Equipment Design as

per Russian Norms

Ravi Mohan Saxena

Mechanical (Static)
GS E&C (India) Pvt. Ltd.
 Factor of Safety as per
GOST 14249 – 89
In Operating Conditions:
On yield strength at design temp - 1.5
On UTS (ultimate tensile strength) at
design temp. - 2.4
On long time strength 10^5 hours at
design temp - 1.5
On 1 % creep stress during 10 ^5 hours at
design temp - 1.0
 Factor of Safety as per
GOST 14249 – 89
In Test Conditions

Hydraulic Tests - 1.1

Pneumatic test -1.2
On yield strength at test temp
 Comparison with ASME Sec VIII Div. 1

Factor Of Safety In Operating Russian ASME

conditions
On yield strength at design temp 1.5 1.5
On UTS (ultimate tensile strength) 2.4 3.5
at design temp.
On long time strength 10^5 hours at 1.5 1.0 (avg.)
design temp - 1.5 ,1.25(min)

On 1 % creep stress during 10 ^5 1.0 1.0 (avg.)

hours at design temp - 1.0
 Comparison with ASME Sec VIII Div. 1

Factor Of Safety in Russian ASME

Test Conditions

Hydraulic Tests 1.1 90 % of yield

(F.S. = 1.111)

Pneumatic test 1.2 90 % of yield

(F.S. = 1.111)
 Shell wall thickness ( internal pressure)

Thichness (Th)= calculated thickness (Thp)+ corrosion allowance ( C )

Thp = p D / 2 σ φ-p

σ =permissible stress at design temp

φ=strength factor of weld seams ( refer table 20 , appendix 5)

(φ=1.0 for FPW and 100 % Radiography)

p (permissible) =2 σφ(th-C)/ D+(th-C)

 Shell wall thickness ( external
pressure)
Thichness (Th)= calculated thickness (Thp)+ corrosion
allowance ( C )
where Thp= max ( K2D10^-2 ; 1.1 p D / 2σ )
(K2 shall be determined from graph fig.5)
L = l + 2H / 3, where H is dish height , and
l= T/L to T/L distance (with no stiffeners) ,
Or, L = min. distance between stiffeners / adjoining
elements (in case of stiffeners)
K3 = L/D
K1 = 0.865 * Sstab.* p / (2.4*10^-6* E)
Sstab. = 2.4 , in operating condition
 Stiffener Rings at External
Pressure
Design effective moment of inertia of rigidity ring
,Ip = 0.1*p*D^3*l1*Sstab*K5/(E*2.4)
l1 is distance between rigidity rings
(K5 shall be determined from fig.11 )
Moment of inertia (Ir)of ring selected such that I ≥
Ip , where
I = Ir +l1(th-c)^3/10.9 +e^2*(th-c)/{Ar+le*(th-c)}
Effective wall length, le = min{l1;t+1.1√ D(th-c)}
e= distance between the centre of gravity of cross
section of rigidity ring and median surface of
shell
 Dished Ends - Elliptical and Hemispherical
(internal pressure)

