PV-1390-CAL-R1

Revision : 2

Date :

DESIGN CALCULATION FOR

THERMAL DEAERATOR( 1350 O.D. x 3000 S/L )

2 18/09/2007 REVISED AS SHOWN NASRUL OMAR

1 18/05/2004 REVISED AS SHOWN Dida OMAR

0 12/04/2004 ISSUE FOR APPROVAL Dida OMAR

Rev Date Issued Status Prep. By Checked By Approved By

18th Sept 2007

Advance Boiler Sdn Bhd

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CONTENTS

PAGE

A CONVERSION TABLE 1

B DESIGN DATA 2

1.0 SHELL THICKNESS CALCULATION 4 - 5

2.0 TORISPHERICAL HEAD THICKNESS CALCULATION 6 - 7

3.0 FIBER ELONGATION 8

4.0 HYDRO-STATIC TEST PRESSURE 9

5.0 HYDRO-TEST SHELL AND HEAD THICKNESS 9

6.0 WEIGHT ANALYSIS 10

7.0 NOZZLE THICKNESS CALCULATION 11

8.0 NOZZLES REINFORCEMENT CALCULATION 12 - 25

9.0 SIZE OF WELD REQUIRED FOR NOZZLES 26

10.0 SADDLE SUPPORT CALCULATION 27 - 28

11.0 BASE PLATE AND ANCHOR BOLTS CALCULATION 29


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Page : 1

A. CONVERSION TABLE

S.I. UNIT IMPERIAL UNITLength 1 mm = 0.03937 in

Volume 1 = 35.31Mass 1 kg = 2.204 lb

Pressure 1 = 145.038 psi= 10 bar

= 10.1969Temperature

X =

m3 ft3

N/mm2

kgf/cm2

From oC to oF oC (XoC x 1.8) + 32 oF


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B. DESIGN DATA FOR THERMAL DEAERATOR Page : 2

ITEM NO. : PV-1390DESCRIPTION : THERMAL DEAERATORORIENTATION : HORIZONTALDESIGN CODE : ASME SEC. VIII DIV. 1 - 2001 EDITION

+ 2002 ADDENDACODE STAMP VESSEL : YES

PROPERTIES DATA UNIT

DIMENSIONa) DIAMETER (ID) 52.52 ( 1334.0 ) in (mm)b) TL/TL LENGTH 118.11 ( 3000.0 ) in (mm)

FLUID / CONTENT STEAM -

DESIGN PRESSURE

a) INTERNAL 15 ( 0.103 )

b) EXTERNAL 0 ( 0.000 )

OPERATING PRESSURE 5 ( 0.034 )

DESIGN TEMPERATURE 120 ( 248 )

MIN. METAL DESIGN TEMPERATURE 20 ( 68 )

HYDRO-STATIC TEST PRESSURE 19.5 ( 0.134 )

POST WELD HEAT TREATMENT See Fiber Elongation -

RADIOGRAPHYa) SHELL - -b) HEADS - -

JOINT EFFICIENCYa) SHELL 0.70 -b) HEADS 0.85 -

CORROSION ALLOWANCE 0.059 ( 1.5 ) in (mm)

WEIGHTa) EMPTY WEIGHT 2354 ( 1068 ) lb (kg)b) HYDRO - TESTING WEIGHT 13135 ( 5960 ) lb (kg)

MATERIAL USEDa) SHELL SA 240 GR 304 -b) HEADS SA 240 GR 304 -c) NOZZLES SA 106 GR B -d) FLANGES SA 105 -e) SADDLE SUPPORT JIS G3101 SS400 -f) BOLTS SA 193 GR B7 -g) NUTS SA 194 GR 2H -

OTHERSIMPACT TESTING N / A -WIND & SEISMIC LOADING N / A -LOCAL LOADING N / A -CYCLIC LOADING N / A -

psig (N/mm2)

psig (N/mm2)

psig (N/mm2)

oC (oF)

oC (oF)

psig (N/mm2)


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B. DESIGN DATA FOR BOOT Page : 3

ITEM NO. : PV-1390DESCRIPTION : THERMAL DEAERATORORIENTATION : HORIZONTALDESIGN CODE : ASME SEC. VIII DIV. 1 - 2001 EDITION

+ 2002 ADDENDACODE STAMP VESSEL : YES

PROPERTIES DATA UNIT

DIMENSIONa) DIAMETER (ID) 23.62 ( 600.0 ) in (mm)b) LENGTH 51.18 ( 1300.0 ) in (mm)

FLUID / CONTENT STEAM -

DESIGN PRESSURE

a) INTERNAL 15 ( 0.103 )

b) EXTERNAL 0 ( 0.000 )

OPERATING PRESSURE 5 ( 0.034 )

DESIGN TEMPERATURE 120 ( 248 )

MIN. METAL DESIGN TEMPERATURE 20 ( 68 )

HYDRO-STATIC TEST PRESSURE 19.5 ( 0.134 )

