March 19, 2017 | Author: CADEM Softwares and Services | Category: N/A
This example covers design with calculations of a simple pressure vessel with a top flat cover and a bottom dished end. ...
CademPVD by CADEM Softwares Most value for money software for the mechanical design of process equipment Trial version available on our website www.cadem.in
Pressure Vessels Reaction Vessels Agitator Shafts Heat Exchangers Process Columns Storage Tank Floating Roof Chimney
•
ASME Sec. VIII Div. 1 TEMA EEUA IS 2825 EN 13445 API 650 API 620 IS 6533
28 years of equipment design experience captured, polished, compacted and is now ready for transfer to designers, fabricators and plant engineers
•
Intelligent, works with minimum inputs For instance, in case of say a body flange, the software automatically evaluates optimum configuration of all undefined parameters: Flange OD, Flange ID, PCD, Number and Size of bolts, Gasket OD & ID, etc. meeting the requirements of the specified equipment design code.
•
Generates final design at estimation stage, saves more than 80% of your design & estimation time
•
Earn more as you save on costing and quotation making time
•
High quality documentation with all formulae and relevant code clauses
•
Most importantly, the user need not be a hard core designer
CADEM Softwares Enhancing your business strengths and design capabilities. Website:
www.cadem.in
Email:
[email protected]
Phone:
+91 9370211312
Address:
Office No. 19, SC-1 Building, Kohinoor Estate, Wakdewadi, Pune-Mumbai Road, Pune 411003, Maharashtra, India
Follow Us: @facebook:
www.facebook.com/cademindia
OR www.cadem.in/facebook
@youtube:
www.youtube.com/cademchannel
OR www.cadem.in/youtube
@linkedin:
www.linkedin.com/company/cadem
OR www.cadem.in/linkedin
@google+:
http://plus.google.com/116314947079178385899
OR www.cadem.in/googleplus
@twitter:
www.twitter.com/cademindia
OR www.cadem.in/twitter
YOU CAN DOWNLOAD THIS DOCUMENT AND OTHERS AT www.cadem.in/links
EXAMPLE NO. PV-01 DESIGN OF PRESSURE VESSEL (GAS FILTER)
This example covers design of a simple pressure vessel. This pressure vessel has a top flat cover and a bottom dished end. The top cover is of bolted type and is connected to the shell through top body flange. The pressure vessel is provided with lugs support and lifting lug.
NOTE: 1) Link to youtube video of this design: http://www.youtube.com/watch?v=3Y0yrt1Z6fI&list=PLPL8SPZUxmmFqQZceyhr13QYDEruelJx 2) As you can see in the video, the inbuilt intelligence in the software generates all information by itself. Eg: 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 specified equipment design code. 3) In case of any changes to the interconnected shell geometry and / or design conditions (pressure / temperature) including material of constructions, these dimensions automatically regenerated by the software to meet the new requirements. 4) The software can generate cost estimation and BOM in Excel.
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date Index
/ R00 , 30-03-2015 23:35:19
Sr. No.
Description
1
Title page & equipment info
2
Design data
3
Material of constructions
4
Effective Pressures
5
Weight summary report
6
Test pressure calculations (shell side)
7
Wind load calculations
8
Seismic load calculations
9
Design of Cover (Front)
10
Design of Cover (Front)
11
Design of Shell Flng (Front)
12
Design of Shell Flng (Front)
13
Design of Main Shell
14
Design of Dished End (Rear)
15
Design of Lug Support
16
Design of Lug Support
17
Design of N 01
18
Design of N 01
19
Design of N 01
20
Design of N 02
21
Design of N 02
22
Design of N 02
23
Design of N 03
24
Design of N 03
25
Design of Lifting Lugs
26
Foundation load data
27
C.G. Data
Page No
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Customer ABC Company Ltd. Project
Soap Plant
Location
Vapi Site
Plant EQUIPMENT INFORMATION : Design Code
Refrigeration Plant
Equipment Name
Gas Filter
Equipment Type
Pressure Vessel
Equipment Class
N.A.
Equipment Category
N.A.
Reference Drawing No
---
Service
Compressed Gas Services
Support Type DESIGN & REVIEWAL :
Lug Supports
ASME VIII Div.1, 10 A11
Designed By Design Date
30-03-2015 23:35:19
Checked By Approved By Revision INSPECTION & APPROVAL : Inspection Agency
R00
Reviewed By EQUIPMENT DATA :
---
Front end
Flat End
Front end flanged
True
Rear end
Dished End
Rear end flanged
False
Shell ID
1250 mm
Shell OD
1270 mm
Length, Shell (W.L. to W.L) / Overall OTHER DATA : Fabricated weight
1650 / 2254.6 mm
Empty weight + external weights
1898.3 kgf
Estimated operating weight
1926.8 kgf
Estimated hydrotest weight
4439.8 kgf
---
1898.3 kgf
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
VESSEL DESIGN DATA (1) PROCESS DETAILS : MEDIA
DENSITY kg/m³
Operating
Process Gas
10
Design1
Process Gas
12
Hydrotest
Water
1000
Pneumatic
Process Gas
1.2
Design2 Startup Shutdown Upset
(2) PR. : kgf/mm² g
INT.
Operating
0.1
0.12
EXT. 0.01055
Design1
0.12
0.12
0.01055
Design2 Startup Shutdown Upset (3) TEST PR. : kgf/mm² g Based on Hydrotest
Input Pr
MAWP
MAP
0.156
0.156
0.169
0.132
0.143
Pneumatic 0.132 (4) TEMPERATURE : °C
MIN.
MAX.
Input
MDMT
Operating
20
-14.28
100
Design1
20
-11.75
150
21.67
-11.57
50
-11.75
50
Design2 Startup Shutdown Upset Hydrotest
Pneumatic 21.67 (5) ALLOWANCES : mm Corrosion
INT.
EXT.
3
0
Polishing 0 0 (6) RADIOGRAPHY & JOINT EFFICIENCY : RADIOGRAPHY
JOINT EFFICIENCY
Shell
Spot + T Joints
0.85
Head
Full
1.00
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date VESSEL DESIGN DATA 1. MATERIAL OF CONSTRUCTION :
/ R00 , 30-03-2015 23:35:19
Shell side Shell
SA-516 GR. 70 Plt. [UNS:K02700]
Head
SA-516 GR. 70 Plt. [UNS:K02700]
Body flange
SA-105 Frg. [UNS:K03504]
Body flange cover
SA-516 GR. 70 Plt. [UNS:K02700]
Liner 2. NOZZLE CONNECTIONS : Shell side Nozzle neck 40 & < 200
SA-106 GR. B Smls. Pipe [UNS:K03006]
Flange
SA-105 Frg. [UNS:K03504]
Cover flange
SA-105 Frg. [UNS:K03504]
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
Spiral metal wound CAF filled (S.S.)
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 3. INSULATION & CLADDING: Mat. / Density / Thk. Rockwool (Mineral Fibre) / 136.2 kg/m³ / 25 mm Mat. / Thk.
Al. sheet / 1.191 mm
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date / R00 , 30-03-2015 23:35:19 SUMMARY OF EFFECTIVE DESIGN PRESSURES IN kgf/mm² g VS TEMPERATURE IN °C Sr.
Item name
Temp.
No.
Inside pr. +ve
-ve
Liquid pr.
Effective pr. +ve
-ve
1
Cover (Front)
150
0.12
0.01055
0
0.12
0.01055
2
Shell Flng (Front)
150
0.12
0.01055
0
0.12
0.01055
3
Main Shell
150
0.12
0.01055
0
0.12
0.01055
4
Dished End (Rear)
150
0.12
0.01055
0
0.12
0.01055
5
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date ITEM WISE WEIGHT SUMMARY
/ R00 , 30-03-2015 23:35:19
Sr.No.
Item name
Item size
Empty wt
Volume
Filled wt
kgf
m³
kgf
1
Cover (Front)
Blind Flange - 1420 OD x 73.411 Thk, RF, 1363 PCD, Tgrv = 1.588
900.5
0
900.5
2
Shell Flng (Front)
Fabricated WN - 1420 OD x 1250 ID x 1363 PCD, RF, 128.692 Thk, Trgv = 1.588, G1 = 20, G0 = 10, hf = 30
312.3
0
312.3
3
Gasket Flng (Front)
1313.5 OD x 1250 ID, 4.763 Thk
0.1
0
0.1
4
Bolt Flng (Front)
Hex Head Bolt M24 x 243.128 Lg, 56 Nos.
48.76
0
48.76
5
Main Shell
1270 OD x 10 Thk, 1650 Lg
517.1
2.025
541.4
6
Dished End (Rear)
Elliptical D/2H = 2.0, 1270 OD x 10 Nom / 9 Min Thk, SF = 50
181.7
0.317
185.5
7
Gusset Plate
200 Long x 190 Wide x 16 Thk, 8 Nos.
38.51
0
38.51
8
Anchor Bolt
Anchor M20 x 200 Lg, 4 Nos.
1.99
0
1.99
9
Support Pad
270 Long x 292 Wide x 10 Thk, 4 Nos.
24.97
0
24.97
10
N 01
ANSIB36.10, 150 NPS Sch.80, 156 Lg
6.697
0.00262
6.728
11
Flange [N 01]
Weld Neck, ANSI B16.5, RF, 150# for 150 NPS Sch 80 Pipe
8.08
0
8.08
12
Gasket [N 01]
166.329 OD x 146.329 ID, 4.763 Thk
0.1
0
0.1
13
Bolt [N 01]
Hex Head Bolt M20 x 86.125 Lg, 8 Nos.
1.714
0
1.714
14
Counter Flng [N 01]
Weld Neck, ANSI B16.5, RF, 150# for 150 NPS Sch 80 Pipe
8.08
0
8.08
15
Reinf [N 01]
292.659 OD x 171.275 ID x 10 Thk
3.501
0
3.501
16
N 02
ANSIB36.10, 150 NPS Sch.80, 156 Lg
6.697
0.00262
6.728
17
Flange [N 02]
Weld Neck, ANSI B16.5, RF, 150# for 150 NPS Sch 80 Pipe
8.08
0
8.08
18
Gasket [N 02]
166.329 OD x 146.329 ID, 4.763 Thk
0.1
0
0.1
19
Bolt [N 02]
Hex Head Bolt M20 x 86.125 Lg, 8 Nos.
1.714
0
1.714
20
Counter Flng [N 02]
Weld Neck, ANSI B16.5, RF, 150# for 150 NPS Sch 80 Pipe
8.08
0
8.08
21
Reinf [N 02]
292.659 OD x 171.275 ID x 10 Thk
3.501
0
3.501
22
N 03
ANSIB36.10, 50 NPS Sch.160, 150 Lg
1.682
0.00022
1.684
23
Flange [N 03]
Weld Neck, ANSI B16.5, RF, 150# for 50 NPS Sch 160 Pipe
2.428
0
2.428
24
Gasket [N 03]
62.85 OD x 42.85 ID, 4.763 Thk
0.1
0
0.1
25
Bolt [N 03]
Hex Head Bolt M16 x 67.725 Lg, 4 Nos.
0.431
0
0.431
26
Bolted Cover [N 03]
Weld Neck, ANSI B16.5, RF, 150# for 50 160 NPS Pipe
2.522
0
2.522
120 Long x 70 Wide x 12 Thk,
27
Lifting Lugs
2 Nos.
1.596
0
1.596
28
Pad (Lifting Lugs)
70 Long x 170 Wide x 8 Thk, 2 Nos.
1.507
0
1.507
29
Insulation
4084.07 W x 3754.584 L, 25 Thk
52.2
0
52.2
30
Cladding
4087.811 W x 3754.584 L, 1.191 Thk
5.058
0
5.058
31 32 33 34 35 ∑
2149.7
∑
4439.8
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date / R00 , 30-03-2015 23:35:19 TEST PRESSURES CALCULATION AS PER UG-99 / UG-100 : Vessel Inside Design Temperature
T
150 °C
Operating Liquid Density
r
12 kg/m³
Hydrotest Liquid Density
rh
1000 kg/m³
Hydrotest Liquid Column
Lh
2254.6 mm
Pressure ( kgf/mm² g )
Sr. No.
Item Name
Pi
Pl
Pc
Pe
Stress Correction ( kgf/mm² ) Peff
Sfo
Sfa
Sfa Sfo
Pt
1
Cover (Front)
0.12
0
0
0.01055
0.12
14.06
14.06
1
0.12
2
Shell Flng (Front)
0.12
0
0
0.01055
0.12
14.06
14.06
1
0.12
3
Main Shell
0.12
0
0
0.01055
0.12
14.06
14.06
1
0.12
4
Dished End (Rear)
0.12
0
0
0.01055
0.12
14.06
14.06
1
0.12
5 Min. Pr., Pt Legend : Pi
=
Internal positive pressure
Pl
=
Pressure due to design liquid column
Pe
=
Internal vacuum pressure
Pc
=
External negative pressure
Peff
=
Pi + Pl + Pc
Sfo
=
Allowabe stress at design temperature
Sfa
=
Allowable stress at ambient temperature
Pt = MAX [ Peff + Pc, Pe ] x ( Sfa / Sfo ) Test Pressure Calculations Pressure due to hydro liquid column, [ Plh ] = Lh x rh x 1E-09 = 0.00225 kgf/mm² g Hydrotest pressure, [ Ph ] = 1.3 x Pt - Plh = 1.3 x 0.12 - 0.00225 = 0.154 kgf/mm² g Pneumatic test pressure, [ Pn ] = 1.1 x Pt = 1.1 x 0.12 = 0.132 kgf/mm² g
0.12
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
CALC. OF MIN. DESIGN METAL TEMPERATURE
Design Mode 1 , Corroded Condition
CODE Vessel Inside
ASME VIII Div.1, 10 A11
Design Pressure
Pi
0.12 kgf/mm² g
T
150 °C
Design Temperature Sr. No.
Item Name / Material / Group
Stress (kgf/mm²)
Thickness (mm)
MDMT (°C)
Smt
Sdt
tn
tg
tr
Tm
Tc
MDMT
1
Cover (Front) SA-516 GR. 70 Plt. [UNS:K02700] Curve : B
14.06
14.06
70.41
17.6
17.6
-11.98
40.56
-52.53
2
Shell Flng (Front) SA-105 Frg. [UNS:K03504] Curve : B
14.06
14.06
125.7
7
6.343
-28.89
-17.14
-11.75
3
Main Shell SA-516 GR. 70 Plt. [UNS:K02700] Curve : B
14.06
14.06
7
7
6.343
-28.89
-14.73
-14.16
4
Dished End (Rear) SA-516 GR. 70 Plt. [UNS:K02700] Curve : B
14.06
14.06
7
7
5.364
-28.89
-14.61
-14.28
5 Max, MDMT Legend : Smt =
Stress at minimum design metal temperature.
Sdt
=
Pressure due to design liquid column
tn
=
Stress at design metal temperature.
tg
=
Nominal item thickness excluding corrosion and thinning.
tr
=
Governing metal thickness for the item.
Tg
=
Required minimum thickness of the item.
Tm
=
Minimum metal temperature for the the item.
Tc
=
MDMT Correction
MDMT
=
Final MDMT for the item = Tm - Tc.
-11.75
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date EXTREME FIBRE ELONGATION CALCULATION
/ R00 , 30-03-2015 23:35:19
Item Name
Sr. No.
MOC
Rf
t
mm
mm
Eqn. No.
e
HT
%
1
Main Shell
SA-516 GR. 70 Plt. [UNS:K02700]
625
10
1
0.8
False
2
Dished End (Rear)
SA-516 GR. 70 Plt. [UNS:K02700]
1130
10
2
0.664
False
3 4 5 Legend : Rf =
Mean radius after forming
Ro
=
Infinity
t
=
Nominal thickness of the plate before forming
Eqn. 1
=
50 x t / Rf x [ 1 - Rf / Ro ]
Eqn. 2
=
75 x t / Rf x [ 1 - Rf / Ro ]
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
WIND LOAD CALCULATION CODE 1. DESIGN CONDITIONS ( Design Mode 1 , Corroded Condition ) : Basic wind speed ( Section 5.2 ) Vb
Wind [IS:875, 87]
Expected life of equipment
( Section 5.3.1 )
25 Years
Probability factor (Risk coeff)
( Section 5.3.1 )
Terrain category
K1
( Section 5.3.2 )
Structure class
( Section 5.3.3 )
Force coefficient (Shape factor) 3. CALCULATION OF FORCES AND MOMENTS:
0.902 Category 2
( Section 5.3.2.2 )
Topography factor
50 m/s
Class B K3
1.3
Cf
0.8
Equivalent diameter
De
1820 mm
Overall length of equipment
L
2254.6 mm
Height of C.G. of equipment
Hcg
1807.5 mm
K2
0.98
A
4103343.3 mm²
Vz
57.44 m/s
Pz
0.0002 kgf/mm²
Size and height factor
( Section 5.3.2 )
Effective transverse cross sectional area = De x L Effective wind speed = K1 x K2 x K3 x Vb Wind pressure = 6E-08 x Vz
2
Longitudinal force = Cf x A x Pz Support elevation
F
649.9 kgf
H
372.5 mm
M
932661.5 kgf-mm
Turning moment = F x ( Hcg - H )
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
SEISMIC LOAD CALCULATION CODE 1. DESIGN CONDITIONS ( Design Mode 1 , Corroded Condition ) : Weight of equipment Wo
Seismic [IS:1893, 02]
Importance factor
1.5
( Table-6 , 2002 )
I
1926.8 kgf
Soil profile type
Stiff Soil Profile (SD)
Foundation type
RCC footings + Tie Beams
Damping factor
5
Seismic zone
Zone III
Seismic zone factor
( Table-2 , 2002 )
Z
0.16
Response reduction factor
( Table-7 , 2002 )
R
2.9
Sa / g
2.5, Use max value
Cf
1
Ah
0.103
Spectral accelerations coeff. Damping correction factor Seismic coefficient
( Fig. 2 , 2002 ) ( Table-3 , 2002 )
( 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 ) 2. CALCULATION OF FORCES AND MOMENTS: Elevation of support
H
372.5 mm
Height of C.G. of equipment
Hcg
1807.5 mm
Vb
199.3 kgf
M
286034.2 kgf-mm
Seismic base shear force = Ah x Wo = 0.103 x 1926.8 Seismic moment of support = Vb x ( Hcg - H ) = 199.3 x ( 1807.5 - 372.5 )
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
DESIGN OF FLAT BOLTED HEAD ( INTERNAL )
Cover (Front)
CODE 1. DESIGN CONDITIONS ( Design Mode 1 , Corroded Condition ) : Design pressure P
ASME VIII Div.1, 10 A11
Design temperature
T
150 °C
Allowance
CA
3 mm
Groove allowance
Tg
0 mm
Joint efficiency 2. COVER DATA : M.O.C.
E
1
Code allw. stress @ design temp.
Sfo
14.06 kgf/mm²
Radiography
0.12 kgf/mm² g
Spot + T Joints
SA-516 GR. 70 Plt. [UNS:K02700]
Code allw. stress @ atm. temp.
Sfa
14.06 kgf/mm²
Young’s modulus
Ey
19888.4 kgf/mm²
A
1420 mm
Self reinforced
False
Flange OD Thickness provided
73.41 mm
Thickness available 3. BOLTING DATA : M.O.C.
70.41 mm SA-193 GR. B7 Bolt [UNS:G41400]
Code allw. stress @ design temp.
Sb
17.58 kgf/mm²
Code allw. stress @ atm. temp.
Sa
17.58 kgf/mm²
Bolt PCD
PCD
1363 mm
Bolt dia.
db
24 mm
No. of bolts 4. LINER DATA :
nb
56
M.O.C. Liner ID
mm
Liner OD
mm
Liner thk. 5. GASKET DATA : M.O.C.
mm Spiral metal wound CAF filled (S.S.)
Gasket seating stress
y
7.031 kgf/mm²
Gasket factor
m
3
Inside diameter
Gi
1256 mm
Outside diameter
Go
1313.5 mm
Width of gasket
N
28.75 mm
Width of gasket
( as per Table 2-5.2 )
31.75 mm
Basic gasket seating width
( as per Table 2-5.2 )
b0
14.38 mm
Effective gasket width
( as per Table 2-5.2 )
b
9.554 mm
( see Table 2-5.2 )
G
1294.4 mm
Wp
0 mm
Dia. at load reaction Pass partition gasket width Pass partition gasket length
Lp
0 mm
Effective pass partition gasket width
b'
0 mm
6. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b1) : Total joint - contact surface compression load [Hp] = 2 x ( x b x G + b' x Lp ) x m x P = 2 x ( x 9.554 x 1294.4 + 0 x 0 ) x 3 x 0.12 = 27973 kgf Total hydrostatic end force [H] = 0.25 x x G 2 x P = 0.25 x x 1294.4 2 x 0.12 = 157907.4 kgf Minimum required bolt load for operating condition [Wm1] = Hp + H
= 27973 + 157907.4 = 185880.4 kgf 7. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b2) : Minimum required bolt load for gasket seating [Wm2] = ( x b x G + b' x Lp ) x y = ( x 9.554 x 1294.4 + 0 x 0 ) x 7.031 = 273152.4 kgf 8. 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 = 15540.6 mm² Actual bolt area using root diameter [Ab] = 17513.9 mm² Flange 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 = 307837.2 kgf ( Full 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 ) = 17513.9 x 17.58 / ( 2 x x 7.031 x 1294.4 ) = 5.384 mm 10. 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 ) ] = 1294.4 x SQRT [ 1.9 x 307837.2 x 0.5 x ( 1363 - 1294.4 ) / ( 14.06 x 1 x 1294.4 3 ) ] = 33.2 mm 11. DESIGN CALCULATION AS PER UG 34, OPERATING CONDITION : Self reinforced False Factor C is user input
False
Factor C taken from fig. UG 34 or user input
0.3
Maximum factor C value Factor C (effective)
C
0.75 0.3
C = Min ( 2 x 0.3, 0.75 ) for self reinf. C = 0.3 in other cases 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 ) } = 1294.4 x SQRT { [ 0.3 x 0.12 / ( 14.06 x 1 ) ] + 1.9 x 185880.4 x 0.5 x ( 1363 - 1294.4 ) / ( 14.06 x 1 x 1294.4 3 ) } = 70.65 mm
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
DESIGN OF FLAT BOLTED HEAD ( EXTERNAL )
Cover (Front)
CODE 1. DESIGN CONDITIONS ( Design Mode 1 , Corroded Condition ) : Design pressure P
ASME VIII Div.1, 10 A11
Design temperature
T
150 °C
Allowance
CA
3 mm
Groove allowance
Tg
0 mm
Joint efficiency 2. COVER DATA : M.O.C.
E
1
Code allw. stress @ design temp.
