v 2154 101 a 214 c_mechanical calculation (v 410)

7/16/2019 V 2154 101 a 214 C_Mechanical Calculation (v 410)

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Project: NOEV LUBE OIL BLENDING PLANT

Job No.: AL-2499

Document No.: V-2154-101-A-214

Reference Drawing: V-2154-101-A-201_Rev.D & V-2154-101-A-205_Rev.A

Vessel Name: Blending Vessel

Vessel Tag No.: V410

C 5/20/2013

B 5/3/2013

A 4/9/2013

Rev Date

L.N.B

MECHANICAL CALCULATION SHEET

Description Prepared Approval

Issue for review / approval

Issue for review / approval

Issue for review / approval L.D.T

L.D.T

L.D.T

L.A.V

L.A.V

L.A.V

Checked

L.N.B

L.N.B



Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. No.: C

INDEX Page

1. Design Data 2

2. Shell Thickness Calculation 2

3. Bottom Head Thickness Calculation 3

4. Top Head Thickness Calculation 4

5. Auxiliary Stiffener Calculation 5

6. Main Stiffener Calculation 6

7. Coil Half-Pipe Calculation 7

8. Weight Calculation Sheet 89. Lug Support 9

10. Nozzle Calculation 12

11. Welding 18

12. Wind Load Analysis 21

13. Seismic Analysis 22

14. Support Analysis for Wind/Seismic 24

15. Stresses in Shell by Wind/Seismic 26

16. Lifting Lug Calculation 27

17. Vibration Calculation 31

18. Baffle Plate Thickness Calculation Sheet 43

19. Conclusion 45

MECHANICAL CALCULATION SHEET

of 45



Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N

1. Design Data

Design Code : None

Service: Blending Vessel

Design pressure

Max. Internal pressure - (Full 3.79 meters of Water) P = 0.372 barg = 0.0372 MPa G

External pressure 0.0 barg = 0.0 MPa GWorking pressure 0.0 barg = 0.0 MPa G

Design temperature 180 degrees C

Working temperature 60 ~ 80 degrees C

Corrosion allowance 0.0 mm

Vessel inside diameter 2400 mm (O/D = 2416 mm)

Vessel length (Flat Head to T.L) 2800 mm

Material S : Maximum allowable stress value

Shell SA-240 TP304 / 304L 112 MPa

Flat Top Head SA-240 TP304 / 304L 112 MPa

Bottom Cone Head SA-240 TP304 / 304L 112 MPa

Nozzle Neck SA-312 TP304 / 304L 112 MPa

Support SA-240 TP304 / 304L 112 MPa

Nozzle Flange: ASME B16.5 Standard

SCH THK.

N1 A/B 150 80S 5.54

N2 150 80S 5.08

N3 150 80S 5.54

N4 150 - 10

N5 150 40S 6.02

N6 150 40S 6.02

N7 A/B/C 150 80S 4.55

N8 A/B/C 150 80S 4.55

N9 150 40S 5.49

N10 150 40S 6.02

2. Shell Thickness Calculation (Refer to ASME Section VIII, Division 1, UG-27)

2.1 Minimum required thickness of shell exclusive corrosion allowance (t):

Circumferential Stress (Longitudinal Joints)

0.0372 x 1200.0

112.0 x 0.85 - 0.6 x 0.0372

where:

P : internal design pressure = 0.0372 MPa < = 36.652 MPa

R : Inside radius of the shell = 1200.0 mm

S : Maximum allowable stress value = 112.0 MPa

E : Joint efficiency = 0.85

Longitudinal Stress (Circumferential Joints)

0.0372 x 1200.0

2.0 x 112.0 x 0.85 + 0.4 x 0.0372

where:


Degree of Radiographic Examination: 10%

2.2 Minimum Thickness of Pressure retaining Components (UG-16 (b)) = 2.5 mm

2.3 Minimum required thickness of shell included corrosion allowance

tr = 0.47 + 0.0 = 0.47 mm

DN 100 (4") SO RF 114.3 102.26

DN 25 (1") SO RF 33.4

DN 100 (4") SO RF 114.3 102.26

DN 100 (4") SO RF 114.3 102.26

DN 25 (1") SO RF 33.4 24.3

77.9288.9SO RFDN 80 (3")

24.3

Nozzle Size Flange Type ClassNozzle Neck Nozzle outside

diameter, mm

Nozzle inside

diameter, mm

DN 50 (2") SO RF 60.3 49.22

DN 40 (1-1/2") SO RF 48.3 38.14

DN 50 (2") SO RF 60.3 49.22

DN 250 (10") SO RF 273.1 253.1

=

= 0.23

95.2

=

=44.6

mm

mm

0.47

=44.6

190.4

=

0.385SE

Page 2




2.4 Choose Nominal thickness of shell, ts = 8.0 mm

3. Bottom Head Thickness Calculation (Refer to ASME Section VIII, Division 1, UG-32)

Type of head: Toriconical Head (with Knuckle)

3.1 Conical Section

3.1.1 Minimum required thickness of Conical Section exclusive corrosion allowance (t):

0.0372 x 2400.0

where:


D : Inside diameter of the head skirt = 2400.0 mm



α : one-half of the included angle of = 60 degrees

the cone at the centerline of head

3.1.2 Minimum required thickness of Head included corrosion allowance

= 0.94 + 0.0 = 0.94 mm

3.1.3 Minimum required thickness of Head, tb = Min. 8.0 mm

3.2 Knuckle Section

r : inside knuckle radius = 250 mm

Di : inside cone diameter at point of tangency = = 2150.0

to knuckle

3.2.1 Minimum required thickness of Knuckle Section exclusive corrosion allowance (t):

where:

3.2.2 Minimum required thickness of Knuckle included corrosion allowance

= 0.62 + 0.0 = 0.62 mm

3.2.3 Minimum required thickness of Knuckle, tK = Min. 8.0 mm

3.3 Stress Relief (Refer to UCS-79)

Type of head: Toriconical Head (Double Curvature)

=> Percent extreme fiber elongation is not exceeded by 5% so that a stress relief is not required

where:

t : Nominal Straight Flange thickness t = 8.0 mm

Rf : Final centerline radius (mean knuckle radius) Rf = 250.0 mm

Ro : Original centerline radius (Crown radius) Ro = 2150.0 mm

4. Top Head Thickness Calculation (Refer to Roark's Formulas for Stress and Strain)

0.94 mm2 x cos(60) x (112 x 0.85 - 0.6 x 0.0372) 95.2

mm2 x 112 x 0.85 - 0.2 x 0.0372 190.4

: Crown radius = 2150 mm

=0.0372 x 2150 x 1.48

=118.6

0.385SE

= 0.6227

: Factor =

= =89.2

1.48

= 2.12 %

=

Page 3



Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev.

Type of head: Flat Head

Assume square plate (axb) 500x500 mm with all edges simply supported

and uniform loads over entire plate.

Top Head Self-Weight = 293.402 kg

F = m x g = 2878.28 N

Area (A) = πD2

/4 = 4.58 m2

P1 = F/A = 0.628 kPa

Structural Weight = 150 kg (Including weight of nozzles, manhole on Top Head - 150 kg)

F = m x g = 1471.5 N

Area (A) = πD2/4 = 4.58 m

2

P2 = F/A = 0.321 kPa

Concentrated Load = 200 kg (Assumed)

F = m x g = 1962 N

Area (A) = πD2/4 = 4.58 m

2

P3 = F/A = 0.428 kPa

Total Dead Load (P) = P1+P2+P3 = 1.38 kPa

Total Live Load (L) = 1.0 kPa (As per API 650 11th Ed. Errata, Oct. 2011, Clause 5.2.1)

Total Uniform Load (q) = P + L = 2.38 kPa

Edges of Plate (a x b) = 500 x 500 mm

a/b = 1

β = 0.2874

α = 0.0444

Elastic Modulus (E) = 183600000 kPa (Interpolate from API 650 11th Ed. Errata, October 2011, Appendix S)

Allowable Stress ([ϭ]) = 112000 kPa (Refer to ASME Section II, Part D, Table 1A)

Required Plate thickness (Refer to Roark's Formulas, Table 11.4, Case 1a)

Choose thickness of Top Head Plate = 8 mm

Max. Deflection (Refer to Roark's Formulas, Table 11.4, Case 1a)

Max. Stress in plate

5. Auxiliary Stiffener Calculation

Length of stiffener L = 500 mm

Width of Plate that using stiffener Wp = 500 mm (Assumed)

Uniform load wa = q x Wp = 1.188 kN/m

= mm1.23

0.07 mm

= 2668 kPa = 112000

= (ACCEPTED)<

kPa (ACCEPTED)

t/2 = 4 mm

< [ϭ]

=

=

=

L

Page 4




Select stiffener properties as below

Area moment of inertia (As per Roark's Formulas, Table A.1, Case 4: Tee section):

Effective area = 1.1 x (D x t)0.5 = 19 x t (Base on ASME Section VIII, Division 1, Appendix 1-8)

where:

t : The thickness of Top Head = 8 mm

b : Effective area (about 19 x t) = 152 mm

tw : The thickness of Stiffener = 8 mm

d : Stiffener height = 50 mm

= 1616 mm2

Elastic modulus (E) = kPa

Plastic section modulus (Zx)

Max. deflection at the center of stiffener (Refer to Roark's Formulas, Table 8.1, Case 2e )

-5 x 1.188 x 7804

Unity Check (UC) ratio calculation

M : Maximum bending moment caused by uniform load wa = 0.037 KN.m

S : Bending Stress caused by M = 2697.2026 KPa

UC ratio : = 0.024 < 1

=> (ACCEPTED)

6. Main Stiffener Calculation



mm=

183600000

384 x 183600 x 342951= -0.015

I = = 342951 mm4

= 11.178 mm

= 13769 mm3

M =

8

S =

=

5 0

L

Page 5





Agitator Concentrated load W = 310 kg = 3.041 kN


b3 : Effective area (about 19 x d3) = 152 mm

d3 : The thickness of Top Head = 8 mm

d2 : Web height = 150 mmb2 : Web thickness = 8 mm

b1 : Bottom flange length = 70 mm

d1 : Bottom flange thickness = 8 mm

PART Area (a) y a x y h h2

bd3/12

mm mm mm mm mm mm

1 560 4 2240 96.41 9295.7 2986.6667

2 1200 83 99600 17.41 303.25 2250000

3 1216 162 196992 -61.59 3792.84 6485.3333TOTAL 2976 298832 2259472

Therefore,

Distance from bottom to Neutral axis

C = 298832 / 2976 = 100.414 mm

Area moment of inertia

I = 10181553.978 + 2259472 = 12441026 mm

Section Modulus

Z = I /C = 123897.35 mm3

Max. deflection at the center of stiffener (Refer to Roark's Formulas, Table 8.1,Case 1e & Case 2e )

-3.0411 x 24003

x 24004


M : Maximum bending moment caused by uniform load W = 2.406 KN.m


UC ratio : = 0.173 < 1

=> (ACCEPTED)

