REV 0

EQUIPMENT : FEED SURGE DRUM

PRPD
CHKD
DOCUMENT NO. : APPD

MECHANICAL DESIGN CALCULATIONS

ITEM :- FEED SURGE DRUM

VESSEL NO. :- D-3801
CUSTOMER :-
DESIGNER :-
VESSEL NAME :-
REVISION :- 1

PREPARED & REVISED BY CHECKED BY APPROVED BY

NAME DATE NAME DATE NAME DATE STATUS
JSG 8/22/2018 BJP 8/22/2018 BJP 8/22/2018 REVISED

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INDEX
APPD 0

SR. NO. DESCRIPTION PAGE NO.

1 COVER PAGE 1

2 INDEX 2

4 RECORDS OF REVISION 3

5 APPLICABLE STANDARDS/ REFERENCES/CONVERSION FACTORS 5

6 DESIGN DATA 6

7 RT REQUIREMENTS & JOINT EFFICIENCY (UW-11,UW-12) 7

8 LOADINGS (UG-22) 8

9 EVALUATION OF MATERIALS 9

10 FLANGE RATING CHECK 10

11 POST FORMING HEAT TREATMENT (UCS-79, UG-79) 11

12 PWHT REQUIREMENTS (UW-2, UCS-56, UCS-68) 12

13 IMPACT TEST REQUIREMENTS (UG-20(f)) 13

14 REQUIREMENT FOR INSPECTION OPENING 14

15 REQUIREMENT FOR DRAIN 15

16 LIFTING LUG DESIGN 16

17 FLANGE CHECK FOR NOZZLE LOAD 17
17 MANHOLE DAVIT CALCULATIONS 18
17 PV ELITE CALCULATION 21

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RECORDS AND SUMMARY OF REVISION
APPD 0

RECORDS OF REVISION :
PRPD CHKD. APPD.
REV DATE PAGES DESCRIPTION
BY BY BY
0 FIRST ISSUE

SUMMARY OF REVISION :
REV
DATE REVISION DETAILS PAGE NO.
NO.
0 ISSUED FOR REVIEW

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APPLICABLE STANDARDS, REFERENCES CHKD 0
AND CONVERSION FACTORS APPD 0

SR. NO. CODE/REFERENCE EDITION

1 ASME SECTION II A FERROUS MATERIAL SPECIFICATIONS 2017

SPECIFICATIONS FOR WELDING RODS,

2 ASME SECTION II C 2017
ELECTRODES AND FILLER METALS

3 ASME SECTION V NON DESTRUCTIVE EXAMINATION 2017

ASME SECTION VIII RULES FOR CONSTRUCTION OF

4 2017
DIV. I PRESSURE VESSEL

5 ASME SECTION IX WELDING, BRAZING AND FUSING QUALIFICATIONS 2017

6 ASME 16.5 PIPE FLANGES AND FLANGED FITTINGS 2013

7 UBC CODE FOR WIND LOADS

8 UBC CODE FOR SEISMIC LOADS

9 PRESSURE VESSEL DESIGN HANDBOOK BY H H BEDNAR

10 PRESSURE VESSEL DESIGN MANUAL BY DENNIS R MOSS

LENGTH/ AREA/ VOLUME LOAD

1 in. = 25.4 mm 1 lbm = 0.4535924 kg

1 ft = 0.3048 m =304.8 mm 1 lbf = 4.448222 N

1 in2 = 645.16 mm2 THEREFORE, 1 kg = 4.448222/0.4535924

1 ft2 = 0.09290304 m2 1 kg = 9.80665 N

1 in3 = 16,387.064 mm3

1 ft3 = 0.02831685 m3

PRESSURE

1 psi = 0.0068948 MPa

1 kg/ cm2 = 2.542 /0.4535924 psi

1 kg/ cm2 = 14.223 psi

Therefore 1 kg/ cm2 = 0.0068948*14.223 MPa

1 kg/ cm2 = 0.098065 MPa

Also, 1 psi = 0.06894757 bar

Therefore 1 MPa = 10 bar

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DESCRIPTION UNIT VALUE REMARKS

