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TL to TL = he = 194 2427 he = 194

R = 1000

O/D = 1000

r = 100 1000 968

e = 16 1750 t = 16 Overall length,L = 2815 12 117.72 Operating Wt, W= Actual Volume, V= INPUT Capacity: Gas : Operating pressure: Design Pressure: Operating Temperature: Joint efficiency: Outside Diameter: Corrosion Allowance : 2 Nitrogen 16 20 50 85 1000 1.5 m . kg/cm2(g) kg/cm (g)
0 2 3

Ton 3 2.26 m . OUTPUT Shell thickness Dished end thickness Hydrostatic test pressure: Overall length Length of Dished end,he Length TL to TL : Actual Volume: Operating weight : Check for Dimensions: Plate thickness for dished end: Design for Shell thickness: Check for Combined Loading: Disgn Check of Shell thickness at Test Condition: Check for Principal Stress Inside Diameter of Vessel. I/D Empty weight of Vessel: Wheather 100% 0r 10% Radiography Required? 16 16 27.59 2815 194 2427.45 2.26 2 mm mm kg/cm2(g) mm mm mm m3. Ton

Vertical

% mm mm kg/m2

Wind Pressure: 194.2 Radiography of Butt Welds: 10 % Design Code : BS:5500 Pressure Range of Cyclic Variation: 10 No. of Cycles: 1,000,000 Cycles. Type of Vessel: Horizontal INPUT TO BE VARIED BASED ON OUTPUT CONDITION: Inside knuckle Radius, r 100 mm Inside Spherical Radius, R 1000 mm Material of Construction: SA 516 GR. 60 SA 516 GR. 70 SA 516 GR. 60

OK 16 mm OK TRUE OK OK 968 mm 1.51 Ton 100% RADIOGRAPHY REQD.

NOZZLE DETAILS: DESCRIPTION MARK MANHOLE N1

SIZE 500

MATL.STD ASTM A 106

THICKNESS(mm) 26.19

RESULT OK

t
PAD PLATE DETAILS for NOZZLE NECK N1: Thickness of shell, t = Thickness of Pad Plate, p = Width of Pad Plate , w = Value of H = Width of Pad Plate , w > H/2 Thickness of Pad Plate, p<40 mm Thickness of Pad plate, p t/4 Test result on thickness & width of Pad Plate 16 20 100 119.5397423 OK OK OK TRUE mm mm mm mm

p
w

NOZZLE MARKED AS N1

NOTE : IF TEST RESULT IS APPEARED AS "FALSE" , VARY THE THICKNESS OF PAD PALTE AND/OR WIDTH OF PAD PLATE.

NOZZLE DETAILS: DESCRIPTION MARK SIZE I/L,O/L & SPARE N2,N3,N4 100

MATL.STD ASTM A 106

THICKNESS(mm) 8.56

RESULT OK

PAD PLATE DETAILS for NOZZLE NECK N2,N3 & N4: Thickness of shell, t = Thickness of Pad Plate, p = Width of Pad Plate , w = Value of H = Width of Pad Plate , w > H/2 Thickness of Pad Plate, p<40 mm Thickness of Pad plate, p t/4 Test result on thickness & width of Pad Plate

16 12 150 41.44 OK OK OK TRUE

mm mm mm mm

Size thickness
t p

NOZZLE MARKED AS N2,N3 and N4

NOTE : IF TEST RESULT IS APPEARED AS "FALSE" , VARY THE THICKNESS OF PAD PALTE AND/OR WIDTH OF PAD PLATE.