7. Coil Half-Pipe Calculation (Refer to ASME Section VIII, Division 1, Nonmandatory Appendix EE)

7.1 Because of the same thickness of shell and cone head, the half-pipe calculation shall be considered for shell only.

ts : Thickness of the shell = 8.0 mm = 1/3 in

R : Inside shell radius = 1200 mm

D = 2R : Inside shell diameter = 2400 mm = 94.5 in

Half-pipe jacket is DN80 (3")

S : Allowable tensile stress of shell = 112.0 MPa

S1 : Allowable tensile stress of coil half-pipe = 112.0 MPa

P : Internal Pressure in vessel = 0.0372 MPa (Positive pressure inside the shell)

P1 : Design Pressure in coil = 0.98 MPa (Positive pressure inside the half-pipe)

From Fig. EE-2, with D = 94.5 in. and t = 1/3 in., so K = 70

=48 x183600 x 12441026

mm4

a x h2

4612091.063

363895.9764

5205566.94

= -0.536-5 x 0.808

mm

10181553.978

+384 x 183600 x 12441026

M =

4+

8

S =

=

Page 6



Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499

Actual longitudinal tensile pressure in shell

S' = PR/2ts = 2.79 MPa

Permissible coil pressure - Maximum allowable external pressure applied to the shell

P' = F / K = (1.5S - S') / K = 2.36 MPa > P1 = 0.98 MPa

=> PASS

The thickness of shell is satisfactory for pressure inside Half-pipe

Choose Half-pipe DN80 (3"), SCH. 40

Half-pipe thickness included 12.5% undertolerance

t = 0.875 x 5.49 = 4.8 mm

Inside half-pipe radius

r = 88.9/2 - 4.8 = 39.65 mm

The required half-pipe thickness

=> PASS

The minimum fillet weld size

= 1.414 x 0.411 = 0.581 mm

Choose Fillet weld size = 6 mm

7.2 Hydrotest Pressure for Coil Half-pipe (Refer to ASME Section VIII, Division 1, UG-99 (b))

Design Temperature = 180 degrees CTest Temperature = A.T.M

Internal Design Pressure P = 0.980 MPa G

Max. Allowable Stress at Design Temperature Sd = 112 MPa

Max. Allowable Stress at Test Temperature St = 115 MPa

Hydrotest Pressure Ph = 1.3 x P x (St/Sd)

Ph = 1.3 x 0.98 (115/112) = 1.31 MPa G

8. Weight Calculation Sheet

No.

Thickness

(mm) Q'ty

Unit Weight

(kg)

Total Weight

(kg)

1 Shell 8 1 1341.7 1341.68

2 Bottom Cone 8 1 418.64 418.64

3 Roof 8 1 330.97 330.97

4 Stiffenner T-150x8+70x8 - 4 33.37 133.48

5 Stiffenner PL.50x8 - 2 19.47 38.94

6 Top Angle Bar L-70x70x8 - 1 68.01 68.01

7 Half Pipe Coil - 160.3 5.76 923.33

8 Support Lug - Reinforcement PL. 8 4 18.20 72.79

9 Support Lug - Base Plate 25 4 30.31 121.26

10 Support Lug - Compress Plate 18 4 13.33 53.32

11 Support Lug - Gusset Plate 1 16 8 3.03 24.26


13 Lifting Lug 25 2 6.33 12.66

14 Nozzle N1A - Neck - 0.15 7.63 1.14 2" SCH 80S

15 Nozzle N1A - Flange - 1 2.30 2.30 2" 150#

16 Nozzle N1B - Neck - 0.15 7.63 1.14 2" SCH 80S

17 Nozzle N1B - Flange - 1 2.30 2.30 2" 150#

18 Nozzle N2 - Neck - 0.172 5.51 0.95 1-1/2" SCH 80S

19 Nozzle N2 - Flange - 1 1.40 1.40 1-1/2" 150#

20 Nozzle N3 - Neck - 0.15 7.63 1.14 2" SCH 80S

21 Nozzle N3 - Flange - 1 2.30 2.30 2" 150#


Description

0.411 mm

Unit

Ea

Ea

=

Remark

m

m

m

m

m

Ea

Ea

Ea

Ea

Ea

Ea

Ea

Ea

Ea

m

Ea

Ea

Ea

Ea

Ea

= 2 ×




23 Nozzle N4 - Flange - 1 19.50 19.50 10" 150#

24 Nozzle N4 - Reinforcement 8 1 21.24 21.24

25 Nozzle N4 - Gusset 16 4 2.68 10.72


27 Nozzle N5 - Flange - 1 5.90 5.90 4" 150#


29 Nozzle N6 - Flange - 1 5.90 5.90 4" 150#30 Nozzle N7A - Neck - 0.19 3.29 0.63 1" SCH 80S

31 Nozzle N7A - Flange - 1 0.90 0.90 1" 150#


33 Nozzle N7B - Flange - 1 0.90 0.90 1" 150#

34 Nozzle N7C - Neck - 0.3 3.29 0.99 1" SCH 80S

35 Nozzle N7C - Flange - 1 0.90 0.90 1" 150#


37 Nozzle N8A - Flange - 1 0.90 0.90 1" 150#


39 Nozzle N8B - Flange - 1 0.90 0.90 1" 150#


41 Nozzle N8C - Flange - 1 0.90 0.90 1" 150#


43 Nozzle N9 - Flange - 1 3.70 3.70 3" 150#


45 Nozzle N10 - Flange - 1 5.90 5.90 4" 150#

46 Nozzle N10 - Spray Nozzle - 1 13.08 13.08

47 MANWAY M1 - Reinforcement 8 1 40.44 40.44

48 MANWAY M1 - Shell 8 1 32.00 32.00

49 MANWAY M1 - Cap 8 1 32.81 32.81

50 Baffle 6 4 15.98 63.94

51 Angle Bar (Baffle Support) L-50x50x6 - 12 1.06 12.67

52 Insulation - 1 900.00 900.00Empty Weight 4856

Weight of Liquid at Operating Level 10083.0

Weight of Full Water 14345.0

Total Weight of Liquid at Operating Level 14939

Total Weight of Full Water 19201

9. Lug Support (Refer to Pressure Vessel Handbook 10th Edition - By Eugene F. Megyesy)

9.1 Wear plate (Refer to Pressure Vessel Handbook 10th Edition - By Eugene F. Megyesy)

BCD : Bolt Circle Diameter 3060 mm

OD : Vessel Outside Diameter 2416 mm

W : Weight of Vessel (Full of Water) = 19511 kg (Total Weight + Agitator weight)

n : Number of lugs = 4

Q = W/n : Load on one lug = 4877.7 kg

R : Radius of shell = 1208 mm

H : Lever arm of load = 322 mm

2A : 1st Dimension of wear plate = 582 mm (Minimum, Including Top Angle Bar Width)*

2B : 2nd Dimension of wear plate = 550 mm (Minimum)

t : Wall thickness of shell = 8.0 mm

tw : Wear plate thickness (approximate shell thickness) = 8.0 mm

P : Internal Pressure at Wear plate location = 0.00 MPa

* Top angle bar connected with wear plate by full welding therefore using this angle bar as a part of wear plate.

Shell material : SA-240 TP304 / 304L

Allowable stress value : 112 0 MPa

Ea

Ea

Ea

m

Ea

Ea

Ea

Ea

m

m

m

m

m

m

m

m

m

Ea

Ea

Pipe & Flange 2",

B. Flange 4", Bolt/Nut

Ea

Ea

Ea

Ea

Ea

Ea

Ea

set

Ea

Ea

Ea



Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. No

Joint Efficiency : 0.85

Shape factors C :

1208 275

8.0 291

C1 = 1C2 = 1

C3 = 1

C4 = 1

The factors K

K1 = 3.3

K2 = 0.01

K3 = 6

K4 = 0.0075

Longitudinal Stress :

= 73.87 MPa

Stress due to internal pressure:

PR

2t

The sum of tensional stresses:

73.87 + 0.00 = 73.87 MPa

It does not exceed the stress value of the girth seam:

112.0 x 0.85 = 95.2 MPa (ACCEPTED)

Circumferential Stress:

= 71.44 MPa


PR

t


71.44 + 0.00 = 71.44 MPa

It does not exceed the stress value of shell material multiplied by 1.5 :

112.0 x 1.50 = 168 MPa (ACCEPTED)

Choose wear plate = 582x550x8 mm

B/A

=

= =0 x 1208

2 x 8

0 x 1208

0.00 MPa

= 0.00 MPa8

= = 151 = 0.945

=

R/t ; =

0.24 =

=291

1208

275

291

= ±

+ 6

+

2 1.17+ /×

= ±

+ 6

Page 9 of




9.2 Gussets (Refer to Pressure Vessel Design Manual 3rd Ed. 2004 - Dennis R. Moss, Procedure 3-13)

Q : Vertical load per lug = 4877.7 kg = 47851 N

n : Number of gussets per lug = 2 (Double Gusset)

b = 372 mm

h = 346.5 mm

tg : Gusset thickness = 16 mm

θ = 57 degrees

Fy : Minimum Yield Strength of gusset material = 170 MPa

Fa : Allowable axial Stress = 68 MPa (0.4 Fy)

Fb : Allowable bending Stress = 102 MPa (0.6 Fy)

Qa = Q.sinθ : Axial load on gusset = 40131 N

Qb = Q.cosθ : Bending load on gusset = 26061 N

A = tg.C : Cross-sectional area of assumed column = 2495.9 mm2

Axial stress

=> PASS

Bending Stress

=> PASS

Choose dimensions of Double Gusset as shown above

9.3 Base Plate for Double Gusset (Refer to Pressure Vessel Design Manual 3rd Ed. 2004 - Dennis R. Moss, Procedure 3-13)

l : Base plate width = 410 mm

a : Bearing width = 100 mm (Client to confirm)

l1 = 340 mm

φ : Bolt hole diameter = 38 mm

mm

: Section modulus

Nmm

64890 mm3

413.15 mm

=

: Bending moment =

=

=

5E+06

Mpa= 82.966 MPa < Fb = 102

8.039 MPa < Fa = 68

= 155.99

MPa

Page 10




9.3.1 Bending (Assume to be between simply supported with two equal spans)

9.3.2 Bearing

9.3.3 Thickness required base plate

where Mb is bending moment

Choose the actual thickness base plate tb = 25 mm

9.4 Compression Plate for Double Gusset (Refer to Pressure Vessel Design Manual 3rd Ed. 2004 - Dennis R. Moss, Procedure 3-13)

e = 322 (Refer to figure of 8.2 Gussets)

Ev : Modulus of elasticity of vessel = 183600 MPa

Es : Modulus of elasticity of compression plate = 183600 MPa

t : Shell Vessel thickness = 8.0 mm

R : Inside Radius of vessel = 1200.0 mm

tc : Assumed Compression Plate thickness = 18.0 mm

y : Compression Plate width = 220.0 mm

x : Distance between loads = 340.0 mm



Concentrated load on Double Gusset

Foundation modulus

Moment of inertial of Compression plate

Section modulus of Compression plate

Damping factor

Internal bending moment in Compression plate

2E+07 mm4

= 145200 mm3

= 0.0005

1.1671 Nmm2

= 13492 Nmm

= 20.78 mm

= 1.02 N/mm3

= 2E+06 Nmm

= (Uniform load on base plate)

= 1E+07 Nmm

=

= 22234 N (Assumed)

Bending

(w.l = Q) =

8=

8

Page 11




Bending stress

=> PASS

Choose Compression Plate thickness, tc = 18.0 mm

10. Nozzle calculation

10.1 Shell Nozzle N2 DN40 (1-1/2") (Refer to ASME Section VIII, Division 1, UG-45)

Minimum Nozzle neck thickness

where:

S : Maximum allowable stress value, S = 112.0 MPa

E : Joint efficiency E = 1.00

Nozzle inside radius Rn = 19.1 mm

tn (min) : minimum required thickness of Nozzle

10.1.1. ta : minimum neck thickness required for internal and external pressure using UG-27 and UG-28

(plus corrosion allowance), as applicable. The effects of external forces and moments from supplemental

loads (see UG-22) shall be considered. Shear stresses caused by UG-22 loadings shall not exceed 70%

of the allowable tensile stress for the nozzle material.