POST WELD HEAT TREATMENT See Fiber Elongation -

RADIOGRAPHYa) SHELL - -b) HEADS - -

JOINT EFFICIENCYa) SHELL 0.70 -b) HEADS 0.85 -

CORROSION ALLOWANCE 0.059 ( 1.5 ) in (mm)

WEIGHTa) EMPTY WEIGHT 2354 ( 1068 ) lb (kg)b) HYDRO - TESTING WEIGHT 13135 ( 5960 ) lb (kg)

MATERIAL USEDa) SHELL SA 240 GR 304 -b) HEADS SA 240 GR 304 -c) NOZZLES SA 106 GR B -d) FLANGES SA 105 -e) SADDLE SUPPORT JIS G3101 SS400 -f) BOLTS SA 193 GR B7 -g) NUTS SA 194 GR 2H -

OTHERSIMPACT TESTING N / A -WIND & SEISMIC LOADING N / A -LOCAL LOADING N / A -CYCLIC LOADING N / A -

psig (N/mm2)

psig (N/mm2)

psig (N/mm2)

oC (oF)

oC (oF)

psig (N/mm2)


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1.0 SHELL THICKNESS Page : 4

( UG27 (c) (1) )

DESIGN DATA

Properties Symbol Data UnitMaterial used - SA 240 GR 304 -Radiography - - -Joint Efficiency E 0.7 -Allowable Stress, at

120 136.985

Internal Design Pressure 0.103Liquid Height H 1350.00 mmFluid / Liquid Specific Gravity SG 1.00 -

Total Design Pressure P 0.117Internal Diameter Di 1334.0 mmCorrosion Allowance,

a) Internal 1.50 mm

b) External 0 mm

Corroded Internal Diameter 1337.00 mm

Corroded Internal Radius 668.50 mm

a) Circumferential StressMinimum required thickness,

=

= 0.814 mm

b) Longitudinal StressMinimum required thickness,

=

= 0.407 mm

c)

>

== 2.314 mm =

Plate used thk = 4.5 mm is Satisfactory!

oC Sd N/mm2

Pi N/mm2

N/mm2

C1

C2

Di,corr

Ri, corr

tcir PRi,corr

SdE - 0.6P

tlong PRi,corr

2SdE + 0.4P

Minimum Required Thickness, tr (included corrosion allowance)

Since tcir tlong

tr tcir + C1 + C2


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1.1 SHELL THICKNESS (BOOT) Page : 5

( UG27 (c) (1) )

DESIGN DATA


120 136.985



a) Internal 1.50 mm

b) External 0 mm



a) Circumferential StressMinimum required thickness,

=

= 0.366 mm

b) Longitudinal StressMinimum required thickness,

=

= 0.183 mm

c)

>

== 1.866 mm ###

Plate used thk = 4.5 mm is Satisfactory!

oC Sd N/mm2

Pi N/mm2

N/mm2

C1

C2

Di,corr

Ri, corr

tcir PRi,corr

SdE - 0.6P

tlong PRi,corr

2SdE + 0.4P


Since tcir tlong

tr tcir + C1 + C2


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2.0 TORISPHERICAL HEAD THICKNESS Page : 6

( Appendix 1-4 (d) )

DESIGN DATA


120 136.985



a) Internal 1.50 mm

b) External 0 mm



Inside Crown Radius of 1334.0 mmDished Head (corroded)Knuckle Radius )corroded) r 133.4 mm


a) Minimum required thickness,

= 10.00

M =Values of Factor M, = 1.54

=

= 1.03 mm

c)

== 2.53 mm

Plate used thk = 6 mm Min. thk after forming = 3.5 mm is Satisfactory!

oC Sd N/mm2

Pi N/mm2

N/mm2

C1

C2

Di,corr

Ri, corr

Lcorr

Ri, corr

Ratio Lcorr/rcorr

0.25(3+(L/r)0.5))

t PLcorrM

2SdE - 0.2P


tr t + C1 + C2


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2.1 TORISPHERICAL HEAD THICKNESS (BOOT) Page : 7

( Appendix 1-4 (d) )

DESIGN DATA


120 136.985



a) Internal 1.50 mm

b) External 0 mm



Inside Crown Radius of 600.0 mmDished Head (corroded)Knuckle Radius )corroded) r 60.0 mm


a) Minimum required thickness,

= 10.00

M =Values of Factor M, = 1.54

=

= 0.46 mm

c)

== 1.96 mm

Plate used thk = 6 mm Min. thk after forming = 3.5 mm is Satisfactory!

oC Sd N/mm2

Pi N/mm2

N/mm2

C1

C2

Di,corr

Ri, corr

Lcorr

Ri, corr

Ratio Lcorr/rcorr

0.25(3+(L/r)0.5))

t PLcorrM

2SdE - 0.2P


tr t + C1 + C2


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3.0 FIBER ELONGATION (UCS-79 (d)) Page : 8

