asme

DESIGN DATADESIGN CODE = ASME SEC VIII DIV I EDITION 2010ADDENDA 2011

*MAWP (MEASURED AT TOP)

OPERTAING PRESSURE = 1.796 mpa

OPERTAING TEMPERATURE = 78 °C

DESIGN PRESSURE = 1.8244392909 mpa [SHT-5]

DESIGN TEMPERATURE = 78 °C

RADIOGRAPHY = FULL

JOINT EFFICIENCY = 1

CORROSION ALLOWANCE = 3 mm

MEDIUM = UTILITY GAS

SPECIFIC GRAVITY OF MEDIUM = 1 (ASSUME AN HIGHER SIDE)

FLUID DENSITY = 1000 Kg/m³

HEIGHT OF MEDIUM = FULL OF WATER [SHT-5]

APPLICABLE LOADING = REFER SHEET No. 4

VESSEL SIZE = 1600 ± 3MM ID x 2100 MM LG (T/L to T/L)

HEIGHT OF SKIRT = 1000 mm

MATERIAL SPECIFICATION Allowable stress(Mpa)

SHELL = SA 516 M Gr. 60 118

DISHED HEAD = SA 516 M Gr. 60

NOZZLE PIPE = SA 106M Gr. B

NOZZLE FLANGE = SA 105M

STUD BOLT = SA 193M Gr. B7 [SHT 39 TO 41]

HEX. NUT = SA 194 Gr. 2HM

MDMT = -27.6°C @1.76MPa

THK OF INSULATION = 40 mm

*MAXIMUM ALLOWABLE WORKING PRESSURE

= 1.76MPa (18 kgf/cm2)

LOADING TO BE CONSIDERED IN DESIGNING THE VESSELAS PER ASME SEC-VIII DIV.I.2010 EDITION UP TO & INCL. ADDENDA 2011 (UG-22)

a. APPLICABLE

EXTERNAL PRESSURE (UG 21) REF. SHEET - NOT APPLICABLE

b. APPLICABLE

c. NOT APPLICABLE

d.

THE ATTACHMENT OF

1. INTERNALS (AS PER APPENDIX D ) REF. SHEET - SADDLE &LUGS

2. VESSEL SUPPORTS SUCH AS LUGS, RINGS, SKIRTS, SADDLES AND LEGS. (AS PER APPENDIX G) APPLICABLE

e NOT APPLICABLE

f WIND, SNOW AND SEISMIC REACTIONS, WHERE REQUIRED.REF. SHEET 11-13, 23- 33

g IMPACT REACTIONS SUCH AS THOSE DUE TO FLUID SHOCK REF. SHEET NOT APPLICABLE

h TEMPERATURE GRADIENTS AND DIFFERENTIAL THERMAL EXPANSION. REF. SHEET NOT APPLICABLE

INTERNAL PRESSURE (UG 21) REF. SHEET 10-14

WEIGHT OF THE VESSEL AND NORMAL CONTENTS UNDER OPERATING OR TEST CONDITIONS. (THIS INCLUDES ADDITIONAL PRESSURE DUE STATIC HEAD OF LIQUIDS.) REF. SHEET 5

SUPERIMPOSED STATIC REACTIONS FROM WEIGHT OF ATTACHED EQUIPMENT SUCH AS MOTORS, MACHINERY, OTHER VESSELS, PIPING, LININGS AND INSULATIONS. REF. SHEET

CYCLIC AND DYNAMIC REACTIONS DUE TO PRESSURE OR THERMAL VARIATIONS OR FROM EQUIPMENT MOUNTED ON A VESSEL AND MECHANICAL LOADINGS.

