Pressure Vessel Design

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Pressure Vessels
Reaction Vessels
Agitator Shafts
Heat Exchangers
Process Columns
Storage Tank
Floating Roof
Chimney
ASME Sec. VIII Div. 1
TEMA
EEUA
IS 2825
EN 13445
API 650
API 620
IS 6533

EXAMPLE NO. PV-01
DESIGN
OF
PRESSURE VESSEL (GAS FILTER)
NOTE:
1) Link to youtube video of this design: http://www.youtube.com/watch?v=3Y0yrt1Z6fI&list=PLPL8SPZUxm-
mFqQZceyhr13QYDEruelJx
2) As you can see in the video, the inbuilt intelligence in the software generates all information by itself. Eg: For
a body flange, the software evaluates all the undefined parameters Flange OD, Flange ID, PCD, Number and
Size of bolts, Gasket OD & ID, etc. meeting the requirements of specified equipment design code.
3) In case of any changes to the interconnected shell geometry and / or design conditions (pressure /
temperature) including material of constructions, these dimensions automatically regenerated by the
software to meet the new requirements.
4) The software can generate cost estimation and BOM in Excel.
This example covers design of a simple pressure vessel. This pressure vessel has a top
flat cover and a bottom dished end. The top cover is of bolted type and is connected to
the shell through top body flange. The pressure vessel is provided with lugs support and
lifting lug.

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in
Index
Licensee :
Sunay Wagle, CADEM Services,
Pune, India
Customer ABC Company Ltd.
Project / Equipment Soap Plant / Gas Filter
Designed By / Revision and Date / R00 , 31-03-2015 00:25:14
Sr. No. Description Page No
1 Title page & equipment info
2 Design data
3 Material of constructions
4 Effective Pressures
5 Weight summary report
6 Test pressure calculations (shell side)
7 Wind load calculations
8 Seismic load calculations
9 Design of Cover (Front)
11 Design of Shell Flng (Front)
13 Design of Main Shell
14 Design of Dished End (Rear)
15 Design of Lug Support
17 Design of N 01
18 Design of N 01
19 Design of N 01
20 Design of N 02
21 Design of N 02
22 Design of N 02
23 Design of N 03
24 Design of N 03
25 Design of Lifting Lugs
26 Foundation load data
27 C.G. Data

EQUIPMENT INFORMATION :
DESIGN & REVIEWAL :
INSPECTION & APPROVAL :
EQUIPMENT DATA :
OTHER DATA :
Project Soap Plant
Location Vapi Site
Plant Refrigeration Plant
Design Code ASME VIII Div.1, 10 A11
Equipment Name Gas Filter
Equipment Type Pressure Vessel
Equipment Class N.A.
Equipment Category N.A.
Reference Drawing No ---
Service Compressed Gas Services
Support Type Lug Supports
Designed By
Design Date 31-03-2015 00:25:14
Checked By
Approved By
Revision R00
Inspection Agency ---
Reviewed By ---
Front end Flat End
Front end flanged True
Rear end Dished End
Rear end flanged False
Shell ID 1250 mm
Shell OD 1270 mm
Length, Shell (W.L. to W.L) / Overall 1650 / 2254.6 mm
Fabricated weight 1898.3 kgf
Empty weight + external weights 1898.3 kgf
Estimated operating weight 1926.8 kgf
Estimated hydrotest weight 4439.8 kgf

(1) PROCESS DETAILS :
(3) TEST PR. : kgf/mm² g
(4) TEMPERATURE : °C
(5) ALLOWANCES : mm
(6) RADIOGRAPHY & JOINT EFFICIENCY :
Licensee :
Pune, India
VESSEL DESIGN DATA
MEDIA DENSITY
kg/m³
Operating Process Gas 10
Design1 Process Gas 12
Design2
Startup
Shutdown
Upset
Hydrotest Water 1000
Pneumatic Process Gas 1.2
(2) PR. : kgf/mm² g INT. EXT.
Operating 0.1 0.12 0.01055
Design1 0.12 0.12 0.01055
Design2
Startup
Shutdown
Upset
Based on
Input Pr MAWP MAP
Hydrotest 0.156 0.156 0.169
Pneumatic 0.132 0.132 0.143
MIN. MAX.
Input MDMT
Operating 20 -14.28 100
Design1 20 -11.75 150
Design2
Startup
Shutdown
Upset
Hydrotest 21.67 -11.57 50
Pneumatic 21.67 -11.75 50
INT. EXT.
Corrosion 3 0
Polishing 0 0
RADIOGRAPHY
JOINT
EFFICIENCY
Shell Spot + T Joints 0.85
Head Full 1.00

