Design of Reactor With Agitator Shaft 1

7/24/2019 Design of Reactor With Agitator Shaft 1

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Pressure Vessels

Reaction VesselsAgitator ShaftsHeat ExchangersProcess ColumnsStorage TankFloating RoofChimney

ASME Sec. VIII Div. 1

TEMAEEUAIS 2825EN 13445

API 650API 620IS 6533


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EXAMPLE NO. PC-01

DESIGN OFREACTION VESSEL WITH AGITATOR SHAFT

NOTE:

1) Link to youtube video of this design:https://www.youtube.com/watch?v=Szl9AE_d4pQ&list=PLPL8SPZUxm-mFqQZceyhr13QYDEruelJx&index=6

2) As you can see in the video, the inbuilt intelligence in the software generates maximum information byitself.

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 designcode.

3) In case of any changes to the interconnected shell geometry and / or design conditions (pressure /temperature) including material of constructions, these dimensions are automatically regenerated by the

software to meet the new requirements.

4) The software can generate cost estimation and BOM in Excel.

This example covers design of a Reaction Vessel with Agitator Shaft.

This reaction vessel has dishes at the top and bottom ends. The jacketing is of plain

shell type, partially covering the main shell and extending on to the bottom dished end.It has an agitator, with say 20 HP power and the agitator shaft RPM is 100. All thecomponents in contact with the internal process liquid are of SS 316 and the jacketing isof SS 304.


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'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in

Index

Licensee :Sunay Wagle, CADEM Services,

Pune, India

Customer ABC Company Ltd.

Project / Equipment Soap Plant / Reactor R101

Designed By / Revision and Date / R00 , 06-04-2015 19:23:54

Sr. No. Description Page No

1 Title page & equipment info

2 Design data

3 Material of constructions

4 Effective Pressures

5 Weight summary report

6 Wind load calculations

7 Seismic load calculations

8 Design of Dished End (Front)

9 Design of Closure Flng (Front)

10 Design of Closure Flng (Front)

11 Design of Shel l Flng (Front)

12 Design of Shel l Flng (Front)

13 Design of Main Shell

14 Design of Dished End (Rear)

15 Design of Jacket Closure (Top)

16 Design of Jacket Shell

17 Design of Jacket Dish (Bottom)

18 Design of Lug Support

19 Design of Lug Support

20 Design of Shaft

21 Design of Impeller (1)

22 Design of Lifting Lugs

23 Foundation load data

24 C.G. Data


4/40


EQUIPMENT INFORMATION :

DESIGN & REVIEWAL :

INSPECTION & APPROVAL :

EQUIPMENT DATA :

JACKETING DATA :

AGITATOR DATA :

OTHER DATA :


Project Soap Plant

Location Vapi Site

Plant Refrigeration Plant

Design Code ASME VIII Div.1, 10 A11

Equipment Name Reactor R101

Equipment Type Reaction Vessel

Equipment Class N.A.

Equipment Category N.A.

Reference Drawing No ---

Service Chemical Services

Support Type Lug Supports

Designed By

Design Date 06-04-2015 19:23:54

Checked By

Approved By

Revision R00

Inspection Agency ---

Reviewed By ---

Front end Dished End

Front end flanged True

Rear end Dished End

Rear end flanged False

Shell ID 1600 mm

Shell OD 1628 mm

Length, Shell (W.L. to W.L) / Overall 2400 / 3338.3 mm

Jacketing system Shell & Bottom End

Jacket type Plain Jacket

Power 20 hp (MKS)

RPM 100

Duty Factor 2

Diameter of shaft 101 mm

Free Length of shaft 3738.3 mm

No of impellers 1

Propped True

Fabricated weight 5065.2 kgf Empty weight + external weights 5065.2 kgf

Estimated operating weight 11231.4 kgf

Estimated hydrotest weight 10964.4 kgf


5/40


(1) PROCESS DETAILS :

(4) TEMPERATURE : C

(5) ALLOWANCES : mm

(6) RADIOGRAPHY & JOINT EFFICIENCY :


Pune, India




REACTION VESSEL DESIGN DATA

SHELL SIDE JACKET SIDE

MEDIA DENSITY MEDIA DENSITY

kg/m kg/m

Operating Process 980 Steam 1.5

Design1 1000 1000

Design2

Startup

Shutdown

Upset

Hydrotest Water 1000 Water 1000

Pneumatic Process 1.2 Steam 1.2

(2) PR. : kgf/mm g INT. EXT. INT. EXT.

Input Pr MAWP Input Pr Input Pr MAWP Input Pr

Operating 0.06 0.06 0.01055 0.04 0.04 0.01055

Design1 0.08 0.08 0.01055 0.05 0.05 0.01055

Design2

Startup

Shutdown

Upset

(3) TEST PR. : kgf/mm g Based on Based on

Input Pr MAWP MAP Input Pr MAWP MAP

Hydrotest 0.106 0.106 0.106 0.07085 0.07085 0.07085

Pneumatic 0.08976 0.08976 0.08976 0.05995 0.05995 0.05995

MIN. MDMT. MAX. MIN. MDMT. MAX

Operating 20 120 20 150

Design1 10 180 10 200

Design2

Startup

Shutdown

Upset

Hydrotest 21.67 50 21.67 50

Pneumatic 21.67 50 21.67

INT. EXT. INT. EXT.

Corrosion 0 0 0 0

Polishing 0 0 0

RADIOGRAPHY JOINTEFFICIENCY

RADIOGRAPHY JOINTEFFICIENCY

Shell Spot + T Joints 0.85 Spot + T Joints 0.85

Head Full 1.00 Full 1.00


6/40


REACTION VESSEL DESIGN DATA

1. MATERIAL OF CONSTRUCTION :

2. NOZZLE CONNECTIONS :

3. AGITATOR:

4. INSULATION & CLADDING:


Pune, India




Shell side Jacket side

Shell / Channel SA-240 GR. 316 Plt. [UNS:S31600] SA-240 GR. 304 Plt. [UNS:S30400]

Head SA-240 GR. 316 Plt. [UNS:S31600] SA-240 GR. 304 Plt. [UNS:S30400]

Body flange SA-240 GR. 316 Plt. [UNS:S31600] SA-240 GR. 304 Plt. [UNS:S30400]

Body flange cover SA-240 GR. 316 Plt. [UNS:S31600] SA-240 GR. 304 Plt. [UNS:S30400]

Liner

Shell side Jacket side

Nozzle neck 40 & < 200SA-312 GR. TP316 Smls. Pipe[UNS:S31600]

SA-312 GR. TP304 Smls. Pipe[UNS:S30400]

Flange SA-240 GR. 316 Plt. [UNS:S31600] SA-240 GR. 304 Plt. [UNS:S30400]

Cover flange SA-240 GR. 316 Plt. [UNS:S31600] SA-240 GR. 304 Plt. [UNS:S30400]

Nozzle neck >= NPS 200 SA-240 GR. 316 Plt. [UNS:S31600] SA-240 GR. 304 Plt. [UNS:S30400]

Flange SA-240 GR. 316 Plt. [UNS:S31600] SA-240 GR. 304 Plt. [UNS:S30400]

Cover flange SA-240 GR. 316 Plt. [UNS:S31600] SA-240 GR. 304 Plt. [UNS:S30400]

Pad flange SA-240 GR. 316 Plt. [UNS:S31600] SA-240 GR. 304 Plt. [UNS:S30400]

Pad flange cover SA-240 GR. 316 Plt. [UNS:S31600] SA-240 GR. 304 Plt. [UNS:S30400]

Manhole flange SA-240 GR. 316 Plt. [UNS:S31600] SA-240 GR. 304 Plt. [UNS:S30400]

Manhole cover SA-240 GR. 316 Plt. [UNS:S31600] SA-240 GR. 304 Plt. [UNS:S30400]Reinforcement pad SA-240 GR. 316 Plt. [UNS:S31600] SA-240 GR. 304 Plt. [UNS:S30400]

External bolt SA-193 GR. B7 Bolt [UNS:G41400] SA-193 GR. B7 Bolt [UNS:G41400]

External gasket Spiral metal wound CAF filled (S.S.) CAF with suitable binder (3 mm.)