A) HEAD PLATE

% Extreme Fiber Elongation : 75t(1- ) = 3.37 % ( > 5%)

where

= Final Center Line Radius = 133.4

= Original Center Line Radius = ¥t = Used Nominal Thickness = 6

The extreme fibre elongation> 5%, thus, HEAT TREATMENT as per UCS-56 is NOT REQUIREDAs refer to UCS-79 (d), when the extreme fiber elongation is more than 5% from the as-rolled condition and any of the condition stated exist. Since, a) the vessel contain no lethal subtances

b) the materials require no impact testingc) the thickness…does not exceed 5/8" (16 mm) before cold forming

the vessel does not required HEAT TREATMENT unless the reduction by cold forming from the as rolled

B) SHELL PLATE

% Extreme Fiber Elongation : 50t(1- ) = 0.34 % ( < 5%)

where

= Final Center Line Radius = 670

= Original Center Line Radius = ¥t = Used Nominal Thickness = 4.5

The extreme fibre elongation < 5%, thus, HEAT TREATMENT as peNOT REQUIRED

Rf

Rf Ro

Rf

Ro

thickness is more than 10% and the temperature of the material during forming is between 250oF to 900oF.

Rf

Rf Ro

Rf

Ro


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4.0 HYDRO-STATIC TEST PRESSURE (UG-99) Page : 9

DESIGN DATA

Properties Symbol Data Unit

Maximum Allowable Working Pressure MAWP 0.103

Design Temperature 120

Ambient Temperature 30

Allowable Stress at design cond. 136.985

Allowable Stress at test cond. 136.985

= 1.3 x

= 0.134 19.5 psi

Note : MAWP is assumed to be same as design pressure as stated in UG-99 (b) note 34.

5.0 HYDRO-TEST THICKNESS CALCULATION


Static Pressure sh 0.013

Hydrostatic Pressure Pt 0.134

HT Pressure + Static Pressure 0.148

Shell Outside Diameter D 1343.00 mm

Shell Outside Radius R 671.50 mm

Yield stress for Shell Sy 206.84

Allowable stress for HT ( 0.9 x Sy ) S 186.16

Outside Crown Radius 1346.00 mm

M 1.54

Joint Efficiency (Shell) E 0.7

Minimum required shell thickness ,

= 0.761 mm

Minimum required head thickness ,

= 1.172 mm

Therefore, check thk used for :

Shell = 4.5 Satisfactory!

Minimum Head thk after forming = 3.5 Satisfactory!

N/mm2

TdoC

TaoC

Sd N/mm2

Sa N/mm2

Hydro-static Pressure, Ph

Ph Sa / Sd x MAWP

N/mm2

N/mm2

N/mm2

PH N/mm2

N/mm2

N/mm2

Lo

Ratio Lcorr/rcorr

PH x R / [SE+0.4PH]

PH x Lo x M / [2SE+PH(M-0.2)]


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6.0 WEIGHT ANALYSIS Page : 10

GROUP ITEM PART NAME

WEIGHT (kg)

SHELL HEAD (rear)

A

1 SHELL 446 - - 4462 TORISPHERICAL HEAD - 92 92 1843 SHELL (BOOT) 884 TORISPHERICAL HEAD (BOOT)-top 195 NOZZLES 196.17 25.96 222.16 SADDLE SUPPORT 58.1 - - 58.1

B7 INT. / EXT. REMOVABLE 8 3 3 14.08 INT. / EXT. NON REMOVABLE 8 2 2 12.0

C 9 OPERATING LIQUID 1140 567 189 1895.9

D 10 TESTING LIQUID 4235 355 326 4917

SUMMARY

1 EMPTY WEIGHT ( A + 5% Additional ) 828 144 97 10682 ERECTION WEIGHT (A+B) 844 149 102 10963 OPERATING WEIGHT (A+B+C) 1945 709 286 29924 HYDRO-TESTING WEIGHT (A+B+D) 5039 497 423 59605 4.23 0.36 0.36 4.95

Surface Area Calculation= Pi() x D x L + 2(0.9286d^2)= 15.88

TOTAL WEIGHT (kg)HEAD

(front)

VOLUME (m3)

mm2


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7.0 NOZZLE THICKNESS CALCULATION (UG-45) Page : 11

DESCRIPTION / PROPERTIES UNITNOZZLE MARK

N1 N2 N3 N4 N5 N6 N7 N8 N9 N10

SIZE OF NOZZLE inch 3 3 2 2 0.375 2 3 4 2 1

0.117 0.117 0.117 0.117 0.117 0.117 0.117 0.117 0.117 0.117

NOZZLE MATERIAL USED - SA 106 GRB SA 106 GRB SA 106 GRB SA 106 GRB SA 106 GRB SA 106 GRB SA 106 GRB SA 106 GRB SA 106 GRB SA 106 GRB

mm 88.9 88.9 60.3 60.3 17.1 60.3 88.9 114.3 60.3 33.4

mm 5.49 5.49 3.91 3.91 3.2 3.91 5.49 6.02 3.91 4.55

117.90 117.90 117.90 117.90 117.90 117.90 117.90 117.90 117.90 117.90

- 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0

MILL TOLERANCE % 12.5 12.5 12.5 12.5 12.5 12.5 12.5 12.5 12.5 12.5

mm 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5

LOCATION OF NOZZLE (SHELL OR HEAD) - SHELL SHELL SHELL SHELL SHELL SHELL SHELL SHELL SHELL HEAD

IF NOZZLE LOCATED AT SHELL

SHELL MATERIAL USED - SA 240 GR 304 SA 240 GR 304 SA 240 GR 304 SA 240 GR 304 SA 240 GR 304 SA 240 GR 304 SA 240 GR 304 SA 240 GR 304