Th = Thp+C
Thp = p R / 2 φ σ - 0.5 p
R = D^2/4H
(For elliptical Dish : R=D , H=0.25D
For hemispherical dish : R=0.5 D,H=0.5D)
 Elliptical and Hemispherical End
Plates (external pressure)
Th1 = Th1p+C
Th1p = max {Kr R/ 510√(Sstab *p / 10^-6 E);
P R / 2 σ}
Kr taken from fig 13
(preliminary Kr=0.9 for elliptical , 1.0 for
hemispherical dish)
 Permissible External Pressure for
Shell (without stiffeners)
From condition of stability:
[p]E =20.8 * 10^-6* E*D *[100*(Th-C)/D]^2.5 /
(Sstab. * B1*l)
where, B1 = min.{ 1.0; (9.45 *D/L)*√[D/100(Th-c)]}
Sstab = 2.4 , for operating conditions
From condition of strength :
[p]s = 2*[σ]*Фp(Th-C) / {D+(Th-c)}
Permissible external pressure ,
[p] = [p]s / √{1+([p]s/[p]E)^2}
 Permissible external pressure
(for Dished End )
From condition of strength :
[p]s = 2*[σ]*(Th1-C) / {R+0.5 (Th-c)}
From condition of stability:
[p]E =26 * 10^-6* E *[100*(Th-C)/Kr R]^2 /
Sstab.
Sstab = 2.4 , for operating conditions
(Kr shall be determined from graph fig.13)
Permissible external pressure ,
[p] = [p]s / √{1+([p]s/[p]E)^2}
Permissible external pressure for
Shell with Rigidity Rings
Permissible external pressure, [p]=min{[p]1;[p]2}
Permissible external pressure for whole shell,
[p]1 = [p]1s / √{1+([p]1s/[p]1E)^2}
From condition of stability:
[p]1E =20.8 * 10^-6* E*D *[100*k*(Th-C)/D]^2.5 / (Sstab.*
k*B2*L)
where, B2 = min.{ 1.0; (9.45 *D/L) * √[D/100k(Th-c)]}
Sstab , for operating conditions = 2.4
Where,coeff. of rigidity of shell, k = √{10.9 I/L(th-c)^3}
From condition of strength:
[p]1s = {2*[σ]*Фds(Th-C)+2Ar[σ]rφr/l1} / {D+(Th-c)}
Where, Фds =1 , φr= 1,
Ar = cross sectional area of stiffener ring
Permissible external pressure [p]2 from stability
conditions between rigidity rings,
[p]2 = [p]2s / √{1+([p]2s/[p]2E)^2}
From condition of strength:
[p]2s = {2*[σ]*Фt*(Th-C)} / {D+(Th-c)} * (2+λs^2)/{1+(φt
*λs^2/φds)}
Where, Фt =1 , λs^2 = b^2/D(Th-c)
From condition of stability [p]2E shall be determined
considering the max length of supports , with the same
rule as for shell without rings,
[p]2E =20.8 * 10^-6* E*D *[100*(Th-C)/D]^2.5 / (Sstab. *
B1*l)
where, B1 = min.{ 1.0; (9.45 *D/L)*√[D/100(Th-c)]}
 Permissible Bending Moment &
Compression Force
Permissible Bending Moment:
[M] ={π D (D+Th-C) ( Th-c) [σ] φ3} /4
Find φ3 from graph (fig.10) based
on D/(Th-c) &10^3*[σ]/E
Permissible Compression Force:
[F] = π (D+Th-C) ( Th-c) [σ] min {φ1 ; φ2}
Find φ1 & φ2 from graph (fig.8 & 9)
Where, λ = 2.83 lr / (D+ Th -c) & lr based on fig. 7
For self supported vertical vessel / column lr =2l
Coeficient φ3
 Permissible Cross Force
From condition of strength:
[Q]s =0.25π D (Th-c) [σ]
From condition of stability:
[Q]E=2.4E(Th-c)^2/Sstab{0.18+3.3 D(Th-
c)/l^2}
Permissible Cross Force [Q],
[Q] = [Q]s / √{1+([Q]s/[Q]E)^2}
 Stability Check
Under combined effect of load :
p/[p] + F/[F] + M/[M] +{Q/[Q]}^2 ≤ 1.0
Where,[p] = permissible external pressure
[F] =permissible axial compression
[M] = permissible bending moment
[Q] = permissible cross force
 Sample Calculations as per
Russian Regulation
Clay Treater 2900R0001A/B
Design Calculations as per GOST 14249-89
1.0 Basic Data
Internal diameter 1400 mm
Head Ellipsoid 2:1
Length Tl To Tl 7200 mm
Skirt height 3000 mm
Shell Thickness (ASME) 20 mm
Head Thickness (ASME) 19.1 mm
Design Pressure (Internal) 2.7 MPa
Design Pressure (external) -F.V. 0.103 MPa
Design Temperature(internal) 230 deg C
Design Temperature(external) 199 deg C
Radiography 100 %
CA 3 mm
Materialof construction 516-60 ASME
Minimum Tensile strength 60000 psi
Minimum Yield strength 32000 psi
2.0 Calculation of Allowable Stresses
Where Ry minimum value of yield stresses at design temperature 32000 psi
Sy coefficient of safety margin on yield strenght 1.5
Rm minimum value of ultimate strength at design temperature 60000 psi
Stem coefficient of safety margin on Rm 2.4
(For factor of safety refer to Table 1,GOST 14249-89 )
Ry / Sy 21333.33 psi
Rm / Stem 25000 psi
Allowable stress [σ] (minimum of above) 21333.33 psi
[σ] (in MPa) 147.088 MPa
Correcion factor to permissible stresses η except for casr steel 1
Strength coefficient of welded seam Фds 1
(For Butt , full penetration welding,100% controlled / radiographed
welds , Фs shall be 1; refer table 20 , GOST 14249-89 )