Stiffener SA-240 GR. 316 Plt. [UNS:S31600] SA-240 GR. 304 Plt. [UNS:S30400]

Lifting lug IS-2062 GR. A Plt. IS-2062 GR. A Plt.

Support IS-2062 GR. A Plt. IS-2062 GR. A Plt.

Anchor bolt SA-36 / IS-1363,67 Bolt [UNS:K02600] SA-36 / IS-1363,67 Bolt [UNS:K02600]

Shaft SA-479 GR. 316 Bar [UNS:S31600]

Impeller SA-240 GR. 316 Plt. [UNS:S31600]

Internal coupling SA-479 GR. 316 Bar [UNS:S31600]

Housing SA-479 GR. 316 Bar [UNS:S31600]

Housing cover SA-240 GR. 316 Plt. [UNS:S31600]

Mat. / Density / Thk. Rockwool (Mineral Fibre) / 136.2 kg/m / 60 mm

Mat. / Thk. Al. sheet / 1.191 mm


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SUMMARY OF EFFECTIVE DESIGN PRESSURES IN kgf/mm g VS TEMPERATURE IN C


Pune, India




Sr. Item name Temp. Inside pr. Liquid pr. Effective pr.

No. +ve -ve +ve -ve

1 Dished End (Front) 180 0.08 0.01055 0 0.08 0.010552 Closure Flng (Front) 180 0.08 0.01055 0 0.08 0.01055

3 Shell Flng (Front) 180 0.08 0.01055 0 0.08 0.01055

4 Main Shell 180 0.08 0.01055 0 0.09055 0.06055

5 Dished End (Rear) 180 0.08 0.01055 0 0.08 0.01055


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ITEM WISE WEIGHT SUMMARY


Pune, India




Sr.No. Item name Item sizeEmptywt

Volume Filled wt

kgf m kgf

1 Dished End (Front)Torispherical End CR = 1440,KR = 272, 8 Nom / 7.2 MinThk, SF = 50

216.5 0.607 823.5

2 Closure Flng (Front)Plate Ring - 1786 OD x 1619ID x 1729 PCD, RF, 154.681Thk, Trgv = 1.588

546.9 0 546.9

3 Shell Flng (Front)Plate Ring - 1786 OD x 1631ID x 1729 PCD, RF, 158.474Thk, Trgv = 1.588

522.1 0 522.1

4 Gasket Flng (Front)1695.2 OD x 1631 ID, 4.763Thk

0.1 0 0.1

5 Bolt Flng (Front)

Hex Head Bolt M24 x 354.18

Lg, 68 Nos. 86.25 0 86.25

6 Main Shell 1628 OD x 14 Thk, 2400 Lg 1362.9 4.825 6188.4

7 Dished End (Rear)Torispherical End CR = 1440,KR = 272, 8 Nom / 7.2 MinThk, SF = 50

216.5 0.607 823.5

8 Jacket Closure (Top)5296 Long x 111 Wide x 18Thk

84.65 0 84.65

9 Jacket Shell 1744 OD x 8 Thk, 1850 Lg 645.7 0.122 767.6

10 Jacket Dish (Bottom)Torispherical End CR = 1728,KR = 175, 8 Nom / 7.2 MinThk, SF = 50

222.2 0 222.2

11 Gusset Plate

220 Long x 240 Wide x 16

Thk, 4 Nos. 26.75 0 26.75

12 Anchor Bolt Anchor M20 x 200 Lg, 8 Nos. 3.979 0 3.979

13 Support Pad330 Long x 300 Wide x 14Thk, 4 Nos.

44.35 0 44.35

14 Motor 20 HP x 1450 RPM 200 0 200

15 Gear Box 20 HP x 14.5 Red. Ratio 200 0 200

16 Coupling Flexible Coupled B5 28.38 0 28.38

17 Bearing Housing 222 OD x 43 Thk, 325 Lg 62.87 0.00472 67.59

18 Top Bearing SKF Taper Roller 30216 0.163 0 0.163

19 Bottom Bearing SKF Taper Roller 30217 0.209 0 0.209

20 Shaft Seal Gland Packing 10 0 10

21 Shaft 101 OD x 4438.311 Lg 284.5 0 284.5

22 Impeller (1)Propeller, Sweep Dia Propellerx 4 Blades

27 0 27

23 Lifting Lugs135 Long x 77 Wide x 28 Thk,2 Nos.

4.608 0 4.608

24 Pad (Lifting Lugs)70 Long x 180 Wide x 8 Thk, 2Nos.

1.613 0 1.613

25 Insulation5805.663 W x 5411.911 L, 60Thk

256.7 0 256.7

26 Cladding 5809.404 W x 5411.911 L,1.191 Thk

10.36 0 10.36

27

28

29


9/40

30

5065.2 10964.4


10/40


1. DESIGN CONDITIONS ( Design Mode 1 , Uncorroded Condition ) :

3. CALCULATION OF FORCES AND MOMENTS:


Pune, India




WIND LOAD CALCULATION

CODE Wind [IS:875, 87]

Basic wind speed ( Section 5.2 ) Vb 50 m/s

Expected life of equipment ( Section 5.3.1 ) 25 Years

Probability factor (Risk coeff) ( Section 5.3.1 ) K1 0.902

Terrain category ( Section 5.3.2 ) Category 2

Structure class ( Section 5.3.2.2 ) Class B

Topography factor ( Section 5.3.3 ) K3 1.3

Force coefficient (Shape factor) Cf 0.8

Equivalent diameter De 2408 mm

Overall length of equipment L 3338.3 mm

Height of C.G. of equipment Hcg 1804.4 mm

Size and height factor ( Section 5.3.2 ) K2 0.98Effective transverse cross sectional area

= De x L A 8038652.8 mm

Effective wind speed

= K1 x K2 x K3 x Vb Vz 57.44 m/s

Wind pressure

= 6E-08 x Vz 2 Pz 0.0002 kgf/mm

Longitudinal force

= Cf x A x Pz F 1273.2 kgf

Support elevation H 456.2 mm

Turning moment

= F x ( Hcg - H ) M 1716622.5 kgf-mm


11/40



2. CALCULATION OF FORCES AND MOMENTS:


Pune, India




SEISMIC LOAD CALCULATION

CODE Seismic [IS:1893, 02]

Weight of equipment Wo 11231.4 kgf

Importance factor ( Table-6 , 2002 ) I 1.5

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

Spectral accelerations coeff. ( Fig. 2 , 2002 ) Sa / g 2.5, Use max value

Damping correction factor ( Table-3 , 2002 ) Cf 1

Seismic coefficient ( 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 ) Ah 0.103

Elevation of support H 456.2 mm

Height of C.G. of equipment Hcg 1804.4 mm

Seismic base shear force

= Ah x Wo

= 0.103 x 11231.4 Vb 1161.9 kgf

Seismic moment of support

= Vb x ( Hcg - H )