0.0372 x 19.1 0.71

112.0 x 1.00 - 0.6 x 0.0372 112.0

ta = 0.01 + 0.0 = 0.01 mm

10.1.2. = min ( 3.22 , 2.5 ) = 2.5 mm

where:

tb1 : for vessels under internal pressure, the thickness (plus corrosion allowance) required for pressure

(assuming E = 1.0) for the shell or head at the location where the nozzle neck or other connection

attaches to the vessel but in no case less than the minimum thickness specified for the material in UG-16(b).

tb1 = 2.5 mm

tb2 : for vessels under external pressure

tb2 = 0.0 mm

Max (tb1, tb2) = Max ( 2.5 , 0.0 ) = 2.5 mm

tb3 : the thickness given in Table UG-45 plus the thickness added for corrosion allowance.

(for standard wall pipe)

tb3 = 3.22 + 0.0 = 3.22 mm

=> = max ( 0.01 , 2.50 ) = 2.50 mm

10.1.3. Choose Nozzle actual thickness = 5.08 mm (SCH 80S)

10.1.4. Nozzle actual thickness is compared with the minimum thickness provided which for pipe

material would include a 12.5% undertolerance

= 0.875 x 5.08 = 4.45 > tn (min) = 2.50 mm

Result: the actual thickness provided meets the rules of UG-45 <PASS>

10.2 Flat Top Head Nozzle N1A/B, N3 DN50 (2") (Refer to API 650 11th Edition, Appendix S)

10.2.1 Minimum Nozzle Neck thickness

Base on table S.3.3.1

== = 0.01

102 MPa= 94.689 MPa < Fb =

mm

bant t t ,max(min)

bant t t ,max(min)

Page 12 o




Minimum thickness of Nozzle Neck = 5.54 mm (SCH 80S)

Corrosion Allowance (C.A) = 0.00 mm

Minimum thickness of Nozzle Neck including C.A = 5.54 mm

10.2.2 Choose Nozzle actual thickness = 5.54 mm (SCH 80S)

10.3 Flat Top Head Nozzle N9 DN80 (3") (Refer to API 650 11th Edition, Appendix S)







10.4 Flat Top Head Nozzle N6, N10 DN100 (4") (Refer to API 650 11th Edition, Appendix S)










Minimum thickness of Nozzle Neck = 6 mm



10.5.2 Choose Nozzle actual thickness = 10 mm

10.6. Cone Bottom Head Nozzle N5 DN100 (4") (Refer to ASME Section VIII, Division 1 & API 650 11th Edition, Appendix S)

10.6.1 Minimum Nozzle neck thickness (Refer to ASME Section VIII, Division 1)

where:

S : Maximum allowable stress value, S = 112 MPa



bant t t ,max(min)

Page 13 o





10.6.1.1 ta : minimum neck thickness required for internal and external pressure using UG-27 and UG-28




0.0372 x 51.1 1.901

112.0 x 1.00 - 0.6 x 0.0372 112.0

ta = 0.02 + 0.0 = 0.02 mm

10.6.1.2 = min ( 5.27 , 2.5 ) = 2.50 mm

where:




tb1 = 2.50 mm


tb2 = 0.00 mm

Max (tb1, tb2) = Max ( 2.50 , 0.00 ) = 2.5 mm



tb3 = 5.27 + 0.0 = 5.27 mm

=> = max ( 0.02 , 2.5 ) = 2.50 mm

10.6.2. Minimum Nozzle neck thickness (Refer to API 650 11th Edition, Appendix S)






10.7 Coil Half-pipe Steam Nozzle N7A/B/C & N8A/B/C DN25 (1") (Refer to ASME Section VIII, Division 1)


where:





10.7.1 ta : minimum neck thickness required for internal and external pressure using UG-27 and UG-28




0.980 x 12.15 11.907

112.0 x 1.00 - 0.6 x 0.980 111.4

ta = 0.11 + 0.0 = 0.11 mm

= = = 0.11 mm

mm= = = 0.02

bant t t ,max(min)

bant t t ,max(min)

Page 14




10.7.2 = min ( 2.96 , 5.49 ) = 2.96 mm

where:




tb1 = 5.49 mm


tb2 = 0.00 mm

Max (tb1, tb2) = Max ( 5.49 , 0.00 ) = 5.49 mm



tb3 = 2.96 + 0.0 = 2.96 mm

=> = max ( 0.11 , 2.96 ) = 2.96 mm


10.7.4 Nozzle actual thickness is compared with the minimum thickness provided which for pipe


= 0.875 x 4.55 = 3.98 > tn (min) = 2.96 mm

Result: The actual thickness provided meets the rules of UG-45 <PASS>

10.8 Spray Nozzle N10 (Refer to ASME Section VIII, Division 1, UG-45)

10.8.1 Outlet Connection DN50 (2")


where:

P : Design Pressure P = 0.98 MPa G (As per Specification)





10.8.1.1. ta : minimum neck thickness required for internal and external pressure using UG-27 and UG-28




0.98 x 24.6 24.12

112.0 x 1.00 - 0.6 x 0.98 111.4

ta = 0.22 + 0.0 = 0.22 mm

10.8.1.2. = min ( 3.42 , 24.0 ) = 3.4 mm

where:




tb1 = 24.0 mm (Thickness of 4" Blind Flange RF 150#)


tb2 = 0.0 mm

= = = 0.22 mm

ban t t t ,max(min)

bant t t ,max(min)

Page 15




Max (tb1, tb2) = Max ( 24.0 , 0.0 ) = 24.0 mm



tb3 = 3.42 + 0.0 = 3.42 mm

=> = max ( 0.22 , 3.42 ) = 3.42 mm

10.8.1.3. Choose Nozzle actual thickness = 5.54 mm (SCH 80S)

10.8.1.4. Nozzle actual thickness is compared with the minimum thickness provided which for pipe


= 0.875 x 5.54 = 4.85 > tn (min) = 3.42 mm


10.8.2 Inlet Connection DN20 (3/4")


where:










0.98 x 9.4 9.25

112.0 x 1.00 - 0.6 x 0.98 111.4

ta = 0.08 + 0.0 = 0.08 mm

10.8.2.2. = min ( 2.51 , 24.0 ) = 2.5 mm

where:






tb2 = 0.0 mm

Max (tb1, tb2) = Max ( 24.0 , 0.0 ) = 24.0 mm



tb3 = 2.51 + 0.0 = 2.51 mm

=> = max ( 0.08 , 2.51 ) = 2.51 mm




= 0.875 x 3.91 = 3.42 > tn (min) = 2.51 mm

= = = 0.08 mm

ban t t t ,max(min)

bant t t ,max(min)

ban t t t ,max(min)

Page 16 o





11. Welding

11.1 Shell Nozzle N2 DN40 (1-1/2") - (Refer to ASME Section VIII, Division 1, UW-16)

11.1.1 Size of weld / Shell thickness

tn (actual) = 5.08 mm

Fillet Leg Length = 6.00 mm

=> tc (actual) = 4.20 mm

t = 8.00 mm

11.1.2 Check for full penetration groove weld and fillet cover weld shown in Fig above

tc (min) = Min ( 6 , 0.7 tmin )

where:

tmin = the smaller of 19 mm or the thickness of the thinner of the parts joined by a fillet, single-bevel, or single-J weld

tmin = Min ( 19.0 , 5.08 , 8.00 ) = 5.08 mm

0.7tmin = 0.7 x 5.08 = 3.56 mm

=> tc (min) = Min ( 6 , 0.7 tmin ) = Min ( 6.00 , 3.56 ) = 3.56 < tc (actual) = 4.2 mm

=> PASS

11.2 Flat Top Head Nozzle N1A/B, N3 DN50 (2") - (Refer to API 650 11th Edition, Clause 5.9)

As per Fig. 5-19 - Flanged Roof Nozzles

where :

DP : Diameter of Hole in Roof Plate (Table 5-14)

DP = 65 mm

11.3 Flat Top Head Nozzle N9 DN80 (3") - (Refer to API 650 11th Edition, Clause 5.9)


where :


DP = 92 mm

Refer to Table 5-14: Reinforcing plates are not required on nozzle DN 80

11.4 Flat Top Head Nozzle N6, N10 DN100 (4") - (Refer to API 650 11th Edition, Clause 5.9)


where :


DP = 120 mm




& Table 5-14

where :

DP : Diameter of Hole in Reinforcing Plate

Page 17



Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev

DP = 280 mm

DR : Minimum Outside Diameter of Reinforcing Plate

DR = 550 mm

11.6 Cone Bottom Head Nozzle N5 DN100 (4")

11.6.1 Size of weld, Nozzle thickness & Shell thickness

tn = 6.02 mm (Nozzle thickness)


tc (actual) = 4.90 mm (Refer to fabrication detail drawing)

t = 8.00 mm (Min. Bottom Head thickness after forming)


tc (min) = Min ( 6 , 0.7 tmin )

where:


tmin = Min ( 19.0 , 6.02 ) = 6.02 mm

0.7tmin = 0.7 x 6.02 = 4.21 mm


=> PASS

11.6.3 Reinforcement Calculation (Refer to ASME Section VIII, Division 1, UG-37)

A : Area of Reinforcement required

A = dtr F + 2tn tr F (1-f r1) = 95.872 mm2

A1 : area in excess thickness in the vessel wall available for reinforcement

(includes consideration of nozzle area through shell if Sn /Sv<1.0)

A1 = larger of below value = 722 mm2

d(E1t - Ftr ) - 2tn(E1t - Ftr )(1 - f r1) = 722.21 mm2

2(t + tn)(E1t - Ftr ) - 2tn(E1t - Ftr )(1 - f r1) = 198.03 mm2

A2 : area in excess thickness in the nozzle wall available for reinforcement (see Fig. UG-37.1)

A2 = smaller of below value = 105.95 mm2

Page 1



Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Re

5(tn - tr n) f r2t = 140.8 mm2

5(tn - tr n) f r2tn = 105.95 mm2

A3 : area available for reinforcement when the nozzle extends inside the vessel wall