VESSEL DESIGN DATA
1. MATERIAL OF CONSTRUCTION :
2. NOZZLE CONNECTIONS :
3. INSULATION & CLADDING:
Licensee :
Pune, India
Shell side
Shell SA-516 GR. 70 Plt. [UNS:K02700]
Head SA-516 GR. 70 Plt. [UNS:K02700]
Body flange SA-105 Frg. [UNS:K03504]
Body flange cover SA-516 GR. 70 Plt. [UNS:K02700]
Liner
Shell side
Nozzle neck <= NPS 40
SA-106 GR. B Smls. Pipe
[UNS:K03006]
Flange SA-105 Frg. [UNS:K03504]
Cover flange SA-105 Frg. [UNS:K03504]
Nozzle NPS > 40 & < 200
[UNS:K03006]
Flange SA-105 Frg. [UNS:K03504]
Cover flange SA-105 Frg. [UNS:K03504]
Nozzle neck >= NPS 200 SA-516 GR. 70 Plt. [UNS:K02700]
Flange SA-516 GR. 70 Plt. [UNS:K02700]
Cover flange SA-516 GR. 70 Plt. [UNS:K02700]
Pad flange SA-516 GR. 70 Plt. [UNS:K02700]
Pad flange cover SA-516 GR. 70 Plt. [UNS:K02700]
Manhole flange SA-516 GR. 70 Plt. [UNS:K02700]
Manhole cover SA-516 GR. 70 Plt. [UNS:K02700]
Reinforcement pad SA-516 GR. 70 Plt. [UNS:K02700]
External bolt SA-193 GR. B7 Bolt [UNS:G41400]
External gasket Spiral metal wound CAF filled (S.S.)
Stiffener SA-516 GR. 70 Plt. [UNS:K02700]
Lifting lug IS-2062 GR. A Plt.
Support IS-2062 GR. A Plt.
Anchor bolt Commercial CS Bolt
Mat. / Density / Thk. Rockwool (Mineral Fibre) / 136.2 kg/m³ / 25 mm
Mat. / Thk. Al. sheet / 1.191 mm

SUMMARY OF EFFECTIVE DESIGN PRESSURES IN kgf/mm² g VS TEMPERATURE IN °C
Licensee :
Pune, India
Sr. Item name Temp. Inside pr. Liquid pr. Effective pr.
No. +ve -ve +ve -ve
1 Cover (Front) 150 0.12 0.01055 0 0.12 0.01055
2 Shell Flng (Front) 150 0.12 0.01055 0 0.12 0.01055
3 Main Shell 150 0.12 0.01055 0 0.12 0.01055
4 Dished End (Rear) 150 0.12 0.01055 0 0.12 0.01055
5

ITEM WISE WEIGHT SUMMARY
Licensee :
Pune, India
Sr.No. Item name Item size
Empty
wt
Volume Filled wt
kgf m³ kgf
1 Cover (Front)
Blind Flange - 1420 OD x
73.411 Thk, RF, 1363 PCD,
Tgrv = 1.588
900.5 0 900.5
2 Shell Flng (Front)
Fabricated WN - 1420 OD x
1250 ID x 1363 PCD, RF,
128.692 Thk, Trgv = 1.588,
G1 = 20, G0 = 10, hf = 30
312.3 0 312.3
3 Gasket Flng (Front)
1313.5 OD x 1250 ID, 4.763
Thk
0.1 0 0.1
4 Bolt Flng (Front)
Hex Head Bolt M24 x 243.128
Lg, 56 Nos.
48.76 0 48.76
5 Main Shell 1270 OD x 10 Thk, 1650 Lg 517.1 2.025 541.4
6 Dished End (Rear)
Elliptical D/2H = 2.0, 1270 OD
x 10 Nom / 9 Min Thk, SF =
50
181.7 0.317 185.5
7 Gusset Plate
200 Long x 190 Wide x 16
Thk, 8 Nos.
38.51 0 38.51
8 Anchor Bolt Anchor M20 x 200 Lg, 4 Nos. 1.99 0 1.99
9 Support Pad
Thk, 4 Nos.
24.97 0 24.97
10 N 01
ANSIB36.10, 150 NPS Sch.80,
156 Lg
6.697 0.00262 6.728
11 Flange [N 01]
Weld Neck, ANSI B16.5, RF,
150# for 150 NPS Sch 80 Pipe
8.08 0 8.08
12 Gasket [N 01]
166.329 OD x 146.329 ID,
4.763 Thk
0.1 0 0.1
13 Bolt [N 01]
Lg, 8 Nos.
1.714 0 1.714
14 Counter Flng [N 01]
8.08 0 8.08
15 Reinf [N 01]
292.659 OD x 171.275 ID x 10
Thk
3.501 0 3.501
16 N 02
156 Lg
6.697 0.00262 6.728
17 Flange [N 02]
8.08 0 8.08
18 Gasket [N 02]
166.329 OD x 146.329 ID,
4.763 Thk
0.1 0 0.1
19 Bolt [N 02]
Lg, 8 Nos.
1.714 0 1.714
8.08 0 8.08
21 Reinf [N 02]
292.659 OD x 171.275 ID x 10
Thk
3.501 0 3.501
22 N 03
150 Lg
1.682 0.00022 1.684
23 Flange [N 03]
2.428 0 2.428
24 Gasket [N 03]
62.85 OD x 42.85 ID, 4.763
Thk
0.1 0 0.1
25 Bolt [N 03]
Lg, 4 Nos.
0.431 0 0.431
26 Bolted Cover [N 03]
150# for 50 160 NPS Pipe
2.522 0 2.522
120 Long x 70 Wide x 12 Thk,