Sfo
14.06 kgf/mm²
Radiography
0.01055 kgf/mm² g
Spot + T Joints
SA-516 GR. 70 Plt. [UNS:K02700]
Code allw. stress @ atm. temp.
Sfa
14.06 kgf/mm²
Young’s modulus
Ey
19888.4 kgf/mm²
A
1420 mm
Self reinforced
False
Flange OD Thickness provided
73.41 mm
Thickness available 3. BOLTING DATA : M.O.C.
70.41 mm SA-193 GR. B7 Bolt [UNS:G41400]
Code allw. stress @ design temp.
Sb
17.58 kgf/mm²
Code allw. stress @ atm. temp.
Sa
17.58 kgf/mm²
Bolt PCD
PCD
1363 mm
Bolt dia.
db
24 mm
No. of bolts 4. LINER DATA :
nb
56
M.O.C. Liner ID
mm
Liner OD
mm
Liner thk. 5. GASKET DATA : M.O.C.
mm Spiral metal wound CAF filled (S.S.)
Gasket seating stress
y
7.031 kgf/mm²
Gasket factor
m
3
Inside diameter
Gi
1256 mm
Outside diameter
Go
1313.5 mm
Width of gasket
N
28.75 mm
Width of gasket
( as per Table 2-5.2 )
31.75 mm
Basic gasket seating width
( as per Table 2-5.2 )
b0
14.38 mm
Effective gasket width
( as per Table 2-5.2 )
b
9.554 mm
( see Table 2-5.2 )
G
1294.4 mm
Wp
0 mm
Dia. at load reaction Pass partition gasket width Pass partition gasket length
Lp
0 mm
Effective pass partition gasket width
b'
0 mm
6. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b1) : Total joint - contact surface compression load [Hp] = 2 x ( x b x G + b' x Lp ) x m x P = 2 x ( x 9.554 x 1294.4 + 0 x 0 ) x 3 x 0.01055 = 2458.4 kgf Total hydrostatic end force [H] = 0.25 x x G 2 x P = 0.25 x x 1294.4 2 x 0.01055 = 13877.8 kgf Minimum required bolt load for operating condition [Wm1] = Hp + H
= 2458.4 + 13877.8 = 16336.3 kgf 7. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b2) : Minimum required bolt load for gasket seating [Wm2] = ( p x b x G + b' x Lp ) x y = ( p x 9.554 x 1294.4 + 0 x 0 ) x 7.031 = 273152.4 kgf 8. 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 = 15540.6 mm² Actual bolt area using root diameter [Ab] = 17513.9 mm² Flange 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 = 307837.2 kgf ( Full 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 ) = 17513.9 x 17.58 / ( 2 x p x 7.031 x 1294.4 ) = 5.384 mm 10. 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 ) ] = 1294.4 x SQRT [ 1.9 x 307837.2 x 0.5 x ( 1363 - 1294.4 ) / ( 14.06 x 1 x 1294.4 3 ) ] = 33.2 mm 11. DESIGN CALCULATION AS PER UG 34, OPERATING CONDITION : Self reinforced False Factor C is user input
False
Factor C taken from fig. UG 34 or user input
0.3
Maximum factor C value Factor C (effective)
C
0.75 0.3
C = Min ( 2 x 0.3, 0.75 ) for self reinf. C = 0.3 in other cases 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 ) } = 1294.4 x SQRT { [ 0.3 x 0.01055 / ( 14.06 x 1 ) ] + 1.9 x 16336.3 x 0.5 x ( 1363 - 1294.4 ) / ( 14.06 x 1 x 1294.4 3 ) } = 32.29 mm
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
FLANGE DESIGN ( INTERNAL )
Shell Flng (Front)
CODE 1. DESIGN CONDITIONS ( Design Mode 1 , Corroded Condition ) : Design pressure P
ASME VIII Div.1, 10 A11
Design temperature
T
150 °C
Allowance
CA
3 mm
Groove allowance 2. FLANGE DATA : M.O.C.
Tg
0 mm
Code allw. stress @ design temp.
Sfo
14.06 kgf/mm²
0.12 kgf/mm² g
SA-105 Frg. [UNS:K03504]
Code allw. stress @ atm. temp.
Sfa
14.06 kgf/mm²
Inside diameter
B
1256 mm
Outside diameter
A
1420 mm
Hub length
h
30 mm
Thickness ( hub end )
g1
17 mm
Thickness ( pipe end )
g0
7 mm
Thickness provided
128.7 mm
Thickness available 3. BOLTING DATA : M.O.C.
125.7 mm SA-193 GR. B7 Bolt [UNS:G41400]
Code allw. stress @ design temp.
Sb
17.58 kgf/mm²
Code allw. stress @ atm. temp.
Sa
17.58 kgf/mm²
Bolt PCD
C
1363 mm
Bolt dia.
db
24 mm
No. of bolts 4. LINER DATA :
nb
56
M.O.C. Liner ID
mm
Liner OD
mm
Liner thk. 5. GASKET DATA : 5a. Flange gasket data : M.O.C.
mm
Gasket type
Ring Gasket
Gasket confinement type
Unconfined
Flange face type
Raised Face
Flange gakset surface finish
Serrated (Normal)
Counter flange face type
Raised Face
Counter gakset surface finish
Serrated (Normal)
Applicalbe gasket sketch in Table 2-5.2
Type 1B
Spiral metal wound CAF filled (S.S.)
Applicable gasket column in Table 2-5.2 Gasket seating stress
( refer to Note 1, Table 2-5.1 )
Gasket factor
( from Table 2-5.1 )
Inside diameter Outside diameter
1 y
7.031 kgf/mm²
m
3
Gi
1256 mm
Go
1313.5 mm
Width of gasket
( as per Table 2-5.2 )
N
28.75 mm
Width of gasket
( as per Table 2-5.2 )
w
28.75 mm
Width of raised face or gasket contact width
31.75 mm
( as per Table 2-5.2 ) Basic gasket seating width
( as per Table 2-5.2 )
b0
14.38 mm
Effective gasket width
( as per Table 2-5.2 )
b
9.554 mm
G
1294.4 mm
Dia. at load reaction ( see Table 2-5.2 ) 5b. Partition groove gasket data (For H.E. body flange) : M.O.C.
--
Gasket seating stress
( refer to Note 1, Table 2-5.1 )
Gasket factor
( from Table 2-5.1 )
y'
0 kgf/mm²
m'
0
Pass partition gasket width
Wp
0 mm
Pass partition gasket length
Lp
0 mm
Effective pass partition gasket width b' 0 mm 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 + b' x Lp x m' ) x P = 2 x ( p x 9.554 x 1294.4 x 3 + 0 x 0 x 0 ) x 0.12 = 27973 kgf Total hydrostatic end force [H] = 0.25 x p x G ² x P = 0.25 x p x 1294.4 ² x 0.12 = 157907.4 kgf Minimum required bolt load for operating condition [Wm1a] = Hp + H = 27973 + 157907.4 = 185880.4 kgf Minimum required bolt load for operating condition [Wm1b] ( from mating flange ) = 185880.4 kgf Governing bolt load for operating condition [Wm1] = MAX [ Wm1a , Wm1b ] = MAX [ 185880.4 , 185880.4 ] = 185880.4 kgf 7. BOLT LOAD CALCULATION AS PER APPENDIX 2-5 (b2) Minimum required bolt load for gasket seating [Wm2] = ( p x b x G x y + b' x Lp x y' ) = ( p x 9.554 x 1294.4 x 7.031 + 0 x 0 x 0 ) = 273152.4 kgf 8. 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 = 15540.6 mm² Actual bolt area using root diameter [Ab] = 17513.9 mm² Flange 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 = 307837.2 kgf ( Full 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 ) = 17513.9 x 17.58 / ( 2 x p x 7.031 x 1294.4 ) = 5.384 mm 10. BOLT SPACING CORRECTION FACTOR As per Brownell & Young or IS 2825, = SQRT [ Bolt spacing / ( 2 x db + t ) ] As per TEMA or BS 5500, = SQRT [ Bolt spacing / Bmax ] ................... where, Bmax = maximum recommended bolt spacing = 2 x db + 6 x t / ( m + 0.5 ) Brownell & Young, Cf = 1 ( min. equal to 1 ) INTEGRAL FLANGE DESIGN Shell Flng (Front) 11. LOADS AND FORCES DURING OPERATING CONDITION AS PER APPENDIX 2-3 Hydrostatic end force on area inside of flange [HD] = 0.25 x p x B 2 x P = 0.25 x p x 1256 2 x 0.12 = 148679.3 kgf Gasket load (difference between flange design bolt load and total hydrostatic end force) [HG] = Wm1 - H = 185880.4 - 157907.4 = 27973 kgf Difference between total hydrostatic end force and hydrostatic end force on area inside of flange [HT] = H - HD = 157907.4 - 148679.3 = 9228.2 kgf 12. MOMENT ARMS FOR FLANGE LOADS AS PER TABLE 2-6 Radial distance from the bolt circle to intersection of hub and back of flange, as per Appendix 2-3 [R] = 0.5 x ( C - B ) - g1 = 0.5 x ( 1363 - 1256 ) - 17
= 36.5 mm Radial distance from the bolt circle to the circle on which HD acts [hD] = R + 0.5 x g1 = 36.5 + 0.5 x 17 = 45 mm Radial distance from gasket load reaction to the bolt circle [hG] = 0.5 x ( C - G ) = 0.5 x ( 1363 - 1294.4 ) = 34.3 mm Radial distance from the bolt circle to the circle on which HT acts [hT] = 0.5 x ( R + g1 + hG ) = 0.5 x ( 36.5 + 17 + 34.3 ) = 43.9 mm 13. FLANGE MOMENTS UNDER OPERATING CONDITION AS PER APPENDIX 2-6 Component of moment due to HD [MD] = HD x hD = 148679.3 x 45 = 6690566.9 kgf-mm Component of moment due to HG [MG] = HG x hG = 27973 x 34.3 = 959588.9 kgf-mm Component of moment due to HT [MT] = HT x hT = 9228.2 x 43.9 = 405136.1 kgf-mm Total moment acting on the flange for operating condition [MO] = MD + MG + MT = 6690566.9 + 959588.9 + 405136.1 = 8055291.9 kgf-mm 14. LOADS AND FORCES DURING GASKET SEATING AS PER APPENDIX 2-3 Gasket load for seating condition [HG] =W = 307837.2 kgf 15. MOMENT UNDER GASKET SEATING AS PER APPENDIX 2-6 Total moment acting on the flange for gasket seating [MO'] = W x hG = 307837.2 x 34.3 = 10560086 kgf-mm 16. SHAPE CONSTANTS A/B K 1.131 Flange factors from Fig. 2-7.1
T
1.866
Z
8.189
Y
15.84
U
17.41
e
0.00922
h0
93.77
F / h0 Factor from Fig. 2-7.2
F
0.864
Factor from Fig. 2-7.3
V
0.261
g1 / g0
2.429
h / h0 ( U / V ) x h0 x g0
0.32 2
Factor from Fig. 2-7.6 17. STRESS FORMULA FACTORS Assumed thickness [t] = 108.7 mm Factor [a] =txe+1 = 108.7 x 0.00922 + 1 = 2.002 Factor [b] = 1.333 x t x e + 1 = 1.333 x 108.7 x 0.00922 + 1 = 2.336 Factor [g] =a/T = 2.002 / 1.866 = 1.073 Factor [d] =t3/d
d
306079.1
f
2.935
= 108.7 3 / 306079.1 = 4.195 Factor [l] =g+d = 1.073 + 4.195 = 5.268 18. FLANGE STRESSES AS PER APPENDIX 2-7 & 2-8 Equivalent moment [Mmax] = MAX [ MO , MO' x Sfo / Sfa ] = MAX [ 8055291.9 , 10560086 x 14.06 / 14.06 ] = 10560086 kgf-mm Corrected equivalent moment per unit length [M] = Mmax x ( Cf / B ) = 10560086 x ( 1 / 1256 ) = 8407.7 kgf Longitudinal hub stress [SH] = f x M / ( l x g1 2 ) = 2.935 x 8407.7 / ( 5.268 x 17 2 ) = 16.21 kgf/mm² .................................... < 1.5 x Sfo Radial flange stress [SR] =bxM/(lxt2) = 2.336 x 8407.7 / ( 5.268 x 108.7 2 ) = 0.316 kgf/mm² .................................... < Sfo Tangential flange stress [ST] = ( M x Y / t 2 ) - Z x SR = ( 8407.7 x 15.84 / 108.7 2 ) - 8.189 x 0.316 = 8.69 kgf/mm² .................................... < Sfo Average stress = MAX [ 0.5 x ( SH + SR ) , 0.5 x ( SH + ST ) ] = MAX [ 0.5 x ( 16.21 + 0.316 ) , 0.5 x ( 16.21 + 8.69 ) ] = 12.45 kgf/mm² .................................... < Sfo 19. FLANGE RIGIDITY CHECKING AS PER APPENDIX 2-14 Modulus of elasticity for flange
Efo
19888.4 kgf/mm²
Rigidity factor Rigidity index [J] = 52.14 x V x Mmax / ( l x Efo x g0 2 x KI x h0 ) = 52.14 x 0.261 x 10560086 / ( 5.268 x 19888.4 x 7 = 0.996 Since J < 1.0, design is safe
KI
0.3
2
x 0.3 x 93.77 )
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
FLANGE DESIGN ( EXTERNAL )
Shell Flng (Front)
CODE 1. DESIGN CONDITIONS ( Design Mode 1 , Corroded Condition ) : Design pressure P
ASME VIII Div.1, 10 A11
Design temperature
T
150 °C
Allowance
CA
3 mm
Groove allowance 2. FLANGE DATA : M.O.C.
Tg
0 mm
Code allw. stress @ design temp.
Sfo
14.06 kgf/mm²
0.01055 kgf/mm² g
SA-105 Frg. [UNS:K03504]
Code allw. stress @ atm. temp.
Sfa
14.06 kgf/mm²
Inside diameter
B
1256 mm
Outside diameter
A
1420 mm
Hub length
h
30 mm
Thickness ( hub end )
g1
17 mm
Thickness ( pipe end )
g0
7 mm
Thickness provided
128.7 mm
Thickness available 3. BOLTING DATA : M.O.C.
125.7 mm SA-193 GR. B7 Bolt [UNS:G41400]
Code allw. stress @ design temp.
Sb
17.58 kgf/mm²
Code allw. stress @ atm. temp.
Sa
17.58 kgf/mm²
Bolt PCD
C
1363 mm
Bolt dia.
db
24 mm
No. of bolts 4. LINER DATA :
nb
56
M.O.C. Liner ID
mm
Liner OD
mm
Liner thk. 5. GASKET DATA : 5a. Flange gasket data : M.O.C.
mm
Gasket type
Ring Gasket
Gasket confinement type
Unconfined
Flange face type
Raised Face
Flange gakset surface finish
Serrated (Normal)
Counter flange face type
Raised Face
Counter gakset surface finish
Serrated (Normal)
Applicalbe gasket sketch in Table 2-5.2
Type 1B
Spiral metal wound CAF filled (S.S.)
Applicable gasket column in Table 2-5.2 Gasket seating stress
( refer to Note 1, Table 2-5.1 )
Gasket factor
( from Table 2-5.1 )
Inside diameter Outside diameter
1 y
7.031 kgf/mm²
m
3
Gi
1256 mm
Go
1313.5 mm
Width of gasket
( as per Table 2-5.2 )
N
28.75 mm
Width of gasket
( as per Table 2-5.2 )
w
28.75 mm
Width of raised face or gasket contact width
31.75 mm
( as per Table 2-5.2 ) Basic gasket seating width
( as per Table 2-5.2 )
b0
14.38 mm
Effective gasket width
( as per Table 2-5.2 )
b
9.554 mm
G
1294.4 mm
Dia. at load reaction ( see Table 2-5.2 ) 5b. Partition groove gasket data (For H.E. body flange) : M.O.C.
--
Gasket seating stress
( refer to Note 1, Table 2-5.1 )
Gasket factor
( from Table 2-5.1 )
y'
0 kgf/mm²
m'
0
Pass partition gasket width
Wp
0 mm
Pass partition gasket length
Lp
0 mm
Effective pass partition gasket width b' 0 mm 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 + b' x Lp x m' ) x P = 2 x ( p x 9.554 x 1294.4 x 3 + 0 x 0 x 0 ) x 0.01055 = 2458.4 kgf Total hydrostatic end force [H] = 0.25 x p x G ² x P = 0.25 x p x 1294.4 ² x 0.01055 = 13877.8 kgf Minimum required bolt load for operating condition [Wm1a] = Hp + H = 2458.4 + 13877.8 = 16336.3 kgf Minimum required bolt load for operating condition [Wm1b] ( from mating flange ) = 16336.3 kgf Governing bolt load for operating condition [Wm1] = MAX [ Wm1a , Wm1b ] = MAX [ 16336.3 , 16336.3 ] = 16336.3 kgf 7. BOLT LOAD CALCULATION AS PER APPENDIX 2-5 (b2) Minimum required bolt load for gasket seating [Wm2] = ( p x b x G x y + b' x Lp x y' ) = ( p x 9.554 x 1294.4 x 7.031 + 0 x 0 x 0 ) = 273152.4 kgf 8. 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 = 15540.6 mm² Actual bolt area using root diameter [Ab] = 17513.9 mm² Flange 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 = 307837.2 kgf ( Full 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 ) = 17513.9 x 17.58 / ( 2 x p x 7.031 x 1294.4 ) = 5.384 mm 10. BOLT SPACING CORRECTION FACTOR As per Brownell & Young or IS 2825, = SQRT [ Bolt spacing / ( 2 x db + t ) ] As per TEMA or BS 5500, = SQRT [ Bolt spacing / Bmax ] ................... where, Bmax = maximum recommended bolt spacing = 2 x db + 6 x t / ( m + 0.5 ) Brownell & Young, Cf = 1 ( min. equal to 1 ) INTEGRAL FLANGE DESIGN Shell Flng (Front) 11. LOADS AND FORCES DURING OPERATING CONDITION AS PER APPENDIX 2-3 Hydrostatic end force on area inside of flange [HD] = 0.25 x p x B 2 x P = 0.25 x p x 1256 2 x 0.01055 = 13066.8 kgf Difference between total hydrostatic end force and hydrostatic end force on area inside of flange [HT] = H - HD = 13877.8 - 13066.8 = 811 kgf 12. MOMENT ARMS FOR FLANGE LOADS AS PER APPENDIX TABLE 2-6 Radial distance from the bolt circle to intersection of hub and back of flange, as per Appendix 2-3 [R] = 0.5 x ( C - B ) - g1 = 0.5 x ( 1363 - 1256 ) - 17 = 36.5 mm Radial distance from the bolt circle to the circle on which HD acts [hD] = R + 0.5 x g1 = 36.5 + 0.5 x 17
= 45 mm Radial distance from gasket load reaction to the bolt circle [hG] = 0.5 x ( C - G ) = 0.5 x ( 1363 - 1294.4 ) = 34.3 mm Radial distance from the bolt circle to the circle on which HT acts [hT] = 0.5 x ( R + g1 + hG ) = 0.5 x ( 36.5 + 17 + 34.3 ) = 43.9 mm 13. FLANGE MOMENTS UNDER OPERATING CONDITION AS PER APPENDIX 2-6 Component of moment due to HD [MD] = HD x ( hD - hG ) = 13066.8 x ( 45 - 34.3 ) = 139760.9 kgf-mm Component of moment due to HT [MT] = HT x ( hT - hG ) = 811 x ( 43.9 - 34.3 ) = 7784.2 kgf-mm Total moment acting on the flange for operating condition [MO] = MD + MT = 139760.9 + 7784.2 = 147545.1 kgf-mm 14. LOADS AND FORCES DURING GASKET SEATING AS PER APPENDIX 2-3 Gasket load for seating condition [HG] =W = 307837.2 kgf 15. MOMENT UNDER GASKET SEATING AS PER APPENDIX 2-6 Total moment acting on the flange for gasket seating [MO'] = W x hG = 307837.2 x 34.3 = 10560086 kgf-mm 16. SHAPE CONSTANTS A/B K 1.131 Flange factors from Fig. 2-7.1
T
1.866
Z
8.189
Y
15.84
U
17.41
h0
93.77
F / h0
e
0.00922
Factor from Fig. 2-7.2
F
0.864
Factor from Fig. 2-7.3
V
0.261
g1 / g0
2.429
h / h0
0.32
( U / V ) x h0 x g0 2
d
306079.1
Factor from Fig. 2-7.6 17. STRESS FORMULA FACTORS Assumed thickness [t] = 108.9 mm Factor [a] =txe+1 = 108.9 x 0.00922 + 1 = 2.004 Factor [b] = 1.333 x t x e + 1 = 1.333 x 108.9 x 0.00922 + 1 = 2.338 Factor [g] =a/T = 2.004 / 1.866 = 1.074 Factor [d] =t3/d = 108.9 3 / 306079.1 = 4.217 Factor [l] =g+d = 1.074 + 4.217 = 5.29 18. FLANGE STRESSES AS PER APPENDIX 2-7 & 2-8 Equivalent moment [Mmax]
f
2.935
= MAX [ MO , MO' x Sfo / Sfa ] = MAX [ 147545.1 , 10560086 x 14.06 / 14.06 ] = 10560086 kgf-mm Corrected equivalent moment per unit length [M] = Mmax x ( Cf / B ) = 10560086 x ( 1 / 1256 ) = 8407.7 kgf Longitudinal hub stress [SH] = f x M / ( l x g1 2 ) = 2.935 x 8407.7 / ( 5.29 x 17 2 ) = 16.14 kgf/mm² .................................... < 1.5 x Sfo Radial flange stress [SR] =bxM/(lxt2) = 2.004 x 8407.7 / ( 5.29 x 108.9 2 ) = 0.313 kgf/mm² .................................... < Sfo Tangential flange stress [ST] = ( M x Y / t 2 ) - Z x SR = ( 8407.7 x 15.84 / 108.9 2 ) - 8.189 x 0.313 = 8.669 kgf/mm² .................................... < Sfo Average stress = MAX [ 0.5 x ( SH + SR ) , 0.5 x ( SH + ST ) ] = MAX [ 0.5 x ( 16.14 + 0.313 ) , 0.5 x ( 16.14 + 8.669 ) ] = 12.4 kgf/mm² .................................... < Sfo 19. FLANGE RIGIDITY CHECKING AS PER APPENDIX AS PER 2-14 Modulus of elasticity for flange
Efo
19888.4 kgf/mm²
Rigidity factor Rigidity index [J] = 52.14 x V x Mmax / ( l x Efo x g0 2 x KI x h0 ) = 52.14 x 0.261 x 10560086 / ( 5.29 x 19888.4 x 7 = 0.992 Since J < 1.0, design is safe
KI
0.3
2
x 0.3 x 93.77 )
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
DESIGN OF SHELL ( INTERNAL AND EXTERNAL PRESSURE )
Main Shell
CODE 1. DESIGN CONDITIONS ( Design Mode 1 , Corroded Condition ) Design pressure ( internal ) Pi
ASME VIII Div.1, 10 A11
Design pressure ( external )
Pe
0.01055 kgf/mm² g
Design temperature
T
150 °C
S
14.06 kgf/mm²
Material of construction Max. allowable stress at design temp.