NOZZLE DETAILS: DESCRIPTION MARK SIZE SAFETY RELIEF N5.1&5.2 50

MATL.STD ASTM A 106

THICKNESS(mm) 3.60

RESULT OK

PAD PLATE DETAILS for NOZZLE NECK N5.1 & N5.2: Thickness of shell, t = Thickness of Pad Plate, p = Width of Pad Plate , w = Value of H = Width of Pad Plate , w > H/2 Thickness of Pad Plate, p<40 mm Thickness of Pad plate, p t/4 Test result on thickness & width of Pad Plate

16 12 50 19.46 OK OK OK TRUE

mm mm mm mm

Size thickness
t p

NOZZLE MARKED AS N2,N3 and N4

NOTE : IF TEST RESULT IS APPEARED AS "FALSE" , VARY THE THICKNESS OF PAD PALTE AND/OR WIDTH OF PAD PLATE. NOZZLE DETAILS: DESCRIPTION MARK VENT, PG & TG N6

SIZE 25

MATL.STD ASTM A 106

THICKNESS(mm) 4.55

RESULT OK

PAD PLATE DETAILS for NOZZLE NECK N 6: Thickness of shell, t = Thickness of Pad Plate, p = Width of Pad Plate , w = Value of H = Width of Pad Plate , w > H/2 Thickness of Pad Plate, p<40 mm Thickness of Pad plate, p t/4 Test result on thickness & width of Pad Plate

16 12 20 7.95 OK OK OK TRUE

mm mm mm mm

Size thickness
t p

NOZZLE MARKED AS N2,N3 and N4

NOTE : IF TEST RESULT IS APPEARED AS "FALSE" , VARY THE THICKNESS OF PAD PALTE AND/OR WIDTH OF PAD PLATE.

1.00

TECHNICAL DATA & DESIGN PARAMETERS: 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 No. of Vessel required Fluid medium Water capacity of vessel Type of construction Operating pressure Design pressure Hydrulic test pressure Operating temperautre Design temperature Corrosion allowance Weld joint efficiency Radiography of butt welds Stress relieving Wind Pressure Seismic co-efficient Design code Relieving capacity of safety relief valve Size limitation (Diameter of vessel) Pressure range of cyclic variation No. of Cycles : 2 : N2 Nos.
3

INPUT INPUT INPUT INPUT 1.6 N/mm 2 2 N/mm


2

m . : 2 : Horizontal kg/cm2.g : 16 : 20 kg/cm2.g kg/cm2.g : 27.59 : Ambient 0 C. : 50 : : : : 1.5 0.85 100 Yes mm 85 % %

INPUT INPUT OUTPUT INPUT INPUT INPUT

kg/m2. : 194.2 : 0.0624 [As per IS : 1893] : BS:5500 Nm3/hr. : : 1000 mm


2 16 kg/cm .g

INPUT

: 10 to : 1000000 cycles SL.NO. 1.0

2.00

MATERIAL OF CONSTRUCTION AND ALLOWABLE STRESS VALUE: ALLOWABLE STRESS VALUE 0 AT 50 C(N/mm2) 105 105 105 120 105 -

Description Check for Dimensions:

Remarks OK

SL.NO. 1.0 2.0 3.0 4.0 5.0 6.0

COMPONEN MATERIAL T SPEC. Shell Dished ends Skirt Shell Skirt Base Nozzle pipe Nozzle Flange SA 516 GR. 60 SA 516 GR. 60 SA 516 GR. 60 IS: 2062 ASTM-A-106 Gr. B ANSI B 16.5, 600#

YIELD STRESS(N/mm2) 260 260 260

i) 0.002De0.12D ii)r0.062D iii)r2e iv)RD 2.0 3.0 4.0 Design of Shell Thickness i) e = Pdi/2f-P&ii)e =Pdo/2f+P Check for Shell Thickness under combined loading Check for Principal Stress:

TRUE TRUE TRUE TRUE OK TRUE OK

7.0

Reinforceme nt pad, lifting SA 516 Gr. lug 70 SA -193B7/SA -1942h SS 316 Spiral wound

5.0

Design Check of Shell thickness under test condition

OK

8.0 9.0

Fasteners Gasket SA 516 GR. 70

170 N/mm2.

SA 516 GR. 60 IS: 2002 GR.2

140 N/mm2. 130 N/mm2.

3.00

SIZE OF VESSEL AND CONSTRUCTION Knucle radius,r= Knucle radius,r= 14.285 % 100.0 INPUT 48 mm

