Pressure Vessel Design (Shell, Head & Nozzle) - By Abdel Halim Galala

DESIGN CALCULATIONS OF PRESSURE VESSEL

Page : 5 of 126

According to ASME Code, Section VIII, Division 1, Edition 2001, Addenda 2002 Designed by : Eng. Abdel Halim Galala, Design General Manager (assist.)

Sheet : 1 of 1 Rev. : 1

Project : Design & Procurement of ASME Pressure Vessel Job Name : Demineralization Plant Serial No. : 7434-33-U-2006 Dwg. No. : 7434-33-3A, Rev. 1 Vessel : Deputanizer Reflux Receiver Drum Item No. : 1-D-5 Capacity : 10.152 M3

Date : 18.2.2004 Job No. : 7434-33 Client : APRC Type : Horizontal

D. Contents.

L. Check of Ellipsoidal Head Thickness for External Pressure (Convex Side), FV.

Page Page : 1 of 126 Page : 3 of 126 Page : 4 of 126 Page : 5 of 126 Page : 6 of 126 Page : 7 of 126 Page : 7 of 126 Page : 8 of 126 Page : 12 of 126 Page : 13 of 126 Page : 14 of 126 Page : 15 of 126

M. Nozzle Neck thicknesses & Nozzle Openings Compensation : Thk., MM N11 1-1/2" M1 300# WNRF Sch. XXS 10.16 N8 24" M2 300# WNRF Sch. 30 14.27 Leg 20" M3 Sch. 30 12.7 N1 8" M4 300# WNRF Sch. 60 12.7 Integral Type Flange (Blind) N1 8" 300# Thickness Calculation N1 6" M5 300# WNRF Sch. 80 10.97 N2 6" M6 300# WNRF Sch. 80 10.97 N9 4" M7 300# WNRF Sch. 120 11.13 N18 3" M8 300# WNRF Sch. 160 8.74 N3,N4&N7 2" M9 300# WNRF Sch. XXS 10.16 1-1/2" M10 N6&N17 300# WNRF Sch. XXS 9.09 1" M11 N16 300# WNRF Sch. XXS 10.16 M12 N5A,N5B&N12 1-1/2" 300# WNRF Sch. XXS 10.16 M13 N10A& N10B 1/2" 300# WNRF Sch. XXS 7.47

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N. Design of Saddle Supports. O. Lowest MDMT Without Impact Test. P. Radiography. Q. Hydrostatic Test Pressure. R. Post Weld Heat Treatment (PWHT). S. Vessel Weight Calculation. T. Sresses in Vessel on Two Saddle Supports. U. Check of the Anchor Bolts Due to Seismic and Wind Loading. V. Lifting Lugs Thickness Calculations. W. Mesh Pad (Demister) Calculations. X. References.

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Description A. Title. B. Copyright. C. Revision Description. D. Contents. E. Applicable Loading Considered in Design. F. Impact Test Requirements. G. Standarad ASME B16.5 Flange Rating Class. H. Cylindrical Shell Thickness. I. Check of Cylindrical Shell Thickness for External Pressure, FV. J. Ellipsoidal Head Thickness Under Internal Pressure. K. Maximum Working Pressure, MWP (New/cold & Operating/corroded).


Page : 6 of 126


Sheet : 1 of 1 Page : 2 of 126



E. Applicable Loading Considered in Design.

[UG-22 & UG-98]

I. By considering UG-22 : 1. The loadings to be considered in design of vessel shall include the following : a. Internal design pressure (see item II below). b. Weight of the vessel and contents under test conditions. c. Attachment of vessel supports such as lifting lugs and saddles. 2. No expected effect for superimposed static reactions such as piping. There is no attached equipment such as motors, machinery, other vessels, lining and insulation. 3. The effect of the following loadings is considered negligible and/or not applicable : a. Cyclic and dynamic reactions due to pressure for thermal variations. b. Wind, snow, and seismic reactions. c. Impact reactions due to fluid chock. d. Temperature gradients and differential thermal expansion. II. By considering UG-21 & UG-98 : The max. allowable working pressure for a vessel part is the max.internal pressure at the highest point of vessel. Since the vessel is intended to be erected horizontaly, the static head equals almost the ID and the hight of leg : 16 18 0

Kg/cm2G Kg/cm2G Kg/cm2G

1556 694 894

MM MM MM

2.21023 PSIG 3.19602 PSIG 3.48011 PSIG

0.1556 0.225 0.245

Kg/cm2G Kg/cm2G Kg/cm2G

257.892 PSIG 258.878 PSIG 259.162 PSIG

2 18.1556 Kg/cm G 2 18.225 Kg/cm G 2 18.245 Kg/cm G

Max. Operating Pressure Internal design pressure, P (MAWP) (at highest point of vessel) External design pressure, Pex