= 1161.9 x ( 1804.4 - 456.2 ) M 1566464.3 kgf-mm


12/40



2. DESIGN CALCULATION AS PER UG 32 e / APPENDIX 1-4 ( d ) :

Factor [M]

= ( 1 / 4 ) x [ 3 + SQRT [ CR / KR ] ]

= ( 1 / 4 ) x [ 3 + SQRT [ 1440 / 272 ] ]

= 1.325

Thickness for internal pressure [t]

= M x Pi x CR / ( 2 x S x E - 0.2 x Pi )

= 1.325 x 0.08 x 1440 / ( 2 x 13.79 x 1 - 0.2 x 0.08 )= 5.54 mm

3. DESIGN CALCULATION AS PER UG 33 e :

Thickness for equivalent external pressure [t]

= M x 1.67 x Pe x CR / ( 2 x S x 1.0 - 0.2 x 1.67 x Pe )

= 1.325 x 1.67 x 0.01055 x 1440 / ( 2 x 13.79 x 1.0 - 0.2 x 1.67 x 0.01055 )

= 1.219 mm

Assumed head thickness, [te]

= 4.454 mm

Assumed outside crown radius, [CRo]

= 1448 mm

Factor [A]

= 0.125 x te / CRo

= 0.125 x 4.454 / 1448

= 0.00038

Factor with reference to chart (HA-2) [B]

= 3.455 kgf/mm

Allowable external pressure [Pa]

= B x te / CRo

= 3.455 x 4.454 / 1448

= 0.01063 kgf/mm

Since Pa > Pe, design is safe

Since available thickness is more than design thickness, design is safe.


Pune, India




DESIGN OF TORISPHERICAL HEAD ( INT. & EXT. PRESSURE ) Dished End (Front)

CODE ASME VIII Div.1, 10 A11

Design pressure ( internal ) Pi 0.08 kgf/mm g

Design pressure ( external ) Pe 0.01055 kgf/mm g

Design temperature T 180 C

Material of construction SA-240 GR. 316 Plt. [UNS:S31600]

Max. allowable stress @ design temp. S 13.79 kgf/mm

Radiography Full

Joint efficiency E 1

Outside diameter of head OD 1616 mm

Crown radius CR 1440 mm

Knuckle radius KR 272 mm

Nominal thickness 8 mm

Nominal thickness required as per TEMA N.A mmInternal allowance, corrosion + polishing 0 mm

External allowance, corrosion + polishing 0 mm

Thinning allowance / Under tolerance 0.8 mm

Available thickness 7.2 mm


13/40



2. FLANGE DATA :

3. BOLTING DATA :

4. LINER DATA :

5. GASKET DATA :

5a. Flange gasket data :

5b. Partition groove gasket data (For H.E. body flange) :


Pune, India




FLANGE DESIGN ( INTERNAL ) Closure Flng (Front)


Design pressure P 0.08 kgf/mm g


Allowance CA 0 mm

Groove allowance Tg 1.588 mm

M.O.C. SA-240 GR. 316 Plt. [UNS:S31600]

Code allw. stress @ design temp. Sfo 10.46 kgf/mm

Code allw. stress @ atm. temp. Sfa 14.06 kgf/mm

Inside diameter B 1619 mm

Outside diameter A 1786 mm

Hub length h 0 mm

Thickness ( hub end ) g1 0 mmThickness ( pipe end ) g0 0 mm

Thickness provided 154.7 mm

Thickness available 153.1 mm

M.O.C. SA-193 GR. B7 Bolt [UNS:G41400]

Code allw. stress @ design temp. Sb 17.58 kgf/mm

Code allw. stress @ atm. temp. Sa 17.58 kgf/mm

Bolt PCD C 1729 mm

Bolt dia. db 24 mm

No. of bolts nb 68

M.O.C.

Liner ID mm

Liner OD mm

Liner thk. mm

M.O.C. Spiral metal wound CAF filled (S.S.)

Gasket type Ring Gasket

Gasket confinement type Unconfined

Flange face type Raised Face

Flange gakset surface finish Serrated (Normal)

Counter flange face type Raised FaceCounter gakset surface finish Serrated (Normal)

Applicalbe gasket sketch in Table 2-5.2 Type 1B

Applicable gasket column in Table 2-5.2 1

Gasket seating stress ( refer to Note 1, Table 2-5.1 ) y 7.031 kgf/mm

Gasket factor ( from Table 2-5.1 ) m 3

Inside diameter Gi 1631 mm

Outside diameter Go 1695.2 mm

Width of gasket ( as per Table 2-5.2 ) N 32.1 mm

Width of gasket ( as per Table 2-5.2 ) w 32.1 mm

Width of raised face or gasket contact width 38.1 mm

( as per Table 2-5.2 )

Basic gasket seating width ( as per Table 2-5.2 ) b0 16.05 mm

Effective gasket width ( as per Table 2-5.2 ) b 10.1 mm

Dia. at load reaction ( see Table 2-5.2 ) G 1675 mm

M.O.C. --


14/40

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 10.1 x 1675 x 3 + 0 x 0 x 0 ) x 0.08

= 25499.6 kgfTotal hydrostatic end force [H]

= 0.25 x x G x P

= 0.25 x x 1675 x 0.08

= 176284.5 kgf

Minimum required bolt load for operating condition [Wm1a]

= Hp + H

= 25499.6 + 176284.5

= 201784.1 kgf

Minimum required bolt load for operating condition [Wm1b]

( from mating flange )

= 201784.1 kgf

Governing bolt load for operating condition [Wm1]

= MAX [ Wm1a , Wm1b ]

= MAX [ 201784.1 , 201784.1 ]= 201784.1 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 10.1 x 1675 x 7.031 + 0 x 0 x 0 )

= 373499.5 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

= 21249.6 mm

Actual bolt area using root diameter [Ab]

= 21266.9 mm

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

= 373650.9 kgf ( Avg. 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 )

= 21266.9 x 17.58 / ( 2 x x 7.031 x 1675 )

= 5.052 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 )

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 2x P

= 0.25 x x 1619 2x 0.08

= 164692.4 kgf

Gasket load (difference between flange design bolt load and total hydrostatic end force) [HG]

= Wm1 - H

= 201784.1 - 176284.5

= 25499.6 kgf

Difference between total hydrostatic end force and hydrostatic end force on area inside of flange [HT]

= H - HD

= 176284.5 - 164692.4

= 11592.1 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 ( 1729 - 1619 ) - 0

Gasket seating stress ( refer to Note 1, Table 2-5.1 ) y' 0 kgf/mm

Gasket factor ( from Table 2-5.1 ) m' 0

Pass partition gasket width Wp 0 mm

Pass partition gasket length Lp 0 mm

Effective pass partition gasket width b' 0 mm

RING FLANGE DESIGN Closure Flng (Front)


15/40

= 55

Radial distance from the bolt circle to the circle on which HD acts [hD]

= R + 0.5 x g1

= 55 + 0.5 x 0

= 55 mm

Radial distance from gasket load reaction to the bolt circle [hG]

= 0.5 x ( C - G )

= 0.5 x ( 1729 - 1675 )

= 27 mm

Radial distance from the bolt circle to the circle on which HT acts [hT]

= 0.5 x ( R + g1 + hG )

= 0.5 x ( 55 + 0 + 27 )= 41 mm

13. FLANGE MOMENTS UNDER OPERATING CONDITION AS PER APPENDIX 2-6

Component of moment due to HD [MD]

= HD x hD

= 164692.4 x 55

= 9058082.2 kgf-mm

Component of moment due to HG [MG]

