10.97 mmInternal allowance , corrosion + polishing CAI 3 mmExternal allowance , corrosion + polishing CAE 0Neck thickness (tnp - CAI - CAE) tn 7.973 mmMax. under tolerance on thickness Alw 1.372 mmAvailable neck thickness ( tn - Alw ) ta 6.601 mmNozzle projection outward ( from vessel outer face ) Lo 150 mmTotal length of nozzle ( Lo + Addn for curvature) L 153 mm

Connection type Pipe NozzleApplication type Process OpeningReinforcement calculation method Isolated OpeningDesign as large opening False

M.O.C. SA-516 GR. 70 Plt. [UNS:K02700]Allowable stress @ design temperature Sv 14.06 kgf/mm²Inside radius R 1178 mmThickness t 13 mmMin. thickness for external pressure tr2 12.38 mm

Nozzle outside weld W1 7.681 mm

= Pe x R / ( Sv x E - 0.6 x Pe )= 0.01055 x 1178 / ( 14.06 x 1.0 - 0.6 x 0.01055 )= 0.884 mmStandard wall thickness as per UG 45(b)(4) , [t3]= 7.112 mmNeck thk as per UG 45 , [trn]= MAX { MAX [ trn1, trn3 ] , MIN [ MAX ( trn2 , trn4 ) , 0.875 x t3 ] } ..... for Process Nozzle= MAX [ trn1, trn3 ] ............................................................................ for Access Opening= 6.223 mm .................................................................................... Process OpeningSince available neck thickness, ta >= trn, selected neck thickness is adequate.


DESIGN CONDITIONS

NOZZLE DATA


WELD DATA

CALCULATION OF NOZZLE NECK THICKNESS AS PER UG 45Neck thickness for internal pressure as per UG 45(a)Formula in Appendix 1-1 , [trn1]= ( 0.5 x Pi x OD ) / ( Sn x E + 0.4 x Pi )= ( 0.5 x 0.145 x 114.3 ) / ( 12.02 x 1.0 + 0.4 x 0.145 )= 0.686 mmNeck thickness for external pressure as per UG 45(a)Neck thickness for external pressure as per UG 28 Assumed neck thickness , [trn3] = 0.403 mmL / OD = 1.312OD / trn3 = 283.4Factor A = 0.00021Factor B = 2.265 kgf/mm²Allowable external pressure , [Pa]= 4 x B / ( 3 x OD / trn3 )= 4 x 2.265 / ( 3 x 283.4 )= 0.01066 kgf/mm² gThickness of shell as per UG 45(b)(1)Min. shell thickness reqd. as per UG 27 , [tr1 = trn2]= Pi x R / ( Sv x E - 0.6 x Pi )= 0.145 x 1178 / ( 14.06 x 1.0 - 0.6 x 0.145 )= 12.22 mmThickness for equivalent pressure as per UG 45(b)(2) , [trn4]











M.O.C. SA-516 GR. 70 Plt. [UNS:K02700]Allowable stress @ design temperature Sv 14.06 kgf/mm²Inside radius R 1178 mmThickness t 13 mmMin. thickness for external pressure tr2 12.38 mm


= Pe x R / ( Sv x E - 0.6 x Pe )= 0.01055 x 1178 / ( 14.06 x 1.0 - 0.6 x 0.01055 )= 0.884 mmStandard wall thickness as per UG 45(b)(4) , [t3]= 6.02 mmNeck thk as per UG 45 , [trn]= MAX { MAX [ trn1, trn3 ] , MIN [ MAX ( trn2 , trn4 ) , 0.875 x t3 ] } ..... for Process Nozzle= MAX [ trn1, trn3 ] ............................................................................ for Access Opening= 5.267 mm .................................................................................... Process OpeningSince available neck thickness, ta >= trn, selected neck thickness is adequate.


DESIGN CONDITIONS

NOZZLE DATA

HEAD DATA ( Dished End (Front) )

WELD DATA

CALCULATION OF NOZZLE NECK THICKNESS AS PER UG 45Thickness of head as per UG 37Min. head thickness reqd. as per UG 27(d) , [tr1]= 0.5 x Pi x ID1 / ( 2 x Sv x E - 0.2 x Pi )= 0.5 x 0.145 x 2356 / ( 2 x 14.06 x 1.0 - 0.2 x 0.145 )= 6.08 mmNeck thickness for internal pressure as per UG 45(a)Formula in Appendix 1-1 , [trn1]= ( 0.5 x Pi x OD ) / ( Sn x E + 0.4 x Pi )= ( 0.5 x 0.145 x 581 ) / ( 14.06 x 1.0 + 0.4 x 0.145 )= 2.366 mmNeck thickness for external pressure as per UG 45(a)Neck thickness for external pressure as per UG 28 Assumed neck thickness , [trn3] = 0.546 mmL / OD = 0.02065OD / trn3 = 1064.1Factor A = 0.00102Factor B = 8.689 kgf/mm²Allowable external pressure , [Pa]= 4 x B / ( 3 x OD / trn3 )= 4 x 8.689 / ( 3 x 1064.1 )








M.O.C. SA-516 GR. 70 Plt. [UNS:K02700]Allowable stress @ design temperature Sn 14.06 kgf/mm²Outside diameter OD 581 mmInside diameter ID 456 mmMaximum chord length D 456 mmNeck thickness ( provided ) tnp 65.5 mmInternal allowance , corrosion + polishing CAI 3 mmExternal allowance , corrosion + polishing CAE 0Neck thickness (tnp - CAI - CAE) tn 62.5 mmMax. under tolerance on thickness Alw 0 mmAvailable neck thickness ( tn - Alw ) ta 62.5 mmNozzle projection outward ( from vessel outer face ) Lo 55 mmTotal length of nozzle ( Lo + Addn for curvature) L 70 mm

Connection type Pad ConnectionApplication type Process OpeningReinforcement calculation method Isolated OpeningDesign as large opening False

Allowable stress @ design temperature Sv 14.06 kgf/mm²Inside diameter of head @ head skirt Dsf 2356 mmD / 2 H for Ellispoidal head 1Factor from Table UG-37 K1 0.5Inside diameter of equivalent sphere, K1 x Dsk x 2 ID1 2356 mmThickness t 9 mmMin. thickness for external pressure tr2 3.375 mm


= 0.01089 kgf/mm² gThickness of head as per UG 45(b)(1)Min. head thickness reqd. as per UG 27(d) , [trn2 = tr1]= 6.08 mmThickness for equivalent pressure as per UG 45(b)(2) , [trn4]= 0.5 x Pe x ID1 / ( 2 x Sv x E - 0.2 x Pe )= 0.5 x 0.01055 x 2356 / ( 2 x 14.06 x 1.0 - 0.2 x 0.01055 )= 0.442 mmStandard wall thickness as per UG 45(b)(4) , [t3]= 9.525 mmNeck thk as per UG 45 , [trn]= MAX { MAX [ trn1, trn3 ] , MIN [ MAX ( trn2 , trn4 ) , 0.875 x t3 ] } ..... for Process Nozzle= MAX [ trn1, trn3 ] ............................................................................ for Access Opening= 6.08 mm .................................................................................... Process OpeningSince available neck thickness, ta >= trn, selected neck thickness is adequate.


