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COVER SHEET

INSPECTION HATCH FOR

ABSORBER SHELL: S-2304

Client : ALSTOM Power, Norway.

User : ORPIC, Sohar, Oman

Equipment Name : ABSORBER

Equipment Tag No. : S-2304

Drawing No : EE3-000786 9.9M - 0087, Rev.A

Designed By Checked By Approved By

Name Raghavendra T.P Venkatesh C V Venkatesh C V
Signature
Date 23/3/2013
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NOZZLE THICKNESS CALCULATION ( UG -45) :- Value Unit

Nozzle Size & Sch 1100 ID / 12 THK.

Nozzle Material S 275 JR
Nozzle Location ABSORBER
Nozzle Mark INSPECTION HATCH

Internal Design Pressure Pi 0.1013 Mpa

External Design Pressure Pe NA Mpa
Allowable Stress at Design Temp.(316C)-Nozzle Sn 183 Mpa
Allowable Stress at Design Temp.(316C)- Shell Sv 156 Mpa
Allowable Stress at Ambient Temp-Shell (S 235 JR) Sav 156 Mpa
Outside Diameter of Nozzle Dn 1124 mm
Outside Diameter of Vessel Dv 11020 mm
Joint Efficiency of Shell seam at Nozzle Ev 0.85
Joint Efficiency of Nozzle En 0.85
Corrosion Allowance C.A 1.5 mm
Selected wall Thickness of Pipe tn 12.00 mm
(ASME B36.10)
Standard wall Thickness of Pipe tstd 9.525 mm

(A) Minimum Thickness UG-45(a) :-

trn = (Pi*Dn/2)/(Sn*En+0.4*Pi) per Appendix 1-1 (a)(1)
= [(0.1013*(1124/2))/(183*0.85+(0.4*0.1013))] = 0.37 mm
t = Required Thickness = (trn + C.A) =0.37+1.5 = 1.87 mm

Thickness determined in step A = 1.87 mm

(B) Minimum Thickness UG-45(b) :-

(i) UG-45 (b)(1) : For Internal Pressure Only
1) Calculation of Thickness for Vessels with efficiency as
1 (Full radiography-all butt weld) + C.A
trv = [ (Pi * Dv/2) / {(Sv * Ev) + (0.4 * Pi)} ] + C.A
= [(0.1013*(11020/2))/(156*0.85+(0.4*0.1013))]+1.5 = 5.71 mm
2) Minimum thickness as per UG-16 (b) (4)
= 2.5 + C.A = 2.5 + 1.5 = 4.00 mm
3) t = Maximum of 1 & 2 Above = Max (5.71 , 4.00) = 5.71 mm

(ii) UG-45 (b)(2) :- For External Pressure Only

by using (External Design pressure =Internal Design pressure)
1) Calculation of Thickness for Vessels with
Efficiency as 1.0 + C.A trv NA mm
2) Minimum thickness as per UG-16 (b) (4)
2.5 + C.A NA mm
3) Maximum of 1 & 2 Above t NA mm
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NOZZLE THICKNESS CALCULATION ( UG -45) :- CONTD/- Value Unit

(iii) UG-45 (b)(3) :- Internal & External Pressure

The Greater of the thicknesses determined by
(b)(1) or (b)(2) = Max (5.71 , NA) = 5.71 mm

UG-45 (b)(4) :-
(iv) tmin = STD. WALL THK. - 12.5% of WALL THK + C.A
= [9.525 - {(12.5/100)*9.525} +1.5 ] = 9.83 mm

(v) Minimum Required Thickness is MIN. of (iii) & (iv)

= Min. (5.71 , 9.83) = 5.71 mm

Thickness determined in step B = 5.71 mm

(C) Minimum required Thickness is Larger of (A) & (B)

= Max. (1.87 , 5.71) = 5.71 mm

(D) Nominal Nozzle Thickness, PROVIDED = 12.00 mm

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REINFORCEMENT CALCULATIONS AS PER UG-39 & UG-37

Value Unit

Nozzle Size & Sch 1100 ID / 12 THK.