A3 = min (5t ti f r2, 5ti ti f r2, 2h ti f r2) = 0 mm2

A41 : cross-sectional area available in outward weld

A41 = (leg)2f r2 = 49.00 mm

2

A42 : cross-sectional area available in inward weld = 0 mm2

where:

leg : Fillet weld size = 7.00 mm

d : finished diameter of circular opening or finished dimension = 102.26 mm

h : distance nozzle projects = 0 mm

t : specified vessel wall thickness = 8.0 mm

tn : nozzle wall thickness = 6.02 mmtr : required thickness of a seamless shell = 0.94 mm

tr n : required thickness of a seamless Nozzle wall = 2.50 mm

ti : nominal thickness of internal projection of nozzle wall = 0 mm

Sn : allowable stress in nozzle = 112 MPa

Sv : allowable stress in vessel = 112 MPa

F : correction factor = 1

E1 = 1

f r1 = 1

f r2 = Sn /Sv = 1

A1 + A2 + A3 + A41 + A42 = 877 mm2 > A = 95.872 mm

2

RESULT : Reforcement for Nozzle N5 is not needed

11.7 Coil Half-pipe Steam Nozzle N7A/B/C & N8A/B/C DN25 (1")





t = 5.49 mm (Coil Half-pipe thickness)


tc (min) = Min ( 6 , 0.7 tmin )

where:


tmin = Min ( 19.0 , 4.55 ) = 4.55 mm

0.7tmin = 0.7 x 4.55 = 3.19 mm


=> PASS

11.8 Cone Bottom Head Welded Joint

Weld type : Butt weld, Full Penetration

Critical weld length K = 8.0 mm (Assumed equal to the thickness of shell)

Inside Diameter of Tank D = 2400 mm

Area of weld Aw = 60319 mm2 Aw = πDK

Page




Allowable Stress of Shell material = 112.0 MPa

Applied by force Total Weight Load (TWL)

Weight Load of Water inside the tank Ww = 140724 N (Estimate)

Weight Load of Cone Bottom Head Wb = 4106.9 N (Estimate)

TWL = 144831 N TWL = Ww + Wb

Tensile Stress on Welded Joint

Tensile = 2.40 MPa Tensile = TWL / Aw

Allowable = 112.0 MPa

Safety Factor = 46.6 => PASS

12. Wind Load Analysis (Refer to Pressure Vessel Design Manual 3rd Ed. 2004 - Dennis R. Moss, Procedure 3-1)

12.1 Design Specification

Vessel Support Type Support Lug

N : Number of Support Lugs = 4

Wo : Operating Weight of Vessel = 14939 kg = 146551 N

h : Overall Height of Vessel = 3798 mm = 12.461 ft.

D : Outside Vessel Diameter = 2416 mm

De : Vessel Effective Diameter from Table 3-4 = 1.4D = 3382.4 mm

Le : Vessel Effective Length = 3798 mm

l : Distance to the center of the projected area = 1349 mm

B : Bolt Circle Diameter = 3060 mm

Structure Category = IV

Exposure Category = BCf : Force Coefficient (shape factor) = 0.8 (for cylindrical Vessel)

G : Gust effect factor = 0.8

KZ : Velocity pressure exposure coefficient from Table 3-3a

= 0.57

KZT : Topographic factor = 1

V : Basic Wind Speed = 39 m/sec = 87.24 mph

I : Importance factor = 1.15

Ct : Period Coefficient (0.02 - 0.035) = 0.035 (Assume Max. Value)

12.2 Design Calculation

h/D ratio

h/D = = 1.57 < 4

Approximate fundamental period

T = = 0.232 sec < 1 sec

=> The Vessel is considered rigid

3798 / 2416

Ct x h3/4

Page 20




Projected area of vessel

Af = Le x De = 3798 x 3382.4 = 1.285E+07 mm2 = 12.85 m

2

Velocity pressure at height z above the ground

qz = = 12.772439 psf = 611.54 N/m2

Design Wind force (Shear force)

= 5027.9145 N

Moment at the base plate

M = F x l = 6782656.7 Nmm

Max. Vertical force per lug

Q = (Wo/N) + (Fl/B) = 38854.259 N

13. Seismic Analysis (Refer to Pressure Vessel Design Manual 3rd Ed. 2004 - Dennis R. Moss, Procedure 3-8)

Neutral Axis Calculation

A = 220.0 mm

B = 364.0 mm

C = 100 mm

D = 25 mm

H = 225 mm

Distance from base to neutral axis

= 78.4 mm

where:

S1 = B x D = 9100 mm2

S2 = B x C = 36400 mm2

S3 = (A+B) x H / 2 = 65700 mm2



=

12

+12

+(2+ )3( + )

+ +

Page 21




L : Level Arm to Neutral axis = 1349 mm


a : Force arm of Vertical Load = 322 mm

b ~ Y : Force arm of Horizontal Load = 78.4 mm

Ch : Horizontal seismic factor = 0.1291 (Assumed)

Cv : Vertical seismic factor = 0.1291 (Assumed)

N : Number of lugs = 4


Horizontal force

Fh = Ch x Wo = = 18919.7 N

Horizontal shear per lug

Vertical force

Fv = (1 + Cv)Wo = = 165470.53 N

Vertical shear per lug

Max. Vertical load Q per lug

Max. moment M per lug

M = ML3 = = 16376900 Nmm

14. Support Analysis for Wind/Seismic (Refer to Pressure Vessel Design Handbook 2nd Ed. 1986 - Henry H. Bednar, Chapter 5)

Maximum Vertical force per lug in Wind Case

Fw = = 38854.259 N

Maximum Moment per lug in Wind Case

Mw = = 6782656.7 Nmm

Maximum Vertical force per lug in Seismic Case

Fs = = 49708.381 N

Maximum Moment per lug in Seismic Case

Ms = = 16376900 Nmm

Maximum Vertical force per lug in Support Lug Analysis

F = = 49708.381 N

Maximum Moment per lug in Support Lug Analysis

M = = 16376900 Nmm

0.1291 x 146551

=18919.71068

= 4729.93 N4

(1 + 0.1291) x 146551

=165470.53

= 41367.63 N4

Q = Q3 = 41367.63 +18919.7 x 1349

= 49708.381 N3060

49708.381 x 322 + 4729.93 x 78.4

Q

M

Q3

ML3

Max(Fw , Fs)

Max(Mw , Ms)

Page 22




w : = 100 mm (Client to confirm)

c : Compression Plate width = 220.0 mm

a : Base plate width = 410 mm

ta : Actual Compression Plate thickness = 18.0 mm

tb : Actual Base plate thickness = 25 mm

tg : Actual Gusset thickness = 16 mm

α : = 57 degrees

[σ] : Allowable stress of support material = 112 MPa

d : Level arm of load F = 322 mm

Sb : Allowable stress in bending for top bar material = 102 MPa (0.6 Fy)

Sa : Allowable stress in compression

h = 346.5 mm

b = 372 mm

14.1 Base plate

Bearing Pressure

q = F/(w x a) = = 1.2124 MPa

Maximum stress in base plate (Refer to Roark's Formulas, Table 11.4, Case 2a)

=> PASS

where

β : Factor from (a/w) = 0.7935

14.2 Compression Plate (Top bar Plate)

The top bar can be assumed to be a simple supported beam with uniformly distributed load.

The minimum compression plate thickness tmin is then given by

=> PASS

14.3 Gusset Plate

Allowable Compressive Stress

where

= 413.2 mm

r : Least radius of gyration of Gusset = 0.289 x tg = 4.624 mm

Maximum compressive stress

49708.381 / (100 x 410)

= 15.39 MPa < [σ] = 112 MPa

= 2.9 mm < ta = 18.0 mm

= psi12469 = 85.977 MPa

=

=0.75 ×

ℎ

= 18000

1 +

18000

= ℎ/sin ()

Page 23




=> PASS

where

= 29635 N

= 114.1 mm

= 312.0 mm

14.4 Size of the lug-to-shell weld

Shear

= 32.9 N/mm

where

Lw = 2 x h + 2 x a = 1513.0 mm

Bending

= 87.9 N/mm

where

Zw = a x h + h2/3 = 182086 mm2

Combined

= 93.8 N/mm

Minimum size of the weld leg

= 2.5 mm

where

f w : Allowable unit force for weld = 0.55 x [σ] x 0.6 = 36.96 MPa

14.5 Anchor Bolts (Refer to Pressure Vessel Design Handbook 2nd Ed. 1986 - Henry H. Bednar, Chapter 5, Size of Anchor Bolts)

By inspection,

=> No Uplift exists and the minimum bolt size is about 3/4 to 1 in.

where:

Mb : Overturning moment at base ~ Maximum moment M = 16376900 Nmm

Db : Bolt Diameter Circle = 3060 mm

W : Operating Weight of Vessel = 14939 kg

N : Number of Support Legs = 4

Choose Anchor Bolt Diameter M36 is satisfactory in this case.

15. Stresses in Shell by Wind/Seismic

(Refer to Pressure Vessel Design Handbook, Chapter 7-Local Stresses in Shell Due to Loads on Attachments)

: Half-length of the loaded square area = 188.45755 mm

β = c/r : Attachment parameter = 0.16

ϒ =r/t : Shell parameter = 150.5

r : Mean Shell Radius = 1204.0 mm

t : Shell thickness = 8.0 mm

Maximum bending stress

85.98 MPa

= -31286

= 19.0 MPa < Sa =

0<

=

+6

= /(2sin ())

= −

2sin ()

= ()

= /

= /

= +

= /

= (ℎ)//2

Page 24 o




where

CLt : Bending Stress factor = 0.125

ML = Fd = 16006099 Nmm

Internal pressure Stress

σt = pr/t = 5.60 MPa

where

p : Internal pressure = 0.0372 MPa

Combined Stress

σ=σb + σt = 171 MPa < 2 x [σ] = 224 MPa

=> PASS

16. Lifting Lug Calculation

Equipment weight We = 4856 kg

Lifting Lug material SA-240 TP304 / 304L

16.1 Check for β = 90 degrees

Angle β = 90.0 degree

Refer to GA Drawing for detail Lifting Lug form

Considered a load factor of 2.0 applied to the structure gravity loads

Design Load P = 2x9.81xWe = 95273.18 N

Force

Fz = 0.5 P = 47637 N

Fx = Fz / tg β = 0 N

Max tensile force in Wire Rope

Ps = Fz / sin β = 47637 N

Lifting lug configuration

where :

SWL = Safe working load

Rh = Hole radiusr = Cheek plate radius

R = Main plate radius

Tp = Main plate thickness

t = Cheek plate thickness

T = Total plate thickness

h = Base width

b = Distance from edge of taper to center of hole

c = Distance from base of plate to center of hole

a = Taper angle

D = Shackle pin diameter

Fy = Yield Strength of lifting lug material

The dimension T should equal 60 - 85% of shackle jaw width.

The pin hole diameter should be 3 mm greater than the selected shackle pin size

Cheek plate radius is approximately r = R - 1.5t

The main plate radius is approximately R = 3 R h

The cheek plate thickness (t) should be less than or equal to the plate thickness (Tp).