= HG x hG

= 25499.6 x 27

= 688371.3 kgf-mm

Component of moment due to HT [MT]

= HT x hT

= 11592.1 x 41

= 475251.3 kgf-mmTotal moment acting on the flange for operating condition [MO]

= MD + MG + MT

= 9058082.2 + 688371.3 + 475251.3

= 10221704.8 kgf-mm

14. LOADS AND FORCES DURING GASKET SEATING AS PER APPENDIX 2-3

Gasket load for seating condition [HG]

= W

= 373650.9 kgf

15. MOMENT UNDER GASKET SEATING AS PER APPENDIX 2-6

Total moment acting on the flange for gasket seating [MO']

= W x hG

= 373650.9 x 27

= 10086863.4 kgf-mm

16. SHAPE CONSTANTSFactor [K]

= A / B

= 1786 / 1619

= 1.103

Flange factor from Fig. 2-7.1 [Y]

= 19.74

17. FLANGE THICKNESS REQUIRED AS PER APPENDIX 2-7

Equivalent moment [Mmax]

= MAX [ MO , MO' x Sfo / Sfa ]

= MAX [ 10221704.8 , 10086863.4 x 10.46 / 14.06 ]

= 10221704.8 kgf-mm

Corrected equivalent moment per unit length [M]

= Mmax x Cf / B

= 10221704.8 x 1 / 1619= 6313.6 kgf

Required thickness of flange [t]

= SQRT [ M x Y / Sfo ]

= SQRT [ 6313.6 x 19.74 / 10.46 ]

= 109.2 mm

18. FLANGE RIGIDITY CHECKING AS PER APPENDIX 2-14

Rigidity index [J]

= 109.4 x Mmax / ( Efo x tr 3x KL x ln ( K ) )

= 109.4 x 10221704.8 / ( 18786 x 144.8 3 x 0.2 x ln ( 1.103 ) )

= 0.999Since J < 1.0, design is safe

Assumed flange thickness tr 144.8 mm

Modulus of elasticity for flange Efo 18786 kgf/mm

Rigidity factor KL 0.2


16/40



2. FLANGE DATA :

3. BOLTING DATA :

4. LINER DATA :

5. GASKET DATA :




Pune, India




FLANGE DESIGN ( EXTERNAL ) Closure Flng (Front)




Allowance CA 0 mm


M.O.C. SA-240 GR. 316 Plt. [UNS:S31600]





Hub length h 0 mm







Bolt PCD C 1729 mm

Bolt dia. db 24 mm

No. of bolts nb 68

M.O.C.

Liner ID mm

Liner OD mm

Liner thk. mm




















M.O.C. --


17/40




= 2 x ( x 10.1 x 1675 x 3 + 0 x 0 x 0 ) x 0.01055


= 0.25 x x G x P

= 0.25 x x 1675 x 0.01055

= 23239.4 kgf


= Hp + H

= 3361.6 + 23239.4

= 26600.9 kgf



= 26600.9 kgf



= MAX [ 26600.9 , 26600.9 ]= 26600.9 kgf



= ( x b x G x y + b' x Lp x y' )

= ( x 10.1 x 1675 x 7.031 + 0 x 0 x 0 )

= 373499.5 kgf





= 21249.6 mm


= 21266.9 mm






= Ab x Sb / ( 2 x x y x G )

= 21266.9 x 17.58 / ( 2 x x 7.031 x 1675 )

= 5.052 mm









= 0.25 x x B 2x P

= 0.25 x x 1619 2x 0.01055

= 21711.2 kgf


= H - HD

= 23239.4 - 21711.2

= 1528.2 kgf



= 0.5 x ( C - B ) - g1

= 0.5 x ( 1729 - 1619 ) - 0

= 55


= R + 0.5 x g1

= 55 + 0.5 x 0






RING FLANGE DESIGN Closure Flng (Front)


18/40

= 55 mm


= 0.5 x ( C - G )

= 0.5 x ( 1729 - 1675 )

= 27 mm


= 0.5 x ( R + g1 + hG )

= 0.5 x ( 55 + 0 + 27 )

= 41 mm



= HD x ( hD - hG )= 21711.2 x ( 55 - 27 )

= 608012.7 kgf-mm


= HT x ( hT - hG )

= 1528.2 x ( 41 - 27 )

= 21398 kgf-mm

Total moment acting on the flange for operating condition [MO]

= MD + MT

= 608012.7 + 21398

= 629410.7 kgf-mm



= W

= 373650.9 kgf15. MOMENT UNDER GASKET SEATING AS PER APPENDIX 2-6


= W x hG

= 373650.9 x 27

= 10086863.4 kgf-mm

16. SHAPE CONSTANTS

Factor [K]

= A / B

= 1786 / 1619

= 1.103


= 19.74


Equivalent moment [Mmax]= MAX [ MO , MO' x Sfo / Sfa ]

= MAX [ 629410.7 , 10086863.4 x 10.46 / 14.06 ]

= 7500591.6 kgf-mm


= Mmax x Cf / B

= 7500591.6 x 1 / 1619

= 4632.9 kgf



= SQRT [ 4632.9 x 19.74 / 10.46 ]

= 93.51 mm


Rigidity index [J]


= 109.4 x 7500591.6 / ( 18786 x 144.3 3 x 0.2 x ln ( 1.103 ) )

= 0.997

Since J < 1.0, design is safe





19/40



2. FLANGE DATA :

3. BOLTING DATA :

4. LINER DATA :

5. GASKET DATA :




Pune, India




FLANGE DESIGN ( INTERNAL ) Shell Flng (Front)




Allowance CA 0 mm


M.O.C. SA-240 GR. 316 Plt. [UNS:S31600]





Hub length h 0 mm







Bolt PCD C 1729 mm

Bolt dia. db 24 mm

No. of bolts nb 68

M.O.C.

Liner ID mm

Liner OD mm

Liner thk. mm




















M.O.C. --


20/40




= 2 x ( x 10.1 x 1675 x 3 + 0 x 0 x 0 ) x 0.08


= 0.25 x x G x P

= 0.25 x x 1675 x 0.08

= 176284.5 kgf


= Hp + H

= 25499.6 + 176284.5

= 201784.1 kgf



= 201784.1 kgf



= MAX [ 201784.1 , 201784.1 ]= 201784.1 kgf



= ( x b x G x y + b' x Lp x y' )

= ( x 10.1 x 1675 x 7.031 + 0 x 0 x 0 )

= 373499.5 kgf





= 21249.6 mm


= 21266.9 mm






= Ab x Sb / ( 2 x x y x G )

= 21266.9 x 17.58 / ( 2 x x 7.031 x 1675 )

= 5.052 mm









= 0.25 x x B 2x P

= 0.25 x x 1631 2x 0.08

= 167142.8 kgf

Gasket load (difference between flange design bolt load and total hydrostatic end force) [HG]

= Wm1 - H

= 201784.1 - 176284.5

= 25499.6 kgf


= H - HD

= 176284.5 - 167142.8

= 9141.7 kgf



= 0.5 x ( C - B ) - g1

= 0.5 x ( 1729 - 1631 ) - 0






RING FLANGE DESIGN Shell Flng (Front)


21/40

= 49


= R + 0.5 x g1

= 49 + 0.5 x 0

= 49 mm


= 0.5 x ( C - G )

= 0.5 x ( 1729 - 1675 )

= 27 mm


= 0.5 x ( R + g1 + hG )

= 0.5 x ( 49 + 0 + 27 )= 38 mm



= HD x hD

= 167142.8 x 49

= 8189999.4 kgf-mm

Component of moment due to HG [MG]

