TOTAL 210 SHEET Vendor DOC. NO. J160165DA002P4 … · Apply interpretation VIII-1-83-66 Yes Apply...

TOTAL 210 SHEET

Vendor DOC. NO. J160165DA002P4

DOCUMENT TITLE: Design Calculations

Axion Campana II Project

P.O. NO: 4618956

Equipment Name: Process Gas Boiler

ITEM NO: 013001Y01E07

AL E&C DOC. NO. 56032-4618956-000030

0 19.01.17 First issue Pirker Leitner Pirker

REV. DATE DESCRIPTION CHECK APPROVED AUTH’D

VENDOR NAME: Bertsch Energy GmbH & Co KG

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2017/03/10

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Content

Equipment: PGB 013001Y01E07

Page:

Saddles ................................................. 3 to 28

Shellside ................................................. 29 to 76

Tubeside ................................................. 77 to 159

Tubesheets ................................................. 160 to 210

ITEM NO: 013001Y01E07 1/210 AL E&C DOC. NO. 56032-4618956-000030

BERTSCHenergy G m b H & Co KG

Herrengasse 23, 6700 Bludenz, Austria

www.bertsch.at

COMPRESS Pressure Vessel Design Calculations

Item: Process Gas Boiler

Vessel No: 013001Y01E07

Customer: Air Liquide Global E&C Solutions SHANGHAI

Contract: 4618956-000SIN

Designer: Pirker

Date: 19.01.2017


Table of ContentsSettings Summary.....................................................................................................................................................1/25

Weight Summary.......................................................................................................................................................3/25

Wind Code.................................................................................................................................................................4/25

Saddles......................................................................................................................................................................5/25

i


Settings Summary

COMPRESS 2017 Build 7700

ASME Section VIII Division 1, 2013 Edition Metric

Units MKS

Datum Line Location 0,00 mm from left seam

Vessel Design Mode Design Mode

Minimum thickness 1,5 mm per UG-16(b)

Design for cold shut down only No

Design for lethal service (full radiography required) No

User has limited MAWP to 42 / 30 bar

Design nozzles for Design P only

Corrosion weight loss 100% of theoretical loss

UG-23 Stress Increase 1,20

Skirt/legs stress increase 1,0

Minimum nozzle projection 152,4 mm

Juncture calculations for α > 30 only Yes

Preheat P-No 1 Materials > 1,25" and <= 1,50" thick Yes

UG-37(a) shell tr calculation considers longitudinal stress No

Cylindrical shells made from pipe are entered as minimum thickness No

Nozzles made from pipe are entered as minimum thickness No

ASME B16.9 fittings are entered as minimum thickness No

Butt weldsTapered per Figure

UCS-66.3(a)

Disallow Appendix 1-5, 1-8 calculations under 15 psi No

Hydro/Pneumatic Test

Shop Hydrotest at user defined pressure 41,35 bar

Test liquid specific gravity 1,00

Field Hydrotest at user defined pressure 41,35 bar

Wind load present @ field 33% of design

Maximum stress during test 90% of yield

Required Marking - UG-116

UG-116(e) Radiography RT1

UG-116(f) Postweld heat treatment HT

Code Cases\Interpretations

Use Code Case 2547 No

1/25



Apply interpretation VIII-1-83-66 Yes





No UCS-66.1 MDMT reduction No

No UCS-68(c) MDMT reduction No

Disallow UG-20(f) exemptions No

UG-22 Loadings

UG-22(a) Internal or External Design Pressure Yes

UG-22(b) Weight of the vessel and normal contents under operating or test

conditionsYes

UG-22(c) Superimposed static reactions from weight of attached equipment

(external loads)Yes

UG-22(d)(2) Vessel supports such as lugs, rings, skirts, saddles and legs Yes

UG-22(f) Wind reactions Yes

UG-22(f) Seismic reactions No

UG-22(j) Test pressure and coincident static head acting during the test: No

Note: UG-22(b),(c) and (f) loads only considered when supports are present.

License Information

Company Name Bertsch Energy GmbH & Co KG

License Commercial

License Key ID 20080

Support Expires January 24, 2018

2/25


Weight Summary

Weight (kg) Contributed by Vessel Elements

Component Metal

New*

Metal

CorrodedInsulation

Insulation

SupportsLining

Piping

+ Liquid

Operating Liquid Test Liquid Surface

Area

m2New Corroded New Corroded

Ellipsoidal Head Inlet 621,7 598,1 1.047,3 0 0 105,7 228,1 230 596,9 601,9 2,28

Shell- Inlet Chamber 3.021,4 2.956,1 2.243,1 0 0 345,4 1.094,8 1.100,1 2.189,5 2.200,2 5,82

Transition 158,1 148,2 18,9 0 0 76,1 128,8 129,4 257,6 258,8 0,82

Shellside 5.260,4 4.929,8 638,9 0 0 1.443,7 4.373,7 4.395,9 8.753,3 8.797,9 27,38

Shell Outlet Chamber 2.284,6 2.214,5 241 0 0 0 956 960,9 2.029,1 2.040,4 6,08

Ellipsoidal Head Outlet 357,8 331,4 103,5 0 0 0 180,2 181,8 360,4 363,6 2,34

Saddles 579,7 579,7 0 0 0 0 0 0 0 0 6,34

TOTAL: 12.283,7 11.757,7 4.292,7 0 0 1.971 6.961,4 6.998,2 14.186,7 14.262,9 51,05

*Shells with attached nozzles have weight reduced by material cut out for opening.

Weight (kg) Contributed by Attachments

ComponentBody Flanges

Nozzles &

FlangesPacked

BedsTrays

Tray

Supports

Rings &

Clips

Vertical

Loads

Surface

Area

m2New Corroded New Corroded

Ellipsoidal Head Inlet 0 0 1.539,6 1.513,4 0 0 0 0 0 3,42

Shell- Inlet Chamber 0 0 551,6 530,8 0 0 0 0 0 0,78

Transition 0 0 0 0 0 0 0 0 0 0

Shellside 0 0 380,2 361,7 0 0 0 0 3.800 1,75

Shell Outlet Chamber 0 0 1.155 1.127,7 0 0 0 0 0 3,49

Ellipsoidal Head Outlet 0 0 31,8 31,3 0 0 0 0 0 0,05

TOTAL: 0 0 3.658,1 3.564,9 0 0 0 0 3.800 9,48

Vessel Totals

New Corroded

Operating Weight (kg) 32.967 32.384

Empty Weight (kg) 25.367 24.747

Test Weight (kg) 39.553 39.010

Surface Area (m2) 60,54 -

Capacity** (liters) 13.698 13.768

**The vessel capacity does not include

volume of nozzle, piping or other

attachments.

Vessel Lift Condition

Vessel Lift Weight, New (kg) 23.032

Center of Gravity from Datum (mm) 3.718,53

Note: Vessel lift weight includes weight of

insulation supports as they are assumed to be

shop installed.

3/25


Wind Code

Building Code: ASCE 7-95

Elevation of base above grade 16,40 ft (5,00 m)

Increase effective outer diameter by 1,64 ft (0,50 m)

Wind Force Coefficient, Cf 0,5900

Basic Wind Speed, V 61,5157 mph (99,0000 km/h)

Importance Factor, I 1,1500

Exposure Category C

Topographic Factor, Kzt 1,0000

Enforce minimum design load of 0.48 kPa per ASCE 6.4.1.2.: Yes

Hazardous, toxic, or explosive contents No

Wind Pressure (WP) Calculations

Kz = 2,01 * (Z/zg)2/α

= 2,01 * (6,86 / 274,32)0,2105

= 0,9244

qz = 0,613 * Kz * Kzt * V2 * I / 1000

= 0,613 * 0,9244 * 1,0000 * 27,50002 * 1,1500 /

1000

= 0,4931 kPa

qz = max[ 0,4931, 0,4788 ]

= 0,4931 kPa

Table Lookup Values

α = 9,5000, zg = 274,32 m [Table C6-2, page 152]

Shear calculations are reported in the saddle report.

4/25


Saddles


Saddle Material SA 516 Gr 60

Saddle Construction Centered web

Welded to Vessel Yes

Saddle Allowable Stress, Ss 1.406 kgf/cm2

Saddle Yield Stress, Sy 2.672 kgf/cm2

Foundation Allowable Stress 117 kgf/cm2

Design

PressureLeft Saddle Right Saddle

Operating 30,93 bar 30,93 bar

Test 41,51 bar 41,51 bar

Vacuum 1 bar

Dimensions

Right saddle distance to datum 7.600 mm

Tangent To Tangent Length, L 9.790,8 mm

Saddle separation, Ls 6.900 mm

Vessel Radius, R 750 mm

Tangent Distance Left, Al 750,8 mm

Tangent Distance Right, Ar 2.140 mm

Saddle Height, Hs 1.105 mm

Saddle Contact Angle, θ 85°

Web Plate Thickness, ts 20 mm

Base Plate Length, E 1.310 mm

Base Plate Width, F 300 mm

Base Plate Thickness, tb 20 mm

Number of Stiffening Ribs, n 4

Largest Stiffening Rib Spacing, di 425 mm

Stiffening Rib Thickness, tw 20 mm

Saddle Width, b 270 mm

Reinforcing Plate

Thickness, tp 20 mm

Width, Wp 400 mm

Contact Angle, θw 90°

Bolting

5/25


Material A283

Bolt Allowable Shear 1.055 kgf/cm2

Description 30 mm

Corrosion on root 1,6 mm

Anchor Bolts per Saddle 4

Base coefficient of friction, µ 0,45

Weight

Operating,

CorrodedHydrotest

Weight on Left Saddle 16.816,94 kg 19.874,15 kg

Weight on Right Saddle 14.988,05 kg 19.099,42 kg

Weight of Saddle Pair 579,69 kg

Notes

(1) Saddle calculations are based on the method presented in "Stresses in Large Cylindrical Pressure Vessels on

Two Saddle Supports" by L.P. Zick.

6/25


Stress Summary

Load Condition Saddle

Bending + pressure between saddles

(kgf/cm2)

Bending + pressure at the saddle

(kgf/cm2)

S1

(+)

allow

(+)

S1

(-)

allow

(-)

S2

(+)

allow

(+)

S2

(-)

allow

(-)

Wind

OperatingRight Saddle

525,341 1.811,015 86,201 1.100,72871,11 1.811,015 431,97 1.100,72

Left Saddle 174,75 1.811,015 17,587 1.259,159

TestRight Saddle

643,197 2.845,006 92,905 1.442,0931.046,94 2.845,006 496,648 1.442,093

Left Saddle 226,724 2.845,006 21,105 1.513,968

VacuumRight Saddle

86,201 1.811,015 100,398 1.100,72431,97 1.811,015 446,167 1.100,72

Left Saddle 17,587 1.811,015 22,668 1.259,159

Weight

OperatingRight Saddle

521,992 1.509,179 82,852 917,267871,11 1.509,179 431,97 917,267

Left Saddle 174,75 1.509,179 17,587 1.049,299

VacuumRight Saddle

82,852 1.509,179 97,05 917,267431,97 1.509,179 446,167 917,267

Left Saddle 17,587 1.509,179 22,668 1.049,299

7/25


Stress Summary

Load Condition Saddle

Tangential

shear (kgf/cm2)

Circumferential

stress (kgf/cm2)

Stress over

saddle (kgf/cm2)Splitting (kgf/cm2)

S3 allowS4

(horns)

allow

(+/-)S5 allow S6 allow

Wind

OperatingRight Saddle 114,209 1.207,343 -422,49 2.263,768 121,325 1.279,743 18,035 937,425

Left Saddle 60,602 1.207,343 -59,905 2.263,768 50,323 1.279,743 19,058 937,425

TestRight Saddle 129,878 2.276,005 -453,271 2.845,006 140,249 2.404,496 21,985 2.404,496

Left Saddle 67,11 2.276,005 -65,89 2.845,006 56,16 2.404,496 21,892 2.404,496

VacuumRight Saddle 114,209 1.207,343 -422,49 2.263,768 121,325 1.279,743 18,035 937,425

Left Saddle 60,602 1.207,343 -59,905 2.263,768 50,323 1.279,743 19,058 937,425

Weight

OperatingRight Saddle 101,798 1.207,343 -397,733 2.263,768 114,215 1.279,743 16,978 937,425

Left Saddle 57,736 1.207,343 -57,578 2.263,768 48,368 1.279,743 18,318 937,425

VacuumRight Saddle 101,798 1.207,343 -397,733 2.263,768 114,215 1.279,743 16,978 937,425

Left Saddle 57,736 1.207,343 -57,578 2.263,768 48,368 1.279,743 18,318 937,425

8/25


Saddle reactions due to weight + wind

Wind longitudinal reaction, Ql

Wind transverse reaction, Qt

Wind pressure, Pw 0,0049 bar

Equations

Vwt = Pw*G*(Cf(shell)*(Projected shell area) + Cf(saddle)*(Projected saddle area))

Vwe = Pw*G*(Cf(shell)*π*Ro2 + Cf(saddle)*(Projected saddle area))

Qt = Vwt*Hs / (Ro*Sin( θ / 2))

Ql = Vwe*Hs / Ls

Q = W + max[ Qt , Ql ]

Results

Operating

Right Saddle

Vwt = 0,005*0,85*10000*(0,59*14,8736 + 2*0,1161) 385,01 kgf

Vwe = 0,005*0,85*10000*(0,5*π*1,32 + 2*0,5899) 163,89 kgf

Qt = 385,01*1.105 / (675*Sin( 85 / 2)) 932,92 kgf

Ql = 163,89*1.105 / 6.900 26,25 kgf

Q = 14.988,05 + max[ 932,92 , 26,25 ] 15.920,97 kgf

Left Saddle

Vwt = 0,005*0,85*10000*(0,59*12,0339 + 2*0,0958) 311,66 kgf

Vwe = 0,005*0,85*10000*(0,5*π*1,32 + 2*0,5304) 158,81 kgf

Qt = 311,66*1.105 / (750*Sin( 85 / 2)) 679,68 kgf

Ql = 158,81*1.105 / 6.900 25,43 kgf

Q = 16.816,94 + max[ 679,68 , 25,43 ] 17.496,62 kgf

Test

Right Saddle

Vwt = 0,0017*0,85*10000*(0,59*14,8736 + 2*0,1161) 127,05 kgf

Vwe = 0,0017*0,85*10000*(0,5*π*1,32 + 2*0,5899) 54,08 kgf

Qt = 127,05*1.105 / (675*Sin( 85 / 2)) 307,86 kgf

Ql = 54,08*1.105 / 6.900 8,66 kgf

Q = 19.099,42 + max[ 307,86 , 8,66 ] 19.407,28 kgf

Left Saddle

Vwt = 0,0017*0,85*10000*(0,59*12,0339 + 2*0,0958) 102,85 kgf

Vwe = 0,0017*0,85*10000*(0,5*π*1,32 + 2*0,5304) 52,41 kgf

Qt = 102,85*1.105 / (750*Sin( 85 / 2)) 224,29 kgf

Ql = 52,41*1.105 / 6.900 8,39 kgf

Q = 19.874,15 + max[ 224,29 , 8,39 ] 20.098,45 kgf

Load Case 1: Wind, Operating

Longitudinal stress between saddles (Wind, Operating, left saddle loading and geometry govern)

9/25


S1 = ± 3*K1*Q*(L / 12) / (π*R2*t)

= 300*0,651*17.496,62*(9.790,8 / 12) / (π*663,32*23,4)

= 86,201 kgf/cm2

Sp = P*R / (2*t)

= 31,54*651,6 / (2*23,4)

= 439,14 kgf/cm2

Maximum tensile stress S1t = S1 + Sp = 525,341 kgf/cm2

Maximum compressive stress (shut down) S1c = S1 = 86,201 kgf/cm2

Tensile stress is acceptable ( ≤ 1,2*S*E = 1.811,015 kgf/cm2)

Compressive stress is acceptable ( ≤ 1,2*Sc = 1.100,72 kgf/cm2)

Longitudinal stress at the right saddle (Wind, Operating)

Le = 2*(Left head depth) / 3 + L + 2*(Right head depth) / 3

= 2*390 / 3 + 9.790,8 + 2*347,5 / 3

= 10.282,47 mm

w = Wt / Le = 31.804,99*10 / 10.282,47 = 30,93 kgf/cm

Bending moment at the right saddle:

Mq = w*(2*H*Ar / 3 + Ar2 / 2 - (R2 - H2) / 4)

= 30,93 / 10000*(2*347,5*2.140 / 3 + 2.1402 / 2 - (6752 - 347,52) / 4)

= 8.357,1 kgf-m

S2 = ± Mq*K1' / (π*R2*t)

= 8.357,1*1e5*16,7177 / (π*663,32*23,4)

= 431,97 kgf/cm2

Sp = P*R / (2*t)

= 31,54*651,6 / (2*23,4)

= 439,14 kgf/cm2



Tensile stress is acceptable ( ≤ 1,2*S = 1.811,015 kgf/cm2)


Tangential shear stress in the shell (right saddle, Wind, Operating)

Qshear = Q - w*(a + 2*H / 3)

= 15.920,97 - 3,09*(2.140 + 2*347,5 / 3)

= 8.585,1 kgf

S3 = K2,2*Qshear / (R*t)

= K2,2*100*8.585,1 / (663,3*23,4)

= 114,209 kgf/cm2

Tangential shear stress is acceptable ( ≤ 0.8*S = 1.207,343 kgf/cm2)

Circumferential stress at the right saddle horns (Wind, Operating)

S4 = -Q / (4*t*(b+1,56*Sqr(Ro*t))) - 3*K3*Q / (2*t2)

10/25


= -100*15.920,97 / (4*23,4*(270+1,56*Sqr(675*23,4))) - 3*0,0885*100*15.920,97 / (2*23,42)

= -422,49 kgf/cm2

Circumferential stress at saddle horns is acceptable ( ≤ 1,5*Sa = 2.263,768 kgf/cm2)

The wear plate was not considered in the calculation of S4 because the wear plate contact angle did not exceed the

saddle contact angle by at least 11,46° and the wear plate width is not at least {b + 1,56*(Ro*t)0,5} =466,06 mm

Ring compression in shell over right saddle (Wind, Operating)

S5 = K5*Q / ((t + tp)*(ts + 1,56*Sqr(Ro*tc)))

= 100*0,9492*15.920,97 / ((23,4 + 20)*(20 + 1,56*Sqr(675*43,4)))

= 121,325 kgf/cm2

Ring compression in shell is acceptable ( ≤ 0,5*Sy = 1.279,743 kgf/cm2)

Saddle splitting load (right, Wind, Operating)

Area resisting splitting force = Web area + wear plate area

Ae = Heff*ts + tp*Wp

= 22,5*2 + 2*40

= 125 cm2

S6 = K8*Q / Ae

= 100*0,1416*15.920,97 / 12.500

= 18,035 kgf/cm2

Stress in saddle is acceptable ( ≤ (2 / 3)*Ss = 937,425 kgf/cm2)

Longitudinal stress at the left saddle (Wind, Operating)


= 2*390 / 3 + 9.790,8 + 2*347,5 / 3

= 10.282,47 mm

w = Wt / Le = 31.804,99*10 / 10.282,47 = 30,93 kgf/cm

Bending moment at the left saddle:

Mq = w*(2*H*Al / 3 + Al2 / 2 - (R2 - H2) / 4)

= 30,93 / 10000*(2*390*750,8 / 3 + 750,82 / 2 - (7502 - 3902) / 4)

= 1.158,2 kgf-m

S2 = ± Mq*K1' / (π*R2*t)

= 1.158,2*1e5*16,7177 / (π*715,82*68,4)

= 17,587 kgf/cm2

Sp = P*R / (2*t)

= 31,54*681,6 / (2*68,4)

= 157,163 kgf/cm2





11/25


Tangential shear stress in the shell (left saddle, Wind, Operating)

Qshear = Q - w*(a + 2*H / 3)

= 17.496,62 - 3,09*(750,8 + 2*390 / 3)

= 14.370,09 kgf


= K2,2*100*14.370,09 / (715,8*68,4)

= 60,602 kgf/cm2


Circumferential stress at the left saddle horns (Wind, Operating)

S4 = -Q / (4*t*(b+1,56*Sqr(Ro*t))) - 3*K3*Q / (2*t2)

= -100*17.496,62 / (4*68,4*(270+1,56*Sqr(750*68,4))) - 3*0,0885*100*17.496,62 / (2*68,42)

= -59,905 kgf/cm2




Ring compression in shell over left saddle (Wind, Operating)


= 100*0,9492*17.496,62 / ((68,4 + 20)*(20 + 1,56*Sqr(750*68,4)))

= 50,323 kgf/cm2


Saddle splitting load (left, Wind, Operating)



= 25*2 + 2*40

= 130 cm2

S6 = K8*Q / Ae

= 100*0,1416*17.496,62 / 13.000

= 19,058 kgf/cm2


Load Case 2: Wind, Test

Longitudinal stress between saddles (Wind, Test, left saddle loading and geometry govern)

S1 = ± 3*K1*Q*(L / 12) / (π*R2*t)

= 300*0,651*20.098,45*(9.790,8 / 12) / (π*662,52*25)

= 92,905 kgf/cm2

Sp = P*R / (2*t)

= 42,33*650 / (2*25)

= 550,292 kgf/cm2


12/25



Tensile stress is acceptable ( ≤ 0,9*Sy*E = 2.845,006 kgf/cm2)


Longitudinal stress at the right saddle (Wind, Test)


= 2*390 / 3 + 9.790,8 + 2*347,5 / 3

= 10.282,47 mm

w = Wt / Le = 38.973,57*10 / 10.282,47 = 37,9 kgf/cm


Mq = w*(2*H*Ar / 3 + Ar2 / 2 - (R2 - H2) / 4)

= 37,9 / 10000*(2*347,5*2.140 / 3 + 2.1402 / 2 - (6752 - 347,52) / 4)

= 10.240,8 kgf-m

S2 = ± Mq*K1' / (π*R2*t)

= 10.240,8*1e5*16,7177 / (π*662,52*25)

= 496,648 kgf/cm2

Sp = P*R / (2*t)

= 42,33*650 / (2*25)

= 550,292 kgf/cm2

Maximum tensile stress S2t = S2 + Sp = 1.046,94 kgf/cm2


Tensile stress is acceptable ( ≤ 0,9*Sy = 2.845,006 kgf/cm2)


Tangential shear stress in the shell (right saddle, Wind, Test)

Qshear = Q - w*(a + 2*H / 3)

= 19.407,28 - 3,79*(2.140 + 2*347,5 / 3)

= 10.417,97 kgf


= K2,2*100*10.417,97 / (662,5*25)

= 129,878 kgf/cm2


Circumferential stress at the right saddle horns (Wind, Test)

S4 = -Q / (4*t*(b+1,56*Sqr(Ro*t))) - 3*K3*Q / (2*t2)

= -100*19.407,28 / (4*25*(270+1,56*Sqr(675*25))) - 3*0,0885*100*19.407,28 / (2*252)

= -453,271 kgf/cm2

Circumferential stress at saddle horns is acceptable ( ≤ 0,9*Sy = 2.845,006 kgf/cm2)