Dished end Thickness,e

(mm) =

16 Inside spherical radius,R= 1000

1300 INPUT 1000 mm Inside Dia, Di =

Outside Dia, Do=

968

mm

16.00 h= 194 Total Length = TL to TL = 2331.45 2815 mm

mm h= 194

4.0

CALCULATION OF WATER VOLUME CAPACITY V = V1 +2V2 V1 = VOLUME OF CYLINDRICAL SHELL. V2 = VOLUME OF DISHED ENDS. V = p R2 H +2 (0.13D3) H = Length of shell = R = Shell radius = D = ID of dished ends = V=
3 2.26 m

2719 484 1000

mm = mm = mm =

2.719 mtr 0.484 mtr 1 mtr OUTPUT

5.0

STANDARD TEST PRESSURE: P = Design pressure = fa = Nominal design stress at amb. Temp = ft = Design stress at disgn temp = t= Nominal thickness under consideration c=Corrosion allowance= Pt = Hydraulic test pressure = Pt = Hydraulic test pressure =1.3 X P= 2 N/mm2
2 105 N/mm 2 N/mm 105

16.00 mm 1.5 mm 2 2.759 N/mm


2 27.59 kg/cm .g 2 kg/cm .g 26.00

OUTPUT

6.0

DESIGN OF DISHED END: D = Outside Dia = R = Inside spherical radius = r = Inside knucle radius = h1 = Inside head height = he/D = 0.20 & e/D = e= Corrected "e=" Adding corrosion allowance, e = P/t =

1000 1000 100 194

mm mm mm mm 0.01905

e= r= 100

16

mm

[h= R-{(R-D)*(R+D/2-2*r)}^0.5]

R= 1000 mm

0.013357903 13.35790299 mm

I/D = O/D =

968 mm 1000 mm

14.85790299 mm 16 mm

OUTPUT

7.0

CHECK FOR DIMENSIONS: I) 0.002D = 0.12D = e= 0.002De0.12D II) r 0.062 D III) r 2e IV) RD R= D= r= 2e = r= 0.06D =

2 mm 120 mm 13.35790299 mm TRUE 100 mm 60 mm TRUE 100 mm 26.71580597 mm TRUE 1000 mm 1000 mm TRUE

I,II,III & IV -TRUE 8.0 PIERCED END: Di =2R(for torrispherical heads) h/D = Do = D x factor(from table) Minimum thickness required = i) e = Pdi/4f-1.2P ii)e =Pdo/4f+0.8P

OK

OUTPUT

2000 mm 0.20 2250 mm 9.58 mm 10.67 mm 14.85790299 mm 16 mm 16 mm

Minimum thick.after corrosion allowance Adding thinning allowance = Plate thickness = 9.0 DESIGN OF SHELL THICKNESS: i) e = Pdi/2f-P ii)e =Pdo/2f+P Therefore, minimum thickness = Adding corrosion allowance = Thickness of shell taken = Remarks 10. WEIGHT OF THE VESSEL: Empty weight of vessel : Weight of Structures : Weight of valves &fittings : Total weight of errection : Weight of water : Test weight with full of water : Total weight considered for calculation : Operating weight with nitrogen : 11.0 CHECK FOR COMBINED LOADING: Q =( W/pDi ) (4Mw/pDi )
2

9.31 9.43 9.43 10.93 16.00 OK

mm mm mm mm mm OUTPUT

1513.30 30.27 15.13 1558.70 2260.00 3818.70 3818.70 1556.39

kg kg kg kg kg kg kg kg

= = = = = = = =

2 1 1 2 3 4 4 2

Ton Ton Ton Ton Ton Ton Ton Ton

Blank Dia =

2221 mm

Q=

-0.87 kg/mm -1.64 kg/mm

Q = Equivalent weight per unit length W = Weight of Vessel at test condition = M=Longitudinal bending moment due to wind load = 8.68 N/mm 16.45 N/mm