CALCULATION OF LIMITS OF REINFORCEMENT AS PER UG 40Parallel to vessel wall as per UG 40 (b) (1) & (2) , [WD1] = MAX [ D , 0.5 x ID + t + tn ]= MAX [ 456 , 0.5 x 456 + 9 + 62.5 ]= 456 mmUser defined reinforcement limit, [WD2]=0 mmGoverning limit parallel to wall, [W]= MIN [ WD1 , WD2 ] ........................................... when WD2 > 0 or is defined= WD1 ................................................................. When WD2 = 0 or undefined= 456 mmNormal to vessel wall as per UG 40 (c) (1) & (2) , outside [ho]= MIN [ 2.5 x t , 2.5 x tn , Lo ]= MIN [ 2.5 x 9 , 2.5 x 62.5 , 55 ]= 22.5 mmDESIGN CALCULATION OF AREA AS PER UG 37

For internal pressure , A1 + A2 + A41 - Ax = 3941 > A ( 2772.5 ) .For external pressure , A1 + A2 + A41 - Ax = 5174.5 > 0.5 x A ( 0.5 x 1539 ) .Therefore , opening is adequately reinforced.





Factor E1 E1 1.00Correction factor F 1.00Sn / Sv fr1 1.00 ( Max. 1 )Sn / Sv fr2 1.00 ( Max. 1 )Sn / Sv fr3 1.00 ( Max. 1 )

Area mm²Under conditions Int. pressure Ext. pressure

tr = 6.08 tr = 3.375

Area required , [A]= D x tr x F + 2 x tn x tr x F x ( 1 - fr1 )= 456 x tr x 1.00 + 2 x 62.5 x tr x 1.00 x ( 1 - 1.00 ) 2772.5 1539

Area available in vessel wall , [A1]= ( 2 x W - D ) x ( E1 x t - F x tr ) - 2 x tn x ( E1 x t - F x tr ) x ( 1 - fr1 )= ( 2 x 456 - 456 ) x ( 1.00 x 9 - 1.00 x tr )

- 2 x 62.5 x ( 1.00 x 9 - 1.00 x tr ) x ( 1 - 1.00 ) 1331.5 2565

Area available in nozzle projection outward , [A2]

= 2 x ho x ( tn - trn ) x fr2= 2 x 22.5 x ( 62.5 - 6.08 ) x 1.00 2538.9 2538.9

Area available in outward weld , [A41]

= W1 2 x fr3

= 8.4 2 x 1.00 70.56 70.56

Area deductions:

Area to be reduced due to overlap in multiple openings, [ Ax ] 0 0


1. GENERAL DATA :

2. DIMENSIONAL DATA :





REINFORCEMENT PAD DETAILS Saddle Plate

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

Length of pad L 2055.2 mmWidth of pad W 892.5 mmNominal thickness T 14 mm



2. COVER DATA :

3. BOLTING DATA :

4. LINER DATA :

5. GASKET DATA :

6. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b1) :Total joint - contact surface compression load [Hp]= 2 x x b x G x m x P= 2 x x 9.275 x 485.6 x 2 x 0.145= 8207.2 kgfTotal hydrostatic end force [H]= 0.25 x x G 2 x P= 0.25 x x 485.6 2 x 0.145= 26858.6 kgfMinimum required bolt load for operating condition [Wm1]= Hp + H= 8207.2 + 26858.6= 35065.8 kgf7. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b2) :Minimum required bolt load for gasket seating [Wm2]= x b x G x y





DESIGN OF FLAT BOLTED HEAD ( INTERNAL ) Bolted Cover [N 03]CODE ASME VIII Div.1, 10 A11

Design pressure P 0.145 kgf/mm² gDesign temperature T 75 °CAllowance CA 3 mmGroove allowance Tg 0 mmRadiography FullJoint efficiency E 1

M.O.C. SA-516 GR. 70 Plt. [UNS:K02700]Code allw. stress @ design temp. Sfo 14.06 kgf/mm²Code allw. stress @ atm. temp. Sfa 14.06 kgf/mm²Young’s modulus Ey 20373.3 kgf/mm²Flange OD A 581 mmThickness provided 34.07 mmThickness available 31.07 mm

M.O.C. SA-193 GR. B7 Bolt [UNS:G41400]Code allw. stress @ design temp. Sb 17.58 kgf/mm²Code allw. stress @ atm. temp. Sa 17.58 kgf/mm²Bolt PCD PCD 534 mmBolt dia. db 20 mmNo. of bolts nb 16

M.O.C.Liner ID mmLiner OD mmLiner thk. mm

M.O.C. CAF with suitable binder (3 mm.)Gasket seating stress y 1.125 kgf/mm²Gasket factor m 2Inside diameter Gi 450 mmOutside diameter Go 504.2 mmWidth of gasket N 27.09 mmWidth of gasket ( as per Table 2-5.2 ) N.A. mmBasic gasket seating width ( as per Table 2-5.2 ) b0 13.55 mmEffective gasket width ( as per Table 2-5.2 ) b 9.275 mmDia. at load reaction ( see Table 2-5.2 ) G 485.6 mm

= x 9.275 x 485.6 x 1.125= 15918 kgf8. BOLT AREAS AS PER APPENDIX 2-5 (d) :Total required cross-sectional area of bolts [Am]= MAX [ Wm2 / Sa , Wm1 / Sb ] ........ For Internal '+' Pr Design = Wm2 / Sa ..................................... For External Pr & Self Sealing Design= 1995 mm²Actual bolt area using root diameter [Ab]= 3472.8 mm²Flange design bolt load for the gasket seating [W]= 0.5 x ( Am + Ab ) x Sa x 1 .................... average bolt area= Ab x Sa x 1 ..........................................full bolt area= 48053.2 kgf ( Avg. bolt area and margin factor of 1 ) 9. CHECK FOR GASKET CRUSHING :Minimum gasket width required [Nmin]= Ab x Sb / ( 2 x x y x G )= 3472.8 x 17.58 / ( 2 x x 1.125 x 485.6 )= 17.78 mm10. DESIGN CALCULATION AS PER UG 34, BOLTING CONDITION :Required thickness for bolting condition [t]= G x SQRT [ 1.9 x W x 0.5 x ( PCD - G ) / ( Sfa x E x G 3 ) ]= 485.6 x SQRT [ 1.9 x 48053.2 x 0.5 x ( 534 - 485.6 ) / ( 14.06 x 1 x 485.6 3 ) ]= 17.98 mm11. DESIGN CALCULATION AS PER UG 34, OPERATING CONDITION :

Required thickness for operating condition [t] = G x SQRT { [ C x P / ( Sfo x E ) ] + 1.9 x Wm1 x 0.5 x ( PCD - G ) / ( Sfo x E x G 3 ) }= 485.6 x SQRT { [ 0.3 x 0.145 / ( 14.06 x 1 ) ] + 1.9 x 35065.8 x 0.5 x ( 534 - 485.6 ) /

( 14.06 x 1 x 485.6 3 ) } = 31.07 mm

Self reinforced FalseFactor C is user input FalseFactor C taken from fig. UG 34 or user input 0.3Maximum factor C value C 0.75Factor C (effective) 0.3

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



2. COVER DATA :

3. BOLTING DATA :

4. LINER DATA :

5. GASKET DATA :

6. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b1) :Total joint - contact surface compression load [Hp]= 2 x p x b x G x m x P= 2 x p x 9.275 x 485.6 x 2 x 0.01055= 596.9 kgfTotal hydrostatic end force [H]= 0.25 x p x G 2 x P= 0.25 x p x 485.6 2 x 0.01055= 1953.5 kgfMinimum required bolt load for operating condition [Wm1]= Hp + H= 596.9 + 1953.5= 2550.4 kgf7. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b2) :Minimum required bolt load for gasket seating [Wm2]= p x b x G x y