Ring compression in shell over right saddle (Wind, Test)

13/25



= 100*0,9492*19.407,28 / ((25 + 20)*(20 + 1,56*Sqr(675*45)))

= 140,249 kgf/cm2


Saddle splitting load (right, Wind, Test)



= 22,5*2 + 2*40

= 125 cm2

S6 = K8*Q / Ae

= 100*0,1416*19.407,28 / 12.500

= 21,985 kgf/cm2

Stress in saddle is acceptable ( ≤ 0,9*Sy = 2.404,496 kgf/cm2)

Longitudinal stress at the left saddle (Wind, Test)


= 2*390 / 3 + 9.790,8 + 2*347,5 / 3

= 10.282,47 mm

w = Wt / Le = 38.973,57*10 / 10.282,47 = 37,9 kgf/cm


Mq = w*(2*H*Al / 3 + Al2 / 2 - (R2 - H2) / 4)

= 37,9 / 10000*(2*390*750,8 / 3 + 750,82 / 2 - (7502 - 3902) / 4)

= 1.419,3 kgf-m

S2 = ± Mq*K1' / (π*R2*t)

= 1.419,3*1e5*16,7177 / (π*7152*70)

= 21,105 kgf/cm2

Sp = P*R / (2*t)

= 42,33*680 / (2*70)

= 205,618 kgf/cm2



Tensile stress is acceptable ( ≤ 0,9*Sy = 2.845,006 kgf/cm2)


Tangential shear stress in the shell (left saddle, Wind, Test)

Qshear = Q - w*(a + 2*H / 3)

= 20.098,45 - 3,79*(750,8 + 2*390 / 3)

= 16.267,22 kgf


= K2,2*100*16.267,22 / (715*70)

= 67,11 kgf/cm2

14/25



Circumferential stress at the left saddle horns (Wind, Test)

S4 = -Q / (4*t*(b+1,56*Sqr(Ro*t))) - 3*K3*Q / (2*t2)

= -100*20.098,45 / (4*70*(270+1,56*Sqr(750*70))) - 3*0,0885*100*20.098,45 / (2*702)

= -65,89 kgf/cm2

Circumferential stress at saddle horns is acceptable ( ≤ 0,9*Sy = 2.845,006 kgf/cm2)



Ring compression in shell over left saddle (Wind, Test)


= 100*0,9492*20.098,45 / ((70 + 20)*(20 + 1,56*Sqr(750*70)))

= 56,16 kgf/cm2


Saddle splitting load (left, Wind, Test)



= 25*2 + 2*40

= 130 cm2

S6 = K8*Q / Ae

= 100*0,1416*20.098,45 / 13.000

= 21,892 kgf/cm2

Stress in saddle is acceptable ( ≤ 0,9*Sy = 2.404,496 kgf/cm2)

Load Case 3: Wind, Vacuum

Longitudinal stress between saddles (Wind, Vacuum, left saddle loading and geometry govern)

S1 = ± 3*K1*Q*(L / 12) / (π*R2*t)

= 300*0,651*17.496,62*(9.790,8 / 12) / (π*663,32*23,4)

= 86,201 kgf/cm2

Sp = P*R / (2*t)

= 1,02*651,6 / (2*23,4)

= 14,198 kgf/cm2

Maximum tensile stress (shut down) S1t = S1 = 86,201 kgf/cm2

Maximum compressive stress S1c = S1 + Sp = 100,398 kgf/cm2

Tensile stress is acceptable ( ≤ 1,2*S*E = 1.811,015 kgf/cm2)


Longitudinal stress at the right saddle (Wind, Vacuum)


= 2*390 / 3 + 9.790,8 + 2*347,5 / 3

15/25


= 10.282,47 mm

w = Wt / Le = 31.804,99*10 / 10.282,47 = 30,93 kgf/cm


Mq = w*(2*H*Ar / 3 + Ar2 / 2 - (R2 - H2) / 4)

= 30,93 / 10000*(2*347,5*2.140 / 3 + 2.1402 / 2 - (6752 - 347,52) / 4)

= 8.357,1 kgf-m

S2 = ± Mq*K1' / (π*R2*t)

= 8.357,1*1e5*16,7177 / (π*663,32*23,4)

= 431,97 kgf/cm2

Sp = P*R / (2*t)

= 1,02*651,6 / (2*23,4)

= 14,198 kgf/cm2





Tangential shear stress in the shell (right saddle, Wind, Vacuum)

Qshear = Q - w*(a + 2*H / 3)

= 15.920,97 - 3,09*(2.140 + 2*347,5 / 3)

= 8.585,1 kgf


= K2,2*100*8.585,1 / (663,3*23,4)

= 114,209 kgf/cm2


Circumferential stress at the right saddle horns (Wind, Vacuum)

S4 = -Q / (4*t*(b+1,56*Sqr(Ro*t))) - 3*K3*Q / (2*t2)

= -100*15.920,97 / (4*23,4*(270+1,56*Sqr(675*23,4))) - 3*0,0885*100*15.920,97 / (2*23,42)

= -422,49 kgf/cm2




Ring compression in shell over right saddle (Wind, Vacuum)


= 100*0,9492*15.920,97 / ((23,4 + 20)*(20 + 1,56*Sqr(675*43,4)))

= 121,325 kgf/cm2


Saddle splitting load (right, Wind, Vacuum)


16/25



= 22,5*2 + 2*40

= 125 cm2

S6 = K8*Q / Ae

= 100*0,1416*15.920,97 / 12.500

= 18,035 kgf/cm2


Longitudinal stress at the left saddle (Wind, Vacuum)


= 2*390 / 3 + 9.790,8 + 2*347,5 / 3

= 10.282,47 mm

w = Wt / Le = 31.804,99*10 / 10.282,47 = 30,93 kgf/cm


Mq = w*(2*H*Al / 3 + Al2 / 2 - (R2 - H2) / 4)

= 30,93 / 10000*(2*390*750,8 / 3 + 750,82 / 2 - (7502 - 3902) / 4)

= 1.158,2 kgf-m

S2 = ± Mq*K1' / (π*R2*t)

= 1.158,2*1e5*16,7177 / (π*715,82*68,4)

= 17,587 kgf/cm2

Sp = P*R / (2*t)

= 1,02*681,6 / (2*68,4)

= 5,081 kgf/cm2





Tangential shear stress in the shell (left saddle, Wind, Vacuum)

Qshear = Q - w*(a + 2*H / 3)

= 17.496,62 - 3,09*(750,8 + 2*390 / 3)

= 14.370,09 kgf


= K2,2*100*14.370,09 / (715,8*68,4)

= 60,602 kgf/cm2


Circumferential stress at the left saddle horns (Wind, Vacuum)

S4 = -Q / (4*t*(b+1,56*Sqr(Ro*t))) - 3*K3*Q / (2*t2)

= -100*17.496,62 / (4*68,4*(270+1,56*Sqr(750*68,4))) - 3*0,0885*100*17.496,62 / (2*68,42)

= -59,905 kgf/cm2

17/25





Ring compression in shell over left saddle (Wind, Vacuum)


= 100*0,9492*17.496,62 / ((68,4 + 20)*(20 + 1,56*Sqr(750*68,4)))

= 50,323 kgf/cm2


Saddle splitting load (left, Wind, Vacuum)



= 25*2 + 2*40

= 130 cm2

S6 = K8*Q / Ae

= 100*0,1416*17.496,62 / 13.000

= 19,058 kgf/cm2


Load Case 4: Weight, Operating

Longitudinal stress between saddles (Weight, Operating, left saddle loading and geometry govern)

S1 = ± 3*K1*Q*(L / 12) / (π*R2*t)

= 300*0,651*16.816,94*(9.790,8 / 12) / (π*663,32*23,4)

= 82,852 kgf/cm2

Sp = P*R / (2*t)

= 31,54*651,6 / (2*23,4)

= 439,14 kgf/cm2



Tensile stress is acceptable ( ≤ S*E = 1.509,179 kgf/cm2)

Compressive stress is acceptable ( ≤ Sc = 917,267 kgf/cm2)

Longitudinal stress at the right saddle (Weight, Operating)


= 2*390 / 3 + 9.790,8 + 2*347,5 / 3

= 10.282,47 mm

w = Wt / Le = 31.804,99*10 / 10.282,47 = 30,93 kgf/cm


Mq = w*(2*H*Ar / 3 + Ar2 / 2 - (R2 - H2) / 4)

= 30,93 / 10000*(2*347,5*2.140 / 3 + 2.1402 / 2 - (6752 - 347,52) / 4)

= 8.357,1 kgf-m

18/25


S2 = ± Mq*K1' / (π*R2*t)

= 8.357,1*1e5*16,7177 / (π*663,32*23,4)

= 431,97 kgf/cm2

Sp = P*R / (2*t)

= 31,54*651,6 / (2*23,4)

= 439,14 kgf/cm2



Tensile stress is acceptable ( ≤ S = 1.509,179 kgf/cm2)


Tangential shear stress in the shell (right saddle, Weight, Operating)

Qshear = Q - w*(a + 2*H / 3)

= 14.988,05 - 3,09*(2.140 + 2*347,5 / 3)

= 7.652,18 kgf


= K2,2*100*7.652,18 / (663,3*23,4)

= 101,798 kgf/cm2


Circumferential stress at the right saddle horns (Weight, Operating)

S4 = -Q / (4*t*(b+1,56*Sqr(Ro*t))) - 3*K3*Q / (2*t2)

= -100*14.988,05 / (4*23,4*(270+1,56*Sqr(675*23,4))) - 3*0,0885*100*14.988,05 / (2*23,42)

= -397,733 kgf/cm2




Ring compression in shell over right saddle (Weight, Operating)


= 100*0,9492*14.988,05 / ((23,4 + 20)*(20 + 1,56*Sqr(675*43,4)))

= 114,215 kgf/cm2


Saddle splitting load (right, Weight, Operating)



= 22,5*2 + 2*40

= 125 cm2

S6 = K8*Q / Ae

= 100*0,1416*14.988,05 / 12.500

= 16,978 kgf/cm2

19/25



Longitudinal stress at the left saddle (Weight, Operating)


= 2*390 / 3 + 9.790,8 + 2*347,5 / 3

= 10.282,47 mm

w = Wt / Le = 31.804,99*10 / 10.282,47 = 30,93 kgf/cm


Mq = w*(2*H*Al / 3 + Al2 / 2 - (R2 - H2) / 4)

= 30,93 / 10000*(2*390*750,8 / 3 + 750,82 / 2 - (7502 - 3902) / 4)

= 1.158,2 kgf-m

S2 = ± Mq*K1' / (π*R2*t)

= 1.158,2*1e5*16,7177 / (π*715,82*68,4)

= 17,587 kgf/cm2

Sp = P*R / (2*t)

= 31,54*681,6 / (2*68,4)

= 157,163 kgf/cm2




Compressive stress is acceptable ( ≤ Sc = 1.049,299 kgf/cm2)

Tangential shear stress in the shell (left saddle, Weight, Operating)

Qshear = Q - w*(a + 2*H / 3)

= 16.816,94 - 3,09*(750,8 + 2*390 / 3)

= 13.690,4 kgf


= K2,2*100*13.690,4 / (715,8*68,4)

= 57,736 kgf/cm2


Circumferential stress at the left saddle horns (Weight, Operating)

S4 = -Q / (4*t*(b+1,56*Sqr(Ro*t))) - 3*K3*Q / (2*t2)

= -100*16.816,94 / (4*68,4*(270+1,56*Sqr(750*68,4))) - 3*0,0885*100*16.816,94 / (2*68,42)

= -57,578 kgf/cm2




Ring compression in shell over left saddle (Weight, Operating)


= 100*0,9492*16.816,94 / ((68,4 + 20)*(20 + 1,56*Sqr(750*68,4)))

= 48,368 kgf/cm2

20/25



Saddle splitting load (left, Weight, Operating)



= 25*2 + 2*40

= 130 cm2

S6 = K8*Q / Ae

= 100*0,1416*16.816,94 / 13.000

= 18,318 kgf/cm2


Load Case 5: Weight, Vacuum

Longitudinal stress between saddles (Weight, Vacuum, left saddle loading and geometry govern)

S1 = ± 3*K1*Q*(L / 12) / (π*R2*t)

= 300*0,651*16.816,94*(9.790,8 / 12) / (π*663,32*23,4)

= 82,852 kgf/cm2

Sp = P*R / (2*t)

= 1,02*651,6 / (2*23,4)

= 14,198 kgf/cm2



Tensile stress is acceptable ( ≤ S*E = 1.509,179 kgf/cm2)


Longitudinal stress at the right saddle (Weight, Vacuum)


= 2*390 / 3 + 9.790,8 + 2*347,5 / 3

= 10.282,47 mm

w = Wt / Le = 31.804,99*10 / 10.282,47 = 30,93 kgf/cm


Mq = w*(2*H*Ar / 3 + Ar2 / 2 - (R2 - H2) / 4)

= 30,93 / 10000*(2*347,5*2.140 / 3 + 2.1402 / 2 - (6752 - 347,52) / 4)

= 8.357,1 kgf-m

S2 = ± Mq*K1' / (π*R2*t)

= 8.357,1*1e5*16,7177 / (π*663,32*23,4)

= 431,97 kgf/cm2

Sp = P*R / (2*t)

= 1,02*651,6 / (2*23,4)

= 14,198 kgf/cm2

21/25






Tangential shear stress in the shell (right saddle, Weight, Vacuum)

Qshear = Q - w*(a + 2*H / 3)

= 14.988,05 - 3,09*(2.140 + 2*347,5 / 3)

= 7.652,18 kgf


= K2,2*100*7.652,18 / (663,3*23,4)

= 101,798 kgf/cm2


Circumferential stress at the right saddle horns (Weight, Vacuum)

S4 = -Q / (4*t*(b+1,56*Sqr(Ro*t))) - 3*K3*Q / (2*t2)

= -100*14.988,05 / (4*23,4*(270+1,56*Sqr(675*23,4))) - 3*0,0885*100*14.988,05 / (2*23,42)

= -397,733 kgf/cm2




Ring compression in shell over right saddle (Weight, Vacuum)


= 100*0,9492*14.988,05 / ((23,4 + 20)*(20 + 1,56*Sqr(675*43,4)))

= 114,215 kgf/cm2


Saddle splitting load (right, Weight, Vacuum)



= 22,5*2 + 2*40

= 125 cm2

S6 = K8*Q / Ae

= 100*0,1416*14.988,05 / 12.500

= 16,978 kgf/cm2


Longitudinal stress at the left saddle (Weight, Vacuum)


= 2*390 / 3 + 9.790,8 + 2*347,5 / 3

= 10.282,47 mm

w = Wt / Le = 31.804,99*10 / 10.282,47 = 30,93 kgf/cm

22/25



Mq = w*(2*H*Al / 3 + Al2 / 2 - (R2 - H2) / 4)

= 30,93 / 10000*(2*390*750,8 / 3 + 750,82 / 2 - (7502 - 3902) / 4)

= 1.158,2 kgf-m

S2 = ± Mq*K1' / (π*R2*t)

= 1.158,2*1e5*16,7177 / (π*715,82*68,4)

= 17,587 kgf/cm2

Sp = P*R / (2*t)

= 1,02*681,6 / (2*68,4)

= 5,081 kgf/cm2




Compressive stress is acceptable ( ≤ Sc = 1.049,299 kgf/cm2)

Tangential shear stress in the shell (left saddle, Weight, Vacuum)

Qshear = Q - w*(a + 2*H / 3)

= 16.816,94 - 3,09*(750,8 + 2*390 / 3)

= 13.690,4 kgf


= K2,2*100*13.690,4 / (715,8*68,4)

= 57,736 kgf/cm2


Circumferential stress at the left saddle horns (Weight, Vacuum)

S4 = -Q / (4*t*(b+1,56*Sqr(Ro*t))) - 3*K3*Q / (2*t2)

= -100*16.816,94 / (4*68,4*(270+1,56*Sqr(750*68,4))) - 3*0,0885*100*16.816,94 / (2*68,42)

= -57,578 kgf/cm2




Ring compression in shell over left saddle (Weight, Vacuum)


= 100*0,9492*16.816,94 / ((68,4 + 20)*(20 + 1,56*Sqr(750*68,4)))

= 48,368 kgf/cm2


Saddle splitting load (left, Weight, Vacuum)



= 25*2 + 2*40

23/25


= 130 cm2

S6 = K8*Q / Ae

= 100*0,1416*16.816,94 / 13.000

= 18,318 kgf/cm2


Shear stress in anchor bolting, one end slotted

Maximum seismic or wind base shear = 163,89 kgf

Thermal expansion base shear = W*µ = 17.106,78*0,45 = 7.698,05 kgf

Corroded root area for a 30 mm bolt = 4,1587 cm2 ( 4 per saddle )

Bolt shear stress = 7.698,05 / (4,1587*1*4) = 462,768 kgf/cm2

Anchor bolt stress is acceptable ( ≤ 1.054,604 kgf/cm2)

Shear stress in anchor bolting, transverse

Maximum seismic or wind base shear = 696,67 kgf

Corroded root area for a 30 mm bolt = 4,1587 cm2 ( 4 per saddle )

Bolt shear stress = 696,67 / (4,1587*2*4) = 20,94 kgf/cm2

Anchor bolt stress is acceptable ( ≤ 1.054,604 kgf/cm2)

Web plate buckling check (Escoe pg 251)

Allowable compressive stress Sc is the lesser of 1.406,138 or 5.223,543 kgf/cm2: (1.406,138)

Sc = Ki*π2*E / (12*(1 - 0,32)*(di / ts)2)

= 1,28*π2*20,39E+05 / (12*(1 - 0,32)*(425 / 20)2)

= 5.223,543 kgf/cm2

Allowable compressive load on the saddle

be = di*ts / (di*ts + 2*tw*(b - 25.4))*25.4

= 425*20 / (425*20 + 2*20*(270 - 25.4))*25.4

= 11,81

Fb = n*(As + 2*be*ts)*Sc

= 4*(5.000 + 2*11,81*20)*1.406,138

= 307.794,07 kgf

Saddle loading of 20.388,29 kgf is ≤ Fb; satisfactory.

Primary bending + axial stress in the saddle due to end loads (assumes one saddle slotted)

σb = V*(Hs - xo)*y / I + Q / A

= 158,81*(1.105 - 614,78)*135 / (100*13.175,33) + 100*17.496,62 / 38.240,94

= 53,73 kgf/cm2

The primary bending + axial stress in the saddle ≤ Ss = 1.406,138 kgf/cm2; satisfactory.

Secondary bending + axial stress in the saddle due to end loads (includes thermal expansion, assumes one

saddle slotted)

24/25


σb = V*(Hs - xo)*y / I + Q / A

= 7.856,86*(1.105 - 614,78)*135 / (100*13.175,33) + 100*17.496,62 / 38.240,94

= 440,402 kgf/cm2

The secondary bending + axial stress in the saddle ≤ 2*Sy = 5.343,324 kgf/cm2; satisfactory.

Saddle base plate thickness check (Roark sixth edition, Table 26, case 7a)

where a = 425, b = 140 mm

tb = (β1*q*b2 / (1,5*Sa))0,5

= (3*5,188*1402 / (1,5*1.406,138))0,5

= 12,03 mm

The base plate thickness of 20 mm is adequate.

Foundation bearing check

Sf = Qmax / (F*E)

= 20.388,29 / (300*1.310)

= 5,188 kgf/cm2

Concrete bearing stress ≤ 116,569 kgf/cm2 ; satisfactory.

25/25




www.bertsch.at



Vessel No: Shellside



Designer: Pirker

Date: 19.01.2017


Table of ContentsNozzle Schedule........................................................................................................................................................1/46

Nozzle Summary.......................................................................................................................................................2/46

Pressure Summary...................................................................................................................................................3/46

Revision History........................................................................................................................................................4/46

Radiography Summary.............................................................................................................................................5/46

Thickness Summary.................................................................................................................................................6/46

Hydrostatic Test........................................................................................................................................................7/46

Vacuum Summary.....................................................................................................................................................9/46

Shellside..................................................................................................................................................................10/46

Inspection Nozzle (A01, A02).................................................................................................................................13/46

Riser / Downcomer (R01- 02, D01-02)....................................................................................................................23/46

Blow Down Nozzle (N03, N04)................................................................................................................................36/46

i


Nozzle Schedule

Specifications

Nozzle

markIdentifier Size Materials

Impact

TestedNormalized Fine Grain Flange Blind

A01, A02 Inspection Nozzle 117,35 OD x 20,57 Nozzle SA-182 F1 No No NoNPS 3 Class 600

LWN A182 F1

NPS 3 Class 600

A182 F1

A02 Inspection Nozzle 117,35 OD x 20,57 Nozzle SA-182 F1 No No NoNPS 3 Class 600

LWN A182 F1

NPS 3 Class 600

A182 F1

D01 Downcomer 325 OD x 41,1 Nozzle SA-182 F1 No No No N/A No

D02 Downcomer 325 OD x 41,1 Nozzle SA-182 F1 No No No N/A No

N03, N04 Blow Down Nozzle 84,07 OD x 16,64 Nozzle SA-182 F1 No No NoNPS 2 Class 600

LWN A182 F1No

N04 Drain Nozzle 84,07 OD x 16,64 Nozzle SA-182 F1 No No NoNPS 2 Class 600

LWN A182 F1No

R01 Riser 325 OD x 41,1 Nozzle SA-182 F1 No No No N/A No

R01- 02, D01-02 Riser / Downcomer 325 OD x 41,1 Nozzle SA-182 F1 No No No N/A No

R03 Riser 263,7 OD x 35 Nozzle SA-182 F1 No No No N/A No

1/46


Nozzle Summary

Dimensions

Nozzle

mark

OD

(mm)

tn(mm)

Req tn(mm)

A1? A2?