INTERNAL DIAMETER OF SHELL INCLUDED mm 600.00 1334.00 1334.00 1334.00 1334.00 1334.00 1334.00 1334.00

mm 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5

136.98 136.98 136.98 136.98 136.98 136.98 136.98 136.98

- 0.7 0.7 0.7 0.7 0.7 0.7 0.7 0.7

IF NOZZLE LOCATED AT HEAD

HEAD MATERIAL USED - SA 240 GR 304 - - - - - - - - SA 240 GR 304

mm 600.00 ` - - - - - - - 1334.00

- 1.54 - - - - - - - - 1.54

mm 1.5 - - - - - - - - 1.5

136.98 - - - - - - - - 136.98

- 0.85 - - - - - - - - 0.85

mm 1.54 1.54 1.53 1.53 1.51 1.53 1.54 1.56 1.53 1.52

mm 1.96 1.87 2.31 2.31 2.31 2.31 2.31 2.31 2.31 2.53

0.46 1.87 2.31 2.31 2.31 2.31 2.31 2.31 2.31 2.53

mm 1.96 1.87 2.31 2.31 2.31 2.31 2.31 2.31 2.31 2.53

mm 5.49 5.49 3.91 3.91 3.2 3.91 5.49 6.02 3.91 4.55

mm 7.80 7.80 6.42 6.42 5.80 6.42 7.80 8.27 6.42 6.98

mm 1.96 1.87 2.31 2.31 2.31 2.31 2.31 2.31 2.31 2.53

mm 1.96 1.87 2.31 2.31 2.31 2.31 2.31 2.31 2.31 2.53

mm 4.80 4.80 3.42 3.42 2.80 3.42 4.80 5.27 3.42 3.98

- OK OK OK OK OK OK OK OK OK OK

REINFORCING REQUIRED - NO NO NO NO NO NO NO NO NO NO

DESIGN PRESSURE, P N/mm2

NOZZLE OUTSIDE DIAMETER, OD

NOZZLE USED THICKNESS, Tn

ALLOWABLE STRESS FOR NOZZLE, Sn N/mm2

JOINT EFFICIENCY FOR NOZZLE, En

CORROSION ALLOWANCE, Cn

CORROSION ALLOWANCE, Di, corr

CORROSION ALLOWANCE, Cs

ALLOWABLE STRESS FOR SHELL, Ss N/mm2

JOINT EFFICIENCY FOR SHELL, Es

HEAD CROWN RADIUS, L

M FACTOR, M

CORROSION ALLOWANCE, Ch

ALLOWABLE STRESS FOR HEAD, Sh N/mm2

JOINT EFFICIENCY FOR HEAD, Eh

NOZZLE NECK REQUIRED THICKNESS, trn1 (UG-27 (c) (1) )

SHELL/HEAD REQUIRED THICKNESS, tr1 (UG-45, UG-37 & UG-39)

SPECIFIED MINIMUM HEAD THICKNESS, tr2 (UG-16 (b))

MINIMUM REQUIRED HEAD THICKNESS, tr (LARGER - tr1 / tr2)

STANDARD WALL THICKNESS (SDT), tns

STANDARD WALL THICKNESS LESS TOLERANCE, trn2 (UG-45)

SMALLER OF tr OR trn 2, trn3

LARGER OF trn1 OR trn3, trn

PIPE USED THICKNESS, Tn*87.5% = Tn1

IF Tn1 > trn, SATISFACTORY OR OTHERWISE


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8.0 REINFORCEMENT CALCULATION FOR Page : 12

N1 - (UG-37)

NOZZLE MARK = N1

NOZZLE SIZE = 3 " x SCH 40NOZZLE MATERIAL USED = SA 106 GR BNOZZLE DIMENSION = 88.9 O.D 5.49 THKNOZZLE LOCATED = BOOT HEADREINFORCEMENT PAD MATERIAL = -

8.1 DESIGN DATA

DESCRIPTION SYMBOL DATA UNIT

Nozzle Internal Diameter (corroded), ID d 77.92 mm

Nozzle Required Thickness (corroded) 1.54 mm

Nozzle Used Thickness (corroded) 4.80 mm

Minimum Shell Required Thickness (corroded) 1.96 mmShell Used Thickness (corroded) t 4.5 mmJoint Efficiency E 1.0 -Correction Factor F 1.0 -

