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OA No 7800078

Project: BIOCON

Vessel 3 KL MST
Tag No. MST-01

Document No :

7800078-DC-3KLMST-007-A

Design Code :

ASME Sec VIII Div-01 Edition 2010 Addenda 2011 (Appendix

Ref Drawing :

7800078-FPEM-3KL-07

Design Condition :

Flange is considered as Optional Flange & designed as an Integral Type

Flange Type Selected for Design :

Optional Type Flange (Fig. 2-4 (8))

2)

1) FLANGE : SA 240 Gr. 316L

Material :

2) BOLT : SA 193 Gr.B8 ( CLASS 1D)

Design Temperature :

150OC

FIG. 2-4(8) OPTION


FLANGE
GREEN COLOUR INDICATES INPUT VALUES

SR. NO

SYMBOL

VALUE

UNIT

REMARK

Outside Diameter of Flange

DESCRIPTION

1248

mm

As this is slotted hole flange the diameter to the bottom of the slots

Inside Diameter of Flange

1175

mm

Equals to I.D. of Vessel for Integral Type Flanges

Flange Thickness

72

mm

Flange thickness is measured at the bottom of O ring Groove

Hub Length

12.0000

mm

Thickness of Hub at back of Flange

g1

20

mm

Thickness of hub at Small End

g0

mm

Outside Diameter of 'O' Ring

GOD

1221

mm

Assuming that the Gasket sits against the Flange at its O.D.

Inside Diameter of 'O' Ring

GID

1205

mm

Gasket ID and OD mentioned are groove diameters for O Ring

Flange is considered as Optional type & designed as an Integral


Type. Gasket ID and OD mentioned are groove diameters for O Ring

Gasket Factor

Refer Table 2-5.1 ( Zero for Self-Energising Gaskets)

10

Gasket Seating Stress

N/mm2

Refer Table 2-5.1 ( Zero for Self-Energising Gaskets)

11

Bolt-Circle Diameter

1272

mm

12

Bolt Hole Diameter

dbh

24

mm

13

Nominal Bolt Diameter

22

mm

14

Number of Bolts

15

Internal Design Pressure

36

3.5

bar(g)

0.35

MPa (g)

1.035

bar(g)

0.1035

MPa (g)

Equals to O.D. of Flange plus Bolt Hole Diameter

16

External Design Pressure

Pe

17

Corrosion allowance

mm

Allowable bolt stress at Atmospheric


Temperature

Sa

130

N/mm2

Allowable bolt stress at Design


Temperature

Sb

103

N/mm2

Allowable Design Stress for material of


Flange at Design Temperature

Sf

87.4

N/mm2

Refer ASME Section II, Part D, 2011a,Table 1A,Pg. No. 66 , Line No.
36 & 'Notes to Table 1A',Pg. No. 146,Note G5

Allowable Flange Stress at Atmospheric


Temperature

Sfa

115

N/mm2

Refer ASME Section II, Part D, 2011a,Table 1A,Pg. No. 66 , Line No.
36

Youngs Modulus at Design Temperature of


Flange

Ef

186000

N/mm2

21

Youngs modulus at atmospheric


temperature of flange

Ea

195000

N/mm2

22

Small End Hub Thickness in Corroded


Condition

g0cor

mm

23

Largel End Hub Thickness in Corroded


Condition

g1cor

20

mm

24

Inside Diameter of flange in Corroded


Condition

Bcor

1175

mm

25

Radial distance from bolt circle to point of


intersection of hub and back of flange.

28.5

mm

26

width used to determine basic gasket


seating width

mm

Refer Table 2-5.2

27

Basic Gasket Seating Width

b0

mm

Refer Table 2-5.2

28

Conversion factor

Cb

2.5

29

Effective Gasket Width

mm

Refer Table 2-5.2

30

Diameter at location of Gasket Load


Reaction

1221

mm

Equals to Gasket O.D. (Acc. To PV Elite)

18

19

20

Refer ASME Section II, Part D, 2011a,Table 1A, Pg. No. 342,
Line No. 20

Refer ASME Section II, Part D,2011a,Table TM-1,Pg. 738, Material


Group G, Note 7

CALCULATIONS

Used to evaluate Effective Gasket Seating Width (b)