DESIGN OF FLAT BOLTED HEAD ( EXTERNAL ) Bolted Cover [N 03]CODE ASME VIII Div.1, 10 A11






= p x 9.275 x 485.6 x 1.125= 15918 kgf8. BOLT AREAS AS PER APPENDIX 2-5 (d) :Total required cross-sectional area of bolts [Am]= MAX [ Wm2 / Sa , Wm1 / Sb ] ........ For Internal '+' Pr Design = Wm2 / Sa ..................................... For External Pr & Self Sealing Design= 905.6 mm²Actual bolt area using root diameter [Ab]= 3472.8 mm²Flange design bolt load for the gasket seating [W]= 0.5 x ( Am + Ab ) x Sa x 1 .................... average bolt area= Ab x Sa x 1 ..........................................full bolt area= 38479.3 kgf ( Avg. bolt area and margin factor of 1 ) 9. CHECK FOR GASKET CRUSHING :Minimum gasket width required [Nmin]= Ab x Sb / ( 2 x p x y x G )= 3472.8 x 17.58 / ( 2 x p x 1.125 x 485.6 )= 17.78 mm10. DESIGN CALCULATION AS PER UG 34, BOLTING CONDITION :Required thickness for bolting condition [t]= G x SQRT [ 1.9 x W x 0.5 x ( PCD - G ) / ( Sfa x E x G 3 ) ]= 485.6 x SQRT [ 1.9 x 38479.3 x 0.5 x ( 534 - 485.6 ) / ( 14.06 x 1 x 485.6 3 ) ]= 16.09 mm11. DESIGN CALCULATION AS PER UG 34, OPERATING CONDITION :


( 14.06 x 1 x 485.6 3 ) } = 8.38 mm




1. LIFTING LUG DATA :

2. DESIGN LOADS :

3. CALCULATION OF REFERENCE DIMENSIONS :

4. DESIGN OF LUG PLATE :

5. CALCULATION OF STRESSES IN LUG PLATE WELDS :





DESIGN OF LIFTING LUG Lifting LugsCODE P V Design Manual, D.R. Moss

Design Mode 1 , Uncorroded Condition

Material IS-2062 GR. A Plt.Length of lug LL 67 mmWidth of lug A 120 mmThickness of lug plate TL 60 mmStraight length B1 10 mmRadius at tip R3 35 mmPin Hole diameter D1 40 mmLug to vessel weld size W1 26.23 mmMin yield stress Sy 24.61 kgf/mm²Allowable tensile stress ( 2 / 3 x Sy ) St 16.4 kgf/mm²Allowable bending stress ( 1.5 x St ) Sb 22.15 kgf/mm²Allowable shear stress (0.6 x St ) Ss 9.843 kgf/mm²

Empty weight of equipment Wt 11373.4 kgfNumber of lifting lugs N 2Jirk load factor j 1.5

Dimension [ L1 ]= LL - B1 - R3= 67 - 10 - 35= 22 mm

Dimension [ L2 ]= L1 / SIN ( q1 ) = 22 / SIN ( 0.351 ) = 63.91 mm

Dimension [ LT ]= LL - R3= 67 - 35 = 32 mm

Angle [ q2 ]= ASIN ( R3 / L2 ) = ASIN ( 35 / 63.91 ) = 0.58 radians

Angle [ q1 ]= ATAN ( 2 x L1 / A )= ATAN ( 2 x 22 / 120 ) = 0.351 radians

Angle [ q3 ]= q1 + q2 = 0.351 + 0.58 = 0.931 radians

Dimension [ L3 ]= R3 / SIN ( q3 ) = 35 / SIN ( 0.931 ) = 43.63 mm

Effective design load on each lug [ P ]= j x Wt / N= 1.5 x 11373.4 / 2= 8533.7 kgf

Required min. thickness of lug plate for shear [ t2 ]= P / [ ( R3 - 0.5 x D1) x ss ] = 8533.7 / [ ( 35 - 0.5 x 40 ) x 9.843 ]= 57.8 mm

Required min. thickness of lug plate for bending [ t1 ]= 6 x P x LT / ( A 2 x Sb ) = 6 x 8533.7 x 32 / ( 120 2 x 22.15 )= 5.138 mm

Required min. thickness of lug plate for shear [ t3 ]= P / [ ( 2 x L3 - D1 ) x ss ] = 8533.7 / [ ( 2 x 43.63 - 40 ) x 9.843 ]= 11.01 mm

Bending stress in weld [ f1 ]= 6 x P x LT / [ 2 x LL2 ]= 6 x 8533.7 x 32 / ( 2 x 67 2 )= 182.5 kgf/mm

Max. shear stress in weld [ f2 ]= P / [ 2 x A ]= 8533.7 / ( 2 x 120 )= 35.56 kgf/mm

Min. Size of lug plate weld [ w1 ]= MAX ( f1 , 2 x f2 ) / ( 0.707 x Ss )

= MAX ( 182.5 , 2 x 35.56 ) / ( 0.707 x 9.843 )= 26.23 mm


FOUNDATION LOAD DATA





Sr.No. Mode Condition

Weight ( kgf ) Wind Seismic

Empty FilledShear ( kgf ) Moment ( kgf-m ) Shear Moment

Tran. Long. Tran. Long. ( kgf ) ( kgf-m )

1 Operating Corroded 9443.5 29019.9 1683.1 5395.5 2524.7 8093.3 3002.1 4503.1

2 Design1 Corroded 9443.5 51095.3 1683.1 5395.5 2524.7 8093.3 5285.7 7928.6

3 Hydro Corroded 9443.5 51095.3 1683.1 5395.5 2524.7 8093.3 5285.7 7928.6

4 Pneumatic Corroded 9443.5 9493.5 1683.1 5395.5 2524.7 8093.3 982.1 1473.1

5 Operating Uncorroded 11373.4 30841.8 1683.1 5395.5 2524.7 8093.3 3190.5 4785.8

6 Design1 Uncorroded 11373.4 52795.4 1683.1 5395.5 2524.7 8093.3 5461.6 8192.4

7 Hydro Uncorroded 11373.4 52795.4 1683.1 5395.5 2524.7 8093.3 5461.6 8192.4

8 Pneumatic Uncorroded 11373.4 11423.1 1683.1 5395.5 2524.7 8093.3 1181.7 1772.6


CENTER OF GRAVITY DATA






Empty Operating / FilledWt ( kgf ) C.G. ( mm ) Wt ( kgf ) C.G. ( mm )

1 Operating Corroded 9443.5 5177 29019.9 51772 Design1 Corroded 9443.5 5177 51095.3 51773 Hydro Corroded 9443.5 5177 51095.3 51774 Pneumatic Corroded 9443.5 5177 9493.5 51775 Operating Uncorroded 11373.4 5177 30841.8 51776 Design1 Uncorroded 11373.4 5177 52795.4 51777 Hydro Uncorroded 11373.4 5177 52795.4 51778 Pneumatic Uncorroded 11373.4 5177 11423.1 5177


Index





Sr. No. Description Page No

1 Title page & equipment info

2 Design data

3 Material of constructions

4 Effective Pressures

5 Weight summary report

6 Wind load calculations

7 Seismic load calculations

8 Design of Dished End (Front)

9 Design of Main Shell

10 Design of Dished End (Rear)




14 Design of N 01

15 Design of N 02

16 Design of N 03

17 Design of N 03

18 Design of Saddle Plate


20 Design of Lifting Lugs

21 Foundation load data

22 C.G. Data


EQUIPMENT INFORMATION :

DESIGN & REVIEWAL :

INSPECTION & APPROVAL :

EQUIPMENT DATA :

OTHER DATA :


Project Horizontal Presure Vessel with Saddle Supports

Location Sample SitePlant LPG Storage Tank

Design Code ASME VIII Div.1, 10 A11Equipment Name LPG Storage Tank Equipment Type Pressure VesselEquipment Class N.A.Equipment Category N.A.Reference Drawing No ---Service Explosive ServicesSupport Type Saddle Supports

Designed ByDesign Date 31-03-2015 22:11:06Checked ByApproved ByRevision R00

Inspection Agency ---

Reviewed By ---

Front end Dished EndFront end flanged FalseRear end Dished EndRear end flanged FalseShell ID 2350 mmShell OD 2382 mmLength, Shell (W.L. to W.L) / Overall 7980 / 10354 mm

Fabricated weight 9443.5 kgfEmpty weight + external weights 9443.5 kgfEstimated operating weight 51095.3 kgfEstimated hydrotest weight 52795.4 kgf


(1) PROCESS DETAILS :

(3) TEST PR. : kgf/mm² g

(4) TEMPERATURE : °C

(5) ALLOWANCES : mm

(6) RADIOGRAPHY & JOINT EFFICIENCY :





VESSEL DESIGN DATA

MEDIA DENSITYkg/m³

Operating LPG 470Design1 1000Design2StartupShutdownUpsetHydrotest Water 1000Pneumatic LPG 1.2

(2) PR. : kgf/mm² g INT. EXT.