Total increase in Predesigned Thickness of the element C C1+C2+C3

Increase for compensation of corrosion C1
Increase for compensation negative tolerance C2
Increase for compensation of Technological processes C3
C 3 mm
The manufacturing thickness Th > = Thp +C
 3.0 Check under internal pressure
a) Shell Thickness
Thp =p.D / ( 2 [σ]Фds-p)

Thp 12.97 mm

C 3

Final design thickness Th 15.97 mm

Say 16 mm

(Note: Thickness as per ASME Sec VIII Div. 1 is 20 mm)

[The above formulae is applicable when Th-C / D < = 0.1

Temperature limit for carbon steel <=380 deg C

Temperature limit for low alloy steel <=420 deg C

Temperature limit for lausenic steel <=520 deg C]

b) Dished End Thickness
( 2:1 Ellipsoidal ):

Th1p =p.R / ( 2Ф [σ]-0.5p)

R=D for 2:1 ellipsoidal dish 1400 mm

Ф 1

Th1p 12.91 mm

Th1 = Th1p+C 15.91 mm

Say ( minimum thickness) 16 mm

(Note : Thickness as per ASME Sec VIII Div.1 is 19.1 mm)

 4.0 Check under External Pressure
a) Shell thickness
Thp = max {K2 D 10^-2 ; 1.1pD/2[σ]}

L = l + 2H / 3

= 7200+ {(1400* 0.25)* 2/3} 7433.33 mm

K3 = L/D 5.309

K1 = 0.865 * Sstab.* p / (2.4*10^-6* E) 0.4325

(where , Sstab. = 2.4 , E = 2.1 * 10^6 kg/cm2)

From Graph (fig.5) , K2 = 0.62

K2 D 10^-2 8.68 mm

1.1pD/2[σ] 0.539 mm

Thp 8.68 mm
 Permissible external pressure (with shell
thickness 16 mm) :
[p]E =20.8 * 10^-6* E*D *[100*(Th-C)/D]^2.5 / (Sstab. * B1*l) 0.279 MPa

where, B1 = min.{ 1.0; (9.45 *D/L) * √[D/100(Th-c)]} 1.0

Sstab , for operating conditions 2.4

[p]s = 2*[σ]*Фp(Th-C) / {D+(Th-c)} 2.715 MPa

Permissible external pressure , [p] = [p]s / √{1+([p]s/[p]E)^2} 0.277 MPa

 b)Dished End Thickness( 2:1Ellipsoidal ):
(Check under external pressure)

Th1 ≥ Th1p + C

Th1p = max. [ (Kr*R/510)* √{(Sstab* p)/(10^-6*E)} ; PR/2[σ] ]

Sstab , for operating conditions 2.4

Th1p = max. [ 2.7 ; 0.49 ] 2.7

Th1 ≥ Th1p + C 5.7 mm

 Permissible external pressure
(with dish min. thickness 16 mm) :
[p]s = 2*[σ]*(Th1-C) / {R+0.5 (Th-c)} 2.718 MPa

[p]E =26 * 10^-6* E *[100*(Th-C)/Kr R]^2 / Sstab. 2.272 MPa

(Kr =0.92 from graph fig.13)