27 Lifting Lugs 2 Nos. 1.596 0 1.596
28 Pad (Lifting Lugs)
70 Long x 170 Wide x 8 Thk, 2
Nos.
1.507 0 1.507
29 Insulation
4084.07 W x 3754.584 L, 25
Thk
52.2 0 52.2
30 Cladding
4087.811 W x 3754.584 L,
1.191 Thk
5.058 0 5.058
31
32
33
34
35
∑ 2149.7 ∑ 4439.8

TEST PRESSURES CALCULATION AS PER UG-99 / UG-100 : Vessel Inside
Legend :
Test Pressure Calculations
Pressure due to hydro liquid column, [ Plh ]
= Lh x rh x 1E-09
= 0.00225 kgf/mm² g
Hydrotest pressure, [ Ph ]
= 1.3 x Pt - Plh
= 1.3 x 0.12 - 0.00225
= 0.154 kgf/mm² g
Pneumatic test pressure, [ Pn ]
= 1.1 x Pt
= 1.1 x 0.12
= 0.132 kgf/mm² g
Licensee :
Pune, India
Design Temperature T 150 °C
Operating Liquid Density r 12 kg/m³
Hydrotest Liquid Density rh 1000 kg/m³
Hydrotest Liquid Column Lh 2254.6 mm
Sr.
No.
Item Name
Pressure ( kgf/mm² g ) Stress Correction ( kgf/mm² )
Pt
Pi Pl Pc Pe Peff Sfo Sfa
Sfa
Sfo
1 Cover (Front) 0.12 0 0 0.01055 0.12 14.06 14.06 1 0.12
2 Shell Flng (Front) 0.12 0 0 0.01055 0.12 14.06 14.06 1 0.12
3 Main Shell 0.12 0 0 0.01055 0.12 14.06 14.06 1 0.12
4 Dished End (Rear) 0.12 0 0 0.01055 0.12 14.06 14.06 1 0.12
5
Min. Pr., Pt 0.12
Pi = Internal positive pressure
Pl = Pressure due to design liquid column
Pe = Internal vacuum pressure
Pc = External negative pressure
Peff = Pi + Pl + Pc
Sfo = Allowabe stress at design temperature
Sfa = Allowable stress at ambient temperature
Pt = MAX [ Peff + Pc, Pe ] x ( Sfa / Sfo )

Vessel Inside
Legend :
Licensee :
Pune, India
CALC. OF MIN. DESIGN METAL TEMPERATURE
Design Mode 1 , Corroded
Condition
CODE ASME VIII Div.1, 10 A11
Design Pressure Pi 0.12 kgf/mm² g
Sr.
No.
Item Name / Material /
Group
Stress (kgf/mm²) Thickness (mm) MDMT (°C)
Smt Sdt tn tg tr Tm Tc MDMT
1
Cover (Front)
SA-516 GR. 70 Plt.
[UNS:K02700]
Curve : B
14.06 14.06 70.41 17.6 17.6 -11.98 40.56 -52.53
2
Shell Flng (Front)
SA-105 Frg. [UNS:K03504]
Curve : B
14.06 14.06 125.7 7 6.343 -28.89 -17.14 -11.75
3
Main Shell
SA-516 GR. 70 Plt.
[UNS:K02700]
Curve : B
14.06 14.06 7 7 6.343 -28.89 -14.73 -14.16
4
Dished End (Rear)
SA-516 GR. 70 Plt.
[UNS:K02700]
Curve : B
14.06 14.06 7 7 5.364 -28.89 -14.61 -14.28
5
Max, MDMT -11.75
Smt = Stress at minimum design metal temperature.
Sdt = Pressure due to design liquid column
tn = Stress at design metal temperature.
tg = Nominal item thickness excluding corrosion and thinning.
tr = Governing metal thickness for the item.
Tg = Required minimum thickness of the item.
Tm = Minimum metal temperature for the the item.
Tc = MDMT Correction
MDMT = Final MDMT for the item = Tm - Tc.