Choose Shackle

= 165.9 MPa

Page 25




Shackle load Ps = 47637 N = 4.856 tonne

Choose Shackle with SWL = 8.5 tonne

As per Table shown above :

Shackle jaw width W = 43 mm

Shackle pin size D = 29 mm

Choose Lug Configuration

Rh = 16 mm

r = 42 mm

R = 50 mm

Tp = 25 mm

t = 6 mm

T = 37 mm

h = 174 mm

b = 210 mm

c = 122 mm

a = 71 degrees

D = 29 mm

Fy = 170 MPa

Stress in Lifting Lug

Bearing Stress

Bearing = 44.40 MPa Bearing = Ps/(T x D)

Allowable = 153 MPa Allowable = 0.9 x Fy


Shear Stress

Shear = 20.50 MPa Shear = Ps/(4(r-Rh)*t+2(R-Rh)*Tp)



Tensile Stress

From Section D3.2 of AISC, the distance used in calculations, across the hole, is the minimum of 4 times the plate

thickness at the pinhole or 0.8 times the hole diameter.

Effective width = 25.6 mm

Plate thickness = 37 mm

Tensile = 50.29 MPa Tensile = Ps/(Effective width*plate thickness)

Allowable = 76.5 MPa Allowable = 0.45 Fy (AISC Section D3.2)


Page 26




Bending Stress

Section modulus Z = 126150 mm3 Z = h

2x Tp / 6

Area of lug base A = 4350 mm2 A = h x Tp

Bending = 46.07 MPa Bending = (Fz*c / Z) + (Fx / A)

Allowable = 102 MPa Allowable = 0.6 Fy


Stress in Weld Joint

Weld type : T-Butt weld, Full Penetration

Critial weld length K = 25 mm (Assumed equal to the thickness of lug)

Section modulus of weld Zw = 252300 mm Zw = h2

x K / 3

Area of weld Aw = 8700 mm Aw = 2 x K x h

Applied by force Fz

Bending S1 = 23.0 MPa Bending S1 = Fz*c/Zw

Shear S2 = 5.5 MPa Shear S2 = Fz/Aw

Combined = 23.68 MPa Combined = (S12

+ S22)0.5



Applied by force Fx

Tensile S3 = 0.00 MPa Tensile S3 = Fx/Aw


=> PASS

16.2 Check for β = 85 degrees (Considering Tolerance 5 degrees)





Force

Fz = 0.5 P = 47637 N

Fx = Fz / tg β = 4168 N


Ps = Fz / sin β = 47819 N


Bearing Stress




Shear Stress




Tensile Stress

From Section D3.2 of AISC, the distance used in calculations, across the hole, is the minimum of 4 times the platethickness at the pinhole or 0.8 times the hole diameter.






Page 2




Bending Stress

Section modulus Z = 126150 mm3 Z = h

2x Tp / 6








Section modulus of weld Zw = 252300 mm Zw = h2

x K / 3


Applied by force Fz




2

+ S2

2

)

0.5



Applied by force Fx




Choose Lug Configuration as shown above is satisfactory

Page 2




19. Conclusion

Shell thickness:

Thickness required: 2.50 mmThickness actual: 8.0 mm

Bottom Head thickness:

Min. Thickness required: 8.00 mm

Top Head thickness:

Thickness actual: 8.00 mm

Auxiliary Stiffener size: 50 x 8 mm

Main Stiffener size: T-150x8 + 70x8 mm (Refer to GA Drawing for more details)

Nozzle thickness:

Shell Nozzle N2 DN40 (1-1/2")

Thickness required: 2.50 mm

Thickness actual: 5.08 mm (SCH 80S)

Flat Top Head Nozzle N1A/B, N3 DN50 (2")



Flat Top Head Nozzle N9 DN80 (3")



Flat Top Head Nozzle N6, N10 DN100 (4")






Cone Bottom Head Nozzle N5 DN100 (4")



Coil Half-pipe Steam Nozzle N7A/B/C & N8A/B/C DN25 (1")



Spray Nozzle N10

Outlet Connection DN50 (2")



Inlet Connection DN20 (3/4")



Baffle thickness:



Page 29




1. Design Data

Design Code : None

Service: Blending Vessel

Design pressure

Max. Internal pressure - (Full 3.79 meters of Water) P = 0.372 barg = 0.0372 MPa G

External pressure 0.0 barg = 0.0 MPa GWorking pressure 0.0 barg = 0.0 MPa G

Design temperature 180 degrees C

Working temperature 60 ~ 80 degrees C

Corrosion allowance 0.0 mm

Vessel inside diameter 2400 mm (O/D = 2416 mm)

Vessel length (Flat Head to T.L) 2800 mm

Material S : Maximum allowable stress value

Shell SA-240 TP304 / 304L 112 MPa

Flat Top Head SA-240 TP304 / 304L 112 MPa

Bottom Cone Head SA-240 TP304 / 304L 112 MPa

Nozzle Neck SA-312 TP304 / 304L 112 MPa

Support SA-240 TP304 / 304L 112 MPa

Nozzle Flange: ASME B16.5 Standard

SCH THK.

N1 A/B 150 80S 5.54

N2 150 80S 5.08

N3 150 80S 5.54

N4 150 - 10

N5 150 40S 6.02

N6 150 40S 6.02

N7 A/B/C 150 80S 4.55

N8 A/B/C 150 80S 4.55

N9 150 40S 5.49

N10 150 40S 6.02

2. Shell Thickness Calculation (Refer to ASME Section VIII, Division 1, UG-27)

2.1 Minimum required thickness of shell exclusive corrosion allowance (t):

Circumferential Stress (Longitudinal Joints)

0.0372 x 1200.0

112.0 x 0.85 - 0.6 x 0.0372

where:


R : Inside radius of the shell = 1200.0 mm



Longitudinal Stress (Circumferential Joints)

0.0372 x 1200.0

2.0 x 112.0 x 0.85 + 0.4 x 0.0372

where:


Degree of Radiographic Examination: 10%

2.2 Minimum Thickness of Pressure retaining Components (UG-16 (b)) = 2.5 mm

2.3 Minimum required thickness of shell included corrosion allowance

tr = 0.47 + 0.0 = 0.47 mm

Nozzle Size Flange Type ClassNozzle Neck Nozzle outside

diameter, mm

DN 50 (2") SO RF 60.3 49.22

DN 250 (10") SO RF 273.1 253.1

Nozzle inside

diameter, mm

DN 50 (2") SO RF 60.3 49.22

DN 40 (1-1/2") SO RF 48.3 38.14

DN 25 (1") SO RF 33.4 24.3

DN 25 (1") SO RF 33.4 24.3

DN 100 (4") SO RF 114.3 102.26

DN 100 (4") SO RF 114.3 102.26

mm95.2

DN 80 (3") SO RF 88.9 77.92

DN 100 (4") SO RF 114.3 102.26

0.385SE

= =44.6

= 0.23

= =44.6

= 0.47

mm190.4

Page 45




2.4 Choose Nominal thickness of shell, ts = 8.0 mm

3. Bottom Head Thickness Calculation (Refer to ASME Section VIII, Division 1, UG-32)

Type of head: Toriconical Head (with Knuckle)

3.1 Conical Section

3.1.1 Minimum required thickness of Conical Section exclusive corrosion allowance (t):

0.0372 x 2400.0

where:


D : Inside diameter of the head skirt = 2400.0 mm



α : one-half of the included angle of = 60 degrees

the cone at the centerline of head

3.1.2 Minimum required thickness of Head included corrosion allowance

= 0.94 + 0.0 = 0.94 mm

3.1.3 Minimum required thickness of Head, tb = Min. 8.0 mm

3.2 Knuckle Section

r : inside knuckle radius = 250 mm

Di : inside cone diameter at point of tangency = = 2150.0

to knuckle

3.2.1 Minimum required thickness of Knuckle Section exclusive corrosion allowance (t):

where:

3.2.2 Minimum required thickness of Knuckle included corrosion allowance

= 0.62 + 0.0 = 0.62 mm

3.2.3 Minimum required thickness of Knuckle, tK = Min. 8.0 mm

3.3 Stress Relief (Refer to UCS-79)

Type of head: Toriconical Head (Double Curvature)

=> Percent extreme fiber elongation is not exceeded by 5% so that a stress relief is not required

where:

t : Nominal Straight Flange thickness t = 8.0 mm

Rf : Final centerline radius (mean knuckle radius) Rf = 250.0 mm

Ro : Original centerline radius (Crown radius) Ro = 2150.0 mm

4. Top Head Thickness Calculation (Refer to Roark's Formulas for Stress and Strain)

0.385SE

=0.0372 x 2150 x 1.48

=118.6

=

= =89.2

= 0.94 mm2 x cos(60) x (112 x 0.85 - 0.6 x 0.0372) 95.2

1.48

= 2.12 %

0.6227 mm2 x 112 x 0.85 - 0.2 x 0.0372 190.4

: Crown radius = 2150 mm

: Factor =

Page 45




Type of head: Flat Head

Assume square plate (axb) 500x500 mm with all edges simply supported

and uniform loads over entire plate.

Top Head Self-Weight = 293.402 kg

F = m x g = 2878.28 N

Area (A) = πD2

/4 = 4.58 m2

P1 = F/A = 0.628 kPa

Structural Weight = 150 kg (Including weight of nozzles, manhole on Top Head - 150 kg)

F = m x g = 1471.5 N

Area (A) = πD2/4 = 4.58 m

2

P2 = F/A = 0.321 kPa

Concentrated Load = 200 kg (Assumed)

F = m x g = 1962 N

Area (A) = πD2/4 = 4.58 m

2

P3 = F/A = 0.428 kPa

Total Dead Load (P) = P1+P2+P3 = 1.38 kPa

Total Live Load (L) = 1.0 kPa (As per API 650 11th Ed. Errata, Oct. 2011, Clause 5.2.1)

Total Uniform Load (q) = P + L = 2.38 kPa

Edges of Plate (a x b) = 500 x 500 mm

a/b = 1

β = 0.2874

α = 0.0444

Elastic Modulus (E) = 183600000 kPa (Interpolate from API 650 11th Ed. Errata, October 2011, Appendix S)

Allowable Stress ([ϭ]) = 112000 kPa (Refer to ASME Section II, Part D, Table 1A)

Required Plate thickness (Refer to Roark's Formulas, Table 11.4, Case 1a)

Choose thickness of Top Head Plate = 8 mm

Max. Deflection (Refer to Roark's Formulas, Table 11.4, Case 1a)

Max. Stress in plate

5. Auxiliary Stiffener Calculation




= 1.23 mm

= 0.07 mm <

kPa (ACCEPTED)

t/2 = 4 mm (ACCEPTED)

= 2668 kPa < [ϭ] = 112000

=

=

=

L

Page 45





Area moment of inertia (As per Roark's Formulas, Table A.1, Case 4: Tee section):

Effective area = 1.1 x (D x t)0.5 = 19 x t (Base on ASME Section VIII, Division 1, Appendix 1-8)

where:

t : The thickness of Top Head = 8 mm

b : Effective area (about 19 x t) = 152 mm

tw : The thickness of Stiffener = 8 mm

d : Stiffener height = 50 mm

= 1616 mm2

Elastic modulus (E) = kPa

Plastic section modulus (Zx)

Max. deflection at the center of stiffener (Refer to Roark's Formulas, Table 8.1, Case 2e )

-5 x 1.188 x 7804


M : Maximum bending moment caused by uniform load wa = 0.037 KN.m


UC ratio : = 0.024 < 1

=> (ACCEPTED)