ShellReinforcement

Pad Corr

(mm)

Aa/Ar

(%)Nom t

(mm)

Design t

(mm)

User t

(mm)

Width

(mm)

tpad

(mm)

A01, A02 117,35 20,57 7,33 Yes Yes 25 20,54 N/A N/A 1,6 129,6

A02 117,35 20,57 7,33 Yes Yes 25 20,54 N/A N/A 1,6 129,6

D01 325 41,1 9,71 Yes Yes 25 20,54 N/A N/A 1,6 105,9

D02 325 41,1 9,71 Yes Yes 25 20,54 N/A N/A 1,6 105,9

N03, N04 84,07 16,64 6,4 Yes Yes 25 N/A N/A N/A 1,6 Exempt

N04 84,07 16,64 6,4 Yes Yes 25 N/A N/A N/A 1,6 Exempt

R01 325 41,1 9,71 Yes Yes 25 20,54 N/A N/A 1,6 105,9

R01- 02, D01-02 325 41,1 9,71 Yes Yes 25 20,54 N/A N/A 1,6 105,9

R03 263,7 35 9,71 Yes Yes 25 20,54 N/A N/A 1,6 111,2

Definitions

tn Nozzle thickness

Req tn Nozzle thickness required per UG-45/UG-16

Nom t Vessel wall thickness

Design t Required vessel wall thickness due to pressure + corrosion allowance per UG-37

User t Local vessel wall thickness (near opening)

Aa Area available per UG-37, governing condition

Ar Area required per UG-37, governing condition

Corr Corrosion allowance on nozzle wall

2/46


Pressure Summary

Component Summary

Identifier

P

Design

(bar)

T

Design

(°C)

MAWP

(bar)

MAP

(bar)

MDMT

(°C)

MDMT

Exemption

Impact

Tested

Shellside 42 260 52,03 55,64 -30,7 Note 1 Yes

Inspection Nozzle (A01, A02) 42 260 48,06 54,64 -48 Note 2 No

Inspection Nozzle (A02) 42 260 48,06 54,64 -48 Note 2 No

Downcomer (D01) 42 260 43,23 47,12 -12,2 Note 3 No

Downcomer (D02) 42 260 43,23 47,12 -12,2 Note 3 No

Blow Down Nozzle (N03, N04) 42 260 52,03 55,64 -48 Note 2 No

Drain Nozzle (N04) 42 260 52,03 55,64 -48 Note 2 No

Riser (R01) 42 260 43,23 47,12 -12,2 Note 3 No

Riser / Downcomer (R01- 02, D01-02) 42 260 43,23 47,12 -12,2 Note 3 No

Riser (R03) 42 260 44,34 48,59 -12,2 Note 3 No

Chamber Summary

Design MDMT -5,4 °C

Rated MDMT -12,2 °C @ 43,23 bar

MAWP hot & corroded 42 bar @ 260 °C

MAP cold & new 47,12 bar @ 25 °C

MAEP 1 bar

(1) The MAWP is limited due to the MAWP limit

set in the Calculations tab of the Set Mode

dialog.

Notes for Maximum Pressure Rating

Note # Details

1. Option to calculate MAEP was not selected. See the Calculation->General tab of the Set Mode dialog.

Notes for MDMT Rating

Note # Exemption Details

1. Material is impact tested per UG-84 to -20°C. UCS-66(i) reduction of 10,7°C applied (ratio = 0,8094).

2.

LWN rated MDMT per UCS-66(c)(4)

Flange rated MDMT per UCS-66(b)(1)(b) = -48°C (Coincident ratio = 0,4375)

Bolts rated MDMT per Fig UCS-66 note (c) = -48°C

3.Nozzle impact test exemption temperature from Fig UCS-66M Curve B = -1,5°C

Fig UCS-66.1M MDMT reduction = 10,7°C, (coincident ratio = 0,8094)UCS-66 governing thickness = 25 mm.

3/46


Revision History

Revisions

No. Date Operator Notes

0 12/19/2016 ph New vessel created ASME Section VIII Division 1 [COMPRESS 2015 Build 7510]

4/46


Radiography Summary

UG-116 Radiography

Component

Longitudinal Seam Left Circumferential Seam Right Circumferential Seam

MarkCategory

(Fig

UW-3)

Radiography / Joint

Type

Category

(Fig

UW-3)

Radiography / Joint

Type

Category

(Fig

UW-3)

Radiography / Joint

Type

Shellside AFull UW-11(a) / Type

1B

Full UW-11(a) / Type

1B

Full UW-11(a) / Type

1RT1

Nozzle Longitudinal SeamNozzle to Vessel Circumferential

Seam

Nozzle free end Circumferential

Seam

Inspection Nozzle (A01, A02) N/A Seamless No RT D N/A / Type 7 C N/A N/A

Riser (R01) N/A Seamless No RT D N/A / Type 7 N/A N/A N/A

Riser (R03) N/A Seamless No RT D N/A / Type 7 N/A N/A N/A

Riser / Downcomer (R01- 02, D01-02) N/A Seamless No RT D N/A / Type 7 N/A N/A N/A

Downcomer (D01) N/A Seamless No RT D N/A / Type 7 N/A N/A N/A

Downcomer (D02) N/A Seamless No RT D N/A / Type 7 N/A N/A N/A

Inspection Nozzle (A02) N/A Seamless No RT D N/A / Type 7 C N/A N/A

Blow Down Nozzle (N03, N04) N/A Seamless No RT D N/A / Type 7 C N/A N/A

Drain Nozzle (N04) N/A Seamless No RT D N/A / Type 7 C N/A N/A

Nozzle Flange Longitudinal Seam Flange FaceNozzle to Flange Circumferential

Seam

ASME B16.5/16.47 flange attached to

Inspection Nozzle (A01, A02)N/A Seamless No RT N/A N/A / Gasketed C N/A N/A


Inspection Nozzle (A02)N/A Seamless No RT N/A N/A / Gasketed C N/A N/A

ASME B16.5/16.47 flange attached to Blow

Down Nozzle (N03, N04)N/A Seamless No RT N/A N/A / Gasketed C N/A N/A

ASME B16.5/16.47 flange attached to Drain

Nozzle (N04)N/A Seamless No RT N/A N/A / Gasketed C N/A N/A

UG-116(e) Required Marking: RT1

5/46


Thickness Summary

Component Data

Component

IdentifierMaterial Diameter

(mm)

Length

(mm)

Nominal t

(mm)

Design t

(mm)

Total Corrosion

(mm)

Joint

ELoad

Shellside SA-387 11 2 1.350 OD 6.400 25 20,54 1,6 1,00 Internal

Definitions

Nominal t Vessel wall nominal thickness

Design t Required vessel thickness due to governing loading + corrosion

Joint E Longitudinal seam joint efficiency

Load

Internal Circumferential stress due to internal pressure governs

External External pressure governs

WindCombined longitudinal stress of pressure + weight + wind

governs

SeismicCombined longitudinal stress of pressure + weight + seismic

governs

6/46


Hydrostatic Test

Horizontal shop hydrostatic test based on MAWP per UG-99(b)

Gauge pressure at 25°C = 1,3*MAWP*LSR

= 1,3*42*1

= 54,6 bar

Horizontal shop hydrostatic test

IdentifierLocal testpressure

(bar)

Test liquidstatic head

(bar)

UG-99(b)stressratio

UG-99(b)pressure

factor

Shellside (1) 54,75 0,15 1 1,30

Blow Down Nozzle (N03, N04) 54,78 0,18 1 1,30

Downcomer (D01) 54,78 0,18 1 1,30

Downcomer (D02) 54,78 0,18 1 1,30

Drain Nozzle (N04) 54,78 0,18 1 1,30

Inspection Nozzle (A01, A02) 54,69 0,09 1 1,30

Inspection Nozzle (A02) 54,69 0,09 1 1,30

Riser (R01) 54,62 0,02 1 1,30

Riser (R03) 54,62 0,02 1 1,30

Riser / Downcomer (R01- 02, D01-02) 54,62 0,02 1 1,30

(1) Shellside limits the UG-99(b) stress ratio.

(2) The zero degree angular position is assumed to be up, and the test liquid

height is assumed to the top-most flange.

The test temperature of 25 °C is warmer than the minimum recommended temperature of 4,8 °C so the brittle

fracture provision of UG-99(h) has been met.

7/46


Horizontal field hydrostatic test based on MAWP per UG-99(b)

Gauge pressure at 25°C = 1,3*MAWP*LSR

= 1,3*42*1

= 54,6 bar

Horizontal field hydrostatic test


(bar)


(bar)

UG-99(b)stressratio

UG-99(b)pressure

factor

Shellside (1) 54,75 0,15 1 1,30

Blow Down Nozzle (N03, N04) 54,78 0,18 1 1,30

Downcomer (D01) 54,78 0,18 1 1,30

Downcomer (D02) 54,78 0,18 1 1,30

Drain Nozzle (N04) 54,78 0,18 1 1,30

Inspection Nozzle (A01, A02) 54,69 0,09 1 1,30

Inspection Nozzle (A02) 54,69 0,09 1 1,30

Riser (R01) 54,62 0,02 1 1,30

Riser (R03) 54,62 0,02 1 1,30

Riser / Downcomer (R01- 02, D01-02) 54,62 0,02 1 1,30

(1) Shellside limits the UG-99(b) stress ratio.

(2) The zero degree angular position is assumed to be up, and the test liquid

height is assumed to the top-most flange.

The test temperature of 25 °C is warmer than the minimum recommended temperature of 4,8 °C so the brittle


8/46


Vacuum Summary

Largest Unsupported Length Le

Component Line of Support

Elevation

above Datum

(mm)

Length Le

(mm)

Shellside Left - 0 6.400

- Shellside Left 0 6.400

- Shellside Right 6.400 6.400

Shellside Right - 6.400 6.400

9/46


Shellside


Component Cylinder

Material SA-387 11 2 (II-D Metric p. 38, ln. 33)

ImpactTested

NormalizedFine GrainPractice

PWHTOptimize MDMT/

Find MAWP

Yes (-20°C) Yes No Yes No

DesignPressure (bar)

DesignTemperature (°C)

DesignMDMT (°C)

Internal 42 260-5,4

External 1 260

Static Liquid Head

Condition Ps (bar) Hs (mm) SG

Test horizontal 0,15 1.550 1

Dimensions

Outer Diameter 1.350 mm

Length 6.400 mm

Nominal Thickness 25 mm

CorrosionInner 1,6 mm

Outer 0 mm

Weight and Capacity

Weight (kg) Capacity (liters)

New 5.134,83 8.494,87

Corroded 4.812,06 8.536,74

Radiography

Longitudinal seam Full UW-11(a) Type 1

Left Circumferentialseam

Full UW-11(a) Type 1

Right Circumferentialseam


10/46


Results Summary

Governing condition Internal pressure

Minimum thickness per UG-16 1,5 mm + 1,6 mm = 3,1 mm

Design thickness due to internal pressure (t) 20,54 mm

Design thickness due to external pressure (te) 10,12 mm

Maximum allowable working pressure (MAWP) 52,03 bar

Maximum allowable pressure (MAP) 55,64 bar

Rated MDMT -30,7 °C

UCS-66 Material Toughness Requirements

Material impact test temperature per UG-84 = -20°C

tr = 42*675 / (1.480*1 + 0.4*42) = 18,94 mm

Stress ratio = tr*E* / (tn - c) = 18,94*1 / (25 - 1,6) = 0,8094

UCS-66(i) reduction in MDMT, TR from Fig UCS-66.1M = 10,7°C

MDMT = max[Timpact - TR, -105] = max[ -20 - 10,7 , -105] = -30,7°C

Design MDMT of -5,4°C is acceptable.

Design thickness, (at 260 °C) Appendix 1-1

t = P*Ro / (S*E + 0,40*P) + Corrosion

= 42*675 / (1.480*1,00 + 0,40*42) + 1,6

= 20,54 mm

Maximum allowable working pressure, (at 260 °C) Appendix 1-1

P = S*E*t / (Ro - 0,40*t) - Ps

= 1.480*1,00*23,4 / (675 - 0,40*23,4) - 0

= 52,03 bar

Maximum allowable pressure, (at 25 °C) Appendix 1-1

P = S*E*t / (Ro - 0,40*t)

= 1.480*1,00*25 / (675 - 0,40*25)

= 55,64 bar

External Pressure, (Corroded & at 260 °C) UG-28(c)

L / Do = 6.400 / 1.350 = 4,7407

Do / t = 1.350 / 8,52 = 158,5081

From table G: A = 0,000131

From table CS-2 Metric: B = 121,2251 kg/cm2 (118,88 bar)

Pa = 4*B / (3*(Do / t))

= 4*118,88 / (3*(1.350 / 8,52))

= 1 bar

11/46


Design thickness for external pressure Pa = 1 bar

ta = t + Corrosion = 8,52 + 1,6 = 10,12 mm

% Extreme fiber elongation - UCS-79(d)

EFE = (50*t / Rf)*(1 - Rf / Ro)

= (50*25 / 662,5)*(1 - 662,5 / infinity)

= 1,8868%

The extreme fiber elongation does not exceed 5%.

12/46


Inspection Nozzle (A01, A02)


Note: round inside edges per UG-76(c)

Location and Orientation

Located on Shellside

Orientation 90°

Nozzle center line offset to datum line 220 mm

End of nozzle to shell center 930 mm

Passes through a Category A joint No

Nozzle

Access opening No

Material specification SA-182 F1 (II-D Metric p. 30, ln. 37)

Inside diameter, new 76,2 mm

Nominal wall thickness 20,57 mm

Corrosion allowance 1,6 mm

Projection available outside vessel, Lpr 216,9 mm

Projection available outside vessel to flange face, Lf 255 mm

Local vessel minimum thickness 25 mm

Liquid static head included 0 bar

Longitudinal joint efficiency 1

Welds

Inner fillet, Leg41 9 mm

Nozzle to vessel groove weld 25 mm

13/46


ASME B16.5-2009 Flange

Description NPS 3 Class 600 LWN A182 F1

Bolt Material SA-193 B7 Bolt <= 64 (II-D Metric p. 352, ln. 31)

Blind included Yes

Rated MDMT -48°C

Liquid static head 0 bar

MAWP rating 88,34 bar @ 260°C

MAP rating 96 bar @ 25°C

Hydrotest rating 145 bar @ 25°C

PWHT performed Yes

Impact Tested No

Gasket

Description Flexitallic Spiral Wound CGI 321 S.S.

Notes




LWN rated MDMT per UCS-66(c)(4) = -48°C

Material is exempt from impact testing at the Design MDMT of -5,4°C.

14/46


Reinforcement Calculations for MAWP

Available reinforcement per UG-37 governs the MAWP of this nozzle.

UG-37 Area Calculation Summary (cm2)UG-45

Summary(mm)

For P = 48,06 bar @ 260 °C

The opening is adequately reinforced

The nozzle

passes UG-45

A

required

A

availableA1 A2 A3 A5

A

weldstreq tmin

17,7367 17,7374 1,4471 15,5348 -- -- 0,7555 7,33 20,57

UG-41 Weld Failure Path Analysis Summary

The nozzle is exempt from weld strength calculations per UW-15(b)(1)

UW-16 Weld Sizing Summary

Weld descriptionRequired weld

throat size (mm)

Actual weld

throat size (mm)Status

Nozzle to shell fillet (Leg41) 6 6,3 weld size is adequate

Calculations for internal pressure 48,06 bar @ 260 °C

Parallel Limit of reinforcement per UG-40

LR = MAX(d, Rn + (tn - Cn) + (t - C))

= MAX(79,4, 39,7 + (20,57 - 1,6) + (25 - 1,6))

= 82,07 mm

Outer Normal Limit of reinforcement per UG-40

LH = MIN(2,5*(t - C), 2,5*(tn - Cn) + te)

= MIN(2,5*(25 - 1,6), 2,5*(20,57 - 1,6) + 0)

= 47,44 mm

Nozzle required thickness per UG-27(c)(1)

trn = P*Rn / (Sn*E - 0,6*P)

= 48,0625*39,7 / (1.380*1 - 0,6*48,0625)

= 1,41 mm

Required thickness tr from UG-37(a)

tr = P*Ro / (S*E + 0,4*P)

= 48,0625*675 / (1.480*1 + 0,4*48,0625)

= 21,64 mm

15/46


Area required per UG-37(c)

Allowable stresses: Sn = 1.407,207, Sv = 1.509,179 kgf/cm2

fr1 = lesser of 1 or Sn / Sv = 0,9324


A = d*tr*F + 2*tn*tr*F*(1 - fr1)

= (79,4*21,64*1 + 2*18,97*21,64*1*(1 - 0,9324)) / 100

= 17,7367 cm2

Area available from FIG. UG-37.1

A1 = larger of the following= 1,4471 cm2

= d*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1)

= (79,4*(1*23,4 - 1*21,64) - 2*18,97*(1*23,4 - 1*21,64)*(1 - 0,9324)) / 100

= 1,3529 cm2

= 2*(t + tn)*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1)

= (2*(23,4 + 18,97)*(1*23,4 - 1*21,64) - 2*18,97*(1*23,4 - 1*21,64)*(1 - 0,9324)) / 100

= 1,4471 cm2

A2 = smaller of the following= 15,5348 cm2

= 5*(tn - trn)*fr2*t

= (5*(18,97 - 1,41)*0,9324*23,4) / 100

= 19,158 cm2

= 5*(tn - trn)*fr2*tn= (5*(18,97 - 1,41)*0,9324*18,97) / 100

= 15,5348 cm2

A41 = Leg2*fr2= (92*0,9324) / 100

= 0,7555 cm2

Area = A1 + A2 + A41

= 1,4471 + 15,5348 + 0,7555

= 17,7374 cm2

As Area >= A the reinforcement is adequate.

16/46


UW-16(c) Weld Check

Fillet weld: tmin = lesser of 19 mm or tn or t = 18,97 mm

tc(min) = lesser of 6 mm or 0,7*tmin = 6 mm

tc(actual) = 0,7*Leg = 0.7*9 = 6,3 mm

The fillet weld size is satisfactory.

Weld strength calculations are not required for this detail which conforms to Fig. UW-16.1, sketch (c-e).

UG-45 Nozzle Neck Thickness Check

ta UG-27 = P*Rn / (Sn*E - 0,6*P) + Corrosion

= 48,0625*39,7 / (1.380*1 - 0,6*48,0625) + 1,6

= 3,01 mm

ta = max[ ta UG-27 , ta UG-22 ]

= max[ 3,01 , 0 ]

= 3,01 mm

tb1 = P*Ro / (S*E + 0,4*P) + Corrosion

= 48,0625*675 / (1.480*1 + 0,4*48,0625) + 1,6

= 23,24 mm

tb1 = max[ tb1 , tb UG16 ]

= max[ 23,24 , 3,1 ]

= 23,24 mm

tb = min[ tb3 , tb1 ]

= min[ 7,33 , 23,24 ]

= 7,33 mm

tUG-45 = max[ ta , tb ]

= max[ 3,01 , 7,33 ]

= 7,33 mm

Available nozzle wall thickness new, tn = 20,57 mm

The nozzle neck thickness is adequate.

17/46


Reinforcement Calculations for MAP

Available reinforcement per UG-37 governs the MAP of this nozzle.


Summary(mm)

For P = 54,64 bar @ 25 °C


The nozzle

passes UG-45

A

required

A


A

weldstreq tmin

19,3973 19,3974 0,3897 18,2522 -- -- 0,7555 5,73 20,57





throat size (mm)

Actual weld





LR = MAX(d, Rn + (tn - Cn) + (t - C))

= MAX(76,2, 38,1 + (20,57 - 0) + (25 - 0))

= 83,67 mm


LH = MIN(2,5*(t - C), 2,5*(tn - Cn) + te)

= MIN(2,5*(25 - 0), 2,5*(20,57 - 0) + 0)

= 51,44 mm


trn = P*Rn / (Sn*E - 0,6*P)

= 54,6436*38,1 / (1.380*1 - 0,6*54,6436)

= 1,54 mm


tr = P*Ro / (S*E + 0,4*P)

= 54,6436*675 / (1.480*1 + 0,4*54,6436)

= 24,56 mm

18/46






A = d*tr*F + 2*tn*tr*F*(1 - fr1)

= (76,2*24,56*1 + 2*20,57*24,56*1*(1 - 0,9324)) / 100

= 19,3973 cm2




= (76,2*(1*25 - 1*24,56) - 2*20,57*(1*25 - 1*24,56)*(1 - 0,9324)) / 100

= 0,3239 cm2


= (2*(25 + 20,57)*(1*25 - 1*24,56) - 2*20,57*(1*25 - 1*24,56)*(1 - 0,9324)) / 100

= 0,3897 cm2



= (5*(20,57 - 1,54)*0,9324*25) / 100

= 22,1793 cm2

= 5*(tn - trn)*fr2*tn= (5*(20,57 - 1,54)*0,9324*20,57) / 100

= 18,2522 cm2

A41 = Leg2*fr2= (92*0,9324) / 100

= 0,7555 cm2

Area = A1 + A2 + A41

= 0,3897 + 18,2522 + 0,7555

= 19,3974 cm2


19/46


UW-16(c) Weld Check

Fillet weld: tmin = lesser of 19 mm or tn or t = 19 mm


tc(actual) = 0,7*Leg = 0.7*9 = 6,3 mm





= 54,6436*38,1 / (1.380*1 - 0,6*54,6436) + 0

= 1,54 mm


= max[ 1,54 , 0 ]

= 1,54 mm


= 54,6436*675 / (1.480*1 + 0,4*54,6436) + 0

= 24,56 mm


= max[ 24,56 , 1,5 ]

= 24,56 mm


= min[ 5,73 , 24,56 ]

= 5,73 mm


= max[ 1,54 , 5,73 ]

= 5,73 mm



20/46


Reinforcement Calculations for External Pressure

UG-37 Area Calculation Summary(cm2)

UG-45Summary

(mm)

For Pe = 1 bar @ 260 °CThe nozzle

passes UG-45

A

required

A


A

weldstreq tmin

This nozzle is exempt from area

calculations per UG-36(c)(3)(a)3,1 20,57


Weld strength calculations are not required for external pressure



throat size (mm)

Actual weld



Calculations for external pressure 1 bar @ 260 °C


LR = MAX(d, Rn + (tn - Cn) + (t - C))

= MAX(79,4, 39,7 + (20,57 - 1,6) + (25 - 1,6))

= 82,07 mm


LH = MIN(2,5*(t - C), 2,5*(tn - Cn) + te)

= MIN(2,5*(25 - 1,6), 2,5*(20,57 - 1,6) + 0)

= 47,44 mm

Nozzle required thickness per UG-28 trn = 0,53 mm

From UG-37(d)(1) required thickness tr = 8,52 mm

This opening does not require reinforcement per UG-36(c)(3)(a)

UW-16(c) Weld Check



tc(actual) = 0,7*Leg = 0.7*9 = 6,3 mm

21/46





ta UG-28 = 2,13 mm


= max[ 2,13 , 0 ]

= 2,13 mm


= 1*675 / (1.480*1 + 0,4*1) + 1,6

= 2,06 mm


= max[ 2,06 , 3,1 ]

= 3,1 mm


= min[ 7,33 , 3,1 ]

= 3,1 mm


= max[ 2,13 , 3,1 ]

= 3,1 mm




L / Do = 257,55 / 117,35 = 2,1948

Do / t = 117,35 / 0,53 = 220,4728



Pa = 4*B / (3*(Do / t))

= 4*165,35 / (3*(117,35 / 0,53))

= 1 bar


ta = t + Corrosion = 0,53 + 1,6 = 2,13 mm

22/46


Riser / Downcomer (R01- 02, D01-02)


Note: Per UW-16(b) minimum inside corner radius r1 = min [1 / 4*t , 3 mm] = 3 mm



Orientation 0°

Nozzle center line offset to datum line 2.070 mm



Nozzle

Access opening No



Wall thickness, tn 41,1 mm

Minimum wall thickness 15,1 mm


Projection available outside vessel, Lpr 225 mm

Heavy barrel length, Lhb 100 mm




Welds



23/46


UCS-66 Material Toughness Requirements Nozzle At Intersection

Governing thickness, tg = 25 mm

Exemption temperature from Fig UCS-66M Curve B = -1,5°C

tr = 42*675 / (1.480*1 + 0,4*42) = 18,94 mm


Reduction in MDMT, TR from Fig UCS-66.1M = 10,7°C

MDMT = max[ MDMT - TR, -48] = max[ -1,5 - 10,7 , -48] = -12,2°C


UCS-66 Material Toughness Requirements Nozzle

Governing thickness, tg = 15,1 mm

Exemption temperature from Fig UCS-66M Curve B = -16,5°C

External nozzle loadings per UG-22 govern the coincident ratio used.