WIND AND SEISMIC APPLICABLE

DESIGN PRESSURE CALCULATIONDESIGN PRESSURE CALCULATION

H-HEIGHT OF LIQUID COLUMN =

(VESSEL WITH FULL HEIGHT WATER CONSIDERED)HEIGHT OF LIQUID COLUMN = 2900 mm

g – DENSITY OF LIQUID = 1000 kg/

PRESSURE DUE TO LIQUID HEAD = Hg/101971.6 = 0.028 MpaDESIGN PRESSURE = MAWP + PRESSURE DUE TO LIQUID HEAD

= 1.824 Mpa

VOLUME OF VESSEL VOLUME OF VESSEL Vc = VOLUME OF SHELL + VOLUME OF HEAD(2:1 ELLIPTICAL HEAD)

=

d1- I.D OF SHELL = 1600 l- LENGTH OF SHELL (T/L TO TL) = 2100d2- I.D OF DISHED HEAD 1600

Vc = = 5.29

WEIGHT OF THE WATER DURING HYD. TEST = Vc X g X Velocity = 51914 N

** Tolerance***Assumed

T/L TO T/L + INNER DEPTH OF BOTTOM HEAD + PROJECTION OF TOP NOZZLE FROM UPPER T/L

*(Density of Water = 1000 kg/M3

3m

2 31 22

4 24d L d

3m

2 31 22

4 24d L d

APPLICABLE CODE, STANDARD AND REFERENCE BOOKSSL.No DESCRIPTION YEAR & ADDENDA REMARKS

1 Section VIII Division I Applicable

2 Section II Part A and D Applicable

3 Section IX Applicable

4 Pipe Flange and Flange Fittings ASME B 16.5 2003 Edition Applicable

5 ASME 36.10M 2004 Edition Applicable

6 Metallic Gaskets for Pipe Flanges ASME 16.20 2004 Edition Applicable

7 ASME 16.11 2001 Edition Applicable

8 -- - -

RADIOGRAPHY EXAMINATION REQUIREMENT

AS PER ASME SEC-VIII DIV.I.2007 EDITION UP TO & INCL. ADDENDA 2008 (UW-11)

APP

ALL BUTT WELDS IN THE SHELL AND HEADS OF VESSEL USED TO CONTAIN LETHAL SUBSTANCES.NOT APP

1

2 NOT APP

3 NOT APP

4 NOT APP

NOT APP

5 NOT APP

6 NOT APP

7 NOT APP

CONCLUSION:

CODES & STANDARDS

ASME Boiler & Pressure Vessel Code

2010 Edition, Addenda 2011





Welded and Seamless Wrought Steel Pipe

Flange Fittings, Socket Welded and Threaded

Design Loads for Buildings and Structures

FULL RADIOGRAPHY: - THE FOLLOWING WELDED JOINTS SHALL BE FULL RADIOGRAPHED.

ALL BUTT WELDS IN THE SHELL AND HEADS OF VESSEL IN WHICH THE LEAST NOMINAL THK AT THE WELDED JOINTS EXCEEDS 32MM AS PER UCS-57

ALL BUTT WELDS IN THE SHELL AND HEADS OF UNFIRED STEAM BOILERS HAVING A DESIGN PRESSURE EXCEEDING 3.4bar

a) ALL BUTT WELDS IN NOZZLE ATTACHED TO SHELL OR HEAD WHICH ARE REQUIRED TO BE FULLY RADIO GRAPHED AS PER POINT 1 OR 3 FOR EXEMPTION REF. POINT 4(b)

b) CATEGORIES B AND C BUTT WELDS IN NOZZLES AND COMMUNICATING CHAMBERS THAT NEITHER EXCEED NPS 10 NOR 29MM WALL THICKNESS DO NOT REQUIRE ANY RADIOGRAPHIC EXEMPTION.

ALL CATEGORY A AND D BUTT WELDS IN SHELL AND HEAD WHERE DESIGN IS BASED ON JOINT EFFICIENCY 1 AS PER UW 12(a) IN WHICH CASE.

a) ALL CATEGORY A AND B WELDS CONNECTING SHELL OR HEADS SHALL BE TYPE NO.1 OR 2 OF TABLE UW-12.

b) ANY CATEGORY B AND C BUTT WELDS (EXCLUDING CATEGORY B AND C BUTT WELDS IN NOZZLES THAT NEITHER EXCEED 250 NB NOR 29MM WALL THICKNESS) WHICH INTERSECT THE CATEGORY A BUTT WELDS IN

SHELL OR HEADS OR CONNECT SEAMLESS SHELL OR HEADS AND WHICH ARE NOT REQUIRED TO BE FULLY RADIOGRAPHED BY POINT 1, 2, 3 OR 4 ABOVE SHELL AS A MINIMUM REQUIREMENT, BE SPOT

RADIOGRAPHED.