227.3 257 0

PSIG PSIG PSIG

Vessel ID Max. leg height = 12 + 12 + 503 + 2 + 165 Max. height of drain N4 = 12 + 12 + 502 + 2 + 165 + 200

61.2598 INCH 27.3228 INCH 35.1969 INCH

Water sp. gr. Fluid sp. gr.at 15 oC

1 0.5

Max. hydrostatic head at internal bottom of vessel Max. hydrostatic head at bottom of leg Max. hydrostatic head at drain N4 Max. pressure for calculation at internal bottom of vessel Max. pressure for calculation at bottom of leg Max. pressure for calculation at outlet drain N4


Page : 7 of 126





F. Impact Test Requirements. Impact test is not mandatory for the following pressure vessels materials : I. Pressure Parts. a. Main Vessel Components : a. Shell : b Heads : c. Flanges : d. Nozzle Necks : e. Fittings, Tees :

ASME SA516 Grade 70 ASME SA516 Grade 70 ASME SA 105 ASME SA 106 Grade B ASME SA 234 Grade WPB

b. Stud Bolts & Nuts : f. Stud Boltshell g. Nuts

ASME SA 193 Grade B7 ASME SA 194 Grade 2H

II. Non-Pressure Parts. a. Saddle plate : b. Lifting lugs & Pads :

ASME SA516 Grade 70 ASME SA516 Grade 70

Thickness of vessel components : - Shell & Heads ASME SA516 Grade 70 - Max. Nozzle Necks Thk. ASME SA 106 Grade B

[UG-22 & UG-98]

P-No. Group No. 1 2 1 2 1 2 1 1 1 1

UNS No. G41400

1 1

Curve D D B B B

[Size < 2-1/2"]

2 2

0.9 INCH 0.56181 INCH

D D

22 14.27

o Where the MDMT is F 10 -12 in accordance with UG-20(f), UCS-66 and FIG. UCS-66, no impact test is required. Please refer pages from Page : 97 of 126

MM MM

o

C

Impct Test is not required as per Code, but is required as a client request. G. Standard ASME Flange Rating Class. 1. Standard ASME B16.5 welded neck flanges shall be used. 2. For standard flange, Carbon Steel material in accordance with ASME SA105, P-No. 1, Group No. 2, and for MAWP 255.682 PSIG o F and Design temp. 149 The rating of flanges shall be 150# class, which satisfys the requirements of Table 2 of ASME B16.5-1996. 3. As a client request, the rating shall be 300#

18 65

Kg/CM2G o

C

DESIGN CALCULATIONS OF PRESSURE VESSEL According to ASME Code, Section VIII, Division 1, Edition 2001, Addenda 2002 Designed by : Eng. Abdel Halim Galala, Design General Manager (assist.)

Page : 8 of 126 Sheet : 1 of 4 Rev. : 1



H. Cylindrical Shell Thickness Under Internal Pressure

[UG-27(c)]

Shell material, Killed Carbon Steel,

ASME SA516 Grade 70 Normalized & Notch Toughness Tested

Shell material Specifications [Table 1A, Suppart 1, ASME Sec. II, Part D] P-No. Group No. External Pressure Chart No.

1 2 CS-2

Vessel Inside Diameter, D Shell Inside Diameter, D Shell Inside Radius, Ri Shell length from Tangent-to-Tangent (T/T), L

61.2598 61.2598 30.6299 189.764

INCH INCH INCH INCH

1556 1556 778 4820

MM MM MM MM

Max. Design Temperature Min. Design Metal Temperature, MDMT Max. Operating Temperature

149 10 122

o

65 -12 50

o

Max. Operating Pressure Max. Internal Design Pressure, P (MAWP) External Design Pressure (Full Vacuum)

227.273 PSIG 255.682 PSIG 0 PSIG

16 18 0

Kg/CM2G

Shell Inside Diameter, D Shell Inside Radius, R Static Head = Vessel Diameter Static Head Pressure (water head x sp. gr. 1.0) Internal Design Pressure at bottom of vessel,

61.26 30.63

MM MM M

2.216 PSIG 257.898 PSIG

1556 778 1.556 0.156 18.156

Max. Allowable Stress @ Design Temp.(65 oC), S Max. Allowable Stress @ Test Temp.(40 oC), St

20000 20000

PSIG PSIG

1408 1408

Kg/CM2G

[Table 1A, SubPart 1, ASME Sec. II, Part D] Hydrostatic Test Pressure, Ph = 1.3 x MAWP x (St/S) [UG-99(b)]

332.386 PSIG

23.4

Kg/CM2G

Hydrostatic Test Pressure, Ph = 1.5 x MAWP x (St/S)