3818.70 kg. 285.7588 kg-m

12.0

CHECK FOR SHELL THICKNESS UNDER COMBINED LOADING: e1 = e2 = e >e1&e2 4.45 mm 4.56 mm TRUE

13.0

sq = pRi/e

CHECK FOR PRINCIPAL STRESS: 2 72.47 N/mm .

sz = pRi2/(2Ri+e)e+W/p((2Ri+e)e 4M/p((2Ri+e)2e 2 sz1 = 14.13 N/mm . sz1 = T=


2 14.08 N/mm . 0

f1=0.5(sq +sz+{(sq-sz)2+4T2}0.5)
2 72.47 N/mm . f2=0.5(sq +sz-{(sq-sz)2+4T2}0.5) 2 f2= 14.13 N/mm .

f1=

Membrane Stress Intencity: i) F1= f1-f2 ii)F2= f1+0.5p iii)F3= f2+0.5p 58.33 N/mm . 2 73.47 N/mm .
2 15.13 N/mm . 2

F= Maximum of F1, F2 & F3 F< Allowable Stress Value 14.0 OK

73.47 N/mm .

DESIGN CHECK FOR SHELL THICKNESS AT TEST CONDITIONS: Inside Dia , Di= 968 mm Outside Dia, Do = 1000 mm 2 Hydrotest pressure, Pt = 27.59 kg/cm .g Hydrostatic Head , Ph Total Pressure, P=Pt+Ph = f=PDi/2e+P/2 Yield Stress of Material = 90% of Yield Stress = f<90% OF Yield Stress Thickness of dished end is OK OK = = 2815 mm 2 0.28 kg/cm .g
2 27.87 kg/cm .g 2 2.79 N/mm . 2 102.37 N/mm . 2 260 N/mm . 2 234 N/mm .

120 110 100 90 80 75 63 56 50 45 40 36 32 30 28 25 22 20 18 16 12 10 8 6 5 h/D 0.18 0.192 0.208 0.227 0.25 0.278 0.313 0.357 0.417 0.5 D' -factor 2.52 2.36 2.17 1.98 1.8 1.63 1.46 1.3 1.14 1

Calculated thickness with corrosion allowance = 12.598779 mm Actual thickness 16 mm calculated Shell thickness without corrosion allowance 11.098779 mm Calculated thickness without corrosion allowance = 11.098779 mm 100% Radiography reqd or not 13.6 mm 100% RADIOGRAPHY REQD.

y = 0.5129x -0.9161 y= 2.25 h/D vs 'D'-factor


3

2.5 2
'D'-factor

1.5 1 y = 0.5129x-0.916 0.5 0

0.1

0.2

0.3
h/D

0.4

0.5

0.6

WIND PRESSURE LOADING CALCULATION SHEET: FOR VERTICAL VESSEL: 1

FOR HORIZONTAL VESSEL:

2.82

Projected area : Wind load = Moment , M =

2 2.8150026 m 546.67351 kg 584.77719 kg-m Type of Vessel : Actual Moment =

Horizontal 285.75879

Projected area : Wind load = Moment , M = Horizontal Vertical W/3.14*Di = 4M/3.14*Di2 = 1.25634931 0.38848945

he/D =

0.20 e/d x 10 3 =

P/t = 13.36

P/t = 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 he/D = 0.34 0.33 0.32 0.31 0.3 0.29 0.28 0.27 0.26 0.25 0.24 0.23 0.22 0.21 0.2 0.19 0.18 0.17 0.16 0.15 0.001 6.4 6.7 6.9 7.1 7.5 8.0 8.5 9.2 9.7 10.6 11.3 12.0 12.7 13.4 14.3 15.1 16.1 17.1 18.3 0.0015 0.0025 0.004 0.006 2.1 2.2 2.3 2.41 2.54 2.73 2.93 3.12 3.34 3.56 3.83 4.12 4.45 4.75 5 5.43 5.8 6.3 6.7 7.2

