Safety valve nozzle M/S.CETHAR VESSELS (P ) LTDM/S.BINANI CEMENTS

Date:-02-09-06Rev:-00 .

Prepared by Verified by Approved by .

SAFETY VALVE NOZZLE DESIGN CALCULATION AS PER ASME B31.1-2010

Description Input Unit

Safety valve set pressure = P 289.30

Design temperature 471.00 °C

Nozzle material specification SA182 F12CL2 -

Young's Modulus of material @ design temp = E 2.48E+07 psi

Allowable stress for saf.valve nozz.matl @ design t 18200.00 psi

Weight of valve = W 422.00 kgs

Nozzle height from od of run pipe = H2 154.94 mm

Dist. betw. od of run pipe to centre line outlet pipe 484.94 mm

Run pipe outside diameter =O.D 273.00 mm

Thickness of run pipe = Tr 33.90 mm

Saf. valve nozz.od @ pipe conn (point-1) = dn1.=2r 204.00 mm

Saf. valve nozz.thk @pipe conn (point-1) = T'b. 63.15 mm

Saf. valve nozz.od @ valve conn (point-2) = dn2. 204.00 mm

Saf. valve nozz.thk @ valve conn (point-2) = tn2. 62.49 mm

Valve rise time = to 0.04 sec

Moment arm = L 610.00 mm

Moment arm for point (1) =L1 19 inch

Moment arm for point (2) =L2 13 inch

Seismic coefficient 1.5 -

Average od of saf.valve nozzle = do 8.031 inch

Average id of saf.valve nozzle = di 3.06 inch

Moment of inertia of saf.valve nozzle = I 199.95

0.006669 sec

Ratio = to/ T 6.00 -

Dynamic load factor (fig II.3.2 of apx.-II of asme b31 1.11 -

BENDING MOMENTS AT POINTS (1) & (2)

Reaction force @ discharge elbow exit = F1 8026.30 kg

471570.83 in-lb

Seismic force = Fs = mass x acceleration 1395 lbf

Bend.moment @ pt 1due to seismic force =Ms(1) = 26505 in-lb

Bend.moment @ pt 2 due to seismic force =Ms(2) = 18135 in-lb

Combined bend.moment @ pt 1 = M1 = M1(1) + Ms 498075.83 in-lb

Combined bend.moment @ pt 2 = M2 = M1(2) + Ms 489705.83 in-lb

Mean radius of run pipe = Rm 4.707 inch

Mean radius of saf valve nozzle @ pt 1 = r'm 2.773 inch

STRESS INTENSIFICATION FACTORS AT POINTS (1 )& ( 2)

Outer radius of saf valve nozz @ pt 1 = rp 4.02 inch

3.43 -

Stress intensification factor for pt 2 (butt weld) = i(2 1.00 -

kg/cm2

inch4

Safety valve installation period = T = 0.1846 x √(Wh3/EI)

Bending moment @ pt 1& 2 due to force F1=M1(1)& M1(2) = F1 X L X DLF

Stress intensification factor for pt 1 (branch conn) = i(1) = ((Rm/Tr)^2/3)x(r'm/Rm)^0.5 x (T'b/ Tr) x (r'm/rp)

Safety valve nozzle M/S.CETHAR VESSELS (P ) LTDM/S.BINANI CEMENTS

Date:-02-09-06Rev:-00 .

Prepared by Verified by Approved by .