ALL BUTT WELDS JOINED BY ELECTRO GAS WELDING WITH ANY SINGLE PASS GREATER THAN 38MM & ALL BUTT WELDS JOINED BY ELECTRO SLAG WELDING

ULTRASONIC EXAMINATION MAY BE SUBSTITUTED FOR RADIOGRAPHY FOR FINAL CLOSURE SEAM IF THE CONSTRUCTION DOSE NOT PERMITS INTERPRETABLE RADIOGRAPHY.

ALL BUTT JOINTS OF SEAM IN THE SHELL, HEAD TO SHELL TO BE FULLY RADIO GRAPHED AS PER CUSTOMER REQUIREMENT.

DATA

MDMT : (TO BE DETERMINED AT 1.04MPa

MATERIAL SPECN.MATERIAL PROVIDED THK

GROUP MAX.

SHELL SA 516 M Gr.60 (NORM) D 18MM[SHT.10]

SHED HEAD SA 516 Gr.60 (NORM) D 20MM[SHT.14]

SA 106 GR B B 10.16MM[SHT.18]

SA 105 NOT APP 10.16MM[SHT.18]

UG 20(f) CONSIDERATION

1 MET

2 THE COMPLETED VESSEL SHALL BE HYDRO TESTED AS PER UG 99(b), (c) OR (K) MET

3 MET

4 MET

5

FOR THE VESSEL

*NOZZLE WHICH IS HAVING MAX. THK IS CONSIDERED.

**MIN. THK OF DISHED HEAD [ NOTE 1 OF FIG UCS 66.2]

DETERMINATION OF COLDEST ALLOWABLE MINIMUM DESIGN METAL TEMPERATURE (MDMT) USING UCS 66 RULES

MAWP : MAX. ALLOWABLE WORKING PRESSURE = 1.76 MPa AT 78°C

DESCRIPTION TO

CURVE

P. NO.1 ; GR. NO. 1

P. NO.1 ; GR. NO. 1

NOZZLE PIPE

P. NO.1 ; GR. NO. 1

NOZZLE FLANGE

P. NO.1 ; GR. NO.2

FOR P.NO.: 1 GROUP NO. 1 (OR) 2 MAX. THK < 12.5MM FOR MATERIAL LISTED IN CURVE A OF FIG. UCS 66 (OR) < 25.4MM FOR MATERIAL LISTED IN CURVE B,C,D OF FIG UCS 66

DESIGN TEMP. WITHIN -29°C TO 345°C

THERMAL (OR) MECHANICAL SHOCK LOADING ARE NOT A CONTROLLING DESIGN REQUIREMENT CYCLIC LOADING IS NOT A CONTROLLING DESIGN REQUIREMENT. SINCE ALL THE ABOVE THE CONDITION ARE MET, IMPACT TEST IS NOT REQUIRED. HOWEVER CALCULATION HAS BEEN

PROCEEDED IN ORDER TO FIND OUT COLDEST ALLOWABLE MINIMUM DESIGN METAL TEMPERATURE (MDMT)

CYCLIC LOADING IS NOT A CONTROLLING DESIGN REQUIREMENT. SINCE ALL THE ABOVE THE CONDITION ARE MET, IMPACT TEST IS NOT REQUIRED. HOWEVER CALCULATION HAS BEEN

PROCEEDED IN ORDER TO FIND OUT COLDEST ALLOWABLE MINIMUM DESIGN METAL TEMPERATURE (MDMT)

POST WELD HEAT TREATMENT REQUIREMENT

POST WELD HEAT TREATMENT OF VESSEL IS REQUIRED UNDER FOLLOWING CONDITIONS: APP

1 WHEN A VESSEL IS USED TO CONTAIN LETHAL SUBSTANCES. NOT APP

2 NOT APP

3 WHEN THE MATERIAL REQUIRE IMPACT TESTING AS PER UCS 66 REF. SHEET NOT APP

4

a). THE THICKNESS OF THE PART BEFORE COLD FORMING EXCEEDS 16 mm

b). THE REDUCTION BY COLD FORMING FROM THE AS ROLLED THICKNESS IS MORE THAN 10%

FOR P.No:1 GR No.1 & 2 MATERIALS EXIST

COMPUTATION OF FIBER ELONGATIONTHE EXTREME FIBER ELONGATION SHALL BE DETERMINED BY THE FOLLOWING FORMULAE.PERCENTAGE OF EXTREME FIBER ELONGATION =FOR DOUBLE CURVATURE(EX.HEAD) DISHED HEAD WHERE, t = THICKNESS OF PLATE IN mm = 30 Rf = FINAL CENTERLINE RADIUS IN mm = Ro = ORIGINAL CENTERLINE RADIUS (EQUALS INFINITY FOR FLAT PLATES) mm. PERCENTAGE FO EXTREME FIBER ELONGATION =