OA No 7800078
Project: BIOCON

Vessel 3 KL MST
Tag No. MST-01

LOADS
31

Total Hydrostatic End Force for Internal


Pressure

409869.4619

0.785G2P

32

Hydrostatic End Force on Area Inside of


Flange due to Internal Pressure

HD

379568.3281

0.785B2P

33

Difference between total hydrostatic end


force and the hydrostatic end force on area
inside of flange

HT

30301.1338

HT=H-HD

34

Total joint-contact surface compression


load

HP

2b*3.14GmP

35

Total hydrostatic end force

He

121127.1041

0.785G2Pe

36

Hydrostatic end force on area inside of


flange

HDe

112172.3297

0.785B2Pe

37

Difference between total hydrostatic end


force and the hydrostatic end force on area
inside of flange

HTe=He-HDe

8954.77446

38

Minimum required bolt load for the


operating conditions

Wm1

409869.4619

39

Minimum required bolt load for gasket


seating

Wm2

40

Gasket load (difference between flange


design bolt load and total hydrostatic end
force)

HG= Wm1-H

41

Total required cross-sectional area of bolts

Am

3979.315

mm2

42

Bolt root area

Aroot

272.419

mm2

43

Cross-sectional area of the bolts using the


root diameter of the thread

Ab

9807.084

mm2

44

Flange design bolt load, for the operating


conditions or gasket seating

896115.95

45

Radial distance from the Bolt Circle, to the


Circle on which HD acts

hD

38.5

mm

46

Radial distance from Gasket Load Reaction


to the Bolt Circle

hG

25.5

mm

47

Radial distance from the bolt circle to the


circle on which HT acts

hT

37

mm

48

Component of moment due to HD

MD

14613380.63

N-mm

49

Component of moment due to HT

MT

1121141.951

N-mm

50

Component of moment due to HG

MG

N-mm

51

Bolt Spacing

Bs

111.0029404

mm

52

Bolt Spacing correction factor

Bsc

0.97822385

Not Applicable as Vessel not in lethal service (Ref 2-6)

53

Maximum bolt spacing

Bsmax

908

mm

Maximum Bolt Spacing permitted

54

Total moment acting upon the flange

M0

15734522.58

N-mm

For the operating conditions

55

Total moment acting upon the flange

Matm

22850956.61

N-mm

For the seating conditions

56

Factor

h0

96.95359715

mm

57

h/h0

0.12377055

mm

58

g1/g0

2.5

59

1.5

60

Ratio of outside diameter of flange to


inside diameter of flange

1.06212766

61

Hub stress correction factor for integral


flanges

4.884223655

62

Flange Factor

0.010250662

63

Flange Factor

E6

-340.374663

64

factor for integral type flanges

0.90207322

65

Flange Factor

0.009304175

factor

Term 1

0.380672331

k2*(1+8.55246logk)-1

Flange Factor

Term 2

0.201365584

(1.04720+(1.9448*k*k))*(k-1)

1.890453789

69

Flange Factor

E4

25.28839088

70

Flange Factor

0.400634629

Term 3

0.010835739

35.13118438

For M22 bolt (TEMA Table D-5M)

FLANGE MOMENT ARMS

66
67
68

71
72

Flange Factor

73

Flange Factor

544111.8792

74

Flange Factor

1.569309766

75
76

Flange Factor

Term 4

0.2304985

31.96944625

Table 2-7.1

Please refer Sheet "Table2-7.1"

1.36136(k2-1)(k-1)

K2*(logk)/(K2-1)

OA No 7800078
Project: BIOCON
77

Flange Factor

Vessel 3 KL MST
Tag No. MST-01
Z

16.61095438

OA No 7800078
Project: BIOCON

Vessel 3 KL MST
Tag No. MST-01

STRESS SUMMARY
Sr. No.

ACTUAL

Longitudinal Hub Stress(Operating)'SHO'

Radial Flange Stress(Operating)'SRO'

ALLOWABLE
104.19

1.5*Allowable Flange Stress at Design Temp.'Sf'

UNIT

RESULT

131.1

N/mm2

PASS

3.11

Allowable Flange Stress at Design Temp.'Sf'

87.4

N/mm2

PASS

Tangential Flange Stress(Operating)'STO'

30.88

Allowable Flange Stress at Design Temp.'Sf'

87.4

N/mm2

PASS

(SHO + SRO)*0.5

53.65

Allowable Flange Stress at Design Temp.'Sf'

87.4

N/mm2

PASS

(SHO + STO)*0.5

67.54

Allowable Flange Stress at Design Temp.'Sf'

Longitudinal Hub Stress(Seating)'SHS'

Radial Flange Stress(Seating)'SRS'

151.32

1.5*Allowable Flange Stress at Design Temp.'Sf'

87.4

N/mm2

PASS

172.5

N/mm2

PASS

4.52

Allowable Flange Stress at Design Temp.'Sf'

115

N/mm2

PASS

Tangential Flange Stress(Seating)'STS'

44.84

Allowable Flange Stress at Design Temp.'Sf'

