GP-QM-7.3-2 R1

GRAND PRIX DESIGN CALCULATIONGP-839

SHT. 1 OF 12

Client : M/s. Bharat Pumps & Compressors Ltd.

Project : MSQU / IOCL

P.O. No. : 461-16430421-1533 Dtd. 14.02.2005

Item : Discharge Volume Bottles - D2A( 6510418/D )

Drg. No. : 2-GP839-1324

Inspection : BPCL/ EIL

G.P. Job No. : GP-839

1 Revised as per clients comment. 1.04.04 A.S.0 Issued for Approval 02.03.05 N.J.

Rev. No. Description Date Prepared By Checked By Approved ByDATE

GRAND PRIX FARIDABADDoc. No. Rev.

GP-QM-7.3-2 R1

GRAND PRIX FARIDABAD02.03.05 GP839-DC-01 1

GRAND PRIX DESIGN CALCULATIONGP-839

SHT. 2 OF 12

DESIGN DATA

Design Code : ASME SEC VIII, DIV. 1 - 2004

Design Pressure : 56.2 Kg/Cm2g

Design Temp. : 204

Flange Rating. : 600 #

Radiography : 100 %

Joint Efficiency : 1.0

Corrosion Allowance : 3.2 mm

Vessel OD, D : 450.0 mm

Vessel Outer Radius, R : 225.0 mm

Name of Part Material of Construction Stress Value at Design Temp.

Shell : SA 516 Gr. 60 1202.47

Dish End : SA 516 Gr. 60 1202.47

Nozzle : SA 106 Gr. B 1202.47

oC

Kg/Cm2

Kg/Cm2

Kg/Cm2

GP-QM-7.3-2 R1

DATE

GRAND PRIX FARIDABADDoc. No. Rev.

02.03.05 GP839-DC-01 1

GRAND PRIX DESIGN CALCULATIONGP-839

SHT. 3 OF 12

DESIGN SUMMARY

S. No. Description Size

1 Shell OD 450 x 14 Thk. 13.52 mm 14.0 mm

2 Dish End OD 450x13.3 Thk(min). 13.29 mm 16.0 mm(nom)

3 S3 6" NB x Sch. 80 7.06 mm 10.972 mm

4 S1,S2 4"NB x Sch. 120 5.82 mm 11.12 mm

5 S4,S5,S8,S9 1½"NB x Sch. XX 4.31 mm 10.16 mm

Calculated Minimum Thickness

Actual Thickness Provided

GP-QM-7.3-2 R1

DATE

GRAND PRIX FARIDABADDoc. No. Rev.

02.03.05 GP839-DC-01 1

GRAND PRIX DESIGN CALCULATIONGP-839

SHT. 4 OF 12

Shell Thickness :-

t = P.R (SE + 0.4P)

= 10.32 mm

= 10.32 + 3.2 Adding 3.2 mm Corrosion Allownace

= 13.52

Used Plate 14 mm Thick

Dish End Tickness :-

Type of D/End, Semi-Elliptical , 2 : 1 K =1.0

t = P.D.K2SE + 2P(K - 0.1)

= 10.09 mm

= 10.09 + 3.2 Adding 3.2 mm Corrosion Allownace

= 13.29 mm

Used Plate 16 mm Thick

GP-QM-7.3-2 R1

DATE

GRAND PRIX FARIDABADDoc. No. Rev.