= HG x hG

= 25499.6 x 27

= 688371.3 kgf-mm


= HT x hT

= 9141.7 x 38

= 347363.7 kgf-mmTotal moment acting on the flange for operating condition [MO]

= MD + MG + MT

= 8189999.4 + 688371.3 + 347363.7

= 9225734.4 kgf-mm



= W

= 373650.9 kgf

15. MOMENT UNDER GASKET SEATING AS PER APPENDIX 2-6


= W x hG

= 373650.9 x 27

= 10086863.4 kgf-mm

16. SHAPE CONSTANTSFactor [K]

= A / B

= 1786 / 1631

= 1.095


= 21.32


Equivalent moment [Mmax]

= MAX [ MO , MO' x Sfo / Sfa ]

= MAX [ 9225734.4 , 10086863.4 x 10.46 / 14.06 ]

= 9225734.4 kgf-mm


= Mmax x Cf / B

= 9225734.4 x 1 / 1631= 5656.5 kgf



= SQRT [ 5656.5 x 21.32 / 10.46 ]

= 107.4 mm


Rigidity index [J]


= 109.4 x 9225734.4 / ( 18786 x 148.1 3 x 0.2 x ln ( 1.095 ) )

= 0.996Since J < 1.0, design is safe





22/40



2. FLANGE DATA :

3. BOLTING DATA :

4. LINER DATA :

5. GASKET DATA :




Pune, India




FLANGE DESIGN ( EXTERNAL ) Shell Flng (Front)




Allowance CA 0 mm


M.O.C. SA-240 GR. 316 Plt. [UNS:S31600]





Hub length h 0 mm







Bolt PCD C 1729 mm

Bolt dia. db 24 mm

No. of bolts nb 68

M.O.C.

Liner ID mm

Liner OD mm

Liner thk. mm




















M.O.C. --


23/40



= 2 x ( px b x G x m + b' x Lp x m' ) x P

= 2 x ( px 10.1 x 1675 x 3 + 0 x 0 x 0 ) x 0.01055


= 0.25 x px G x P

= 0.25 x px 1675 x 0.01055

= 23239.4 kgf


= Hp + H

= 3361.6 + 23239.4

= 26600.9 kgf



= 26600.9 kgf



= MAX [ 26600.9 , 26600.9 ]= 26600.9 kgf



= ( px b x G x y + b' x Lp x y' )

= ( px 10.1 x 1675 x 7.031 + 0 x 0 x 0 )

= 373499.5 kgf





= 21249.6 mm


= 21266.9 mm






= Ab x Sb / ( 2 x px y x G )

= 21266.9 x 17.58 / ( 2 x px 7.031 x 1675 )

= 5.052 mm









= 0.25 x px B 2x P

= 0.25 x px 1631 2x 0.01055

= 22034.2 kgf


= H - HD

= 23239.4 - 22034.2

= 1205.1 kgf



= 0.5 x ( C - B ) - g1

= 0.5 x ( 1729 - 1631 ) - 0

= 49


= R + 0.5 x g1

= 49 + 0.5 x 0






RING FLANGE DESIGN Shell Flng (Front)


24/40

= 49 mm


= 0.5 x ( C - G )

= 0.5 x ( 1729 - 1675 )

= 27 mm


= 0.5 x ( R + g1 + hG )

= 0.5 x ( 49 + 0 + 27 )

= 38 mm



= HD x ( hD - hG )= 22034.2 x ( 49 - 27 )

= 484853.9 kgf-mm


= HT x ( hT - hG )

= 1205.1 x ( 38 - 27 )

= 13259.3 kgf-mm

Total moment acting on the flange for operating condition [MO]

= MD + MT

= 484853.9 + 13259.3

= 498113.2 kgf-mm



= W

= 373650.9 kgf15. MOMENT UNDER GASKET SEATING AS PER APPENDIX 2-6


= W x hG

= 373650.9 x 27

= 10086863.4 kgf-mm

16. SHAPE CONSTANTS

Factor [K]

= A / B

= 1786 / 1631

= 1.095


= 21.32


Equivalent moment [Mmax]= MAX [ MO , MO' x Sfo / Sfa ]

= MAX [ 498113.2 , 10086863.4 x 10.46 / 14.06 ]

= 7500591.6 kgf-mm


= Mmax x Cf / B

= 7500591.6 x 1 / 1631

= 4598.8 kgf



= SQRT [ 4598.8 x 21.32 / 10.46 ]

= 96.83 mm


Rigidity index [J]


= 109.4 x 7500591.6 / ( 18786 x 148.4 3 x 0.2 x ln ( 1.095 ) )

= 0.99

Since J < 1.0, design is safe





25/40


1. DESIGN CONDITIONS ( Design Mode 1 , Uncorroded Condition )

2. DESIGN CALCULATION AS PER UG-27

Thickness of shell under internal pressure [ti]

= Pi x R / ( S x E - 0.6 x Pi )

= 0.09055 x 800 / ( 13.79 x 0.85 - 0.6 x 0.09055 )

= 6.211 mm

3. DESIGN CALCULATION OF SHELL THICKNESS UNDER EXTERNAL PRESSURE AS PER UG-28


= 4 x B / ( 3 x ( OD / te ) )

= 4 x 5.516 / ( 3 x 120.9 )

= 0.06086 kgf/mm g




Pune, India




DESIGN OF SHELL ( INTERNAL AND EXTERNAL PRESSURE ) Main Shell






Max. allowable stress at design temp. S 13.79 kgf/mm

Radiography Spot + T Joints

Joint efficiency long. seam Ec 0.85

Outside diameter OD 1628 mm

Inside radius ( corroded ) R 800 mm

Shell length L 2400 mm

Design length L1 2400 mm

Nominal thickness 14 mmNominal thickness required as per TEMA N.A. mm

Internal allowance, corrosion + polishing 0 mm


Thickness undertolerance 0 mm

Available thickness 14 mm

Assumed te 13.47 mm

L1 / OD 1.474

OD / te 120.9

Factor A ( Refer to Fig. G in Subpart 3 of Sec. II, Part D ) 0.00067

Factor B ( HA-2 ) 5.516 kgf/mm


26/40




Factor [M]

= ( 1 / 4 ) x [ 3 + SQRT [ CR / KR ] ]

= ( 1 / 4 ) x [ 3 + SQRT [ 1440 / 272 ] ]

= 1.325


= M x Pi x CR / ( 2 x S x E - 0.2 x Pi )

= 1.325 x 0.08 x 1440 / ( 2 x 13.79 x 1 - 0.2 x 0.08 )= 5.54 mm




= 1.325 x 1.67 x 0.01055 x 1440 / ( 2 x 13.79 x 1.0 - 0.2 x 1.67 x 0.01055 )

= 1.219 mm


= 4.454 mm


= 1448 mm

Factor [A]

= 0.125 x te / CRo

= 0.125 x 4.454 / 1448

= 0.00038


= 3.455 kgf/mm


= B x te / CRo

= 3.455 x 4.454 / 1448

= 0.01063 kgf/mm




Pune, India




DESIGN OF TORISPHERICAL HEAD ( INT. & EXT. PRESSURE ) Dished End (Rear)







Radiography Full











27/40


1. DESIGN CONDITIONS :

2. SHELL DATA :

3. JACKET DATA :

4. MAX. ALLOWABLE WIDTH OF JACKET SPACE

Maximum allowed jacket spacing [Jmax]

= [ 4 x S x ts 2/ ( Pi x ID ) ] - 0.5 x ( ts + tj )

= [ 4 x 12.9 x 14 2/ ( 0.05 x 1728 ) ] - 0.5 x ( 14 + 8 )

= 106.1 mm.