383.523 PSIG

27

Kg/CM2G

0.236 0.85 15%

6

MM

Corrosion Allowance, C Joint Efficiency, E [Spot Radiography],

Not Applicable

[Client request]

[UG-25] [TABLE UW-12] [Table UCS-57]

F F o F o

INCH INCH

INCH

C C o C o

Kg/CM2G Kg/CM2G

Kg/CM2G Kg/CM2G

Kg/CM2G


Page : 9 of 126




Date : 18.2.2004

H. Cylinderical Shell Thickness Under Internal Pressure (cont.)

Job No. : 7434-33

Client : APRC Type : Horizontal

[UG-27(c)]

Value of 0.385 SE [UG-27(c)(1)] Since P does not exceed 0.385 SE, Use Thin Wall Equation: [1] Min. Wall Thickness for Longitudinal Joints, t1 = PR / (SE - 0.6P) [UG-27(c)(1)]

6545

PSIG

460.768

Kg/CM2G

0.469

INCH

11.913

MM

[UG-27(c)(1)] Value of 1.25 SE Since P does not exceed 1.25 SE, Use Thin Wall Equation: [2] Min. Wall Thickness for Circumferential Joints, t2 = PR / (2SE + 0.4P) [UG-27(c)(2)]

21250

PSIG

1496

Kg/CM2G

0.232

INCH

5.893

MM

The min. wall thickness shall be the greater of t1 or t2 By Adding Corrosion Allowance to Wall Tickness, t Use Thickness of Construction, t (Adopted thickness) Corroded Thickness = Adopted thk. - Corrosion allowance

0.469 0.705 0.866 0.63

INCH INCH INCH INCH

11.913 17.907 22 16

MM MM MM MM

In case of using shell fab. from pipe '20" Pipe nominal thickness, t (Sch.40)

0.472440945

INCH

12

MM

20" Pipe nominal thickness under tolerance tn = t - 0.125 t

0.472440945

INCH

12

MM

20" Pipe Corroded Thickness = tn - Corrosion allow ance

0.236440945

INCH

6

MM

Using 20" pipe sch. 40 is

OK

0.458

INCH

11.633

MM

By using APPENDIX 1-1 (In terms of the Outside Diameter) :

tm = P Ro / (SE + 0.4 P)

Thickness adjusted for w all thickness tolerance :

0.523

INCH

13.284

MM

By Adding Corrosion Allow ance to Wall Tickness, t

t = tm / (100%-12.5%)

0.759

INCH

19.284

MM

Using 20" pipe w ith commercial w all thickness, sch. 40 is

OK

Ladders and Platforms Vessel saddle supports Hot/cold Insulation Post Weld Heat Treatment, PWHT Impact Test Note. Impact test is required as a client request.

N.A. Yes Page : 90 of 126 N.A. Not required per Code Page : 110 of 126 Per Code Page : 7 of 126


Page : 10 of 126




Date : 18.2.2004 Job No. : 7434-33


H. Check of Shell Thickness Under Internal Pressure [ For horizontal pressure vessels, with supplemental loading ] (vessel weight & hydrostatic liquid content) [APPENDIX L-2.2.2] Vessel OD 61.2598 INCH Vessel Wall Thickness in the Corroded Condition, t 0.63 INCH Vessel I.D. in the Corroded Condition, 2R = OD - 2 t 59.9998 INCH Shell length from Tangent-to-Tangent (T/T), L 189.764 INCH Shell Length from W.L.- to - W.L, L' 186.614 INCH

Joint Efficiency (Longitudinal Seams), E Joint Efficiency (Circumferential Seams), E Weight of Vessel, W Weight of Contents, Wc Total Weight of Vessel and Contents, Wt Assume a Total no. of Saddles Reaction at each Saddle, Q Head (Cap) Depth - to - T.L, [Table 8, ASME B16.9-1993] Saddle - to - T.L., A Material to Chart for Compressive Stress,

0.85 0.85 16377.3 lb 22383.2 lb 38760.5 lb 19380.3 lb 15.315 INCH 22.047 INCH

1600 16 1568 4820 4740

MM MM MM MM MM

7428 10152 17580 2 8790 389 560

Kg Kg Kg Kg MM MM

[ FIG.CS-2 CHART, SUBPART 3 , ASME SEC.II , PART D ]

Shell, Ro N.B. See vessel drawing layout,

* Here three cases must be investigated: Case 1. Circumferential Stress due to Internal Pressure, t = PR / ( SE-0.6 P) [UG-27C(1)] Case 2. Longitudinal Tensile Strength due to Bending ( at the midpoint between the saddles) must be added to the longitudinal Stress due to Internal Pressure.

31.4961 INCH 800 Page : 91 of 126

MM

0.465

MM

INCH

11.811

[ APPENDIX L-2.2.2]

t

0.238

N.B. Circumferential joint at center of vessel is the point of max. positive moment. Max. negative moment is at supports but there is no joint there.Other circumferential joint must be investigated using moment at the joint in calculating the compined stresses.