CONFIGURATION - HORIZONTAL
ASME SEC. VIII DIV. 1
DESIGN CODE -
EDITION 2017
ASME CERIFICATION MARK - -
INTERNAL DESIGN PRESSURE MPa(g) 1.379 [200 PSI]
EXTERNAL DESIGN PRESSURE bar(g) 0.1035
DESIGN TEMPERATURE FOR
°C 260 [500 °F]
INTERNAL PRESSURE DESIGN
DESIGN TEMPERATURE FOR
°C 260 [500 °F]
EXTERNAL PRESSURE DESIGN
INNER DIAMETER mm 2134 [7 FT]
T.L. TO.TL. LENGTH mm 4268 [14 FT]
M.D.M.T °C 0
CORROSION ALLOWANCE mm 3 INTERNAL
RADIOGRAPHY (SHELL/ D'END) - FULL/SEAMLESS RT1( UG-116)
FOR SHELL 1/1
JOINT EFFICIENCY (LONG/CIRC SEAM)
FOR D'END 1/1
INTERNAL OPERATING PRESSURE bar(g) 3.448 [50 PSI]
EXTERNAL OPERATING PRESSURE MPa(g) N.A.
OPERATING TEMPERATURE °C 142.78 [289 °F]
FLUID - NAPTHA NONLETHAL
DENSITY kg/m3 694
SEISMIC CODE - UBC
WIND CODE - UBC
PWHT - YES - DUE TO PROCESS SEE NOTE 2
IMPACT TESTING - EXEMPT SEE NOTE 3

NOTES:
1) As per endnote 36 of UG-99(b) & as defined in Appendix 3, MAWP is considered same as Design
Pressure as calculations are not made to determine MAWP. e.g. MAWP = Design Press.
2) Exempted As per UW-2,UCS-56,UCS-68
3) As per UG-20(f),UCS-66(c) and note (c) OF Fig UCS-66.

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RT REQUIREMENTS AND JOINT EFFICIENCY CHKD 0
AS PER UW-11, UW-12 APPD 0

SUBSEQUENT CONDITIONS MUST BE CHECKED FOR FULL RADIOGRAPHY REQUIREMENT.

SR. NO. CONDITION APPLICABLE

1 LETHAL SERVICE NO

ALL BUTT WELDS WITH NOMINAL THICKNESS EXCEEDING 32 mm

2 NO
(STRINGENT OF UW-11(a)(2) AND TABLE UCS-57)

ALL BUTT WELDS IN SHELLS AND HEADS OF UNFIRED STEAM BOILERS

3 NO
HAVING DESIGN PRESSURE EXCEEDING 0.345 MPa

CATEGORY B & C BUTT WELDS IN NOZZLES AND COMMUNICATING

4 NO
CHAMBERS THAT EXCEED DN 250 AND 29 mm WALL THK

CATEGORY A & B BUTT WELDS, FOR WHICH, THE JOINT EFFICIENCY

5 NO
IS TAKEN FROM TABLE UW-12, COLUMN - a.

CONCLUSION:

1) FULL RT IS CONSIDERED AS PER CLIENT REQUIREMENT

2) RT IS CONSIDERED AS FOLLOWS:

FOR SHELL - FULL

FOR D'END - SEAMLESS

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LOADINGS CHKD 0
AS PER UG-22 APPD 0
APPLICABLE
CLAUSE DESCRIPTION APPLICABLE
INTERNAL DESIGN PRESSURE YES
UG-22(a)
EXTERNAL DESIGN PRESSURE YES
UG-22(b) WEIGHT OF CONTENT & STATIC HEAD YES
UG-22(c) SUPER IMPOSED STATIC REACTIONS FROM WEIGHT OF ATTACHED EQUIPMENT NO
ATTACHMENT OF INTERNALS YES
UG-22(d)
VESSEL SUPPORT YES
CYCLIC & DYNAMIC REACTIONS NO
UG-22( e)
MECHANICAL LOADING NO
WIND LOAD YES
UG-22(f)
SEISMIC LOAD YES
UG-22(g) IMPACT REACTIONS (DUE TO FLUID SHOCK) NO
UG-22(h) TEMPERATURE GRADIENT AND DIFFERNTIAL NO
UG-22(i) ABNORMAL PRESSURE (CAUSED BY DEFLAGRATION) NO
UG-22(j) TEST PRESSURE AND COINCIDENT STATIC LOAD ACTING DURING TEST YES