Stress ratio = tr*E* / (tn - c) = 6,42*1 / (15,1 - 1,6) = 0,4754

Reduction in MDMT, TR from Fig UCS-66.1M = 34,7°C

MDMT = max[ MDMT - TR, -48] = max[ -16,5 - 34,7 , -48] = -48°C


24/46





Summary(mm)

For P = 43,23 bar @ 260 °C


The nozzle

passes UG-45

A

required

A


A

weldstreq tmin

48,9784 48,9793 9,4168 38,807 -- -- 0,7555 9,71 15,1





throat size (mm)

Actual weld



WRC 107

Load CaseP

(bar)

Pr

(kgf)

Mc

(kgf-m)

Vc

(kgf)

ML

(kgf-m)

VL

(kgf)

Mt

(kgf-m)

Max

Comb

Stress

(kgf/cm2)

Allow

Comb

Stress

(kgf/cm2)

Max

Local

Primary

Stress

(kgf/cm2)

Allow

Local

Primary

Stress

(kgf/cm2)

Over

stressed

Load case 1 43,23 1.580 3.950 0 2.300 0 0 3.789,401 4.527,536 1.842,603 2.263,768 No

Load case 1 (Hot Shut Down) 0 1.580 3.950 0 2.300 0 0 -2.869,928 4.527,536 -411,014 2.263,768 No


Parallel Limit of reinforcement per UG-40 and Fig. UG-40 sketch (e-2)

LR = MAX(d, Rn + (tn - Cn) + (t - C))

= MAX(246, 123 + (41,1 - 1,6) + (25 - 1,6))

= 246 mm

Outer Normal Limit of reinforcement per UG-40 and Fig. UG-40 sketch (e-2)

LH = MIN(2,5*(t - C), 2,5*(tn - Cn) + te)

= MIN(2,5*(25 - 1,6), 2,5*(41,1 - 1,6) + 0)

= 58,5 mm


trn = P*Rn / (Sn*E - 0,6*P)

= 43,2258*123 / (1.380*1 - 0,6*43,2258)

= 3,93 mm

25/46



tr = P*Ro / (S*E + 0,4*P)

= 43,2258*675 / (1.480*1 + 0,4*43,2258)

= 19,49 mm





A = d*tr*F + 2*tn*tr*F*(1 - fr1)

= (246*19,49*1 + 2*39,5*19,49*1*(1 - 0,9324)) / 100

= 48,9784 cm2




= (246*(1*23,4 - 1*19,49) - 2*39,5*(1*23,4 - 1*19,49)*(1 - 0,9324)) / 100

= 9,4168 cm2


= (2*(23,4 + 39,5)*(1*23,4 - 1*19,49) - 2*39,5*(1*23,4 - 1*19,49)*(1 - 0,9324)) / 100

= 4,7135 cm2



= (5*(39,5 - 3,93)*0,9324*23,4) / 100

= 38,807 cm2

= 5*(tn - trn)*fr2*tn= (5*(39,5 - 3,93)*0,9324*39,5) / 100

= 65,5076 cm2

A41 = Leg2*fr2= (92*0,9324) / 100

= 0,7555 cm2

Area = A1 + A2 + A41

= 9,4168 + 38,807 + 0,7555

26/46


= 48,9793 cm2


UW-16(c) Weld Check



tc(actual) = 0,7*Leg = 0.7*9 = 6,3 mm





= 43,2258*123 / (1.380*1 - 0,6*43,2258) + 1,6

= 5,53 mm

ta UG-22 = 8,09 mm


= max[ 5,53 , 8,09 ]

= 8,09 mm


= 43,2258*675 / (1.480*1 + 0,4*43,2258) + 1,6

= 21,09 mm


= max[ 21,09 , 3,1 ]

= 21,09 mm


= min[ 9,71 , 21,09 ]

= 9,71 mm


= max[ 8,09 , 9,71 ]

= 9,71 mm



27/46


WRC 107 Load case 1

Applied Loads

Radial load, Pr 1.580 kgf

Circumferential moment, Mc 3.950 kgf-m

Circumferential shear, Vc 0 kgf

Longitudinal moment, ML 2.300 kgf-m

Longitudinal shear, VL 0 kgf

Torsion moment, Mt 0 kgf-m

Internal pressure, P 43,23 bar

Mean shell radius, Rm 663,3 mm

Local shell thickness, T 23,4 mm

Design factor 3

Maximum stresses due to the applied loads at the nozzle OD (includes pressure)

γ = Rm / T = 663,3 / 23,4 = 28,3464

β = 0,875*ro / Rm = 0,875*162,5 / 663,3 = 0,2144

Pressure stress intensity factor, I = 1,2736 (derived from Division 2 Part 4.5)

Local circumferential pressure stress = I*P*Ri / T =1.563,204 kgf/cm2

Local longitudinal pressure stress = I*P*Ri / (2*T) =781,602 kgf/cm2

Maximum combined stress (PL+P

b+Q) = 3.789,4 kgf/cm2

Allowable combined stress (PL+P

b+Q) = ±3*S = ±4.527,54 kgf/cm2

The maximum combined stress (PL+P

b+Q) is within allowable limits.

Maximum local primary membrane stress (PL) = 1.842,6 kgf/cm2

Allowable local primary membrane stress (PL) = ±1,5*S = ±2.263,77 kgf/cm2

The maximum local primary membrane stress (PL) is within allowable limits.

28/46


Stresses at the nozzle OD per WRC Bulletin 107

Figure value Au Al Bu Bl Cu Cl Du Dl

3C* Nφ / (P / Rm) 2,7305 0 0 0 0 -27,771 -27,771 -27,771 -27,771

4C* Nφ / (P / Rm) 4,0369 -41,13 -41,13 -41,13 -41,13 0 0 0 0

1C Mφ / P 0,0729 0 0 0 0 -126,201 126,201 -126,201 126,201

2C-1 Mφ / P 0,0413 -71,502 71,502 -71,502 71,502 0 0 0 0

3A* Nφ / [Mc / (Rm2*β)] 1,1768 0 0 0 0 -210,639 -210,639 210,639 210,639

1A Mφ / [Mc / (Rm*β)] 0,0823 0 0 0 0 -2.505,316 2.505,316 2.505,316 -2.505,316

3B* Nφ / [ML / (Rm2*β)] 3,0757 -320,529 -320,529 320,529 320,529 0 0 0 0

1B-1 Mφ / [ML / (Rm*β)] 0,0294 -521,115 521,115 521,115 -521,115 0 0 0 0

Pressure stress* 1.563,204 1.563,204 1.563,204 1.563,204 1.227,418 1.227,418 1.227,418 1.227,418

Total circumferential stress 608,928 1.794,162 2.292,216 1.392,991 -1.642,51 3.620,524 3.789,401 -968,829

Primary membrane circumferential

stress*1.201,545 1.201,545 1.842,603 1.842,603 989,007 989,007 1.410,286 1.410,286

3C* Nx / (P / Rm) 2,7305 -27,771 -27,771 -27,771 -27,771 0 0 0 0

4C* Nx / (P / Rm) 4,0369 0 0 0 0 -41,13 -41,13 -41,13 -41,13

1C-1 Mx / P 0,0777 -134,497 134,497 -134,497 134,497 0 0 0 0

2C Mx / P 0,0421 0 0 0 0 -72,908 72,908 -72,908 72,908

4A* Nx / [Mc / (Rm2*β)] 2,0666 0 0 0 0 -369,885 -369,885 369,885 369,885

2A Mx / [Mc / (Rm*β)] 0,0429 0 0 0 0 -1.305,951 1.305,951 1.305,951 -1.305,951

4B* Nx / [ML / (Rm2*β)] 1,1435 -119,17 -119,17 119,17 119,17 0 0 0 0

2B-1 Mx / [ML / (Rm*β)] 0,0479 -849,026 849,026 849,026 -849,026 0 0 0 0

Pressure stress* 613,709 613,709 613,709 613,709 781,602 781,602 781,602 781,602

Total longitudinal stress -516,756 1.450,291 1.419,637 -9,421 -1.008,271 1.749,447 2.343,399 -122,686

Primary membrane longitudinal stress* 466,768 466,768 705,108 705,108 370,588 370,588 1.110,357 1.110,357

Shear from Mt 0 0 0 0 0 0 0 0

Circ shear from Vc 0 0 0 0 0 0 0 0

Long shear from VL 0 0 0 0 0 0 0 0

Total Shear stress 0 0 0 0 0 0 0 0

Combined stress (PL+Pb+Q) -1.125,684 1.794,162 2.292,216 -1.402,412 -1.642,51 3.620,524 3.789,401 -968,829

* denotes primary stress.

Longitudinal stress in the nozzle wall due to internal pressure + external loads

σn (Pm) = P*Ri / (2*tn) - Pr / (π*(Ro2 - Ri

2)) + M*Ro / I

= 43,23*1,02*123 / (2*13,5) - 1.580 / (π*(136,52 - 1232))*100 + 4.570.813,1*136,5 / 9,2892E+07*100

= 858,101 kgf/cm2

The average primary stress Pm (see Division 2 5.6.a.1) across the nozzle wall due to internal pressure + external

loads is acceptable ( ≤ S = 1.407,207 kgf/cm2)

29/46





Summary(mm)

For P = 47,12 bar @ 25 °C


The nozzle

passes UG-45

A

required

A


A

weldstreq tmin

52,6967 52,698 8,9722 42,9702 -- -- 0,7555 8,11 15,1





throat size (mm)

Actual weld





LR = MAX(d, Rn + (tn - Cn) + (t - C))

= MAX(242,8, 121,4 + (15,1 - 0) + (25 - 0))

= 242,8 mm


LH = MIN(2,5*(t - C), 2,5*(tn - Cn) + te)

= MIN(2,5*(25 - 0), 2,5*(15,1 - 0) + 45,03)

= 62,5 mm

te = MIN( 100 + 26*tan(30) , 26*tan(60) )

= 45,03 mm


trn = P*Rn / (Sn*E - 0,6*P)

= 47,1153*121,4 / (1.380*1 - 0,6*47,1153)

= 4,23 mm


tr = P*Ro / (S*E + 0,4*P)

= 47,1153*675 / (1.480*1 + 0,4*47,1153)

30/46


= 21,22 mm





A = d*tr*F + 2*tn*tr*F*(1 - fr1)

= (242,8*21,22*1 + 2*41,1*21,22*1*(1 - 0,9324)) / 100

= 52,6967 cm2




= (242,8*(1*25 - 1*21,22) - 2*41,1*(1*25 - 1*21,22)*(1 - 0,9324)) / 100

= 8,9722 cm2


= (2*(25 + 41,1)*(1*25 - 1*21,22) - 2*41,1*(1*25 - 1*21,22)*(1 - 0,9324)) / 100

= 4,7897 cm2



= (5*(41,1 - 4,23)*0,9324*25) / 100

= 42,9702 cm2

= 2*(tn - trn)*(2,5*tp + te)*fr2= (2*(41,1 - 4,23)*(2,5*15,1 + 45,03)*0,9324) / 100

= 56,916 cm2

A41 = Leg2*fr2= (92*0,9324) / 100

= 0,7555 cm2

Area = A1 + A2 + A41

= 8,9722 + 42,9702 + 0,7555

= 52,698 cm2


31/46


UW-16(c) Weld Check



tc(actual) = 0,7*Leg = 0.7*9 = 6,3 mm





= 47,1153*121,4 / (1.380*1 - 0,6*47,1153) + 0

= 4,23 mm

ta UG-22 = 6,71 mm


= max[ 4,23 , 6,71 ]

= 6,71 mm


= 47,1153*675 / (1.480*1 + 0,4*47,1153) + 0

= 21,22 mm


= max[ 21,22 , 1,5 ]

= 21,22 mm


= min[ 8,11 , 21,22 ]

= 8,11 mm


= max[ 6,71 , 8,11 ]

= 8,11 mm



32/46




Summary(mm)

For Pe = 1 bar @ 260 °C


The nozzle

passes UG-45

A

required

A


A

weldstreq tmin

10,7032 78,6405 35,8173 42,0677 -- -- 0,7555 5,84 15,1





throat size (mm)

Actual weld





LR = MAX(d, Rn + (tn - Cn) + (t - C))

= MAX(246, 123 + (41,1 - 1,6) + (25 - 1,6))

= 246 mm


LH = MIN(2,5*(t - C), 2,5*(tn - Cn) + te)

= MIN(2,5*(25 - 1,6), 2,5*(41,1 - 1,6) + 45,03)

= 58,5 mm



Area required per UG-37(d)(1)




A = 0,5*(d*tr*F + 2*tn*tr*F*(1 - fr1))

33/46


= (0,5*(246*8,52*1 + 2*39,5*8,52*1*(1 - 0,9324))) / 100

= 10,7032 cm2




= (246*(1*23,4 - 1*8,52) - 2*39,5*(1*23,4 - 1*8,52)*(1 - 0,9324)) / 100

= 35,8173 cm2


= (2*(23,4 + 39,5)*(1*23,4 - 1*8,52) - 2*39,5*(1*23,4 - 1*8,52)*(1 - 0,9324)) / 100

= 17,9277 cm2



= (5*(39,5 - 0,94)*0,9324*23,4) / 100

= 42,0677 cm2

= 5*(tn - trn)*fr2*tn= (5*(39,5 - 0,94)*0,9324*39,5) / 100

= 71,0121 cm2

A41 = Leg2*fr2= (92*0,9324) / 100

= 0,7555 cm2

Area = A1 + A2 + A41

= 35,8173 + 42,0677 + 0,7555

= 78,6405 cm2


UW-16(c) Weld Check



tc(actual) = 0,7*Leg = 0.7*9 = 6,3 mm



34/46



ta UG-28 = 2,54 mm

ta UG-22 = 5,84 mm


= max[ 2,54 , 5,84 ]

= 5,84 mm


= 1*675 / (1.480*1 + 0,4*1) + 1,6

= 2,06 mm


= max[ 2,06 , 3,1 ]

= 3,1 mm


= min[ 9,71 , 3,1 ]

= 3,1 mm


= max[ 5,84 , 3,1 ]

= 5,84 mm




L / Do = 244,85 / 325 = 0,7534

Do / t = 325 / 0,94 = 346,6448



Pa = 4*B / (3*(Do / t))

= 4*259,99 / (3*(325 / 0,94))

= 1 bar


ta = t + Corrosion = 0,94 + 1,6 = 2,54 mm

35/46


Blow Down Nozzle (N03, N04)





Orientation 180°




Nozzle

Access opening No










Welds



36/46



Description NPS 2 Class 600 LWN A182 F1


Blind included No

Rated MDMT -48°C


Consider External Loads on Flange MAWP Rating No


MAP rating 96 bar @ 25°C


PWHT performed Yes

Impact Tested No

Gasket


Notes




LWN rated MDMT per UCS-66(c)(4) = -48°C


37/46



The vessel wall thickness governs the MAWP of this nozzle.


UG-45Summary

(mm)

For P = 52,03 bar @ 260 °CThe nozzle

passes UG-45

A

required

A


A

weldstreq tmin







throat size (mm)

Actual weld



WRC 107

Load CaseP

(bar)

Pr

(kgf)

Mc

(kgf-m)

Vc

(kgf)

ML

(kgf-m)

VL

(kgf)

Mt

(kgf-m)

Max

Comb

Stress

(kgf/cm2)

Allow

Comb

Stress

(kgf/cm2)

Max

Local

Primary

Stress

(kgf/cm2)

Allow

Local

Primary

Stress

(kgf/cm2)

Over

stressed

Load case 1 52,03 77 110 0 73 0 0 2.238,08 4.527,536 2.123,971 2.263,768 No

Load case 1 (Hot Shut Down) 0 77 110 0 73 0 0 -376,001 4.527,536 -21,233 2.263,768 No



LR = MAX(d, Rn + (tn - Cn) + (t - C))

= MAX(54, 27 + (16,64 - 1,6) + (25 - 1,6))

= 65,44 mm


LH = MIN(2,5*(t - C), 2,5*(tn - Cn) + te)

= MIN(2,5*(25 - 1,6), 2,5*(16,64 - 1,6) + 0)

= 37,59 mm


trn = P*Rn / (Sn*E - 0,6*P)

= 52,0273*27 / (1.380*1 - 0,6*52,0273)

= 1,04 mm

38/46



tr = P*Ro / (S*E + 0,4*P)

= 52,0273*675 / (1.480*1 + 0,4*52,0273)

= 23,4 mm


UW-16(c) Weld Check



tc(actual) = 0,7*Leg = 0.7*9 = 6,3 mm





= 52,0273*27 / (1.380*1 - 0,6*52,0273) + 1,6

= 2,64 mm

ta UG-22 = 4,18 mm


= max[ 2,64 , 4,18 ]

= 4,18 mm


= 52,0273*675 / (1.480*1 + 0,4*52,0273) + 1,6

= 25 mm


= max[ 25 , 3,1 ]

= 25 mm


= min[ 6,4 , 25 ]

= 6,4 mm


= max[ 4,18 , 6,4 ]

= 6,4 mm


39/46



40/46


WRC 107 Load case 1

Applied Loads

Radial load, Pr 77 kgf

Circumferential moment, Mc 110 kgf-m


Longitudinal moment, ML 73 kgf-m






Design factor 3


γ = Rm / T = 663,3 / 23,4 = 28,3464

β = 0,875*ro / Rm = 0,875*42,04 / 663,3 = 0,0555



Local longitudinal pressure stress = I*P*Ri / (2*T) =1.053,971 kgf/cm2


b+Q) = 2.238,08 kgf/cm2


b+Q) = ±3*S = ±4.527,54 kgf/cm2






41/46




3C* Nφ / (P / Rm) 5,2958 0 0 0 0 -2,601 -2,601 -2,601 -2,601

4C* Nφ / (P / Rm) 5,4353 -2,672 -2,672 -2,672 -2,672 0 0 0 0

1C Mφ / P 0,1969 0 0 0 0 -16,592 16,592 -16,592 16,592

2C-1 Mφ / P 0,1585 -13,358 13,358 -13,358 13,358 0 0 0 0

3A* Nφ / [Mc / (Rm2*β)] 0,3711 0 0 0 0 -7,171 -7,171 7,171 7,171

1A Mφ / [Mc / (Rm*β)] 0,1067 0 0 0 0 -349,636 349,636 349,636 -349,636

3B* Nφ / [ML / (Rm2*β)] 1,4503 -18,561 -18,561 18,561 18,561 0 0 0 0

1B-1 Mφ / [ML / (Rm*β)] 0,0586 -127,466 127,466 127,466 -127,466 0 0 0 0

Pressure stress* 2.108,082 2.108,082 2.108,082 2.108,082 1.477,359 1.477,359 1.477,359 1.477,359

Total circumferential stress 1.946,025 2.227,674 2.238,08 2.009,863 1.101,358 1.833,815 1.814,973 1.148,885


stress*2.086,849 2.086,849 2.123,971 2.123,971 1.467,586 1.467,586 1.481,929 1.481,929

3C* Nx / (P / Rm) 5,2958 -2,601 -2,601 -2,601 -2,601 0 0 0 0

4C* Nx / (P / Rm) 5,4353 0 0 0 0 -2,672 -2,672 -2,672 -2,672

1C-1 Mx / P 0,205 -17,296 17,296 -17,296 17,296 0 0 0 0

2C Mx / P 0,1581 0 0 0 0 -13,358 13,358 -13,358 13,358

4A* Nx / [Mc / (Rm2*β)] 0,4817 0 0 0 0 -9,281 -9,281 9,281 9,281

2A Mx / [Mc / (Rm*β)] 0,0624 0 0 0 0 -204,452 204,452 204,452 -204,452

4B* Nx / [ML / (Rm2*β)] 0,3666 -4,711 -4,711 4,711 4,711 0 0 0 0

2B-1 Mx / [ML / (Rm*β)] 0,0993 -215,983 215,983 215,983 -215,983 0 0 0 0

Pressure stress* 738,644 738,644 738,644 738,644 1.053,971 1.053,971 1.053,971 1.053,971

Total longitudinal stress 498,054 964,611 939,441 542,066 824,208 1.259,829 1.251,674 869,485

Primary membrane longitudinal stress* 731,332 731,332 740,754 740,754 1.042,019 1.042,019 1.060,58 1.060,58

Shear from Mt 0 0 0 0 0 0 0 0




Combined stress (PL+Pb+Q) 1.946,025 2.227,674 2.238,08 2.009,863 1.101,358 1.833,815 1.814,973 1.148,885




2)) + M*Ro / I

= 52,03*1,02*27 / (2*15,04) - 77 / (π*(42,042 - 272))*100 + 132.018,4*42,04 / 2.035.151*100

= 317,96 kgf/cm2



42/46



The vessel wall thickness governs the MAP of this nozzle.