0.12 kgf/mm² g
SA-516 GR. 70 Plt. [UNS:K02700]
Radiography
Spot + T Joints
Joint efficiency long. seam
Ec
0.85
Outside diameter
OD
1270 mm
Inside radius ( corroded )
R
628 mm
Shell length
L
1650 mm
Design length
L1
1650 mm
Nominal thickness
10 mm
Nominal thickness required as per TEMA
N.A. mm
Internal allowance, corrosion + polishing
3 mm
External allowance, corrosion + polishing
0 mm
Thickness undertolerance
0 mm
Available thickness
7 mm
2. DESIGN CALCULATION AS PER UG-27 Thickness of shell under internal pressure [ti] = Pi x R / ( S x E - 0.6 x Pi ) = 0.12 x 628 / ( 14.06 x 0.85 - 0.6 x 0.12 ) = 6.343 mm 3. DESIGN CALCULATION OF SHELL THICKNESS UNDER EXTERNAL PRESSURE AS PER UG-28 Assumed te
4.466 mm
L1 / OD
1.299
OD / te
284.4
Factor A ( Refer to Fig. G in Subpart 3 of Sec. II, Part D )
0.00021
Factor B ( CS-2 )
2.272 kgf/mm²
Allowable external pressure [Pa] = 4 x B / ( 3 x ( OD / te ) ) = 4 x 2.272 / ( 3 x 284.4 ) = 0.01065 kgf/mm² g Since Pa > Pe, design is safe Since available thickness is more than design thickness, design is safe.
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
DESIGN OF ELLIPSOIDAL HEAD ( INT. & EXT. PRESSURE )
Dished End (Rear)
CODE 1. DESIGN CONDITIONS ( Design Mode 1 , Corroded Condition ) : Design pressure ( internal ) Pi
ASME VIII Div.1, 10 A11
Design pressure ( external )
Pe
0.01055 kgf/mm² g
Design temperature
T
150 °C
S
14.06 kgf/mm²
Material of construction Max. allowable stress @ design temp.
0.12 kgf/mm² g
SA-516 GR. 70 Plt. [UNS:K02700]
Radiography
Full
Joint efficiency
E
1
Outside diameter of head
OD
1270 mm
Inside diameter of shell
ID
1256 mm
Head shape
Elliptical D/2H = 2.0
Nominal thickness
10 mm
Nominal thickness required as per TEMA
N.A mm
Internal allowance, corrosion + polishing
3 mm
External allowance, corrosion + polishing
0 mm
Thinning allowance / Under tolerance
1 mm
Available thickness 2. DESIGN CALCULATION AS PER UG 32 d / APPENDIX 1-4 ( c ) : Factor [K] =1 Thickness for internal pressure [t] = K x Pi x ID / ( 2 x S x E - 0.2 x Pi ) = 1 x 0.12 x 1256 / ( 2 x 14.06 x 1 - 0.2 x 0.12 ) = 5.364 mm 3. DESIGN CALCULATION AS PER UG 33 d : Thickness for equivalent external pressure [t] = K x 1.67 x Pe x ID / ( 2 x S x 1.0 - 0.2 x 1.67 x Pe ) = 1 x 1.67 x 0.01055 x 1256 / ( 2 x 14.06 x 1.0 - 0.2 x 1.67 x 0.01055 ) = 0.787 mm Factor [Ko] = 0.77 Assumed head thickness, [te] = 2.779 mm Factor [A] = 0.125 x te / ( Ko x OD ) = 0.125 x 2.779 / ( 0.77 x 1270 ) = 0.00036 Factor with reference to chart (CS-2) [B] = 3.743 kgf/mm² Allowable external pressure [Pa] = B / ( Ko x OD / te ) = 3.743 x 2.779 / ( 0.77 x 1270 ) = 0.01064 kgf/mm² Since Pa > Pe, design is safe Since available thickness is more than design thickness, design is safe.
6 mm
109
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
LUG SUPPORT DESIGN
Lug Support
CODE
P V Design Manual, D.R. Moss Design Mode 1 , Corroded Condition
1. LUG DATA : M.O.C
IS-2062 GR. A Plt.
No. of support
N
4
Base plate width
b1
242 mm
Base plate depth
Lb
200 mm
Thickness of base plate
tb
16 mm
Allowable bending stress 2. BOLT DATA : M.O.C
Sb
22.15 kgf/mm² Commercial CS Bolt
No. of bolt / lug
Nb
1
Bolt diameter
db
20 mm
PCD
D
1570 mm
Fs
20.88 kgf/mm²
Diameter of bolt hole
24 mm
Allowable tensile stress 3. GUSSET DATA : Thickness
tg
16 mm
Height
h
190 mm
Gusset angle
θ
51.71
Gusset depth at top
Lc
50 mm
Number of gussets
n
2
Distance between gussets 4. SHELL DATA :
b
200 mm
OD diameter
OD
1270 mm
Inside diameter
ID
1256 mm
Thickness available 5. PAD DATA :
ts
7 mm
Thickness
tp
10 mm
Width
W
270 mm
Length 6. LOAD AND MOMENT ( Wind ) :
L
292 mm
Material
SA-516 GR. 70 Plt. [UNS:K02700]
Material
SA-516 GR. 70 Plt. [UNS:K02700]
Max. overturning moment
M
940925.4 kgf-mm
Design weight of vessel 7. DESIGN OF ANCHOR BOLTS : Total uplift force on bolts [T]
Wt
2388.5 kgf
= [ 4 x M / ( D x N ) ] - Wt / N = [ 4 x 940925.4 / ( 1570 x 4 ) ] - 2388.5 / 4 = 2.203 kgf Required area of bolts [Am] = MAX [ ( T / Fs ) , 0 ] = MAX [ ( 2.203 / 20.88 ) , 0 ] = 0.106 mm² Available area of bolts [Ab] = Ar x Nb ........................................................................................ where, Ar = 217.1 mm², is root area of bolt = 217.1 x 1 = 217.1 mm² Since Ab > Am, bolts provided are sufficient 8. GUSSET DESIGN : Reaction force at each support [Q] = [ 4 x M / ( D x N ) ] + Wt / N
= [ 4 x 940925.4 / ( 1570 x 4 ) ] + 2388.5 / 4 = 1196.4 kgf Maximum axial force in gusset [P1] =Q/n = 1196.4 / 2 = 598.2 kgf Allowable compr. stress in gusset [Sg] = 1800 / [ ( 1 + 12 / 18000 ) x ( h’ / tg )
2
] ....................................... where, h’ = 242.1 mm 2
]
= 2 x P1 x ( 3 x a - Lb ) / [ Sg x Lb 2 x ( sin θ )
2
= 1800 / [ ( 1 + 12 / 18000 ) x ( 242.1 / 16 ) = 15616.8 psi = 10.98 kgf/mm² Required thickness of gusset [tg’]
]
= 2 x 598.2 x ( 3 x 150 - 200 ) / [ 10.98 x ( 200 ) 2 x ( sin 51.71 ) 2 ] = 1.106 mm 9. BASE PLATE DESIGN : Bending moment [Mb] = Q x b1 / 6 = 1196.4 x 242 / 6 = 48255.9 kgf-mm Bearing pressure [bp] = Q / ( w x b1 ) ............................................................................... where, w = 120 mm = 1196.4 / ( 120 x 242 ) = 0.0412 kgf/mm² Bending moment due to bearing pressure [Mb’] = bp x b
2
/ 10
= 0.0412 x 200 2 / 10 = 164.8 kgf-mm Required thickness of base plate between chairs [tb’] = SQRT { 6 x MAX [ Mb , Mb' ] / [ ( Lb - db ) x Sb ] } = SQRT { 6 x MAX [ 48255.9 , 164.8 ] / [ ( 200 - 20 ) x 22.15 ] } = 8.619 mm 10. CHECK FOR COMPRESSION PLATE : Equivalent radial load [f] =Qxa/h = 1196.4 x 150 / 190 = 472.3 kgf Angle between supports [b] =2xp/N =2xp/4 = 1.571 rad Internal bending moment coefficient [Kr] = 0.5 x [ 1 / a - cot ( a ) ] = 0.5 x [ 1 / 1.571 - cot ( 1.571 ) ] = 0.318 Internal bending moment [Mc] = 0.5 x Kr x f x OD = 0.5 x 0.318 x 472.3 x 1270 = 95459.3 kgf-mm Bending stress induced [fb] = Mo / Zc = 95459.3 / 7785.1 = 12.26 kgf/mm² ......................................................................... < Sb = 22.15 kgf/mm² Since, induced stress fb < allow. stress Sb in shell material, design is safe.
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
LUG SUPPORT DESIGN
Lug Support
CODE
P V Design Manual, D.R. Moss Design Mode 1 , Corroded Condition
1. LUG DATA : M.O.C
IS-2062 GR. A Plt.
No. of support
N
4
Base plate width
b1
242 mm
Base plate depth
Lb
200 mm
Thickness of base plate
tb
16 mm
Allowable bending stress 2. BOLT DATA : M.O.C
Sb
22.15 kgf/mm² Commercial CS Bolt
No. of bolt / lug
Nb
1
Bolt diameter
db
20 mm
PCD
D
1570 mm
Fs
20.88 kgf/mm²
Diameter of bolt hole
24 mm
Allowable tensile stress 3. GUSSET DATA : Thickness
tg
16 mm
Height
h
190 mm
Gusset angle
θ
51.71
Gusset depth at top
Lc
50 mm
Number of gussets
n
2
Distance between gussets 4. SHELL DATA :
b
200 mm
OD diameter
OD
1270 mm
Inside diameter
ID
1256 mm
Thickness available 5. PAD DATA :
ts
7 mm
Thickness
tp
10 mm
Width
W
270 mm
Length 6. LOAD AND MOMENT ( Seismic ) :
L
292 mm
Material
SA-516 GR. 70 Plt. [UNS:K02700]
Material
SA-516 GR. 70 Plt. [UNS:K02700]
Max. overturning moment
M
288590.5 kgf-mm
Design weight of vessel 7. DESIGN OF ANCHOR BOLTS : Total uplift force on bolts [T]
Wt
1841.2 kgf
= [ 4 x M / ( D x N ) ] - Wt / N = [ 4 x 288590.5 / ( 1570 x 4 ) ] - 1841.2 / 4 = -276.5 kgf Required area of bolts [Am] = MAX [ ( T / Fs ) , 0 ] = MAX [ ( -276.5 / 20.88 ) , 0 ] = 0 mm² Available area of bolts [Ab] = Ar x Nb ........................................................................................ where, Ar = 217.1 mm², is root area of bolt = 217.1 x 1 = 217.1 mm² Since Ab > Am, bolts provided are sufficient 8. GUSSET DESIGN : Reaction force at each support [Q] = [ 4 x M / ( D x N ) ] + Wt / N
= [ 4 x 288590.5 / ( 1570 x 4 ) ] + 1841.2 / 4 = 644.1 kgf Maximum axial force in gusset [P1] =Q/n = 644.1 / 2 = 322.1 kgf Allowable compr. stress in gusset [Sg] = 1800 / [ ( 1 + 12 / 18000 ) x ( h’ / tg )
2
] ....................................... where, h’ = 242.1 mm 2
]
= 2 x P1 x ( 3 x a - Lb ) / [ Sg x Lb 2 x ( sin θ )
2
= 1800 / [ ( 1 + 12 / 18000 ) x ( 242.1 / 16 ) = 15616.8 psi = 10.98 kgf/mm² Required thickness of gusset [tg’]
]
= 2 x 322.1 x ( 3 x 150 - 200 ) / [ 10.98 x ( 200 ) 2 x ( sin 51.71 ) 2 ] = 0.595 mm 9. BASE PLATE DESIGN : Bending moment [Mb] = Q x b1 / 6 = 644.1 x 242 / 6 = 25979.7 kgf-mm Bearing pressure [bp] = Q / ( w x b1 ) ............................................................................... where, w = 120 mm = 644.1 / ( 120 x 242 ) = 0.02218 kgf/mm² Bending moment due to bearing pressure [Mb’] = bp x b
2
/ 10
= 0.02218 x 200 = 88.72 kgf-mm
2
/ 10
Required thickness of base plate between chairs [tb’] = SQRT { 6 x MAX [ Mb , Mb' ] / [ ( Lb - db ) x Sb ] } = SQRT { 6 x MAX [ 25979.7 , 88.72 ] / [ ( 200 - 20 ) x 22.15 ] } = 6.324 mm 10. CHECK FOR COMPRESSION PLATE : Equivalent radial load [f] =Qxa/h = 644.1 x 150 / 190 = 254.3 kgf Angle between supports [b] =2xp/N =2xp/4 = 1.571 rad Internal bending moment coefficient [Kr] = 0.5 x [ 1 / a - cot ( a ) ] = 0.5 x [ 1 / 1.571 - cot ( 1.571 ) ] = 0.318 Internal bending moment [Mc] = 0.5 x Kr x f x OD = 0.5 x 0.318 x 254.3 x 1270 = 51392.7 kgf-mm Bending stress induced [fb] = Mo / Zc = 51392.7 / 7785.1 = 6.601 kgf/mm² ......................................................................... < Sb = 22.15 kgf/mm² Since, induced stress fb < allow. stress Sb in shell material, design is safe.
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
NOZZLE NECK THICKNESS AND REINFORCEMENT DESIGN
N 01
CODE
ASME VIII Div.1, 10 A11 Design Mode 1 , Corroded Condition
DESIGN CONDITIONS Design pressure ( internal )
Pi
0.12 kgf/mm² g
Design pressure ( external )
Pe
0.01055 kgf/mm² g
Design temperature NOZZLE DATA
T
150 °C SA-106 GR. B Smls. Pipe [UNS:K03006]
M.O.C. Allowable stress @ design temperature
Sn
12.02 kgf/mm²
Outside diameter
OD
168.3 mm
Inside diameter
ID
152.3 mm
Maximum chord length
D
152.3 mm
Neck thickness ( provided )
tnp
10.97 mm
Internal allowance , corrosion + polishing
CAI
3 mm
External allowance , corrosion + polishing
CAE
0
Neck thickness (tnp - CAI - CAE)
tn
7.973 mm
Max. under tolerance on thickness
Alw
1.372 mm
Available neck thickness ( tn - Alw )
ta
6.601 mm
Nozzle projection outward ( from vessel outer face )
Lo
150 mm
Total length of nozzle ( Lo + Addn for curvature)
L
156 mm
Connection type
Pipe Nozzle
Application type
Process Opening
Reinforcement calculation method
Isolated Opening
Design as large opening SHELL DATA ( Main Shell )
False
M.O.C.
SA-516 GR. 70 Plt. [UNS:K02700]
Allowable stress @ design temperature
Sv
14.06 kgf/mm²
Inside radius
R
628 mm
Thickness
t
7 mm
Min. thickness for external pressure WELD DATA
tr2
4.466 mm
Nozzle outside weld CALCULATION OF NOZZLE NECK THICKNESS AS PER UG 45 Neck 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 0.12 x 168.3 ) / ( 12.02 x 1.0 + 0.4 x 0.12 ) = 0.983 mm Neck thickness for external pressure as per UG 45(a) Neck thickness for external pressure as per UG 28 Assumed neck thickness , [trn3] = 0.512 mm L / OD = 0.891 OD / trn3 = 328.5 Factor A = 0.00025 Factor B = 2.679 kgf/mm² Allowable external pressure , [Pa] = 4 x B / ( 3 x OD / trn3 ) = 4 x 2.679 / ( 3 x 328.5 ) = 0.01088 kgf/mm² g Thickness 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 ) = 0.12 x 628 / ( 14.06 x 1.0 - 0.6 x 0.12 ) = 5.387 mm Thickness for equivalent pressure as per UG 45(b)(2) , [trn4] = Pe x R / ( Sv x E - 0.6 x Pe )
W1
7 mm
= 0.01055 x 628 / ( 14.06 x 1.0 - 0.6 x 0.01055 ) = 0.471 mm Standard wall thickness as per UG 45(b)(4) , [t3] = 7.112 mm Neck 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 = 5.387 mm .................................................................................... Process Opening Since available neck thickness, ta >= trn, selected neck thickness is adequate.
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
LOCAL STRESS ANALYSIS (EDGE OF ATTACHMENT)
N 01
CODE
D.R. MOSS (EXTRACT OF WRC 107) Design Mode 1, Corroded Condition
1. DESIGN CONDITION : Design pressure ( internal ) Design temperature 2. ATTACHMENT DATA :
Pi
0.12 kgf/mm² g
T
150 °C SA-106 GR. B Smls. Pipe [UNS:K03006]
M.O.C Outside diameter
OD
168.3 mm
Weld size
w
7 mm
Pad diameter
Dp
292.7 mm
Pad thickness
tp
10 mm
0.5 x OD 3. EXTERNAL LOADS :
C
84.14 mm
Radial force
Fr
344.6 kgf
Long. moment
ML
254724.1 kgf-mm
Circ. moment
Mc
254724.1 kgf-mm
Torsional moment
Mt
254724.1 kgf-mm
Total eff. shear load 4. SHELL DATA :
Q
487.4 kgf
Sv
14.06 kgf/mm²
M.O.C
SA-516 GR. 70 Plt. [UNS:K02700]
Allowable stress Inside radius
R
628 mm
Thickness of shell
tv
7 mm
Mean radius of shell , [ Rm ] = R + 0.5 x ( tv + tp ) = 628 + 0.5 x ( 7 + 10 ) = 636.5 mm
Thickness , [t]
Calculate ratio , [ g ] = Rm / te = 636.5 / 12.21 = 52.14
Calculate ratio , [ b ] = 0.875 x C / Rm = 0.875 x 84.14 / 636.5 = 0.116
= SQRT [ tv 2 + tp 2 ] = SQRT [ 7 2 + 10 2 ] = 12.21 mm
5. STRESS CONCENTRATION FACTORS : Factor , [ Kn ] = 1
Factor , [ Kb ] = 1
6. COMPUTING STRESSES : Shear stress due to Q , [ t1 ]
Shear stress due to Mt , [ t2 ] = Mt / ( 2 x p x Ro 2 x t ) = 254724.1 / ( 2 x p x 84.14 = 0.469 kgf/mm²
= Q / ( p x Ro x t ) = 487.4 / ( p x 84.14 x 12.21 ) = 0.151 kgf/mm²
2
x 12.21 )
Total shear stress , [ t ] = t1 + t2 = 0.151 + 0.469 = 0.62 kgf/mm² STRESSES
FACT
FIG.
FORCES( kgf ) & MOMENTS( kgf-mm )
5-17A
7.023 x Fr Rm
Nf
3.803
Kn x Nf t
σf
0.312
5-17B
8.616 x Fr Rm
Nx
4.665
Kn x Nx t
σx
0.382
5-18A
0.117 x Fr
Mf
40.25
6 x Kb x Mf t2
σf
1.621
Membrane Radial load Bending
STRESS ( kgf/mm² )
6 x Kb x Mx
5-18B
0.0707 x Fr
Mx
24.37
t
CL=1
5-19A
3.516 x CL x ML Rm 2 x b
Nf
19.11
σx
0.981
Kn x Nf t
σf
1.566
CL=1
5-19B
1.697 x CL x ML Rm 2 x b
Nx
9.222
Kn x Nx t
σx
0.756
5-20A
0.03827 x ML Rm x b
Mf
132.4
6 x Kb x Mf t2
σf
5.331
5-20B
0.06937 x ML Rm x B
Mx
240
6 x Kb x Mx t2
σx
9.665
Cc=1
5-21A
1.893 x Cc x Mc Rm 2 x b
Nf
10.29
Kn x Nf t
σf
0.843
Cc=1
5-21B
2.973 x Cc x Mc Rm 2 x b
Nx
16.16
Kn x Nx t
σx
1.324
5-22A
0.09066 x Mc Rm x b
Mf
313.7
6 x Kb x Mf t2
σf
12.63
5-22B
0.04678 x Mc Rm x b
Mx
161.9
6 x Kb x Mx t2
σx
6.518
Membrane Long. moment Bending
Membrane Circ. moment
2
Bending 7. COMBINING STRESSES :
σx
Stress due to Radial load, Fr.(1)
Membrane Bending
Nf Nx Mf Mx
σf
0°
90°
180°
270°
0.382
0.382
0.382
0.382
0.981
0.981
0.981
0.981
Nf Membrane Nx
Long. moment, ML.
+ ( 0.756 )
Mx
90° 0.312
180° 0.312
270° 0.312
1.621
1.621
1.621
1.621
+ ( 1.566 )
-( 1.566 )
+ ( 5.331 )
-( 5.331 )
-( 0.756 )
Mf Bending
0° 0.312
+ ( 9.665 )
-( 9.665 )
Nf Membrane Nx
Circ moment, Mc.