6. Main Stiffener Calculation



I = = 342951 mm4

= 11.178 mm

183600000

= 13769 mm3

= = -0.015 mm384 x 183600 x 342951

M =

8

S =

=

5 0

L

Page 45





Agitator Concentrated load W = 310 kg = 3.041 kN


b3 : Effective area (about 19 x d3) = 152 mm

d3 : The thickness of Top Head = 8 mm

d2 : Web height = 150 mmb2 : Web thickness = 8 mm

b1 : Bottom flange length = 70 mm

d1 : Bottom flange thickness = 8 mm

PART Area (a) y a x y h h2

bd3/12

mm mm mm mm mm mm

1 560 4 2240 96.41 9295.7 2986.6667

2 1200 83 99600 17.41 303.25 2250000

3 1216 162 196992 -61.59 3792.84 6485.3333

TOTAL 2976 298832 2259472

Therefore,

Distance from bottom to Neutral axis

C = 298832 / 2976 = 100.414 mm

Area moment of inertia

I = 10181553.978 + 2259472 = 12441026 mm

Section Modulus

Z = I /C = 123897.35 mm3

Max. deflection at the center of stiffener (Refer to Roark's Formulas, Table 8.1,Case 1e & Case 2e )

-3.0411 x 24003

x 24004


M : Maximum bending moment caused by uniform load W = 2.406 KN.m


UC ratio : = 0.173 < 1

=> (ACCEPTED)

7. Coil Half-Pipe Calculation (Refer to ASME Section VIII, Division 1, Nonmandatory Appendix EE)

7.1 Because of the same thickness of shell and cone head, the half-pipe calculation shall be considered for shell only.

ts : Thickness of the shell = 8.0 mm = 1/3 in

R : Inside shell radius = 1200 mm

D = 2R : Inside shell diameter = 2400 mm = 94.5 in

Half-pipe jacket is DN80 (3")

S : Allowable tensile stress of shell = 112.0 MPa

S1 : Allowable tensile stress of coil half-pipe = 112.0 MPa

P : Internal Pressure in vessel = 0.0372 MPa (Positive pressure inside the shell)

P1 : Design Pressure in coil = 0.98 MPa (Positive pressure inside the half-pipe)

From Fig. EE-2, with D = 94.5 in. and t = 1/3 in., so K = 70

= +-5 x 0.808

a x h2

= -0.536 mm48 x183600 x 12441026 384 x 183600 x 12441026

mm4

5205566.94

363895.9764

4612091.063

10181553.978

M =

4+

8

S =

=

Page 45




Actual longitudinal tensile pressure in shell

S' = PR/2ts = 2.79 MPa

Permissible coil pressure - Maximum allowable external pressure applied to the shell

P' = F / K = (1.5S - S') / K = 2.36 MPa > P1 = 0.98 MPa

=> PASS

The thickness of shell is satisfactory for pressure inside Half-pipe

Choose Half-pipe DN80 (3"), SCH. 40

Half-pipe thickness included 12.5% undertolerance

t = 0.875 x 5.49 = 4.8 mm

Inside half-pipe radius

r = 88.9/2 - 4.8 = 39.65 mm

The required half-pipe thickness

=> PASS

The minimum fillet weld size

= 1.414 x 0.411 = 0.581 mm

Choose Fillet weld size = 6 mm

7.2 Hydrotest Pressure for Coil Half-pipe (Refer to ASME Section VIII, Division 1, UG-99 (b))

Design Temperature = 180 degrees CTest Temperature = A.T.M

Internal Design Pressure P = 0.980 MPa G

Max. Allowable Stress at Design Temperature Sd = 112 MPa

Max. Allowable Stress at Test Temperature St = 115 MPa

Hydrotest Pressure Ph = 1.3 x P x (St/Sd)

Ph = 1.3 x 0.98 (115/112) = 1.31 MPa G

8. Weight Calculation Sheet

No.

Thickness

(mm) Q'ty

Unit Weight

(kg)

Total Weight

(kg)

1 Shell 8 1 1341.7 1341.68

2 Bottom Cone 8 1 418.64 418.64

3 Roof 8 1 330.97 330.97

4 Stiffenner T-150x8+70x8 - 4 33.37 133.48

5 Stiffenner PL.50x8 - 2 19.47 38.94

6 Top Angle Bar L-70x70x8 - 1 68.01 68.01

7 Half Pipe Coil - 106.3 5.76 612.29

8 Support Lug - Reinforcement PL. 8 4 18.20 72.79

9 Support Lug - Base Plate 25 4 30.31 121.26

10 Support Lug - Compress Plate 18 4 13.33 53.32



13 Lifting Lug 25 2 6.33 12.66


15 Nozzle N1A - Flange - 1 2.30 2.30 2" 150#


17 Nozzle N1B - Flange - 1 2.30 2.30 2" 150#

18 Nozzle N2 - Neck - 0.172 5.51 0.95 1-1/2" SCH 80S

19 Nozzle N2 - Flange - 1 1.40 1.40 1-1/2" 150#


21 Nozzle N3 - Flange - 1 2.30 2.30 2" 150#


= 0.411 mm

Remark

Ea

Ea

Ea

Ea

Ea

Description Unit

Ea

Ea

m

Ea

m

Ea

Ea

m

Ea

Ea

Ea

Ea

m

Ea

m

Ea

m

= 2 ×




23 Nozzle N4 - Flange - 1 19.50 19.50 10" 150#

24 Nozzle N4 - Reinforcement 8 1 21.24 21.24

25 Nozzle N4 - Gusset 16 4 2.68 10.72


27 Nozzle N5 - Flange - 1 5.90 5.90 4" 150#


29 Nozzle N6 - Flange - 1 5.90 5.90 4" 150#30 Nozzle N7A - Neck - 0.19 3.29 0.63 1" SCH 80S

31 Nozzle N7A - Flange - 1 0.90 0.90 1" 150#


33 Nozzle N7B - Flange - 1 0.90 0.90 1" 150#


35 Nozzle N7C - Flange - 1 0.90 0.90 1" 150#


37 Nozzle N8A - Flange - 1 0.90 0.90 1" 150#


39 Nozzle N8B - Flange - 1 0.90 0.90 1" 150#


41 Nozzle N8C - Flange - 1 0.90 0.90 1" 150#


43 Nozzle N9 - Flange - 1 3.70 3.70 3" 150#


45 Nozzle N10 - Flange - 1 5.90 5.90 4" 150#

46 Nozzle N10 - Spray Nozzle - 1 13.08 13.08

47 MANWAY M1 - Reinforcement 8 1 40.44 40.44

48 MANWAY M1 - Shell 8 1 32.00 32.00

49 MANWAY M1 - Cap 8 1 32.81 32.81

50 Baffle 6 4 15.98 63.94

51 Angle Bar (Baffle Support) L-50x50x8 - 12 1.41 16.90

52 Insulation - 1 900.00 900.00

Empty Weight 4549.1

Weight of Liquid at Operating Level 10083.0

Weight of Full Water 14345.0

Total Weight of Liquid at Operating Level 14632.1

Total Weight of Full Water 18894.1

9. Lug Support (Refer to Pressure Vessel Handbook 10th Edition - By Eugene F. Megyesy)

9.1 Wear plate (Refer to Pressure Vessel Handbook 10th Edition - By Eugene F. Megyesy)

BCD : Bolt Circle Diameter 3060 mm

OD : Vessel Outside Diameter 2416 mm

W : Weight of Vessel (Full of Water) = 19204 kg (Total Weight + Agitator weight)

n : Number of lugs = 4

Q = W/n : Load on one lug = 4801 kgR : Radius of shell = 1208 mm

H : Lever arm of load = 322 mm

2A : 1st Dimension of wear plate = 512 mm (Minimum)

2B : 2nd Dimension of wear plate = 550 mm (Minimum)

t : Wall thickness of shell = 8.0 mm

tw : Wear plate thickness (approximate shell thickness) = 8.0 mm

P : Internal Pressure at Wear plate location = 0.00 MPa

Shell material : SA-240 TP304 / 304L

Allowable stress value : 112.0 MPa

Joint Efficiency : 0.85

Ea

Ea

m

Ea

m

Ea

Ea

Pipe & Flange 2",

B. Flange 4", Bolt/Nut

m

Ea

m

Ea

m

Ea

m

Ea

m

Ea

m

Ea

Ea

Ea

Ea

Ea

Ea

set

m

Ea

m

Ea

Ea




Shape factors C :

1208 275

8.0 256

C1 = 1

C2 = 1

C3 = 1C4 = 1

The factors K

K1 = 3.8

K2 = 0.012

K3 = 7

K4 = 0.0075

Longitudinal Stress :

= 92.94 MPa


PR

2t


92.94 + 0.00 = 92.94 MPa

It does not exceed the stress value of the girth seam:

112.0 x 0.85 = 95.2 MPa (ACCEPTED)

Circumferential Stress:

= 82.57 MPa


PR

t


82.57 + 0.00 = 82.57 MPa

It does not exceed the stress value of shell material multiplied by 1.5 :

112.0 x 1.50 = 168 MPa (ACCEPTED)

Choose wear plate = 512x550x8 mm

9.2 Gussets (Refer to Pressure Vessel Design Manual 3rd Ed. 2004 - Dennis R. Moss, Procedure 3-13)

= = 1.0742

= 0.22

R/t = = 151 ; B/A

=0 x 1208

= 0.00 MPa8

=0 x 1208

= 0.00 MPa2 x 8

=

=256

1208

275

256

= ±

+ 6

+

2 1.17+ /×

= ±

+ 6

Page 45 of




Q : Vertical load per lug = 4801 kg = 47098 N

n : Number of gussets per lug = 2 (Double Gusset)

b = 372 mm

h = 346.5 mm

tg : Gusset thickness = 16 mm

θ = 57 degrees


Fa : Allowable axial Stress = 68 MPa (0.4 Fy)


Qa = Q.sinθ : Axial load on gusset = 39500 N

Qb = Q.cosθ : Bending load on gusset = 25651 N

A = tg.C : Cross-sectional area of assumed column = 2495.9 mm2

Axial stress

=> PASS

Bending Stress

=> PASS

Choose dimensions of Double Gusset as shown above

9.3 Base Plate for Double Gusset (Refer to Pressure Vessel Design Manual 3rd Ed. 2004 - Dennis R. Moss, Procedure 3-13)

l : Base plate width = 410 mm

a : Bearing width = 100 mm (Client to confirm)

l1 = 340 mm

φ : Bolt hole diameter = 38 mm

= 413.15 mm

: Bending moment = 5E+06 Nmm

= 155.99 mm

: Section modulus = 64890 mm3

68 MPa

= 81.661 MPa < Fb = 102 Mpa

= 7.913 MPa < Fa =

Page 45




9.3.1 Bending (Assume to be between simply supported with two equal spans)

9.3.2 Bearing

9.3.3 Thickness required base plate

where Mb is bending moment

Choose the actual thickness base plate tb = 25 mm

9.4 Compression Plate for Double Gusset (Refer to Pressure Vessel Design Manual 3rd Ed. 2004 - Dennis R. Moss, Procedure 3-13)

e = 322 (Refer to figure of 8.2 Gussets)