UG-45Summary

(mm)

For P = 55,64 bar @ 25 °CThe nozzle

passes UG-45

A

required

A


A

weldstreq tmin







throat size (mm)

Actual weld





LR = MAX(d, Rn + (tn - Cn) + (t - C))

= MAX(50,8, 25,4 + (16,64 - 0) + (25 - 0))

= 67,04 mm


LH = MIN(2,5*(t - C), 2,5*(tn - Cn) + te)

= MIN(2,5*(25 - 0), 2,5*(16,64 - 0) + 0)

= 41,59 mm


trn = P*Rn / (Sn*E - 0,6*P)

= 55,639*25,4 / (1.380*1 - 0,6*55,639)

= 1,05 mm


tr = P*Ro / (S*E + 0,4*P)

= 55,639*675 / (1.480*1 + 0,4*55,639)

= 25 mm


43/46


UW-16(c) Weld Check



tc(actual) = 0,7*Leg = 0.7*9 = 6,3 mm





= 55,639*25,4 / (1.380*1 - 0,6*55,639) + 0

= 1,05 mm

ta UG-22 = 2,63 mm


= max[ 1,05 , 2,63 ]

= 2,63 mm


= 55,639*675 / (1.480*1 + 0,4*55,639) + 0

= 25 mm


= max[ 25 , 1,5 ]

= 25 mm


= min[ 4,8 , 25 ]

= 4,8 mm


= max[ 2,63 , 4,8 ]

= 4,8 mm



44/46




UG-45Summary

(mm)

For Pe = 1 bar @ 260 °CThe nozzle

passes UG-45

A

required

A


A

weldstreq tmin







throat size (mm)

Actual weld





LR = MAX(d, Rn + (tn - Cn) + (t - C))

= MAX(54, 27 + (16,64 - 1,6) + (25 - 1,6))

= 65,44 mm


LH = MIN(2,5*(t - C), 2,5*(tn - Cn) + te)

= MIN(2,5*(25 - 1,6), 2,5*(16,64 - 1,6) + 0)

= 37,59 mm




UW-16(c) Weld Check



tc(actual) = 0,7*Leg = 0.7*9 = 6,3 mm

45/46





ta UG-28 = 2,04 mm

ta UG-22 = 3,44 mm


= max[ 2,04 , 3,44 ]

= 3,44 mm


= 1*675 / (1.480*1 + 0,4*1) + 1,6

= 2,06 mm


= max[ 2,06 , 3,1 ]

= 3,1 mm


= min[ 6,4 , 3,1 ]

= 3,1 mm


= max[ 3,44 , 3,1 ]

= 3,44 mm




L / Do = 256,31 / 84,07 = 3,0486

Do / t = 84,07 / 0,44 = 191,8449



Pa = 4*B / (3*(Do / t))

= 4*143,88 / (3*(84,07 / 0,44))

= 1 bar


ta = t + Corrosion = 0,44 + 1,6 = 2,04 mm

46/46




www.bertsch.at



Vessel No: Tubeside



Designer: Pirker

Date: 19.01.2017


Table of ContentsSettings Summary.....................................................................................................................................................1/81

Deficiencies Summary..............................................................................................................................................3/81

Nozzle Schedule........................................................................................................................................................4/81

Nozzle Summary.......................................................................................................................................................5/81

Pressure Summary...................................................................................................................................................6/81

Thickness Summary.................................................................................................................................................8/81

Revision History........................................................................................................................................................9/81

Radiography Summary...........................................................................................................................................10/81

Test Report..............................................................................................................................................................11/81

Ellipsoidal Head Inlet..............................................................................................................................................13/81

Straight Flange on Ellipsoidal Head Inlet..............................................................................................................15/81

Shell- Inlet Chamber...............................................................................................................................................17/81

Manhole (A03)..........................................................................................................................................................19/81

Inlet (N01).................................................................................................................................................................29/81

Transition #1............................................................................................................................................................41/81

Shell Outlet Chamber..............................................................................................................................................48/81

Manhole (A04)..........................................................................................................................................................50/81

Outlet (N02)..............................................................................................................................................................60/81

Ellipsoidal Head Outlet...........................................................................................................................................70/81

Straight Flange on Ellipsoidal Head Outlet...........................................................................................................72/81

Nozzle (Control Valve)............................................................................................................................................74/81

i


Settings Summary

COMPRESS 2017 Build 7700


Units MKS

Datum Line Location 0,00 mm from left seam

Vessel Design Mode Design Mode

Minimum thickness 1,5 mm per UG-16(b)

Design for cold shut down only No

Design for lethal service (full radiography required) No

User has limited MAWP to 30 bar

Design nozzles for Design P only

Corrosion weight loss 100% of theoretical loss

UG-23 Stress Increase 1,20

Skirt/legs stress increase 1,0

Minimum nozzle projection 152,4 mm

Juncture calculations for α > 30 only Yes

Preheat P-No 1 Materials > 1,25" and <= 1,50" thick Yes

UG-37(a) shell tr calculation considers longitudinal stress No

Cylindrical shells made from pipe are entered as minimum thickness No

Nozzles made from pipe are entered as minimum thickness No

ASME B16.9 fittings are entered as minimum thickness No

Butt weldsTapered per Figure

UCS-66.3(a)

Disallow Appendix 1-5, 1-8 calculations under 15 psi No

Hydro/Pneumatic Test

Shop Hydrotest at user defined pressure 41,35 bar

Test liquid specific gravity 1,00

Field Hydrotest at user defined pressure 41,35 bar

Wind load present @ field 33% of design

Maximum stress during test 90% of yield

Required Marking - UG-116

UG-116(e) Radiography RT1

UG-116(f) Postweld heat treatment HT

Code Cases\Interpretations


1/81








No UCS-66.1 MDMT reduction No

No UCS-68(c) MDMT reduction No

Disallow UG-20(f) exemptions No

UG-22 Loadings

UG-22(a) Internal or External Design Pressure Yes

UG-22(b) Weight of the vessel and normal contents under operating or test

conditionsNo

UG-22(c) Superimposed static reactions from weight of attached equipment

(external loads)No

UG-22(d)(2) Vessel supports such as lugs, rings, skirts, saddles and legs No

UG-22(f) Wind reactions No

UG-22(f) Seismic reactions No

UG-22(j) Test pressure and coincident static head acting during the test: No

Note: UG-22(b),(c) and (f) loads only considered when supports are present.

License Information

Company Name Bertsch Energy GmbH & Co KG

License Commercial

License Key ID 20080

Support Expires J� nner 24, 2018

2/81


Deficiencies Summary

No deficiencies found.

3/81


Nozzle Schedule

Specifications

Nozzle

markIdentifier Size Materials

Impact

TestedNormalized Fine Grain Flange Blind

A03 Manhole 881,13 OD x 54 Nozzle SA-182 F11 2 Yes Yes NoApp 2 Weld Neck Integral

SA-182 F11 2SA-182 F11 2

A04 Manhole 701,7 OD x 50 Nozzle SA-182 F11 2 Yes Yes NoApp 2 Weld Neck Integral

SA-182 F11 2SA-182 F11 2

Control Valve Nozzle 320 OD x 75 Nozzle SA-182 F11 2 Yes Yes No N/A No

N01 Inlet 996 OD x 50 Nozzle SA-387 11 2 Yes Yes No N/A No

N02 Outlet 374,65 OD x 34,92 Nozzle SA-182 F11 2 Yes Yes NoNPS 12 Class 300

LWN A182 F11 Cl.2 NNo

4/81


Nozzle Summary

Dimensions

Nozzle

mark

OD

(mm)

tn(mm)

Req tn(mm)

A1? A2?

ShellReinforcement

Pad Corr

(mm)

Aa/Ar

(%)Nom t

(mm)

Design t

(mm)

User t

(mm)

Width

(mm)

tpad

(mm)

A03 881,13 54 10,28 Yes Yes 30* 15,81 N/A N/A 1,6 131,7

A04 701,7 50 9,93 Yes Yes 30 15,64 N/A N/A 1,6 127,0

Control Valve 320 75 9,93 Yes Yes 20* 14,21 N/A N/A 1,6 169,8

N01 996 50 16,54 Yes Yes 50 16,68 N/A N/A 1,6 254,8

N02 374,65 34,92 10,47 Yes Yes 30 15,64 N/A N/A 1,6 187,0

*Head minimum thickness after forming

Definitions

tn Nozzle thickness

Req tn Nozzle thickness required per UG-45/UG-16

Nom t Vessel wall thickness

Design t Required vessel wall thickness due to pressure + corrosion allowance per UG-37

User t Local vessel wall thickness (near opening)

Aa Area available per UG-37, governing condition

Ar Area required per UG-37, governing condition

Corr Corrosion allowance on nozzle wall

5/81


Pressure Summary

Component Summary

Identifier

P

Design

(bar)

T

Design

(°C)

MAWP

(bar)

MAP

(bar)

MDMT

(°C)

MDMT

Exemption

Impact

Tested

Ellipsoidal Head Inlet 30 400 59,85 63,16 -50,9 Note 1 Yes

Straight Flange on Ellipsoidal Head Inlet 30 400 58,49 61,84 -50,9 Note 2 Yes

Shell- Inlet Chamber 30 400 98,04 101,37 -105 Note 3 Yes

Transition #1 30 450 45,08 49,9 -40,2 Note 4 Yes

Shell Outlet Chamber 30 450 61,2 66,97 -54,3 Note 5 Yes

Straight Flange on Ellipsoidal Head Outlet 30 450 39,41 44,38 -34,7 Note 7 Yes

Ellipsoidal Head Outlet 30 450 40,09 45,05 -34,7 Note 6 Yes

Manhole (A03) 30 400 34,64 36,56 -48 Note 8 Yes

Manhole A03 30 450 30,28 35,1 -28,1 Note 9 Yes

Manhole A03 - Flange Hub 30 450 162,34 177,87 -105 Note 10 Yes

Bolted Cover for A03 30 450 32,65 35,81 -27,5 Note 11 Yes

Manhole (A04) 30 450 34,51 37,99 -54,3 Note 12 Yes

Manhole A04 30 450 47,62 53,46 -30 Note 13 Yes

Manhole A04 - Flange Hub 30 450 189,81 208,55 -105 Note 14 Yes

Bolted Cover A04 30 450 34,64 38,29 -30,3 Note 15 Yes

Nozzle (Control Valve) 30 450 43,95 49,37 -38,9 Note 16 Yes

Inlet (N01) 30 400 34,33 56,29 -40,2 Note 17 Yes

Outlet (N02) 30 450 33,7 48,11 -44,6 Note 18 Yes

Chamber Summary

Design MDMT -5,4 °C

Rated MDMT -27,5 °C @ 30,28 bar

MAWP hot & corroded 30 bar @ 400 °C

MAP cold & new 35,1 bar @ 20 °C

(1) The MAWP is limited due to the MAWP limit

set in the Calculations tab of the Set Mode

dialog.

(2) This pressure chamber is not designed for

external pressure.

6/81


Notes for MDMT Rating

Note # Exemption Details

1. Straight Flange governs MDMT


3. Material is impact tested per UG-84 to -20°C. Stress ratio = 0,3116 ≤ 0,35, MDMT per UCS-66(b)(3) = -105°C.



6. Straight Flange governs MDMT


8. Nozzle is impact tested per UG-84 to -20°C. UCS-66(i) reduction of 31,6°C applied (ratio = 0,5003).

9.

UCS-66(b)(1)(b) has been applied.

Flange is impact tested per UG-84 to -20°C.

UCS-66(i) reduction of 8,1°C applied (ratio = 0,8547).



11. Bolted cover is impact tested per UG-84 to -20°C. UCS-66(i) reduction of 7,5°C applied (ratio = 0,8656).


13.

UCS-66(b)(1)(b) has been applied.





15. Bolted cover is impact tested per UG-84 to -20°C. UCS-66(i) reduction of 10,3°C applied (ratio = 0,8158).

16.Pad is impact tested per UG-84 to -20°C.

UCS-66(i) reduction of 18,9°C applied (ratio = 0,6623).Bolts rated MDMT per Fig UCS-66 note (c) = -48°C


18.

LWN rated MDMT per UCS-66(c)(4)




7/81


Thickness Summary

Component Data

Component

IdentifierMaterial Diameter

(mm)

Length

(mm)

Nominal t

(mm)

Design t

(mm)

Total Corrosion

(mm)

Joint

ELoad

Ellipsoidal Head Inlet SA-387 11 2 1.400 ID 380 30* 15,81 1,6 1,00 Internal

Straight Flange on Ellipsoidal Head Inlet SA-387 11 2 1.400 ID 50,8 30 16 1,6 1,00 Internal

Shell- Inlet Chamber SA-387 11 2 1.500 OD 1.400 50 16,68 1,6 1,00 Internal

Transition #1 SA-387 11 2 1.300 / 1.400 ID 180 25 17,07 1,6 1,00 Internal

Shell Outlet Chamber SA-387 11 2 1.350 OD 1.550 30 15,64 1,6 1,00 Internal

Straight Flange on Ellipsoidal Head Outlet SA-387 11 2 1.350 OD 50,8 20 15,64 1,6 1,00 Internal

Ellipsoidal Head Outlet SA-387 11 2 1.350 OD 347,5 20* 15,46 1,6 1,00 Internal

Bolted Cover for A03 SA-182 F11 2 1.149,35 OD 98,5 98,5 94,49 1,6 1,00 Internal

Bolted Cover A04 SA-182 F11 2 914,4 OD 80 80 74,56 1,6 1,00 Internal

*Head minimum thickness after forming

Definitions

Nominal t Vessel wall nominal thickness

Design t Required vessel thickness due to governing loading + corrosion

Joint E Longitudinal seam joint efficiency

Load

Internal Circumferential stress due to internal pressure governs

External External pressure governs

WindCombined longitudinal stress of pressure + weight + wind

governs

SeismicCombined longitudinal stress of pressure + weight + seismic

governs

8/81


Revision History

Revisions

No. Date Operator Notes

0 12/19/2016 ph New vessel created ASME Section VIII Division 1 [COMPRESS 2015 Build 7510]

9/81


Radiography Summary

UG-116 Radiography

Component

Longitudinal Seam Left Circumferential Seam Right Circumferential Seam

MarkCategory

(Fig UW-3)

Radiography / Joint

Type

Category

(Fig UW-3)

Radiography / Joint

Type

Category

(Fig UW-3)

Radiography / Joint

Type

Ellipsoidal Head Inlet N/A Seamless No RT N/A N/A B Full UW-11(a) / Type 1 RT1

Bolted Cover for A03 N/A Seamless No RT N/A N/A / Gasketed N/A N/A N/A

Shell- Inlet Chamber A Full UW-11(a) / Type 1 B Full UW-11(a) / Type 1 B Full UW-11(a) / Type 1 RT1

Transition #1 A Full UW-11(a) / Type 1 B Full UW-11(a) / Type 1 B Full UW-11(a) / Type 1 RT1

Shell Outlet Chamber A Full UW-11(a) / Type 1 B Full UW-11(a) / Type 1 B Full UW-11(a) / Type 1 RT1

Bolted Cover A04 N/A Seamless No RT N/A N/A / Gasketed N/A N/A N/A

Ellipsoidal Head Outlet N/A Seamless No RT B Full UW-11(a) / Type 1 N/A N/A RT1

Nozzle Longitudinal SeamNozzle to Vessel Circumferential

Seam

Nozzle free end Circumferential

Seam

Manhole (A03) N/A Seamless No RT D N/A / Type 7 C Full UW-11(a) / Type 1 RT1

Inlet (N01) A User Defined (E = 1,00) D N/A / Type 7 N/A N/A RT1

Manhole (A04) N/A Seamless No RT D N/A / Type 7 C Full UW-11(a) / Type 1 RT1

Outlet (N02) N/A Seamless No RT D N/A / Type 7 C N/A N/A

Nozzle (Control Valve) N/A Seamless No RT D N/A / Type 7 N/A N/A N/A

Nozzle Flange Longitudinal Seam Flange FaceNozzle to Flange Circumferential

Seam

Manhole A03 N/A Seamless No RT N/A N/A / Gasketed C Full UW-11(a) / Type 1 RT1

Manhole A04 N/A Seamless No RT N/A N/A / Gasketed C Full UW-11(a) / Type 1 RT1


Outlet (N02)N/A Seamless No RT N/A N/A / Gasketed C N/A N/A

UG-116(e) Required Marking: RT1

10/81


Test Report

Horizontal shop test based on user defined pressure

Gauge pressure at 20°C = 41,35 bar

Horizontal shop test


(bar)


(bar)

Ellipsoidal Head Inlet 41,52 0,17

Straight Flange on Ellipsoidal Head Inlet 41,52 0,17

Shell- Inlet Chamber 41,52 0,17

Transition #1 41,52 0,17

Shell Outlet Chamber 41,51 0,16

Straight Flange on Ellipsoidal Head Outlet 41,51 0,16

Ellipsoidal Head Outlet 41,51 0,16

Manhole A03 - Flange Hub 41,49 0,14


Bolted Cover for A03 41,49 0,14

Manhole A03 41,49 0,14

Bolted Cover A04 41,48 0,13

Manhole A04 41,48 0,13

Inlet (N01) 41,49 0,14

Manhole (A03) 41,49 0,14

Manhole (A04) 41,48 0,13

Nozzle (Control Valve) 41,46 0,11

Outlet (N02) 41,38 0,03

(1) The zero degree angular position is assumed to be

up, and the test liquid height is assumed to the top-most

flange.

The test temperature of 20 °C is warmer than the minimum recommended temperature of -10,5 °C so the brittle


11/81


Horizontal field test based on user defined pressure

Gauge pressure at 20°C = 41,35 bar

Horizontal field test


(bar)


(bar)

Ellipsoidal Head Inlet 41,52 0,17

Straight Flange on Ellipsoidal Head Inlet 41,52 0,17

Shell- Inlet Chamber 41,52 0,17

Transition #1 41,52 0,17

Shell Outlet Chamber 41,51 0,16

Straight Flange on Ellipsoidal Head Outlet 41,51 0,16

Ellipsoidal Head Outlet 41,51 0,16



Bolted Cover for A03 41,49 0,14

Manhole A03 41,49 0,14

Bolted Cover A04 41,48 0,13

Manhole A04 41,48 0,13

Inlet (N01) 41,49 0,14

Manhole (A03) 41,49 0,14

Manhole (A04) 41,48 0,13

Nozzle (Control Valve) 41,46 0,11

Outlet (N02) 41,38 0,03

(1) The zero degree angular position is assumed to be

up, and the test liquid height is assumed to the top-most

flange.

The test temperature of 20 °C is warmer than the minimum recommended temperature of -10,5 °C so the brittle


12/81


Ellipsoidal Head Inlet


Component Ellipsoidal Head


Attached To Shell- Inlet Chamber

ImpactTested


PWHTOptimize MDMT/

Find MAWP




DesignMDMT (°C)

Internal 30 400 -5,4

Static Liquid Head



Dimensions

Inner Diameter 1.400 mm

Head Ratio 2

Minimum Thickness 30 mm


Outer 0 mm

Length Lsf 50,8 mm

Nominal Thickness tsf 30 mm

Weight and Capacity

Weight (kg)1 Capacity (liters)1

New 469,8 437,39

Corroded 446,26 441,04

Radiography

Category A joints Seamless No RT

Head to shell seam Full UW-11(a) Type 11 includes straight flange

13/81


Results Summary

Governing condition internal pressure





Straight Flange governs MDMT -50,9°C

Factor K

K = (1/6)*[2 + (D / (2*h))2]

Corroded K = (1/6)*[2 + (1.403,2 / (2*351,6))2] 0,997

New K = (1/6)*[2 + (1.400 / (2*350))2] 1

Design thickness for internal pressure, (Corroded at 400 °C) Appendix 1-4(c)

t = P*D*K / (2*S*E - 0,2*P) + Corrosion

= 30*1.403,2*0,996969 / (2*1.480*1 - 0,2*30) + 1,6

= 15,81 mm

Maximum allowable working pressure, (Corroded at 400 °C) Appendix 1-4(c)

P = 2*S*E*t / (K*D + 0,2*t) - Ps

= 2*1.480*1*28,4 / (0,996969*1.403,2 +0,2*28,4) - 0

= 59,85 bar

Maximum allowable pressure, (New at 20 °C) Appendix 1-4(c)

P = 2*S*E*t / (K*D + 0,2*t) - Ps

= 2*1.480*1*30 / (1*1.400 +0,2*30) - 0

= 63,16 bar


EFE = (75*t / Rf)*(1 - Rf / Ro)

= (75*30 / 253)*(1 - 253 / infinity)

= 8,8933%

14/81


Straight Flange on Ellipsoidal Head Inlet


Component Cylinder


ImpactTested


PWHTOptimize MDMT/

Find MAWP




DesignMDMT (°C)


Static Liquid Head



Dimensions

Inner Diameter 1.400 mm

Length 50,8 mm



Outer 0 mm

Weight and Capacity


New 53,63 78,2

Corroded 50,83 78,56

Radiography

Longitudinal seam Seamless No RT



15/81


Results Summary



Design thickness due to internal pressure (t) 16 mm






tr = 30*701,6 / (1.480*1 - 0.6*30) = 14,4 mm





Design thickness, (at 400 °C) UG-27(c)(1)

t = P*R / (S*E - 0,60*P) + Corrosion

= 30*701,6 / (1.480*1,00 - 0,60*30) + 1,6

= 16 mm

Maximum allowable working pressure, (at 400 °C) UG-27(c)(1)

P = S*E*t / (R + 0,60*t) - Ps

= 1.480*1,00*28,4 / (701,6 + 0,60*28,4) - 0

= 58,49 bar

Maximum allowable pressure, (at 20 °C) UG-27(c)(1)

P = S*E*t / (R + 0,60*t)

= 1.480*1,00*30 / (700 + 0,60*30)

= 61,84 bar


EFE = (50*t / Rf)*(1 - Rf / Ro)

= (50*30 / 715)*(1 - 715 / infinity)

= 2,0979%


16/81


Shell- Inlet Chamber


Component Cylinder


ImpactTested


PWHTOptimize MDMT/

Find MAWP




DesignMDMT (°C)


Static Liquid Head



Dimensions


Length 1.400 mm



Outer 0 mm

Weight and Capacity


New 2.192,58 2.155,13

Corroded 2.125,07 2.165

Radiography






17/81


Results Summary






Rated MDMT -105 °C



tr = 30*750 / (1.480*1 + 0.4*30) = 15,08 mm


Stress ratio ≤ 0,35, MDMT per UCS-66(b)(3) = -105°C

MDMT = min[-20 , -105] = -105°C




= 30*750 / (1.480*1,00 + 0,40*30) + 1,6

= 16,68 mm


P = S*E*t / (Ro - 0,40*t) - Ps

= 1.480*1,00*48,4 / (750 - 0,40*48,4) - 0

= 98,04 bar


P = S*E*t / (Ro - 0,40*t)

= 1.480*1,00*50 / (750 - 0,40*50)

= 101,37 bar


EFE = (50*t / Rf)*(1 - Rf / Ro)

= (50*50 / 725)*(1 - 725 / infinity)

= 3,4483%


18/81


Manhole (A03)




Located on Ellipsoidal Head Inlet

Orientation 0°

End of nozzle to datum line -700 mm

Calculated as hillside No

Distance to head center, R 0 mm


Nozzle

Access opening No

Material specification SA-182 F11 2 (II-D Metric p. 38, ln. 30) (normalized)


Nominal wall thickness 54 mm



Projection available outside vessel to flange face, Lf 346,21 mm




Welds



19/81




tr = 30*1.403,2*0,996969 / (2*1.480*1 - 0,2*30) = 14,21 mm







tr = 30*388,17 / (1.380*1 - 0,6*30) = 8,55 mm



MDMT = min[-20 , -105] = -105°C


20/81





Summary(mm)

For P = 34,64 bar @ 400 °C


The nozzle

passes UG-45

A

required

A


A

weldstreq tmin

128,7819 128,7843 92,0695 35,9703 -- -- 0,7445 11,64 54

UG-41 Weld Failure Path Analysis Summary(kgf)

All failure paths are stronger than the applicable weld loads

Weld load

W

Weld load

W1-1

Path 1-1

strength

Weld load

W2-2

Path 2-2

strength

72.833 55.409 746.835 96.684 369.059



size (mm)

Actual weld

size (mm)Status


Combined weld check (t1 + t2) 23,75 24,7 weld size is adequate

Nozzle to shell groove (Lower) 17,45 18,4 weld size is adequate



LR = MAX(d, Rn + (tn - Cn) + (t - C))

= MAX(776,33, 388,17 + (54 - 1,6) + (30 - 1,6))

= 776,33 mm


LH = MIN(2,5*(t - C), 2,5*(tn - Cn) + te)

= MIN(2,5*(30 - 1,6), 2,5*(54 - 1,6) + 0)

= 71 mm


trn = P*Rn / (Sn*E - 0,6*P)

= 34,6377*388,17 / (1.360*1 - 0,6*34,6377)

= 10,04 mm

21/81



tr = P*D*K / (2*S*E - 0,2*P)

= 34,64*1.403,2*0,996969 / (2*1.480*1 - 0,2*34,64)

= 16,41 mm





A = d*tr*F + 2*tn*tr*F*(1 - fr1)

= (776,33*16,41*1 + 2*52,4*16,41*1*(1 - 0,9189)) / 100

= 128,7819 cm2




= (776,33*(1*28,4 - 1*16,41) - 2*52,4*(1*28,4 - 1*16,41)*(1 - 0,9189)) / 100

= 92,0695 cm2


= (2*(28,4 + 52,4)*(1*28,4 - 1*16,41) - 2*52,4*(1*28,4 - 1*16,41)*(1 - 0,9189)) / 100

= 18,358 cm2


= 2*(tn - trn)*fr2*Lpr

= (2*(52,4 - 10,04)*0,9189*46,21) / 100

= 35,9703 cm2


= (2*(52,4 - 10,04)*0,9189*46,21) / 100

= 35,9703 cm2

A41 = Leg2*fr2= (92*0,9189) / 100

= 0,7445 cm2

Area = A1 + A2 + A41

= 92,0695 + 35,9703 + 0,7445

= 128,7843 cm2

22/81



UW-16(d) Weld Check

tmin = lesser of 19 mm or tn or t = 19 mm

t1(min) or t2(min) = lesser of 6 mm or 0,7*tmin = 6 mm

t1(actual) = 0,7*Leg = 0.7*9 = 6,3 mm

The weld size t1 is satisfactory.

t2(actual) = 18,4 mm


t1 + t2 = 24,7 >= 1,25*tmin = 23,75

The combined weld sizes for t1 and t2 are satisfactory.