115

N/mm2

PASS

(SHS + SRS)*0.5

77.92

Allowable Flange Stress at Design Temp.'Sf'

115

N/mm2

PASS

10

(SHS + STS)*0.5

98.08

Allowable Flange Stress at Design Temp.'Sf'

115

N/mm2

PASS

FLANGE RIGIDITY FACTORS


1

K1

0.3

Factor
Rigidity factor for operating condition

0.60490379

< 1 Hence SAFE

RESULT

Rigidity factor for seating condition

0.83794488

< 1 Hence SAFE

OA No 7800078
Project: BIOCON

Vessel 3 KL MST
Tag No. MST-01

OPTIONAL TYPE
ANGE

OA No 7800078
Project: BIOCON

Vessel 3 KL MST
Tag No. MST-01

OA No 7800078
Project: BIOCON

Vessel 3 KL MST
Tag No. MST-01

OA No 7800078
Project: BIOCON

Vessel 3 KL MST
Tag No. MST-01

OA No 7800078
Project Biocon

Vessel 5000 L FermentorDoc No: 7800078-5KL-FERM-FLG


Tag No FER-04 FER-05
Rev.00

Reference
1) ASME Sec VIII Div:01 Appendix 02
2) AS 1210 (Australian Standard for Pressure vessels)
3) Ref Drawing : 7800078-BODYFLG-01
nomenclature
value
unit
A
357 mm
B
290 mm
t
30 mm
(This flange thickness is measured at the bottom
h
7 mm
g1
12 mm
g0
5 mm

Remark
flange OD (Ref Fig:01)
flange ID
flange thk
of O ring Groove)
hub length
large end hub thk
small end hub thk

Gasket ID and OD mentioned are groove diameters for O Ring


GOD

321 mm

gasket od

GID
m
y

304 mm
00 N/mm2

gasket id
gasket factor
gasket seating stress

PCD
a
n

369 mm
12 mm
8-

bolt circle diameter


nominal bolt diameter
number of bolts

P
Pe
T
c
bolt material
Flange Material
Shell Material

3.5
0.35
1.035
0.1035
150

bar(g)
N/mm2 (g)
bar(g)
N/mm2 (g)
deg cen

0 mm

internal design pressure


External design pressure
Design Temperature (Int/Ext)
corrosion allowance

SA 193 Gr.B8
SA 240 Gr. 316L SA 240 Gr. 316L -

Sa
Sb

130 N/mm2
103.4 N/mm2

Sf

87.4 N/mm2

allowable flange stress at design temp

115 N/mm2

allowable flange stress at atmospheric


temp

Sfa
Ef

186072.445 N/mm2

Ea

195124 N/mm2

allowable bolt stress at atmospheric temp


allowable bolt stress at design temp

Youngs modulus at design temperature of


flange
Youngs modulus at atmospheric
temperature of flange

12 mm

Nominal Bolt Diameter

OA No 7800078
Project Biocon

Vessel 5000 L FermentorDoc No: 7800078-5KL-FERM-FLG


Tag No FER-04 FER-05
Rev.00

Calculations
g0cor
g1cor
Bcor

5 mm
12 mm
290 mm

corroded small end hub thk


corroded large end hub thk
corroded flange ID
radial distance from bolt circle to point of
intersection of hub and back of flange.

27.36 mm

N
b0
Cb
b
G

1.0625
0.53125
2.5
0.53125
312.5

width used to determine basic gasket


seating width TABLE 2-5.2
factor

mm
mm
mm
mm

Loads
H

total hydrostatic end force internal


pressure

26831.0546875 N

HD
HT=H-HD

hydrostatic end force on area inside of


flange ude to internal pressure

23106.475 N
3724.5796875 N

total joint-contact surface compression


load

HP

0N

He

7934.32617188 N

HDe
HTe=He-Hde
Wm1
Wm2
HG= Wm1-H

6832.91475
1101.41142188
26831.0546875
0
0

Am
Aroot
Ab

259.487956359 mm2
72.398 mm2
579.184 mm2

for M12 bolt (TEMA Table D-5M)

43359.3401438 N

seating bolt laod

total hydrostatic end force externap


pressure
hydrostatic end force on area inside of
flange ude to external pressure

N
N
N
N
N

Flange moment arms


hD
hG
hT

33.4285714286 mm
28.25 mm
33.875 mm

MD
MT
MG

772416.45 N-mm
126170.136914 N-mm
0 N-mm

component of moment due to HD,


component of moment due to HT
component of moment due to HG

Bs

144.905961147 mm

Bolt Spacing

10

OA No 7800078
Project Biocon
Bsc

Vessel 5000 L FermentorDoc No: 7800078-5KL-FERM-FLG


Tag No FER-04 FER-05
Rev.00
1.6381220116 -

Bolt Spacing correction factor


Not Applied Since Vessel not in
lethal service (2-6)

