TL to TL = he =
194
*
R = 1000
he = 194
2427
O/D = 1000
*
r = 100 1000
968
e = 16 1750 t = 16 Overall length,L = 2815 12 117.72 Operating Wt, W= Actual Volume, V= INPUT
Ton 3 2.26 m .
Vertical
OUTPUT 3
Capacity: Gas :
2 Nitrogen
m .
Operating pressure:
16
kg/cm2(g)
Design Pressure:
2
20
Operating Temperature: Joint efficiency:
50 85
Outside Diameter: Corrosion Allowance :
1000 1.5
2
kg/cm (g) 0
C
% mm mm kg/m2
Wind Pressure: 194.2 Radiography of Butt Welds: 10 % Design Code : BS:5500 Pressure Range of Cyclic Variation: 10 No. of Cycles: 1,000,000 Cycles. Type of Vessel: Horizontal INPUT TO BE VARIED BASED ON OUTPUT CONDITION: Inside knuckle Radius, r 100 mm Inside Spherical Radius, R 1000 mm Material of Construction: SA 516 GR. 60 SA 516 GR. 70 SA 516 GR. 60
Shell thickness Dished end thickness
16 16
Hydrostatic test pressure:
27.59
mm mm kg/cm2(g)
Overall length
2815
mm
Length of Dished end,he Length TL to TL :
194 2427.45
Actual Volume: Operating weight :
2.26 2
mm mm m3.
Check for Dimensions: Plate thickness for dished end: Design for Shell thickness: Check for Combined Loading: Disgn Check of Shell thickness at Test Condition: Check for Principal Stress Inside Diameter of Vessel. I/D Empty weight of Vessel: Wheather 100% 0r 10% Radiography Required?
OK 16 mm OK TRUE OK OK 968 mm 1.51 Ton 100% RADIOGRAPHY REQD.
Ton
NOZZLE DETAILS: DESCRIPTION MARK MANHOLE N1
SIZE 500
MATL.STD ASTM A 106
THICKNESS(mm) 26.19
RESULT OK
t PAD PLATE DETAILS for NOZZLE NECK N1: Thickness of shell, t = Thickness of Pad Plate, p = Width of Pad Plate , w = Value of H = Width of Pad Plate , w > H/2 Thickness of Pad Plate, p<40 mm Thickness of Pad plate, p ≥ t/4 Test result on thickness & width of Pad Plate
16 20 100 119.5397423 OK OK OK TRUE
p
mm mm mm mm
w
NOZZLE MARKED AS N1
NOTE : IF TEST RESULT IS APPEARED AS "FALSE" , VARY THE THICKNESS OF PAD PALTE AND/OR WIDTH OF PAD PLATE.
PAD PLATE DETAILS for NOZZLE NECK N2,N3 & N4: Thickness of shell, t = Thickness of Pad Plate, p = Width of Pad Plate , w = Value of H = Width of Pad Plate , w > H/2 Thickness of Pad Plate, p<40 mm Thickness of Pad plate, p ≥ t/4 Test result on thickness & width of Pad Plate
THICKNESS(mm) 8.56
16 12 150 41.44 OK OK OK TRUE
RESULT OK
mm mm mm mm
Size thickness p
MATL.STD ASTM A 106
t
NOZZLE DETAILS: DESCRIPTION MARK SIZE I/L,O/L & SPARE N2,N3,N4 100
w
NOZZLE MARKED AS N2,N3 and N4
NOTE : IF TEST RESULT IS APPEARED AS "FALSE" , VARY THE THICKNESS OF PAD PALTE AND/OR WIDTH OF PAD PLATE.
PAD PLATE DETAILS for NOZZLE NECK N5.1 & N5.2: Thickness of shell, t = Thickness of Pad Plate, p = Width of Pad Plate , w = Value of H = Width of Pad Plate , w > H/2 Thickness of Pad Plate, p<40 mm Thickness of Pad plate, p ≥ t/4 Test result on thickness & width of Pad Plate
THICKNESS(mm) 3.60
16 12 50 19.46 OK OK OK TRUE
RESULT OK
mm mm mm mm
Size thickness p
MATL.STD ASTM A 106
t
NOZZLE DETAILS: DESCRIPTION MARK SIZE SAFETY RELIEF N5.1&5.2 50
w
NOZZLE MARKED AS N2,N3 and N4
NOTE : IF TEST RESULT IS APPEARED AS "FALSE" , VARY THE THICKNESS OF PAD PALTE AND/OR WIDTH OF PAD PLATE.