0.86 -

0.86 -

0.86 -

1.0 -Distance nozzle projects beyond the inner surface h 0.0 mm

Nominal thickness of internal projection of nozzle wall 0.0 mm

Outward nozzle weld leg leg 9 mm

8.2 REQUIRED AREA OF REINFORCEMENT

A = = 155.59

a) Limit of Reinforcement (UG 40 (b))Parallel to vessel wall shall be the greater of the either :-

d = 77.92 mm

OR

= 48.26 mm

Thus, use the value 77.92 mm

8.3 AREA AVAILABLE FOR REINFORCEMENT (UG-37)

a) In vessel wall, the larger value of the following : -

= = 194.28

OR

= 43.81

thus, = 194.28

trn

tn

tr

Ratio, fr1 = Sn / Sv fr1


Ratio, fr3 = (smaller of Sp or Sn / Sv) fr3

Ratio, fr4 = Sp / Sv fr4

ti

d tr F + 2 tn tr F (1-fr1) mm2

Rn + tn + t

A1 d (E1t - Ftr) - 2 tn (E1t - Ftr) (1 - fr1) mm2

A1 2(t+tn) (E1t - Ftr) - 2tn (E1t - Ftr)(1-fr1) = mm2

A1 mm2


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Page : 13b) In nozzle wall projecting outward, the smaller of the following :-

= = 63.13

OR

= = 67.39

thus, = 63.13

c) In nozzle wall projecting inward, the smallest of the following :-

= = 0.0

OR

= = 0.0

OR

= = 0.0

d) In outward nozzle weld

= = 69.72

e)

= = 327.12

8.4

Since > A

327.12 > 155.59

Hence, reinforcement pad is NOT REQUIRED

A2 5 (tn - trn) fr2 t mm2

A2 5 (tn - trn) fr2 tn mm2

A2 mm2

A3 5 t ti fr2 mm2

A3 5 ti ti fr2 mm2

A3 2 h ti fr2 mm2

A41 (leg)2 fr2 mm2

Total Area Available, AT

AT A1 + A2 + A3 + A41 mm2

Comparison between Total Area Required, A and Total Area Available, AT

AT


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N2 - (UG-37)

NOZZLE MARK = N2

NOZZLE SIZE = 3 " x SCH 40NOZZLE MATERIAL USED = SA 106 GR BNOZZLE DIMENSION = 88.9 O.D 5.49 THKNOZZLE LOCATED = BOOT SHELLREINFORCEMENT PAD MATERIAL = -

8.1 DESIGN DATA

DESCRIPTION SYMBOL DATA UNITNozzle Internal Diameter (corroded), ID d 77.92 mm




0.86 -

0.86 -

0.86 -





A = = 147.84


d = 77.92 mm

OR

= 48.26 mm




= = 201.77

OR

= 45.50

thus, = 201.77

trn

tn

tr





ti


Rn + tn + t



A1 mm2


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= = 63.13

OR

= = 67.39

thus, = 63.13


= = 0.0

OR

= = 0.0

OR

= = 0.0


= = 69.72

e)

= = 334.61

8.4

Since > A

334.61 > 147.84




A2 mm2

A3 5 t ti fr2 mm2

A3 5 ti ti fr2 mm2

A3 2 h ti fr2 mm2

A41 (leg)2 fr2 mm2


AT A1 + A2 + A3 + A41 mm2


AT


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N3-N4-N6-N9 - (UG-37)

NOZZLE MARK ` = N3-N4-N6-N9

NOZZLE SIZE = 2 " x SCH 40NOZZLE MATERIAL USED = SA 106 GR BNOZZLE DIMENSION = 60.3 O.D 3.91 THKNOZZLE LOCATED = SHELLREINFORCEMENT PAD MATERIAL = -

8.1 DESIGN DATA





0.86 -

0.86 -

0.86 -





A = = 123.54


d = 52.48 mm

OR

= 34.16 mm




= = 112.74

OR

= 32.58

thus, = 112.74

trn

tn

tr





ti


Rn + tn + t



A1 mm2


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= = 36.63

OR

= = 27.85

thus, = 27.85


= = 0.0

OR

= = 0.0

OR

= = 0.0


= = 69.72

e)

= = 210.30

8.4

Since > A

210.30 > 123.54




A2 mm2

A3 5 t ti fr2 mm2

A3 5 ti ti fr2 mm2

A3 2 h ti fr2 mm2

A41 (leg)2 fr2 mm2


AT A1 + A2 + A3 + A41 mm2


AT


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N5 - (UG-37)

NOZZLE MARK ` = N5

NOZZLE SIZE = 3/8 " x SCH 80NOZZLE MATERIAL USED = SA 106 GR BNOZZLE DIMENSION = 60.3 O.D 3.20 THKNOZZLE LOCATED = SHELLREINFORCEMENT PAD MATERIAL = -

8.1 DESIGN DATA





0.86 -

0.86 -

0.86 -





A = = 126.42


d = 53.90 mm

OR

= 34.25 mm




= = 116.22

OR

= 30.24

thus, = 116.22

trn

tn

tr





ti


Rn + tn + t



A1 mm2


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= = 25.01

OR

= = 15.56

thus, = 15.56


= = 0.0

OR

= = 0.0

OR

= = 0.0


= = 69.72

e)