In this case J < Jmax , jacket width is acceptable.

5. DESIGN CALCULATION AS PER 9.5 (c)(5) :

Calculated thickness of closure member for pressure [t1]

= 1.414 x SQRT [ 0.5 x OD1 x Pi x J / S ]

= 1.414 x SQRT [ 0.5 x 1628 x 0.05 x 50 / 12.9 ]

= 17.76 mmRequired minimum thickness of closure member [tr]

= MAX [ t1 , trj ]

= MAX [ 17.76 , 3.951 ]

= 17.76 mm

Since required minimum thickness of closure (tr) < available thickness of jacket closure (tc) , design is safe.


Pune, India




DESIGN OF JACKET CLOSURE Jacket Closure (Top)

Code ASME VIII Div.1, 10 A11

Design pressure ( INTERNAL ) Pi 0.05 kgf/mm g





Joint efficiency E 0.85

Jacketing type Shell & Bottom End

Closure type Figure (f2)

Jacket spacing J 50 mm

Nominal closure thickness t 18 mm


External allowance, corrosion + polishing 0 mmAvailable thickness tc 18 mm


Outside diameter OD1 1628 mm

Inside diameter ID1 1600 mm

Provided thickness 14 mm

Nominal thickness ts 14 mm



Inside diameter ID 1728 mm

Provided thickness 8 mm

Nominal thickness tj 8 mm

Required minimum thickness of outer jacket wall trj 3.951 mm


28/40


1. DESIGN CONDITIONS ( Design Mode 1 , Uncorroded Condition )

2. DESIGN CALCULATION AS PER UG-27

Thickness of shell under internal pressure [ti]

= Pi x R / ( S x E - 0.6 x Pi )

= 0.05 x 864 / ( 12.9 x 0.85 - 0.6 x 0.05 )

= 3.951 mm

3. DESIGN CALCULATION OF SHELL THICKNESS UNDER EXTERNAL PRESSURE AS PER UG-28


= 4 x B / ( 3 x ( OD / te ) )

= 4 x 2.272 / ( 3 x 284.6 )

= 0.01064 kgf/mm g




Pune, India




DESIGN OF SHELL ( INTERNAL AND EXTERNAL PRESSURE ) Jacket Shell






Max. allowable stress at design temp. S 12.9 kgf/mm


Joint efficiency long. seam Ec 0.85


Inside radius ( corroded ) R 864 mm

Shell length L 1850 mm

Design length L1 1850 mm

Nominal thickness 8 mmNominal thickness required as per TEMA N.A. mm



Thickness undertolerance 0 mm

Available thickness 8 mm

Assumed te 6.128 mm

L1 / OD 1.061

OD / te 284.6

Factor A ( Refer to Fig. G in Subpart 3 of Sec. II, Part D ) 0.00026

Factor B ( HA-1 ) 2.272 kgf/mm


29/40




Factor [M]

= ( 1 / 4 ) x [ 3 + SQRT [ CR / KR ] ]

= ( 1 / 4 ) x [ 3 + SQRT [ 1728 / 175 ] ]

= 1.536


= M x Pi x CR / ( 2 x S x E - 0.2 x Pi )

= 1.536 x 0.05 x 1728 / ( 2 x 12.9 x 1 - 0.2 x 0.05 )= 5.144 mm




= 1.536 x 1.67 x 0.01055 x 1728 / ( 2 x 12.9 x 1.0 - 0.2 x 1.67 x 0.01055 )

= 1.812 mm


= 5.337 mm


= 1736 mm

Factor [A]

= 0.125 x te / CRo

= 0.125 x 5.337 / 1736

= 0.00038


= 3.456 kgf/mm


= B x te / CRo

= 3.456 x 5.337 / 1736

= 0.01062 kgf/mm




Pune, India




DESIGN OF TORISPHERICAL HEAD ( INT. & EXT. PRESSURE ) Jacket Dish (Bottom)







Radiography Full











30/40


1. LUG DATA :

2. BOLT DATA :

3. GUSSET DATA :

4. SHELL DATA :

5. PAD DATA :

6. LOAD AND MOMENT ( Wind ) :

7. DESIGN OF ANCHOR BOLTS :

Total uplift force on bolts [T]

= [ 4 x M / ( D x N ) ] - Wt / N

= [ 4 x 2107478.2 / ( 1928 x 4 ) ] - 6175 / 4

= -450.7 kgf

Required area of bolts [Am]

= MAX [ ( T / Fs ) , 0 ]

= MAX [ ( -450.7 / 20.88 ) , 0 ]

= 0 mm

Available area of bolts [Ab]

= Ar x Nb ........................................................................................ where, Ar = 217.1 mm, is root area of bolt= 217.1 x 2

= 434.1 mm

Since Ab > Am, bolts provided are sufficient

8. GUSSET DESIGN :

Reaction force at each support [Q]


Pune, India




LUG SUPPORT DESIGN Lug Support

CODE P V Design Manual, D.R. Moss

Design Mode 1 , Uncorroded

Condition

M.O.C IS-2062 GR. A Plt.

No. of support N 4

Base plate width b1 42 mm

Base plate depth Lb 220 mm

Thickness of base plate tb 16 mm

Allowable bending stress Sb 22.15 kgf/mm

M.O.C SA-36 / IS-1363,67 Bolt [UNS:K02600]

No. of bolt / lug Nb 2

Bolt diameter db 20 mm

PCD D 1928 mm

Diameter of bolt hole 24 mm

Allowable tensile stress Fs 20.88 kgf/mm

Thickness tg 16 mm

Height h 240 mm

Gusset angle ! 54.69

Gusset depth at top Lc 50 mm

Number of gussets n 1

Distance between gussets b 0 mm

Material SA-240 GR. 316 Plt. [UNS:S31600]

OD diameter OD 1628 mm


Thickness available ts 14 mm


Thickness tp 14 mm

Width W 330 mm

Length L 300 mm

Max. overturning moment M 2107478.2 kgf-mm

Design weight of vessel Wt 6175 kgf


31/40

= [ 4 x M / ( D x N ) ] + Wt / N

= [ 4 x 2107478.2 / ( 1928 x 4 ) ] + 6175 / 4

= 2636.8 kgf

Maximum axial force in gusset [P1]

= Q

= 2636.8

= 2636.8 kgf

Allowable compr. stress in gusset [Sg]

= 1800 / [ ( 1 + 12 / 18000 ) x ( h / tg ) 2] ....................................... where, h = 294.1 mm

= 1800 / [ ( 1 + 12 / 18000 ) x ( 294.1 / 16 ) 2]

= 14690.8 psi

= 10.33 kgf/mm

Required thickness of gusset [tg]

= 2 x P1 x ( 3 x a - Lb ) / [ Sg x Lb 2x ( sin !) 2]

= 2 x 2636.8 x ( 3 x 150 - 220 ) / [ 10.33 x ( 220 ) 2x ( sin 54.69 ) 2]

= 3.644 mm

9. BASE PLATE DESIGN :

Bending moment [Mb]

= Q x b1 / 4

= 2636.8 x 42 / 4

= 27686.9 kgf-mmBearing pressure [bp]

= Q / ( w x b1 ) ............................................................................... where, w = 132 mm

= 2636.8 / ( 132 x 42 )

= 0.476 kgf/mm

Bending moment due to bearing pressure [Mb]

= bp x b 2/ 2

= 0.476 x 0 2/ 2

= 40.19 kgf-mm

Required thickness of base plate between chairs [tb]

= SQRT { 6 x MAX [ Mb , Mb' ] / [ ( Lb - db ) x Sb ] }

= SQRT { 6 x MAX [ 27686.9 , 40.19 ] / [ ( 220 - 20 ) x 22.15 ] }

= 6.186 mm

10. CHECK FOR COMPRESSION PLATE :

Equivalent radial load [f]

= Q x a / h

= 2636.8 x 150 / 240

= 1648 kgf

Angle between supports [b]

= 2 x p/ N

= 2 x p/ 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 1648 x 1628

= 427011.1 kgf-mm

Bending stress induced [fb]

= Mo / Zc

= 427011.1 / 30687.7

= 13.91 kgf/mm ......................................................................... < Sb = 22.15 kgf/mm

Since, induced stress fb < allow. stress Sb in shell material, design is safe.