MATL.STD ASTM A 106
PAD PLATE DETAILS for NOZZLE NECK N 6: Thickness of shell, t = Thickness of Pad Plate, p = Width of Pad Plate , w = Value of H = Width of Pad Plate , w > H/2 Thickness of Pad Plate, p<40 mm Thickness of Pad plate, p ≥ t/4 Test result on thickness & width of Pad Plate
THICKNESS(mm) 4.55
16 12 20 7.95 OK OK OK TRUE
RESULT OK
mm mm mm mm
Size thickness p
SIZE 25
t
NOZZLE DETAILS: DESCRIPTION MARK VENT, PG & TG N6
w
NOZZLE MARKED AS N2,N3 and N4
NOTE : IF TEST RESULT IS APPEARED AS "FALSE" , VARY THE THICKNESS OF PAD PALTE AND/OR WIDTH OF PAD PLATE.
1.00
TECHNICAL DATA & DESIGN PARAMETERS: 1.0 2.0
SL.NO.
: 2 : N2
5.0
Operating pressure
6.0
Design pressure
: 20
7.0 8.0
Hydrulic test pressure Operating temperautre
9.0 10.0 11.0 12.0 13.0
Design temperature Corrosion allowance Weld joint efficiency Radiography of butt welds Stress relieving
kg/cm2.g : 27.59 : Ambient 0 C. : 50
14.0 15.0 16.0
Wind Pressure Seismic co-efficient Design code
17.0 18.0
Relieving capacity of safety relief valve Size limitation (Diameter of vessel)
19.0 20.0
Pressure range of cyclic variation No. of Cycles
COMPONEN MATERIAL T SPEC.
YIELD STRESS(N/mm2)
INPUT INPUT OUTPUT INPUT INPUT INPUT
mm 85 % %
kg/m2. : 194.2 : 0.0624 [As per IS : 1893] : BS:5500 Nm3/hr. : : 1000
mm
: 10 to : 1000000 cycles SL.NO. 1.0
ALLOWABLE STRESS VALUE 0 AT 50 C(N/mm2)
INPUT 2 16 kg/cm .g
Description Check for Dimensions:
Remarks OK
105
ii)r≥0.062D
TRUE
260
105
iii)r≥2e
TRUE
260
105 120
iv)R≤D 2.0
Design of Shell Thickness i) e = Pdi/2f-P&ii)e =Pdo/2f+P
TRUE OK
105
3.0
Check for Shell Thickness under combined loading
TRUE
-
4.0
Check for Principal Stress:
OK
-
5.0
Design Check of Shell thickness under test condition
OK
Dished ends
3.0 4.0
Skirt Shell Skirt Base
SA 516 GR. 60 IS: 2062
5.0
Nozzle pipe
ASTM-A-106 Gr. B
6.0
Nozzle Flange
ANSI B 16.5, 600#
7.0
Reinforceme nt pad, lifting SA 516 Gr. lug 70
Fasteners
SA -193B7/SA -1942h
-
Gasket
SS 316 Spiral wound
-
SA 516 GR. 70
1.6 N/mm 2 2 N/mm
TRUE
260
9.0
1.5 0.85 100 Yes
kg/cm2.g
INPUT INPUT 2
i) 0.002D≤e≤0.12D
SA 516 GR. 60
8.0
: : : :
MATERIAL OF CONSTRUCTION AND ALLOWABLE STRESS VALUE:
Shell
2.0
INPUT INPUT
3
Water capacity of vessel Type of construction
SA 516 GR. 60
1.0
Nos.