EXTREME FIBRE ELONGATION CALCULATION
Legend :
Licensee :
Pune, India
Sr.
No.
Item Name MOC Rf t Eqn.
No.
e HT
mm mm %
1 Main Shell SA-516 GR. 70 Plt. [UNS:K02700] 625 10 1 0.8 False
2 Dished End (Rear) SA-516 GR. 70 Plt. [UNS:K02700] 1130 10 2 0.664 False
3
4
5
Rf = Mean radius after forming
Ro = Infinity
t = Nominal thickness of the plate before forming
Eqn. 1 = 50 x t / Rf x [ 1 - Rf / Ro ]
Eqn. 2 = 75 x t / Rf x [ 1 - Rf / Ro ]

1. DESIGN CONDITIONS ( Design Mode 1 , Corroded Condition ) :
3. CALCULATION OF FORCES AND MOMENTS:
Licensee :
Pune, India
WIND LOAD CALCULATION
CODE Wind [IS:875, 87]
Basic wind speed ( Section 5.2 ) Vb 50 m/s
Expected life of equipment ( Section 5.3.1 ) 25 Years
Probability factor (Risk coeff) ( Section 5.3.1 ) K1 0.902
Terrain category ( Section 5.3.2 ) Category 2
Structure class ( Section 5.3.2.2 ) Class B
Topography factor ( Section 5.3.3 ) K3 1.3
Force coefficient (Shape factor) Cf 0.8
Equivalent diameter De 1820 mm
Overall length of equipment L 2254.6 mm
Height of C.G. of equipment Hcg 1807.5 mm
Size and height factor ( Section 5.3.2 ) K2 0.98
Effective transverse cross sectional area
= De x L A 4103343.3 mm²
Effective wind speed
= K1 x K2 x K3 x Vb Vz 57.44 m/s
Wind pressure
= 6E-08 x Vz 2 Pz 0.0002 kgf/mm²
Longitudinal force
= Cf x A x Pz F 649.9 kgf
Support elevation H 372.5 mm
Turning moment
= F x ( Hcg - H ) M 932661.5 kgf-mm

Licensee :
Pune, India
SEISMIC LOAD CALCULATION
CODE Seismic [IS:1893, 02]
Weight of equipment Wo 1926.8 kgf
Importance factor ( Table-6 , 2002 ) I 1.5
Soil profile type Stiff Soil Profile (SD)
Foundation type RCC footings + Tie Beams
Damping factor 5
Seismic zone Zone III
Seismic zone factor ( Table-2 , 2002 ) Z 0.16
Response reduction factor ( Table-7 , 2002 ) R 2.9
Spectral accelerations coeff. ( Fig. 2 , 2002 ) Sa / g 2.5, Use max value
Damping correction factor ( Table-3 , 2002 ) Cf 1
Seismic coefficient ( Clause-6.4.2 , 2002 )
= 0.5 x Z x I x Cf x ( Sa / g ) x ( 1 / R )
= 0.5 x 0.16 x 1.5 x 1 x
2.5 x ( 1 / 2.9 ) Ah 0.103
Elevation of support H 372.5 mm
Seismic base shear force
= Ah x Wo
= 0.103 x 1926.8 Vb 199.3 kgf
Seismic moment of support
= Vb x ( Hcg - H )
= 199.3 x ( 1807.5 - 372.5 ) M 286034.2 kgf-mm