INCH

6.045

MM


Page : 11 of 126




Date : 18.2.2004 Job No. : 7434-33


H. Check of Shell Thickness Under Internal Pressure (cont.) [ For horizontal pressure vessels, with supplemental loading ] (vessel weight & hydrostatic liquid content) [APPENDIX L-2.2.2] Case 3 . Longitudinal Compressive Stress due to Bending.

First determine the max. allowable compressive stress : Factor A = 0.125 / (Ro / t ) [UG-23(b)]

0.00344

Therefore, B

16000

[SUBPART 3 OF ASME SEC.II, PART D, FIG.CS-2]

PSIG

1126.4

Kg/CM2G

0.229

MM

NOTES:

1. No need to calculate the value of B by equation B = AE / 2 , since the value of A falls under the applicable Material/Temp. line. [ Suppart 3 of ASME Sec.II, Part D, Fig. CS-2]

2. The general equatioin for thickness is the same as for longitudinal tensile stress except the pressure portion drops out since the most severe condition occurs when there is no pressure in the vessel . 3. The joint efficiency for butt-welded joints shall be taken as unity when investigating longitudinal compression. [UG-23(b)]

[ APPENDIX L-2.2.2]

Thickness ,

t

0.00902 INCH


Page : 12 of 126




Date : 18.2.2004 Job No. : 7434-33


I. Check of Shell Thickness for External Pressure (Full Vacuum) Design Temperature For external pressure on cylinder, use UG-28 and Subpart 3. Determine the effective length of shell without stiffening rings, L

149

o

65

o

Shell length from Tangent-to-Tangent (T/T), L1 Internal Height of Elliptical Head 2:1, h = ID/4 Head Wall Thickness, th Internal Height of Ellipsoidal Head 2:1, ho = h + th Effective shell length without stiffening, L = L1 + 2/3 ho

189.764 15.315 0.7874 16.1024 200.499

INCH INCH INCH INCH INCH

4820 389 20 409 5092.667

MM MM MM MM MM

Assume t for internal pressure (at corroded condition) Do = ID + 2 t L / Do Do / t

0.62992 INCH 62.7559 INCH 3.1949 99.625 > 10

16 1594

MM MM

Since Do/t > 10, use UG-28(c)(1) a. Enter Fig. G with L / Do and read across to sloping line of Do/t Read factor A

0.00038 387.2

Kg/CM2G

73.6094 PSI

5.1821

Kg/CM2G

15

1.056 OK 2024352 2055680

Kg/CM2G

b. Enter Fig. CS-2 with A (to find factor B), which falls under the curve. Follow step (6) of UG-28(c)(1), and calculate the value of max. allowable external working pressure, PA = 4B / 3 (Do / t) Change t untill PA > 15 PSI (full vacuum) E = Modulus of elasticity at design temp. at amp. temp. Notes. 1. For value of A falling to the left of the material-temp. line, the value of Pa can be calculated as follows : Pa = 2 A E / 3 (Do /t) 2. For L/Do > 50, use L/Do = 50 For L/Do < 0.05, use L/Do = 0.05 3. For Do/t > 10, For Do/t < 10,

use UG-28(c)(1) use UG-28(c)(2)

5500

F

PSI

PSI

2.9E+07 PSI 2.9E+07 PSI

C

Kg/CM2G Kg/CM2G


Page : 13 of 126




Date : 18.2.2004

J. Ellipsoidal Head Thickness Under Internal Pressure

Job No. : 7434-33


[UG-32(f)]

Head material, Carbon Steel Head type [Seamless] Head material Specifications [Table 1A, Suppart 1, ASME Sec. II, Part D] P-No. Group No. External Pressure Chart No.

ASME SA516 Grade 70 Ellipsoidal 2:1

Head ID Head OD Head Outside Radius

61.2598 INCH 62.9921 INCH 31.4961 INCH

[ASME B16.5-1996]

1 2 CS-2 1556 1600 800

MM MM MM o

149 10 257.898 227.273 257.898 61.26 30.63 20000 20000

o

PSIG PSIG

65 -12 18.156 16 18.156 1556 778 1408 1408

Hydrostatic Test Pressure, Ph = 1.3*MAWP(St/S)

335.27

PSIG

23.603

Kg/CM2G

[UG-25] Corrosion Allowance, C Joint Efficiency, E (Seamless & Full Radiography) [TABLE UW-12]

0.23622 INCH 0.85

6

MM

Outside Diameter of Head, Do Outside Radius of Head, Ro

62.9921 INCH 31.4961 INCH

1600 800

MM MM

Value of 0.665 SE Since the value of 0.66SE > P, Use Thin Wall Equation for Calculating the Min. required Thickness of Head, t: t1 = PD / (2SE-0.2P) [UG-32(d)] (1)