PREDICTED STRESSES AT POINT (1) - BRANCH CONNECTION

Ratio = Do/ Tr for run pipe 8.05 -

Ratio = dn1/ T'b for safety valve nozzle 3.23040380048 -

ts = lesser of Tr or (i1)T'b 1 inch

rb = r'm 2.773 inch

Section modulus of point (1) =Z1= π rb^2 ts 32.00

Pressure stress(1) for branch conn. =Ps(1) 8282.30 psi

40040.63 psi

PREDICTED STRESSES AT POINT (2) - BUTT WELD

Ratio = dn1/ tn2 for safety valve nozzle 3.26 -

49.79

Pressure stress(2) for butt weld =Ps(2) 3357.44 psi

Factor 0.75 x i(2) 0.75 -

1 -

9835.21 psi

COMPARISON OF PREDICTED STRESS WITH ALLOWABLE STRESS

Increase factor for hot allowable stress = k 1.20 -

Allowable hot stress @ design temp = k x Sh 21840.00 psi

48322.93 psi

13192.64 psi

Comb stress(1) condition check Cs(1) <= (k x Sh) NOT SAFE -

Comb stress(2) condition check Cs(2 )<= (k x Sh) SAFE -

inch3

Flexure stress(1) for branch connection = Fs(1)=(0.75x i(1)x M(1))/ Z(1)

Section modulus of point (2) =Z2= (π/32) x (dn2^4- di^4)/dn2 inch3

If factor 0.75x i(2) is less than 1.0 it should be taken as 1.0

Flexure stress(2) for butt weld = Fs(2)=(0.75x i(2)x M(2))/ Z(2)

Combined stress at point (1) branch conn = Cs(1)= Pr.stress Ps(1) +Flex.stress Fs(1)

Combined stress at point (2) butt weld =Cs(2) = Pr.stress Ps(2) + Flex.stress Fs(2)

Safety valve nozzle M/S.CETHAR VESSELS (P ) LTDM/S.BINANI CEMENTS

Date:-02-09-06Rev:-00 .

Prepared by Verified by Approved by .

SAFETY VALVE NOZZLE DESIGN CALCULATION AS PER ASME B31.1-2010

Description Input Unit

Safety valve set pressure = P 270.30

Design temperature 573.60 °C

Nozzle material specification SA182 F12CL2 -

Young's Modulus of material @ design temp = E 2.48E+07 psi

Allowable stress for saf.valve nozz.matl @ design t 4000.00 psi

Weight of valve = W 422.00 kgs

Nozzle height from od of run pipe = H2 200.00 mm

Dist. betw. od of run pipe to centre line outlet pipe 520.00 mm

Run pipe outside diameter =O.D 273.00 mm

Thickness of run pipe = Tr 34.10 mm

Saf. valve nozz.od @ pipe conn (point-1) = dn1.=2rp 184.20 mm

Saf. valve nozz.thk @pipe conn (point-1) = T'b. 59.60 mm

Saf. valve nozz.od @ valve conn (point-2) = dn2. 184.20 mm

Saf. valve nozz.thk @ valve conn (point-2) = tn2. 58.80 mm

Valve rise time = to 0.04 sec

Moment arm = L 610.00 mm

Moment arm for point (1) =L1 20 inch

Moment arm for point (2) =L2 13 inch

Seismic coefficient 1.5 -

Average od of saf.valve nozzle = do 7.252 inch

Average id of saf.valve nozzle = di 2.56 inch

Moment of inertia of saf.valve nozzle = I 133.66

0.009058 sec

Ratio = to/ T 4.42 -

Dynamic load factor (fig II.3.2 of apx.-II of asme b31 1.15 -

BENDING MOMENTS AT POINTS (1) & (2)

Reaction force @ discharge elbow exit = F1 9297.74 kg

565950.31 in-lb

Seismic force = Fs = mass x acceleration 1395 lbf

Bend.moment @ pt 1due to seismic force =Ms(1) = 27900 in-lb

Bend.moment @ pt 2 due to seismic force =Ms(2) = 18135 in-lb

Combined bend.moment @ pt 1 = M1 = M1(1) + Ms( 593850.31 in-lb

Combined bend.moment @ pt 2 = M2 = M1(2) + Ms( 584085.31 in-lb

Mean radius of run pipe = Rm 4.703 inch

Mean radius of saf valve nozzle @ pt 1 = r'm 2.453 inch

STRESS INTENSIFICATION FACTORS AT POINTS (1 )& ( 2)