2. COVER DATA :
3. BOLTING DATA :
4. LINER DATA :
5. GASKET DATA :
6. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b1) :
Total joint - contact surface compression load [Hp]
= 2 x (  x b x G + b' x Lp ) x m x P
= 2 x (  x 9.554 x 1294.4 + 0 x 0 ) x 3 x 0.12
= 27973 kgf
Total hydrostatic end force [H]
= 0.25 x  x G 2
x P
= 0.25 x  x 1294.4 2
x 0.12
= 157907.4 kgf
Minimum required bolt load for operating condition [Wm1]
= Hp + H
Licensee :
Pune, India
DESIGN OF FLAT BOLTED HEAD ( INTERNAL ) Cover (Front)
Design pressure P 0.12 kgf/mm² g
Design temperature T 150 °C
Allowance CA 3 mm
Groove allowance Tg 0 mm
Radiography Spot + T Joints
Joint efficiency E 1
M.O.C. SA-516 GR. 70 Plt. [UNS:K02700]
Code allw. stress @ design temp. Sfo 14.06 kgf/mm²
Code allw. stress @ atm. temp. Sfa 14.06 kgf/mm²
Young’s modulus Ey 19888.4 kgf/mm²
Self reinforced False
Flange OD A 1420 mm
Thickness provided 73.41 mm
Thickness available 70.41 mm
M.O.C. SA-193 GR. B7 Bolt [UNS:G41400]
Code allw. stress @ design temp. Sb 17.58 kgf/mm²
Code allw. stress @ atm. temp. Sa 17.58 kgf/mm²
Bolt PCD PCD 1363 mm
Bolt dia. db 24 mm
No. of bolts nb 56
M.O.C.
Liner ID mm
Liner OD mm
Liner thk. mm
M.O.C. Spiral metal wound CAF filled (S.S.)
Gasket seating stress y 7.031 kgf/mm²
Gasket factor m 3
Inside diameter Gi 1256 mm
Outside diameter Go 1313.5 mm
Width of gasket N 28.75 mm
Width of gasket ( as per Table 2-5.2 ) 31.75 mm
Basic gasket seating width ( as per Table 2-5.2 ) b0 14.38 mm
Effective gasket width ( as per Table 2-5.2 ) b 9.554 mm
Dia. at load reaction ( see Table 2-5.2 ) G 1294.4 mm
Pass partition gasket width Wp 0 mm
Pass partition gasket length Lp 0 mm
Effective pass partition gasket width b' 0 mm

= 27973 + 157907.4
= 185880.4 kgf
Minimum required bolt load for gasket seating [Wm2]
= (  x b x G + b' x Lp ) x y
= (  x 9.554 x 1294.4 + 0 x 0 ) x 7.031
= 273152.4 kgf
8. BOLT AREAS AS PER APPENDIX 2-5 (d) :
Total required cross-sectional area of bolts [Am]
= MAX [ Wm2 / Sa , Wm1 / Sb ] ........ For Internal '+' Pr Design
= Wm2 / Sa ..................................... For External Pr & Self Sealing Design
= 15540.6 mm²
Actual bolt area using root diameter [Ab]
= 17513.9 mm²
Flange design bolt load for the gasket seating [W]
= 0.5 x ( Am + Ab ) x Sa x 1 .................... average bolt area
= Ab x Sa x 1 ..........................................full bolt area
= 307837.2 kgf ( Full bolt area and margin factor of 1 )
9. CHECK FOR GASKET CRUSHING :
Minimum gasket width required [Nmin]
= Ab x Sb / ( 2 x  x y x G )
= 17513.9 x 17.58 / ( 2 x  x 7.031 x 1294.4 )
= 5.384 mm
10. DESIGN CALCULATION AS PER UG 34, BOLTING CONDITION :
Required thickness for bolting condition [t]
= G x SQRT [ 1.9 x W x 0.5 x ( PCD - G ) / ( Sfa x E x G 3 ) ]
= 1294.4 x SQRT [ 1.9 x 307837.2 x 0.5 x ( 1363 - 1294.4 ) / ( 14.06 x 1 x 1294.4 3
) ]
= 33.2 mm
11. DESIGN CALCULATION AS PER UG 34, OPERATING CONDITION :
Required thickness for operating condition [t]
= G x SQRT { [ C x P / ( Sfo x E ) ] + 1.9 x Wm1 x 0.5 x ( PCD - G ) / ( Sfo x E x G 3
) }
= 1294.4 x SQRT { [ 0.3 x 0.12 / ( 14.06 x 1 ) ] + 1.9 x 185880.4 x 0.5 x ( 1363 - 1294.4 ) /
( 14.06 x 1 x 1294.4 3 ) }
= 70.65 mm
Factor C is user input False
Factor C taken from fig. UG 34 or user input 0.3
Maximum factor C value C 0.75
Factor C (effective) 0.3
C = Min ( 2 x 0.3, 0.75 ) for self reinf.
C = 0.3 in other cases

2. COVER DATA :
3. BOLTING DATA :
4. LINER DATA :
5. GASKET DATA :
= 2 x (  x b x G + b' x Lp ) x m x P
= 2 x (  x 9.554 x 1294.4 + 0 x 0 ) x 3 x 0.01055
= 2458.4 kgf
= 0.25 x  x G 2
x P
= 0.25 x  x 1294.4 2
x 0.01055
= 13877.8 kgf
= Hp + H
Licensee :
Pune, India
DESIGN OF FLAT BOLTED HEAD ( EXTERNAL ) Cover (Front)
Allowance CA 3 mm
M.O.C. SA-516 GR. 70 Plt. [UNS:K02700]
Flange OD A 1420 mm
Bolt dia. db 24 mm
No. of bolts nb 56
M.O.C.
Liner ID mm
Liner OD mm
Liner thk. mm
Gasket factor m 3