11305

795.872

KG/CM2G

Design Temperature Min. Design Metal Temperature, MDMT Max. Allowable Working Pressure, MAWP Operating Pressure Internal Design Pressure, P Head Skirt Inside Diameter, D Head Inside Radius, L ( ri ) Max. Allowable Stress @ Design Temp.(60 oC), S Max. Allowable Stress @ Test Temp.(40 oC), St [TABLE 1A , SUBPART 1 , ASME SEC. II , PART D] [UG-99(b)]

F F PSIG PSIG PSIG

o

INCH INCH

PSIG

C C

o

Kg/CM2G Kg/CM2G Kg/CM2G

MM MM Kg/CM2G Kg/CM2G

0.46538 INCH

11.82059 MM

11305

795.872

Compare to Thickness of Seamless Spherical Shell :

Ps = 0.665 SE Since P < Ps, Calculate Thickness for thin Wall Spherical Shell: t2 = PRo/(2SE+0.8P) [APPENDIX 1-1] (2) For thin Wall ellipsoidal 2:1 head : t = PD/(2SE-0.2P) [UG-32(d)]

PSIG

KG/CM2G

0.23746 INCH

6.031587 MM

0.46538 INCH

11.82059 MM


Page : 14 of 126




Date : 18.2.2004

J. Ellipsoidal Head Thickness Under Internal Pressure (cont.)

Head Thickness due to Internal Pressure, t = MAX ( t1 , t2) By adding Corrosion Allowance to Wall Thickness, Use Thickness of Construction, t (Adopted thickness)

Job No. : 7434-33


[UG-32(f)]

0.46538 INCH 0.7016 INCH 0.787 INCH

11.82059 MM 17.82059 MM 20 MM

Corroded Thickness = Adopted thk. - Corrosion allowance

0.55118 INCH

14

MM

In case of using '20" Cap nominal thickness, t (Sch. 40)

0.787401575

INCH

20

MM

20" Cap nominal thickness under tolerance tn = t - 0.125 t

0.787401575

INCH

20

MM

20" Cap Corroded Thickness = tn - Corrosion allow ance

0.551181102

INCH

14

MM

Using 20" Cap sch. 80 is

OK

Required Head Thickness : Head tr = PD / (2SE - 0.2 P)

0.46538 INCH

11.82059 MM

a. For Shell : MWP, New & cold (20 MM) P = SE t /(R + 0.6 t) [UG-27(c)(1)] MWP, Operating & corroded (14 MM) P = SE t /(R + 0.6 t)

472.622 PSIG 345.395 PSIG

33.273 24.316

b. For Head : MWP, New & cold (20 MM) P = 2SE t /(D + 0.2 t) [UG-32(d)(1)] MWP, Operating & corroded (14 MM), P = 2SE t /(D + 0.2 t)

435.675 PSIG 305.362 PSIG [

30.67149 Kg/CM2G 21.49751 Kg/CM2G

[ t Represents the Min. Thickness after Forming ]

K. Maximum Working Pressure, MWP (New & Operating)

Kg/CM2G Kg/CM2G


Page : 15 of 126




Date : 18.2.2004 Job No. : 7434-33


L. Check of Ellipsoidal Head Thickness for External Pressure (Convex Side), (Full Vacuum) [UG-33(d)]

Assumed corroded thickness of head, t Outside diameter of the head skirt, Do The equivalent outside spherical, Ro = Ko Do [UG-33(b)] Outside height of the ellipsoidal head (measured from head-bend line), ho Ratio of the major to the minor axis of ellipsoidal head, Do/2ho

0.55118 62.3622 54.342 16.1024 1.93643

Factor depending on the ellipsoidal head proportions Do/2ho, Ko

0.87139

(use interpolation)

INCH INCH INCH INCH

14 1584 1380.288 409

MM MM MM MM

PSI

668.8

Kg/CM2G

[See Table UG-33.1]

The required thickness of an ellipsoidal head having pressure on the convex side, either seamless or of built-up construction with butt joints, shall not be less than that determined by the following procedure : Step 1. Assume a value for t and calculate the value of factor A using the following formula : A = 0.125 / (Ro / t)

0.00127

Step 2. Using the value of A calculate in Step 1, follow the same procedure as that given for spherical shells in UG-28(d), Step 2 through 6 : a. Enter Fig. CS-2 with A (to find factor B), which is under the curve, B Follow step (4) of UG-28(d), and calculate the value of max. allowable external working pressure, PA = B / (Ro / t) Change t untill PA > 15 PSI (full vacuum)

9500

96.3567 PSI 0

PSI

Notes. 1. For value of A falling to the left of the material-temp. line, the value of Pa can be calculated in accordance with Step 5 of UG-28(d), as follows : Pa = 0.0625 E / (Ro /t)2 E = Modulus of elasticity at design temp.