Operating 0.1 0.1 0.01055Design1 0.145 0.145 0.01055Design2StartupShutdownUpset

Based onInput Pr MAWP MAP

Hydrotest 0.189 0.189 0.189Pneumatic 0.16 0.16 0.16

MIN. MAX.Input MDMT

Operating 20 55Design1 -10 75Design2StartupShutdownUpsetHydrotest 21.67 50Pneumatic 21.67 50

INT. EXT.Corrosion 3 0Polishing 0 0

RADIOGRAPHY JOINT EFFICIENCY

Shell Full 1.00Head Full 1.00


VESSEL DESIGN DATA1. MATERIAL OF CONSTRUCTION :

2. NOZZLE CONNECTIONS :

3. INSULATION & CLADDING:





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

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

Body flange SA-516 GR. 70 Plt. [UNS:K02700]Body flange cover SA-516 GR. 70 Plt. [UNS:K02700]Liner

Shell side

Nozzle neck <= NPS 40 SA-106 GR. B Smls. Pipe[UNS:K03006]


Nozzle NPS > 40 & < 200 SA-106 GR. B Smls. Pipe [UNS:K03006]


Nozzle neck >= NPS 200 SA-516 GR. 70 Plt. [UNS:K02700]Flange SA-516 GR. 70 Plt. [UNS:K02700]Cover flange SA-516 GR. 70 Plt. [UNS:K02700]

Pad flange SA-516 GR. 70 Plt. [UNS:K02700]Pad flange cover SA-516 GR. 70 Plt. [UNS:K02700]Manhole flange SA-516 GR. 70 Plt. [UNS:K02700]Manhole cover SA-516 GR. 70 Plt. [UNS:K02700]Reinforcement pad SA-516 GR. 70 Plt. [UNS:K02700]External bolt SA-193 GR. B7 Bolt [UNS:G41400]External gasket CAF with suitable binder (3 mm.)Stiffener SA-516 GR. 70 Plt. [UNS:K02700]Lifting lug IS-2062 GR. A Plt.Support IS-2062 GR. A Plt.Anchor bolt Commercial CS Bolt

Mat. / Density / Thk. N.A. / kg/m³ / mmMat. / Thk. N.A. / mm


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





Sr. Item name Temp. Inside pr. Liquid pr. Effective pr.No. +ve -ve +ve -ve1 Dished End (Front) 50 0.145 0 0.00235 0.147 02 Main Shell 50 0.145 0 0.00235 0.147 03 Dished End (Rear) 50 0.145 0 0.00235 0.147 045


ITEM WISE WEIGHT SUMMARY





Sr.No. Item name Item size Empty wt Volume Filled wt

kgf m³ kgf

1 Dished End (Front) Hemispherical End 2374 OD x 12 Nom / 10.8 Min Thk 1037.5 3.398 4435.2

2 Main Shell 2382 OD x 16 Thk, 7980 Lg 7513.1 34.61 42125.2

3 Dished End (Rear) Hemispherical End 2374 OD x 12 Nom / 10.8 Min Thk 1037.5 3.398 4435.2

4 Saddle Plate 892.5 Long x 2055.16 Wide x 14 Thk, 2 Nos. 406.6 0 406.6



7 Bolting Plate 2055.16 Long x 514 Wide x 22 Thk, 2 Nos. 368 0 368

8 Anchor Bolt Anchor M24 x 600 Lg, 8 Nos. 17.19 0 17.19

9 Support Pad 674 Long x 2695.914 Wide x 20 Thk, 2 Nos. 575.4 0 575.4

10 N 01 ANSIB36.10, 150 NPS Sch.80, 153 Lg 6.568 0.00257 9.141

11 Flange [N 01] Weld Neck, ANSI B16.5, RF, 300# for 150 NPS Sch 80 Pipe 17.34 0 17.34




15 N 02 ANSIB36.10, 100 NPS Sch.160, 151 Lg 5.106 0.0009 6.011

16 Flange [N 02]Weld Neck, ANSI B16.5, RF, 300# for 100 NPS Sch 160 Pipe

11.02 0 11.02




20 N 03 581 OD x 450 ID, 70 Thk 58.78 0.01113 69.92

21 Bolted Cover [N 03]Blind Flange - 581 OD x 34.073 Thk, RF, 534 PCD, Tgrv = 1.588

68.18 0 68.18

22 Cover Gasket [N 03] 504.188 OD x 450 ID, 3.175Thk 0.1 0 0.1

23 Cover Bolts [N 03] Hex Head Bolt M20 x 73.485 Lg, 16 Nos. 2.924 0 2.924

24 Lifting Lugs 120 Long x 67 Wide x 60 Thk, 2 Nos. 7.638 0 7.638

25 Pad (Lifting Lugs) 70 Long x 210 Wide x 8 Thk, 2Nos. 1.862 0 1.862

26

27

28

29

30

∑ 11373.4 ∑ 52795.4


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






WIND LOAD CALCULATIONCODE Wind [IS:875, 87]

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

Equivalent diameter De 3290 mmOverall length of equipment L 10354 mmHeight of C.G. of equipment Hcg 1500 mmHeight and size factor ( Section 5.3.2 ) K2 0.98Effective longitudinal cross sectional area

= 0.25 x x De 2 Al 8501228.3 mm²

Effective transverse cross sectional area= De x L At 34064660 mm²

Effective wind speed= K1 x K2 x K3 x Vb Vz 57.44 m/s

Wind pressure

= 6E-08 x Vz 2 Pz 0.0002 kgf/mm²

Longitudinal force= Al x Pz Fl 1683.1 kgf

Transverse force= Cf x At x Pz Ft 5395.5 kgf

Longitudinal turning moment= Fl x ( Hcg - H ) M 2524711.2 kgf-mm

Transverse turning moment= Ft x ( Hcg - H ) M 8093271 kgf-mm








SEISMIC LOAD CALCULATIONCODE Seismic [IS:1893, 02]

Weight of equipment Wo 51095.3 kgfImportance factor ( Table-6 , 2002 ) I 1.5Soil profile type Stiff Soil Profile (SD)Foundation type RCC footings + Tie BeamsDamping factor 5Seismic zone Zone IIISeismic zone factor ( Table-2 , 2002 ) Z 0.16Response reduction factor ( Table-7 , 2002 ) R 2.9Spectral accelerations coeff. ( Fig. 2 , 2002 ) Sa / g 2.5, Use max valueDamping correction factor ( Table-3 , 2002 ) Cf 1Seismic coefficient ( Clause-6.4.2 , 2002 )

= 0.5 x Z x I x Cf x ( Sa / g ) x ( 1 / R )= 0.5 x 0.16 x 1.5 x 1 x

2.5 x ( 1 / 2.9 ) Ah 0.103

Elevation of support H 0 mmHeight of C.G. of equipment Hcg 1500 mmSeismic base shear force

= Ah x Wo= 0.103 x 51095.3 Vb 5285.7 kgf

Seismic moment of support= Vb x ( Hcg - H )= 5285.7 x ( 1500 - 0 ) M 7928582.9 kgf-mm


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

2. DESIGN CALCULATION AS PER UG 32 f :Factor [K] = 0.5Thickness for internal pressure [t]= K x Pi x ID / ( 2 x S x E - 0.2 x Pi )= 0.5 x 0.147 x 2356 / ( 2 x 14.06 x 1 - 0.2 x 0.147 )= 6.179 mmSince available thickness is more than design thickness, design is safe.