Interpretation VIII-1-83-66 has been applied.


= 34,6377*388,17 / (1.360*1 - 0,6*34,6377) + 1,6

= 11,64 mm


= max[ 11,64 , 0 ]

= 11,64 mm

tb1 = 18,01 mm


= max[ 18,01 , 3,1 ]

= 18,01 mm


= min[ 9,93 , 18,01 ]

= 9,93 mm


= max[ 11,64 , 9,93 ]

= 11,64 mm

Available nozzle wall thickness new, tn = 54 mm


Allowable stresses in joints UG-45 and UW-15(c)

Groove weld in tension: 0,74*1.509,179 = 1.116,792 kgf/cm2

Nozzle wall in shear: 0,7*1.386,813 = 970,769 kgf/cm2

23/81


Inner fillet weld in shear: 0,49*1.386,813 = 679,538 kgf/cm2

Strength of welded joints:

(1) Inner fillet weld in shear

(π / 2)*Nozzle OD*Leg*Si = (π / 2)*881,13*9*679,538 = 84.648,01 kgf

(3) Nozzle wall in shear

(π / 2)*Mean nozzle dia*tn*Sn = (π / 2)*828,73*52,4*970,769 = 662.186,84 kgf

(4) Groove weld in tension

(π / 2)*Nozzle OD*tw*Sg = (π / 2)*881,13*18,4*1.116,792 = 284.410,6 kgf

Loading on welds per UG-41(b)(1)

W = (A - A1 + 2*tn*fr1*(E1*t - F*tr))*Sv

= (12.878,19 - 9.206,9493 + 2*52,4*0,9189*(1*28,4 - 1*16,41))*1.509,179

= 72.832,64 kgf

W1-1 = (A2 + A5 + A41 + A42)*Sv

= (3.597,0251 + 0 + 74,4515 + 0)*1.509,179

= 55.409,2 kgf

W2-2 = (A2 + A3 + A41 + A43 + 2*tn*t*fr1)*Sv

= (3.597,0251 + 0 + 74,4515 + 0 + 2*52,4*28,4*0,9189)*1.509,179

= 96.684,08 kgf

Load for path 1-1 lesser of W or W1-1 = 55.409,2 kgf

Path 1-1 through (1) & (3) = 84.648,01 + 662.186,84 = 746.834,84 kgf

Path 1-1 is stronger than W1-1 so it is acceptable per UG-41(b)(1).


Path 2-2 through (1), (4) = 84.648,01 + 284.410,6 = 369.058,6 kgf

Path 2-2 is stronger than W so it is acceptable per UG-41(b)(2).

24/81





Summary(mm)

For P = 36,56 bar @ 20 °C


The nozzle

passes UG-45

A

required

A


A

weldstreq tmin

135,2975 135,3004 96,9824 37,5625 -- -- 0,7555 10,41 54

UG-41 Weld Failure Path Analysis Summary(kgf)

All failure paths are stronger than the applicable weld loads

Weld load

W

Weld load

W1-1

Path 1-1

strength

Weld load

W2-2

Path 2-2

strength

77.070 57.829 776.998 103.421 395.038



size (mm)

Actual weld

size (mm)Status


Combined weld check (t1 + t2) 23,75 26,3 weld size is adequate

Nozzle to shell groove (Lower) 17,45 20 weld size is adequate



LR = MAX(d, Rn + (tn - Cn) + (t - C))

= MAX(773,13, 386,57 + (54 - 0) + (30 - 0))

= 773,13 mm


LH = MIN(2,5*(t - C), 2,5*(tn - Cn) + te)

= MIN(2,5*(30 - 0), 2,5*(54 - 0) + 0)

= 75 mm


trn = P*Rn / (Sn*E - 0,6*P)

= 36,5635*386,57 / (1.380*1 - 0,6*36,5635)

= 10,41 mm

25/81



tr = P*D / (2*S*E - 0,2*P)

= 36,56*1.400 / (2*1.480*1 - 0,2*36,56)

= 17,34 mm





A = d*tr*F + 2*tn*tr*F*(1 - fr1)

= (773,13*17,34*1 + 2*54*17,34*1*(1 - 0,9324)) / 100

= 135,2975 cm2




= (773,13*(1*30 - 1*17,34) - 2*54*(1*30 - 1*17,34)*(1 - 0,9324)) / 100

= 96,9824 cm2


= (2*(30 + 54)*(1*30 - 1*17,34) - 2*54*(1*30 - 1*17,34)*(1 - 0,9324)) / 100

= 20,3503 cm2



= (2*(54 - 10,41)*0,9324*46,21) / 100

= 37,5625 cm2


= (2*(54 - 10,41)*0,9324*46,21) / 100

= 37,5625 cm2

A41 = Leg2*fr2= (92*0,9324) / 100

= 0,7555 cm2

Area = A1 + A2 + A41

= 96,9824 + 37,5625 + 0,7555

= 135,3004 cm2

26/81



UW-16(d) Weld Check

tmin = lesser of 19 mm or tn or t = 19 mm

t1(min) or t2(min) = lesser of 6 mm or 0,7*tmin = 6 mm

t1(actual) = 0,7*Leg = 0.7*9 = 6,3 mm


t2(actual) = 20 mm


t1 + t2 = 26,3 >= 1,25*tmin = 23,75

The combined weld sizes for t1 and t2 are satisfactory.




= 36,5635*386,57 / (1.380*1 - 0,6*36,5635) + 0

= 10,41 mm


= max[ 10,41 , 0 ]

= 10,41 mm

tb1 = 17,34 mm


= max[ 17,34 , 1,5 ]

= 17,34 mm


= min[ 8,33 , 17,34 ]

= 8,33 mm


= max[ 10,41 , 8,33 ]

= 10,41 mm



Allowable stresses in joints UG-45 and UW-15(c)

Groove weld in tension: 0,74*1.509,179 = 1.116,792 kgf/cm2

Nozzle wall in shear: 0,7*1.407,207 = 985,045 kgf/cm2

27/81


Inner fillet weld in shear: 0,49*1.407,207 = 689,532 kgf/cm2

Strength of welded joints:

(1) Inner fillet weld in shear

(π / 2)*Nozzle OD*Leg*Si = (π / 2)*881,13*9*689,532 = 85.892,83 kgf

(3) Nozzle wall in shear

(π / 2)*Mean nozzle dia*tn*Sn = (π / 2)*827,13*54*985,045 = 691.104,79 kgf

(4) Groove weld in tension

(π / 2)*Nozzle OD*tw*Sg = (π / 2)*881,13*20*1.116,792 = 309.145,31 kgf

Loading on welds per UG-41(b)(1)

W = (A - A1 + 2*tn*fr1*(E1*t - F*tr))*Sv

= (13.529,75 - 9.698,2387 + 2*54*0,9324*(1*30 - 1*17,34))*1.509,179

= 77.069,94 kgf

W1-1 = (A2 + A5 + A41 + A42)*Sv

= (3.756,2506 + 0 + 75,5482 + 0)*1.509,179

= 57.828,75 kgf

W2-2 = (A2 + A3 + A41 + A43 + 2*tn*t*fr1)*Sv

= (3.756,2506 + 0 + 75,5482 + 0 + 2*54*30*0,9324)*1.509,179

= 103.420,72 kgf


Path 1-1 through (1) & (3) = 85.892,83 + 691.104,79 = 776.997,62 kgf

Path 1-1 is stronger than W1-1 so it is acceptable per UG-41(b)(1).


Path 2-2 through (1), (4) = 85.892,83 + 309.145,31 = 395.038,14 kgf

Path 2-2 is stronger than W so it is acceptable per UG-41(b)(2).

28/81


Inlet (N01)


Note: Per UW-16(b) minimum inside corner radius r1 = min [1 / 4*t , 3 mm] = 3 mm


Located on Shell- Inlet Chamber

Orientation 270°

Nozzle center line offset to datum line 700 mm

End of nozzle to shell center 1.000 mm


Nozzle

Access opening No

Material specification SA-387 11 2 (II-D Metric p. 38, ln. 33) (normalized)

Inside diameter, new 896 mm

Wall thickness, tn 50 mm

Minimum wall thickness 25 mm



Heavy barrel length, Lhb 120 mm




Welds



29/81




tr = 30*750 / (1.480*1 + 0,4*30) = 15,08 mm



MDMT = min[-20 , -105] = -105°C




External nozzle loadings per UG-22 govern the coincident ratio used.





30/81



Local stresses at the nozzle OD per WRC 107 govern the MAWP of this nozzle.


Summary(mm)

For P = 34,33 bar @ 400 °C


The nozzle

passes UG-45

A

required

A


A

weldstreq tmin

103,3252 217,9318 140,1113 77,0102 -- -- 0,8103 17,26 25





throat size (mm)

Actual weld



WRC 107

Load CaseP

(bar)

Pr

(kgf)

Mc

(kgf-m)

Vc

(kgf)

ML

(kgf-m)

VL

(kgf)

Mt

(kgf-m)

Max

Comb

Stress

(kgf/cm2)

Allow

Comb

Stress

(kgf/cm2)

Max

Local

Primary

Stress

(kgf/cm2)

Allow

Local

Primary

Stress

(kgf/cm2)

Over

stressed

Load case 1 34,33 13.200,01 94.999,6 0 66.799,7 0 0 4.389,611 4.527,536 2.263,742 2.263,768 No

Load case 1 (Hot Shut

Down)0 13.200,01 94.999,6 0 66.799,7 0 0 -4.320,218 4.527,536 -1.071,829 2.263,768 No



LR = MAX(d, Rn + (tn - Cn) + (t - C))

= MAX(899,2, 449,6 + (25 - 1,6) + (50 - 1,6))

= 899,2 mm


LH = MIN(2,5*(t - C), 2,5*(tn - Cn) + te)

= MIN(2,5*(50 - 1,6), 2,5*(25 - 1,6) + 43,3)

= 101,8 mm

te = MIN( 120 + 25*tan(30) , 25*tan(60) )

= 43,3 mm

31/81



trn = P*Rn / (Sn*E - 0,6*P)

= 34,3283*449,6 / (1.480*1 - 0,6*34,3283)

= 10,58 mm


tr = P*Ro / (S*E + 0,4*P)

= 34,3283*750 / (1.480*1 + 0,4*34,3283)

= 17,24 mm



fr1 = lesser of 1 or Sn / Sv = 1


A = d*tr*F + 2*tn*tr*F*(1 - fr1)

= (899,2*17,24*1 + 2*48,4*17,24*1*(1 - 1)) / 100

= 154,9878 cm2




= (899,2*(1*48,4 - 1*17,24) - 2*48,4*(1*48,4 - 1*17,24)*(1 - 1)) / 100

= 280,2233 cm2


= (2*(48,4 + 48,4)*(1*48,4 - 1*17,24) - 2*48,4*(1*48,4 - 1*17,24)*(1 - 1)) / 100

= 60,3328 cm2


= 5*(tn - trn)*fr2*t - (LIMIT - Lhb)2*fr2 / tan(30)

= (5*(48,4 - 10,58)*1*48,4 - (121 - 120)2*1 / tan(30)) / 100

= 91,5153 cm2

= 2*(tn - trn)*(2,5*tp + te)*fr2= (2*(48,4 - 10,58)*(2,5*23,4 + 43,3)*1) / 100

= 77,0102 cm2

A41 = Leg2*fr2

32/81


= (92*1) / 100

= 0,8103 cm2

Area = A1 + A2 + A41

= 280,2233 + 77,0102 + 0,8103

= 358,0438 cm2


UW-16(c) Weld Check



tc(actual) = 0,7*Leg = 0.7*9 = 6,3 mm





= 34,3283*449,6 / (1.480*1 - 0,6*34,3283) + 1,6

= 12,18 mm

ta UG-22 = 17,26 mm


= max[ 12,18 , 17,26 ]

= 17,26 mm


= 34,3283*750 / (1.480*1 + 0,4*34,3283) + 1,6

= 18,84 mm


= max[ 18,84 , 3,1 ]

= 18,84 mm


= min[ 9,93 , 18,84 ]

= 9,93 mm


= max[ 17,26 , 9,93 ]

= 17,26 mm


33/81



Check Large Opening per Appendix 1-7(a)

Area required within 75 percent of the limits of reinforcement

= 2 / 3*A = (2 / 3)*154,9878 = 103,3252 cm2

LR = MAX(0,75*d, Rn + (tn - Cn) + (t - C))

= MAX(0,75*899,2, 449,6 + (25 - 1,6) + (50 - 1,6))

= 674,4 mm

A1 = (2*LR - d)*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1)

= (2*674,4 - 899,2)*(1*48,4 - 1*17,24) - 2*48,4*(1*48,4 - 1*17,24)*(1 - 1)

= 140,1113 cm2

Area = A1 + A2 + A3 + A41 + A42 + A43 + A5

= 140,1113 + 77,0102 + 0 + 0,8103 + 0 + 0 + 0

= 217,9318 cm2

The area replacement requirements of Appendix 1-7(a) are satisfied.

Check Large Opening per Appendix 1-7(b)

1-7(b)(1)(a) Di = 1.403,2 mm > 1.520 mm False

1-7(b)(1)(b) d = 899,2 mm > 1.020 mm False

1-7(b)(1)(b) d = 899,2 mm > 3,4*(701,6*48,4)0,5 = 626,54 mm True

1-7(b)(1)(c) Rn / R = 449,6 / 701,6 = 0,6408 ≤ 0,7 True

The opening is not within the size range defined by 1-7(b)(1)(a) and (b) so it is exempt from the requirements of

1-7(b)(2),(3) and (4).

Rn / R = 0,6408 does not exceed 0,7 so a U-2(g) analysis is not required per 1-7(b)(1)(c).

34/81


WRC 107 Load case 1

Applied Loads

Radial load, Pr 13.200,01 kgf

Circumferential moment, Mc 94.999,6 kgf-m


Longitudinal moment, ML 66.799,7 kgf-m






Design factor 3


γ = Rm / T = 725,8 / 48,4 = 14,9959

β = 0,875*ro / Rm = 0,875*498 / 725,8 = 0,6004





b+Q) = 4.389,61 kgf/cm2


b+Q) = ±3*S = ±4.527,54 kgf/cm2






35/81




3C* Nφ / (P / Rm) 0,8799 0 0 0 0 -33,044 -33,044 -33,044 -33,044

4C* Nφ / (P / Rm) 1,6097 -60,464 -60,464 -60,464 -60,464 0 0 0 0

1C Mφ / P 0,055 0 0 0 0 -185,962 185,962 -185,962 185,962

2C-1 Mφ / P 0,0148 -50,059 50,059 -50,059 50,059 0 0 0 0

3A* Nφ / [Mc / (Rm2*β)] 0,5799 0 0 0 0 -359,901 -359,901 359,901 359,901

1A Mφ / [Mc / (Rm*β)] 0,067 0 0 0 0 -3.741,311 3.741,311 3.741,311 -3.741,311

3B* Nφ / [ML / (Rm2*β)] 1,1699 -510,569 -510,569 510,569 510,569 0 0 0 0

1B-1 Mφ / [ML / (Rm*β)] 0,0135 -530,044 530,044 530,044 -530,044 0 0 0 0

Pressure stress* 1.813,637 1.813,637 1.813,637 1.813,637 507,405 507,405 507,405 507,405

Total circumferential stress 662,502 1.822,706 2.743,727 1.783,756 -3.812,813 4.041,733 4.389,611 -2.721,088


stress*1.242,604 1.242,604 2.263,742 2.263,742 114,46 114,46 834,262 834,262

3C* Nx / (P / Rm) 0,8799 -33,044 -33,044 -33,044 -33,044 0 0 0 0

4C* Nx / (P / Rm) 1,6097 0 0 0 0 -60,464 -60,464 -60,464 -60,464

1C-1 Mx / P 0,029 -98,078 98,078 -98,078 98,078 0 0 0 0

2C Mx / P 0,03 0 0 0 0 -101,453 101,453 -101,453 101,453

4A* Nx / [Mc / (Rm2*β)] 1,6296 0 0 0 0 -1.011,365 -1.011,365 1.011,365 1.011,365

2A Mx / [Mc / (Rm*β)] 0,032 0 0 0 0 -1.786,92 1.786,92 1.786,92 -1.786,92

4B* Nx / [ML / (Rm2*β)] 0,5899 -257,394 -257,394 257,394 257,394 0 0 0 0

2B-1 Mx / [ML / (Rm*β)] 0,024 -942,323 942,323 942,323 -942,323 0 0 0 0

Pressure stress* 253,667 253,667 253,667 253,667 906,678 906,678 906,678 906,678

Total longitudinal stress -1.077,172 1.003,631 1.322,262 -366,229 -2.053,524 1.723,222 3.543,046 172,111

Primary membrane longitudinal stress* -36,771 -36,771 478,017 478,017 -165,151 -165,151 1.857,579 1.857,579

Shear from Mt 0 0 0 0 0 0 0 0




Combined stress (PL+Pb+Q) -1.739,674 1.822,706 2.743,727 -2.149,985 -3.812,813 4.041,733 4.389,611 2.893,199




2)) + M*Ro / I

= 34,33*1,02*449,6 / (2*23,4) - 13.200,01 / (π*(4732 - 449,62))*100 + 1,1613E+08*473 / 7,221E+09*100

= 1.077,55 kgf/cm2



36/81



The large opening provisions of Appendix 1-7(a) govern the MAP of this nozzle.


Summary(mm)

For P = 56,29 bar @ 20 °C


The nozzle

passes UG-45

A

required

A


A

weldstreq tmin

167,8356 167,8377 98,123 68,9044 -- -- 0,8103 19,29 25





throat size (mm)

Actual weld





LR = MAX(d, Rn + (tn - Cn) + (t - C))

= MAX(896, 448 + (25 - 0) + (50 - 0))

= 896 mm


LH = MIN(2,5*(t - C), 2,5*(tn - Cn) + te)

= MIN(2,5*(50 - 0), 2,5*(25 - 0) + 43,3)

= 105,8 mm

te = MIN( 120 + 25*tan(30) , 25*tan(60) )

= 43,3 mm


trn = P*Rn / (Sn*E - 0,6*P)

= 56,2891*448 / (1.480*1 - 0,6*56,2891)

= 17,44 mm


tr = P*Ro / (S*E + 0,4*P)

= 56,2891*750 / (1.480*1 + 0,4*56,2891)

37/81


= 28,1 mm





A = d*tr*F + 2*tn*tr*F*(1 - fr1)

= (896*28,1*1 + 2*50*28,1*1*(1 - 1)) / 100

= 251,7534 cm2




= (896*(1*50 - 1*28,1) - 2*50*(1*50 - 1*28,1)*(1 - 1)) / 100

= 196,2467 cm2


= (2*(50 + 50)*(1*50 - 1*28,1) - 2*50*(1*50 - 1*28,1)*(1 - 1)) / 100

= 43,8051 cm2


= 5*(tn - trn)*fr2*t - (LIMIT - Lhb)2*fr2 / tan(30)

= (5*(50 - 17,44)*1*50 - (125 - 120)2*1 / tan(30)) / 100

= 80,974 cm2

= 2*(tn - trn)*(2,5*tp + te)*fr2= (2*(50 - 17,44)*(2,5*25 + 43,3)*1) / 100

= 68,9044 cm2

A41 = Leg2*fr2= (92*1) / 100

= 0,8103 cm2

Area = A1 + A2 + A41

= 196,2467 + 68,9044 + 0,8103

= 265,9614 cm2


38/81


UW-16(c) Weld Check



tc(actual) = 0,7*Leg = 0.7*9 = 6,3 mm





= 56,2891*448 / (1.480*1 - 0,6*56,2891) + 0

= 17,44 mm

ta UG-22 = 19,29 mm


= max[ 17,44 , 19,29 ]

= 19,29 mm


= 56,2891*750 / (1.480*1 + 0,4*56,2891) + 0

= 28,1 mm


= max[ 28,1 , 1,5 ]

= 28,1 mm


= min[ 8,33 , 28,1 ]

= 8,33 mm


= max[ 19,29 , 8,33 ]

= 19,29 mm





= 2 / 3*A = (2 / 3)*251,7534 = 167,8356 cm2

LR = MAX(0,75*d, Rn + (tn - Cn) + (t - C))

= MAX(0,75*896, 448 + (25 - 0) + (50 - 0))

= 672 mm

39/81



= (2*672 - 896)*(1*50 - 1*28,1) - 2*50*(1*50 - 1*28,1)*(1 - 1)

= 98,123 cm2

Area = A1 + A2 + A3 + A41 + A42 + A43 + A5

= 98,123 + 68,9044 + 0 + 0,8103 + 0 + 0 + 0

= 167,8377 cm2



1-7(b)(1)(a) Di = 1.400 mm > 1.520 mm False

1-7(b)(1)(b) d = 896 mm > 1.020 mm False

1-7(b)(1)(b) d = 896 mm > 3,4*(700*50)0,5 = 636,08 mm True

1-7(b)(1)(c) Rn / R = 448 / 700 = 0,64 ≤ 0,7 True


1-7(b)(2),(3) and (4).