+ ( 1.324 )
Mx
+ ( 6.518 )
-( 0.843 )
+ ( 12.63 )
( 12.63 )
-( 1.324 )
Mf Bending
+ ( 0.843 )
-( 6.518 )
Pi x + Rm σf ( 10.91 ) t Int. pr., P. Pi x + + + + Rm σx ( 5.456 ) ( 5.456 ) ( 5.456 ) ( 5.456 ) 2xt Membrane 6.593 7.162 5.082 4.514 12.86 Total, ∑ Mem+Bend 17.24 14.66 -3.601 -1.023 19.74 ** Only absolute values of quantities in bracket shall be used while combining stresses ( 1 ) : Fr sign is (+) for outward load, & (-) for inward load. Allowabe Stresses for various catergories: 1. Membrane only, Sm = 1.5 x Sv 2. Membrane + Bending, Sa = 3 x Sv 3. Shear only, Sh = 0.5 x Sv DESIGN IS ACCEPTABLE ? : YES
+ ( 10.91)
+ ( 10.91 )
+ ( 10.91 )
12.14 26.32
9.728 5.946
10.45 -0.631
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
LOCAL STRESS ANALYSIS (EDGE OF PAD)
N 01
CODE
D.R. MOSS (EXTRACT OF WRC 107) Design Mode 1, Corroded Condition
1. DESIGN CONDITION : Design pressure ( internal ) Design temperature 2. ATTACHMENT DATA :
Pi
0.12 kgf/mm² g
T
150 °C SA-106 GR. B Smls. Pipe [UNS:K03006]
M.O.C Outside diameter
OD
168.3 mm
Weld size
w
7 mm
Pad diameter
Dp
292.7 mm
Pad thickness
tp
0 mm
0.5 x OD 3. EXTERNAL LOADS :
C
146.3 mm
Radial force
Fr
344.6 kgf
Long. moment
ML
254724.1 kgf-mm
Circ. moment
Mc
254724.1 kgf-mm
Torsional moment
Mt
254724.1 kgf-mm
Total eff. shear load 4. SHELL DATA :
Q
487.4 kgf
Sv
14.06 kgf/mm²
M.O.C
SA-516 GR. 70 Plt. [UNS:K02700]
Allowable stress Inside radius
R
628 mm
Thickness of shell
t
7 mm
Calculate ratio , [ g ] = Rm / t = 631.5 / 7 = 90.21
Mean radius of shell , [ Rm ] = R + 0.5 x t = 628 + 0.5 x 7 = 631.5 mm Calculate ratio , [ b ] = 0.875 x C / Rm = 0.875 x 146.3 / 631.5 = 0.203 5. STRESS CONCENTRATION FACTORS : Factor , [ Kn ] = 1
Factor , [ Kb ] = 1
6. COMPUTING STRESSES : Shear stress due to Q , [ t1 ]
Shear stress due to Mt , [ t2 ] = Mt / ( 2 x p x Ro 2 x t ) = 254724.1 / ( 2 x p x 146.3 = 0.27 kgf/mm²
= Q / ( p x Ro x t ) = 487.4 / ( p x 146.3 x 7 ) = 0.151 kgf/mm²
2
x7)
Total shear stress , [ t ] = t1 + t2 = 0.151 + 0.27 = 0.422 kgf/mm² STRESSES
FACT
FIG.
FORCES( kgf ) & MOMENTS( kgf-mm )
5-17A
4.941 x Fr Rm
Nf
2.696
Kn x Nf t
σf
0.385
5-17B
11.06 x Fr Rm
Nx
6.037
Kn x Nx t
σx
0.862
5-18A
0.04175 x Fr
Mf
14.39
6 x Kb x Mf t2
σf
1.762
Membrane Radial load Bending
STRESS ( kgf/mm² )
6 x Kb x Mx
5-18B
0.01857 x Fr
Mx
6.398
t
CL=1
5-19A
6.231 x CL x ML Rm 2 x b
Nf
19.63
σx
0.783
Kn x Nf t
σf
2.804
CL=1
5-19B
3.293 x CL x ML Rm 2 x b
Nx
10.38
Kn x Nx t
σx
1.482
5-20A
0.0128 x ML Rm x b
Mf
25.46
6 x Kb x Mf t2
σf
3.117
5-20B
0.01693 x ML Rm x B
Mx
33.68
6 x Kb x Mx t2
σx
4.124
Cc=1
5-21A
3.869 x Cc x Mc Rm 2 x b
Nf
12.19
Kn x Nf t
σf
1.741
Cc=1
5-21B
7.986 x Cc x Mc Rm 2 x b
Nx
25.16
Kn x Nx t
σx
3.594
5-22A
0.06043 x Mc Rm x b
Mf
120.2
6 x Kb x Mf t2
σf
14.72
5-22B
0.026 x Mc Rm x b
Mx
51.73
6 x Kb x Mx t2
σx
6.334
Membrane Long. moment Bending
Membrane Circ. moment
2
Bending 7. COMBINING STRESSES :
σx
Stress due to Radial load, Fr.(1)
Membrane Bending
Nf Nx Mf Mx
σf
0°
90°
180°
270°
( 0.862 )
( 0.862 )
( 0.862 )
( 0.862 )
( 0.783 )
( 0.783 )
( 0.783 )
( 0.783 )
Nf Membrane Nx
Long. moment, ML.
+ ( 1.482 )
Mx
90° ( 0.385)
180° ( 0.385 )
270° ( 0.385 )
( 1.762 )
( 1.762 )
( 1.762 )
( 1.762 )
+ ( 2.804 )
-( 2.804 )
+ ( 3.117 )
-( 3.117 )
-( 1.482 )
Mf Bending
0° ( 0.385 )
+ ( 4.124 )
-( 4.124 )
Nf Membrane Nx
Circ moment, Mc.
+ ( 3.594 )
Mx
+ ( 6.334 )
-( 1.741 )
+ ( 14.72 )
( 14.72 )
-( 3.594 )
Mf Bending
+ ( 1.741 )
-( 6.334 )
Pi x + Rm σf ( 10.83 ) t Int. pr., P. Pi x + + + + Rm σx ( 5.413 ) ( 5.413 ) ( 5.413 ) ( 5.413 ) 2xt Membrane 7.757 9.869 4.793 2.681 14.49 Total, ∑ Mem+Bend 12.67 16.99 1.452 -2.87 18.89 ** Only absolute values of quantities in bracket shall be used while combining stresses ( 1 ) : Fr sign is (+) for outward load, & (-) for inward load. Allowabe Stresses for various catergories: 1. Membrane only, Sm = 1.5 x Sv 2. Membrane + Bending, Sa = 3 x Sv 3. Shear only, Sh = 0.5 x Sv DESIGN IS ACCEPTABLE ? : YES
+ ( 10.83)
+ ( 10.83 )
+ ( 10.83 )
13.43 29.44
8.884 7.051
9.947 -3.49
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
NOZZLE NECK THICKNESS AND REINFORCEMENT DESIGN
N 02
CODE
ASME VIII Div.1, 10 A11 Design Mode 1 , Corroded Condition
DESIGN CONDITIONS Design pressure ( internal )
Pi
0.12 kgf/mm² g
Design pressure ( external )
Pe
0.01055 kgf/mm² g
Design temperature NOZZLE DATA
T
150 °C SA-106 GR. B Smls. Pipe [UNS:K03006]
M.O.C. Allowable stress @ design temperature
Sn
12.02 kgf/mm²
Outside diameter
OD
168.3 mm
Inside diameter
ID
152.3 mm
Maximum chord length
D
152.3 mm
Neck thickness ( provided )
tnp
10.97 mm
Internal allowance , corrosion + polishing
CAI
3 mm
External allowance , corrosion + polishing
CAE
0
Neck thickness (tnp - CAI - CAE)
tn
7.973 mm
Max. under tolerance on thickness
Alw
1.372 mm
Available neck thickness ( tn - Alw )
ta
6.601 mm
Nozzle projection outward ( from vessel outer face )
Lo
150 mm
Total length of nozzle ( Lo + Addn for curvature)
L
156 mm
Connection type
Pipe Nozzle
Application type
Process Opening
Reinforcement calculation method
Isolated Opening
Design as large opening SHELL DATA ( Main Shell )
False
M.O.C.
SA-516 GR. 70 Plt. [UNS:K02700]
Allowable stress @ design temperature
Sv
14.06 kgf/mm²
Inside radius
R
628 mm
Thickness
t
7 mm
Min. thickness for external pressure WELD DATA
tr2
4.466 mm
Nozzle outside weld CALCULATION OF NOZZLE NECK THICKNESS AS PER UG 45 Neck 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 0.12 x 168.3 ) / ( 12.02 x 1.0 + 0.4 x 0.12 ) = 0.983 mm Neck thickness for external pressure as per UG 45(a) Neck thickness for external pressure as per UG 28 Assumed neck thickness , [trn3] = 0.512 mm L / OD = 0.891 OD / trn3 = 328.5 Factor A = 0.00025 Factor B = 2.679 kgf/mm² Allowable external pressure , [Pa] = 4 x B / ( 3 x OD / trn3 ) = 4 x 2.679 / ( 3 x 328.5 ) = 0.01088 kgf/mm² g Thickness 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 ) = 0.12 x 628 / ( 14.06 x 1.0 - 0.6 x 0.12 ) = 5.387 mm Thickness for equivalent pressure as per UG 45(b)(2) , [trn4] = Pe x R / ( Sv x E - 0.6 x Pe )
W1
7 mm
= 0.01055 x 628 / ( 14.06 x 1.0 - 0.6 x 0.01055 ) = 0.471 mm Standard wall thickness as per UG 45(b)(4) , [t3] = 7.112 mm Neck 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 = 5.387 mm .................................................................................... Process Opening Since available neck thickness, ta >= trn, selected neck thickness is adequate.
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
LOCAL STRESS ANALYSIS (EDGE OF ATTACHMENT)
N 02
CODE
D.R. MOSS (EXTRACT OF WRC 107) Design Mode 1, Corroded Condition
1. DESIGN CONDITION : Design pressure ( internal ) Design temperature 2. ATTACHMENT DATA :
Pi
0.12 kgf/mm² g
T
150 °C SA-106 GR. B Smls. Pipe [UNS:K03006]
M.O.C Outside diameter
OD
168.3 mm
Weld size
w
7 mm
Pad diameter
Dp
292.7 mm
Pad thickness
tp
10 mm
0.5 x OD 3. EXTERNAL LOADS :
C
84.14 mm
Radial force
Fr
344.6 kgf
Long. moment
ML
254724.1 kgf-mm
Circ. moment
Mc
254724.1 kgf-mm
Torsional moment
Mt
254724.1 kgf-mm
Total eff. shear load 4. SHELL DATA :
Q
487.4 kgf
Sv
14.06 kgf/mm²
M.O.C
SA-516 GR. 70 Plt. [UNS:K02700]
Allowable stress Inside radius
R
628 mm
Thickness of shell
tv
7 mm
Mean radius of shell , [ Rm ] = R + 0.5 x ( tv + tp ) = 628 + 0.5 x ( 7 + 10 ) = 636.5 mm
Thickness , [t]
Calculate ratio , [ g ] = Rm / te = 636.5 / 12.21 = 52.14
Calculate ratio , [ b ] = 0.875 x C / Rm = 0.875 x 84.14 / 636.5 = 0.116
= SQRT [ tv 2 + tp 2 ] = SQRT [ 7 2 + 10 2 ] = 12.21 mm
5. STRESS CONCENTRATION FACTORS : Factor , [ Kn ] = 1
Factor , [ Kb ] = 1
6. COMPUTING STRESSES : Shear stress due to Q , [ t1 ]
Shear stress due to Mt , [ t2 ] = Mt / ( 2 x p x Ro 2 x t ) = 254724.1 / ( 2 x p x 84.14 = 0.469 kgf/mm²
= Q / ( p x Ro x t ) = 487.4 / ( p x 84.14 x 12.21 ) = 0.151 kgf/mm²
2
x 12.21 )
Total shear stress , [ t ] = t1 + t2 = 0.151 + 0.469 = 0.62 kgf/mm² STRESSES
FACT
FIG.
FORCES( kgf ) & MOMENTS( kgf-mm )
5-17A
7.023 x Fr Rm
Nf
3.803
Kn x Nf t
σf
0.312
5-17B
8.616 x Fr Rm
Nx
4.665
Kn x Nx t
σx
0.382
5-18A
0.117 x Fr
Mf
40.25
6 x Kb x Mf t2
σf
1.621
Membrane Radial load Bending
STRESS ( kgf/mm² )
6 x Kb x Mx
5-18B
0.0707 x Fr
Mx
24.37
t
CL=1
5-19A
3.516 x CL x ML Rm 2 x b
Nf
19.11
σx
0.981
Kn x Nf t
σf
1.566
CL=1
5-19B
1.697 x CL x ML Rm 2 x b
Nx
9.222
Kn x Nx t
σx
0.756
5-20A
0.03827 x ML Rm x b
Mf
132.4
6 x Kb x Mf t2
σf
5.331
5-20B
0.06937 x ML Rm x B
Mx
240
6 x Kb x Mx t2
σx
9.665
Cc=1
5-21A
1.893 x Cc x Mc Rm 2 x b
Nf
10.29
Kn x Nf t
σf
0.843
Cc=1
5-21B
2.973 x Cc x Mc Rm 2 x b
Nx
16.16
Kn x Nx t
σx
1.324
5-22A
0.09066 x Mc Rm x b
Mf
313.7
6 x Kb x Mf t2
σf
12.63
5-22B
0.04678 x Mc Rm x b
Mx
161.9
6 x Kb x Mx t2
σx
6.518
Membrane Long. moment Bending
Membrane Circ. moment
2
Bending 7. COMBINING STRESSES :
σx
Stress due to Radial load, Fr.(1)
Membrane Bending
Nf Nx Mf Mx
σf
0°
90°
180°
270°
0.382
0.382
0.382
0.382
0.981
0.981
0.981
0.981
Nf Membrane Nx
Long. moment, ML.
+ ( 0.756 )
Mx
90° 0.312
180° 0.312
270° 0.312
1.621
1.621
1.621
1.621
+ ( 1.566 )
-( 1.566 )
+ ( 5.331 )
-( 5.331 )
-( 0.756 )
Mf Bending
0° 0.312
+ ( 9.665 )
-( 9.665 )
Nf Membrane Nx
Circ moment, Mc.
+ ( 1.324 )
Mx
+ ( 6.518 )
-( 0.843 )
+ ( 12.63 )
( 12.63 )
-( 1.324 )
Mf Bending
+ ( 0.843 )
-( 6.518 )
Pi x + Rm σf ( 10.91 ) t Int. pr., P. Pi x + + + + Rm σx ( 5.456 ) ( 5.456 ) ( 5.456 ) ( 5.456 ) 2xt Membrane 6.593 7.162 5.082 4.514 12.86 Total, ∑ Mem+Bend 17.24 14.66 -3.601 -1.023 19.74 ** Only absolute values of quantities in bracket shall be used while combining stresses ( 1 ) : Fr sign is (+) for outward load, & (-) for inward load. Allowabe Stresses for various catergories: 1. Membrane only, Sm = 1.5 x Sv 2. Membrane + Bending, Sa = 3 x Sv 3. Shear only, Sh = 0.5 x Sv DESIGN IS ACCEPTABLE ? : YES
+ ( 10.91)
+ ( 10.91 )
+ ( 10.91 )
12.14 26.32
9.728 5.946
10.45 -0.631
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
LOCAL STRESS ANALYSIS (EDGE OF PAD)
N 02
CODE
D.R. MOSS (EXTRACT OF WRC 107) Design Mode 1, Corroded Condition
1. DESIGN CONDITION : Design pressure ( internal ) Design temperature 2. ATTACHMENT DATA :
Pi
0.12 kgf/mm² g
T
150 °C SA-106 GR. B Smls. Pipe [UNS:K03006]
M.O.C Outside diameter
OD
168.3 mm
Weld size
w
7 mm
Pad diameter
Dp
292.7 mm
Pad thickness
tp
0 mm
0.5 x OD 3. EXTERNAL LOADS :
C
146.3 mm
Radial force
Fr
344.6 kgf
Long. moment
ML
254724.1 kgf-mm
Circ. moment
Mc
254724.1 kgf-mm
Torsional moment
Mt
254724.1 kgf-mm
Total eff. shear load 4. SHELL DATA :
Q
487.4 kgf
Sv
14.06 kgf/mm²
M.O.C
SA-516 GR. 70 Plt. [UNS:K02700]
Allowable stress Inside radius
R
628 mm
Thickness of shell
t
7 mm
Calculate ratio , [ g ] = Rm / t = 631.5 / 7 = 90.21
Mean radius of shell , [ Rm ] = R + 0.5 x t = 628 + 0.5 x 7 = 631.5 mm Calculate ratio , [ b ] = 0.875 x C / Rm = 0.875 x 146.3 / 631.5 = 0.203 5. STRESS CONCENTRATION FACTORS : Factor , [ Kn ] = 1
Factor , [ Kb ] = 1
6. COMPUTING STRESSES : Shear stress due to Q , [ t1 ]
Shear stress due to Mt , [ t2 ] = Mt / ( 2 x p x Ro 2 x t ) = 254724.1 / ( 2 x p x 146.3 = 0.27 kgf/mm²
= Q / ( p x Ro x t ) = 487.4 / ( p x 146.3 x 7 ) = 0.151 kgf/mm²
2
x7)
Total shear stress , [ t ] = t1 + t2 = 0.151 + 0.27 = 0.422 kgf/mm² STRESSES
FACT
FIG.
FORCES( kgf ) & MOMENTS( kgf-mm )
5-17A
4.941 x Fr Rm
Nf
2.696
Kn x Nf t
σf
0.385
5-17B
11.06 x Fr Rm
Nx
6.037
Kn x Nx t
σx
0.862
5-18A
0.04175 x Fr
Mf
14.39
6 x Kb x Mf t2
σf
1.762
Membrane Radial load Bending
STRESS ( kgf/mm² )
6 x Kb x Mx
5-18B
0.01857 x Fr
Mx
6.398
t
CL=1
5-19A
6.231 x CL x ML Rm 2 x b
Nf
19.63
σx
0.783
Kn x Nf t
σf
2.804
CL=1
5-19B
3.293 x CL x ML Rm 2 x b
Nx
10.38
Kn x Nx t
σx
1.482
5-20A
0.0128 x ML Rm x b
Mf
25.46
6 x Kb x Mf t2
σf
3.117
5-20B
0.01693 x ML Rm x B
Mx
33.68
6 x Kb x Mx t2
σx
4.124
Cc=1
5-21A
3.869 x Cc x Mc Rm 2 x b
Nf
12.19
Kn x Nf t
σf
1.741
Cc=1
5-21B
7.986 x Cc x Mc Rm 2 x b
Nx
25.16
Kn x Nx t
σx
3.594
5-22A
0.06043 x Mc Rm x b
Mf
120.2
6 x Kb x Mf t2
σf
14.72
5-22B
0.026 x Mc Rm x b
Mx
51.73
6 x Kb x Mx t2
σx
6.334
Membrane Long. moment Bending
Membrane Circ. moment
2
Bending 7. COMBINING STRESSES :
σx
Stress due to Radial load, Fr.(1)
Membrane Bending
Nf Nx Mf Mx
σf
0°
90°
180°
270°
( 0.862 )
( 0.862 )
( 0.862 )
( 0.862 )
( 0.783 )
( 0.783 )
( 0.783 )
( 0.783 )
Nf Membrane Nx
Long. moment, ML.
+ ( 1.482 )
Mx
90° ( 0.385)
180° ( 0.385 )
270° ( 0.385 )
( 1.762 )
( 1.762 )
( 1.762 )
( 1.762 )
+ ( 2.804 )
-( 2.804 )
+ ( 3.117 )
-( 3.117 )
-( 1.482 )
Mf Bending
0° ( 0.385 )
+ ( 4.124 )
-( 4.124 )
Nf Membrane Nx
Circ moment, Mc.
+ ( 3.594 )
Mx
+ ( 6.334 )
-( 1.741 )
+ ( 14.72 )
( 14.72 )
-( 3.594 )
Mf Bending
+ ( 1.741 )
-( 6.334 )
Pi x + Rm σf ( 10.83 ) t Int. pr., P. Pi x + + + + Rm σx ( 5.413 ) ( 5.413 ) ( 5.413 ) ( 5.413 ) 2xt Membrane 7.757 9.869 4.793 2.681 14.49 Total, ∑ Mem+Bend 12.67 16.99 1.452 -2.87 18.89 ** Only absolute values of quantities in bracket shall be used while combining stresses ( 1 ) : Fr sign is (+) for outward load, & (-) for inward load. Allowabe Stresses for various catergories: 1. Membrane only, Sm = 1.5 x Sv 2. Membrane + Bending, Sa = 3 x Sv 3. Shear only, Sh = 0.5 x Sv DESIGN IS ACCEPTABLE ? : YES
+ ( 10.83)
+ ( 10.83 )
+ ( 10.83 )
13.43 29.44
8.884 7.051
9.947 -3.49
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
NOZZLE NECK THICKNESS AND REINFORCEMENT DESIGN
N 03
CODE
ASME VIII Div.1, 10 A11 Design Mode 1 , Corroded Condition
DESIGN CONDITIONS Design pressure ( internal )
Pi
0.12 kgf/mm² g
Design pressure ( external )
Pe
0.01055 kgf/mm² g
Design temperature NOZZLE DATA
T
150 °C SA-106 GR. B Smls. Pipe [UNS:K03006]
M.O.C. Allowable stress @ design temperature
Sn
12.02 kgf/mm²
Outside diameter
OD
60.33 mm
Inside diameter
ID
48.85 mm
Maximum chord length
D
48.85 mm
Neck thickness ( provided )
tnp
8.738 mm
Internal allowance , corrosion + polishing
CAI
3 mm
External allowance , corrosion + polishing
CAE
0
Neck thickness (tnp - CAI - CAE)
tn
5.738 mm
Max. under tolerance on thickness
Alw
1.092 mm
Available neck thickness ( tn - Alw )
ta
4.645 mm
Nozzle projection outward ( from vessel outer face )
Lo
150 mm
Total length of nozzle ( Lo + Addn for curvature)
L
150 mm
Connection type
Pipe Nozzle
Application type
Process Opening
Reinforcement calculation method
Isolated Opening
Design as large opening HEAD DATA ( Dished End (Rear) )
False
Allowable stress @ design temperature
Sv
14.06 kgf/mm²
Inside diameter of head @ head skirt
Dsf
1256 mm
Factor from Table UG-37
K1
0.9
Inside diameter of equivalent sphere, K1 x Dsk x 2
ID1
2260.8 mm
D / 2 H for Ellispoidal head
2
Thickness
t
7 mm
Min. thickness for external pressure WELD DATA Nozzle outside weld CALCULATION OF NOZZLE NECK THICKNESS AS PER UG 45 Thickness of head as per UG 37 Min. 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 0.12 x 2260.8 / ( 2 x 14.06 x 1.0 - 0.2 x 0.12 ) = 4.828 mm Neck 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 0.12 x 60.33 ) / ( 12.02 x 1.0 + 0.4 x 0.12 ) = 0.353 mm Neck thickness for external pressure as per UG 45(a) Neck thickness for external pressure as per UG 28 Assumed neck thickness , [trn3] = 0.279 mm L / OD = 2.487 OD / trn3 = 216.3 Factor A = 0.00016 Factor B = 1.763 kgf/mm² Allowable external pressure , [Pa] = 4 x B / ( 3 x OD / trn3 ) = 4 x 1.763 / ( 3 x 216.3 )
tr2
2.779 mm
W1
6.35 mm
= 0.01087 kgf/mm² g Thickness of head as per UG 45(b)(1) Min. head thickness reqd. as per UG 27(d) , [trn2 = tr1] = 4.828 mm Thickness 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 2260.8 / ( 2 x 14.06 x 1.0 - 0.2 x 0.01055 ) = 0.424 mm Standard wall thickness as per UG 45(b)(4) , [t3] = 3.912 mm Neck 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 = 3.423 mm .................................................................................... Process Opening Since available neck thickness, ta >= trn, selected neck thickness is adequate.