DESIGN OF HEMISPHERICAL HEAD ( INTERNAL PRESSURE ) Dished End (Front)CODE ASME VIII Div.1, 10 A11

Design pressure ( internal ) Pi 0.147 kgf/mm² gDesign temperature T 50 °CMaterial of construction SA-516 GR. 70 Plt. [UNS:K02700]Max. allowable stress @ design temp. S 14.06 kgf/mm²Radiography FullJoint efficiency E 1Inside diameter of shell ID 2356 mmHead shapeNominal thickness 12 mmNominal thickness required as per TEMA N.A mmInternal allowance, corrosion + polishing 3 mmExternal allowance, corrosion + polishing 0 mmThinning allowance / Under tolerance 1.2 mmAvailable thickness 7.8 mm


1. DESIGN CONDITIONS ( Hydrotest Mode , Corroded Condition )

2. DESIGN CALCULATION AS PER UG-27

Thickness of shell under internal pressure [ti]= Pi x R / ( S x E - 0.6 x Pi ) = 0.147 x 1178 / ( 14.06 x 1 - 0.6 x 0.147 )= 12.42 mm

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





DESIGN OF SHELL ( INTERNAL PRESSURE ) Main ShellCODE ASME VIII Div.1, 10 A11

Design pressure ( internal ) Pi 0.147 kgf/mm² gDesign temperature T 50 °CMaterial of construction SA-516 GR. 70 Plt. [UNS:K02700]Max. allowable stress at design temp. S 14.06 kgf/mm²Radiography FullJoint efficiency long. seam Ec 1Outside diameter OD 2382 mmInside radius ( corroded ) R 1178 mmShell length L 7980 mmNominal thickness 16 mmNominal thickness required as per TEMA N.A. mmInternal allowance, corrosion + polishing 3 mmExternal allowance, corrosion + polishing 0 mmThickness undertolerance 0 mmAvailable thickness 13 mm


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

2. DESIGN CALCULATION AS PER UG 32 f :Factor [K] = 0.5Thickness for internal pressure [t]= K x Pi x ID / ( 2 x S x E - 0.2 x Pi )= 0.5 x 0.147 x 2356 / ( 2 x 14.06 x 1 - 0.2 x 0.147 )= 6.179 mmSince available thickness is more than design thickness, design is safe.





DESIGN OF HEMISPHERICAL HEAD ( INTERNAL PRESSURE ) Dished End (Rear)CODE ASME VIII Div.1, 10 A11

Design pressure ( internal ) Pi 0.147 kgf/mm² gDesign temperature T 50 °CMaterial of construction SA-516 GR. 70 Plt. [UNS:K02700]Max. allowable stress @ design temp. S 14.06 kgf/mm²Radiography FullJoint efficiency E 1Inside diameter of shell ID 2356 mmHead shapeNominal thickness 12 mmNominal thickness required as per TEMA N.A mmInternal allowance, corrosion + polishing 3 mmExternal allowance, corrosion + polishing 0 mmThinning allowance / Under tolerance 1.2 mmAvailable thickness 7.8 mm






5. AREAS :

6. LOADS :







Hydrotest Mode , CorrodedCondition






Design load WindDesign weight W 7741.4 kgfLong. load F1 1683.1 kgfTrans. load F2 5395.5 kgfFriction factor μ 0.3Friction load F3 1161.2 kgf

= F1 x B / L= 1683.1 x 1500 / 4788= 527.3 kgfSaddle reaction due to trans. force [QR]= 6 x F2 x B / E= 6 x 5395.5 x 1500 / 2055.2= 23628.2 kgfTotal reaction force on saddle [Q]= MAX [ QL , QR ] + 0.5 x W= MAX [ 527.3 , 23628.2 ] + 0.5 x 7741.4= 27498.9 kgf8. DESIGN OF PAD PLATE : Saddle angle [θ]= a x p / 360= 120 x p / 360= 1.047 radSaddle angle [β]= p - θ= p - 1.047= 2.094 radUnit load on pad plate [Fv]= [ Q / ( 0.5 x OD ) ] x [ ( 1 + cos b ) / ( p - b + sin b x cos b ) ]= [ 27498.9 / ( 0.5 x 2382 ) ] x [ ( 1 + cos 2.094 ) / ( p - 2.094 + sin 2.094 x cos 2.094 ) ]= 18.8 kgf/mmMoment on pad plate [Mp]= Fv x b’ / 8 ................................................................ where, b’ = 330 mm= 18.8 x 330 / 8= 775.4 kgf-mmThickness of pad plate [tp1]= SQRT [ 6 x Mp / S2 ]= SQRT [ 6 x 775.4 / 17.34 ]= 13.91 mm9. DESIGN OF SADDLE WEB AND GUSSET : Saddle coefficient [K1]= ( 1 + cos b - 0.5 x sin 2 b ) / ( p - b + sin b x cos b )= ( 1 + cos 2.094 - 0.5 x sin 2 2.094 ) / ( p - 2.094 + sin 2.094 x cos 2.094 )= 0.204Saddle splitting force [Fh]= Q x K1= 27498.9 x 0.204= 5596.6 kgfStress due to splitting force [σt]= Fh / As = 5596.6 / 28526




= 0.196 kgf/mm² ............................................. < Sa

= 0 kgfBolt tensile stress [Stb]= T / ( S3 x Nb )= 0 / ( 20.88 x 4 )= 0 kgf/mm²Shear force on bolt [F]= MAX [ MAX ( F1 , F2 ) - F3 , 0 ] = MAX [ MAX ( 1683.1 , 5395.5 ) - 1161.2 , 0 ]= 4234.3 kgfBolt shear load [Sh]= F / ( Nb x Ar ) .......................................................... where, Ar = 312.7 mm²= 4234.3 / [ 4 x 312.7 ]

= 3.385 kgf/mm² ............................................. < 0.7 x S

101






5. AREAS :

6. LOADS :













Design load SeismicDesign weight W 51095.5 kgfLong. load F1 5285.7 kgfTrans. load F2 5285.7 kgfFriction factor μ 0.3Friction load F3 7664.3 kgf