Nozzle Material S 275 JR
Nozzle Location ABSORBER
Nozzle Mark INSPECTION HATCH

Nominal thickness of the Shell Section in Corroded

Condition (t) = Nominal thickness - C.A = 10 - 1.5 = 8.50 mm
Required Thk. (tr) of Seamless Shell / Head based on
Circumferential Stress (Using E = 1.0) = 3.58 mm
Correction Factor (F) = 1.0 mm
Excess Thk in Shell or Head = (E1*t) - (F*tr)
= (1.0*8.5)-(1.0*3.58) = 3.65 mm
Internal Design Pressure (P) = 0.1013 Mpa
Allowable Stress at Design Temp., - NOZZLE (Sn) = 183 Mpa
Allowable Stress at Design Temp., - SHELL(Sv) = 156 Mpa
Outside Diameter of Nozzle Connection (Dn) = 1124 mm
Outside Radius of Nozzle Connection (Rn) = 562 mm
Longitudinal Joint Efficiency (E1) = 0.85
Corrosion Allowance (C.A.) = 1.50 mm
Nozzle Thickness in Corroded Condition (tn)
= (Thickness with mill tolerance - C.A.) = (12 - 1.5) = 10.50 mm
Minium thickness reqd. for nozzle under internal pressure
without C.A. (trn) = 0.37 mm
Excess Thickness in Nozzle = (tn - trn) = (10.5 - 0.37) = 10.13 mm
fr1 = Sn/Sv, fr1 = 1 for Fig. UG-40 Sketch (n) = 1.00
fr2 = Sn/Sv = 1.17
I.D of Finished Opening (Corroded) (d) = 1126 mm
Distance Nozzle Projects beyond Inner surface
of Vessel Wall (h) = 0.0 mm
Weld Fillet Size for Outward Nozzle (leg1) = 7.0 mm
Weld Fillet Size for Inward Nozzle (leg2) = 0.0 mm

REINFORCEMENT CALCULATION :
(a) A1 = Area available in Shell or Head
(i) = (E1*t-F*tr)*d - 2*tn*(E1*t-F*tr)*(1-fr1)
= [{(0.85*8.50)-(1.0*3.58)}*1126] -
[2*10.50*{(0.85*8.50)-1.0*3.58)}*(1-1.0)] 4090.54 mm
(ii) = 2(E1*t-F*tr)*(t+tn) - 2*tn*(E1*t-F*tr)*(1-fr1)
= [2*{(0.85*8.50)-(1.0*3.58)}*(8.50+10.50] - 124.08 mm
[2*10.50*{(0.85*8.50)-(1.0*3.58)}*(1-1.0)]
(iii) A1 = Greater Value of (i) OR (ii) above 4090.54 mm
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REINFORCEMENT CALCULATIONS AS PER UG-39 & UG-37

Value Unit

Nozzle Size & Sch 1100 ID / 12 THK.

Nozzle Material S 275 JR
Nozzle Location ABSORBER
Nozzle Mark INSPECTION HATCH

(b) A2 = Area available in Nozzle Projecting Outward

(i) =[ 5 * t * ( tn - trn ) * fr2] = [5 * 8.50 * (10.50-0.37) * 1.17] 505.24 mm
(ii) =[5 * tn * ( tn - trn ) * fr2] = [5 * 10.50 * (10.50-0.37) * 1.17] 624.12 mm
(iii) A2 = Smaller Value of (i) OR (ii) above 505.24 mm

(c) A3 = Area available in Inward Nozzle

(i) = 5 * t * ti * fr2 = 0.00 mm
(ii) = 5 * ti * ti * fr2 = 0.00 mm
(iii) = 2 * h * ti * fr2 = 0.00 mm
(iv) A3 = Smaller value of (i) OR (ii) OR (iii) above = 0.00 mm

(d) A41 = Area available in Outward Nozzle Weld

(i) = (leg1) * fr2 = (7 * 1.17) = 57.48 mm

(e) A43 = Area available in Inward Nozzle Weld

(i) = (leg2) * fr2 = (0 * 1.17) = 0.00 mm

(f) A' = Reinforcement available without Pad

(i) = [A1 + A2 + A3 + A41 + A43]
=[4090.54 + 505.24 + 0.00 + 57.48 + 0.00] 4653.26 mm

(g) A = Reinforcement area required

(i) = d * tr *F + 2 * tn * tr * F*( 1 - fr1 )
= [( 1126.00 * 3.58 * 1.00 )+(2 * 10.503.58 * 1.0 * (1 - 1.00))] 4030.36 mm
CHECK WHETHER A' > A YES
CHECK WHETHER AREA AVAILABLE WITHOUT PAD IS
SUFFICIENT OR INSUFFICIENT SUFFICIENT
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BODY FLANGE CALCULATION (Appendix - 2) Value Unit