2.6E+07 PSI

2 6.783514 Kg/CM G

0 OK

Kg/CM2G


Page : 21 of 126


Shee t : 1 of 5 Rev. : 1


Date : 18.2.2004 Job No. : 7434-33


M2. Nozzle Mark : N8 24" NPS, Sch. 30, 300# WNRF (Manhole Located at Shell with Reinforcement) No. of nozzles, n 1 Nozzle Neck Thickness Calculation [UG-27(c) & Appendix 1-1] Nozzle Size, NPS Nozzle Material

24 INCH 600 ASME SA 106 Grade B

DN

Design Pressure, P Design Temperature For nominated Design Pressure & Temperature, Flange Rating

257.898 PSIG o 149 F 300#

18.156 65

17100 17100

1203.84 1203.84

Kg/CM2G

12 INCH 1 0.23622 INCH

304.8

MM

6

MM

0.1799

INCH

4.569353 MM

0.41612 INCH

10.56935 MM

By adding Pipe Tolerance 12.5% to the Thickness of Nozzle, t

0.46813 INCH

11.89052 MM

Use Nozzle 24" NPS with Selected Neck Sch. 30, with Thickness 0.562" (14.27 MM). [Table 2 of ANSI B 36.10M-1985-(R-1994)]

0.562

INCH

14.2748

MM

Nozzle Neck Maximum Working Pressure, MWP (New & Operating) Nozzle wall thickness less tolerance 12.5% Nozzle wall thickness less tolerance 12.5% - Corrosion allowance MWP, New & cold (14.275 MM) P = Snt E t /(Ron - 0.4 t) [App. 1.1] MWP, Operating & corroded (9.49 MM) P = Sn E t /(Ron - 0.4 t)

0.49175 0.25553 712.422 367.258

INCH INCH

MM MM

PSIG PSIG

12.49045 6.49045 50.15448 25.85495

Nozzle Flange Maximum Working Pressure, MWP (New & Operating) MWP, New & cold, 300# @ 100 oF [ASME B.165, Table 2] MWP, Operating & corroded, 300# @ 149 oF [ANSI B16.5, Table 2]

740 708.15

PSIG PSIG

Kg/CM2G 52.096 49.85376 Kg/CM2G

Kg/CM2G o

C

[ANSI/ASME B16.5-1996]

Max. Allowable Stress of Nozzle Material @ Design Temp.(75 oC), Sn Max. Allowable Stress of Nozzle Materiall @ Test Temp.(40 oC), Snt

PSIG PSIG

Kg/CM2G

[Table 1A, SubPart 1, ASME Sec. II, Part D]

Outside Radius of Nozzle, Ron Joint Efficiency of Nozzle, En (Seamless Pipe) Nozzle Corrosion Allowance, Can Nozzle Thickness Calculation : Longitudinal Stress, t = PRon /(Sn*En + 0.4 P) By adding Corrosion Allowance, t

[APPENDIX 1.1] [UG-25]

Kg/CM2G Kg/CM2G


Page : 22 of 126


Sheet : 2 of 5 Date : 18.2.2004


Client : APRC Job No. : 7434-33


M2. Nozzle Mark : N8 24" Sch. 30, 300# WNRF Manhole (cont.) Nozzle Opening Calculation With Reinforcing

[UG-27(c) & Appendix 1-1]

Nozzle Pipe Size, NPS Nozzle Pipe Sch. Design Pressure, P Design Temparture

24 INCH 30 257.898 PSIG o 149 F

Shell Material Nozzle Material Reinforcing Pad Material Allowable Stress of Shell Material, Sv Allowable Stress of Nozzle Material, Sn Allowable Stress of Pad Material, Sp

ASME SA516 Grade 70 ASME SA 106 Grade B ASME SA516 Grade 70 20000 PSIG 1408 17100 PSIG 1203.84 20000 PSIG 1408

Shell Thickness Shell Corrosion Allowance, Cas Shell Thickness l Shell Thickness less Corrosion Allowance

0.86614 0.23622 0.86614 0.62992

INCH INCH INCH INCH

22 6 22 16

MM MM MM MM

0.562 0.49175 0.23622 0.25553 0.25553 0.86614 1 1 1 1 62.9921 61.7323 30.8661

INCH INCH INCH INCH INCH INCH

14.2748 12.49045 6 6.49045 6.49045 22

MM MM MM MM MM MM

INCH INCH INCH

1600 1568 784

MM MM MM

24 22.876 0 1.5748 0.63882 23.4889 11.7445

INCH INCH INCH INCH INCH INCH INCH

609.6 581.0504 0 40 16.22613 596.6191 298.3096

MM MM MM MM MM MM MM

ess Pipe Tolerance 12.5% (12.5% NA)