02.03.05 GP839-DC-01 1

GRAND PRIX DESIGN CALCULATIONGP-839

SHT. 5 OF 12

Nozzle Thickness :- (6"NB Size)

Do = 168.27 mm

t = Ro = 84.135 mm (SE + 0.4P) E = 1.0

= 3.86 mm

= 3.86 + 3.2 Adding 3.2 mm Corrosion Allownace

= 7.06 mm

Used 6" NB x Sch. 80 Pipe (10.972 mm)

Nozzle Thickness :- (4" NB Size)

Do = 114.3 mm

t = Ro = 57.15 mm

(SE + 0.4P) E = 1.0

= 2.62 mm

= 2.62 + 3.2 Adding 3.2 mm Corrosion Allownace

= 5.82 mm

Used 4" NB x Sch. 120 Pipe (11.12 mm)

Nozzle Thickness :-

Do = 48.26 mm

t = Ro = 24.13 mm

(SE + 0.4P) E = 1.0

= 1.11 mm

= 1.11 + 3.2 Adding 3.2 mm Corrosion Allownace

P.Ro

P.Ro

(1½" NB Size)

P.Ro

GP-QM-7.3-2 R1

= 4.31 mm

Used 1½" NB x Sch. XX Pipe (10.16 mm)

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GRAND PRIX FARIDABADDoc. No. Rev.

02.03.05 GP839-DC-01 1

GRAND PRIX DESIGN CALCULATIONGP-839

SHT. 6 OF 12

Table 1

Nozzle Size (NB)

S3 150 13.29 9.42 7.06 9.42 10.77

S1 100 13.52 8.46 5.82 8.46 9.67

S2 100 13.29 8.46 5.82 8.46 9.67

40 13.52 6.42 4.31 6.42 7.34

Shell/ D.End Thk.+C.A. (T1)

Std. Wall Thk. Less 12.5% + C.A. (T2)

Cal. Nozzle Thk.+C.A.

(T3)

Smaller of T1 & T2 (T4)

Greater of T3 & T4 / 0.875 for (Pipes)

Provided Thk. / Sch.

10.972 Sch. 80

11.12 Sch. 120

11.12 Sch. 120

S4,S5,S8, S9

10.16 Sch. XX

GP-QM-7.3-2 R1

DATE

GRAND PRIX FARIDABADDoc. No. Rev.

02.03.05 GP839-DC-01 1

GRAND PRIX DESIGN CALCULATIONGP-839

SHT. 7 OF 12

Nozzle Reinforcement 1.0 Nozzle No.2.0 Size (NB) 150 100

3.0 10.09 10.094.0 t = Provied Shell Thk. - C.A. 10.8 10.8

5.0 3.86 2.62

6.0 7.772 7.927.0 d = Inside Dia of Nozzle + C.A. 149.52 95.24

8.0 1202.47 1202.47

9.0 1202.47 1202.47

10.0 1202.47 1202.47

11.0 1.0 1.0

12.0 1.0 1.0

13.0 1.0 1.014.0 F = Correction Factor 1.0 1.0

15.0 14.0 14.0

16.0299.04 190.48

250.0 200.0

17.0 1508.86 961.10

18.0 1.0 1.0

19.0 105.95 67.49

20.0 152.02 209.88

21.0 100.0 100.0

22.0 1189.104 1244.88

tr = Required Shell Thk.

tm= Required Nozzle Thk.

tn = Provied Nozzle Thk. - C.A.

Sn = Allowable Stress in Nozzle (Kg/Cm2)

Sv = Allowable Stress in Vessel (Kg/Cm2)

Sp = Allowable Stress in RF. Pad (Kg/Cm2)

fr1 = Sn/Sv (1.0 Max.)

fr2 = Sn/Sv (1.0 Max.)

fr3 , fr4= Sp/Sv (1.0 Max.)

te = Thickness of RF. Pad

Dr = Dia. of RF. Pad (Available)

Dp = Dia. of RF. Pad (Provided)

Area Required, A = dtrF+2tntrF(1-fr1)

Value , E1

Area Available in Shell, A1 = Larger of d(E1t-Ftr)-2tn(E1t-Ftr)(1-fr1) OR 2(t+tn)(E1t-Ftr)-2tn(E1t-Ftr)(1-fr1)

Area Available in Nozzle, A2 = Smaller of 5(tn-tm)t.fr2 OR 5(tn-tm)tn.fr2

Welding Area, A41 = (LEG)2.fr2

Area in RF. Pad, A5 = (Dp-d-2tn)te.fr3

GP-QM-7.3-2 R1

23.0 100.0 100.0

24.0 1647.08 1722.25

Remarks :- 1. Reinforcement Provided is OK 2. No Reinforcement Required.