40/81


Transition #1


Component Cone


ImpactTested


PWHTOptimize MDMT/

Find MAWP




DesignMDMT (°C)


Static Liquid Head


Test horizontalLarge 0,17 1.700

1

Small 0,16 1.650

Dimensions

Inner DiameterLarge 1.400 mm

Small 1.300 mm

Length 180 mm



Outer 0 mm

Weight and Capacity


New 158,14 257,77

Corroded 148,19 259,04

Radiography


Left Circumferential seam Full UW-11(a) Type 1

Right Circumferential seam Full UW-11(a) Type 1

41/81


Results Summary









tr = 30*1.403,32 / (2*0,9635*(1.480*1 - 0.6*30)) = 14,94 mm





Design thickness, (at 450 °C) UG-32(g) (Large End)

t = P*D / (2*cos(α)*(S*E - 0,60*P)) + Corrosion

= 30*1.403,32 / (2*cos(15,5241)*(1.430*1,00 - 0,60*30)) + 1,6

= 17,07 mm

Small End design thickness (t = 15,97 mm) does not govern.

Maximum allowable working pressure, (Corroded at 450 °C) UG-32(g) (Large End)

P = 2*S*E*t*cos(α) / (D + 1,20*t*cos(α)) - Ps

=2*1.430*1,00*23,4*cos(15,5241) / (1.403,32 +

1,20*23,4*cos(15,5241)) - 0

= 45,08 bar

Small End MAWP (48,47 bar) does not govern.

Maximum allowable pressure, (New at 20 °C) UG-32(g) (Large End)

P = 2*S*E*t*cos(α) / (D + 1,20*t*cos(α))

=2*1.480*1,00*25*cos(15,5241) / (1.400 +

1,20*25*cos(15,5241))

= 49,9 bar

Small End MAP (53,65 bar) does not govern.


EFE = (50*t / Rf)*(1 - Rf / Ro)

= (50*25,95 / 662,97)*(1 - 662,97 / infinity)

= 1,9568%


42/81


43/81


Cone juncture large end calculations, P =45,08 barAppendix 1-5(d)

Loading

Area check

required

(∆ < α)

U-2(g)

analysis

required

f1(kgf/cm)

QL(kgf/cm)

ArL(cm2)

AeL(cm2)

Ring

area (cm2)Status

Pressure No No 0 1.612,6 0 49,08 none OK

Cone large end calculations per Appendix 1-5(d)(1), pressure, corroded

Lmin = 2*(RL*ts)0,5

= 2*(701,6*48,4)0,5

= 368,55 mm

The length of the attached cylinder (1.400 mm) ≥ Lmin.

f1 = -Wl / (π*2*Rm) + Ml / (π*R

m

2)

= -10*0 / (π*2*725,8) + 1e4*0 / (π*725,82)

= 0 kgf/cm

P*RL / 2 = 1.612,6 kgf/cm

|f1| <= P*RL / 2 so a U-2(g) analysis is not required.

P / (Ss*E1) = 45,08 / (1.480*1) = 0,03046

From table 1-5.1 ∆ = 30°

As ∆ >= α no additional reinforcement is required.

44/81


Cone juncture small end calculations, P =45,08 barAppendix 1-5(e)

Loading

Area check

required

(∆ < α)

U-2(g)

analysis

required

f2(kgf/cm)

Qs(kgf/cm)

Ars(cm2)

Aes(cm2)

Ring

area (cm2)Status

Pressure Yes No 0 1.486,18 0,17 10,07 none OK

Cone small end calculations per Appendix 1-5(e)(1), pressure, corroded

Lmin = 1,4*(RS*ts)0,5

= 1,4*(646,6*28,4)0,5

= 189,72 mm


f2 = -Ws / (π*2*Rm) + Ms / (π*R

m

2)

= -10*0 / (π*2*660,8) + 1e4*0 / (π*660,82)

= 0 kgf/cm

P*Rs / 2 = 1.486,1836 kgf/cm

|f2| <= P*Rs / 2 so a U-2(g) analysis is not required.

P / (Ss*E1) = 45,08 / (1.430*1) = 0,031525

From table 1-5.2 ∆ = 15,38°

As ∆ < α reinforcement is required.

Qs = P*Rs / 2 + f2= 1.486,18 + 0

= 1.486,18 kgf/cm

Ars = (k*Qs*Rs / (Ss*E1))*(1 - ∆ / α)*tan(α)

= (1*1.486,18*646,6 / (10*1.458,193*1))*(1 - 15,38 / 15,5241)*tan(15,5241)

= 0,1699 cm2

Aes = 0,78*(Rs*ts)0,5*[(ts - t) + (tc - tr) / cos(α)]

= 0.01*0,78*(646,6*28,4)0,5*[(28,4 - 20,78) + (23,4 - 21,56) / cos(15,5241)]

= 10,0717 cm2

Aes >= Ars therefore the small end juncture is adequately reinforced.

45/81


MAP Cone juncture large end calculations, P =49,9 barAppendix 1-5(d)

Loading

Area check

required

(∆ < α)

U-2(g)

analysis

required

f1(kgf/cm)

QL(kgf/cm)

ArL(cm2)

AeL(cm2)

Ring

area (cm2)Status


Cone large end calculations per Appendix 1-5(d)(1), pressure, new

Lmin = 2*(RL*ts)0,5

= 2*(700*50)0,5

= 374,17 mm


f1 = -Wl / (π*2*Rm) + Ml / (π*R

m

2)

= -10*0 / (π*2*725) + 1e4*0 / (π*7252)

= 0 kgf/cm

P*RL / 2 = 1.780,88 kgf/cm

|f1| <= P*RL / 2 so a U-2(g) analysis is not required.

P / (Ss*E1) = 49,9 / (1.480*1) = 0,033715

From table 1-5.1 ∆ = 30°


46/81


MAP Cone juncture small end calculations, P =49,9 barAppendix 1-5(e)

Loading

Area check

required

(∆ < α)

U-2(g)

analysis

required

f2(kgf/cm)

Qs(kgf/cm)

Ars(cm2)

Aes(cm2)

Ring

area (cm2)Status


Cone small end calculations per Appendix 1-5(e)(1), pressure, new

Lmin = 1,4*(RS*ts)0,5

= 1,4*(645*30)0,5

= 194,75 mm


f2 = -Ws / (π*2*Rm) + Ms / (π*R

m

2)

= -10*0 / (π*2*660) + 1e4*0 / (π*6602)

= 0 kgf/cm

P*Rs / 2 = 1.640,9558 kgf/cm

|f2| <= P*Rs / 2 so a U-2(g) analysis is not required.

P / (Ss*E1) = 49,9 / (1.480*1) = 0,033715

From table 1-5.2 ∆ = 15,93°


47/81


Shell Outlet Chamber


Component Cylinder


ImpactTested


PWHTOptimize MDMT/

Find MAWP




DesignMDMT (°C)


Static Liquid Head



Dimensions


Length 1.550 mm



Outer 0 mm

Weight and Capacity


New 1.393,67 2.025,82

Corroded 1.321,06 2.035,89

Radiography






48/81


Results Summary









tr = 30*675 / (1.480*1 + 0.4*30) = 13,57 mm







= 30*675 / (1.430*1,00 + 0,40*30) + 1,6

= 15,64 mm


P = S*E*t / (Ro - 0,40*t) - Ps

= 1.430*1,00*28,4 / (675 - 0,40*28,4) - 0

= 61,2 bar


P = S*E*t / (Ro - 0,40*t)

= 1.480*1,00*30 / (675 - 0,40*30)

= 66,97 bar


EFE = (50*t / Rf)*(1 - Rf / Ro)

= (50*30 / 660)*(1 - 660 / infinity)

= 2,2727%


49/81


Manhole (A04)




Located on Shell Outlet Chamber

Orientation 270°




Nozzle

Access opening No



Nominal wall thickness 50 mm







Welds



50/81




tr = 30*675 / (1.480*1 + 0,4*30) = 13,57 mm







tr = 30*302,45 / (1.380*1 - 0,6*30) = 6,66 mm



MDMT = min[-20 , -105] = -105°C


51/81



The large opening provisions of Appendix 1-7(a) govern the MAWP of this nozzle.


Summary(mm)

For P = 34,51 bar @ 450 °C


The nozzle

passes UG-45

A

required

A


A

weldstreq tmin

66,015 66,0179 36,0148 29,267 -- -- 0,7361 9,93 50





throat size (mm)

Actual weld





LR = MAX(d, Rn + (tn - Cn) + (t - C))

= MAX(604,9, 302,45 + (50 - 1,6) + (30 - 1,6))

= 604,9 mm


LH = MIN(2,5*(t - C), 2,5*(tn - Cn) + te)

= MIN(2,5*(30 - 1,6), 2,5*(50 - 1,6) + 0)

= 71 mm


trn = P*Rn / (Sn*E - 0,6*P)

= 34,5132*302,45 / (1.300*1 - 0,6*34,5132)

= 8,16 mm


tr = P*Ro / (S*E + 0,4*P)

= 34,5132*675 / (1.430*1 + 0,4*34,5132)

= 16,14 mm

52/81






A = d*tr*F + 2*tn*tr*F*(1 - fr1)

= (604,9*16,14*1 + 2*48,4*16,14*1*(1 - 0,9091)) / 100

= 99,0225 cm2




= (604,9*(1*28,4 - 1*16,14) - 2*48,4*(1*28,4 - 1*16,14)*(1 - 0,9091)) / 100

= 73,1082 cm2


= (2*(28,4 + 48,4)*(1*28,4 - 1*16,14) - 2*48,4*(1*28,4 - 1*16,14)*(1 - 0,9091)) / 100

= 17,7587 cm2



= (2*(48,4 - 8,16)*0,9091*40) / 100

= 29,267 cm2


= (2*(48,4 - 8,16)*0,9091*40) / 100

= 29,267 cm2

A41 = Leg2*fr2= (92*0,9091) / 100

= 0,7361 cm2

Area = A1 + A2 + A41

= 73,1082 + 29,267 + 0,7361

= 103,1114 cm2


53/81


UW-16(c) Weld Check



tc(actual) = 0,7*Leg = 0.7*9 = 6,3 mm





= 34,5132*302,45 / (1.300*1 - 0,6*34,5132) + 1,6

= 9,76 mm


= max[ 9,76 , 0 ]

= 9,76 mm


= 34,5132*675 / (1.430*1 + 0,4*34,5132) + 1,6

= 17,74 mm


= max[ 17,74 , 3,1 ]

= 17,74 mm


= min[ 9,93 , 17,74 ]

= 9,93 mm


= max[ 9,76 , 9,93 ]

= 9,93 mm





= 2 / 3*A = (2 / 3)*99,0225 = 66,015 cm2

LR = MAX(0,75*d, Rn + (tn - Cn) + (t - C))

= MAX(0,75*604,9, 302,45 + (50 - 1,6) + (30 - 1,6))

= 453,68 mm


54/81


= (2*453,68 - 604,9)*(1*28,4 - 1*16,14) - 2*48,4*(1*28,4 - 1*16,14)*(1 - 0,9091)

= 36,0148 cm2

Area = A1 + A2 + A3 + A41 + A42 + A43 + A5

= 36,0148 + 29,267 + 0 + 0,7361 + 0 + 0 + 0

= 66,0179 cm2



1-7(b)(1)(a) Di = 1.293,2 mm > 1.520 mm False

1-7(b)(1)(b) d = 604,9 mm > 1.020 mm False

1-7(b)(1)(b) d = 604,9 mm > 3,4*(646,6*28,4)0,5 = 460,74 mm True

1-7(b)(1)(c) Rn / R = 302,45 / 646,6 = 0,4678 ≤ 0,7 True


1-7(b)(2),(3) and (4).


55/81



The large opening provisions of Appendix 1-7(a) govern the MAP of this nozzle.


Summary(mm)

For P = 37,99 bar @ 20 °C


The nozzle

passes UG-45

A

required

A


A

weldstreq tmin

69,5635 69,5644 37,7935 31,0154 -- -- 0,7555 8,42 50





throat size (mm)

Actual weld





LR = MAX(d, Rn + (tn - Cn) + (t - C))

= MAX(601,7, 300,85 + (50 - 0) + (30 - 0))

= 601,7 mm


LH = MIN(2,5*(t - C), 2,5*(tn - Cn) + te)

= MIN(2,5*(30 - 0), 2,5*(50 - 0) + 0)

= 75 mm


trn = P*Rn / (Sn*E - 0,6*P)

= 37,9868*300,85 / (1.380*1 - 0,6*37,9868)

= 8,42 mm


tr = P*Ro / (S*E + 0,4*P)

= 37,9868*675 / (1.480*1 + 0,4*37,9868)

= 17,15 mm

56/81






A = d*tr*F + 2*tn*tr*F*(1 - fr1)

= (601,7*17,15*1 + 2*50*17,15*1*(1 - 0,9324)) / 100

= 104,3452 cm2




= (601,7*(1*30 - 1*17,15) - 2*50*(1*30 - 1*17,15)*(1 - 0,9324)) / 100

= 76,4553 cm2


= (2*(30 + 50)*(1*30 - 1*17,15) - 2*50*(1*30 - 1*17,15)*(1 - 0,9324)) / 100

= 19,6929 cm2



= (2*(50 - 8,42)*0,9324*40) / 100

= 31,0154 cm2


= (2*(50 - 8,42)*0,9324*40) / 100

= 31,0154 cm2

A41 = Leg2*fr2= (92*0,9324) / 100

= 0,7555 cm2

Area = A1 + A2 + A41

= 76,4553 + 31,0154 + 0,7555

= 108,2262 cm2


57/81


UW-16(c) Weld Check



tc(actual) = 0,7*Leg = 0.7*9 = 6,3 mm





= 37,9868*300,85 / (1.380*1 - 0,6*37,9868) + 0

= 8,42 mm


= max[ 8,42 , 0 ]

= 8,42 mm


= 37,9868*675 / (1.480*1 + 0,4*37,9868) + 0

= 17,15 mm


= max[ 17,15 , 1,5 ]

= 17,15 mm


= min[ 8,33 , 17,15 ]

= 8,33 mm


= max[ 8,42 , 8,33 ]

= 8,42 mm





= 2 / 3*A = (2 / 3)*104,3452 = 69,5635 cm2

LR = MAX(0,75*d, Rn + (tn - Cn) + (t - C))

= MAX(0,75*601,7, 300,85 + (50 - 0) + (30 - 0))

= 451,28 mm


58/81


= (2*451,28 - 601,7)*(1*30 - 1*17,15) - 2*50*(1*30 - 1*17,15)*(1 - 0,9324)

= 37,7935 cm2

Area = A1 + A2 + A3 + A41 + A42 + A43 + A5

= 37,7935 + 31,0154 + 0 + 0,7555 + 0 + 0 + 0

= 69,5644 cm2



1-7(b)(1)(a) Di = 1.290 mm > 1.520 mm False

1-7(b)(1)(b) d = 601,7 mm > 1.020 mm False

1-7(b)(1)(b) d = 601,7 mm > 3,4*(645*30)0,5 = 472,95 mm True

1-7(b)(1)(c) Rn / R = 300,85 / 645 = 0,4664 ≤ 0,7 True


1-7(b)(2),(3) and (4).


59/81


Outlet (N02)




Located on Shell Outlet Chamber

Orientation 0°




Nozzle

Access opening No










Welds



60/81



Description NPS 12 Class 300 LWN A182 F11 Cl.2 N


Blind included No

Rated MDMT -44,6°C


Consider External Loads on Flange MAWP Rating No


MAP rating 51,7 bar @ 20°C


PWHT performed Yes

Impact Tested Yes (-20°C)

Gasket


Notes




ASME B16.5: Use normalized and tempered flange material only.


LWN rated MDMT per UCS-66(c)(4) = -44,6°C


61/81



The attached ASME B16.5 flange limits the nozzle MAWP.


Summary(mm)

For P = 33,7 bar @ 450 °C


The nozzle

passes UG-45

A

required

A


A

weldstreq tmin

49,4922 76,6876 38,1683 37,7832 -- -- 0,7361 10,74 34,93





throat size (mm)

Actual weld



WRC 107

Load CaseP

(bar)

Pr

(kgf)

Mc

(kgf-m)

Vc

(kgf)

ML

(kgf-m)

VL

(kgf)

Mt

(kgf-m)

Max

Comb

Stress

(kgf/cm2)

Allow

Comb

Stress

(kgf/cm2)

Max

Local

Primary

Stress

(kgf/cm2)

Allow

Local

Primary

Stress

(kgf/cm2)

Over

stressed

Load case 1 33,7 2.510 8.860 0 3.410 0 0 4.214,688 4.374,579 1.716,684 2.187,29 No

Load case 1 (Hot Shut Down) 0 2.510 8.860 0 3.410 0 0 -3.730,414 4.374,579 -548,042 2.187,29 No



LR = MAX(d, Rn + (tn - Cn) + (t - C))

= MAX(308, 154 + (34,93 - 1,6) + (30 - 1,6))

= 308 mm


LH = MIN(2,5*(t - C), 2,5*(tn - Cn) + te)

= MIN(2,5*(30 - 1,6), 2,5*(34,93 - 1,6) + 0)

= 71 mm


trn = P*Rn / (Sn*E - 0,6*P)

= 33,7*154 / (1.300*1 - 0,6*33,7)

= 4,06 mm

62/81



tr = P*Ro / (S*E + 0,4*P)

= 33,7*675 / (1.430*1 + 0,4*33,7)

= 15,76 mm





A = d*tr*F + 2*tn*tr*F*(1 - fr1)

= (308*15,76*1 + 2*33,33*15,76*1*(1 - 0,9091)) / 100

= 49,4922 cm2




= (308*(1*28,4 - 1*15,76) - 2*33,33*(1*28,4 - 1*15,76)*(1 - 0,9091)) / 100

= 38,1683 cm2


= (2*(28,4 + 33,33)*(1*28,4 - 1*15,76) - 2*33,33*(1*28,4 - 1*15,76)*(1 - 0,9091)) / 100

= 14,8393 cm2



= (5*(33,33 - 4,06)*0,9091*28,4) / 100

= 37,7832 cm2

= 5*(tn - trn)*fr2*tn= (5*(33,33 - 4,06)*0,9091*33,33) / 100

= 44,336 cm2

A41 = Leg2*fr2= (92*0,9091) / 100

= 0,7361 cm2

Area = A1 + A2 + A41

= 38,1683 + 37,7832 + 0,7361

63/81


= 76,6876 cm2


UW-16(c) Weld Check



tc(actual) = 0,7*Leg = 0.7*9 = 6,3 mm





= 33,7*154 / (1.300*1 - 0,6*33,7) + 1,6

= 5,66 mm

ta UG-22 = 10,74 mm


= max[ 5,66 , 10,74 ]

= 10,74 mm


= 33,7*675 / (1.430*1 + 0,4*33,7) + 1,6

= 17,36 mm


= max[ 17,36 , 3,1 ]

= 17,36 mm


= min[ 9,93 , 17,36 ]

= 9,93 mm


= max[ 10,74 , 9,93 ]

= 10,74 mm



64/81


WRC 107 Load case 1

Applied Loads

Radial load, Pr 2.510 kgf

Circumferential moment, Mc 8.860 kgf-m


Longitudinal moment, ML 3.410 kgf-m






Design factor 3


γ = Rm / T = 660,8 / 28,4 = 23,2678

β = 0,875*ro / Rm = 0,875*187,33 / 660,8 = 0,248





b+Q) = 4.214,69 kgf/cm2


b+Q) = ±3*S = ±4.374,58 kgf/cm2






65/81




3C* Nφ / (P / Rm) 2,1409 0 0 0 0 -28,615 -28,615 -28,615 -28,615

4C* Nφ / (P / Rm) 3,2537 -43,52 -43,52 -43,52 -43,52 0 0 0 0

1C Mφ / P 0,0645 0 0 0 0 -120,436 120,436 -120,436 120,436

2C-1 Mφ / P 0,0362 -67,565 67,565 -67,565 67,565 0 0 0 0

3A* Nφ / [Mc / (Rm2*β)] 1,0139 0 0 0 0 -292,055 -292,055 292,055 292,055

1A Mφ / [Mc / (Rm*β)] 0,0818 0 0 0 0 -3.289,308 3.289,308 3.289,308 -3.289,308

3B* Nφ / [ML / (Rm2*β)] 2,4553 -272,158 -272,158 272,158 272,158 0 0 0 0

1B-1 Mφ / [ML / (Rm*β)] 0,0273 -422,474 422,474 422,474 -422,474 0 0 0 0

Pressure stress* 1.488,046 1.488,046 1.488,046 1.488,046 782,375 782,375 782,375 782,375

Total circumferential stress 682,328 1.662,407 2.071,593 1.361,774 -2.948,039 3.871,449 4.214,688 -2.123,057


stress*1.172,368 1.172,368 1.716,684 1.716,684 461,705 461,705 1.045,815 1.045,815

3C* Nx / (P / Rm) 2,1409 -28,615 -28,615 -28,615 -28,615 0 0 0 0

4C* Nx / (P / Rm) 3,2537 0 0 0 0 -43,52 -43,52 -43,52 -43,52

1C-1 Mx / P 0,069 -128,873 128,873 -128,873 128,873 0 0 0 0

2C Mx / P 0,0354 0 0 0 0 -66,088 66,088 -66,088 66,088

4A* Nx / [Mc / (Rm2*β)] 1,7515 0 0 0 0 -504,522 -504,522 504,522 504,522

2A Mx / [Mc / (Rm*β)] 0,0417 0 0 0 0 -1.676,82 1.676,82 1.676,82 -1.676,82

4B* Nx / [ML / (Rm2*β)] 0,971 -107,64 -107,64 107,64 107,64 0 0 0 0

2B-1 Mx / [ML / (Rm*β)] 0,0463 -716,568 716,568 716,568 -716,568 0 0 0 0

Pressure stress* 391,188 391,188 391,188 391,188 744,058 744,058 744,058 744,058

Total longitudinal stress -590,508 1.100,373 1.057,908 -117,483 -1.546,892 1.938,924 2.815,791 -405,671

Primary membrane longitudinal stress* 254,933 254,933 470,213 470,213 196,016 196,016 1.205,06 1.205,06

Shear from Mt 0 0 0 0 0 0 0 0




Combined stress (PL+Pb+Q) -1.272,836 1.662,407 2.071,593 -1.479,257 -2.948,039 3.871,449 4.214,688 -2.123,057




2)) + M*Ro / I

= 33,7*1,02*154 / (2*33,33) - 2.510 / (π*(187,332 - 1542))*100 + 9.493.522,9*187,33 / 5,2536E+08*100

= 410,886 kgf/cm2



66/81





Summary(mm)

For P = 48,11 bar @ 20 °C


The nozzle

passes UG-45

A

required

A


A

weldstreq tmin

67,0404 67,0418 25,0283 41,258 -- -- 0,7555 9,55 34,93





throat size (mm)

Actual weld





LR = MAX(d, Rn + (tn - Cn) + (t - C))

= MAX(304,8, 152,4 + (34,93 - 0) + (30 - 0))

= 304,8 mm


LH = MIN(2,5*(t - C), 2,5*(tn - Cn) + te)

= MIN(2,5*(30 - 0), 2,5*(34,93 - 0) + 0)

= 75 mm


trn = P*Rn / (Sn*E - 0,6*P)

= 48,1074*152,4 / (1.380*1 - 0,6*48,1074)