= = 201.50

8.4

Since > A

201.50 > 126.42




A2 mm2

A3 5 t ti fr2 mm2

A3 5 ti ti fr2 mm2

A3 2 h ti fr2 mm2

A41 (leg)2 fr2 mm2


AT A1 + A2 + A3 + A41 mm2


AT


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N7 - (UG-37)

NOZZLE MARK = N7


8.1 DESIGN DATA





0.86 -

0.86 -

0.86 -





A = = 183.55


d = 77.92 mm

OR

= 48.73 mm




= = 167.27

OR

= 39.53

thus, = 167.27

trn

tn

tr





ti


Rn + tn + t



A1 mm2


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= = 71.86

OR

= = 84.12

thus, = 71.86


= = 0.0

OR

= = 0.0

OR

= = 0.0


= = 69.72

e)

= = 308.85

8.4

Since > A

308.85 > 183.55




A2 mm2

A3 5 t ti fr2 mm2

A3 5 ti ti fr2 mm2

A3 2 h ti fr2 mm2

A41 (leg)2 fr2 mm2


AT A1 + A2 + A3 + A41 mm2


AT


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N8 - (UG-37)

NOZZLE MARK = N8


8.1 DESIGN DATA





0.86 -

0.86 -

0.86 -





A = = 239.83


d = 102.26 mm

OR

= 60.90 mm




= = 220.52

OR

= 39.53

thus, = 220.52

trn

tn

tr





ti


Rn + tn + t



A1 mm2


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= = 71.86

OR

= = 84.12

thus, = 71.86


= = 0.0

OR

= = 0.0

OR

= = 0.0


= = 69.72

e)

= = 362.10

8.4

Since > A

362.10 > 239.83




A2 mm2

A3 5 t ti fr2 mm2

A3 5 ti ti fr2 mm2

A3 2 h ti fr2 mm2

A41 (leg)2 fr2 mm2


AT A1 + A2 + A3 + A41 mm2


AT


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N10 - (UG-37)

NOZZLE MARK = N10


8.1 DESIGN DATA





0.86 -

0.86 -

0.86 -





A = = 70.20


d = 26.64 mm

OR

= 21.80 mm




= = 50.30

OR

= 31.24

thus, = 50.30

trn

tn

tr





ti


Rn + tn + t



A1 mm2


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= = 47.73

OR

= = 42.23

thus, = 42.23


= = 0.0

OR

= = 0.0

OR

= = 0.0


= = 69.72

e)

= = 162.25

8.4

Since > A

162.25 > 70.20




A2 mm2

A3 5 t ti fr2 mm2

A3 5 ti ti fr2 mm2

A3 2 h ti fr2 mm2

A41 (leg)2 fr2 mm2


AT A1 + A2 + A3 + A41 mm2


AT


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9.0 SIZE OF WELD REQUIRED (UW-16 (c) ) Page : 26

DESCRIPTION / PROPERTIES UNITNOZZLE MARK

N1 N2 N3 N4 N5 N6 N7 N8 N9 N10

SIZE OF NOZZLE inch 4 4 4 1.5 2 4 2 4 2 4

mm 6 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 6

mm 5.49 5.49 3.91 3.91 3.2 3.91 5.49 6.02 3.91 4.55

mm 6 6 6 6 6 6 6 6 6 6

mm 5.49 4.5 3.91 3.91 3.2 3.91 4.5 4.5 3.91 4.55

mm 5.49 4.5 3.91 3.91 3.2 3.91 4.5 4.5 3.91 4.55

mm 3.843 3.150 2.737 2.737 2.240 2.737 3.150 3.150 2.737 3.185

mm 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2

- OK OK OK OK OK OK OK OK OK OK

STRENGTH CALCULATION FOR ATTACHED - NO NO NO NO NO NO NO NO NO NO

WELD REQUIRED (UW-15 (b))

NOMINAL SHELL / HEAD THICKNESS, t

NOZZLE USED THICKNESS, Tn

LEG OF FILLET WELD a, Wa

LESSER OF t OR Tn, tsn

LESSER OF 19.05 mm OR tsn, tmin

LESSER OF 6.35 mm OR 0.7tmin, tc (min)

SIZE OF WELD, tc = 0.7 x Wa

IF tc > tc (min), OK OR OTHERWISE


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10.0 SADDLE SUPPORT CALCULATION Page : 27(Ref : Pressure Vessel Design Manual : 2nd Edition, Dennis R.Moss)

Vessel empty weight, WE = 1068.09 kg= 10477.9 N

Vessel hydrotest weight, Q = 5959.82 kg246.00 = 58465.8 N

B) SADDLE PROPERTIES

a) Moment of Inertia of Saddle , I

H + 1.56 R ts = 356ts = 5

270

C1

tw = 12.0 h = 246.0tr = 12

C2

tb = 12

150

MARK Y (mm)