DATE

GRAND PRIX FARIDABADDoc. No. Rev.

02.03.05 GP839-DC-01 1

GRAND PRIX DESIGN CALCULATIONGP-839

SHT. 8 OF 12

Nozzle Reinforcement 1.0 Nozzle No.2.0 Size (NB) 100

3.0 10.324.0 t = Provied Shell Thk. - C.A. 10.8

5.0 2.62

6.0 7.927.0 d = Inside Dia of Nozzle + C.A. 95.24

8.0 1202.47

9.0 1202.47

10.0 1202.47

11.0 1.0

12.0 1.0

13.0 1.014.0 F = Correction Factor 1.0

15.0 10.8

16.0190.48

200.0

17.0 983.15

18.0 1.0

19.0 45.44

20.0 198

21.0 100.0

Welding Area, A42 = (LEG)2.fr4

Total Area Available = A1+A2+A41+A5+A42

tr = Required Shell Thk.

tm= Required Nozzle Thk.

tn = Provied Nozzle Thk. - C.A.

Sn = Allowable Stress in Nozzle (Kg/Cm2)

Sv = Allowable Stress in Vessel (Kg/Cm2)

Sp = Allowable Stress in RF. Pad (Kg/Cm2)

fr1 = Sn/Sv (1.0 Max.)

fr2 = Sn/Sv (1.0 Max.)

fr3 , fr4= Sp/Sv (1.0 Max.)

te = Thickness of RF. Pad

Dr = Dia. of RF. Pad (Available)

Dp = Dia. of RF. Pad (Provided)

Area Required, A = dtrF+2tntrF(1-fr1)

Value , E1

Area Available in Shell, A1 = Larger of d(E1t-Ftr)-2tn(E1t-Ftr)(1-fr1) OR 2(t+tn)(E1t-Ftr)-2tn(E1t-Ftr)(1-fr1)

Area Available in Nozzle, A2 = Smaller of 5(tn-tm)t.fr2 OR 5(tn-tm)tn.fr2

Welding Area, A41 = (LEG)2.fr2

GP-QM-7.3-2 R1

22.0 960.336

23.0 100.0

24.0 1403.78

Remarks :- 1. Reinforcement Provided is OK 2. No Reinforcement Required.

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GRAND PRIX FARIDABADDoc. No. Rev.

02.03.05 GP839-DC-01 1

GRAND PRIX DESIGN CALCULATIONGP-839

SHT. 9 OF 12

Calculation for Nozzle Loads( Code used : BSI-PD 5500 :2000)

(a) Calculation for Nozzles S1 & S2 ( 4" NB ) :-

= 422.4 mm

= 200.15 mm

Corrosion Allowance , CA = 3.2 mm

= 14.0 mm

= 14.0 mm

= 11.12 mm

= 28 mm

=

= 12.0247

= 12.0247

Constant ,S = 1

Area in RF. Pad, A5 = (Dp-d-2tn)te.fr3

Welding Area, A42 = (LEG)2.fr4

Total Area Available = A1+A2+A41+A5+A42

Inside Diametre of Shell , Di

Nozzle Flange bolt ( PCD ) , do

Shell Thickness, ts

Reinforcing Pad Thickness, tp

Nozzle Thickness , tn

Shell, Calculation Thickness, tcs

AllowableStress of Shell Material,Sa Kg/mm2

AllowableStress of Pad Material ,Sp Kg/mm2

GP-QM-7.3-2 R1

(As per Table 1)

(As per PD 5500)

= 2.90760147956962

= 5.33964267969865

= 13.81

DATE

GRAND PRIX FARIDABADDoc. No. Rev.