& 12.5%, t (12.5% NA)

Nozzle Wall Nominal Thickness Nozzle Wall Thickness less Pipe Tolerance 12.5% Nozzle Corrosion Allowance, Can Nozzle Wall Thick. less Corr. Allowance & 12.5% , tn Nozzle Wall Thick.of Internal Projection (less Corr. Allowance & 12.5%), ti

Reinforced Pad Thickness, te Joint Efficiency of Shell, E Joint Efficiency of Nozzle, En Correction Factor, F [UG-37(a)] E1 [Nozzle in solid plate] Shell Outside Diameter, OD Shell Inside Diameter in Corroded Condition, 2R = OD - 2 t Shell Inside Radius in Corroded Condition, R Nozzle Outside Diameter, OD Nozzle Inside Diameter, ID Nozzle Projection beyond Inner Vessel Wall, h = min. (h1,h2) h1 = 2.5 t h2 = 2.5 ti Nozzle ID Without Corrosion Allowance & 12.5% , d = OD - 2*tn

Finished Radius of Circular Opening, Rn

600

DN

18.15602 Kg/CM2G o 65 C

Kg/CM2G Kg/CM2G Kg/CM2G


Page : 23 of 126




Date : 18.2.2004 Job No. : 7434-33


M2. Nozzle Mark : N8 24" Sch. 30, 300# WNRF Manhole (cont.) Nozzle Opening Calculation With Reinforcing (cont.) [UG-27(c) & APPENDIX 1-1] * Outside Diameter of Reinforced Pad (if used) [UG-40(b)&FIG.UG-37.1]

Dp1 = 2 d Dp2 = 2 (Rn + nozzle wall thk. , tn + vessel wall thk. , t ) OD of Reinf. Pad, Dp = the greater of Dp1 or Dp2 Calculating Siz of Fillet Welds : [UW-16(c)(2)&FIG.UW-16.1] * For Outward Nozzle Weld [UW-16(c)(2)&FIG.UW-16.1SKETCH (c)] Calculation of tmin. : tmin.1 = 0.75 inch tmin.2 (nozzle wall nominal thickness) tmin.3 (shell wall thickness) tmin. = lesser of tmin.1, tmin. & tmin.3 Calculation of tc : tc1 = 0.25 inch tc2 = 0.7 t min. tc = lesser of tc1 & tc2 By Considering Equal Legs Fillet Welds : Leg of Outward Nozzle Weld = SQRT2 * tc Use Leg with Dimension E in Dwg. No. 7434-33-3A * For Outer Reinforcing Pad Weld [FIG.UW-16 SKETCH (c)] tmin.1 = 0.75 inch tmin.2 ( te = thk. of reinforcing element) tmin.3 ( shell wall thickness) tmin. = lesser of tmin.1, tmin. 2 & tmin.3 1/2 tmin. By Considering Equal Legs Fillet Welds : Leg of Outer Pad Weld = SQRT(2)*(tmin./2) Use Leg with Dimension D in Dwg. No. 7434-33-3A * Wall Thickness Required : Shell Nozzle

46.9779 INCH 25.2598 INCH 46.9779 INCH

1193.238 MM 641.6 MM 1193.238 MM

0.75 0.562 0.47244 0.47244 0.25 0.33071 0.25

19.05 14.2748 12 12 6.35 8.4 6.35

INCH INCH INCH INCH INCH INCH INCH

MM MM MM MM MM MM MM

0.35355 INCH 0.35433 INCH

8.980256 MM 9 MM

0.75 0.86614 0.86614 0.75 0.375

19.05 22 22 19.05 9.525

MM MM MM MM MM

0.53033 INCH 0.55118 INCH

13.5 14

MM MM

0.47256 INCH 0.17874 INCH

12.0029 MM 4.540115 MM

INCH INCH INCH INCH INCH

[UG-27(c)(1)]

tr = PR / (SE - 0.6 P) trn = PRn /(SnEn - 0.6 P)

* Strength Reduction Factors : Sp / Sv fr1 = Sn / Sv fr2 = Sn / Sv fr3 = lesser of Sn/Sv or Sp/Sv fr4 = Sp / Sv

1 0.855 0.855 0.855 1


Page : 24 of 126




Date : 18.2.2004 Job No. : 7434-33


M2. Nozzle Mark : N8 24" Sch. 30, 300# WNRF Manhole (cont.) Min. Nozzle Neck Wall Thickness Check Per UG-45 A. Wall Thickness per UG-45(a) :

trna = trn + Can

B*. Wall Thickness per UG-45(b) : trnb = Min. (trnb1, trnb2, trnb3, trnb4) Wall Thickness per UG-45(b)(1), trnb1 = Min. (trnb11, trnb12) trnb11 = tr + Cas (tr for shell or head at E=1) trnb12 = Min Wall Thickness per UG-16(b), see below Wall Thickness per UG-45(b)(2), trnb2 (apply to external pressure only),