Ev : Modulus of elasticity of vessel = 183600 MPa

Es : Modulus of elasticity of compression plate = 183600 MPa

t : Shell Vessel thickness = 8.0 mm

R : Inside Radius of vessel = 1200.0 mm

tc : Assumed Compression Plate thickness = 18.0 mm

y : Compression Plate width = 220.0 mm

x : Distance between loads = 340.0 mm



Concentrated load on Double Gusset

Foundation modulus

Moment of inertial of Compression plate

Section modulus of Compression plate

Damping factor

Internal bending moment in Compression plate

Bending stress

=> PASS

Bending

= 2E+06 Nmm (w.l = Q)

= 1.1487 Nmm2 (Uniform load on base plate)

= 21884 N (Assumed)

= 1.02 N/mm3

= 13279 Nmm

= 20.62 mm

= 0.0005

= 1E+07 Nmm

= 2E+07 mm4

= 145200 mm3

102 MPa= 93.2 MPa < Fb =

=

8=

8

Page 45




Choose Compression Plate thickness, tc = 18.0 mm

10. Nozzle calculation

10.1 Shell Nozzle N2 DN40 (1-1/2") (Refer to ASME Section VIII, Division 1, UG-45)


where:

S : Maximum allowable stress value, S = 112.0 MPa




10.1.1. ta : minimum neck thickness required for internal and external pressure using UG-27 and UG-28




0.0372 x 19.1 0.71

112.0 x 1.00 - 0.6 x 0.0372 112.0

ta = 0.01 + 0.0 = 0.01 mm

10.1.2. = min ( 3.22 , 2.5 ) = 2.5 mm

where:




tb1 = 2.5 mm


tb2 = 0.0 mm

Max (tb1, tb2) = Max ( 2.5 , 0.0 ) = 2.5 mm



tb3 = 3.22 + 0.0 = 3.22 mm

=> = max ( 0.01 , 2.50 ) = 2.50 mm


10.1.4. Nozzle actual thickness is compared with the minimum thickness provided which for pipe


= 0.875 x 5.08 = 4.45 > tn (min) = 2.50 mm


10.2 Flat Top Head Nozzle N1A/B, N3 DN50 (2") (Refer to API 650 11th Edition, Appendix S)



= = = 0.01 mm

bant t t ,max(min)

bant t t ,max(min)

Page 45 o















10.4 Flat Top Head Nozzle N6, N10 DN100 (4") (Refer to API 650 11th Edition, Appendix S)










Minimum thickness of Nozzle Neck = 6 mm



10.5.2 Choose Nozzle actual thickness = 10 mm

10.6. Cone Bottom Head Nozzle N5 DN100 (4") (Refer to ASME Section VIII, Division 1 & API 650 11th Edition, Appendix S)

10.6.1 Minimum Nozzle neck thickness (Refer to ASME Section VIII, Division 1)

where:





10.6.1.1 ta : minimum neck thickness required for internal and external pressure using UG-27 and UG-28



bant t t ,max(min)

Page 45 o





0.0372 x 51.1 1.901

112.0 x 1.00 - 0.6 x 0.0372 112.0

ta = 0.02 + 0.0 = 0.02 mm

10.6.1.2 = min ( 5.27 , 2.5 ) = 2.50 mm

where:




tb1 = 2.50 mm


tb2 = 0.00 mm

Max (tb1, tb2) = Max ( 2.50 , 0.00 ) = 2.5 mm



tb3 = 5.27 + 0.0 = 5.27 mm

=> = max ( 0.02 , 2.5 ) = 2.50 mm

10.6.2. Minimum Nozzle neck thickness (Refer to API 650 11th Edition, Appendix S)






10.7 Coil Half-pipe Steam Nozzle N7A/B/C & N8A/B/C DN25 (1") (Refer to ASME Section VIII, Division 1)


where:





10.7.1 ta : minimum neck thickness required for internal and external pressure using UG-27 and UG-28




0.980 x 12.15 11.907

112.0 x 1.00 - 0.6 x 0.980 111.4

ta = 0.11 + 0.0 = 0.11 mm

10.7.2 = min ( 2.96 , 5.49 ) = 2.96 mm

where:

= = = 0.02 mm

= = = 0.11 mm

bant t t ,max(min)

bant t t ,max(min)

Page 45 o







tb1 = 5.49 mm


tb2 = 0.00 mm

Max (tb1, tb2) = Max ( 5.49 , 0.00 ) = 5.49 mm



tb3 = 2.96 + 0.0 = 2.96 mm

=> = max ( 0.11 , 2.96 ) = 2.96 mm


10.7.4 Nozzle actual thickness is compared with the minimum thickness provided which for pipe

material would include a 12.5% undertolerance= 0.875 x 4.55 = 3.98 > tn (min) = 2.96 mm

Result: The actual thickness provided meets the rules of UG-45 <PASS>

10.8 Spray Nozzle N10 (Refer to ASME Section VIII, Division 1, UG-45)

10.8.1 Outlet Connection DN50 (2")


where:










0.98 x 24.6 24.12

112.0 x 1.00 - 0.6 x 0.98 111.4

ta = 0.22 + 0.0 = 0.22 mm

10.8.1.2. = min ( 3.42 , 24.0 ) = 3.4 mm

where:






tb2 = 0.0 mm

Max (tb1, tb2) = Max ( 24.0 , 0.0 ) = 24.0 mm



tb3 = 3.42 + 0.0 = 3.42 mm

0.22 mm= = =

bant t t ,max(min)

bant t t ,max(min)

Page 45




=> = max ( 0.22 , 3.42 ) = 3.42 mm




= 0.875 x 5.54 = 4.85 > tn (min) = 3.42 mm


10.8.2 Inlet Connection DN20 (3/4")


where:










0.98 x 9.4 9.25

112.0 x 1.00 - 0.6 x 0.98 111.4

ta = 0.08 + 0.0 = 0.08 mm

10.8.2.2. = min ( 2.51 , 24.0 ) = 2.5 mm

where:






tb2 = 0.0 mm

Max (tb1, tb2) = Max ( 24.0 , 0.0 ) = 24.0 mm



tb3 = 2.51 + 0.0 = 2.51 mm

=> = max ( 0.08 , 2.51 ) = 2.51 mm




= 0.875 x 3.91 = 3.42 > tn (min) = 2.51 mm


11. Welding

11.1 Shell Nozzle N2 DN40 (1-1/2") - (Refer to ASME Section VIII, Division 1, UW-16)

= = = 0.08 mm

bant t t ,max(min)

bant t t ,max(min)

bant t t ,max(min)

o




11.1.1 Size of weld / Shell thickness

tn (actual) = 5.08 mm


=> tc (actual) = 4.20 mm

t = 8.00 mm


tc (min) = Min ( 6 , 0.7 tmin )

where:


tmin = Min ( 19.0 , 5.08 , 8.00 ) = 5.08 mm

0.7tmin = 0.7 x 5.08 = 3.56 mm


=> PASS

11.2Flat Top Head Nozzle N1A/B, N3 DN50 (2") - (Refer to API 650 11th Edition, Clause 5.9)


where :


DP = 65 mm



where :


DP = 92 mm


11.4 Flat Top Head Nozzle N6, N10 DN100 (4") - (Refer to API 650 11th Edition, Clause 5.9)


where :DP : Diameter of Hole in Roof Plate (Table 5-14)

DP = 120 mm




& Table 5-14

where :

DP : Diameter of Hole in Reinforcing Plate

DP = 280 mm

Page 45




DR : Minimum Outside Diameter of Reinforcing Plate

DR = 550 mm

11.6 Cone Bottom Head Nozzle N5 DN100 (4")





t = 8.00 mm (Min. Bottom Head thickness after forming)


tc (min) = Min ( 6 , 0.7 tmin )

where:


tmin = Min ( 19.0 , 6.02 ) = 6.02 mm

0.7tmin = 0.7 x 6.02 = 4.21 mm


=> PASS

11.6.3 Reinforcement Calculation (Refer to ASME Section VIII, Division 1, UG-37)

A : Area of Reinforcement required

A = dtr F + 2tn tr F (1-f r1) = 95.872 mm2

A1 : area in excess thickness in the vessel wall available for reinforcement

(includes consideration of nozzle area through shell if Sn /Sv<1.0)

A1 = larger of below value = 722 mm2

d(E1t - Ftr ) - 2tn(E1t - Ftr )(1 - f r1) = 722.21 mm2

2(t + tn)(E1t - Ftr ) - 2tn(E1t - Ftr )(1 - f r1) = 198.03 mm2

A2 : area in excess thickness in the nozzle wall available for reinforcement (see Fig. UG-37.1)

A2 = smaller of below value = 105.95 mm2

5(tn - tr n) f r2t = 140.8 mm2

Page 4



Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Re

5(tn - tr n) f r2tn = 105.95 mm2

A3 : area available for reinforcement when the nozzle extends inside the vessel wall

A3 = min (5t ti f r2, 5ti ti f r2, 2h ti f r2) = 0 mm2

A41 : cross-sectional area available in outward weld

A41 = (leg)2f r2 = 49.00 mm

2

A42 : cross-sectional area available in inward weld = 0 mm2

where:

leg : Fillet weld size = 7.00 mm

d : finished diameter of circular opening or finished dimension = 102.26 mm

h : distance nozzle projects = 0 mm

t : specified vessel wall thickness = 8.0 mm

tn : nozzle wall thickness = 6.02 mm

tr : required thickness of a seamless shell = 0.94 mmtr n : required thickness of a seamless Nozzle wall = 2.50 mm

ti : nominal thickness of internal projection of nozzle wall = 0 mm

Sn : allowable stress in nozzle = 112 MPa

Sv : allowable stress in vessel = 112 MPa

F : correction factor = 1

E1 = 1

f r1 = 1

f r2 = Sn /Sv = 1

A1 + A2 + A3 + A41 + A42 = 877 mm2 > A = 95.872 mm

2

RESULT : Reforcement for Nozzle N5 is not needed

11.7 Coil Half-pipe Steam Nozzle N7A/B/C & N8A/B/C DN25 (1")





t = 5.49 mm (Coil Half-pipe thickness)


tc (min) = Min ( 6 , 0.7 tmin )

where:


tmin = Min ( 19.0 , 4.55 ) = 4.55 mm

0.7tmin = 0.7 x 4.55 = 3.19 mm


=> PASS

11.8 Cone Bottom Head Welded Joint

Weld type : Butt weld, Full Penetration

Critical weld length K = 8.0 mm (Assumed equal to the thickness of shell)

Inside Diameter of Tank D = 2400 mm

Area of weld Aw = 60319 mm2 Aw = πDK

Allowable Stress of Shell material = 112.0 MPa

Page




Applied by force Total Weight Load (TWL)

Weight Load of Water inside the tank Ww = 140724 N (Estimate)

Weight Load of Cone Bottom Head Wb = 4106.9 N (Estimate)

TWL = 144831 N TWL = Ww + Wb

Tensile Stress on Welded Joint

Tensile = 2.40 MPa Tensile = TWL / Aw

Allowable = 112.0 MPa


12. Wind Load Analysis (Refer to Pressure Vessel Design Manual 3rd Ed. 2004 - Dennis R. Moss, Procedure 3-1)


Vessel Support Type Support Lug

N : Number of Support Lugs = 4


h : Overall Height of Vessel = 3798 mm = 12.461 ft.