Outer radius of saf valve nozz @ pt 1 = rp 3.63 inch

2.95 -

Stress intensification factor for pt 2 (butt weld) = i(2 1.00 -

PREDICTED STRESSES AT POINT (1) - BRANCH CONNECTION

Ratio = Do/ Tr for run pipe 8.01 -

Ratio = dn1/ T'b for safety valve nozzle 3.09060402685 -

ts = lesser of Tr or (i1)T'b 1 inch

rb = r'm 2.453 inch

kg/cm2

inch4

Safety valve installation period = T = 0.1846 x √(Wh3/EI)

Bending moment @ pt 1& 2 due to force F1=M1(1)& M1(2) = F1 X L X DLF

Stress intensification factor for pt 1 (branch conn) = i(1) = ((Rm/Tr)^2/3)x(r'm/Rm)^0.5 x (T'b/ Tr) x (r'm/rp)

Safety valve nozzle M/S.CETHAR VESSELS (P ) LTDM/S.BINANI CEMENTS

Date:-02-09-06Rev:-00 .

Prepared by Verified by Approved by .

Section modulus of point (1) =Z1= π rb^2 ts 25.00

Pressure stress(1) for branch conn. =Ps(1) 7692.97 psi

52555.75 psi

PREDICTED STRESSES AT POINT (2) - BUTT WELD

Ratio = dn1/ tn2 for safety valve nozzle 3.13 -

36.86

Pressure stress(2) for butt weld =Ps(2) 3010.22 psi

Factor 0.75 x i(2) 0.75 -

1 -

15845.12 psi

COMPARISON OF PREDICTED STRESS WITH ALLOWABLE STRESS

Increase factor for hot allowable stress = k 1.20 -

Allowable hot stress @ design temp = k x Sh 4800.00 psi

60248.72 psi

18855.34 psi

Comb stress(1) condition check Cs(1) <= (k x Sh) NOT SAFE -

Comb stress(2) condition check Cs(2 )<= (k x Sh) NOT SAFE -

inch3

Flexure stress(1) for branch connection = Fs(1)=(0.75x i(1)x M(1))/ Z(1)

Section modulus of point (2) =Z2= (π/32) x (dn2^4- di^4)/dn2 inch3

If factor 0.75x i(2) is less than 1.0 it should be taken as 1.0

Flexure stress(2) for butt weld = Fs(2)=(0.75x i(2)x M(2))/ Z(2)

Combined stress at point (1) branch conn = Cs(1)= Pr.stress Ps(1) +Flex.stress Fs(1)

Combined stress at point (2) butt weld =Cs(2) = Pr.stress Ps(2) + Flex.stress Fs(2)

Safety valve nozzle M/S.CETHAR VESSELS (P ) LTDM/S.BINANI CEMENTS

Date:-02-09-06Rev:-00 .

Prepared by Verified by Approved by .

NONMANDATORY Rules for the design of saftey valve installation

a Design pressure and velocity

P inlet pressure (Absolute) 925 psi

T Inlet tempereature 1000

Atmospheric pressure 15 psia

W Weight of the valve 800 lb From SV data sheet

Valve opening time 0.04 sec From SV data sheet

Discharge elbow area 50.03

Gravitational constant 32.2

1507.30 Btu/lbm From steam tables

j constant 778.16 Btu/lbm

W Actual mass flow rate 116.38 lbm/sec

Pressure @ the discharge elbow 118 psia

Velocity @ the discharge elbow 2116 ft/sec

B Discharge Elbow max operating pressure

For 8 in. class 150 ASME Weld neck flange

L 4 in Σ (L/D) =D 7.981 in 32.00

L/D 0.50 f 0.013

k 1.3For 8 in. SCH 40 short radius elbow

L/D 30 0.416

For 12 in. of 8 in. SCH 40 pipe, 1.647

L 12

D 7.981 194 psiaL/D 1.50

C Recation force at Discharge elbow Exit

12778 lbf

oF

Pa

t0

A1 in 2

gc lm-ft/lbf-sec2

hoStagnation enthalpy @ the safety valve inlet

P1

V1

(Lmax/D)

f(Lmax/D)