Description of Flange Geometry (Type) = LOOSE SLIP ON

Design Pressure P = 0.1013 Mpa
Design Temperature T = 316 C
Internal Corrosion Allowance Ci = 1.5 mm
External Corrosion Allowance Ce = 0 mm

Flange Inside Diameter B = 1126 mm

Flange Outside Diameter A = 1236 mm
Flange Thickness t = 16 mm

Flange Material = S 275 JR

Flange Allowable Stress At Temperature Sfo = 183 Mpa
Flange Allowable Stress At Ambient Sfa = 183 Mpa

Bolt Material Grade 8.8

Bolt Allowable Stress At Temperature Sb = 200 Mpa
Bolt Allowable Stress At Ambient Sa = 200 Mpa

Diameter of Bolt Circle C = 1155 mm

Nominal Bolt Diameter Db = 12 mm

Flange Face Outside Diameter Fod = 1156 mm

Flange Face Inside Diameter Fid = 1136 mm

Gasket Outside Diameter Go = 1156 mm

Gasket Inside Diameter Gi = 1136 mm
Gasket Factor (From table 2.5.1, Page 355) m = 1.4
Gasket Design Seating Stress
(From table 2.5.1, Page 355) y = 11.00 Mpa
Gasket Thickness tg = 3 mm

Length of Partition Gasket Lpart = 0 mm

Width of Partition Gasket tpart = 0 mm
Partition Gasket Factor mpart = 0
Partition Gasket Design Seating Stress ypart = 0.00 Mpa

ASME Code, Section VIII, Division 1, 2007-Table 2-5.2 ( EFFECTIVE GASKET WIDTH )

Gasket Contact Width,

N = (Go - Gi) / 2
= (1156 - 1136) / 2 = 10 mm

Basic Gasket Width,

bo = N / 2 =10.0 / 2 = 5 mm
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BODY FLANGE CALCULATION (Appendix-2):- Contd/- Value Unit

Effective Gasket Width,

b = bo
= 5 mm

Gasket Reaction Diameter,

G = Go - 2 * b
= 1156 - 2 * 5 = 1146 mm

Gasket Contact Width, tpart = 0.00 mm

Basic Gasket Width,
bopart = tpart / 2
= 0/2 = 0.00 mm

Effective Gasket Width,

bpart = bopart = 0.00 mm

Basic Flange and Bolt Loads:

Hydrostatic End Load due to Pressure,
H = 0.785 * G * P
= 0.785 * (1146.00) * 0.1013 = 104435.54 N

Contact Load on Gasket Surfaces,

Hp = 2 * b * 3.14 * G * m * P + 2 * lp * bPart * mPart * P
= 2 * 5.0 * 3.14 * 1146 * 1.4 * 0.1013 + 2 * 0
* 0.0 * 0.0 * 0.1013 = 5103.31 N

Hydrostatic End Load at Flange ID,

Hd = 0.785 * B * P
= 0.785 * (1126) * 0.1013 = 100822.133 N

Pressure Force on Flange Face,

Ht = H - Hd
= 104435.545 - 100822.133 = 3613.41 N

Operating Bolt Load,

Wm1 = H + Hp
= 104435.545 + 5103.308 = 109538.85 N

Gasket Seating Bolt Load,

Wm2 = 3.14 * b * G * y + ypart * bpart * Lpart
= 3.14 * 5.0 * 1146.0 *11 + 0 * 0.0 * 0.0
= 197914.20 N
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BODY FLANGE CALCULATION (Appendix-2):- Contd/- Value Unit

Required Bolt Area,

Am = MAX ( Wm1/Sb, Wm2/Sa)
MAX (109538.9/200 , 197914.2/200.0) = 989.57 mm

Using M-12 Bolts of root diameter, = 12 mm

From TEMA, Pg. No.189. Root Area = 72.398 mm

No. of studs required = Am / Root Area

= 989.57 / 72.398 = 13.67 No's

Provided No. of Studs = 16 No's

Actual Bolt Area,

Ab = Provided No. of Studs * Root Area
= 16 * 72.398 = 1158.37 mm

Min. Gasket Contact Width (Brownell Young),

Nmin = Ab * Sa/( y * 3.14 * (Go + Gi) )
= (1158.37*200.0) / (11*3.14* (1156+1136))
= 2.93 mm