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
LOCAL STRESS ANALYSIS ( ROUND ATTACHMENT )
N 03
CODE
D.R. MOSS (EXTRACT OF WRC 107) Design Mode 1, Corroded Condition
1. DESIGN CONDITION : Design pressure ( internal ) Design temperature 2. ATTACHMENT DATA :
Pi
0.12 kgf/mm² g
T
150 °C SA-106 GR. B Smls. Pipe [UNS:K03006]
M.O.C Outside diameter
OD
60.33 mm
Weld size
w
7 mm
0.5 x OD
Ro = C
30.16 mm
3. EXTERNAL LOADS : Radial force
Fr
74.92 kgf
Latitudinal moment
ML
29967.5 kgf-mm
Meridional moment Total eff. moment, [ ML
2
+ Mc
2
]
0.5
Mc
29967.5 kgf-mm
M
42380.5 kgf-mm
Shear load
Q
106 kgf
Torsional moment 4. HEAD DATA :
Mt
29967.5 kgf-mm
Sv
14.06 kgf/mm²
M.O.C
SA-516 GR. 70 Plt. [UNS:K02700]
Allowable stress Inside radius
R
1130.4 mm
Thickness ( corroded )
t
7 mm
Mean radius of shell , [ Rm ] = R + 0.5 x t = 1130.4 + 0.5 x 7 = 1133.9 mm
Calculate factor , [ U ] = 1.82 x 30.16 / SQRT [ 1133.9 x 7 ]] = 0.616
Calculate factor , [ S ] = 1.82 x 0.5 x Dp / SQRT [ Rm x t ] = 1.82 x 0.5 x / SQRT [ 1133.9 x 7 ] = 0.616 5. STRESS CONCENTRATION FACTORS : Factor , [ Kn ] = 1
Factor , [ Kb ] = 1
6. COMPUTING STRESSES : Shear stress due to Q , [ t1 ]
Shear stress due to Mt , [ t2 ] = Mt / ( 2 x p x Ro 2 x t ) = 29967.5 / ( 2 x p x 30.16 = 0.749 kgf/mm²
= Q / ( p x Ro x t ) = 106 / ( p x 30.16 x 7 ) = 0.16 kgf/mm²
2
x7)
Total shear stress , [ t ] = t1 + t2 = 0.16 + 0.749 = 0.909 kgf/mm² STRESS
FIGURE
Bending
STRESS ( kgf/mm² )
5-25A
Nx x t Fr
0.06044
Kn x Fr t2
σx
0.09241
5-25B
Nf x t Fr
-0.179
Kn x Fr t2
σf
-0.274
5-26A
Mx Fr
0.0621
6 x Kb x Fr t2
σx
0.57
Membrane Radial load
VALUE FROM FIGURE
5-26B
Mf Fr
0.131
6 x Kb x Fr t2
σf
1.203
5-27A
Nx x t x SQRT [ Rm x t ] M
0.05621
Kn x M t 2 x SQRT [ Rm x t ]
σx
-0.546
5-27B
Nf x t x SQRT [ Rm x t ] M
-0.159
Kn x M t 2x SQRT [ Rm x t ]
σf
-1.541
5-28A
Mx x SQRT [ Rm x t ] M
0.117
6 x Kb x M t 2 x SQRT [ Rm x t ]
σx
6.794
5-28B
Mf x SQRT [ Rm x t ] M
0.43
6 x Kb x M t 2x SQRT [ Rm x t ]
σf
25.07
Membrane Moment , M Bending 7. COMBINING STRESSES :
σx
Stress due to Nx Radial load, Fr.(1)
Memberane
0° +( 0.274 )
90° +( 0.274 )
σf 180° +( 0.274 )
270° +( 0.274 )
Nf Bending
Mx
+ ( 1.203 )
+ ( 1.203 )
+ ( 1.203 )
Mf Nx Memberane
+( 1.541 )
Mx Bending Mf
+ ( 25.07 )
90°
180°
270°
+( 0.09241 )
+( 0.09241 )
+( 0.09241 )
+( 0.09241 )
+( 0.57 )
+( 0.57 )
+( 0.57 )
+( 0.57 )
+ ( 1.203 )
-( 1.541 )
Nf
Moment, M.
0°
+( 0.546 )
-( 0.546 )
+ ( 6.794 )
-( 6.794 )
( 25.07 )
Pi x + + + + + Rm σf ( 9.719 ) ( 9.719) ( 9.719 ) ( 9.719 ) ( 9.719 ) t Membrane 1.815 0.274 -1.267 0.274 0.82 Total, ∑ Mem+Bend 28.09 1.477 -25.14 1.477 8.002 ** Only absolute values of quantities in bracket shall be used while combining stresses ( 1 ) : Fr sign is (+) for outward load, & (-) for inward load. Allowabe Stresses for various catergories: 1. Membrane only, Sm = 1.5 x Sv 2. Membrane + Bending, Sa = 3 x Sv 3. Shear only, Sh = 0.5 x Sv DESIGN IS ACCEPTABLE ? : YES Int. pr., P.
+( 9.719)
+ ( 9.719 )
+ ( 9.719 )
0.274 0.662
-0.272 -6.678
0.274 0.662
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
DESIGN OF LIFTING LUG
Lifting Lugs
CODE
P V Design Manual, D.R. Moss Design Mode 1 , Uncorroded Condition
1. LIFTING LUG DATA : Material
IS-2062 GR. A Plt.
Length of lug
LL
70 mm
Width of lug
A
120 mm
Thickness of lug plate
TL
12 mm
Straight length
B1
10 mm
Radius at tip
R3
35 mm
Pin Hole diameter
D1
40 mm
Lug to vessel weld size
W1
8 mm
Min yield stress
Sy
24.61 kgf/mm²
Allowable tensile stress ( 2 / 3 x Sy )
St
16.4 kgf/mm²
Allowable bending stress ( 1.5 x St )
Sb
22.15 kgf/mm²
Allowable shear stress (0.6 x St ) 2. DESIGN LOADS : Empty weight of equipment
Ss
9.843 kgf/mm²
Wt
2149.7 kgf
Number of lifting lugs
N
2
Jirk load factor 3. CALCULATION OF REFERENCE DIMENSIONS :
j
1.5
Dimension [ L1 ] = LL - B1 - R3 = 70 - 10 - 35 = 25 mm
Dimension [ L2 ] = L1 / SIN ( q1 ) = 25 / SIN ( 0.395 ) = 65 mm
Dimension [ LT ] = LL - R3 = 70 - 35 = 35 mm
Angle [ q2 ] = ASIN ( R3 / L2 ) = ASIN ( 35 / 65 ) = 0.569 radians
Angle [ q1 ] = ATAN ( 2 x L1 / A ) = ATAN ( 2 x 25 / 120 ) = 0.395 radians
Angle [ q3 ] = q1 + q2 = 0.395 + 0.569 = 0.963 radians Dimension [ L3 ] = R3 / SIN ( q3 ) = 35 / SIN ( 0.963 ) = 42.62 mm
4. DESIGN OF LUG PLATE : Effective design load on each lug [ P ] = j x Wt / N = 1.5 x 2149.7 / 2 = 1633 kgf
Required min. thickness of lug plate for shear [ t2 ] = P / [ ( R3 - 0.5 x D1) x ss ] = 1633 / [ ( 35 - 0.5 x 40 ) x 9.843 ] = 11.06 mm
Required min. thickness of lug plate for bending [ t1 ]
Required min. thickness of lug plate for shear [ t3 ] = P / [ ( 2 x L3 - D1 ) x ss ] = 1633 / [ ( 2 x 42.62 - 40 ) x 9.843 ] = 2.2 mm
2
= 6 x P x LT / ( A x Sb ) = 6 x 1633 x 35 / ( 120 2 x 22.15 ) = 1.075 mm 5. CALCULATION OF STRESSES IN LUG PLATE WELDS : Bending stress in weld [ f1 ] = 6 x P x LT / [ 2 x LL2 ] = 6 x 1633 x 35 / ( 2 x 70 = 34.99 kgf/mm
2
)
Min. Size of lug plate weld [ w1 ] = MAX ( f1 , 2 x f2 ) / ( 0.707 x Ss ) = MAX ( 34.99 , 2 x 6.804 ) / ( 0.707 x 9.843 )
Max. shear stress in weld [ f2 ] =P/[2xA] = 1633 / ( 2 x 120 ) = 6.804 kgf/mm
= 5.028 mm
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date FOUNDATION LOAD DATA
/ R00 , 30-03-2015 23:35:19 Weight ( kgf )
Sr. No.
Mode
Condition
Wind Shear ( kgf )
Empty
Filled
Seismic
Moment ( kgf-m )
Shear
Moment
Tran.
Long.
Tran.
Long.
( kgf )
( kgfm)
1
Operating
Corroded
1898.3
1922.1
649.9
649.9
940.9
940.9
198.8
285.7
2
Design1
Corroded
1898.3
1926.8
649.9
649.9
940.9
940.9
199.3
286
3
Hydro
Corroded
1841.1
4212.7
649.9
649.9
940.9
940.9
435.8
436.7
4
Pneumatic
Corroded
1841.1
1843.9
649.9
649.9
940.9
940.9
190.8
275.9
5
Operating
Uncorroded
2149.7
2173.2
649.9
649.9
882.1
882.1
224.8
303.3
6
Design1
Uncorroded
2149.7
2177.9
649.9
649.9
882.1
882.1
225.3
303.6
7
Hydro
Uncorroded
2092.5
4439.8
649.9
649.9
882.1
882.1
459.3
454.2
8
Pneumatic
Uncorroded
2092.5
2095.3
649.9
649.9
882.1
882.1
216.8
294
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date CENTER OF GRAVITY DATA
/ R00 , 30-03-2015 23:35:19
Sr. No.
Mode
Condition
Empty Wt ( kgf )
C.G. ( mm )
Operating / Filled Wt ( kgf )
C.G. ( mm )
1
Operating
Corroded
1898.3
1820.2
1922.1
1809.6
2
Design1
Corroded
1898.3
1820.2
1926.8
1807.5
3
Hydro
Corroded
1841.1
1820.2
4212.7
1374.5
4
Pneumatic
Corroded
1841.1
1820.2
1843.9
1818.9
5
Operating
Uncorroded
2149.7
1729.8
2173.2
1721.7
6
Design1
Uncorroded
2149.7
1729.8
2177.9
1720.1
7
Hydro
Uncorroded
2092.5
1729.8
4439.8
1361.3
8
Pneumatic
Uncorroded
2092.5
1729.8
2095.3
1728.8
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date Index
/ R00 , 30-03-2015 23:35:19
Sr. No.
Description
1
Title page & equipment info
2
Design data
3
Material of constructions
4
Effective Pressures
5
Weight summary report
6
Test pressure calculations (shell side)
7
Wind load calculations
8
Seismic load calculations
9
Design of Cover (Front)
10
Design of Shell Flng (Front)
11
Design of Main Shell
12
Design of Dished End (Rear)
13
Design of Lug Support
14
Design of Lug Support
15
Design of N 01
16
Design of N 01
17
Design of N 01
18
Design of N 02
19
Design of N 02
20
Design of N 02
21
Design of N 03
22
Design of N 03
23
Design of Lifting Lugs
24
Foundation load data
25
C.G. Data
Page No
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Customer ABC Company Ltd. Project
Soap Plant
Location
Vapi Site
Plant EQUIPMENT INFORMATION : Design Code
Refrigeration Plant
Equipment Name
Gas Filter
Equipment Type
Pressure Vessel
Equipment Class
N.A.
Equipment Category
N.A.
Reference Drawing No
---
Service
Compressed Gas Services
Support Type DESIGN & REVIEWAL :
Lug Supports
ASME VIII Div.1, 10 A11
Designed By Design Date
30-03-2015 23:35:19
Checked By Approved By Revision INSPECTION & APPROVAL : Inspection Agency
R00
Reviewed By EQUIPMENT DATA :
---
Front end
Flat End
Front end flanged
True
Rear end
Dished End
Rear end flanged
False
Shell ID
1250 mm
Shell OD
1270 mm
Length, Shell (W.L. to W.L) / Overall OTHER DATA : Fabricated weight
1650 / 2254.6 mm
Empty weight + external weights
1841.1 kgf
Estimated operating weight
4212.7 kgf
Estimated hydrotest weight
4439.8 kgf
---
1841.1 kgf
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
VESSEL DESIGN DATA (1) PROCESS DETAILS : MEDIA
DENSITY kg/m³
Operating
Process Gas
10
Design1
Process Gas
12
Hydrotest
Water
1000
Pneumatic
Process Gas
1.2
Design2 Startup Shutdown Upset
(2) PR. : kgf/mm² g
INT.
Operating
0.1
0.12
EXT. 0.01055
Design1
0.12
0.12
0.01055
Design2 Startup Shutdown Upset (3) TEST PR. : kgf/mm² g Based on Hydrotest
Input Pr
MAWP
MAP
0.156
0.156
0.169
0.132
0.143
Pneumatic 0.132 (4) TEMPERATURE : °C
MIN.
MAX.
Input
MDMT
Operating
20
-14.28
100
Design1
20
-11.75
150
21.67
-11.57
50
-11.75
50
Design2 Startup Shutdown Upset Hydrotest
Pneumatic 21.67 (5) ALLOWANCES : mm Corrosion
INT.
EXT.
3
0
Polishing 0 0 (6) RADIOGRAPHY & JOINT EFFICIENCY : RADIOGRAPHY
JOINT EFFICIENCY
Shell
Spot + T Joints
0.85
Head
Full
1.00
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date VESSEL DESIGN DATA 1. MATERIAL OF CONSTRUCTION :
/ R00 , 30-03-2015 23:35:19
Shell side Shell
SA-516 GR. 70 Plt. [UNS:K02700]
Head
SA-516 GR. 70 Plt. [UNS:K02700]
Body flange
SA-105 Frg. [UNS:K03504]
Body flange cover
SA-516 GR. 70 Plt. [UNS:K02700]
Liner 2. NOZZLE CONNECTIONS : Shell side Nozzle neck 40 & < 200
SA-106 GR. B Smls. Pipe [UNS:K03006]
Flange
SA-105 Frg. [UNS:K03504]
Cover flange
SA-105 Frg. [UNS:K03504]
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
Spiral metal wound CAF filled (S.S.)
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 3. INSULATION & CLADDING: Mat. / Density / Thk. Rockwool (Mineral Fibre) / 136.2 kg/m³ / 25 mm Mat. / Thk.
Al. sheet / 1.191 mm
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date / R00 , 30-03-2015 23:35:19 SUMMARY OF EFFECTIVE DESIGN PRESSURES IN kgf/mm² g VS TEMPERATURE IN °C Sr.
Item name
Temp.
No.
Inside pr. +ve
-ve
Liquid pr.
Effective pr. +ve
-ve
1
Cover (Front)
50
0.12
0
0.00007
0.12
0
2
Shell Flng (Front)
50
0.12
0
0.00023
0.12
0
3
Main Shell
50
0.12
0
0.00188
0.122
0
4
Dished End (Rear)
50
0.12
0
0.00225
0.122
0
5
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date ITEM WISE WEIGHT SUMMARY
/ R00 , 30-03-2015 23:35:19
Sr.No.
Item name
Item size
Empty wt
Volume
Filled wt
kgf
m³
kgf
1
Cover (Front)
Blind Flange - 1420 OD x 73.411 Thk, RF, 1363 PCD, Tgrv = 1.588
900.5
0
900.5
2
Shell Flng (Front)
Fabricated WN - 1420 OD x 1250 ID x 1363 PCD, RF, 128.692 Thk, Trgv = 1.588, G1 = 20, G0 = 10, hf = 30
312.3
0
312.3
3
Gasket Flng (Front)
1313.5 OD x 1250 ID, 4.763 Thk
0.1
0
0.1
4
Bolt Flng (Front)
Hex Head Bolt M24 x 243.128 Lg, 56 Nos.
48.76
0
48.76
5
Main Shell
1270 OD x 10 Thk, 1650 Lg
517.1
2.025
2541.9
6
Dished End (Rear)
Elliptical D/2H = 2.0, 1270 OD x 10 Nom / 9 Min Thk, SF = 50
181.7
0.317
498.7
7
Gusset Plate
200 Long x 190 Wide x 16 Thk, 8 Nos.
38.51
0
38.51
8
Anchor Bolt
Anchor M20 x 200 Lg, 4 Nos.
1.99
0
1.99
9
Support Pad
270 Long x 292 Wide x 10 Thk, 4 Nos.
24.97
0
24.97
10
N 01
ANSIB36.10, 150 NPS Sch.80, 156 Lg
6.697
0.00262
9.32
11
Flange [N 01]
Weld Neck, ANSI B16.5, RF, 150# for 150 NPS Sch 80 Pipe
8.08
0
8.08
12
Gasket [N 01]
166.329 OD x 146.329 ID, 4.763 Thk
0.1
0
0.1
13
Bolt [N 01]
Hex Head Bolt M20 x 86.125 Lg, 8 Nos.
1.714
0
1.714
14
Counter Flng [N 01]
Weld Neck, ANSI B16.5, RF, 150# for 150 NPS Sch 80 Pipe
8.08
0
8.08
15
Reinf [N 01]
292.659 OD x 171.275 ID x 10 Thk
3.501
0
3.501
16
N 02
ANSIB36.10, 150 NPS Sch.80, 156 Lg
6.697
0.00262
9.32
17
Flange [N 02]
Weld Neck, ANSI B16.5, RF, 150# for 150 NPS Sch 80 Pipe
8.08
0
8.08
18
Gasket [N 02]
166.329 OD x 146.329 ID, 4.763 Thk
0.1
0
0.1
19
Bolt [N 02]
Hex Head Bolt M20 x 86.125 Lg, 8 Nos.
1.714
0
1.714
20
Counter Flng [N 02]
Weld Neck, ANSI B16.5, RF, 150# for 150 NPS Sch 80 Pipe
8.08
0
8.08
21
Reinf [N 02]
292.659 OD x 171.275 ID x 10 Thk
3.501
0
3.501
22
N 03
ANSIB36.10, 50 NPS Sch.160, 150 Lg
1.682
0.00022
1.898
23
Flange [N 03]
Weld Neck, ANSI B16.5, RF, 150# for 50 NPS Sch 160 Pipe
2.428
0
2.428
24
Gasket [N 03]
62.85 OD x 42.85 ID, 4.763 Thk
0.1
0
0.1
25
Bolt [N 03]
Hex Head Bolt M16 x 67.725 Lg, 4 Nos.
0.431
0
0.431
26
Bolted Cover [N 03]
Weld Neck, ANSI B16.5, RF, 150# for 50 160 NPS Pipe
2.522
0
2.522
120 Long x 70 Wide x 12 Thk,
27
Lifting Lugs
2 Nos.
1.596
0
1.596
28
Pad (Lifting Lugs)
70 Long x 170 Wide x 8 Thk, 2 Nos.
1.507
0
1.507
29 30 31 32 33 34 35 ∑
2092.5
∑
4439.8
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date / R00 , 30-03-2015 23:35:19 TEST PRESSURES CALCULATION AS PER UG-99 / UG-100 : Vessel Inside Design Temperature
T
50 °C
Operating Liquid Density
1000 kg/m³
Hydrotest Liquid Density
h
1000 kg/m³
Hydrotest Liquid Column
Lh
2254.6 mm
Pressure ( kgf/mm² g )
Sr. No.
Item Name
Pi
Pl
Stress Correction ( kgf/mm² )
Pc
Pe
Peff
Sfo
Sfa
Sfa Sfo
Pt
1
Cover (Front)
0.12
0.00007
0
0
0.12
14.06
14.06
1
2
Shell Flng (Front)
0.12
0.00023
0
0
0.12
14.06
14.06
1
0.12 0.12
3
Main Shell
0.12
0.00188
0
0
0.122
14.06
14.06
1
0.122
4
Dished End (Rear)
0.12
0.00225
0
0
0.122
14.06
14.06
1
0.122
5 Min. Pr., Pt Legend : Pi
=
Internal positive pressure
Pl
=
Pressure due to design liquid column
Pe
=
Internal vacuum pressure
Pc
=
External negative pressure
Peff
=
Pi + Pl + Pc
Sfo
=
Allowabe stress at design temperature
Sfa
=
Allowable stress at ambient temperature
Pt = MAX [ Peff + Pc, Pe ] x ( Sfa / Sfo ) Test Pressure Calculations Pressure due to hydro liquid column, [ Plh ] = Lh x h x 1E-09 = 0.00225 kgf/mm² g Hydrotest pressure, [ Ph ] = 1.3 x Pt - Plh = 1.3 x 0.122 - 0.00225 = 0.157 kgf/mm² g Pneumatic test pressure, [ Pn ] = 1.1 x Pt = 1.1 x 0.122 = 0.134 kgf/mm² g
0.122
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
CALC. OF MIN. DESIGN METAL TEMPERATURE
Hydrotest Mode , Corroded Condition
CODE Vessel Inside
ASME VIII Div.1, 10 A11
Design Pressure
Pi
0.12 kgf/mm² g
T
50 °C
Design Temperature Sr. No.
Item Name / Material / Group
Stress (kgf/mm²)
Thickness (mm)
MDMT (°C)
Smt
Sdt
tn
tg
tr
Tm
Tc
MDMT
1
Cover (Front) SA-516 GR. 70 Plt. [UNS:K02700] Curve : B
14.06
14.06
70.41
17.6
17.6
-11.98
40.56
-52.53
2
Shell Flng (Front) SA-105 Frg. [UNS:K03504] Curve : B
14.06
14.06
125.7
7
6.443
-28.89
-17.32
-11.57
3
Main Shell SA-516 GR. 70 Plt. [UNS:K02700] Curve : B
14.06
14.06
7
7
6.443
-28.89
-15.08
-13.81
4
Dished End (Rear) SA-516 GR. 70 Plt. [UNS:K02700] Curve : B
14.06
14.06
7
7
5.465
-28.89
-15.04
-13.85
5 Max, MDMT Legend : Smt =
Stress at minimum design metal temperature.
Sdt
=
Pressure due to design liquid column
tn
=
Stress at design metal temperature.
tg
=
Nominal item thickness excluding corrosion and thinning.
tr
=
Governing metal thickness for the item.
Tg
=
Required minimum thickness of the item.
Tm
=
Minimum metal temperature for the the item.
Tc
=
MDMT Correction
MDMT
=
Final MDMT for the item = Tm - Tc.