= 2458.4 + 13877.8
= 16336.3 kgf
= ( p x b x G + b' x Lp ) x y
= ( p x 9.554 x 1294.4 + 0 x 0 ) x 7.031
= 273152.4 kgf
= 15540.6 mm²
= 17513.9 mm²
= Ab x Sb / ( 2 x p x y x G )
= 17513.9 x 17.58 / ( 2 x p x 7.031 x 1294.4 )
= 5.384 mm
= 1294.4 x SQRT [ 1.9 x 307837.2 x 0.5 x ( 1363 - 1294.4 ) / ( 14.06 x 1 x 1294.4 3
) ]
= 33.2 mm
) }
= 1294.4 x SQRT { [ 0.3 x 0.01055 / ( 14.06 x 1 ) ] + 1.9 x 16336.3 x 0.5 x ( 1363 - 1294.4 ) /
( 14.06 x 1 x 1294.4 3 ) }
= 32.29 mm

2. FLANGE DATA :
3. BOLTING DATA :
4. LINER DATA :
5. GASKET DATA :
5a. Flange gasket data :
5b. Partition groove gasket data (For H.E. body flange) :
Licensee :
Pune, India
FLANGE DESIGN ( INTERNAL ) Shell Flng (Front)
Allowance CA 3 mm
M.O.C. SA-105 Frg. [UNS:K03504]
Inside diameter B 1256 mm
Outside diameter A 1420 mm
Hub length h 30 mm
Thickness ( hub end ) g1 17 mm
Thickness ( pipe end ) g0 7 mm
Bolt PCD C 1363 mm
Bolt dia. db 24 mm
No. of bolts nb 56
M.O.C.
Liner ID mm
Liner OD mm
Liner thk. mm
Gasket type Ring Gasket
Gasket confinement type Unconfined
Flange face type Raised Face
Flange gakset surface finish Serrated (Normal)
Counter flange face type Raised Face
Counter gakset surface finish Serrated (Normal)
Applicalbe gasket sketch in Table 2-5.2 Type 1B
Applicable gasket column in Table 2-5.2 1
Gasket seating stress ( refer to Note 1, Table 2-5.1 ) y 7.031 kgf/mm²
Gasket factor ( from Table 2-5.1 ) m 3
Width of gasket ( as per Table 2-5.2 ) N 28.75 mm
Width of gasket ( as per Table 2-5.2 ) w 28.75 mm
Width of raised face or gasket contact width 31.75 mm
( as per Table 2-5.2 )
M.O.C. --

6. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b1)
= 2 x ( p x b x G x m + b' x Lp x m' ) x P
= 2 x ( p x 9.554 x 1294.4 x 3 + 0 x 0 x 0 ) x 0.12
= 27973 kgf
= 0.25 x p x G ² x P
= 0.25 x p x 1294.4 ² x 0.12
= 157907.4 kgf
Minimum required bolt load for operating condition [Wm1a]
= Hp + H
= 27973 + 157907.4
= 185880.4 kgf
Minimum required bolt load for operating condition [Wm1b]
( from mating flange )
= 185880.4 kgf
Governing bolt load for operating condition [Wm1]
= MAX [ Wm1a , Wm1b ]
= MAX [ 185880.4 , 185880.4 ]
= 185880.4 kgf
7. BOLT LOAD CALCULATION AS PER APPENDIX 2-5 (b2)
= ( p x b x G x y + b' x Lp x y' )
= ( p x 9.554 x 1294.4 x 7.031 + 0 x 0 x 0 )
= 273152.4 kgf
8. BOLT AREAS AS PER APPENDIX 2-5 (d)
= 15540.6 mm²
= 17513.9 mm²
9. CHECK FOR GASKET CRUSHING
= Ab x Sb / ( 2 x p x y x G )
= 17513.9 x 17.58 / ( 2 x p x 7.031 x 1294.4 )
= 5.384 mm
10. BOLT SPACING CORRECTION FACTOR
As per Brownell & Young or IS 2825,
= SQRT [ Bolt spacing / ( 2 x db + t ) ]
As per TEMA or BS 5500,
= SQRT [ Bolt spacing / Bmax ] ................... where,
Bmax = maximum recommended bolt spacing = 2 x db + 6 x t / ( m + 0.5 )
Brownell & Young, Cf = 1 ( min. equal to 1 )
11. LOADS AND FORCES DURING OPERATING CONDITION AS PER APPENDIX 2-3
Hydrostatic end force on area inside of flange [HD]
= 0.25 x p x B 2
x P
= 0.25 x p x 1256 2
x 0.12
= 148679.3 kgf
Gasket load (difference between flange design bolt load and total hydrostatic end force) [HG]
= Wm1 - H
= 185880.4 - 157907.4
= 27973 kgf
Difference between total hydrostatic end force and hydrostatic end force on area inside of flange [HT]
= H - HD
= 157907.4 - 148679.3
= 9228.2 kgf
12. MOMENT ARMS FOR FLANGE LOADS AS PER TABLE 2-6
Radial distance from the bolt circle to intersection of hub and back of flange, as per Appendix 2-3 [R]
= 0.5 x ( C - B ) - g1
= 0.5 x ( 1363 - 1256 ) - 17
Gasket seating stress ( refer to Note 1, Table 2-5.1 ) y' 0 kgf/mm²
Gasket factor ( from Table 2-5.1 ) m' 0
INTEGRAL FLANGE DESIGN Shell Flng (Front)