Flange Design Bolt Load, Gasket Seating,

W = Sa * ( Am + Ab ) / 2
= 200 * ( 989.57 + 1158.37) / 2 = 214793.8 N

= Sa * Ab ( Additional Safety )
= 200 * 1158.37 = 231673.60 N

Gasket Seating Force,

= Wm1 - H
= (109538.85 - 104435.54) = 5103.31 N

Moment Arm Calculations :-

Distance to Gasket Load Reaction,

hg = (C - G) / 2
= ( 1155 - 1146 )/2 = 4.5 mm

Distance to Face Pressure Reaction,

ht = (hd + hg) / 2
= ( 15 - 5 )/2 = 9.50 mm

Gasket load,
Hg = W-H
= (231673.60 - 104435.54) = 127238.06
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BODY FLANGE CALCULATION (Appendix-2):- Contd/- Value Unit

Moment Arm Calculations :-

Distance to End Pressure Reaction,

hd = ( C - B )/ 2
= ( 1155 - 1126 )/2 = 14.50 mm

Summary of Moments for Internal Pressure :-

Loading Force Distance Bolt Moment
End Pressure, Md = Hd * hd 100822.13 14.50 1461920.94 N-mm
Face Pressure, Mt = Ht * ht 3613.41 9.50 34327.41 N-mm
Gasket Load, Mg = Hg * hg 127238.06 4.5 572571.25 N-mm
Gasket Seating, Mamb = W * hg 231673.60 4.5 1042531.20 N-mm

Total Moment for Operation

Mop = (Md + Mt + Mg)
= (1461920.94 + 34327.41 + 572571.25) = 2068819.60 N-mm

Total Moment for Gasket seating, Matm = 1042531.20 N-mm

Factors from Figure 2-7.1

K=A/B 1236 / 1126 1.10

Y= 1/K-1 [ 0.66845 + 5.1769 K log10 K / K -1]

= 1/1.10-1 [0.66845+ 5.7169*((1.10) *log10 (1.10)/
(1.10)-1)] = 20.32

Minimum Required Flange Thickness

top = SQRT(( Y * Mop )/( STop * B ))

= SQRT((20.32*2068819.60)/(183*1126) = 14.28 mm

tamb = SQRT(( Y * Mamb )/( STamb * B ))

= SQRT((20.32*1042531.20)/(183*1126) = 10.14 mm

Hence, Required Thickness is

= MAX (top, tamb)
= MAX ( 14.28 ,10.14) = 14.28 mm

Tangential Flange Stress, Operating

STop = ( Y * Mop )/( t * B )
= (20.32*2068819.60)/(14.28*1126) = 183.08 Mpa
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BODY FLANGE CALCULATION (Appendix-2):- Contd/- Value Unit

Tangential Flange Stress, Seating

ST amb = ( Y * Matm )/( t * B )
= (20.32*1042531.20)/(14.28*1126) = 92.26 Mpa

Bolt Stress, Operating

= Wm1 / Ab
= 109538.85 / 1158.37 = 94.56 Mpa

Bolt Stress, Seating

= Wm2 / Ab
= 197914.20 / 1158.37 = 170.86 Mpa

Stress Computation Results : Operating Gasket Seating

Actual Allowed Actual Allowed
Tangential Flange, Mpa 183.08 183 92.26 183
Bolting, Mpa 94.56 200 170.86 200

Hence, Provided Flange Thickness

t = MAX (top, tamb) + CA

= 14.28 + 1.5 = 16 mm

LEGEND :
CA = Corrosion Allowance.
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BODY FLANGE CALCULATION (Appendix - 2) Value Unit

Description of Flange Geometry (Type) = BLIND

Design Pressure P = 0.1013 Mpa
Design Temperature T = 316 C
Internal Corrosion Allowance Ci = 1.5 mm
External Corrosion Allowance Ce = 0 mm

Flange Inside Diameter B = 1126 mm

Flange Outside Diameter A = 1236 mm
Flange Thickness t = 17 mm

Flange Material = S 275 JR

Flange Allowable Stress At Temperature Sfo = 183 Mpa
Flange Allowable Stress At Ambient Sfa = 183 Mpa

Bolt Material Grade 8.8

Bolt Allowable Stress At Temperature Sb = 200 Mpa
Bolt Allowable Stress At Ambient Sa = 200 Mpa