-11.57
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
WIND LOAD CALCULATION CODE 1. DESIGN CONDITIONS ( Hydrotest Mode , Corroded Condition ) : Basic wind speed ( Section 5.2 ) Vb
Wind [IS:875, 87]
Expected life of equipment
( Section 5.3.1 )
25 Years
Probability factor (Risk coeff)
( Section 5.3.1 )
Terrain category
K1
( Section 5.3.2 )
Structure class
( Section 5.3.3 )
Force coefficient (Shape factor) 3. CALCULATION OF FORCES AND MOMENTS:
0.902 Category 2
( Section 5.3.2.2 )
Topography factor
50 m/s
Class B K3
1.3
Cf
0.8
Equivalent diameter
De
1820 mm
Overall length of equipment
L
2254.6 mm
Height of C.G. of equipment
Hcg
1374.5 mm
K2
0.98
A
4103343.3 mm²
Vz
57.44 m/s
Pz
0.0002 kgf/mm²
Size and height factor
( Section 5.3.2 )
Effective transverse cross sectional area = De x L Effective wind speed = K1 x K2 x K3 x Vb Wind pressure = 6E-08 x Vz
2
Longitudinal force = Cf x A x Pz Support elevation
F
649.9 kgf
H
372.5 mm
M
651245.2 kgf-mm
Turning moment = F x ( Hcg - H )
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
SEISMIC LOAD CALCULATION CODE 1. DESIGN CONDITIONS ( Hydrotest Mode , Corroded Condition ) : Weight of equipment Wo
Seismic [IS:1893, 02]
Importance factor
1.5
( Table-6 , 2002 )
I
4212.7 kgf
Soil profile type
Stiff Soil Profile (SD)
Foundation type
RCC footings + Tie Beams
Damping factor
5
Seismic zone
Zone III
Seismic zone factor
( Table-2 , 2002 )
Z
0.16
Response reduction factor
( Table-7 , 2002 )
R
2.9
Sa / g
2.5, Use max value
Cf
1
Ah
0.103
Spectral accelerations coeff. Damping correction factor Seismic coefficient
( Fig. 2 , 2002 ) ( Table-3 , 2002 )
( 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 ) 2. CALCULATION OF FORCES AND MOMENTS: Elevation of support
H
372.5 mm
Height of C.G. of equipment
Hcg
1374.5 mm
Vb
435.8 kgf
M
436679.3 kgf-mm
Seismic base shear force = Ah x Wo = 0.103 x 4212.7 Seismic moment of support = Vb x ( Hcg - H ) = 435.8 x ( 1374.5 - 372.5 )
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
DESIGN OF FLAT BOLTED HEAD ( INTERNAL )
Cover (Front)
CODE 1. DESIGN CONDITIONS ( Hydrotest Mode , Corroded Condition ) : Design pressure P
ASME VIII Div.1, 10 A11
Design temperature
T
50 °C
Allowance
CA
3 mm
Groove allowance
Tg
0 mm
Joint efficiency 2. COVER DATA : M.O.C.
E
1
Code allw. stress @ design temp.
Sfo
14.06 kgf/mm²
Radiography
0.12 kgf/mm² g
Spot + T Joints
SA-516 GR. 70 Plt. [UNS:K02700]
Code allw. stress @ atm. temp.
Sfa
14.06 kgf/mm²
Young’s modulus
Ey
20543.7 kgf/mm²
A
1420 mm
Self reinforced
False
Flange OD Thickness provided
73.41 mm
Thickness available 3. BOLTING DATA : M.O.C.
70.41 mm SA-193 GR. B7 Bolt [UNS:G41400]
Code allw. stress @ design temp.
Sb
26.37 kgf/mm²
Code allw. stress @ atm. temp.
Sa
26.37 kgf/mm²
Bolt PCD
PCD
1363 mm
Bolt dia.
db
24 mm
No. of bolts 4. LINER DATA :
nb
56
M.O.C. Liner ID
mm
Liner OD
mm
Liner thk. 5. GASKET DATA : M.O.C.
mm Spiral metal wound CAF filled (S.S.)
Gasket seating stress
y
7.031 kgf/mm²
Gasket factor
m
3
Inside diameter
Gi
1256 mm
Outside diameter
Go
1313.5 mm
Width of gasket
N
28.75 mm
Width of gasket
( as per Table 2-5.2 )
31.75 mm
Basic gasket seating width
( as per Table 2-5.2 )
b0
14.38 mm
Effective gasket width
( as per Table 2-5.2 )
b
9.554 mm
( see Table 2-5.2 )
G
1294.4 mm
Wp
0 mm
Dia. at load reaction Pass partition gasket width Pass partition gasket length
Lp
0 mm
Effective pass partition gasket width
b'
0 mm
6. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b1) : Total joint - contact surface compression load [Hp] = 2 x ( x b x G + b' x Lp ) x m x P = 2 x ( x 9.554 x 1294.4 + 0 x 0 ) x 3 x 0.12 = 28027.1 kgf Total hydrostatic end force [H] = 0.25 x x G 2 x P = 0.25 x x 1294.4 2 x 0.12 = 158212.8 kgf Minimum required bolt load for operating condition [Wm1] = Hp + H
= 28027.1 + 158212.8 = 186239.9 kgf 7. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b2) : Minimum required bolt load for gasket seating [Wm2] = ( x b x G + b' x Lp ) x y = ( x 9.554 x 1294.4 + 0 x 0 ) x 7.031 = 273152.4 kgf 8. 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 = 10360.4 mm² Actual bolt area using root diameter [Ab] = 17513.9 mm² Flange 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 = 461755.8 kgf ( Full 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 ) = 17513.9 x 26.37 / ( 2 x x 7.031 x 1294.4 ) = 8.075 mm 10. 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 ) ] = 1294.4 x SQRT [ 1.9 x 461755.8 x 0.5 x ( 1363 - 1294.4 ) / ( 14.06 x 1 x 1294.4 3 ) ] = 40.66 mm 11. DESIGN CALCULATION AS PER UG 34, OPERATING CONDITION : Self reinforced False Factor C is user input
False
Factor C taken from fig. UG 34 or user input
0.3
Maximum factor C value Factor C (effective)
C
0.75 0.3
C = Min ( 2 x 0.3, 0.75 ) for self reinf. C = 0.3 in other cases 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 ) } = 1294.4 x SQRT { [ 0.3 x 0.12 / ( 14.06 x 1 ) ] + 1.9 x 186239.9 x 0.5 x ( 1363 - 1294.4 ) / ( 14.06 x 1 x 1294.4 3 ) } = 70.67 mm
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
FLANGE DESIGN ( INTERNAL )
Shell Flng (Front)
CODE 1. DESIGN CONDITIONS ( Hydrotest Mode , Corroded Condition ) : Design pressure P
ASME VIII Div.1, 10 A11
Design temperature
T
50 °C
Allowance
CA
3 mm
Groove allowance 2. FLANGE DATA : M.O.C.
Tg
0 mm
Code allw. stress @ design temp.
Sfo
14.06 kgf/mm²
0.12 kgf/mm² g
SA-105 Frg. [UNS:K03504]
Code allw. stress @ atm. temp.
Sfa
14.06 kgf/mm²
Inside diameter
B
1256 mm
Outside diameter
A
1420 mm
Hub length
h
30 mm
Thickness ( hub end )
g1
17 mm
Thickness ( pipe end )
g0
7 mm
Thickness provided
128.7 mm
Thickness available 3. BOLTING DATA : M.O.C.
125.7 mm SA-193 GR. B7 Bolt [UNS:G41400]
Code allw. stress @ design temp.
Sb
26.37 kgf/mm²
Code allw. stress @ atm. temp.
Sa
26.37 kgf/mm²
Bolt PCD
C
1363 mm
Bolt dia.
db
24 mm
No. of bolts 4. LINER DATA :
nb
56
M.O.C. Liner ID
mm
Liner OD
mm
Liner thk. 5. GASKET DATA : 5a. Flange gasket data : M.O.C.
mm
Gasket type
Ring Gasket
Gasket confinement type
Unconfined
Flange face type
Raised Face
Flange gakset surface finish
Serrated (Normal)
Counter flange face type
Raised Face
Counter gakset surface finish
Serrated (Normal)
Applicalbe gasket sketch in Table 2-5.2
Type 1B
Spiral metal wound CAF filled (S.S.)
Applicable gasket column in Table 2-5.2 Gasket seating stress
( refer to Note 1, Table 2-5.1 )
Gasket factor
( from Table 2-5.1 )
Inside diameter Outside diameter
1 y
7.031 kgf/mm²
m
3
Gi
1256 mm
Go
1313.5 mm
Width of gasket
( as per Table 2-5.2 )
N
28.75 mm
Width of gasket
( as per Table 2-5.2 )
w
28.75 mm
Width of raised face or gasket contact width
31.75 mm
( as per Table 2-5.2 ) Basic gasket seating width
( as per Table 2-5.2 )
b0
14.38 mm
Effective gasket width
( as per Table 2-5.2 )
b
9.554 mm
G
1294.4 mm
Dia. at load reaction ( see Table 2-5.2 ) 5b. Partition groove gasket data (For H.E. body flange) : M.O.C.
--
Gasket seating stress
( refer to Note 1, Table 2-5.1 )
Gasket factor
( from Table 2-5.1 )
y'
0 kgf/mm²
m'
0
Pass partition gasket width
Wp
0 mm
Pass partition gasket length
Lp
0 mm
Effective pass partition gasket width b' 0 mm 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 + b' x Lp x m' ) x P = 2 x ( x 9.554 x 1294.4 x 3 + 0 x 0 x 0 ) x 0.12 = 28027.1 kgf Total hydrostatic end force [H] = 0.25 x x G ² x P = 0.25 x x 1294.4 ² x 0.12 = 158212.8 kgf Minimum required bolt load for operating condition [Wm1a] = Hp + H = 28027.1 + 158212.8 = 186239.9 kgf Minimum required bolt load for operating condition [Wm1b] ( from mating flange ) = 186239.9 kgf Governing bolt load for operating condition [Wm1] = MAX [ Wm1a , Wm1b ] = MAX [ 186239.9 , 186239.9 ] = 186239.9 kgf 7. BOLT LOAD CALCULATION AS PER APPENDIX 2-5 (b2) Minimum required bolt load for gasket seating [Wm2] = ( x b x G x y + b' x Lp x y' ) = ( x 9.554 x 1294.4 x 7.031 + 0 x 0 x 0 ) = 273152.4 kgf 8. 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 = 10360.4 mm² Actual bolt area using root diameter [Ab] = 17513.9 mm² Flange 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 = 461755.8 kgf ( Full 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 ) = 17513.9 x 26.37 / ( 2 x x 7.031 x 1294.4 ) = 8.075 mm 10. BOLT SPACING CORRECTION FACTOR As per Brownell & Young or IS 2825, = SQRT [ Bolt spacing / ( 2 x db + t ) ] As per TEMA or BS 5500, = SQRT [ Bolt spacing / Bmax ] ................... where, Bmax = maximum recommended bolt spacing = 2 x db + 6 x t / ( m + 0.5 ) Brownell & Young, Cf = 1 ( min. equal to 1 ) INTEGRAL FLANGE DESIGN Shell Flng (Front) 11. LOADS AND FORCES DURING OPERATING CONDITION AS PER APPENDIX 2-3 Hydrostatic end force on area inside of flange [HD] = 0.25 x x B 2 x P = 0.25 x x 1256 2 x 0.12 = 148966.8 kgf Gasket load (difference between flange design bolt load and total hydrostatic end force) [HG] = Wm1 - H = 186239.9 - 158212.8 = 28027.1 kgf Difference between total hydrostatic end force and hydrostatic end force on area inside of flange [HT] = H - HD = 158212.8 - 148966.8 = 9246 kgf 12. MOMENT ARMS FOR FLANGE LOADS AS PER TABLE 2-6 Radial distance from the bolt circle to intersection of hub and back of flange, as per Appendix 2-3 [R] = 0.5 x ( C - B ) - g1 = 0.5 x ( 1363 - 1256 ) - 17
= 36.5 mm Radial distance from the bolt circle to the circle on which HD acts [hD] = R + 0.5 x g1 = 36.5 + 0.5 x 17 = 45 mm Radial distance from gasket load reaction to the bolt circle [hG] = 0.5 x ( C - G ) = 0.5 x ( 1363 - 1294.4 ) = 34.3 mm Radial distance from the bolt circle to the circle on which HT acts [hT] = 0.5 x ( R + g1 + hG ) = 0.5 x ( 36.5 + 17 + 34.3 ) = 43.9 mm 13. FLANGE MOMENTS UNDER OPERATING CONDITION AS PER APPENDIX 2-6 Component of moment due to HD [MD] = HD x hD = 148966.8 x 45 = 6703506.7 kgf-mm Component of moment due to HG [MG] = HG x hG = 28027.1 x 34.3 = 961444.8 kgf-mm Component of moment due to HT [MT] = HT x hT = 9246 x 43.9 = 405919.6 kgf-mm Total moment acting on the flange for operating condition [MO] = MD + MG + MT = 6703506.7 + 961444.8 + 405919.6 = 8070871.1 kgf-mm 14. LOADS AND FORCES DURING GASKET SEATING AS PER APPENDIX 2-3 Gasket load for seating condition [HG] =W = 461755.8 kgf 15. MOMENT UNDER GASKET SEATING AS PER APPENDIX 2-6 Total moment acting on the flange for gasket seating [MO'] = W x hG = 461755.8 x 34.3 = 15840129 kgf-mm 16. SHAPE CONSTANTS A/B K 1.131 Flange factors from Fig. 2-7.1
T
1.866
Z
8.189
Y
15.84
U
17.41
e
0.00922
h0
93.77
F / h0 Factor from Fig. 2-7.2
F
0.864
Factor from Fig. 2-7.3
V
0.261
g1 / g0
2.429
h / h0 ( U / V ) x h0 x g0
0.32 2
Factor from Fig. 2-7.6 17. STRESS FORMULA FACTORS Assumed thickness [t] = 125.7 mm Factor [a] =txe+1 = 125.7 x 0.00922 + 1 = 2.159 Factor [b] = 1.333 x t x e + 1 = 1.333 x 125.7 x 0.00922 + 1 = 2.545 Factor [g] =a/T = 2.159 / 1.866 = 1.157 Factor [d] =t3/d
d
306079.1
f
2.935
= 125.7 3 / 306079.1 = 6.488 Factor [l] =g+d = 1.157 + 6.488 = 7.644 18. FLANGE STRESSES AS PER APPENDIX 2-7 & 2-8 Equivalent moment [Mmax] = MAX [ MO , MO' x Sfo / Sfa ] = MAX [ 8070871.1 , 15840129 x 14.06 / 14.06 ] = 15840129 kgf-mm Corrected equivalent moment per unit length [M] = Mmax x ( Cf / B ) = 15840129 x ( 1 / 1256 ) = 12611.6 kgf Longitudinal hub stress [SH] = f x M / ( l x g1 2 ) = 2.935 x 12611.6 / ( 7.644 x 17 2 ) = 16.75 kgf/mm² .................................... < 1.5 x Sfo Radial flange stress [SR] =bxM/(lxt2) = 2.545 x 12611.6 / ( 7.644 x 125.7 2 ) = 0.266 kgf/mm² .................................... < Sfo Tangential flange stress [ST] = ( M x Y / t 2 ) - Z x SR = ( 12611.6 x 15.84 / 125.7 2 ) - 8.189 x 0.266 = 10.47 kgf/mm² .................................... < Sfo Average stress = MAX [ 0.5 x ( SH + SR ) , 0.5 x ( SH + ST ) ] = MAX [ 0.5 x ( 16.75 + 0.266 ) , 0.5 x ( 16.75 + 10.47 ) ] = 13.61 kgf/mm² .................................... < Sfo 19. FLANGE RIGIDITY CHECKING AS PER APPENDIX 2-14 Modulus of elasticity for flange
Efo
20543.7 kgf/mm²
Rigidity factor Rigidity index [J] = 52.14 x V x Mmax / ( l x Efo x g0 2 x KI x h0 ) = 52.14 x 0.261 x 15840129 / ( 7.644 x 20543.7 x 7 = 0.997 Since J < 1.0, design is safe
KI
0.3
2
x 0.3 x 93.77 )
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
DESIGN OF SHELL ( INTERNAL PRESSURE )
Main Shell
CODE
ASME VIII Div.1, 10 A11
1. DESIGN CONDITIONS ( Hydrotest Mode , Corroded Condition ) Design pressure ( internal )
Pi
0.122 kgf/mm² g
Design temperature
T
50 °C
S
14.06 kgf/mm²
Material of construction Max. allowable stress at design temp.
SA-516 GR. 70 Plt. [UNS:K02700]
Radiography
Spot + T Joints
Joint efficiency long. seam
Ec
0.85
Outside diameter
OD
1270 mm
Inside radius ( corroded )
R
628 mm
Shell length
L
1650 mm
Nominal thickness
10 mm
Nominal thickness required as per TEMA
N.A. mm
Internal allowance, corrosion + polishing
3 mm
External allowance, corrosion + polishing
0 mm
Thickness undertolerance
0 mm
Available thickness
7 mm
2. DESIGN CALCULATION AS PER UG-27 Thickness of shell under internal pressure [ti] = Pi x R / ( S x E - 0.6 x Pi ) = 0.122 x 628 / ( 14.06 x 0.85 - 0.6 x 0.122 ) = 6.443 mm Since available thickness is more than design thickness, design is safe.
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
DESIGN OF ELLIPSOIDAL HEAD ( INTERNAL PRESSURE )
Dished End (Rear)
CODE 1. DESIGN CONDITIONS (Hydrotest Mode , Corroded Condition ) : Design pressure ( internal ) Pi
ASME VIII Div.1, 10 A11
Design temperature
50 °C
T
Material of construction Max. allowable stress @ design temp.
0.122 kgf/mm² g SA-516 GR. 70 Plt. [UNS:K02700]
S
14.06 kgf/mm²
Joint efficiency
E
1
Inside diameter of shell
ID
1256 mm
Radiography
Full
Head shape
Elliptical D/2H = 2.0
Nominal thickness
10 mm
Nominal thickness required as per TEMA
N.A mm
Internal allowance, corrosion + polishing
3 mm
External allowance, corrosion + polishing
0 mm
Thinning allowance / Under tolerance
1 mm
Available thickness 2. DESIGN CALCULATION AS PER UG 32 d / APPENDIX 1-4 ( c ) : Factor [K] =1 Thickness for internal pressure [t] = K x Pi x ID / ( 2 x S x E - 0.2 x Pi ) = 1 x 0.122 x 1256 / ( 2 x 14.06 x 1 - 0.2 x 0.122 ) = 5.465 mm Since available thickness is more than design thickness, design is safe.
6 mm
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
LUG SUPPORT DESIGN
Lug Support
CODE
P V Design Manual, D.R. Moss Hydrotest Mode , Corroded Condition
1. LUG DATA : M.O.C
IS-2062 GR. A Plt.
No. of support
N
4
Base plate width
b1
242 mm
Base plate depth
Lb
200 mm
Thickness of base plate
tb
16 mm
Allowable bending stress 2. BOLT DATA : M.O.C
Sb
22.15 kgf/mm² Commercial CS Bolt
No. of bolt / lug
Nb
1
Bolt diameter
db
20 mm
PCD
D
1570 mm
Fs
20.88 kgf/mm²
Diameter of bolt hole
24 mm
Allowable tensile stress 3. GUSSET DATA : Thickness
tg
16 mm
Height
h
190 mm
Gusset angle
θ
51.71
Gusset depth at top
Lc
50 mm
Number of gussets
n
2
Distance between gussets 4. SHELL DATA :
b
200 mm
OD diameter
OD
1270 mm
Inside diameter
ID
1256 mm
Thickness available 5. PAD DATA :
ts
7 mm
Thickness
tp
10 mm
Width
W
270 mm
Length 6. LOAD AND MOMENT ( Wind ) :
L
292 mm
Material
SA-516 GR. 70 Plt. [UNS:K02700]
Material
SA-516 GR. 70 Plt. [UNS:K02700]
Max. overturning moment
M
940925.4 kgf-mm
Design weight of vessel 7. DESIGN OF ANCHOR BOLTS : Total uplift force on bolts [T]
Wt
2331.2 kgf
= [ 4 x M / ( D x N ) ] - Wt / N = [ 4 x 940925.4 / ( 1570 x 4 ) ] - 2331.2 / 4 = 16.52 kgf Required area of bolts [Am] = MAX [ ( T / Fs ) , 0 ] = MAX [ ( 16.52 / 20.88 ) , 0 ] = 0.791 mm² Available area of bolts [Ab] = Ar x Nb ........................................................................................ where, Ar = 217.1 mm², is root area of bolt = 217.1 x 1 = 217.1 mm² Since Ab > Am, bolts provided are sufficient 8. GUSSET DESIGN : Reaction force at each support [Q] = [ 4 x M / ( D x N ) ] + Wt / N
= [ 4 x 940925.4 / ( 1570 x 4 ) ] + 2331.2 / 4 = 1182.1 kgf Maximum axial force in gusset [P1] =Q/n = 1182.1 / 2 = 591.1 kgf Allowable compr. stress in gusset [Sg] = 1800 / [ ( 1 + 12 / 18000 ) x ( h’ / tg )
2
] ....................................... where, h’ = 242.1 mm 2
]
= 2 x P1 x ( 3 x a - Lb ) / [ Sg x Lb 2 x ( sin θ )
2
= 1800 / [ ( 1 + 12 / 18000 ) x ( 242.1 / 16 ) = 15616.8 psi = 10.98 kgf/mm² Required thickness of gusset [tg’]
]
= 2 x 591.1 x ( 3 x 150 - 200 ) / [ 10.98 x ( 200 ) 2 x ( sin 51.71 ) 2 ] = 1.092 mm 9. BASE PLATE DESIGN : Bending moment [Mb] = Q x b1 / 6 = 1182.1 x 242 / 6 = 47678.6 kgf-mm Bearing pressure [bp] = Q / ( w x b1 ) ............................................................................... where, w = 120 mm = 1182.1 / ( 120 x 242 ) = 0.04071 kgf/mm² Bending moment due to bearing pressure [Mb’] = bp x b
2
/ 10
= 0.04071 x 200 = 162.8 kgf-mm
2
/ 10
Required thickness of base plate between chairs [tb’] = SQRT { 6 x MAX [ Mb , Mb' ] / [ ( Lb - db ) x Sb ] } = SQRT { 6 x MAX [ 47678.6 , 162.8 ] / [ ( 200 - 20 ) x 22.15 ] } = 8.567 mm 10. CHECK FOR COMPRESSION PLATE : Equivalent radial load [f] =Qxa/h = 1182.1 x 150 / 190 = 466.6 kgf Angle between supports [b] =2xp/N =2xp/4 = 1.571 rad Internal bending moment coefficient [Kr] = 0.5 x [ 1 / a - cot ( a ) ] = 0.5 x [ 1 / 1.571 - cot ( 1.571 ) ] = 0.318 Internal bending moment [Mc] = 0.5 x Kr x f x OD = 0.5 x 0.318 x 466.6 x 1270 = 94317.2 kgf-mm Bending stress induced [fb] = Mo / Zc = 94317.2 / 7785.1 = 12.12 kgf/mm² ......................................................................... < Sb = 22.15 kgf/mm² Since, induced stress fb < allow. stress Sb in shell material, design is safe.