= 36.5 mm
Radial distance from the bolt circle to the circle on which HD acts [hD]
= R + 0.5 x g1
= 36.5 + 0.5 x 17
= 45 mm
Radial distance from gasket load reaction to the bolt circle [hG]
= 0.5 x ( C - G )
= 0.5 x ( 1363 - 1294.4 )
= 34.3 mm
Radial distance from the bolt circle to the circle on which HT acts [hT]
= 0.5 x ( R + g1 + hG )
= 0.5 x ( 36.5 + 17 + 34.3 )
= 43.9 mm
13. FLANGE MOMENTS UNDER OPERATING CONDITION AS PER APPENDIX 2-6
Component of moment due to HD [MD]
= HD x hD
= 148679.3 x 45
= 6690566.9 kgf-mm
Component of moment due to HG [MG]
= HG x hG
= 27973 x 34.3
= 959588.9 kgf-mm
Component of moment due to HT [MT]
= HT x hT
= 9228.2 x 43.9
= 405136.1 kgf-mm
Total moment acting on the flange for operating condition [MO]
= MD + MG + MT
= 6690566.9 + 959588.9 + 405136.1
= 8055291.9 kgf-mm
14. LOADS AND FORCES DURING GASKET SEATING AS PER APPENDIX 2-3
Gasket load for seating condition [HG]
= W
= 307837.2 kgf
15. MOMENT UNDER GASKET SEATING AS PER APPENDIX 2-6
Total moment acting on the flange for gasket seating [MO']
= W x hG
= 307837.2 x 34.3
= 10560086 kgf-mm
16. SHAPE CONSTANTS
17. STRESS FORMULA FACTORS
Assumed thickness [t]
= 108.7 mm
Factor [a]
= t x e + 1
= 108.7 x 0.00922 + 1
= 2.002
Factor [b]
= 1.333 x t x e + 1
= 1.333 x 108.7 x 0.00922 + 1
= 2.336
Factor [g]
= a / T
= 2.002 / 1.866
= 1.073
Factor [d]
= t 3
/ d
A / B K 1.131
Flange factors from Fig. 2-7.1 T 1.866
Z 8.189
Y 15.84
U 17.41
h0 93.77
F / h0 e 0.00922
Factor from Fig. 2-7.2 F 0.864
Factor from Fig. 2-7.3 V 0.261
g1 / g0 2.429
h / h0 0.32
( U / V ) x h0 x g0 2 d 306079.1
Factor from Fig. 2-7.6 f 2.935

= 108.7 3
/ 306079.1
= 4.195
Factor [l]
= g + d
= 1.073 + 4.195
= 5.268
18. FLANGE STRESSES AS PER APPENDIX 2-7 & 2-8
Equivalent moment [Mmax]
= MAX [ MO , MO' x Sfo / Sfa ]
= MAX [ 8055291.9 , 10560086 x 14.06 / 14.06 ]
= 10560086 kgf-mm
Corrected equivalent moment per unit length [M]
= Mmax x ( Cf / B )
= 10560086 x ( 1 / 1256 )
= 8407.7 kgf
Longitudinal hub stress [SH]
= f x M / ( l x g1 2 )
= 2.935 x 8407.7 / ( 5.268 x 17 2
)
Radial flange stress [SR]
= b x M / ( l x t 2
)
= 2.336 x 8407.7 / ( 5.268 x 108.7 2
)
Tangential flange stress [ST]
= ( M x Y / t 2
) - Z x SR
= ( 8407.7 x 15.84 / 108.7 2
) - 8.189 x 0.316
Average stress
= MAX [ 0.5 x ( SH + SR ) , 0.5 x ( SH + ST ) ]
= MAX [ 0.5 x ( 16.21 + 0.316 ) , 0.5 x ( 16.21 + 8.69 ) ]
19. FLANGE RIGIDITY CHECKING AS PER APPENDIX 2-14
Rigidity index [J]
= 52.14 x V x Mmax / ( l x Efo x g0 2 x KI x h0 )
= 52.14 x 0.261 x 10560086 / ( 5.268 x 19888.4 x 7 2
x 0.3 x 93.77 )
= 0.996
Since J < 1.0, design is safe
= 16.21 kgf/mm² .................................... < 1.5 x Sfo
= 0.316 kgf/mm² .................................... < Sfo
= 8.69 kgf/mm² .................................... < Sfo
= 12.45 kgf/mm² .................................... < Sfo
Modulus of elasticity for flange Efo 19888.4 kgf/mm²
Rigidity factor KI 0.3