= F1 x B / L= 5285.7 x 1500 / 4788= 1655.9 kgfSaddle reaction due to trans. force [QR]= 6 x F2 x B / E= 6 x 5285.7 x 1500 / 2055.2= 23147.4 kgfTotal reaction force on saddle [Q]= MAX [ QL , QR ] + 0.5 x W= MAX [ 1655.9 , 23147.4 ] + 0.5 x 51095.5= 48695.2 kgf8. DESIGN OF PAD PLATE : Saddle angle [θ]= a x p / 360= 120 x p / 360= 1.047 radSaddle angle [β]= p - θ= p - 1.047= 2.094 radUnit load on pad plate [Fv]= [ Q / ( 0.5 x OD ) ] x [ ( 1 + cos b ) / ( p - b + sin b x cos b ) ]= [ 48695.2 / ( 0.5 x 2382 ) ] x [ ( 1 + cos 2.094 ) / ( p - 2.094 + sin 2.094 x cos 2.094 ) ]= 33.28 kgf/mmMoment on pad plate [Mp]= Fv x b’ / 8 ................................................................ where, b’ = 330 mm= 33.28 x 330 / 8= 1373 kgf-mmThickness of pad plate [tp1]= SQRT [ 6 x Mp / S2 ]= SQRT [ 6 x 1373 / 17.34 ]= 18.51 mm9. DESIGN OF SADDLE WEB AND GUSSET : Saddle coefficient [K1]= ( 1 + cos b - 0.5 x sin 2 b ) / ( p - b + sin b x cos b )= ( 1 + cos 2.094 - 0.5 x sin 2 2.094 ) / ( p - 2.094 + sin 2.094 x cos 2.094 )= 0.204Saddle splitting force [Fh]= Q x K1= 48695.2 x 0.204= 9910.5 kgfStress due to splitting force [σt]= Fh / As = 9910.5 / 28526




= 0.347 kgf/mm² ............................................. < Sa

= 0 kgfBolt tensile stress [Stb]= T / ( S3 x Nb )= 0 / ( 20.88 x 4 )= 0 kgf/mm²Shear force on bolt [F]= MAX [ MAX ( F1 , F2 ) - F3 , 0 ] = MAX [ MAX ( 5285.7 , 5285.7 ) - 7664.3 , 0 ]= 0 kgfBolt shear load [Sh]= F / ( Nb x Ar ) .......................................................... where, Ar = 312.7 mm²= 0 / [ 4 x 312.7 ]

= 0 kgf/mm² ............................................. < 0.7 x S

101


1. DESIGN CONDITION :


3. HEAD DESIGN DATA :



6. LOAD :

7. FACTORS :

8. BENDING MOMENT AT SADDLE : Bending moment at saddle [M1]= ( Q / 2 ) x [ ( 6 x A 2 + 8 x A x H - 3 x R 2 + 3 x H 2 ) / ( 3 x L + 4 x H ) ]= ( 48695.2 / 2 ) x [ ( 6 x 1596 2 + 8 x 1596 x 1187 - 3 x 1191 2 + 3 x 1187 2 )





SADDLE SUPPORT - ZICK ANALYSIS Saddle SupportCODE BS 5500


Design pressure ( internal ) Pi 0.145 kgf/mm² gDesign pressure ( external ) Pe 0 kgf/mm² gDesign temperature T 50 °C

M.O.C IS-2062 GR. A Plt.Outside diameter OD 2382 mmMean radius R 1191 mmThickness ( provided ) t 16 mmThickness ts 13 mmAllowance internal / external CA 0 / 0 mmJoint efficiency ( circ.) Ec 1Yield strength Sy 26.72 kgf/mm²Allowable stress Sa 14.06 kgf/mm²Young’s modulus Ey 20543.7 kgf/mm²Allowable tensile stress S 14.06 kgf/mm²Factor A 0.00136Chart for factor B CS-2Factor B 9.452 kgf/mm²Allowable compr. stress Sc 9.452 kgf/mm²

Height of head H 1187 mmThickness of head th 9 mm

M.O.C IS-2062 GR. A Plt.No. of supports N 2Equivalent equipment length L 7980 mmDistance between saddles Ls 4788 mmDistance of saddle from T.L. A 1596 mmEquivalent equipment length L 7980 mmSaddle angle a 120 °Gusset width ( top ) b2 250 mm

M.O.C SA-516 GR. 70 Plt. [UNS:K02700]Thickness tp 20 mmWidth b 674 mmLength L1 2695.9 mm

Max. reaction at support Q 48695.2 kgf

K1 0.107K2 0.192K3 1.171K4 -K5 0.76K6 0.053

/ ( 3 x 7980 + 4 x 1187 ) ]= 25809394 kgf-mm9. BENDING MOMENT AT MIDSPAN : Bending moment at midspan [M2]= ( Q / 4 ) x [ ( 3 x L 2 - 12 x A x L - 16 x A x H + 6 x R 2 - 6 x H 2 ) / ( 3 x L + 4 x H ) ]= ( 48695.2 / 4 ) x [ ( 3 x 7980 2 - 12 x 1596 x 7980 - 16 x 1596 x 1187 + 6 x 1191 2 - 6 x 1187 2 )

/ ( 3 x 7980 + 4 x 1187 ) ]= 3375328 kgf-mm10. STRESS CALCULATION :As per G.3.3.2.2 ( G.9 )Longitudinal bending compr. stress in shell at midspan [S1]= [ M2 / ( x R 2 x ts ) ] + [ Pe x R / ( 2 x ts ) ]= [ 3375328 / ( x 1191 2 x 13 ) ] + [ ( 0 x 1191 ) / ( 2 x 13 ) ]

As per G.3.3.2.2 ( G.10 )Longitudinal bending tensile stress in shell at midspan [S2]= [ M2 / ( x R 2 x ts ) ] + [ Pi x R / ( 2 x ts ) ]= [ 3375328 / ( x 1191 2 x 13 ) ] + [ ( 0.145 x 1191 ) / ( 2 x 13 ) ]

As per G.3.3.2.3 ( G.11 )Longitudinal tensile stress in shell at saddle [S3]= [ M1 / ( x K1 x R 2 x ts ) ] + [ Pi x R / ( 2 x ts ) ]= [ 25809394 / x 0.107 x 1191 2 x 13 ] + [ ( 0.145 x 1191 ) / ( 2 x 13 ) ]

As per G.3.3.2.3 ( G.12 )Longitudinal compr. stress in shell at saddle [S4]= [ M1 / ( x K2 x R 2 x ts ) ] + [ Pe x R / ( 2 x ts ) ]= [ 25809394 / ( x 0.192 x 1191 2 x 13 ) ] + [ ( 0 x 1191 ) / ( 2 x 13 ) ]

As per G.3.3.2.4 ( G.13 )Tangential shear stress in shell for A > 0.5 R [S6]= [ K3 x Q / ( R x ts ) ] x [ ( L - 2 x A ) / ( L + ( 4 / 3 ) x H ) ]= [ 1.171 x 48695.2 / ( 1191 x 13 ) ] x [ ( 7980 - 2 x 1596 ) / ( 7980 + ( 4 / 3 ) x 1187 ) ]

Θ Refer noteAs per G.3.3.2.5.1 ( G.16 )Circumferential compr. stress [S8]= K5 x Q / ( ts x b )= 0.76 x 48695.2 / ( 33 x 674 )

Θ Refer noteAs per G.3.3.2.5.1 ( G.17 )Circum. bending stress compr. at horn of saddle for L < 8 x R [S10]= [ Q / ( 4 x ts x b ) ] + [ 12 x K6 x Q x R / ( L x ts 2 ) ]= [ 48695.2 / ( 4 x 33 x 674 ) ] + [ 12 x 0.053 x 48695.2 x 1191 / ( 7980 x 33 2 ) ]

Θ If b > b2 + 10 x t and pad plate extends by more than 6° above saddle plate then, use b = b + 10 x t and ts = ts + tp. Since, induced stresses are less than allowable, design is safe.