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
LUG SUPPORT DESIGN
Lug Support
CODE
P V Design Manual, D.R. Moss Hydrotest Mode , Corroded Condition
1. LUG DATA : M.O.C
IS-2062 GR. A Plt.
No. of support
N
4
Base plate width
b1
242 mm
Base plate depth
Lb
200 mm
Thickness of base plate
tb
16 mm
Allowable bending stress 2. BOLT DATA : M.O.C
Sb
22.15 kgf/mm² Commercial CS Bolt
No. of bolt / lug
Nb
1
Bolt diameter
db
20 mm
PCD
D
1570 mm
Fs
20.88 kgf/mm²
Diameter of bolt hole
24 mm
Allowable tensile stress 3. GUSSET DATA : Thickness
tg
16 mm
Height
h
190 mm
Gusset angle
θ
51.71
Gusset depth at top
Lc
50 mm
Number of gussets
n
2
Distance between gussets 4. SHELL DATA :
b
200 mm
OD diameter
OD
1270 mm
Inside diameter
ID
1256 mm
Thickness available 5. PAD DATA :
ts
7 mm
Thickness
tp
10 mm
Width
W
270 mm
Length 6. LOAD AND MOMENT ( Seismic ) :
L
292 mm
Material
SA-516 GR. 70 Plt. [UNS:K02700]
Material
SA-516 GR. 70 Plt. [UNS:K02700]
Max. overturning moment
M
630940.4 kgf-mm
Design weight of vessel 7. DESIGN OF ANCHOR BOLTS : Total uplift force on bolts [T]
Wt
1841.2 kgf
= [ 4 x M / ( D x N ) ] - Wt / N = [ 4 x 630940.4 / ( 1570 x 4 ) ] - 1841.2 / 4 = -58.44 kgf Required area of bolts [Am] = MAX [ ( T / Fs ) , 0 ] = MAX [ ( -58.44 / 20.88 ) , 0 ] = 0 mm² Available area of bolts [Ab] = Ar x Nb ........................................................................................ where, Ar = 217.1 mm², is root area of bolt = 217.1 x 1 = 217.1 mm² Since Ab > Am, bolts provided are sufficient 8. GUSSET DESIGN : Reaction force at each support [Q] = [ 4 x M / ( D x N ) ] + Wt / N
= [ 4 x 630940.4 / ( 1570 x 4 ) ] + 1841.2 / 4 = 862.2 kgf Maximum axial force in gusset [P1] =Q/n = 862.2 / 2 = 431.1 kgf Allowable compr. stress in gusset [Sg] = 1800 / [ ( 1 + 12 / 18000 ) x ( h’ / tg )
2
] ....................................... where, h’ = 242.1 mm 2
]
= 2 x P1 x ( 3 x a - Lb ) / [ Sg x Lb 2 x ( sin θ )
2
= 1800 / [ ( 1 + 12 / 18000 ) x ( 242.1 / 16 ) = 15616.8 psi = 10.98 kgf/mm² Required thickness of gusset [tg’]
]
= 2 x 431.1 x ( 3 x 150 - 200 ) / [ 10.98 x ( 200 ) 2 x ( sin 51.71 ) 2 ] = 0.797 mm 9. BASE PLATE DESIGN : Bending moment [Mb] = Q x b1 / 6 = 862.2 x 242 / 6 = 34774.7 kgf-mm Bearing pressure [bp] = Q / ( w x b1 ) ............................................................................... where, w = 120 mm = 862.2 / ( 120 x 242 ) = 0.02969 kgf/mm² Bending moment due to bearing pressure [Mb’] = bp x b
2
/ 10
= 0.02969 x 200 = 118.8 kgf-mm
2
/ 10
Required thickness of base plate between chairs [tb’] = SQRT { 6 x MAX [ Mb , Mb' ] / [ ( Lb - db ) x Sb ] } = SQRT { 6 x MAX [ 34774.7 , 118.8 ] / [ ( 200 - 20 ) x 22.15 ] } = 7.316 mm 10. CHECK FOR COMPRESSION PLATE : Equivalent radial load [f] =Qxa/h = 862.2 x 150 / 190 = 340.3 kgf Angle between supports [b] =2xp/N =2xp/4 = 1.571 rad Internal bending moment coefficient [Kr] = 0.5 x [ 1 / a - cot ( a ) ] = 0.5 x [ 1 / 1.571 - cot ( 1.571 ) ] = 0.318 Internal bending moment [Mc] = 0.5 x Kr x f x OD = 0.5 x 0.318 x 340.3 x 1270 = 68790.8 kgf-mm Bending stress induced [fb] = Mo / Zc = 68790.8 / 7785.1 = 8.836 kgf/mm² ......................................................................... < Sb = 22.15 kgf/mm² Since, induced stress fb < allow. stress Sb in shell material, design is safe.
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
NOZZLE NECK THICKNESS AND REINFORCEMENT DESIGN
N 01
CODE
ASME VIII Div.1, 10 A11 Hydrotest Mode , Corroded Condition
DESIGN CONDITIONS Design pressure ( internal )
Pi
0.122 kgf/mm² g
Design temperature NOZZLE DATA
T
50 °C SA-106 GR. B Smls. Pipe [UNS:K03006]
M.O.C. Allowable stress @ design temperature
Sn
12.02 kgf/mm²
Outside diameter
OD
168.3 mm
Inside diameter
ID
152.3 mm
Maximum chord length
D
152.3 mm
Neck thickness ( provided )
tnp
10.97 mm
Internal allowance , corrosion + polishing
CAI
3 mm
External allowance , corrosion + polishing
CAE
0
Neck thickness (tnp - CAI - CAE)
tn
7.973 mm
Max. under tolerance on thickness
Alw
1.372 mm
Available neck thickness ( tn - Alw )
ta
6.601 mm
Nozzle projection outward ( from vessel outer face )
Lo
150 mm
Total length of nozzle ( Lo + Addn for curvature)
L
156 mm
Connection type
Pipe Nozzle
Application type
Process Opening
Reinforcement calculation method
Isolated Opening
Design as large opening SHELL DATA ( Main Shell ) M.O.C.
False SA-516 GR. 70 Plt. [UNS:K02700]
Allowable stress @ design temperature
Sv
Inside radius
R
Thickness t WELD DATA Nozzle outside weld W1 CALCULATION OF NOZZLE NECK THICKNESS AS PER UG 45 Neck 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 0.122 x 168.3 ) / ( 12.02 x 1.0 + 0.4 x 0.122 ) = 0.999 mm Thickness 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 ) = 0.122 x 628 / ( 14.06 x 1.0 - 0.6 x 0.122 ) = 5.472 mm Standard wall thickness as per UG 45(b)(4) , [t3] = 7.112 mm Neck thk as per UG 45 , [trn] = MAX { trn1 , MIN [ trn2 , 0.875 x t3 ] } ................. for Process Nozzle = trn1 ................................................................... for Access Opening = 5.472 mm ....................................................... Process Opening Since available neck thickness, ta >= trn, selected neck thickness is adequate.
14.06 kgf/mm² 628 mm 7 mm 7 mm
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
LOCAL STRESS ANALYSIS (EDGE OF ATTACHMENT)
N 01
CODE
D.R. MOSS (EXTRACT OF WRC 107) Hydrotest Mode, Corroded Condition
1. DESIGN CONDITION : Design pressure ( internal ) Design temperature 2. ATTACHMENT DATA :
Pi
0.122 kgf/mm² g
T
50 °C SA-106 GR. B Smls. Pipe [UNS:K03006]
M.O.C Outside diameter
OD
168.3 mm
Weld size
w
7 mm
Pad diameter
Dp
292.7 mm
Pad thickness
tp
10 mm
0.5 x OD 3. EXTERNAL LOADS :
C
84.14 mm
Radial force
Fr
344.6 kgf
Long. moment
ML
254724.1 kgf-mm
Circ. moment
Mc
254724.1 kgf-mm
Torsional moment
Mt
254724.1 kgf-mm
Total eff. shear load 4. SHELL DATA :
Q
487.4 kgf
Sv
14.06 kgf/mm²
M.O.C
SA-516 GR. 70 Plt. [UNS:K02700]
Allowable stress Inside radius
R
628 mm
Thickness of shell
tv
7 mm
Mean radius of shell , [ Rm ] = R + 0.5 x ( tv + tp ) = 628 + 0.5 x ( 7 + 10 ) = 636.5 mm
Thickness , [t]
Calculate ratio , [ g ] = Rm / te = 636.5 / 12.21 = 52.14
Calculate ratio , [ b ] = 0.875 x C / Rm = 0.875 x 84.14 / 636.5 = 0.116
= SQRT [ tv 2 + tp 2 ] = SQRT [ 7 2 + 10 2 ] = 12.21 mm
5. STRESS CONCENTRATION FACTORS : Factor , [ Kn ] = 1
Factor , [ Kb ] = 1
6. COMPUTING STRESSES : Shear stress due to Q , [ t1 ]
Shear stress due to Mt , [ t2 ] = Mt / ( 2 x p x Ro 2 x t ) = 254724.1 / ( 2 x p x 84.14 = 0.469 kgf/mm²
= Q / ( p x Ro x t ) = 487.4 / ( p x 84.14 x 12.21 ) = 0.151 kgf/mm²
2
x 12.21 )
Total shear stress , [ t ] = t1 + t2 = 0.151 + 0.469 = 0.62 kgf/mm² STRESSES
FACT
FIG.
FORCES( kgf ) & MOMENTS( kgf-mm )
5-17A
7.023 x Fr Rm
Nf
3.803
Kn x Nf t
σf
0.312
5-17B
8.616 x Fr Rm
Nx
4.665
Kn x Nx t
σx
0.382
5-18A
0.117 x Fr
Mf
40.25
6 x Kb x Mf t2
σf
1.621
Membrane Radial load Bending
STRESS ( kgf/mm² )
6 x Kb x Mx
5-18B
0.0707 x Fr
Mx
24.37
t
CL=1
5-19A
3.516 x CL x ML Rm 2 x b
Nf
19.11
σx
0.981
Kn x Nf t
σf
1.566
CL=1
5-19B
1.697 x CL x ML Rm 2 x b
Nx
9.222
Kn x Nx t
σx
0.756
5-20A
0.03827 x ML Rm x b
Mf
132.4
6 x Kb x Mf t2
σf
5.331
5-20B
0.06937 x ML Rm x B
Mx
240
6 x Kb x Mx t2
σx
9.665
Cc=1
5-21A
1.893 x Cc x Mc Rm 2 x b
Nf
10.29
Kn x Nf t
σf
0.843
Cc=1
5-21B
2.973 x Cc x Mc Rm 2 x b
Nx
16.16
Kn x Nx t
σx
1.324
5-22A
0.09066 x Mc Rm x b
Mf
313.7
6 x Kb x Mf t2
σf
12.63
5-22B
0.04678 x Mc Rm x b
Mx
161.9
6 x Kb x Mx t2
σx
6.518
Membrane Long. moment Bending
Membrane Circ. moment
2
Bending 7. COMBINING STRESSES :
σx
Stress due to Radial load, Fr.(1)
Membrane Bending
Nf Nx Mf Mx
σf
0°
90°
180°
270°
0.382
0.382
0.382
0.382
0.981
0.981
0.981
0.981
Nf Membrane Nx
Long. moment, ML.
+ ( 0.756 )
Mx
90° 0.312
180° 0.312
270° 0.312
1.621
1.621
1.621
1.621
+ ( 1.566 )
-( 1.566 )
+ ( 5.331 )
-( 5.331 )
-( 0.756 )
Mf Bending
0° 0.312
+ ( 9.665 )
-( 9.665 )
Nf Membrane Nx
Circ moment, Mc.
+ ( 1.324 )
Mx
+ ( 6.518 )
-( 0.843 )
+ ( 12.63 )
( 12.63 )
-( 1.324 )
Mf Bending
+ ( 0.843 )
-( 6.518 )
Pi x + Rm σf ( 11.08 ) t Int. pr., P. Pi x + + + + Rm σx ( 5.541 ) ( 5.541 ) ( 5.541 ) ( 5.541 ) 2xt Membrane 6.679 7.247 5.168 4.599 13.03 Total, ∑ Mem+Bend 17.32 14.75 -3.515 -0.937 19.91 ** Only absolute values of quantities in bracket shall be used while combining stresses ( 1 ) : Fr sign is (+) for outward load, & (-) for inward load. Allowabe Stresses for various catergories: 1. Membrane only, Sm = 1.5 x Sv 2. Membrane + Bending, Sa = 3 x Sv 3. Shear only, Sh = 0.5 x Sv DESIGN IS ACCEPTABLE ? : YES
+ ( 11.08)
+ ( 11.08 )
+ ( 11.08 )
12.31 26.49
9.899 6.118
10.62 -0.46
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
LOCAL STRESS ANALYSIS (EDGE OF PAD)
N 01
CODE
D.R. MOSS (EXTRACT OF WRC 107) Hydrotest Mode, Corroded Condition
1. DESIGN CONDITION : Design pressure ( internal ) Design temperature 2. ATTACHMENT DATA :
Pi
0.122 kgf/mm² g
T
50 °C SA-106 GR. B Smls. Pipe [UNS:K03006]
M.O.C Outside diameter
OD
168.3 mm
Weld size
w
7 mm
Pad diameter
Dp
292.7 mm
Pad thickness
tp
0 mm
0.5 x OD 3. EXTERNAL LOADS :
C
146.3 mm
Radial force
Fr
344.6 kgf
Long. moment
ML
254724.1 kgf-mm
Circ. moment
Mc
254724.1 kgf-mm
Torsional moment
Mt
254724.1 kgf-mm
Total eff. shear load 4. SHELL DATA :
Q
487.4 kgf
Sv
14.06 kgf/mm²
M.O.C
SA-516 GR. 70 Plt. [UNS:K02700]
Allowable stress Inside radius
R
628 mm
Thickness of shell
t
7 mm
Calculate ratio , [ g ] = Rm / t = 631.5 / 7 = 90.21
Mean radius of shell , [ Rm ] = R + 0.5 x t = 628 + 0.5 x 7 = 631.5 mm Calculate ratio , [ b ] = 0.875 x C / Rm = 0.875 x 146.3 / 631.5 = 0.203 5. STRESS CONCENTRATION FACTORS : Factor , [ Kn ] = 1
Factor , [ Kb ] = 1
6. COMPUTING STRESSES : Shear stress due to Q , [ t1 ]
Shear stress due to Mt , [ t2 ] = Mt / ( 2 x p x Ro 2 x t ) = 254724.1 / ( 2 x p x 146.3 = 0.27 kgf/mm²
= Q / ( p x Ro x t ) = 487.4 / ( p x 146.3 x 7 ) = 0.151 kgf/mm²
2
x7)
Total shear stress , [ t ] = t1 + t2 = 0.151 + 0.27 = 0.422 kgf/mm² STRESSES
FACT
FIG.
FORCES( kgf ) & MOMENTS( kgf-mm )
5-17A
4.941 x Fr Rm
Nf
2.696
Kn x Nf t
σf
0.385
5-17B
11.06 x Fr Rm
Nx
6.037
Kn x Nx t
σx
0.862
5-18A
0.04175 x Fr
Mf
14.39
6 x Kb x Mf t2
σf
1.762
Membrane Radial load Bending
STRESS ( kgf/mm² )
6 x Kb x Mx
5-18B
0.01857 x Fr
Mx
6.398
t
CL=1
5-19A
6.231 x CL x ML Rm 2 x b
Nf
19.63
σx
0.783
Kn x Nf t
σf
2.804
CL=1
5-19B
3.293 x CL x ML Rm 2 x b
Nx
10.38
Kn x Nx t
σx
1.482
5-20A
0.0128 x ML Rm x b
Mf
25.46
6 x Kb x Mf t2
σf
3.117
5-20B
0.01693 x ML Rm x B
Mx
33.68
6 x Kb x Mx t2
σx
4.124
Cc=1
5-21A
3.869 x Cc x Mc Rm 2 x b
Nf
12.19
Kn x Nf t
σf
1.741
Cc=1
5-21B
7.986 x Cc x Mc Rm 2 x b
Nx
25.16
Kn x Nx t
σx
3.594
5-22A
0.06043 x Mc Rm x b
Mf
120.2
6 x Kb x Mf t2
σf
14.72
5-22B
0.026 x Mc Rm x b
Mx
51.73
6 x Kb x Mx t2
σx
6.334
Membrane Long. moment Bending
Membrane Circ. moment
2
Bending 7. COMBINING STRESSES :
σx
Stress due to Radial load, Fr.(1)
Membrane Bending
Nf Nx Mf Mx
σf
0°
90°
180°
270°
( 0.862 )
( 0.862 )
( 0.862 )
( 0.862 )
( 0.783 )
( 0.783 )
( 0.783 )
( 0.783 )
Nf Membrane Nx
Long. moment, ML.
+ ( 1.482 )
Mx
90° ( 0.385)
180° ( 0.385 )
270° ( 0.385 )
( 1.762 )
( 1.762 )
( 1.762 )
( 1.762 )
+ ( 2.804 )
-( 2.804 )
+ ( 3.117 )
-( 3.117 )
-( 1.482 )
Mf Bending
0° ( 0.385 )
+ ( 4.124 )
-( 4.124 )
Nf Membrane Nx
Circ moment, Mc.
+ ( 3.594 )
Mx
+ ( 6.334 )
-( 1.741 )
+ ( 14.72 )
( 14.72 )
-( 3.594 )
Mf Bending
+ ( 1.741 )
-( 6.334 )
Pi x Rm σf +( 11 ) t Int. pr., P. Pi x + + + + Rm σx ( 5.498 ) ( 5.498 ) ( 5.498 ) ( 5.498 ) 2xt Membrane 7.842 9.954 4.878 2.766 14.66 Total, ∑ Mem+Bend 12.75 17.07 1.537 -2.785 19.06 ** Only absolute values of quantities in bracket shall be used while combining stresses ( 1 ) : Fr sign is (+) for outward load, & (-) for inward load. Allowabe Stresses for various catergories: 1. Membrane only, Sm = 1.5 x Sv 2. Membrane + Bending, Sa = 3 x Sv 3. Shear only, Sh = 0.5 x Sv DESIGN IS ACCEPTABLE ? : YES
+( 11)
+( 11 )
+( 11 )
13.6 29.6
9.054 7.221
10.12 -3.32
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
NOZZLE NECK THICKNESS AND REINFORCEMENT DESIGN
N 02
CODE
ASME VIII Div.1, 10 A11 Hydrotest Mode , Corroded Condition
DESIGN CONDITIONS Design pressure ( internal )
Pi
0.122 kgf/mm² g
Design temperature NOZZLE DATA
T
50 °C SA-106 GR. B Smls. Pipe [UNS:K03006]
M.O.C. Allowable stress @ design temperature
Sn
12.02 kgf/mm²
Outside diameter
OD
168.3 mm
Inside diameter
ID
152.3 mm
Maximum chord length
D
152.3 mm
Neck thickness ( provided )
tnp
10.97 mm
Internal allowance , corrosion + polishing
CAI
3 mm
External allowance , corrosion + polishing
CAE
0
Neck thickness (tnp - CAI - CAE)
tn
7.973 mm
Max. under tolerance on thickness
Alw
1.372 mm
Available neck thickness ( tn - Alw )
ta
6.601 mm
Nozzle projection outward ( from vessel outer face )
Lo
150 mm
Total length of nozzle ( Lo + Addn for curvature)
L
156 mm
Connection type
Pipe Nozzle
Application type
Process Opening
Reinforcement calculation method
Isolated Opening
Design as large opening SHELL DATA ( Main Shell ) M.O.C.
False SA-516 GR. 70 Plt. [UNS:K02700]
Allowable stress @ design temperature
Sv
Inside radius
R
Thickness t WELD DATA Nozzle outside weld W1 CALCULATION OF NOZZLE NECK THICKNESS AS PER UG 45 Neck 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 0.122 x 168.3 ) / ( 12.02 x 1.0 + 0.4 x 0.122 ) = 0.999 mm Thickness 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 ) = 0.122 x 628 / ( 14.06 x 1.0 - 0.6 x 0.122 ) = 5.472 mm Standard wall thickness as per UG 45(b)(4) , [t3] = 7.112 mm Neck thk as per UG 45 , [trn] = MAX { trn1 , MIN [ trn2 , 0.875 x t3 ] } ................. for Process Nozzle = trn1 ................................................................... for Access Opening = 5.472 mm ....................................................... Process Opening Since available neck thickness, ta >= trn, selected neck thickness is adequate.
14.06 kgf/mm² 628 mm 7 mm 7 mm
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
LOCAL STRESS ANALYSIS (EDGE OF ATTACHMENT)
N 02
CODE
D.R. MOSS (EXTRACT OF WRC 107) Hydrotest Mode, Corroded Condition
1. DESIGN CONDITION : Design pressure ( internal ) Design temperature 2. ATTACHMENT DATA :
Pi
0.122 kgf/mm² g
T
50 °C SA-106 GR. B Smls. Pipe [UNS:K03006]
M.O.C Outside diameter
OD
168.3 mm
Weld size
w
7 mm
Pad diameter
Dp
292.7 mm
Pad thickness
tp
10 mm
0.5 x OD 3. EXTERNAL LOADS :
C
84.14 mm
Radial force
Fr
344.6 kgf
Long. moment
ML
254724.1 kgf-mm
Circ. moment
Mc
254724.1 kgf-mm
Torsional moment
Mt
254724.1 kgf-mm
Total eff. shear load 4. SHELL DATA :
Q
487.4 kgf
Sv
14.06 kgf/mm²
M.O.C
SA-516 GR. 70 Plt. [UNS:K02700]
Allowable stress Inside radius
R
628 mm
Thickness of shell
tv
7 mm
Mean radius of shell , [ Rm ] = R + 0.5 x ( tv + tp ) = 628 + 0.5 x ( 7 + 10 ) = 636.5 mm
Thickness , [t]
Calculate ratio , [ g ] = Rm / te = 636.5 / 12.21 = 52.14
Calculate ratio , [ b ] = 0.875 x C / Rm = 0.875 x 84.14 / 636.5 = 0.116
= SQRT [ tv 2 + tp 2 ] = SQRT [ 7 2 + 10 2 ] = 12.21 mm
5. STRESS CONCENTRATION FACTORS : Factor , [ Kn ] = 1
Factor , [ Kb ] = 1
6. COMPUTING STRESSES : Shear stress due to Q , [ t1 ]
Shear stress due to Mt , [ t2 ] = Mt / ( 2 x p x Ro 2 x t ) = 254724.1 / ( 2 x p x 84.14 = 0.469 kgf/mm²
= Q / ( p x Ro x t ) = 487.4 / ( p x 84.14 x 12.21 ) = 0.151 kgf/mm²
2
x 12.21 )
Total shear stress , [ t ] = t1 + t2 = 0.151 + 0.469 = 0.62 kgf/mm² STRESSES
FACT
FIG.