m . : 2 : Horizontal kg/cm2.g : 16
3.0 4.0
2.00
No. of Vessel required Fluid medium
170 N/mm2.
SA 516 GR. 60
140 N/mm2.
IS: 2002 GR.2
130 N/mm2.
3.00
SIZE OF VESSEL AND CONSTRUCTION Knucle radius,r= Knucle radius,r=
Dished end Thickness,e
(mm) =
14.285 % 100.0
16
INPUT
48
mm
1300 Inside spherical radius,R= 1000 Outside Dia, Do=
INPUT 1000
mm Inside Dia, Di =
16.00 h=
194 Total Length =
968
mm
mm h=
TL to TL = 2331.45 2815 mm
194
4.0
CALCULATION OF WATER VOLUME CAPACITY V = V1 +2V2 V1 = VOLUME OF CYLINDRICAL SHELL. V2 = VOLUME OF DISHED ENDS. V = p R2 H +2 (0.13D3) H = Length of shell = R = Shell radius = D = ID of dished ends =
mm = mm = mm =
OUTPUT
STANDARD TEST PRESSURE: 2 N/mm2
P = Design pressure =
2 105 N/mm 2 N/mm 105
fa = Nominal design stress at amb. Temp = ft = Design stress at disgn temp = t= Nominal thickness under consideration c=Corrosion allowance=
6.0
Pt = Hydraulic test pressure =
16.00 mm 1.5 mm 2 2.759 N/mm
Pt = Hydraulic test pressure =1.3 X P=
2 27.59 kg/cm .g 2 kg/cm .g 26.00
DESIGN OF DISHED END: D = Outside Dia = R = Inside spherical radius = r = Inside knucle radius = h1 = Inside head height = he/D =
0.20
1000 1000 100 194 &
P/t =
e/D = e= Corrected "e=" Adding corrosion allowance, e =
7.0
2.719 mtr 0.484 mtr 1 mtr
3 2.26 m
V= 5.0
2719 484 1000
CHECK FOR DIMENSIONS: I) 0.002D = 0.12D = e= 0.002D≤e≤0.12D II) r ≥ 0.062 D III) r ≥ 2e IV) R≤D
1000 mm 1000 mm
R= 1000 mm
0.01905
OUTPUT
100 mm 26.71580597 mm TRUE
TRUE
r= 100
14.85790299 mm 16 mm
100 mm 60 mm
R= D=
[h= R-{(R-D)*(R+D/2-2*r)}^0.5]
I/D = O/D =
TRUE r= 2e =
e=
0.013357903 13.35790299 mm
2 mm 120 mm 13.35790299 mm TRUE
r= 0.06D =
mm mm mm mm
OUTPUT
968 mm 1000 mm
16
mm
I,II,III & IV -TRUE 8.0
OK
PIERCED END: Di =2R(for torrispherical heads) h/D = Do = D x factor(from table) Minimum thickness required = i) e = Pdi/4f-1.2P ii)e =Pdo/4f+0.8P Minimum thick.after corrosion allowance Adding thinning allowance = Plate thickness =
9.0
Therefore, minimum thickness = Adding corrosion allowance = Thickness of shell taken = Remarks
2
Q=
9.31 9.43 9.43 10.93 16.00 OK
1513.30 30.27 15.13 1558.70 2260.00 3818.70 3818.70 1556.39
mm mm mm mm mm OUTPUT
kg kg kg kg kg kg kg kg
= = = = = = = =
2 1 1 2 3 4 4 2
Ton Ton Ton Ton Ton Ton Ton Ton
-0.87 kg/mm -1.64 kg/mm
Q = Equivalent weight per unit length W = Weight of Vessel at test condition = M=Longitudinal bending moment due to wind load = 8.68 N/mm 16.45 N/mm
CHECK FOR SHELL THICKNESS UNDER COMBINED LOADING: e1 = e2 = e >e1&e2
13.0
14.85790299 mm 16 mm 16 mm
Blank Dia =
CHECK FOR COMBINED LOADING: Q =( W/pDi ) ± (4Mw/pDi )
12.0
9.58 mm 10.67 mm
WEIGHT OF THE VESSEL: Empty weight of vessel : Weight of Structures : Weight of valves &fittings : Total weight of errection : Weight of water : Test weight with full of water : Total weight considered for calculation : Operating weight with nitrogen :
11.0
2000 mm 0.20 2250 mm
DESIGN OF SHELL THICKNESS: i) e = Pdi/2f-P ii)e =Pdo/2f+P
10.