= 6.7 kgf/mm² ......................................... < [ S x Ec = 14.06 kgf/mm² ]

= 10.81 kgf/mm² ......................................... < [ S x Ec = 14.06 kgf/mm² ]





202


DESIGN CONDITIONS

NOZZLE DATA


WELD DATA

CALCULATION OF NOZZLE NECK THICKNESS AS PER UG 45Neck thickness for internal pressure as per UG 45(a)Formula in Appendix 1-1 , [trn1]= ( 0.5 x Pi x OD ) / ( Sn x E + 0.4 x Pi )= ( 0.5 x 0.145 x 168.3 ) / ( 12.02 x 1.0 + 0.4 x 0.145 )= 1.01 mmThickness of shell as per UG 45(b)(1)Min. shell thickness reqd. as per UG 27 , [tr = trn2]= Pi x R / ( Sv x E - 0.6 x Pi )= 0.145 x 1178 / ( 14.06 x 1.0 - 0.6 x 0.145 )= 12.42 mmStandard wall thickness as per UG 45(b)(4) , [t3]= 7.112 mmNeck thk as per UG 45 , [trn]= MAX { trn1 , MIN [ trn2 , 0.875 x t3 ] } ................. for Process Nozzle= trn1 ................................................................... for Access Opening= 6.223 mm ....................................................... Process OpeningSince available neck thickness, ta >= trn, selected neck thickness is adequate.






Hydrotest Mode , Corroded Condition

Design pressure ( internal ) Pi 0.145 kgf/mm² gDesign temperature T 50 °C




M.O.C. SA-516 GR. 70 Plt. [UNS:K02700]Allowable stress @ design temperature Sv 14.06 kgf/mm²Inside radius R 1178 mmThickness t 13 mm



DESIGN CONDITIONS

NOZZLE DATA


WELD DATA

CALCULATION OF NOZZLE NECK THICKNESS AS PER UG 45Neck thickness for internal pressure as per UG 45(a)Formula in Appendix 1-1 , [trn1]= ( 0.5 x Pi x OD ) / ( Sn x E + 0.4 x Pi )= ( 0.5 x 0.145 x 114.3 ) / ( 12.02 x 1.0 + 0.4 x 0.145 )= 0.686 mmThickness of shell as per UG 45(b)(1)Min. shell thickness reqd. as per UG 27 , [tr = trn2]= Pi x R / ( Sv x E - 0.6 x Pi )= 0.145 x 1178 / ( 14.06 x 1.0 - 0.6 x 0.145 )= 12.42 mmStandard wall thickness as per UG 45(b)(4) , [t3]= 6.02 mmNeck thk as per UG 45 , [trn]= MAX { trn1 , MIN [ trn2 , 0.875 x t3 ] } ................. for Process Nozzle= trn1 ................................................................... for Access Opening= 5.267 mm ....................................................... Process OpeningSince available neck thickness, ta >= trn, selected neck thickness is adequate.











M.O.C. SA-516 GR. 70 Plt. [UNS:K02700]Allowable stress @ design temperature Sv 14.06 kgf/mm²Inside radius R 1178 mmThickness t 13 mm



DESIGN CONDITIONS

NOZZLE DATA

HEAD DATA ( Dished End (Front) )

WELD DATA

CALCULATION OF NOZZLE NECK THICKNESS AS PER UG 45Thickness of head as per UG 37Min. head thickness reqd. as per UG 27(d) , [tr]= 0.5 x Pi x ID1 / ( 2 x Sv x E - 0.2 x Pi )= 0.5 x 0.145 x 2356 / ( 2 x 14.06 x 1.0 - 0.2 x 0.145 )= 6.179 mmNeck thickness for internal pressure as per UG 45(a)Formula in Appendix 1-1 , [trn1]= ( 0.5 x Pi x OD ) / ( Sn x E + 0.4 x Pi )= ( 0.5 x 0.145 x 581 ) / ( 14.06 x 1.0 + 0.4 x 0.145 )= 2.366 mmThickness of head as per UG 45(b)(1)Min. head thickness reqd. as per UG 27(d) , [trn2 = tr]= 6.179 mmStandard wall thickness as per UG 45(b)(4) , [t3]= 9.525 mmNeck thk as per UG 45 , [trn]= MAX { trn1 , MIN [ trn2 , 0.875 x t3 ] } ................. for Process Nozzle= trn1 ................................................................... for Access Opening= 6.179 mm ....................................................... Process OpeningSince available neck thickness, ta >= trn, selected neck thickness is adequate.








M.O.C. SA-516 GR. 70 Plt. [UNS:K02700]Allowable stress @ design temperature Sn 14.06 kgf/mm²Outside diameter OD 581 mmInside diameter ID 456 mmMaximum chord length D 456 mmNeck thickness ( provided ) tnp 65.5 mmInternal allowance , corrosion + polishing CAI 3 mmExternal allowance , corrosion + polishing CAE 0Neck thickness (tnp - CAI - CAE) tn 62.5 mmMax. under tolerance on thickness Alw 0 mmAvailable neck thickness ( tn - Alw ) ta 62.5 mmNozzle projection outward ( from vessel outer face ) Lo 55 mmTotal length of nozzle ( Lo + Addn for curvature) L 70 mm

Connection type Pad ConnectionApplication type Process OpeningReinforcement calculation method Isolated OpeningDesign as large opening False

Allowable stress @ design temperature Sv 14.06 kgf/mm²Inside diameter of head @ head skirt Dsf 2356 mmD / 2 H for Ellispoidal head 1Factor from Table UG-37 K1 0.5Inside diameter of equivalent sphere, K1 x Dsk x 2 ID1 2356 mmThickness t 9 mm



CALCULATION OF LIMITS OF REINFORCEMENT AS PER UG 40Parallel to vessel wall as per UG 40 (b) (1) & (2) , [WD1] = MAX [ D , 0.5 x ID + t + tn ]= MAX [ 456 , 0.5 x 456 + 9 + 62.5 ]= 456 mmUser defined reinforcement limit, [WD2]=0 mmGoverning limit parallel to wall, [W]= MIN [ WD1 , WD2 ] ........................................... when WD2 > 0 or is defined= WD1 ................................................................. When WD2 = 0 or undefined= 456 mmNormal to vessel wall as per UG 40 (c) (1) & (2) , outside [ho]= MIN [ 2.5 x t , 2.5 x tn , Lo ]= MIN [ 2.5 x 9 , 2.5 x 62.5 , 55 ]= 22.5 mmDESIGN CALCULATION OF AREA AS PER UG 37

A1 + A2 + A41 - Ax1 = 3891.6 > A ( 2817.5 ) .Therefore , opening is adequately reinforced.





Factor E1 E1 1.00Correction factor F 1.00Sn / Sv fr1 1.00 ( Max. 1 )Sn / Sv fr2 1.00 ( Max. 1 )Sn / Sv fr3 1.00 ( Max. 1 )

Area mm²Under conditions Int. pressure

tr = 6.179

Area required , [A]= D x tr x F + 2 x tn x tr x F x ( 1 - fr1 )= 456 x 6.179 x 1.00 + 2 x 62.5 x 6.179 x 1.00 x ( 1 - 1.00 ) 2817.5

Area available in vessel wall , [A1]= ( 2 x W - D ) x ( E1 x t - F x tr ) - 2 x tn x ( E1 x t - F x tr ) x ( 1 - fr1 )= ( 2 x 456 - 456 ) x ( 1.00 x 9 - 1.00 x 6.179 )

- 2 x 62.5 x ( 1.00 x 9 - 1.00 x 6.179 ) x ( 1 - 1.00 ) 1286.5

Area available in nozzle projection outward , [A2]= 2 x ho x ( tn - trn ) x fr2= 2 x 22.5 x ( 62.5 - 6.179 ) x 1.00 2534.5

Area available in outward weld , [A41]

= W1 2 x fr3

= 8.4 2 x 1.00 70.56

Area deductions:

Area to be reduced due to overlap in multiple openings, [ Ax ] 0


1. GENERAL DATA :

2. DIMENSIONAL DATA :





REINFORCEMENT PAD DETAILS Saddle Plate

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

Length of pad L 2055.2 mmWidth of pad W 892.5 mmNominal thickness T 14 mm



2. COVER DATA :

3. BOLTING DATA :

4. LINER DATA :

5. GASKET DATA :

6. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b1) :Total joint - contact surface compression load [Hp]= 2 x p x b x G x m x P= 2 x p x 9.275 x 485.6 x 2 x 0.145= 8207.2 kgfTotal hydrostatic end force [H]= 0.25 x p x G 2 x P= 0.25 x p x 485.6 2 x 0.145= 26858.6 kgfMinimum required bolt load for operating condition [Wm1]= Hp + H= 8207.2 + 26858.6= 35065.8 kgf7. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b2) :Minimum required bolt load for gasket seating [Wm2]= p x b x G x y





DESIGN OF FLAT BOLTED HEAD ( INTERNAL ) Bolted Cover [N 03]CODE ASME VIII Div.1, 10 A11






= p x 9.275 x 485.6 x 1.125= 15918 kgf8. BOLT AREAS AS PER APPENDIX 2-5 (d) :Total required cross-sectional area of bolts [Am]= MAX [ Wm2 / Sa , Wm1 / Sb ] ........ For Internal '+' Pr Design = Wm2 / Sa ..................................... For External Pr & Self Sealing Design= 1330 mm²Actual bolt area using root diameter [Ab]= 3472.8 mm²Flange design bolt load for the gasket seating [W]= 0.5 x ( Am + Ab ) x Sa x 1 .................... average bolt area= Ab x Sa x 1 ..........................................full bolt area= 63313.3 kgf ( Avg. bolt area and margin factor of 1 ) 9. CHECK FOR GASKET CRUSHING :Minimum gasket width required [Nmin]= Ab x Sb / ( 2 x p x y x G )= 3472.8 x 26.37 / ( 2 x p x 1.125 x 485.6 )= 26.67 mm10. DESIGN CALCULATION AS PER UG 34, BOLTING CONDITION :Required thickness for bolting condition [t]= G x SQRT [ 1.9 x W x 0.5 x ( PCD - G ) / ( Sfa x E x G 3 ) ]= 485.6 x SQRT [ 1.9 x 63313.3 x 0.5 x ( 534 - 485.6 ) / ( 14.06 x 1 x 485.6 3 ) ]= 20.64 mm11. DESIGN CALCULATION AS PER UG 34, OPERATING CONDITION :


( 14.06 x 1 x 485.6 3 ) } = 31.07 mm




1. LIFTING LUG DATA :

2. DESIGN LOADS :

3. CALCULATION OF REFERENCE DIMENSIONS :

4. DESIGN OF LUG PLATE :

5. CALCULATION OF STRESSES IN LUG PLATE WELDS :





DESIGN OF LIFTING LUG Lifting LugsCODE P V Design Manual, D.R. Moss

Design Mode 1 , Uncorroded Condition

Material IS-2062 GR. A Plt.Length of lug LL 67 mmWidth of lug A 120 mmThickness of lug plate TL 60 mmStraight length B1 10 mmRadius at tip R3 35 mmPin Hole diameter D1 40 mmLug to vessel weld size W1 26.23 mmMin yield stress Sy 24.61 kgf/mm²Allowable tensile stress ( 2 / 3 x Sy ) St 16.4 kgf/mm²Allowable bending stress ( 1.5 x St ) Sb 22.15 kgf/mm²Allowable shear stress (0.6 x St ) Ss 9.843 kgf/mm²

Empty weight of equipment Wt 11373.4 kgfNumber of lifting lugs N 2Jirk load factor j 1.5

Dimension [ L1 ]= LL - B1 - R3= 67 - 10 - 35= 22 mm

Dimension [ L2 ]= L1 / SIN ( q1 ) = 22 / SIN ( 0.351 ) = 63.91 mm

Dimension [ LT ]= LL - R3= 67 - 35 = 32 mm

Angle [ q2 ]= ASIN ( R3 / L2 ) = ASIN ( 35 / 63.91 ) = 0.58 radians

Angle [ q1 ]= ATAN ( 2 x L1 / A )= ATAN ( 2 x 22 / 120 ) = 0.351 radians

Angle [ q3 ]= q1 + q2 = 0.351 + 0.58 = 0.931 radians

Dimension [ L3 ]= R3 / SIN ( q3 ) = 35 / SIN ( 0.931 ) = 43.63 mm

Effective design load on each lug [ P ]= j x Wt / N= 1.5 x 11373.4 / 2= 8533.7 kgf

Required min. thickness of lug plate for shear [ t2 ]= P / [ ( R3 - 0.5 x D1) x ss ] = 8533.7 / [ ( 35 - 0.5 x 40 ) x 9.843 ]= 57.8 mm

Required min. thickness of lug plate for bending [ t1 ]= 6 x P x LT / ( A 2 x Sb ) = 6 x 8533.7 x 32 / ( 120 2 x 22.15 )= 5.138 mm

Required min. thickness of lug plate for shear [ t3 ]= P / [ ( 2 x L3 - D1 ) x ss ] = 8533.7 / [ ( 2 x 43.63 - 40 ) x 9.843 ]= 11.01 mm

Bending stress in weld [ f1 ]= 6 x P x LT / [ 2 x LL2 ]= 6 x 8533.7 x 32 / ( 2 x 67 2 )= 182.5 kgf/mm

Max. shear stress in weld [ f2 ]= P / [ 2 x A ]= 8533.7 / ( 2 x 120 )= 35.56 kgf/mm

Min. Size of lug plate weld [ w1 ]= MAX ( f1 , 2 x f2 ) / ( 0.707 x Ss )

= MAX ( 182.5 , 2 x 35.56 ) / ( 0.707 x 9.843 )= 26.23 mm


FOUNDATION LOAD DATA






Weight ( kgf ) Wind Seismic

Empty FilledShear ( kgf ) Moment ( kgf-m ) Shear Moment

Tran. Long. Tran. Long. ( kgf ) ( kgf-m )

1 Operating Corroded 9443.5 29019.9 1683.1 5395.5 2524.7 8093.3 3002.1 4503.1

2 Design1 Corroded 9443.5 51095.3 1683.1 5395.5 2524.7 8093.3 5285.7 7928.6

3 Hydro Corroded 9443.5 51095.3 1683.1 5395.5 2524.7 8093.3 5285.7 7928.6

4 Pneumatic Corroded 9443.5 9493.5 1683.1 5395.5 2524.7 8093.3 982.1 1473.1

5 Operating Uncorroded 11373.4 30841.8 1683.1 5395.5 2524.7 8093.3 3190.5 4785.8

6 Design1 Uncorroded 11373.4 52795.4 1683.1 5395.5 2524.7 8093.3 5461.6 8192.4

7 Hydro Uncorroded 11373.4 52795.4 1683.1 5395.5 2524.7 8093.3 5461.6 8192.4

8 Pneumatic Uncorroded 11373.4 11423.1 1683.1 5395.5 2524.7 8093.3 1181.7 1772.6


CENTER OF GRAVITY DATA






Empty Operating / FilledWt ( kgf ) C.G. ( mm ) Wt ( kgf ) C.G. ( mm )

1 Operating Corroded 9443.5 5177 29019.9 51772 Design1 Corroded 9443.5 5177 51095.3 51773 Hydro Corroded 9443.5 5177 51095.3 51774 Pneumatic Corroded 9443.5 5177 9493.5 51775 Operating Uncorroded 11373.4 5177 30841.8 51776 Design1 Uncorroded 11373.4 5177 52795.4 51777 Hydro Uncorroded 11373.4 5177 52795.4 51778 Pneumatic Uncorroded 11373.4 5177 11423.1 5177

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