FORCES( kgf ) & MOMENTS( kgf-mm )
5-17A
7.023 x Fr Rm
Nf
3.803
Kn x Nf t
σf
0.312
5-17B
8.616 x Fr Rm
Nx
4.665
Kn x Nx t
σx
0.382
5-18A
0.117 x Fr
Mf
40.25
6 x Kb x Mf t2
σf
1.621
Membrane Radial load Bending
STRESS ( kgf/mm² )
6 x Kb x Mx
5-18B
0.0707 x Fr
Mx
24.37
t
CL=1
5-19A
3.516 x CL x ML Rm 2 x b
Nf
19.11
σx
0.981
Kn x Nf t
σf
1.566
CL=1
5-19B
1.697 x CL x ML Rm 2 x b
Nx
9.222
Kn x Nx t
σx
0.756
5-20A
0.03827 x ML Rm x b
Mf
132.4
6 x Kb x Mf t2
σf
5.331
5-20B
0.06937 x ML Rm x B
Mx
240
6 x Kb x Mx t2
σx
9.665
Cc=1
5-21A
1.893 x Cc x Mc Rm 2 x b
Nf
10.29
Kn x Nf t
σf
0.843
Cc=1
5-21B
2.973 x Cc x Mc Rm 2 x b
Nx
16.16
Kn x Nx t
σx
1.324
5-22A
0.09066 x Mc Rm x b
Mf
313.7
6 x Kb x Mf t2
σf
12.63
5-22B
0.04678 x Mc Rm x b
Mx
161.9
6 x Kb x Mx t2
σx
6.518
Membrane Long. moment Bending
Membrane Circ. moment
2
Bending 7. COMBINING STRESSES :
σx
Stress due to Radial load, Fr.(1)
Membrane Bending
Nf Nx Mf Mx
σf
0°
90°
180°
270°
0.382
0.382
0.382
0.382
0.981
0.981
0.981
0.981
Nf Membrane Nx
Long. moment, ML.
+ ( 0.756 )
Mx
90° 0.312
180° 0.312
270° 0.312
1.621
1.621
1.621
1.621
+ ( 1.566 )
-( 1.566 )
+ ( 5.331 )
-( 5.331 )
-( 0.756 )
Mf Bending
0° 0.312
+ ( 9.665 )
-( 9.665 )
Nf Membrane Nx
Circ moment, Mc.
+ ( 1.324 )
Mx
+ ( 6.518 )
-( 0.843 )
+ ( 12.63 )
( 12.63 )
-( 1.324 )
Mf Bending
+ ( 0.843 )
-( 6.518 )
Pi x + Rm σf ( 11.08 ) t Int. pr., P. Pi x + + + + Rm σx ( 5.541 ) ( 5.541 ) ( 5.541 ) ( 5.541 ) 2xt Membrane 6.679 7.247 5.168 4.599 13.03 Total, ∑ Mem+Bend 17.32 14.75 -3.515 -0.937 19.91 ** Only absolute values of quantities in bracket shall be used while combining stresses ( 1 ) : Fr sign is (+) for outward load, & (-) for inward load. Allowabe Stresses for various catergories: 1. Membrane only, Sm = 1.5 x Sv 2. Membrane + Bending, Sa = 3 x Sv 3. Shear only, Sh = 0.5 x Sv DESIGN IS ACCEPTABLE ? : YES
+ ( 11.08)
+ ( 11.08 )
+ ( 11.08 )
12.31 26.49
9.899 6.118
10.62 -0.46
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
LOCAL STRESS ANALYSIS (EDGE OF PAD)
N 02
CODE
D.R. MOSS (EXTRACT OF WRC 107) Hydrotest Mode, Corroded Condition
1. DESIGN CONDITION : Design pressure ( internal ) Design temperature 2. ATTACHMENT DATA :
Pi
0.122 kgf/mm² g
T
50 °C SA-106 GR. B Smls. Pipe [UNS:K03006]
M.O.C Outside diameter
OD
168.3 mm
Weld size
w
7 mm
Pad diameter
Dp
292.7 mm
Pad thickness
tp
0 mm
0.5 x OD 3. EXTERNAL LOADS :
C
146.3 mm
Radial force
Fr
344.6 kgf
Long. moment
ML
254724.1 kgf-mm
Circ. moment
Mc
254724.1 kgf-mm
Torsional moment
Mt
254724.1 kgf-mm
Total eff. shear load 4. SHELL DATA :
Q
487.4 kgf
Sv
14.06 kgf/mm²
M.O.C
SA-516 GR. 70 Plt. [UNS:K02700]
Allowable stress Inside radius
R
628 mm
Thickness of shell
t
7 mm
Calculate ratio , [ g ] = Rm / t = 631.5 / 7 = 90.21
Mean radius of shell , [ Rm ] = R + 0.5 x t = 628 + 0.5 x 7 = 631.5 mm Calculate ratio , [ b ] = 0.875 x C / Rm = 0.875 x 146.3 / 631.5 = 0.203 5. STRESS CONCENTRATION FACTORS : Factor , [ Kn ] = 1
Factor , [ Kb ] = 1
6. COMPUTING STRESSES : Shear stress due to Q , [ t1 ]
Shear stress due to Mt , [ t2 ] = Mt / ( 2 x p x Ro 2 x t ) = 254724.1 / ( 2 x p x 146.3 = 0.27 kgf/mm²
= Q / ( p x Ro x t ) = 487.4 / ( p x 146.3 x 7 ) = 0.151 kgf/mm²
2
x7)
Total shear stress , [ t ] = t1 + t2 = 0.151 + 0.27 = 0.422 kgf/mm² STRESSES
FACT
FIG.
FORCES( kgf ) & MOMENTS( kgf-mm )
5-17A
4.941 x Fr Rm
Nf
2.696
Kn x Nf t
σf
0.385
5-17B
11.06 x Fr Rm
Nx
6.037
Kn x Nx t
σx
0.862
5-18A
0.04175 x Fr
Mf
14.39
6 x Kb x Mf t2
σf
1.762
Membrane Radial load Bending
STRESS ( kgf/mm² )
6 x Kb x Mx
5-18B
0.01857 x Fr
Mx
6.398
t
CL=1
5-19A
6.231 x CL x ML Rm 2 x b
Nf
19.63
σx
0.783
Kn x Nf t
σf
2.804
CL=1
5-19B
3.293 x CL x ML Rm 2 x b
Nx
10.38
Kn x Nx t
σx
1.482
5-20A
0.0128 x ML Rm x b
Mf
25.46
6 x Kb x Mf t2
σf
3.117
5-20B
0.01693 x ML Rm x B
Mx
33.68
6 x Kb x Mx t2
σx
4.124
Cc=1
5-21A
3.869 x Cc x Mc Rm 2 x b
Nf
12.19
Kn x Nf t
σf
1.741
Cc=1
5-21B
7.986 x Cc x Mc Rm 2 x b
Nx
25.16
Kn x Nx t
σx
3.594
5-22A
0.06043 x Mc Rm x b
Mf
120.2
6 x Kb x Mf t2
σf
14.72
5-22B
0.026 x Mc Rm x b
Mx
51.73
6 x Kb x Mx t2
σx
6.334
Membrane Long. moment Bending
Membrane Circ. moment
2
Bending 7. COMBINING STRESSES :
σx
Stress due to Radial load, Fr.(1)
Membrane Bending
Nf Nx Mf Mx
σf
0°
90°
180°
270°
( 0.862 )
( 0.862 )
( 0.862 )
( 0.862 )
( 0.783 )
( 0.783 )
( 0.783 )
( 0.783 )
Nf Membrane Nx
Long. moment, ML.
+ ( 1.482 )
Mx
90° ( 0.385)
180° ( 0.385 )
270° ( 0.385 )
( 1.762 )
( 1.762 )
( 1.762 )
( 1.762 )
+ ( 2.804 )
-( 2.804 )
+ ( 3.117 )
-( 3.117 )
-( 1.482 )
Mf Bending
0° ( 0.385 )
+ ( 4.124 )
-( 4.124 )
Nf Membrane Nx
Circ moment, Mc.
+ ( 3.594 )
Mx
+ ( 6.334 )
-( 1.741 )
+ ( 14.72 )
( 14.72 )
-( 3.594 )
Mf Bending
+ ( 1.741 )
-( 6.334 )
Pi x Rm σf +( 11 ) t Int. pr., P. Pi x + + + + Rm σx ( 5.498 ) ( 5.498 ) ( 5.498 ) ( 5.498 ) 2xt Membrane 7.842 9.954 4.878 2.766 14.66 Total, ∑ Mem+Bend 12.75 17.07 1.537 -2.785 19.06 ** Only absolute values of quantities in bracket shall be used while combining stresses ( 1 ) : Fr sign is (+) for outward load, & (-) for inward load. Allowabe Stresses for various catergories: 1. Membrane only, Sm = 1.5 x Sv 2. Membrane + Bending, Sa = 3 x Sv 3. Shear only, Sh = 0.5 x Sv DESIGN IS ACCEPTABLE ? : YES
+( 11)
+( 11 )
+( 11 )
13.6 29.6
9.054 7.221
10.12 -3.32
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
NOZZLE NECK THICKNESS AND REINFORCEMENT DESIGN
N 03
CODE
ASME VIII Div.1, 10 A11 Hydrotest Mode , Corroded Condition
DESIGN CONDITIONS Design pressure ( internal )
Pi
0.122 kgf/mm² g
Design temperature NOZZLE DATA
T
50 °C SA-106 GR. B Smls. Pipe [UNS:K03006]
M.O.C. Allowable stress @ design temperature
Sn
12.02 kgf/mm²
Outside diameter
OD
60.33 mm
Inside diameter
ID
48.85 mm
Maximum chord length
D
48.85 mm
Neck thickness ( provided )
tnp
8.738 mm
Internal allowance , corrosion + polishing
CAI
3 mm
External allowance , corrosion + polishing
CAE
0
Neck thickness (tnp - CAI - CAE)
tn
5.738 mm
Max. under tolerance on thickness
Alw
1.092 mm
Available neck thickness ( tn - Alw )
ta
4.645 mm
Nozzle projection outward ( from vessel outer face )
Lo
150 mm
Total length of nozzle ( Lo + Addn for curvature)
L
150 mm
Connection type
Pipe Nozzle
Application type
Process Opening
Reinforcement calculation method
Isolated Opening
Design as large opening HEAD DATA ( Dished End (Rear) ) Allowable stress @ design temperature
False Sv
14.06 kgf/mm²
Inside diameter of head @ head skirt
Dsf
1256 mm
K1
0.9
D / 2 H for Ellispoidal head Factor from Table UG-37
2
Inside diameter of equivalent sphere, K1 x Dsk x 2
ID1
2260.8 mm
Thickness WELD DATA
t
7 mm
Nozzle outside weld W1 CALCULATION OF NOZZLE NECK THICKNESS AS PER UG 45 Thickness of head as per UG 37 Min. 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 0.122 x 2260.8 / ( 2 x 14.06 x 1.0 - 0.2 x 0.122 ) = 4.918 mm Neck 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 0.122 x 60.33 ) / ( 12.02 x 1.0 + 0.4 x 0.122 ) = 0.359 mm Thickness of head as per UG 45(b)(1) Min. head thickness reqd. as per UG 27(d) , [trn2 = tr] = 4.918 mm Standard wall thickness as per UG 45(b)(4) , [t3] = 3.912 mm Neck thk as per UG 45 , [trn] = MAX { trn1 , MIN [ trn2 , 0.875 x t3 ] } ................. for Process Nozzle = trn1 ................................................................... for Access Opening = 3.423 mm ....................................................... Process Opening Since available neck thickness, ta >= trn, selected neck thickness is adequate.
6.35 mm
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
LOCAL STRESS ANALYSIS ( ROUND ATTACHMENT )
N 03
CODE
D.R. MOSS (EXTRACT OF WRC 107) Hydrotest Mode, Corroded Condition
1. DESIGN CONDITION : Design pressure ( internal ) Design temperature 2. ATTACHMENT DATA :
Pi
0.122 kgf/mm² g
T
50 °C SA-106 GR. B Smls. Pipe [UNS:K03006]
M.O.C Outside diameter
OD
60.33 mm
Weld size
w
7 mm
0.5 x OD
Ro = C
30.16 mm
3. EXTERNAL LOADS : Radial force
Fr
74.92 kgf
Latitudinal moment
ML
29967.5 kgf-mm
Meridional moment Total eff. moment, [ ML
2
+ Mc
2
]
0.5
Mc
29967.5 kgf-mm
M
42380.5 kgf-mm
Shear load
Q
106 kgf
Torsional moment 4. HEAD DATA :
Mt
29967.5 kgf-mm
Sv
14.06 kgf/mm²
M.O.C
SA-516 GR. 70 Plt. [UNS:K02700]
Allowable stress Inside radius
R
1130.4 mm
Thickness ( corroded )
t
7 mm
Mean radius of shell , [ Rm ] = R + 0.5 x t = 1130.4 + 0.5 x 7 = 1133.9 mm
Calculate factor , [ U ] = 1.82 x 30.16 / SQRT [ 1133.9 x 7 ]] = 0.616
Calculate factor , [ S ] = 1.82 x 0.5 x Dp / SQRT [ Rm x t ] = 1.82 x 0.5 x / SQRT [ 1133.9 x 7 ] = 0.616 5. STRESS CONCENTRATION FACTORS : Factor , [ Kn ] = 1
Factor , [ Kb ] = 1
6. COMPUTING STRESSES : Shear stress due to Q , [ t1 ]
Shear stress due to Mt , [ t2 ] = Mt / ( 2 x p x Ro 2 x t ) = 29967.5 / ( 2 x p x 30.16 = 0.749 kgf/mm²
= Q / ( p x Ro x t ) = 106 / ( p x 30.16 x 7 ) = 0.16 kgf/mm²
2
x7)
Total shear stress , [ t ] = t1 + t2 = 0.16 + 0.749 = 0.909 kgf/mm² STRESS
FIGURE
Bending
STRESS ( kgf/mm² )
5-25A
Nx x t Fr
0.06044
Kn x Fr t2
σx
0.09241
5-25B
Nf x t Fr
-0.179
Kn x Fr t2
σf
-0.274
5-26A
Mx Fr
0.0621
6 x Kb x Fr t2
σx
0.57
Membrane Radial load
VALUE FROM FIGURE
5-26B
Mf Fr
0.131
6 x Kb x Fr t2
σf
1.203
5-27A
Nx x t x SQRT [ Rm x t ] M
0.05621
Kn x M t 2 x SQRT [ Rm x t ]
σx
-0.546
5-27B
Nf x t x SQRT [ Rm x t ] M
-0.159
Kn x M t 2x SQRT [ Rm x t ]
σf
-1.541
5-28A
Mx x SQRT [ Rm x t ] M
0.117
6 x Kb x M t 2 x SQRT [ Rm x t ]
σx
6.794
5-28B
Mf x SQRT [ Rm x t ] M
0.43
6 x Kb x M t 2x SQRT [ Rm x t ]
σf
25.07
Membrane Moment , M Bending 7. COMBINING STRESSES :
σx
Stress due to Nx Radial load, Fr.(1)
Memberane
0° +( 0.274 )
90° +( 0.274 )
σf 180° +( 0.274 )
270° +( 0.274 )
Nf Bending
Mx
+ ( 1.203 )
+ ( 1.203 )
+ ( 1.203 )
Mf Nx Memberane
+( 1.541 )
Mx Bending Mf
+ ( 25.07 )
90°
180°
270°
+( 0.09241 )
+( 0.09241 )
+( 0.09241 )
+( 0.09241 )
+( 0.57 )
+( 0.57 )
+( 0.57 )
+( 0.57 )
+ ( 1.203 )
-( 1.541 )
Nf
Moment, M.
0°
+( 0.546 )
-( 0.546 )
+ ( 6.794 )
-( 6.794 )
( 25.07 )
Pi x + + + + + Rm σf ( 9.902 ) ( 9.902) ( 9.902 ) ( 9.902 ) ( 9.902 ) t Membrane 1.815 0.274 -1.267 0.274 0.82 Total, ∑ Mem+Bend 28.09 1.477 -25.14 1.477 8.002 ** Only absolute values of quantities in bracket shall be used while combining stresses ( 1 ) : Fr sign is (+) for outward load, & (-) for inward load. Allowabe Stresses for various catergories: 1. Membrane only, Sm = 1.5 x Sv 2. Membrane + Bending, Sa = 3 x Sv 3. Shear only, Sh = 0.5 x Sv DESIGN IS ACCEPTABLE ? : YES Int. pr., P.
+( 9.902)
+ ( 9.902 )
+ ( 9.902 )
0.274 0.662
-0.272 -6.678
0.274 0.662
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date
/ R00 , 30-03-2015 23:35:19
DESIGN OF LIFTING LUG
Lifting Lugs
CODE
P V Design Manual, D.R. Moss Design Mode 1 , Uncorroded Condition
1. LIFTING LUG DATA : Material
IS-2062 GR. A Plt.
Length of lug
LL
70 mm
Width of lug
A
120 mm
Thickness of lug plate
TL
12 mm
Straight length
B1
10 mm
Radius at tip
R3
35 mm
Pin Hole diameter
D1
40 mm
Lug to vessel weld size
W1
8 mm
Min yield stress
Sy
24.61 kgf/mm²
Allowable tensile stress ( 2 / 3 x Sy )
St
16.4 kgf/mm²
Allowable bending stress ( 1.5 x St )
Sb
22.15 kgf/mm²
Allowable shear stress (0.6 x St ) 2. DESIGN LOADS : Empty weight of equipment
Ss
9.843 kgf/mm²
Wt
2149.7 kgf
Number of lifting lugs
N
2
Jirk load factor 3. CALCULATION OF REFERENCE DIMENSIONS :
j
1.5
Dimension [ L1 ] = LL - B1 - R3 = 70 - 10 - 35 = 25 mm
Dimension [ L2 ] = L1 / SIN ( q1 ) = 25 / SIN ( 0.395 ) = 65 mm
Dimension [ LT ] = LL - R3 = 70 - 35 = 35 mm
Angle [ q2 ] = ASIN ( R3 / L2 ) = ASIN ( 35 / 65 ) = 0.569 radians
Angle [ q1 ] = ATAN ( 2 x L1 / A ) = ATAN ( 2 x 25 / 120 ) = 0.395 radians
Angle [ q3 ] = q1 + q2 = 0.395 + 0.569 = 0.963 radians Dimension [ L3 ] = R3 / SIN ( q3 ) = 35 / SIN ( 0.963 ) = 42.62 mm
4. DESIGN OF LUG PLATE : Effective design load on each lug [ P ] = j x Wt / N = 1.5 x 2149.7 / 2 = 1633 kgf
Required min. thickness of lug plate for shear [ t2 ] = P / [ ( R3 - 0.5 x D1) x ss ] = 1633 / [ ( 35 - 0.5 x 40 ) x 9.843 ] = 11.06 mm
Required min. thickness of lug plate for bending [ t1 ]
Required min. thickness of lug plate for shear [ t3 ] = P / [ ( 2 x L3 - D1 ) x ss ] = 1633 / [ ( 2 x 42.62 - 40 ) x 9.843 ] = 2.2 mm
2
= 6 x P x LT / ( A x Sb ) = 6 x 1633 x 35 / ( 120 2 x 22.15 ) = 1.075 mm 5. CALCULATION OF STRESSES IN LUG PLATE WELDS : Bending stress in weld [ f1 ] = 6 x P x LT / [ 2 x LL2 ] = 6 x 1633 x 35 / ( 2 x 70 = 34.99 kgf/mm
2
)
Min. Size of lug plate weld [ w1 ] = MAX ( f1 , 2 x f2 ) / ( 0.707 x Ss ) = MAX ( 34.99 , 2 x 6.804 ) / ( 0.707 x 9.843 )
Max. shear stress in weld [ f2 ] =P/[2xA] = 1633 / ( 2 x 120 ) = 6.804 kgf/mm
= 5.028 mm
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date FOUNDATION LOAD DATA
/ R00 , 30-03-2015 23:35:19 Weight ( kgf )
Sr. No.
Mode
Condition
Wind Shear ( kgf )
Empty
Filled
Seismic
Moment ( kgf-m )
Shear
Moment
Tran.
Long.
Tran.
Long.
( kgf )
( kgfm)
1
Operating
Corroded
1898.3
1922.1
649.9
649.9
940.9
940.9
198.8
285.7
2
Design1
Corroded
1898.3
1926.8
649.9
649.9
940.9
940.9
199.3
286
3
Hydro
Corroded
1841.1
4212.7
649.9
649.9
940.9
940.9
435.8
436.7
4
Pneumatic
Corroded
1841.1
1843.9
649.9
649.9
940.9
940.9
190.8
275.9
5
Operating
Uncorroded
2149.7
2173.2
649.9
649.9
882.1
882.1
224.8
303.3
6
Design1
Uncorroded
2149.7
2177.9
649.9
649.9
882.1
882.1
225.3
303.6
7
Hydro
Uncorroded
2092.5
4439.8
649.9
649.9
882.1
882.1
459.3
454.2
8
Pneumatic
Uncorroded
2092.5
2095.3
649.9
649.9
882.1
882.1
216.8
294
'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in Sunay Wagle, CADEM Services, Licensee : Pune, India Customer
ABC Company Ltd.
Project / Equipment
Soap Plant / Gas Filter
Designed By / Revision and Date CENTER OF GRAVITY DATA
/ R00 , 30-03-2015 23:35:19
Sr. No.
Mode
Condition
Empty Wt ( kgf )
C.G. ( mm )
Operating / Filled Wt ( kgf )
C.G. ( mm )
1
Operating
Corroded
1898.3
1820.2
1922.1
1809.6
2
Design1
Corroded
1898.3
1820.2
1926.8
1807.5
3
Hydro
Corroded
1841.1
1820.2
4212.7
1374.5
4
Pneumatic
Corroded
1841.1
1820.2
1843.9
1818.9
5
Operating
Uncorroded
2149.7
1729.8
2173.2
1721.7
6
Design1
Uncorroded
2149.7
1729.8
2177.9
1720.1
7
Hydro
Uncorroded
2092.5
1729.8
4439.8
1361.3
8
Pneumatic
Uncorroded
2092.5
1729.8
2095.3
1728.8