2.13

2.11 2.3 2.5 2.7

2.08 2.22 2.39 2.55 2.77 2.99 3.24 3.5 3.73

2.12 2.25 2.4 2.58 2.76 2.95 3.2 3.42 3.64 3.95 4.23 4.58 4.9 5.22

715

3000

0.24

0.24 10.612086

Calclation of Allowable Stress(Cluase no. K 3.2 of BS: 5500): Rm[UTS (Min)] Re(T)[Yield(Min)] Grade of Material : Unit SA 516 GR. 70 Psi 70000 38000 SA 516 GR. 60 Psi 60000 32000

Allowable Stress , fe =Re(T)/1.5 or Rm/2.35 for SA 516 Gr.70 Actual allowable Strees, fe =

25333.33

Psi or

25333.33 Psi
2 1781.11 Kg/cm . 2 17.81 Kg/mm 2 174.73 N/mm

Allowable Stress , fe =Re(T)/1.5 or Rm/2.35 for SA 516 Gr.60 Actual allowable Strees, fe =

21333.33

Psi or

21333.33 Psi
2 1499.88 Kg/cm . 2 15.00 Kg/mm 2 147.14 N/mm

ZONTAL VESSEL:

Blank Dia =

2221 mm

1.743485 338.58479 285.75879 285.75879 584.77719

m2 kg kg-m kg-m kg-m

0.019047619

/t = 0.01 3.5 3.65 3.8 3.95 4.2 4.5 4.8 5.15 5.5 5.9 6.3 6.84 7.3 7.7 8.3 8.8 9.6 10.2 10.9 0.015 0.025 0.05 y=325x+0.25 y=337.5x +0.275 y=347.5x+0.325 y=352.5x+0.425 y=367.5x+0.525 y=393.07+0.5606 y=41318x+0.6272 y=449.33x+0.6284 y=474.63x+0.707 y=515.74x+0.7291 y=551.36x+0.765 y=583.49x+0.8903 y=613.17x+1.0228 y=639.14x+1.1839 y=676.2x+1.3825 y=717.57x+1.4284 y=758.3x+1.6592 y=801.25x+1.8072 y=864.41x+1.8192

6.45 6.8 7.35 7.8 8.5 9.1 9.7 10.4 11 11.8 12.6 13.5 14.3 15.4

13.6 14.5 15.4 16.2 17.3 18.5 19.7 21 22.2 24

33 35 37 39.2 41.5 44.5

fe(N/mm2) 174.73 147.14

29787.23404 Psi

25531.91489 Psi

CALCULATION OF DENSITY OF A GAS Gas density = rg =Mw/V =(P*Mw)/(R*T) where, rg = Gas Density in kg/m3 Oxygen 32 0 16 50 323 0.083143

Type of Gas Mw = Mean Molecular weight V= Molar Volume P= Pressure in Bar Temperature of Gas in 0C T= R= Temperature of Gas in Kelvin Universal gas Constant =

OUTPUT RESULTS Gas Density = 3 rg 19.0652 kg/m

Gas Ammonia Argon Carbon dioxide Carbon monoxide Chlorine

Ethane Ethylene Fluorine Hydrogen Hydrochloric acid fume Hydrogen fluoride Hydrogen sulphide Methane Nitric oxide Nitrogen Nitrous oxide Oxygen Sulphur dioxide Sulphuric acid fume

OF DENSITY OF A GAS Gas Ammonia Argon Carbon dioxide Carbon monoxide INPUT Nil Nil Bar 0 C
0

INPUT INPUT

Chlorine Ethane Ethylene Fluorine Hydrogen Hydrochloric acid fume Hydrogen fluoride Hydrogen sulphide Methane Nitric oxide Nitrogen Nitrous oxide Oxygen Sulphur dioxide Sulphuric acid fume

bar m3/kmol K

Mol Wt.(Mw) 17.03 39.91 44 28 70.91 30.05 28.03 38 2.016 36.47 20.01 34.08 16.03 30.01 28.02 44.02 32 64.06 98