32/40


1. LUG DATA :

2. BOLT DATA :

3. GUSSET DATA :

4. SHELL DATA :

5. PAD DATA :

6. LOAD AND MOMENT ( Seismic ) :

7. DESIGN OF ANCHOR BOLTS :

Total uplift force on bolts [T]

= [ 4 x M / ( D x N ) ] - Wt / N

= [ 4 x 1923130.8 / ( 1928 x 4 ) ] - 4385.1 / 4

= -98.79 kgf

Required area of bolts [Am]

= MAX [ ( T / Fs ) , 0 ]

= MAX [ ( -98.79 / 20.88 ) , 0 ]

= 0 mm

Available area of bolts [Ab]

= Ar x Nb ........................................................................................ where, Ar = 217.1 mm, is root area of bolt= 217.1 x 2

= 434.1 mm

Since Ab > Am, bolts provided are sufficient

8. GUSSET DESIGN :

Reaction force at each support [Q]


Pune, India




LUG SUPPORT DESIGN Lug Support



Condition

M.O.C IS-2062 GR. A Plt.

No. of support N 4

Base plate width b1 42 mm

Base plate depth Lb 220 mm

Thickness of base plate tb 16 mm

Allowable bending stress Sb 22.15 kgf/mm

M.O.C SA-36 / IS-1363,67 Bolt [UNS:K02600]

No. of bolt / lug Nb 2

Bolt diameter db 20 mm

PCD D 1928 mm

Diameter of bolt hole 24 mm

Allowable tensile stress Fs 20.88 kgf/mm

Thickness tg 16 mm

Height h 240 mm

Gusset angle ! 54.69

Gusset depth at top Lc 50 mm

Number of gussets n 1

Distance between gussets b 0 mm


OD diameter OD 1628 mm


Thickness available ts 14 mm


Thickness tp 14 mm

Width W 330 mm

Length L 300 mm

Max. overturning moment M 1923130.8 kgf-mm

Design weight of vessel Wt 4385.1 kgf


33/40

= [ 4 x M / ( D x N ) ] + Wt / N

= [ 4 x 1923130.8 / ( 1928 x 4 ) ] + 4385.1 / 4

= 2093.7 kgf

Maximum axial force in gusset [P1]

= Q

= 2093.7

= 2093.7 kgf

Allowable compr. stress in gusset [Sg]

= 1800 / [ ( 1 + 12 / 18000 ) x ( h / tg ) 2] ....................................... where, h = 294.1 mm

= 1800 / [ ( 1 + 12 / 18000 ) x ( 294.1 / 16 ) 2]

= 14690.8 psi

= 10.33 kgf/mm

Required thickness of gusset [tg]

= 2 x P1 x ( 3 x a - Lb ) / [ Sg x Lb 2x ( sin !) 2]

= 2 x 2093.7 x ( 3 x 150 - 220 ) / [ 10.33 x ( 220 ) 2x ( sin 54.69 ) 2]

= 2.893 mm

9. BASE PLATE DESIGN :

Bending moment [Mb]

= Q x b1 / 4

= 2093.7 x 42 / 4

= 21984.3 kgf-mmBearing pressure [bp]

= Q / ( w x b1 ) ............................................................................... where, w = 132 mm

= 2093.7 / ( 132 x 42 )

= 0.378 kgf/mm

Bending moment due to bearing pressure [Mb]

= bp x b 2/ 2

= 0.378 x 0 2/ 2

= 31.91 kgf-mm

Required thickness of base plate between chairs [tb]

= SQRT { 6 x MAX [ Mb , Mb' ] / [ ( Lb - db ) x Sb ] }

= SQRT { 6 x MAX [ 21984.3 , 31.91 ] / [ ( 220 - 20 ) x 22.15 ] }

= 5.513 mm

10. CHECK FOR COMPRESSION PLATE :

Equivalent radial load [f]

= Q x a / h

= 2093.7 x 150 / 240

= 1308.6 kgf

Angle between supports [b]

= 2 x p/ N

= 2 x p/ 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 1308.6 x 1628

= 339060.9 kgf-mm

Bending stress induced [fb]

= Mo / Zc

= 339060.9 / 30687.7

= 11.05 kgf/mm ......................................................................... < Sb = 22.15 kgf/mm

Since, induced stress fb < allow. stress Sb in shell material, design is safe.


34/40


1. SHAFT DATA :

2. IMPELLER TORQUE, FORCES AND MOMENTS :

Formulae used in the above table :

Tm(i) = [ 736 x 60 x HP(i) / ( 9.81 x 2 x px RPM ) ] kgf-m = [ 716440.6 x P(i) / RPM ] kgf-mm

F(i) = Tm(i) / ( 0.75 x Rb ) kgf

M(i) = F(i) x L(i) kgf-mm

M'(i) = F(i) x ( L - L(i) ) kgf-mm

M"(i) = F(i) x ( L - L(i) ) 3kgf-mm 3

3. CHECK FOR EQUIVALENT BENDING MOMENT

Reaction at top bearing [R1]

= [ M" - M' x L 2] / [ 2 x A x L x ( A + L ) ]

= [ 146.8E09 - 424140.7 x 3738.3 2] / [ 2 x 250 x 3738.3 x ( 250 + 3738.3 ) ]

= -775.4 kgf

Reaction at bottom bearing [R2]

= [ - M' - R1 x ( A + L ) ] / L

= [ - 424140.7 - -775.4 x ( 250 + 3738.3 ) ] / 3738.3

= 713.8 kgf

Reaction at bush [R3]

= - [ R1 + R2 + F ]

= - [ -775.4 + 713.8 + 720.9 ]

= -659.3 kgf

Bending moment at the bottom bearing [Mt]

= M + R3 x L

= 2270981.5 + -659.3 x 3738.3

= -193854.1 kgf-mm

Induced equivalent moment in shaft [Me]

= ( Mt 2+ 0.75 x Tm 2) 0.5

= ( -193854.1 2+ 0.75 x 143288.1 2) 0.5

= 230169.6 kgf-mm

Stress induced in shaft [Fy]


Pune, India




AGITATOR SHAFT WITH INTERMEDIATE BEARING HOUSING Shaft

Power P 20 hp (MKS)

Pumping capacity (RPM) RPM 100

Service (Duty) factor sf 2

Material of impeller SA-479 GR. 316 Bar [UNS:S31600]