Permissible external pressure ,

1.743 MPa
[p] = [p]s / √{1+([p]s/[p]E)^2}
1.0 Wind Load Calculations
a) Wind Multiplication Factor

OD of vessel 1432 mm

Insulation thickness 100 mm

Vessel OD +2*insulation thk D1 1632 mm

Ladder Projection Lp 300 mm

Overhead line +2*insulation thk Np 300 mm

Platform width (average) Wp 200 mm

Wind Multiplication Factor, Wf=(D1+Lp+Np+Wp) /D1 1.49

b) Wind Pressure
Wind pressure upto 5 m 225 N/m2
Wind pressure ( 5m to 10m ) 300 N/m2

c) Shape Factor
H/D 7.78
Shape Factor ( for 5<H/D<10 = 0.9 ) 0.9

d) Wind load
Wind Load on Reactor (upto 5 m) 2160.4 N
(Wind Load = 0.9*225*D1*5*Wf)
Wind Load on Reactor ( 5 to 10.9 m) 3398.9 N
Total Wind Load on Reactor 5559.2 N
e) Wind Load (at base)

Wind Load Shear at base of reactor 5559.2 N

Wind Load Moment at base of reactor 32422.1 N-m

f) Wind Load (at bottom T.L.)

Wind Load Shear at bottom T.L. 4263 N

Wind Load Moment at bottom T.L. 17688.7 N-m

2.0 Check for Load Combination (in
operating condition)
a) At Bottom T.L. :

i) Governing loads: (Refer Table 1 of GOST R 51274)

Governing Moment M 1803.74 kg-m
Dead Load F 26000 kg
Internal pressure p 27.53 kg/cm2

ii) Longitudinal stress on windward side (Refer para 6.2

of GOST R 51274)
σx1=p(D+s)/4(s-c) -F/πD(s-c)+ 4M/πD^2(s-c) 713.25 kg/cm2
(where s-c =16 - 3 = 13 mm , corroded shell thickness)
iii) Longitudinal stress on leeward side
σx2=p(D+s)/4(s-c) -F/πD(s-c)- 4M/πD^2(s-c) 695.22 kg/cm2
iv) Circumferential stress
σy = p(D+s)/2(s-c) 1499.42 kg/cm2
v) Equivalent stress on windward side
σE1 = √( σx12 - σx1 σy+σy2) 1299.04 kg/cm2
vi) Equivalent stress on leeward side
σE2 = √( σx22 - σx2 σy+σy2) 1299.67 kg/cm2
vii) Max stress on windward side
max {│σx1│: σE1} 1299.04 kg/cm2
viii) Max stress on leeward side
max {│σx2│: σE2} 1299.67 kg/cm2
ix) Allowable stress = [σ]k φ 1499.85 kg/cm2
(φ=1 for FPW and 100 % radiography)
Max stress < Allowable stress , Hence safe
b) At Skirt Base :

i) Governing loads:

Governing Moment M 3306.13 kg-m

Dead Load F 27000 kg

Internal pressure p 0 kg/cm2

ii) Longitudinal stress on windward side

σx1=p(D+s)/4(s-c) -F/πD(s-c)+ 4M/πD^2(s-c) -49.88 kg/cm2

(where s-c = 10-2 = 8 mm , corroded skirt thickness)

iii) Longitudinal stress on leeward side

σx2=p(D+s)/4(s-c) -F/πD(s-c)- 4M/πD^2(s-c) -103.57 kg/cm2

iv) Circumferential stress
σy = p(D+s)/2(s-c) 0 kg/cm2
v) Equivalent stress on windward side
σE1 = √( σx12 - σx1 σy+σy2) 49.88 kg/cm2
vi) Equivalent stress on leeward side
σE2 = √( σx22 - σx2 σy+σy2) 103.57 kg/cm2
vii) Max stress on windward side
max {│σx1│: σE1} 49.88 kg/cm2
viii) Max stress on leeward side
max {│σx2│: σE2} 103.57 kg/cm2
ix) Allowable stress = [σ]k φ 1499.85 kg/cm2
(φ=1 for FPW and 100 % radiography)
Max stress < Allowable stress , Hence safe
3.0 Check for Load Combination
(in Test condition)
a) At Bottom T.L. : (Refer Table 1 of GOST R 51274 )