= 5,43 mm


tr = P*Ro / (S*E + 0,4*P)

= 48,1074*675 / (1.480*1 + 0,4*48,1074)

= 21,66 mm

67/81






A = d*tr*F + 2*tn*tr*F*(1 - fr1)

= (304,8*21,66*1 + 2*34,93*21,66*1*(1 - 0,9324)) / 100

= 67,0404 cm2




= (304,8*(1*30 - 1*21,66) - 2*34,93*(1*30 - 1*21,66)*(1 - 0,9324)) / 100

= 25,0283 cm2


= (2*(30 + 34,93)*(1*30 - 1*21,66) - 2*34,93*(1*30 - 1*21,66)*(1 - 0,9324)) / 100

= 10,4368 cm2



= (5*(34,93 - 5,43)*0,9324*30) / 100

= 41,258 cm2

= 5*(tn - trn)*fr2*tn= (5*(34,93 - 5,43)*0,9324*34,93) / 100

= 48,0315 cm2

A41 = Leg2*fr2= (92*0,9324) / 100

= 0,7555 cm2

Area = A1 + A2 + A41

= 25,0283 + 41,258 + 0,7555

= 67,0418 cm2


68/81


UW-16(c) Weld Check



tc(actual) = 0,7*Leg = 0.7*9 = 6,3 mm





= 48,1074*152,4 / (1.380*1 - 0,6*48,1074) + 0

= 5,43 mm

ta UG-22 = 9,55 mm


= max[ 5,43 , 9,55 ]

= 9,55 mm


= 48,1074*675 / (1.480*1 + 0,4*48,1074) + 0

= 21,66 mm


= max[ 21,66 , 1,5 ]

= 21,66 mm


= min[ 8,33 , 21,66 ]

= 8,33 mm


= max[ 9,55 , 8,33 ]

= 9,55 mm



69/81


Ellipsoidal Head Outlet


Component Ellipsoidal Head


Attached To Shell Outlet Chamber

ImpactTested


PWHTOptimize MDMT/

Find MAWP




DesignMDMT (°C)


Static Liquid Head



Dimensions


Head Ratio 2

Minimum Thickness 20 mm


Outer 0 mm

Length Lsf 50,8 mm

Nominal Thickness tsf 20 mm

Weight and Capacity

Weight (kg)1 Capacity (liters)1

New 342,3 362,74

Corroded 315,83 365,96

Radiography

Category A joints Seamless No RT

Head to shell seam Full UW-11(a) Type 11 includes straight flange

70/81


Results Summary

Governing condition internal pressure





Straight Flange governs MDMT -34,7°C

Factor K

K = (1/6)*[2 + (D / (2*h))2]

Corroded K = (1/6)*[2 + (1.313,2 / (2*329,1))2] 0,9968

New K = (1/6)*[2 + (1.310 / (2*327,5))2] 1

Design thickness for internal pressure, (Corroded at 450 °C) Appendix 1-4(c)

t = P*Do*K / (2*S*E + 2*P*(K - 0,1)) + Corrosion

= 30*1.350*0,996762 / (2*1.430*1 + 2*30*(0,996762 - 0,1)) + 1,6

= 15,45 mm

Maximum allowable working pressure, (Corroded at 450 °C) Appendix 1-4(c)

P = 2*S*E*t / (K*Do - 2*t*(K - 0,1)) - Ps

= 2*1.430*1*18,4 / (0,996762*1.350 - 2*18,4*(0,996762 - 0,1)) - 0

= 40,09 bar

Maximum allowable pressure, (New at 20 °C) Appendix 1-4(c)

P = 2*S*E*t / (K*Do - 2*t*(K - 0,1)) - Ps

= 2*1.480*1*20 / (1*1.350 - 2*20*(1 - 0,1)) - 0

= 45,05 bar


EFE = (75*t / Rf)*(1 - Rf / Ro)

= (75*20 / 232,7)*(1 - 232,7 / infinity)

= 6,4461%

71/81


Straight Flange on Ellipsoidal Head Outlet


Component Cylinder


ImpactTested


PWHTOptimize MDMT/

Find MAWP




DesignMDMT (°C)


Static Liquid Head



Dimensions


Length 50,8 mm



Outer 0 mm

Weight and Capacity


New 33,25 68,47

Corroded 30,63 68,8

Radiography

Longitudinal seam Seamless No RT



72/81


Results Summary









tr = 30*675 / (1.480*1 + 0.4*30) = 13,57 mm







= 30*675 / (1.430*1,00 + 0,40*30) + 1,6

= 15,64 mm


P = S*E*t / (Ro - 0,40*t) - Ps

= 1.430*1,00*18,4 / (675 - 0,40*18,4) - 0

= 39,41 bar


P = S*E*t / (Ro - 0,40*t)

= 1.480*1,00*20 / (675 - 0,40*20)

= 44,38 bar


EFE = (50*t / Rf)*(1 - Rf / Ro)

= (50*20 / 665)*(1 - 665 / infinity)

= 1,5038%


73/81


Nozzle (Control Valve)



Note: Thread engagement shall comply with the requirements of UG-43(g).


Located on Ellipsoidal Head Outlet

Orientation 0°

End of nozzle to datum line 3.573,4 mm

Calculated as hillside No

Distance to head center, R 0 mm


Nozzle

Access opening No


Bolt material specification SA-193 B7 Bolt <= 64 (II-D Metric p. 352, ln. 31)

Bolt rated MDMT -48°C

Pad inner diameter 170 mm

Pad outer diameter, Dp 320 mm

Pad thickness 75 mm

Figure UG-40 thickness, te 55 mm

Tapped hole diameter 27 mm

Tapped hole depth 46 mm

Tapped hole bolt circle 255 mm

Raised face height 0 mm

Raised face outer diameter 320 mm

74/81







Welds



UCS-66 Material Toughness Requirements Pad


tr = 30*0,8978*1.350 / (2*1.480*1 + 0,8*30) = 12,19 mm





75/81



The vessel wall thickness governs the MAWP of this nozzle.


Summary(mm)

For P = 43,95 bar @ 450 °C


The nozzle

passes UG-45

A

required

A


A

weldstreq tmin

54,3034 64,6052 -- -- -- 61,389 3,2161 9,93 75





throat size (mm)

Actual weld


Pad to shell fillet (Leg41) 6 14 weld size is adequate



LR = MAX(d, Rn + (tn - Cn) + (t - C))

= MAX(173,2, 86,6 + (0) + (20 - 1,6))

= 173,2 mm


LH = MIN(2,5*(t - C), 2,5*(tn - Cn) + te)

= MIN(2,5*(20 - 1,6), 2,5*(0) + 55)

= 46 mm

Required thickness tr from UG-37(a)(c)

tr = P*K1*Do / (2*S*E + 0,8*P)

= 43,9515*0,8978*1.350 / (2*1.430*1 + 0,8*43,9515)

= 18,4 mm

Required thickness tr per Interpretation VIII-1-07-50

tr = P*Do*K / (2*S*E + 2*P*(K - 0,1))

= 43,95*1.350*0,996762 / (2*1.430*1 + 2*43,95*(0,996762 - 0,1))

= 20,12 mm

76/81



Allowable stresses: Sn = 1.325,63, Sv = 1.458,193, Sp = 1.325,63 kgf/cm2



fr4 = lesser of 1 or Sp / Sv = 0,9091

A = d*tr*F + 2*tn*tr*F*(1 - fr1) + Tapped hole area loss

= (173,2*18,4*1 + 2*73,4*18,4*1*(1 - 0,9091)) / 100 + 19,9797

= 54,3034 cm2


A1 = larger of the following= 0 cm2


= (173,2*(1*18,4 - 1*18,4) - 2*73,4*(1*18,4 - 1*18,4)*(1 - 0,9091)) / 100

= 0 cm2


= (2*(18,4 + 0)*(1*18,4 - 1*18,4) - 2*73,4*(1*18,4 - 1*18,4)*(1 - 0,9091)) / 100

= 0 cm2

Area A2 is not included in these calculations.

A42 = Leg2*fr4= (18,812*0,9091) / 100

= 3,2161 cm2

(Part of the weld is outside of the limits)

A5 = (Dp - Pad ID)*te*fr4= ((320 - 173,2)*46*0,9091) / 100

= 61,389 cm2

Area = A1 + A42 + A5

= 0 + 3,2161 + 61,389

= 64,6052 cm2


UW-16(c) Weld Check

Fillet weld: tmin = lesser of 19 mm or te or t = 18,4 mm


77/81


tc(actual) = 0,7*Leg = 0.7*20 = 14 mm






= 43,9515*86,6 / (1.300*1 - 0,6*43,9515) + 1,6

= 4,59 mm


= max[ 4,59 , 0 ]

= 4,59 mm

tb1 = 21,72 mm


= max[ 21,72 , 3,1 ]

= 21,72 mm


= min[ 9,93 , 21,72 ]

= 9,93 mm


= max[ 4,59 , 9,93 ]

= 9,93 mm



78/81



The vessel wall thickness governs the MAP of this nozzle.


Summary(mm)

For P = 49,37 bar @ 20 °C


The nozzle

passes UG-45

A

required

A


A

weldstreq tmin

58,1679 72,7274 -- -- -- 69,93 2,7974 8,33 75





throat size (mm)

Actual weld


Pad to shell fillet (Leg41) 6 14 weld size is adequate



LR = MAX(d, Rn + (tn - Cn) + (t - C))

= MAX(170, 85 + (0) + (20 - 0))

= 170 mm


LH = MIN(2,5*(t - C), 2,5*(tn - Cn) + te)

= MIN(2,5*(20 - 0), 2,5*(0) + 55)

= 50 mm

Required thickness tr from UG-37(a)(c)

tr = P*K1*Do / (2*S*E + 0,8*P)

= 49,3741*0,9*1.350 / (2*1.480*1 + 0,8*49,3741)

= 20 mm

Required thickness tr per Interpretation VIII-1-07-50

tr = P*Do*K / (2*S*E + 2*P*(K - 0,1))

= 49,37*1.350*1 / (2*1.480*1 + 2*49,37*(1 - 0,1))

= 21,86 mm

79/81



Allowable stresses: Sn = 1.407,207, Sv = 1.509,179, Sp = 1.407,207 kgf/cm2



fr4 = lesser of 1 or Sp / Sv = 0,9324

A = d*tr*F + 2*tn*tr*F*(1 - fr1) + Tapped hole area loss

= (170*20*1 + 2*75*20*1*(1 - 0,9324)) / 100 + 22,14

= 58,1679 cm2


A1 = larger of the following= 0 cm2


= (170*(1*20 - 1*20) - 2*75*(1*20 - 1*20)*(1 - 0,9324)) / 100

= 0 cm2


= (2*(20 + 0)*(1*20 - 1*20) - 2*75*(1*20 - 1*20)*(1 - 0,9324)) / 100

= 0 cm2

Area A2 is not included in these calculations.

A42 = Leg2*fr4= (17,322*0,9324) / 100

= 2,7974 cm2

(Part of the weld is outside of the limits)

A5 = (Dp - Pad ID)*te*fr4= ((320 - 170)*50*0,9324) / 100

= 69,93 cm2

Area = A1 + A42 + A5

= 0 + 2,7974 + 69,93

= 72,7274 cm2


UW-16(c) Weld Check

Fillet weld: tmin = lesser of 19 mm or te or t = 19 mm


80/81


tc(actual) = 0,7*Leg = 0.7*20 = 14 mm






= 49,3741*85 / (1.380*1 - 0,6*49,3741) + 0

= 3,11 mm


= max[ 3,11 , 0 ]

= 3,11 mm

tb1 = 21,86 mm


= max[ 21,86 , 1,5 ]

= 21,86 mm


= min[ 8,33 , 21,86 ]

= 8,33 mm


= max[ 3,11 , 8,33 ]

= 8,33 mm



81/81


Structural calculation

Process Gas Boiler Axion_Campana J160165DA for

Bertsch Energy Ges.m.b.H&Co.KG Herrengasse 23 A-6700 Bludenz

Processed by: Dipl. Ing. E. Schöpf Eccon Ges.m.b.H Industriestrraße 8 A-6832 Sulz

Date: 1.February 2017

Signature:

Remarks:


1 DESCRIPTION: 3

2 MATERIAL: 7

3 LOADS: 10

4 RESULTS: 14

4.1 Load case 8: Test pressure water side 42bar*1.3=54.6bar 15

4.2 Load case 9: Test pressure gas side 30bar*1.38=41.35bar 22

4.3 Load cases 10 to 14: Pressure 42bar/30bar + Temp 32

4.4 Load cases 15 to 19: Pressure 42bar/-1bar + Temp 37

4.1 Load cases 20 to 24: Pressure -1bar/30bar + Temp 42

5 WELDING DETAILS HEATING TUBE AND BYPASS TUBE: 47


1 Description:

A FE calculation is carried out for the “Process Gas Boiler” comprising the following parts according PG-16.1:

Jacket tube Inlet plate Heating surface tubes Bypass tubes Outlet plate

This division of Section VIII-1 does not contain rules to cover the design and construction. The design of this point is checked under consideration of U-2(g) by a finite element analysis. This needs the acceptance of the AI.

The calculation is carried out on a 180-degree sector taking symmetry into account with the help of peripheral conditions. The load is applied through the internal pressure in the jacket space (water side) and the pressure in the gas space as well as by initial expansions due to the various temperatures.

The heating surface tubes as well as the bypass tubes are welded to the inlet plate and outlet plate at the walls of the drilled holes in the plates.

The temperatures in the structure are taken as defined by customer.

The heating surface tubes and bypass tubes have the following nominal dimensions

heating surface 33.4 * 3.38 mm bypass tubes 73.0 * 7.01 mm

Calculation is done for reduced wall thickness because of corrosion. The values for the reduction of wall thickness are: heating tubes 0.0 mm bypass tube 0.0 mm Jacket tube 1.6 mm jacket tube at gas outlet 1.6 mm jacket tube at gas inlet 1.6 mm tube sheets 3.2 mm

Allowable Stresses for FEM:

Section I defines in PG-23 that the allowable stress values from Section II, Part D, tables 1A and 1B have to be used for the equations given in Section I. Even the preamble and PG-16.1 define under the restrictions given in PG-16.1 that alternative methods can be used but does not show specific limits.


To fulfil the requirements of Section I, especially the preamble and PG-16.1, to calculate as safe as the rules of Section I the limits for the allowable stresses will be defined equal to ASME VIII-1, UG-23. Because VIII-1 uses also the allowable stresses from Section II, Part D, tables 1A und 1B.

Additionally, to the limits of UG-23 the maximum allowable membrane stress values for test conditions shall not exceed 90% of yield strength as given in Section II, Part D.

The linear elastic calculation is carried out with the finite element program FENAS. Bar elements and shell elements are employed. The program was developed at the Imperial College in London. For this calculation hybrid finite elements are used. The program is intended for linear elastic calculations as well as nonlinear calculations for bar-elements, shell-elements and solids.

Computer program verification:

Computer programs have been used to prepare this design calculation. Each program module used to prepare this design calculation was verified prior to use for the applicable standard. A verification report was prepared and approved. The verification report and evidence of verification are available to the AI upon request.


2 Material:

Following materials are used:

SA-387 11 2 jacket tube SA-182 F11 2 tube sheets for inlet and outlet SA 335 P11 heating surface and bypass tubes

with the following material values:

Modulus of elasticity (at temperature 300C) 192 000 N/mm2

Poisson’s ratio 0.3 Thermal expansion coefficient 12. 10-6 m/m C

SA-387 Gr.11 Cl.2 jacket tube Yield limit (20C) 310 N/mm2

ASME allowable (260C) 148 N/mm2

SA-182 F.11 2 inlet plate and outlet plate Yield limit (20C) 276 N/mm2

ASME allowable (310C) inlet 138 N/mm2

SA 335 P11 heating surface and bypass tubes Yield limit (20C) 207 N/mm2

ASME allowable (310C) 108 N/mm2

The material behaviour is linear elastic.


3 Loads:

The calculation is carried out for pressure and temperature loads in separate load cases. The result of the overall load is calculated by way of superimposing the load cases.

Load case 1: Design pressure water side 42bar

A pressure of 42bar against the surroundings prevails in the jacket space, the pressure in the heating surface tubes and bypass tubes corresponds to the surrounding pressure.

Load case 2: Design pressure gas side 30bar

A pressure of 30bar against the surroundings prevails in the heating surface tubes and bypass tubes as well as in the inlet and outlet chambers. The pressure in the jacket space (water side) corresponds to the surrounding pressure.

Load cases 3-7: Temperature load cases:

All components are given initial expansions which are proportional to the temperatures as defined by customer.


4 Results:

In order to be able to evaluate the calculation results according to the ASME the membrane stresses and the maximum comparison stresses are output separately for all operating load cases, test pressures and special load cases. All shell stresses are shown on the deformed structure with deformations increased 50 times. Under the title “equivalent stress” the comparison stresses according to Mises in the central plane of the finite elements (membrane stress component) are shown. The stress “max.equivalent stress” shows the resultant comparison stress on the outer fibre of the elements and constitutes the more unfavourable value of element top or bottom. These stresses show the superposition of membrane stresses and plate bending.

For the in-service loads and the special load cases only the load combinations showing the highest stresses are printed here. The following load cases are evaluated:

Load case

8 Test pressure water side 42bar*1.3 = 54.6 bar

9 Test pressure gas side 30bar*1.38 = 41.35 bar

10 to 14 Water side 42bar, gas side 30bar, temp

15 to 19 Water side 42bar, gas side -1bar, temp

20 to 24 Water side -1bar, gas side 30bar, temp

load cases 8 and 9 each constitute the one-sided test pressures load cases 10 to 14 are the standard operating load cases load cases 15 to 24 are malfunctions with total drop of pressure at water side or gas side and require the shut down of the boiler.


4.1 Load case 8: Test pressure water side 42bar*1.3=54.6bar

In addition to the stresses in the shell elements, the longitudinal stress is shown for the heating tubes and for the bypass tubes. The allowable primary stresses for test pressure are acc. to ASME section VIII-1, UG-23. The allowable membrane stress values for test conditions shall not exceed 90% of yield strength as given in Section II, Part D.

Temperature yield Strength allowable Pm 0.9*yield

allowable Pl+Pb 0.9*yield*1.5

inlet and outlet plate 20ºC 276 N/mm2 248 N/mm2 373 N/mm2

Heating tubes and bypass tube

20ºC 207 N/mm2 186 N/mm2 279 N/mm2

Jacket tubes 20°C 310 N/mm2 279 N/mm2 419 N/mm2

The actual stresses in the components are calculated as:

Component Pm Pl and Pb

Inlet plate 40 N/mm2 233 N/mm2

outlet plate 35 N/mm2 232 N/mm2

Heating tubes 101 N/mm2 180 N/mm2

bypass tubes 91 N/mm2 214 N/mm2

jacket tube 147 N/mm2 255 N/mm2

All stresses are within the allowable limits.


4.2 Load case 9: Test pressure gas side 30bar*1.38=41.35bar

In addition to the stresses in the shell elements, the longitudinal stress is shown for the heating tubes and for the bypass tubes. The allowable primary stresses for test pressure are acc. to ASME section VIII-1, UG-23. The allowable membrane stress values for test conditions shall not exceed 90% of yield strength as given in Section II, Part D.

Temperature yield Strength allowable Pm 0.9*yield



Heating tubes and bypass tubes

20ºC 207 N/mm2 186 N/mm2 279 N/mm2

Jacket tubes 20°C 310 N/mm2 279 N/mm2 419 N/mm2

The actual stresses in the components are calculated as:

Component Pm Pl and Pb

Inlet plate 53 N/mm2 222 N/mm2

outlet plate 43 N/mm2 217 N/mm2

Heating tubes 87 N/mm2 115 N/mm2

bypass tubes 78 N/mm2 164 N/mm2

jacket tube 87 N/mm2 244 N/mm2

All stresses are within the allowable values.


Proof of stability is furnished for the heating tube with the greatest compressive stress by means of an FE bar model. With a compressive force of -18.0 KN (normal stress of –56.4 N/mm2) the safety against elastic buckling is calculated as

Safety against elastic buckling = 2.66

Clamping of the tube at both ends in the plates and moment-free support of the tube on the 4 support plates in the shell space is taken into account. In the load case with vacuum in the water space the compressive force is -13.7 KN and the resulting safety against elastic buckling is 3.49.


4.3 Load cases 10 to 14: Pressure 42bar/30bar + Temp

These are the standard operating load cases with 42bar on the water side and 30bar on the gas side and temperatures as defined. Stress intensity factor is taken as stress intensity factor k=1.0 acc. to ASME Section VIII-1 UG23

Temperature allowable stress intensity k*Sm

allowable secondary stress Q 3*k*Sm

Inlet and outlet plate 310ºC 138 N/mm2 414 N/mm2

Heating and bypass tubes

310ºC 108 N/mm2 324 N/mm2

Jacket tube 260ºC 148 N/mm2 444 N/mm2

For documentation the maximum stresses out of the load cases 10 to 14 are used. The maximum stresses in the parts of the structure are evaluated as:

Component Secondary stresses Q

Inlet plate 227 N/mm2

Outlet plate 218 N/mm2

Heating tubes 165 N/mm2

bypass tube 124 N/mm2

jacket tube 179 N/mm2



4.4 Load cases 15 to 19: Pressure 42bar/-1bar + Temp

This load case with total drop of pressure on the gas side and 42bar on the water side is a malfunction and requires the shut down of the boiler. Stress intensity factor is taken as stress intensity factor k=1.0 acc. to ASME Section VIII-1 UG23





310ºC 108 N/mm2 324 N/mm2


The maximum stresses for load cases 15 to 19 in the parts of the structure are evaluated as:









4.1 Load cases 20 to 24: Pressure -1bar/30bar + Temp

This load case with total drop of pressure on the gas side and 42bar on the water side is a malfunction and requires the shut down of the boiler. Stress intensity factor is taken as stress intensity factor k=1.0 acc. to ASME Section VIII-1 UG23





310ºC 108 N/mm2 324 N/mm2


The maximum stresses for load cases 15 to 19 in the parts of the structure are evaluated as:









5 Welding details heating tube and bypass tube:

For the welding details of the heating tubes and the bypass tubes additional axisymmetric FE-calculations are made. The maximum axial loads are taken from the shell-calculation (load case test pressure water side), acting simultaneously with the pressure in the water side of the vessel. The characteristic material strength has to be taken for room temperature.

Temperature yield strength allowable Pm 0.9*yield



Heating tubes and bypass tubes

20ºC 207 N/mm2 186 N/mm2 279 N/mm2

For test-pressure 54.6bar and axial forces in tubes

axial force

heating surface tube 23.0 KN

bypass tube 84 KN

the following stresses are evaluated:

welding heating tubes 177 N/mm2

welding bypass tube 165 N/mm2



TOTAL 210 SHEET Vendor DOC. NO. J160165DA002P4 … · Apply interpretation VIII-1-83-66 Yes Apply...

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Transcript of TOTAL 210 SHEET Vendor DOC. NO. J160165DA002P4 … · Apply interpretation VIII-1-83-66 Yes Apply...