1 1.60E+03 243.8 3.9E+05 9.5E+07 2.7E+032 3.24E+03 -3.8 -1.2E+04 4.6E+04 3.9E+043 2.75E+03 243.8 6.7E+05 1.6E+08 -0.0E+004 1.80E+03 6.0 1.1E+04 6.5E+04 0.0E+00S 9.39E+03 489.8 1.1E+06 2.6E+08 4.2E+04

i) C1 = S AY / SA= 112.84 Where : A = Area of section

Y = Distance from axis to center of sectionii) C2 = h - C1 Io = Moment of Inertia of section

= 133.2 As = Cross sectional area of saddle (excluding shell)

iii) As = SA - A1 CI & C2 = Centroid= 7794.00 H = Width of wear plate

iv) I == 1.39E+08

A (mm2) AY (mm3) AY2 (mm4) Io (mm4)

mm2

SAY2 - SIo - C1 SAY mm4

32

4

1


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10.1 DESIGN OF SADDLE PARTS Page : 28

i) Saddle coefficient, k1 = 0.204 ( From table 3-20 )

ii) Saddle splitting force, fh = k1 x Empty Weight= 2137.50 N

iii) Tension stress, s = 2 x fhAs

= 0.55 0.6 Fy = 124.10 N/mm2

SATISFACTORY

iv) Bending Moment, d = Where ;

O O = rad

= 278.80 mm B = 917.50 mmR = 671.50 mm

M = 2 x fh x d= 1.19E+06 Nmm

v) Bending stress, fb == 0.97 < 0.66 Fy = 136.51

SATISFACTORY

N/mm2 <

B - R sin O

60o = 1.05

M x C1 / IN/mm2 N/mm2


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11.0 BASE PLATE DESIGN CALCULATION Page : 29

Vessel hydrotest weight, Q = 5959.82 kg= 58465.8 N

Material used , = JIS G3101 SS400

Base plate size,(Width) F = 150.00 mm(Length) A = 1254 mm

Ab = A x F

= 188100

Yield Strength , Fy = 206.84 `Allowable Stress , Fb = 137.90

fp = Q/Ab

= 0.311

tb = SQRT( 3QF/4AFb)

= 6.167 mm

Base plate thickness = 12 mm Satisfactory

11.1 ANCHOR BOLTS DESIGN CALCULATION

Bolt size used = M20Root area of bolt Ab = 194.84Number of bolts N = 4Bolt allowable stress Sa = 108.25Erection weight W = 10755.55 N(per saddle)

Design tension load F = W / N= 2688.89 N

Checking stress in anchor bolt

Sb = F / Ab

= 13.80

Since S < Sa = Bolt size is adequate

mm2

N/mm2

N/mm2

N/mm2

mm2

N/mm2

N/mm2

LENGTH T.L to T.L 3000.0 mm

VESSEL ID 1334.0 mm

VESSEL THK 4.50 mm ts

VESSEL OD 1343.00 mm

R 671.50 mm R

WEIR PLATE WIDTH 270.00 mm

SADDLE HEIGHT (min) MIDDLE RIB 246.00 mm h

RIB THK 12.00 mm tr

WEIR PLATE THK 12.00 mm tw

BASE PLATE THK 12.00 mm tb

BASE PLATE WIDTH 150.00 mm tw

B 917.50

Ls 1800.00 mm

A 600.00 mm

SQRT(R*TS) 54.97

BREADTH 85.75

TOTAL 355.75


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T = 300 °C T = 400 °CF = 134.921545 N/mm² F = 88.5712857 N/mm²

Et = 202.382318 N/mm² Et = 132.856929 N/mm²

SA 516 GR 70 SA 106 GR B°C Allow. Stress (N/mm²) °C Allow. Stress (N/mm²)

250 137.931 137.931 343 117.931 96.8715357260 137.931 134.921545 371 107.586 88.3267778315 133.793 136.009786 398 89.655 88.5712857343 129.655 137.069429 426 74.483 87.9315371 124.827 184.674741 454 60 52.8634361398 102.068 169.653426 82.758 166.548454 64.138 42.3819383


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T = 250 °C T = 250F = 158 N/mm² F = 168

Et = 237 N/mm² Et = 252

BS 1501 - 223 - 490 A ( UP TO 40 mm) BS 1501 - 223 - 490 B ( UP TO 40 mm)°C Allow. Stress (N/mm²) °C Allow. Stress (N/mm²)

250 158 158 250 168300 139 147 300 147350 131 146 350 137390 125 139 390 133400 124 77.5 400 128


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°C N/mm² N/mm²

BS 1501 - 223 - 490 B ( UP TO 40 mm)Allow. Stress (N/mm²)

168157147203

80


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1.0 IMPACT TESTING EVALUATION (UG-20 (f))

The impact testing as per UG-84 is not required if all the requirements as per UG-20 (f)are complied with the vessel