*KNUCKLE RADIUS CONSIDERED SINCE MORE CRITICAL = 3.6

6 .31> 5PERCENTAGE OF EXTREME FIBER ELONGATION FOR SINGLE CURVE(EX.CLYLINDER) =WHERE, t = THICKNESS OF PLATE IN mm = 30 Rf = FINAL CENTERLINE RADIUS IN mm = 803 Ro = ORIGINAL CENTERLINE RADIUS (EQUALS INFINITY FOR FLAT PLATES) MM.

FOR SHELL FOR MAN WAY

PERCENTAGE FOR EXTREME FIBER ELONGATION 1.86799501868

2.7 < 5

AS PER ASME SEC - VIII DIV. I. 2007 EDITION UP TO & INCL. ADDENDA 2008 (UCS -79)

WHEN THE BUTT WELDS IN THE SHELL AND HEADS OF VESSEL IN WHICH THE LEAST NOMINAL THICKNESS AT THE WELDED JOINTS EXCEEDS 38mm. MATERIAL OVER 32mm THROUGH 38mm NOMINAL THK WHEN

PREHEAT IS NOT APPLIED AT A MIN. TEMPERATURE OF 200°F DURING WELDING (TABLE UCS 56)

VESSEL SHELL SECTIONS, HEADS, AND OTHER PRESSURE BOUNDARY PARTS OF ALL CARBON AND LOW ALLOY STEEL FABRICATED BY COLD FORMING SHALL BE HEAT TREATED. SUBSEQUENTLY (SEE UCS 56) WHEN THE

RESULTING EXTREME FIBER ELONGATION IS MORE THAN 5% FROM THE AS ROLLED CONDITION AND ANY ONE OF THE FOLLOWING CONDITION EXISTS.

c). THE TEMP. OF THE MATERIAL DURING FORMING IS IN THE RANGE OF 250°F(120°C) -900°F(480°C)

THE EXTREME FIBER ELONGATION MAY BE AS GREAT AS 40% WHEN NONE OF THE CONDITION LISTED ABOVE IN 1, 3, & 4 EXISTS.

CONCLUSIONS: POST WELD HEAT TREATMENT REQ. FOR DISHED HEAD. HOWEVER STRESS RELIEVING OF EQUIPMENT AS A WHOLE IS DONE AS PER CUSTOMER REQUIREMENT

75 24 = 6.31

285.2

75(1 )t Rf

Rf Ro

50(1 )t Rf

Rf Ro

DESIGN SHEET FOR CYLINDRICAL SHELL (INTERNAL PRESSURE)AS PER ASME SEC – VIII. DIV. I. 2007 EDITION UP TO & INCL. ADDENDA 2008

CYLINDRICAL SHELL UG-27(C )

INTERNAL PRESSURE DESIGN

DETERMINE SHELL THICKNESS DESIGN CONDITIONS ALLOWABLE STRESS [TABLE 1A***] = 118 Mpa

t1 25.0 mm

t2 = CALCULATED MINIMUM THK. OF SHELL [UG -16(4)] = 2.4 mm

With CORRODED ALLO. = t1+C 28.0 mm

t = REQUIRED THK. ‘t’ =GREATER OF t1 OR t2 ( t + CA) = 28.0 mm

USE 8mm. AS PER CUSTOMER REQUIREMENT 30 MMREQD. THK. FOR NOZZ. REINFORCEMENT UG 37 (a)tr = = 25.0

CONDITIONPH* - PRESSURE DUE TO LIQUID HEAD*** OF ASME SEC II PART D 2007 EDITION UP TO & INCL. ADDENDA 2008CONDITION FOR USING THE FORMULA