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MATERIAL P. NO. TEMPERATURE ALL. STRESS (2) RATIO
DESCRIPTION SPECIFICATION GR. NO. DESIGN PERMITTED S Sa Sa/S
°C °C Mpa Mpa 3)
1
SHELL SA-516 GR 60 300 538 118 118 1
1

1
DISHED END SA-516 GR 60 300 538 118 118 1
1
1
PADS SA-516 GR 60 300 538 136 138 1.015
2
NOZZLE FLANGES/ 1
SA-105 300 538 129 138 1.070
COUPLINGS 2
1
SUPPORTS SA-36 300 538 114 114 -
1
1
PIPE SA-106 GR B 300 538 118 118 1
1
BOLTING FOR SA 193 GR B7 1
300 538 172 172 -
FLANGES SA 194 GR 2H 1

NOTES:-
1) P NO. & GROUP NO. ARE FROM ASME BOILER & PRESSURE VESSEL CODE, SEC II PART D, ED-2017
2) S = ALLOWABLE STRESS AT DESIGN TEMPERATURE
Sa = ALLOWABLE STRESS AT AMBIENT TEMPERATURE

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FLANGE RATING CHECK CHKD 0
UG 44, ASME B16.5 APPD 0
FLANGE RATING CHECK:
AS PER UG 44, FLANGES AS PER ASME B16.5 ARE ACCEPTABLE
DESCRIPTION UNIT VALUE
STANDARD FOR FLANGES - ASME B16.5
SELECTED RATING - CL.300
MATERIAL - SA 105
MATERIAL GROUP - 1.1
DESIGN TEMPERATURE °C 260
ALLOWABLE PRESSURE FOR SELECTED RATING AT 300°C bar g 119.5
Mpa g 11.95
DESIGN PRESSURE INCLUSIVE OF STATIC HEAD(MAX.) Mpa g 8.4
CONCLUSION 11.95>8.4
SAFE

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POST FORMING HEAT TREATMENT CHKD
UCS-79, UG-79 APPD
POST FORMING HEAT TREATMENT
AS PER UCS-79(d), AFTER COLD FORMING, HEAT TREATMENT IS REQUIRED WHEN
THE RESULTING EXTREME FIBER ELONGATION IS MORE THAN 5% AND ANY OF
FOLLOWING CONDITION EXIST :

SR.NO. CONDITION APPLICABLE

1 LETHAL SERVICE NO
2 WHETHER MATERIAL REQUIRES IMPACT TESTING NO
3 PART THICKNESS EXCEEDS 16 mm BEFORE COLD FORMING NO

REDUCTION IN THICKNESS BY FORMING IS MORE THAN 10% WHERE

4 NO
THE EXTREME FIBER ELONGATION IS MORE THAN 5%

5 THE FORMING TEMPERATURE IS BETWEEN 120 - 480 °C NO

CONCLUSION:
POST FORMING HEAT TREATMENT IS NOT REQUIRED AS FIBRE ELONGATION IS EXCEEDING FOR
SHELL AND DISHED END.