Bsmax

384 mm

Maximum Bolt Spacing permitted

M0

898586.586914 N-mm

total moment acting upon the flange, for


the operating conditions

Matm

1224901.35906 N-mm

total moment acting upon the flange, for


the seating conditions

h0
h/h0
g1/g0
A
K

38.0788655293
0.1875806184
2.4285714286
1.4285714286
1.2310344828

mm
mm
-

5.0278772919 -

0.0102506618 -

E6

-340.37466278 -

0.9840318871 -

0.0258419434 -

Table 2-7.1
Please refer Sheet "Table2-7.1"

factor

30 mm

Flange thickness (same as above)

Term 1

1.6854192774 -

k2*(1+8.55246logk)-1

Term 2

0.9228531903 -

(1.04720+(1.9448*k*k))*(k-1)

1.8263135406 -

E4

25.2883908771 -

0.4370346454 -

Term 3

0.1621186125 -

10.3962108431 -

22645.5681997 -

2.1643309155

Term 4

0.2654005638 -

9.4605725397 -

4.8801356433 -

1.36136(k2-1)(k-1)

K2*(logk)/(K2-1)

11

OA No 7800078
Project Biocon

Vessel 5000 L FermentorDoc No: 7800078-5KL-FERM-FLG


Tag No FER-04 FER-05
Rev.00

Stress Summary
Stress
SH operating

Actual
48.8181333429

Allowable
131.1

SR operating

3.2309161441

87.4

ST operating

16.8041223393

87.4

(SH operating + SR
operating)*0.5

26.0245247435

87.4

(SH operating +
ST operating)*0.5

32.8111278411

87.4

SH seating

66.5460610578

172.5

SR seating

4.4041983639

115

ST seating

22.9064094556

115

(SH seating +
SR seating)*0.5

35.4751297108

115

(SH seating + ST
seating)*0.5

44.7262352567

115

Flange rigidity
factors
Ki

0.3

0.1780310828 -

0.231423998 -

Rigidity factor for operating condition


Rigidity factor for seating condition

Ref Fig.2-4 (8)


Optional Flange

Ref Fig.3.21.6.2 Flange Notation


(AS-1210)

(ASME Sec.VIII
Div:01-Appendix2)

(Australian Standard for Pressure


Vessels)

12

OA No 7800078
Project Biocon

Vessel 5000 L FermentorDoc No: 7800078-5KL-FERM-FLG


Tag No FER-04 FER-05
Rev.00

13

OA No 7800078
Project Biocon

Vessel 5000 L FermentorDoc No: 7800078-5KL-FERM-FLG


Tag No FER-04 FER-05
Rev.00

14

OA No 7800078
Project Biocon

Vessel 5000 L FermentorDoc No: 7800078-5KL-FERM-FLG


Tag No FER-04 FER-05
Rev.00

15

OA No 7800078
Project Biocon

Unit
N/mm2

Result
PASS

N/mm2

PASS

N/mm2

PASS

N/mm2

PASS

N/mm2

PASS

N/mm2

PASS

N/mm2

PASS

N/mm2

PASS

N/mm2

PASS

N/mm2

PASS

Vessel 5000 L FermentorDoc No: 7800078-5KL-FERM-FLG


Tag No FER-04 FER-05
Rev.00

16

OA No 7800078
Project: BIOCON

Vessel 3 KL MST
Tag No. MST-01

Reference
1) ASME Sec VIII Div:01 Appendix 02
Table 2-7.1
A
C1
C
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
C13
C14
C15
C16
C17
C18
C19
C20
C21
C22
C23
C24
C25

1.5
0.4583333
0.0102507
0.1949405
0.0089286
536.59884
-1524.2733
97.568069
6362.9692
923.1357
797.45325
-1385.3494
330.99818
222.41269
76.477658
-114.10319
37.280365
258047.65
1170.7151
-3325.6271
212.85328
0.1166108
-0.1527592
0.0563545
-0.1871419
0.254515
-0.0748292

17

C26
C27
C28
C29
C30
C31
C32
C33
C34
C35
C36
C37
E1
E2
E3
E4
E5
E6

OA No 7800078
Project: BIOCON

Vessel 3 KL MST
Tag No. MST-01

-0.224995
-1434.42
-260.7712
-0.050623
-0.01139
15.584299
2.9243721
-8.43768
-4073.641
37.878475
12.210559
-51.64899
-24.19739
-1.639529
1.83426
25.288391
-18.82757
-340.3747

18