27 < 400 OK1.82 < 45.43 OK

BASED ON OUT SIDE RADIUS

USE SHELL THICKNESS

1) t < R/22) P < 0.385 SE

0.6

PR

SE P

0.6

PR

SE P

CALCULATIONCYLINDRICAL SHELL DESIGN (APPENDIX-L)THREE CASE MUST BE INVESTIGATED TO DETERMINE THE MINIMUM SHELL THICKNESS

CASE 1 (a) CIRCUMFERENTIAL TENSILE STRESS:REQUIRED SHELL THK ‘ t’ MM =

P-DESIGN PRESSURE MPa = 1.8244392909

R-CORRODED INNER RADIUS MM = 803S-ALLOWABLE STRESS MPa = 118

MM = 25.19

CASE (b) LONGITUDINAL TENSILE STRESS:REQUIRED SHELL THK ‘ t’ =

P-DESIGN PRESSURE MPa 1.796R-CORRODED INNER RADIUS MM 807S-ALLOWABLE STRESS MPa 118

MPa 141.6 [ UG – 23 (d)]E- JOINT EFFICIENCY = 1TO CALCULATED WIND MOMENT (M)Vb-MAX WIND VELOCITY = 225 Km/hr = 62.5 m/s [ Max. wind speed as per customer spec. GS-18 page 3]Vz-DESIGN WIND SPEED = Vb x K1 x K2 x K3IS 875 PART-3K1-RISK COEFFICIENT = 1.08 [TABLE 1 PAGE No. 11]

= 1 [TABLE 1 PAGE No. 12]

K3-TOPOGRAPHY FACTOR = 1.36SHELL DIA / SHELL LENGTH = 0.76 MVz = 91.8 m/s

DESIGN WIND PRESSURE ‘Pz’ = 0.6 = 5056.344

SAY = 0.005 (for conversion factor see below)

DEFF = OUTSIDE DIA (Do) + 2 x INSULATION THK = (1600 +8+2x18)+ 2x40H-OVER ALL HEIGHT = T/L TO T/L + TOP DISHED HEAD +HEIGHT + SKIRT HEIGHT .

= 2100 + (402+24)*1000 = 3526mmH/Deff

Cf – FORCE COEFFICIENT = 0.7 [TABLE 23 OF IS 875 PART-3-2007]M-WIND MOMENT =

T/L TO T/L + TOP DISHED HEAD +HEIGHT HEIGHT + SKIRT HEIGHT JUNCTION HEIGHT

= 2100 + (402.0+24)*+75.72600.9

1. TENSILE STRESSa) CIRCUMFERENTIAL TENSILE STRESS [UG-27(C)(1)]b) LONGITUDINAL TENSILE STRESS [UG-27(C)(2)]

2. COMPRESSIVE STRESS [UG-23(b)]

K2-TERRAIN, HEIGHT AND STRUCTURE SIZE FACTOR

H 1– HEIGHT OF VESSEL

( /144)

0.6 0.6( /144)

PR Hg R

SE P SE Hg

22 0.4CW WPR M

SE P R SE DSE

2( )ZV2/N m

2/N mm

3526.2 = 2.4

1723.64

21( / 2) 1.3Deff H Cf PZ

21600.91723.64 0.7 19.05 1.3

2

M 27433927.8

t

= 5.9mmPROVIDED THK OF SHELL‘t’ 15

= 15mmWhich is greater than the above two required thickness

WIND ALLOWANCE FACTOR FOR PIPING AND PLAT FORM EFFECT*INNER DEPTH OF DISHED HEAD [SHT 5] + NOM.THK. OF DISHED HEAD [SHT-14]** REF DRG. NO : 1936 /B SHT 1 OF 2CASE (2) COMPRESSIVE STRESSFACTOR ‘A’ =

Ro – OUTER RADIUS =

=

t – CORRODED THK = 15mmFACTOR A =

=

FACTOR BALLOWABLE COMPRESSIVE STRESS = 1.2 x 103.42= 124.1 MPaWEIGHT OF VESSEL EXCLUDING EXTERNAL WEIGHT = 39366.7 NWEIGHT OF EXTERNALS = 8896 NEMPTY OF VESSEL = 48263 N SAY 49000NWEIGHT OF LIQUID = CAPACITY OF VESSEL x DENSITY OF LIQUID