D : Outside Vessel Diameter = 2416 mm

De : Vessel Effective Diameter from Table 3-4 = 1.4D = 3382.4 mm

Le : Vessel Effective Length = 3798 mm

l : Distance to the center of the projected area = 1349 mm


Structure Category = IV

Exposure Category = B

Cf : Force Coefficient (shape factor) = 0.8 (for cylindrical Vessel)G : Gust effect factor = 0.8

KZ : Velocity pressure exposure coefficient from Table 3-3a

= 0.57

KZT : Topographic factor = 1

V : Basic Wind Speed = 39 m/sec = 87.24 mph

I : Importance factor = 1.15

Ct : Period Coefficient (0.02 - 0.035) = 0.035 (Assume Max. Value)


h/D ratio

h/D = = 1.57 < 4

Approximate fundamental period

T = = 0.232 sec < 1 sec

=> The Vessel is considered rigid

Projected area of vessel

3798 / 2416

Ct x h3/4

Page 45




Af = Le x De = 3798 x 3382.4 = 1.285E+07 mm2 = 12.85 m

2

Velocity pressure at height z above the ground

qz = = 12.772439 psf = 611.54 N/m2

Design Wind force (Shear force)

= 5027.9145 N

Moment at the base plate

M = F x l = 6782656.7 Nmm

Max. Vertical force per lug

Q = (Wo/N) + (Fl/B) = 38101.793 N

13. Seismic Analysis (Refer to Pressure Vessel Design Manual 3rd Ed. 2004 - Dennis R. Moss, Procedure 3-8)

Neutral Axis Calculation

A = 220.0 mm

B = 364.0 mm

C = 100 mm

D = 25 mm

H = 225 mm

Distance from base to neutral axis

= 78.4 mm

where:

S1 = B x D = 9100 mm2

S2 = B x C = 36400 mm2

S3 = (A+B) x H / 2 = 65700 mm2



L : Level Arm to Neutral axis = 1349 mm

=

12

+12

+(2+ )3( + )

+ +

Page 45





a : Force arm of Vertical Load = 322 mm

b ~ Y : Force arm of Horizontal Load = 78.4 mm

Ch : Horizontal seismic factor = 0.1291 (Assumed)

Cv : Vertical seismic factor = 0.1291 (Assumed)

N : Number of lugs = 4


Horizontal force

Fh = Ch x Wo = = 18531.1 N

Horizontal shear per lug

Vertical force

Fv = (1 + Cv)Wo = = 162072.09 N

Vertical shear per lug

Max. Vertical load Q per lug

Max. moment M per lug

M = ML3 = = 16040551 Nmm

14. Support Analysis for Wind/Seismic (Refer to Pressure Vessel Design Handbook 2nd Ed. 1986 - Henry H. Bednar, Chapter 5)

Maximum Vertical force per lug in Wind Case

Fw = = 38101.793 N

Maximum Moment per lug in Wind Case

Mw = = 6782656.7 Nmm

Maximum Vertical force per lug in Seismic Case

Fs = = 48687.468 N

Maximum Moment per lug in Seismic Case

Ms = = 16040551 Nmm

Maximum Vertical force per lug in Support Lug Analysis

F = = 48687.468 N

Maximum Moment per lug in Support Lug Analysis

M = = 16040551 Nmm

0.1291 x 143541

=18531.13711

= 4632.78 N4

(1 + 0.1291) x 143541

=162072.09

= 40518.02 N4

N3060

48687.468

48687.468 x 322 + 4632.78 x 78.4

Q

M

Q3

Q = Q3 = 40518.02 +18531.1 x 1349

=

ML3

Max(Fw , Fs)

Max(Mw , Ms)

Page 45




w : = 100 mm (Client to confirm)

c : Compression Plate width = 220.0 mm

a : Base plate width = 410 mm

ta : Actual Compression Plate thickness = 18.0 mm

tb : Actual Base plate thickness = 25 mm

tg : Actual Gusset thickness = 16 mm

α : = 57 degrees

[σ] : Allowable stress of support material = 112 MPa

d : Level arm of load F = 322 mm

Sb : Allowable stress in bending for top bar material = 102 MPa (0.6 Fy)

Sa : Allowable stress in compression

h = 346.5 mm

b = 372 mm

14.1 Base plate

Bearing Pressure

q = F/(w x a) = = 1.1875 MPa

Maximum stress in base plate (Refer to Roark's Formulas, Table 11.4, Case 2a)

=> PASS

where

β : Factor from (a/w) = 0.7935

14.2 Compression Plate (Top bar Plate)

The top bar can be assumed to be a simple supported beam with uniformly distributed load.

The minimum compression plate thickness tmin is then given by

=> PASS

14.3 Gusset Plate

Allowable Compressive Stress

where

= 413.2 mm

r : Least radius of gyration of Gusset = 0.289 x tg = 4.624 mm

Maximum compressive stress

MPa < [σ] = 112 MPa

48687.468 / (100 x 410)

= 15.08

18.0 mm

= 12469 psi = 85.977 MPa

= 2.8 mm < ta =

=

=0.75×

ℎ

=18000

1 +

18000

= ℎ/sin ()

Page 45




=> PASS

where

= 29027 N

= 114.1 mm

= 312.0 mm

14.4 Size of the lug-to-shell weld

Shear

= 32.2 N/mm

where

Lw = 2 x h + 2 x a = 1513.0 mm

Bending

= 86.1 N/mm

where

Zw = a x h + h2/3 = 182086 mm2

Combined

= 91.9 N/mm

Minimum size of the weld leg

= 2.5 mm

where

f w : Allowable unit force for weld = 0.55 x [σ] x 0.6 = 36.96 MPa

14.5 Anchor Bolts (Refer to Pressure Vessel Design Handbook 2nd Ed. 1986 - Henry H. Bednar, Chapter 5, Size of Anchor Bolts)

By inspection,

=> No Uplift exists and the minimum bolt size is about 3/4 to 1 in.

where:

Mb : Overturning moment at base ~ Maximum moment M = 16040551 Nmm

Db : Bolt Diameter Circle = 3060 mm

W : Operating Weight of Vessel = 14632 kg

N : Number of Support Legs = 4

Choose Anchor Bolt Diameter M36 is satisfactory in this case.

15. Stresses in Shell by Wind/Seismic

(Refer to Pressure Vessel Design Handbook, Chapter 7-Local Stresses in Shell Due to Loads on Attachments)

: Half-length of the loaded square area = 188.45755 mm

β = c/r : Attachment parameter = 0.16

ϒ =r/t : Shell parameter = 150.5

r : Mean Shell Radius = 1204.0 mm

t : Shell thickness = 8.0 mm

Maximum bending stress

85.98 MPa

= -30643 < 0

= 18.6 MPa < Sa = =

+6

= /(2sin ())

= −

2 sin ()

= ()

= /

= /

= +

= /

= (ℎ)//2

Page 45 o




where

CLt : Bending Stress factor = 0.125

ML = Fd = 15677365 Nmm

Internal pressure Stress

σt = pr/t = 5.60 MPa

where

p : Internal pressure = 0.0372 MPa

Combined Stress

σ=σb + σt = 168 MPa < 2 x [σ] = 224 MPa

=> PASS

16. Lifting Lug Calculation

Equipment weight We = 4549 kg

Lifting Lug material SA-240 TP304 / 304L

16.1 Check for β = 90 degrees





Force

Fz = 0.5 P = 44627 N

Fx = Fz / tg β = 0 N


Ps = Fz / sin β = 44627 N

Lifting lug configuration

where :

SWL = Safe working load

Rh = Hole radius

r = Cheek plate radiusR = Main plate radius

Tp = Main plate thickness

t = Cheek plate thickness

T = Total plate thickness

h = Base width

b = Distance from edge of taper to center of hole

c = Distance from base of plate to center of hole

a = Taper angle

D = Shackle pin diameter

Fy = Yield Strength of lifting lug material

The dimension T should equal 60 - 85% of shackle jaw width.

The pin hole diameter should be 3 mm greater than the selected shackle pin size

Cheek plate radius is approximately r = R - 1.5t

The main plate radius is approximately R = 3 R h

The cheek plate thickness (t) should be less than or equal to the plate thickness (Tp).

Choose Shackle

Shackle load Ps = 44627 N = 4.549 tonne

= 162.5 MPa

Page 45




Choose Shackle with SWL = 8.5 tonne

As per Table shown above :

Shackle jaw width W = 43 mm

Shackle pin size D = 29 mm

Choose Lug Configuration

Rh = 16 mm

r = 42 mm

R = 50 mm

Tp = 25 mm

t = 6 mm

T = 37 mm

h = 174 mm

b = 210 mm

c = 122 mm

a = 71 degrees

D = 29 mm

Fy = 170 MPa


Bearing StressBearing = 41.59 MPa Bearing = Ps/(T x D)



Shear Stress




Tensile Stress


thickness at the pinhole or 0.8 times the hole diameter.






Page 45




Bending Stress

Section modulus Z = 126150 mm3 Z = h x Tp / 6








Section modulus of weld Zw = 252300 mm Zw = h x K / 3


Applied by force Fz



Combined = 22.18 MPa Combined =(S

1+ S

2)

.



Applied by force Fx



=> PASS

16.2 Check for β = 85 degrees (Considering Tolerance 5 degrees)





Force

Fz = 0.5 P = 44627 N

Fx = Fz / tg β = 3904 N


Ps = Fz / sin β = 44797 N


Bearing Stress




Shear Stress




Tensile Stress


thickness at the pinhole or 0.8 times the hole diameter.Effective width = 25.6 mm





Bending Stress

Page 4




Section modulus Z = 126150 mm3 Z = h x Tp / 6








Section modulus of weld Zw = 252300 mm Zw = h x K / 3


Applied by force Fz




+ S22)0.5

Allowable = 102 MPa Allowable = 0.6 FySafety Factor = 4.60 => PASS

Applied by force Fx




Choose Lug Configuration as shown above is satisfactory

Page 4




19. Conclusion

Shell thickness:



Bottom Head thickness:

Min. Thickness required: 8.00 mm

Top Head thickness:


Auxiliary Stiffener size: 50 x 8 mm

Main Stiffener size: T-150x8 + 70x8 mm (Refer to GA Drawing for more details)

Nozzle thickness:

Shell Nozzle N2 DN40 (1-1/2")



Flat Top Head Nozzle N1A/B, N3 DN50 (2")






Flat Top Head Nozzle N6, N10 DN100 (4")Thickness required: 6.02 mm





Cone Bottom Head Nozzle N5 DN100 (4")



Coil Half-pipe Steam Nozzle N7A/B/C & N8A/B/C DN25 (1")



Spray Nozzle N10

Outlet Connection DN50 (2")



Inlet Connection DN20 (3/4")



v 2154 101 a 214 c_mechanical calculation (v 410)

Documents

asme section

thickness of halfpipe

shell thickness calculation23

head thickness calculation34

head thickness calculation45

asme b16

design data design code

internal pressure