i) Governing loads:
Governing Moment M ( 60% of normal wind moment) 1082.24 kg-m
Dead Load F (including the weight of water) 36750 kg
Internal test pressure (at top) p2 =1.25*p*( [σ]20 / [σ]temp ) 34.41 kg/cm2
Adding static head 8.1 m (0.81 kg/cm2), total pressure 35.22 kg/cm2
ii) Longitudinal stress on windward side
(Refer para 6.2 of GOST R 51274)
σx1=p(D+s)/4(s-c) -F/πD(s-c)+ 4M/πD^2(s-c) 900.26 kg/cm2
(where s-c = 16 - 3 =13 mm , corroded shell thickness)
iii) Longitudinal stress on leeward side
σx2=p(D+s)/4(s-c) -F/πD(s-c)- 4M/πD^2(s-c) 889.37 kg/cm2
iv) Circumferential stress
σy = p(D+s)/2(s-c) 1918.13 kg/cm2
v) Equivalent stress on windward side
σE1 = √( σx12 - σx1 σy+σy2) 1674.02 kg/cm2
vi) Equivalent stress on leeward side
σE2 = √( σx22 - σx2 σy+σy2) 1662.61 kg/cm2
vii) Max stress on windward side
max {│σx1│: σE1} 1674.02 kg/cm2
viii) Max stress on leeward side
max {│σx2│: σE2} 1662.61 kg/cm2
ix) Allowable stress (hydrotest condition)
(Refer to Table 1,GOST 14249-89) 2045.77 kg/cm2
= [σ]k φ =[σy/1.1]*1.0=32000/1.1=29090.9 psi
(φ=1 for FPW and 100 % radiography)
Max stress < Allowable stress , Hence safe
4.0 Stability Check
a) In operating condition under external pressure
At Bottom T.L. :

i) Governing loads:
Governing Moment M 1803.74 kg-m
Dead Load F 26000 kg
External pressure p 1.05 kg/cm2

ii) Allowable Moment [M]

(Refer cl. 2.3.5.2 GOST 14249-89)
D/(Th-c) = 1400/(16-3) 107.69
103*[σ]/E 0.7142
φ3 0.98
[M] ={π D (D+Th-C) ( Th-c) [σ] φ3} /4 302937.5 kg-m
iii) Allowable Compression Force [F]
(Refer cl. 2.3.4.2 GOST 14249-89)
D/(Th-c) = 1400/(16-3) 107.69
103*[σ]/E 0.714
λ√103*[σ]/E 36.89
lr =2*l 21800 mm
λ = 2.83 lr / (D+ Th -c) 43.66
Φ1 (From graph fig.8 GOST 14249-89) 1.0
Φ2 (From graph fig.9 GOST 14249-89) 0.95
[F] = π (D+Th-C) ( Th-c) [σ] min {φ1 ; φ2} 822259.03 kg

iv) p/[p] + F/[F] + M/[M] ≤ 1.0 0.408

= 0.371 + 0.03162 + 0.00595 = 0.408
Hence safe, (Refer cl. 6.3.2 GOST R51274 – 99)
b) In hydrotest conditions
At Skirt Base :

i) Governing loads:
Governing Moment M 1082.24 kg-m
Dead Load F 36750 kg

ii) Allowable Moment [M]

(Refer cl. 2.3.5.2 GOST 14249-89)
D/(Th-c) = 1400/(16-3) 107.69
103*[σ]/E 0.7142
φ3 (From graph fig.10) 0.98
[M] ={π D (D+Th-C) ( Th-c) [σ] φ3} /4 302937.5 kg-m
iii) Allowable Compression Force [F]
(Refer cl. 2.3.4.2 GOST 14249-89)
D/(Th-c) = 1400/(16-3) 107.69
103*[σ]/E 0.714
λ√103*[σ]/E 36.89
lr =2*l 21800 mm
λ = 2.83 lr / (D+ Th -c) 43.66
φ1 (From graph fig.8 GOST 14249-89) 1.0
Φ2 (From graph fig.9 GOST 14249-89) 0.95
[F] = π (D+Th-C) ( Th-c) [σ] min {φ1 ; φ2} 822259.0 kg

iv) F/[F] + M/[M] ≤ 1.0 0.048

= 0.0446 + 0.00357= 0.048
Hence safe, (Refer cl. 6.3.1 GOST R51274 – 99)
Thank You