Diameter of Bolt Circle C = 1160 mm

Nominal Bolt Diameter Db = 12 mm

Flange Face Outside Diameter Fod = 1156 mm

Flange Face Inside Diameter Fid = 1136 mm

Gasket Outside Diameter Go = 1156 mm

Gasket Inside Diameter Gi = 1136 mm
Gasket Factor (From table 2.5.1, Page 355) m = 1.4
Gasket Design Seating Stress
(From table 2.5.1, Page 355) y = 11.00 Mpa
Gasket Thickness tg = 3 mm

Length of Partition Gasket Lpart = 0 mm

Width of Partition Gasket tpart = 0 mm
Partition Gasket Factor mpart = 0
Partition Gasket Design Seating Stress ypart = 0.00 Mpa

ASME Code, Section VIII, Division 1, 2007-Table 2-5.2 ( EFFECTIVE GASKET WIDTH )

Gasket Contact Width,

N = (Go - Gi) / 2
= (1156 - 1136) / 2 = 10 mm

Basic Gasket Width,

bo = N / 2 =10.0 / 2 = 5 mm
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BODY FLANGE CALCULATION (Appendix-2):- Contd/- Value Unit

Effective Gasket Width,

b = bo
= 5 mm

Gasket Reaction Diameter,

G = Go - 2 * b
= 1156 - 2 * 5 = 1146 mm

Gasket Contact Width, tpart = 0.00 mm

Basic Gasket Width,
bopart = tpart / 2
= 0/2 = 0.00 mm

Effective Gasket Width,

bpart = bopart = 0.00 mm

Basic Flange and Bolt Loads:

Hydrostatic End Load due to Pressure,
H = 0.785 * G * P
= 0.785 * (1146.00) * 0.1013 = 104435.54 N

Contact Load on Gasket Surfaces,

Hp = 2 * b * 3.14 * G * m * P + 2 * lp * bPart * mPart * P
= 2 * 5.0 * 3.14 * 1146 * 1.4 * 0.1013 + 2 * 0
* 0.0 * 0.0 * 0.1013 = 5103.31 N

Hydrostatic End Load at Flange ID,

Hd = 0.785 * B * P
= 0.785 * (1126) * 0.1013 = 100822.133 N

Pressure Force on Flange Face,

Ht = H - Hd
= 104435.545 - 100822.133 = 3613.41 N

Operating Bolt Load,

Wm1 = H + Hp
= 104435.545 + 5103.308 = 109538.85 N

Gasket Seating Bolt Load,

Wm2 = 3.14 * b * G * y + ypart * bpart * Lpart
= 3.14 * 5.0 * 1146.0 *11 + 0 * 0.0 * 0.0
= 197914.20 N
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BODY FLANGE CALCULATION (Appendix-2):- Contd/- Value Unit

Required Bolt Area,

Am = MAX ( Wm1/Sb, Wm2/Sa)
MAX (109538.9/200 , 197914.2/200.0) = 989.57 mm

Using M-24 studs of root diameter, = 12 mm

From TEMA, Pg. No.189. Root Area = 72.398 mm

No. of studs required = Am / Root Area

= 989.57 / 72.398 = 13.67 No's

Provided No. of Studs = 16 No's

Actual Bolt Area,

Ab = Provided No. of Studs * Root Area
= 16 * 72.398 = 1158.37 mm

Min. Gasket Contact Width (Brownell Young),

Nmin = Ab * Sa/( y * 3.14 * (Go + Gi) )
= (1158.37*200.0) / (11*3.14* (1156+1136))
= 2.93 mm

Flange Design Bolt Load, Gasket Seating,

W = Sa * ( Am + Ab ) / 2
= 200 * ( 989.57 + 1158.37) / 2 = 214793.8 N

= Sa * Ab ( Additional Safety )
= 200 * 1158.37 = 231673.60 N

Gasket Seating Force,

= Wm1 - H
= (109538.85 - 104435.54) = 5103.31 N

Distance to Gasket Load Reaction,

hg = (C - G) / 2
= ( 1155 - 1146 )/2 = 4.5 mm

Minimum Required Flange Thickness

t = G*SQRT[{(C*P)/(S*E)}+{(1.9*W*hg)/(S*E*G^3)}]
= 1146 * SQRT[{(0.3*0.1013)/(183*1)} = 15.08 mm
+{(1.9*231673.60*4.5)/(183*1(*1146^3))}]

Factor 'C' in above formula from Firg. UG-34(j), equal to 0.3

Hence, Provided Flange Thickness

t = t + CA
= 15.08 + 1.5 = 17 mm