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 0
0
0
0

APPLICABLE
NO
NO
NO

NO

NO

N IS EXCEEDING FOR

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PWHT REQUIREMENT CHKD 0
UW-2, UCS-56, UCS-68 APPD 0
POST WELD HEAT TREATMENT IS REQUIRED WHEN ANY OF FOLLOWING CONDITION EXIST:

SR NO. APPLICABLE DESCRIPTION APPLICABLE REMARKS

CLAUSE
1 UW 2 (a) LETHAL SERVICE NO
UNFIRED STEAM BOILER WITH DESIGN
2 UW 2(c) NO
PRESSURE EXCEEDING 0.345 MPa

IF MDMT IS COLDER THAN -48°C AND THE

3 UCS-68(b) COINCIDENT RATIO DEFINED IN FIG UCS-66.1 NO
IS 0.35 OR GREATER

MATERIAL OVER 32 mm NOMINAL THICKNESS

4 UCS-56 NO
AS DEFINED IN UW-40(f)
5 - IS PWHT CLIENT'S SERVICE REQUIREMENT? YES

POST WELD HEAT TREATMENT IS REQUIRED

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IMPACT TEST CHKD 0
UG-20(f), UCS-66 APPD 0

AS PER UG-20(f), IMPACT TESING AS PER UG-84 IS NOT REQUIRED FOR PRESSURE VESSEL MATERIALS
WHICH SATISFY ALL OF THE FOLLOWING:
CONDITION
SR NO. CONDITION
SATISFIED

MATERIAL IS LIMITED TO P NO. 1, GR. NO. 1 & 2 THK IS LESS THAN

1 13 mm FOR MATERIAL LISTED IN CURVE-A OF FIG. UCS-66 THK IS YES
LESS THAN 25 mm FOR MATERIAL LISTED IN CURVE-B,C,D OF FIG.
UCS-66.
THE VESSEL IS HYDRAULICALLY TESTED AS PER UG-99(b) OR (c)
2 YES
OR 27-4

DESIGN TEMPERATURE IS NO WARMER THAN -345 °C NOR

3 YES
COLDER THAN -29 °C

THE THERMAL OR MECHANICAL SHOCK LOADINGS ARE NOT

4 YES
CONTROLLING DESIGN REQUIREMENTS (UG-22)

CYCLIC LOADING IS NOT A CONTROLLING DESIGN

5 YES
REQUIREMENT (UG-22)

- AS ALL ABOVE CONDITIONS ARE SATISFIED, REQUIREMENTS OF UCS-66 ARE NOT

REQUIRED TO BE CHECKED
MATERIAL
AS PER CLAUSE UCS-66(c) OF ASME SEC VIII DIV 1,
IMPACT TESTING IS NOT REQUIRED FOR ASME B16.5
FORGINGS SA 105
FLANGES OF FERRITIC STEEL FOR MDMT WARMER
THAN -29 °C.

AS PER NOTE (c) OF FIG UCS-66 OF ASME SEC VIII DIV 1,

BOLTS SA 193 GR B7 BOLT SIZES UPTO M64 ARE EXEMPTED FROM IMPACT
TESTING FOR MDMT WARMER THAN -48 °C.

AS PER NOTE (c) OF FIG UCS-66 OF ASME SEC VIII DIV 1,

NUTS SA 194 GR 2H NUTS ARE EXEMPTED FROM IMPACT TESTING FOR MDMT
WARMER THAN -48 °C.

CONCLUSION:
IMPACT TEST IS NOT REQUIRED.

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REQUIREMENT FOR INSPECTION OPENING CHKD 0
UG-46 APPD 0

1. AS PER UG-46(a), ALL PRESSURE VESSELS FOR USE WITH COMPRESSED AIR AND
THOSE SUBJECT TO INTERNAL CORROSION OR HAVING PARTS SUBJECT TO EROSION
OR MECHANICAL ABRASION (SEE UG-25) EXCEPT AS PERMITTED OTHERWISE IN THIS
PARAGRAPH, SHALL BE PROVIDED WITH SUITABLE MANHOLE, HANDHOLE, OR OTHER
INSPECTION OPENINGS FOR EXAMINATION AND CLEANING.