OUTPUT
4.45 mm 4.56 mm TRUE
CHECK FOR PRINCIPAL STRESS: 2 72.47 N/mm .
sq = pRi/e
sz = pRi2/(2Ri+e)e+W/p((2Ri+e)e ± 4M/p((2Ri+e)2e 2 sz1 = 14.13 N/mm . sz1 = T=
2 14.08 N/mm . 0
3818.70 kg. 285.7588 kg-m
2221 mm
f1=0.5(sq +sz+{(sq-sz)2+4T2}0.5) 2 72.47 N/mm . f2=0.5(sq +sz-{(sq-sz)2+4T2}0.5) 2 f2= 14.13 N/mm .
f1=
Membrane Stress Intencity: 2
ii)F2= f1+0.5p
58.33 N/mm . 2 73.47 N/mm .
iii)F3= f2+0.5p
2 15.13 N/mm .
i) F1= f1-f2
2
73.47 N/mm .
F= Maximum of F1, F2 & F3 F< Allowable Stress Value 14.0
OK
DESIGN CHECK FOR SHELL THICKNESS AT TEST CONDITIONS: Inside Dia , Di= 968 mm Outside Dia, Do = 1000 mm 2 Hydrotest pressure, Pt = 27.59 kg/cm .g Hydrostatic Head , Ph
= =
2815 mm 2 0.28 kg/cm .g
=
2 27.87 kg/cm .g 2 2.79 N/mm .
Total Pressure, P=Pt+Ph
2 102.37 N/mm . 2 260 N/mm .
f=PDi/2e+P/2 Yield Stress of Material = 90% of Yield Stress = f<90% OF Yield Stress Thickness of dished end is
2 234 N/mm .
OK OK
120 110 100 90 80 75 63 56 50 45 40 36 32 30 28 25 22 20 18 16 12 10 8 6 5 h/D 0.18 0.192 0.208 0.227 0.25 0.278 0.313 0.357 0.417 0.5
Calculated thickness with corrosion allowance = 12.598779 mm Actual thickness 16 mm calculated Shell thickness without corrosion allowance 11.098779 mm Calculated thickness without corrosion allowance = 11.098779 mm 100% Radiography reqd or not 13.6 mm 100% RADIOGRAPHY REQD.
D' -factor 2.52 2.36 2.17 1.98 1.8 1.63 1.46 1.3 1.14 1
y = 0.5129x -0.9161 y= 2.25 h/D vs 'D'-factor 3
2.5
'D'-factor
2 1.5 1 y = 0.5129x-0.916 0.5 0
0
0.1
0.2
0.3
0.4
0.5
0.6
h/D
WIND PRESSURE LOADING CALCULATION SHEET: FOR VERTICAL VESSEL: 1
FOR HORIZONTAL VESSEL:
2.82
Projected area : Wind load = Moment , M =
2 2.8150026 m 546.67351 kg 584.77719 kg-m Type of Vessel : Actual Moment =
Horizontal 285.75879
Projected area : Wind load = Moment , M = Horizontal Vertical W/3.14*Di = 4M/3.14*Di2 =
1.25634931 0.38848945
he/D =
0.20
P/t =
e/d x 10 3 =
13.36
P/t = 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
he/D = 0.34 0.33 0.32 0.31 0.3 0.29 0.28 0.27 0.26 0.25 0.24 0.23 0.22 0.21 0.2 0.19 0.18 0.17 0.16 0.15
6.4 6.7 6.9 7.1 7.5 8.0 8.5 9.2 9.7 10.6 11.3 12.0 12.7 13.4 14.3 15.1 16.1 17.1 18.3
715
3000
0.24
0.001
2.13
0.0015
2.11 2.3 2.5 2.7
0.0025
0.004
2.08 2.22 2.39 2.55 2.77 2.99 3.24 3.5 3.73
2.12 2.25 2.4 2.58 2.76 2.95 3.2 3.42 3.64 3.95 4.23 4.58 4.9 5.22