0.2% Proof stress Sy 21.09 kgf/mm

Allowable stress Sa 14.05 kgf/mm

Youngs modulus Es 18786 kgf/mm

Weight density rho 7999.5 kg/m

Shaft OD OD 101 mm

Shaft ID ID 0 mm

Total length 4438.3 mm

Allowance CA 0 mm

Shaft is propped at bottom TrueDistance between bearings A 250 mm

Overhanging length L 3738.3 mm

Type of shaft seal Gland Packing

Distance of packing /seal Y 300 mm

Allowable deflection at packing 0.5 mm

Impeller Length, Power, Radius, Torque, Force, Moment, Moment, Moment,

HubNo

L(i) mmP(i) hp(MKS)

Rb(i) mmTm(i) kgf-mm

F(i) kgf M(i) kgf-mm M'(i) kgf-mmM''(i) kgf-

mm3

1 3150 20 265 143288.1 720.9 2270981.5 424140.7 146.8E09

2

3

4

5

P = 20Tm =

143288.1F = 720.9

M =

2270981.5

M' =

424140.7

M" =

146.8E09


35/40

= ( 32 x sf x Me x D1 ) / [ px ( D1 4 - ID 4) ] .......................... where, assumed D1 = 60.58 mm

= ( 32 x 2 x 230169.6 x 60.58 ) / [ px ( 60.58 4 - 0 4) ]

= 21.09 kgf/mm

Since induced stress (Fy)


36/40


1. DESIGN DATA :

2. SHAFT DATA :

3. BLADE DATA :

4. CALCULATION OF BLADE THICKNESS

Torsional moment on shaft [Tm]

= 736 x 60 x H.P. / ( 9.81 x 2 x px RPM ) kg-m

= 716440.6 x P / RPM kgf-mm

= 716440.6 x 20 / 100

= 143288.1 kgf-mm

Effective force on blade [Fm]= Tm / ( 0.75 x Rb )

= 143288.1 / ( 0.75 x 265 )

= 720.9 kgf

Minimum blade thickness required [tb]

= SQRT [ 6 x sf x Tm / ( Nb x d x Sa ) ]

= SQRT [ 6 x 2 x 143288.1 / ( 4 x 125 x 21.09 ) ]

= 12.77 mm

Since the calculated thickness 12.77 mm is less that provided thickness 14 mm of blade, blade thickness is adequate.


Pune, India




DESIGN OF IMPELLER BLADE WITH STIFFENER : Impeller (1)

Power P 20 hp (MKS)

Pumping capacity (RPM) RPM 100

Service (Duty) factor sf 2

Material of impeller SA-240 GR. 316 Plt. [UNS:S31600]

0.2% Proof stress Sy 21.09 kgf/mm

Youngs modulus Es 18786 kgf/mm

Weight density r 7999.5 kg/m

Allowance CA 0 mm

Shaft OD at Impeller OD 101 mm

Total length L 3150 mm

Type of impellerImpellar radius R 265 mm

Distance of impeller from bottom bearing c 3150 mm

No of blades Nb 4 mm

Width of blade w 125 mm

Blade thickness tb 14 mm

Blade angle a 0


37/40


1. LIFTING LUG DATA :

2. DESIGN LOADS :

3. CALCULATION OF REFERENCE DIMENSIONS :

4. DESIGN OF LUG PLATE :

5. CALCULATION OF STRESSES IN LUG PLATE WELDS :


Pune, India




DESIGN OF LIFTING LUG Lifting Lugs



Condition

Material IS-2062 GR. A Plt.

Length of lug LL 77 mm

Width of lug A 135 mm

Thickness of lug plate TL 28 mm

Straight length B1 10 mm

Radius at tip R3 40 mm

Pin Hole diameter D1 50 mm

Lug to vessel weld size W1 10.22 mm

Min yield stress Sy 24.61 kgf/mm

Allowable tensile stress ( 2 / 3 x Sy ) St 16.4 kgf/mm

Allowable bending stress ( 1.5 x St ) Sb 22.15 kgf/mm

Allowable shear stress (0.6 x St ) Ss 9.843 kgf/mm

Empty weight of equipment Wt 5065.2 kgf

Number of lifting lugs N 2

Jirk load factor j 1.5

Dimension [ L1 ]

= LL - B1 - R3

= 77 - 10 - 40

= 27 mm

Dimension [ L2 ]

= L1 / SIN ( q1 )

= 27 / SIN ( 0.381 )

= 72.7 mm

Dimension [ LT ]= LL - R3

= 77 - 40

= 37 mm

Angle [ q2 ]= ASIN ( R3 / L2 )

= ASIN ( 40 / 72.7 )

= 0.583 radians

Angle [q1 ]

= ATAN ( 2 x L1 / A )

= ATAN ( 2 x 27 / 135 )

= 0.381 radians

Angle [ q3 ]

= q1 + q2

= 0.381 + 0.583

= 0.963 radians

Dimension [ L3 ]

= R3 / SIN ( q3 )

= 40 / SIN ( 0.963 )

= 48.72 mm

Effective design load on each lug [ P ]

= j x Wt / N

= 1.5 x 5065.2 / 2

= 3798.9 kgf

Required min. thickness of lug plate for shear [ t2 ]

= P / [ ( R3 - 0.5 x D1) x ss ]

= 3798.9 / [ ( 40 - 0.5 x 50 ) x 9.843 ]

= 25.73 mm

Required min. thickness of lug plate for bending [ t1 ]

= 6 x P x LT / ( A 2x Sb )

= 6 x 3798.9 x 37 / ( 135 2x 22.15 )

= 2.089 mm

Required min. thickness of lug plate for shear [ t3 ]

= P / [ ( 2 x L3 - D1 ) x ss ]

= 3798.9 / [ ( 2 x 48.72 - 50 ) x 9.843 ]

= 4.881 mm

Bending stress in weld [ f1 ]

= 6 x P x LT / [ 2 x LL2

]= 6 x 3798.9 x 37 / ( 2 x 77 2)

= 71.12 kgf/mm

Max. shear stress in weld [ f2 ]

= P / [ 2 x A ]= 3798.9 / ( 2 x 135 )

= 14.07 kgf/mm

Min. Size of lug plate weld [ w1 ]

= MAX ( f1 , 2 x f2 ) / ( 0.707 x Ss )

= MAX ( 71.12 , 2 x 14.07 ) / ( 0.707 x 9.843 )


38/40

= 10.22 mm


39/40


FOUNDATION LOAD DATA


Pune, India




Sr.

No.

Mode Condition

Weight ( kgf ) Wind Seismic

Empty Filled

Shear ( kgf ) Moment ( kgf-m ) Shear Moment

Tran. Long. Tran. Long. ( kgf ) ( kgf-m )

1 Operating Uncorroded 5065.2 10988.8 1273.2 1273.2 2107.5 2107.5 1136.8 1534.9

2 Design1 Uncorroded 5065.2 11231.4 1273.2 1273.2 2107.5 2107.5 1161.9 1566.5

3 Hydro Uncorroded 4798.1 10964.4 1273.2 1273.2 2107.5 2107.5 1134.2 1529.2

4 Pneumatic Uncorroded 4798.1 4805.5 1273.2 1273.2 2107.5 2107.5 497.1 822.3


40/40


CENTER OF GRAVITY DATA


Pune, India




Sr.

No.Mode Condition

Empty Operating / Filled

Wt ( kgf ) C.G. ( mm ) Wt ( kgf ) C.G. ( mm )

1 Operating Uncorroded 5065.2 2111.4 10988.8 1806.42 Design1 Uncorroded 5065.2 2111.4 11231.4 1804.4

3 Hydro Uncorroded 4798.1 2111.4 10964.4 1804.4

4 Pneumatic Uncorroded 4798.1 2111.4 4805.5 2110.2

Design of Reactor With Agitator Shaft 1

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Transcript of Design of Reactor With Agitator Shaft 1