2. AS PER UG-46(d), VESSELS 300 mm OR LESS IN INSIDE DIAMETER , OPENINGS FOR INSPECTION
ONLY BE OMITTED IF THERE ARE ATLEAST TWO REMOVABLE PIPE CONNECTIONS NOT
LESS THAN DN 20

CONCLUSION :
PROVIDED 24" OF MANWAY ON SHELL AS INSPECTION OPENING.

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S FOR INSPECTION

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AS PER UG-25(f), VESSEL SUBJECTED TO CORROSION SHALL BE SUPPLIED WITH A

DRAIN OPENING AT THE LOWEST PRACTICABLE POINT.

CONCLUSION :
ONE DRAIN NOZZLE (DN 50) IS PROVIDED AT SUMP D'END.

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Description Symbol Unit Value
Empty weight of equipment We N 6513.84
Shock factor Sf - 2
Erection weight for design Wer N 13027.68
Number of lifting lugs N - 2
Sling angle with horizontal θ degree 90
Load along sling line = (Wer/sinθ)/N F N 6513.84
Width of lifting lug at hole centre b mm 80
Width of lifting lug at base b1 mm 80
Thickness of lifting lug t mm 20
Hole diameter d mm 34
Hole location from base of lug L mm 65
Pad length Lp mm 0
Pad width Wp mm 0
Pad thickness Tp mm 0
Pad to dish end fillet weld size Fp mm 16
Lifting lug to pad weld length = 2*(b1+t) Lpl mm 0
Lifting lug to pad weld size Fpl mm 0
Material - - SA 516 GR 70

Allowable stress for tension S MPa 138

Allowable stress for bearing = 1.6*S SB MPa 220.8
Allowable stress for shear = 0.8*S Ss MPa 110.4
Allowable stress for bending = S Sbend MPa 138

Design for Shear

σS = F / {2*{(b/2-d/2)*t} σS MPa 7.08
AS ACTUAL STRESS < ALLOWBLE STRESS, DESIGN IS SAFE
Design for Bearing
σB = F / (d * t) σB MPa 9.58
AS ACTUAL STRESS < ALLOWBLE STRESS, DESIGN IS SAFE
Design for Bending
Section modulus Z = t * b1²/ 6 Z mm³ 21333.3
σbend = F*L/Z σbend MPa 19.8
AS ACTUAL STRESS < ALLOWBLE STRESS, DESIGN IS SAFE
Shear Stress Check for Welds
Pad to shell weld
σSW = F/[2*(Wp+Lp)*0.707*Fp] σSW MPa 1.80
AS ACTUAL STRESS < ALLOWBLE STRESS, DESIGN IS SAFE

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FLANGE CHECK FOR NOZZLE LOAD CHKD 0
CODE CASE 2901 APPD 0
FLANGE RATING CHECK:
AS PER UG 44, FLANGES AS PER ASME B16.5 ARE ACCEPTABLE
DESCRIPTION SYMBOL UNIT VALUE
NOZZLE MARK - - N1,N2
SIZE - - DN 150
FLANGE CLASS - - 300
DESIGN PRESSURE INCLUDING STATIC HEAD PD MPa g 8.4
DESIGN TEMPERATURE T °C 300
FLANGE PRESSURE RATING AT TEMPERATURE PR MPa g 11.95
MOMENT FACTOR FROM TABLE 1 FM - 0.5
LONGITUDINALBENDING MOMENT ML N-M 5370
CIRCUMFERENTIAL BENDING MOMENT MC N-M 6985

ME=SQRT( N-M
EXTRERNAL MOMENT ML2+Mc2) 8810.6256872029
EXTERNAL TENSILE AXIAL FORCE FE N 8025
GASKET O.D. Go MM 368.3
GASKET I.D. Gi MM 323.9
GASKET LOAD REACTION DIAMETER G MM 351.5
TOTAL EQUIVALENT MOMENT M1 N-M 152253.160995247
=16*ME + 4*FE*G/1000
PERMISSIBLE MOMENT M2 N-M 1298884.75789744
= π*G3*((PR-PD) + (FM*PR))/1000
CHECK WHETHER M1≤M2 - YES
CONCLUSION - SAFE

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