02.03.05 GP839-DC-01 1

GRAND PRIX DESIGN CALCULATIONGP-839

SHT. 10 OF 12

= 453.6 mm

= 192.23 mm

= 2.41226571099003

Maximum allowable Axial Force

= 27411.0198409225 Kg268902.10463945 N

Maximum allowable Circumferential

= 50338.7594431687 Kg493823.230137485 N

Maximum allowable Longitudinal Force

= 130167.342017879 Kg

1276941.62519539 N

Maximum allowable Axial Moment

= 1317318.79151505 Kg-mm

12922.8973447627 NmMaximum Allowable Circumferential

= 2419180.1013198 Kg-mm23732.1567939473 Nm

Maximum Allowable Longitudinal

Polynomial Coeffecients ,a0 to a4

Calculation Factors , C2 to C4

C2

C3

C4

Shell effective mean Diametre, De

Nozzle Mean Diametre, dm

Geometric Parametre for shells λ C

on the Nozzle ,FX Max

Forceon the Nozzle ,FY Max

on the Nozzle ,FZ Max

on the Nozzle ,M X Max

moment on the Nozzle , MY Max

GP-QM-7.3-2 R1

= 6255582.12269522 Kg-mm61367.2606236401 Nm

TABLE 1 Coefficients to define factore C2 , C3 or C4

FactorC2 0.60072181 0.95196257 0.00520 -0.0014064 0C3 4.526315 0.064021889 0.15888 -0.0214193 0.00104C4 with

4.8844124 -0.07138921 0.79991 -0.0241557 0C4 with

6.3178075 -3.6618209 4.51454 -0.8309484 0.0507

DATE

GRAND PRIX FARIDABADDoc. No. Rev.

02.03.05 GP839-DC-01 1

GRAND PRIX DESIGN CALCULATIONGP-839

SHT. 11 OF 12

CALCULATED

MAX ALLOWABLE 268902.1 493823.2 1276941.6 12922.90 23732.157 61367.26

LOAD N / Nm

ALLOWABLE2700.00 3350.00 3350.00 1250.00 850.00 850.00

LOAD N / Nm

The forces and Moments are on the safer Side.

moment on the Nozzle , MZ Max

a0 a1 a2 a3 a4

tp / ts ≤ 0.2

tp / ts ≥ 0.5

FX FY FZ MX MY MZ

GP-QM-7.3-2 R1

DATE

GRAND PRIX FARIDABADDoc. No. Rev.

02.03.05 GP839-DC-01 1

GRAND PRIX DESIGN CALCULATIONGP-839

SHT. 12 OF 12

Calculation for Saddle Support.( Code used : BS- PD 5500 )

Allowable Stress of Saddle Mat. = 9.80

Design Stress of the web section = 6.533

Outer Dia of Vessel , D = 450 mm

Outer radius of Vessel , R = 225 mm

Test Weight of the Vessel , W = 640.00 Kg.

The load on one Saddle , Q = 640.00 Kg.

0.204 ( From Table 1)

Web Plate Thickness , T = 10.00 mm

Horizontal Force F = 130.56 Kg.

Kg/mm2

Kg/mm2

( Considered 2/3rd of the allowable stress )

Numerical Constant , k9 =

GP-QM-7.3-2 R1

CONTACT ANGLE 120 130 140 150 160 170 180

0.222 0.241 0.259 0.279 0.298 0.318

R / 3 = 75 mm.

To Resist this Force The effective area of Web Plate = 750

Stress due to Horizontal Force, F = 0.17408

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GRAND PRIX FARIDABADDoc. No. Rev.

02.03.05 GP839-DC-01 1

VALUE OF CONSTANT K9 (As per PD 5500:2000 Annex. G)

K9 0.204

mm2

kg/mm2

Since the allowable Stress is 6.533 Kg/mm2 , The Selected size is satisfactory

Prepared By Checked By Approved By