ITEM PART NAME MATERIALS

A SHELL PLATE SA516 GR 70 9.5 9.5 -20

B HEAD PLATE SA516 GR 70 9.5 9.5 -20

C NOZZLEFLANGE SA 105 N - - -20

NECK SA 106 GR B 9.5 9.5 -20

D BOLTS SA 193 GR B7 - - -55

E NUTS SA 194 GR 2H - - -55

MINIMUM DESIGN METAL TEMPERATURE, MDMT = -20 oF (-29oC),

NOMINAL THICKNESS

(mm)

GOVERNING

THICKNESS (mm)

LOWEST PERMISSIBLE TEMPERATURE

oF


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WITH REFERENCE TO

-29 UG-20 (f) NO

-29 UG-20 (f) NO

-29 UCS-66 (c), ASME FLANGE NO

-29 UG-20 (f) NO

-48 FIG.UCS-66 (e) NO

-48 FIG.UCS-66 (e) NO

LOWEST PERMISSIBLE TEMPERATURE IMPACT TESTING

REQUIREDoC

10.0 LARGE OPENING REINFORCEMENT CALCULATION(Ref : Pressure Vessel Design Manual : 2nd Edition, Dennis R.Moss)

B) BOOT PROPERTIES

mm in

R = 692.00 27.24Rm = 696.75 27.43

t = 6.50 0.26te = 0.00 0.00

= 67.30 2.65

Rn = 292.00 11.50Rnm = 296.75 11.68

tn = 6.50 0.26= 67.30 2.65

16tn + te = 104.00 4.090.00

b1 = 67.30 2.65b2 = 0.00 0.00b3 = 6.50 0.26d1 = 6.50 0.26d2 = 0.00 0.00d3 = 1775.00 69.88

Y

MARK Y (mm)

1 6.78E-01 3.3 2.2E+00 7.2E+00 1.5E+032 0.00E+00 6.5 0.0E+00 0.0E+00 0.0E+003 1.15E+04 887.5 1.0E+07 9.1E+09 3.0E+09S 1.15E+04 8.97E+02 1.0E+07 9.1E+09 3.0E+09

i) C1 = S AY / SA= 887.45 Where : A = Area of section

Y = Distance from axis to center of section Io = Moment of Inertia of section

ii) I == 3.03E+09

iii) e = C - 0.5t884.20

iii) a = e + t/2887.45

P = 18.73 psiAs = 11538.18

Sm =

(Rmt)0.5

(Rmt)0.5 + te

A (mm2) AY (mm3) AY2 (mm4) Io (mm4)

SAY2 + SIo - C1 SAY mm4

mm2

P ( R ( Rn + (Rmt)0.5) + (Rnm x tn)0.5)) / As


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4.0 HYDRO-STATIC TEST PRESSURE (UG-99) Page : 10

DESIGN DATA


Maximum Allowable Working Pressure MAWP 0.103

Design Temperature 120

Ambient Temperature 30

Allowable Stress at design cond. 136.985

Allowable Stress at test cond. 136.985

= 1.3 x

= 0.134 19.5 psi

Note : MAWP is assumed to be same as design pressure as stated in UG-99 (b) note 34.

N/mm2

TdoC

TaoC

Sd N/mm2

Sa N/mm2

Hydro-static Pressure, Ph

Ph Sa / Sd x MAWP

N/mm2


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WEIGHT SUMMARYITEM NO. : 2V-240 ( FUEL GAS SCRUBBER )

ALL UNITS ARE IN KG UNLESS SPECIFIED

GROUP NO. PART NAME SECTION / COMPONENTNO.1 NO.2 NO.3

HEAD SHELL HEAD

A 1 SHELL 4462 TORISPHERICAL HEAD 92 92

1.1 SHELL (BOOT) 882.1 TORISPHERICAL HEAD (BOOT) 19 193 MANHOLE 0 25.96 04 NOZZLES 10.194 186.82 05 STIFFENER RING 0.006 SUPPORT ( SADDLE ) 58.1

B 7 INT. / EXT. NON REMOVABLE 0 10 10

C 8 INT. / EXT. REMOVABLE 0 0 09 INSULATION 0 0 010 FIRE PROOFING 0 0 011 PLATFORM & LADDER 0 0 0

D 12 OPERATING LIQUID 378 1140 18

E 13 TESTING LIQUID 29 4235 326

SUMMARY

I ERECTION WEIGHT ( A + 5% CONTINGENCY + B ) 188 794 127II EMPTY WEIGHT ( I + C ) 188 794 127III OPERATING WEIGHT ( I + C + D ) 566 1934 145VI HYDRO - TESTING WEIGHT ( I + C + E ) 217 5029 453V VOLUME [ m³ ] 0.029 4.235 0.326

( Assumed Full of Fluid with SG = 0.6458 )


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TOTAL

446.00184.00

25.96197.02

0.0058.10

20

0000

1536.373382

4590

11091109264556994.59

PV-1390-CAL-R1

Documents

included corrosion allowance

sn sv

heads joint efficiency

surface nominal thickness

static test pressure

minimum required thickness

sa sd

nozzle wall projecting