= 5.4 x 1000 x 9.81 = 52974N SAY 53000OPERATING / TEST WEIGHT = 49000 +53000 = 102000 NREQUIRED THK ‘t’ =

=

= 0.1+ 0.162 = 0.262MMPROVIDED THK. = 15MM [EXCLUSIVE OF CORROSION ALLO.]CORRODED I.D OF SHELL = 2 x R

DESIGN SHEET FOR ELLIPSOIDAL HEAD (INTERNAL PRESSURE)AS PER ASME SEC. VIII DIV.I-2007 EDITION UP TO & INCL. ADDENDA-2008

ELLIPSOIDAL HEAD UG-32(d)INTERNAL PRESSURE DESIGNMATERIAL SA 516 M GR 485(Gr.60)DESIGN TEMPERATURE 78°C

DETERMINE HEAD THICKNESS DESIGN CONDITIONP – DESIGN PRESSURE (MAWP+PH*) Mpa 1.80CA - CORROSION ALLOWANCE MM 3ID - INSIDE DIAMETER MM 1614**S - ALLOWABLE STRESS [TABLE -1A ***] N/mm² 103.42E - JOINT EFFICIENCY 1t 1 =

=

1 Psi = 6894.757 Pa = 6894.757 N/m2 = 0.00511 N/mm2 [page 765 of ASME SEC II PART D]

= 103.42 MPa [ Fig–cs-2 of ASME SEC II PART D 2007]

(BASED ON IN SIDE DIAMETER)

21600.91723.64 0.7 19.05 1.3

2

.N mm

2

1.796 807 27433927.8

2 124.1 1 0.4 1.796 807 124.1 1

5.8 0.1

0.125 where

( / )Ro t

2

Do

1644* = 822mm

2

0.125

(822 /15)0.0022 SAY 0.002

2

M W

R SE D SE 2

27433927.8 102000

807 124.1 1 2 807 124.1 1

2 0.2

P ID

SE P

14 MM 14t 2 = MINIMUM THK OF HEAD (UG-16) MM 2.4REQD. THK ‘t’ = GREATER OF = t1 (OR) t2 MM 14t + CAUSE MIN. HEAD THICKNESSPROVIDE THK. MM

USE NOM. HEAD THICKNESS MM 20

(FOR NOZZLE LOCATED AT CENTER LINE OF HEAD ONLY)P = DESIGN PRESSURE (MAWP. + )

Mpa 1.80E = 0.85K = 0.9 [TABLE UG- 37]t 1 =

12.7 MM 12.7* - PRESSURE DUE TO LIQUID HEAD

** CORRODED ID OF SHELL = 1600+2x3+8(TOLERANCE) = 1614MM

*** OF ASME SEC II PART D – 2007 EDITION UP TO AND INCL. ADDENDA 2008.

USE 20MM MIN. AND 24MM NOM. AS PER AVAILABILITY OF MATERIAL

DESIGN SHEET FOR STD FLANGE RATTING – UG -11(a) (2)AS PER ASME SEC. VIII DIV.I-2007 EDITION UP TO & INCL. ADDENDA-2008

: 1.796 MPa

: 78 °C

: SA 105 M [ MATERIAL GR. No. 1 & P. No.1]

: 150 #

: 1.8 MPa(AS PER TABLE -2 FOR CLASS 150 # OF ANSI B16.5 -2007)

NOTES:** PRESSURE RATING AT 100°F = 285 psiPRESSURE RATING AT 200°F = 260 psi PRESSURE RATING AT 149°F = 272.75 psi

= 1.8 MPa

*FROM TABLE 1A OF ANSI B16.5-2007

REQD. THK FOR NOZZLE REINFORCEMENTUG 37(a)(3)

1. DESIGN PRESSURE

2. DESIGN TEMPERATURE

3. MATL. SPEC. OF FLANGE

4. FLANGE RATTING ASSUMED

5. PRESSURE RATTING AT 149 °F

6. DESIGN PRESSURE 1.796 MPa ≤ PRESSURE RATTING

7. SELECTED RATTING 150 # IS OK

8. ANSI B16.5 STD FLANGE USED FOR ALL FLANGED CONNECTIONS

2 0.2

P ID

SE P

HP

K

2 0.2

P D

SE P

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