0.006 2.1 2.2 2.3 2.41 2.54 2.73 2.93 3.12 3.34 3.56 3.83 4.12 4.45 4.75 5 5.43 5.8 6.3 6.7 7.2
0.24 10.612086
Calclation of Allowable Stress(Cluase no. K 3.2 of BS: 5500): Rm[UTS (Min)] Re(T)[Yield(Min)] Grade of Material : Unit SA 516 GR. 70 Psi 70000 38000 SA 516 GR. 60 Psi 60000 32000
Allowable Stress , fe =Re(T)/1.5 or Rm/2.35 for SA 516 Gr.70
25333.33
Actual allowable Strees, fe =
25333.33 Psi
Psi or
2 1781.11 Kg/cm . 2 17.81 Kg/mm 2 174.73 N/mm
Allowable Stress , fe =Re(T)/1.5 or Rm/2.35 for SA 516 Gr.60
21333.33
Actual allowable Strees, fe =
21333.33 Psi
Psi or
2 1499.88 Kg/cm . 2 15.00 Kg/mm 2 147.14 N/mm
ZONTAL VESSEL:
Blank Dia =
1.743485 338.58479 285.75879 285.75879 584.77719
m2 kg kg-m kg-m kg-m
2221 mm
0.019047619
/t = 0.01 3.5 3.65 3.8 3.95 4.2 4.5 4.8 5.15 5.5 5.9 6.3 6.84 7.3 7.7 8.3 8.8 9.6 10.2 10.9
fe(N/mm2) 174.73 147.14
0.015
6.45 6.8 7.35 7.8 8.5 9.1 9.7 10.4 11 11.8 12.6 13.5 14.3 15.4
0.025
13.6 14.5 15.4 16.2 17.3 18.5 19.7 21 22.2 24
0.05
33 35 37 39.2 41.5 44.5
y=325x+0.25 y=337.5x +0.275 y=347.5x+0.325 y=352.5x+0.425 y=367.5x+0.525 y=393.07+0.5606 y=41318x+0.6272 y=449.33x+0.6284 y=474.63x+0.707 y=515.74x+0.7291 y=551.36x+0.765 y=583.49x+0.8903 y=613.17x+1.0228 y=639.14x+1.1839 y=676.2x+1.3825 y=717.57x+1.4284 y=758.3x+1.6592 y=801.25x+1.8072 y=864.41x+1.8192
29787.23404 Psi
25531.91489 Psi
CALCULATION OF DENSITY OF A GAS Gas density = rg =Mw/V =(P*Mw)/(R*T) where,
rg =
Gas Density in kg/m3
Type of Gas Mw = Mean Molecular weight V= Molar Volume P= Pressure in Bar Temperature of Gas in 0C T= R=
Temperature of Gas in Kelvin Universal gas Constant =
OUTPUT RESULTS Gas Density = 3 rg 19.0652 kg/m
Gas Ammonia Argon Carbon dioxide Carbon monoxide Chlorine
Oxygen 32 0 16 50 323 0.083143
Ethane Ethylene Fluorine Hydrogen Hydrochloric acid fume Hydrogen fluoride Hydrogen sulphide Methane Nitric oxide Nitrogen Nitrous oxide Oxygen Sulphur dioxide Sulphuric acid fume
OF DENSITY OF A GAS Gas Ammonia Argon Carbon dioxide Carbon monoxide
INPUT
Chlorine Ethane Ethylene Fluorine Hydrogen
INPUT
Hydrochloric acid fume
INPUT Nil Nil Bar 0 C 0
K
bar m3/kmol K
Hydrogen fluoride Hydrogen sulphide Methane Nitric oxide Nitrogen Nitrous oxide Oxygen Sulphur dioxide Sulphuric acid fume
Mol Wt.(Mw) 17.03 39.91 44 28 70.91 30.05 28.03 38 2.016 36.47 20.01 34.08 16.03 30.01 28.02 44.02 32 64.06 98