0.41497 INCH

10.54012 MM

0.29872 0.29872 0.70878 0.29872

INCH INCH INCH INCH

7.5875 7.5875 18.0029 7.5875

NA

INCH

#VALUE! MM

Wall Thickness per UG-45(b)(3), trnb3 (apply to internal & external pressure) = Max. (trnb1, trnb2) 0.29872 INCH Wall Thickness per UG-45(b)(4), trnb4 = Min. thickness of std. wall pipe (1-0.125)+ Can 0.56435 INCH

7.5875

MM MM MM MM

MM

14.33438 MM

(Under tolerance12.5% in accordance with ASME B36.10M)

Nominal thickness of std. pipe wall thickness, NPS 24", Sch. Std. Wall Thickness per UG-16(b), trnb12 I - Min. Wall Thickness 1/16" + Cas II - Min. Wall Thickness of Unfired Steam Boilers = 1/4" + Cas III - Min. Wall Thickness of Shell/Head in Compressed Air Service, Steam Service, and Water Service = 3/32" + Cas Selected Vessel Service in our case is : Case III (compressed air) So, the Min. Wall Thickness per UG-16(b), trnb12

The min. nozzle wall thk. = Max. thk. determined by UG-45(a), or by UG-45(b) The nominal nozzle pipe wall thk. The min. nozzle thk. provided = t (1-0.125) So, the thickness provided meets the rules of UG-45.

0.375

9.525

MM

0.29872 INCH 0.48622 INCH

7.5875 12.35

MM MM

0.32997 INCH

8.38125

MM

0.29872 INCH

7.5875

MM

0.41497 INCH 0.562 INCH 0.49175 INCH OK

10.54012 MM 14.2748 MM 12.49045 MM

Since there is no superimposed loads, the vessel doesn't require a calculationon shear stresses caused by UG-22(c). * Since the opening is access/inspection, UG-45(b) is not applicable

[UG-45(b)[

INCH


Page : 25 of 126




Date : 18.2.2004

M2. Nozzle Mark : N8 24" Sch. 30, 300# WNRF Manhole (cont.) Nozzle Opening Calculation With Reinforcing (cont.)

Job No. : 7434-33


[UG-27]

Area of Reinforcement (witht Reinforcing element) : Required Area, A = d tr F + 2 tn tr F(1-fr1)

11.1348 INCH2

7183.753 MM2

Area Available in Shell, A1: A11 = d (E1 t - F tr) - 2tn (E1 t - F tr)(1-fr1) A12 = 2 (t + tn)(E1 t - F tr) - 2tn (E1 t - F tr)(1-f r1) A1 = The Greater of A11 or A12

3.6847 INCH 0.26702 INCH2 3.6847 INCH2

2

2377.221 MM 172.2696 MM2 2377.221 MM2

Area Available in Nozzle Projecting Outward, A2 : A21 = 5 (tn - trn) fr2 t A22 = 2 (tn - trn)(2.5tn+te) fr2 A2 = The Lesser of A21 or A22

0.20677 INCH2 0.19761 INCH2 0.19761 INCH2

133.4029 MM2 127.4869 MM2 127.4869 MM2

Area Available in Inward Nozzle, A3 : (Not applicable) A31 = 5 t ti fr2 A32 = 5 ti ti fr2 A33 = 2 h ti fr2 A3 = The Greater of A31, A32 or A33

0.68812 0.27914 0 0

Area Available in Outward Nozzle Weld, A41: A41 = (LEG)2 fr2

0.10735 INCH2

Area Available in Outer Reinforcing Pad Weld, A42: A42 = (LEG)2 fr4

0.3038

Area Available in Inward Nozzle Weld, A43 : A43 = (LEG)2 fr2

443.9468 180.0884 0 0

MM2 MM2 MM2 MM2

69.255

MM2

196

MM2

0.10735 INCH2

69.255

MM2

Area Available in Reinforcing Pad, A5 : A5 = (Dp - d - 2tn) te fr4

19.9021 INCH2

12840.04 MM2

Total Area Available, AT : AT = A1 + A2 + A41 + A42 + A43 + A5

24.3029 INCH2

15679.26 MM2

AT is greater than A, therefore opening is adequately reinforced. NOTE. No need for Strength Path Calculations.

INCH2 INCH2 INCH2 INCH2

2

INCH2

Pressure Vessel Design (Shell, Head & Nozzle) - By Abdel Halim Galala

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