From tabel P/P*

P1a = P1 (P/P*)P1a =

F1

D Bending Moment at points (1) and (2)

(A)Bending moment at the point (1) & (2) due to recation at point (1)

= F1 x L x DLFL moment arm 24.00 in

DFL Dynamic load factor 1.11 from graph

To Find DFL

E = Youngs modulus of inlet pipe @ design temp 23000000 Psi

h = distance from run pipe to centerline of outlet piping 19 in

I = Moment of inertia of inlet pipe OD 9.875 inID 6 inI 403

Bending moment T 0.0045 sec

For a valve rise time

340407.23 in-lb

(A) Bending moment at the point (1) & (2) due to Seismic loading

Acceleration 1.5 Data fron structure

mass x acceleration

1200 lbf

moment arm for point (1) 19 in

22800 in-lb

moment arm for point (2) 12 in

14400 in-lb

(c) Bending moment at the point (1) & (2) due to Seismic loading

363207.23 in-lb

354807.23 in-lb

M1(1) = M1(2)

in4

M1(1) = M1(2)

M1(1) = M1(2)

Fs =

Fs =

MS(1)

MS(2)

M(1) = M1(1) + MS(1)

M(2) = M1(2) + MS(2)

steam condition a, Btu/ibm b

1 291 11a

2 823 4.33b

3 831 4.33

wet steam< 90 % qualitySaturated steam ≥

90 % quality 15 psia ≤ p1 ≤ 1,000

psia

superheated steam ≥ 90 % quality 1000 psia ≤ p1 ≤ 2,000 psia

8234.33

Metal-200 -129 -73 21 93 149 204 260

-325 -200 -100 70 200 300 400 500

Cast iron

Gray cast iron 13.4 13.2 12.9 12.6 12.2

Steel

31.4 30.8 30.2 29.5 28.8 28.3 27.7 27.3

31.2 30.6 30 29.3 28.6 28.1 27.5 27.1

Carbon-moly steels 31.1 30.5 29.9 29.2 28.5 28 27.4 27

29.6 29.1 28.5 27.8 27.1 26.7 26.1 25.7

31.6 31 30.4 29.7 29 28.5 27.9 27.5

32.6 32 31.4 30.6 29.8 29.4 28.8 28.3

32.9 32.3 31.7 30.9 30.1 29.7 29 28.6

31.2 30.7 30.1 29.2 28.5 27.9 27.3 26.7

30.3 29.7 29.1 28.3 27.6 27 26.5 25.8

Young Modulus of Elasticity - E - (106 psi)

Temperature (oC)

Temperature (oF)

Carbon steel C <= 0.3%

Carbon steel C => 0.3%

Nickel steels Ni 2% - 9%

Cr-Mo steels Cr 1/2% - 2%

Cr-Mo steels Cr 2 1/4% - 3%

Cr-Mo steels Cr 5% - 9%

Chromium steels Cr 12%, 17%, 27%

Austenitic steels (TP304, 310, 316,

321, 347)

316 371 427 482 538 593 649

600 700 800 900 1000 1100 1200

Cast iron

11.7 11 10.2

Steel

26.7 25.5 24.2 22.4 20.4 18

26.5 25.3 24 22.2 20.2 17.9 15.4

26.4 25.3 23.9 22.2 20.1 17.8 15.3

25.2 24.6 23

26.9 26.3 25.5 24.8 23.9 23 21.8

27.7 27.1 26.3 25.6 24.6 23.7 22.5

28 27.3 26.1 24.7 22.7 20.4 18.2

26.1 25.6 24.7 23.2 21.5 19.1 16.6

25.3 24.8 24.1 23.5 22.8 22.1 21.2

Young Modulus of Elasticity - E - (106 psi)

Temperature (oC)

Temperature (oF)