2. FLANGE DATA :
3. BOLTING DATA :
4. LINER DATA :
5. GASKET DATA :
Licensee :
Pune, India
FLANGE DESIGN ( EXTERNAL ) Shell Flng (Front)
Allowance CA 3 mm
M.O.C. SA-105 Frg. [UNS:K03504]
Hub length h 30 mm
Bolt PCD C 1363 mm
Bolt dia. db 24 mm
No. of bolts nb 56
M.O.C.
Liner ID mm
Liner OD mm
Liner thk. mm
M.O.C. --

6. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b1)
= 2 x ( p x b x G x m + b' x Lp x m' ) x P
= 2 x ( p x 9.554 x 1294.4 x 3 + 0 x 0 x 0 ) x 0.01055
= 2458.4 kgf
= 0.25 x p x G ² x P
= 0.25 x p x 1294.4 ² x 0.01055
= 13877.8 kgf
Minimum required bolt load for operating condition [Wm1a]
= Hp + H
= 2458.4 + 13877.8
= 16336.3 kgf
Minimum required bolt load for operating condition [Wm1b]
( from mating flange )
= 16336.3 kgf
Governing bolt load for operating condition [Wm1]
= MAX [ Wm1a , Wm1b ]
= MAX [ 16336.3 , 16336.3 ]
= 16336.3 kgf
7. BOLT LOAD CALCULATION AS PER APPENDIX 2-5 (b2)
= ( p x b x G x y + b' x Lp x y' )
= ( p x 9.554 x 1294.4 x 7.031 + 0 x 0 x 0 )
= 273152.4 kgf
8. BOLT AREAS AS PER APPENDIX 2-5 (d)
= 15540.6 mm²
= 17513.9 mm²
9. CHECK FOR GASKET CRUSHING
= Ab x Sb / ( 2 x p x y x G )
= 17513.9 x 17.58 / ( 2 x p x 7.031 x 1294.4 )
= 5.384 mm
10. BOLT SPACING CORRECTION FACTOR
As per Brownell & Young or IS 2825,
= SQRT [ Bolt spacing / ( 2 x db + t ) ]
As per TEMA or BS 5500,
= SQRT [ Bolt spacing / Bmax ] ................... where,
Bmax = maximum recommended bolt spacing = 2 x db + 6 x t / ( m + 0.5 )
Brownell & Young, Cf = 1 ( min. equal to 1 )
11. LOADS AND FORCES DURING OPERATING CONDITION AS PER APPENDIX 2-3
Hydrostatic end force on area inside of flange [HD]
= 0.25 x p x B 2
x P
= 0.25 x p x 1256 2
x 0.01055
= 13066.8 kgf
Difference between total hydrostatic end force and hydrostatic end force on area inside of flange [HT]
= H - HD
= 13877.8 - 13066.8
= 811 kgf
12. MOMENT ARMS FOR FLANGE LOADS AS PER APPENDIX TABLE 2-6
Radial distance from the bolt circle to intersection of hub and back of flange, as per Appendix 2-3 [R]
= 0.5 x ( C - B ) - g1
= 0.5 x ( 1363 - 1256 ) - 17
= 36.5 mm
Radial distance from the bolt circle to the circle on which HD acts [hD]
= R + 0.5 x g1
= 36.5 + 0.5 x 17
Gasket seating stress ( refer to Note 1, Table 2-5.1 ) y' 0 kgf/mm²
Gasket factor ( from Table 2-5.1 ) m' 0
INTEGRAL FLANGE DESIGN Shell Flng (Front)

= 45 mm
Radial distance from gasket load reaction to the bolt circle [hG]
= 0.5 x ( C - G )
= 0.5 x ( 1363 - 1294.4 )
= 34.3 mm
Radial distance from the bolt circle to the circle on which HT acts [hT]
= 0.5 x ( R + g1 + hG )
= 0.5 x ( 36.5 + 17 + 34.3 )
= 43.9 mm
13. FLANGE MOMENTS UNDER OPERATING CONDITION AS PER APPENDIX 2-6
Component of moment due to HD [MD]
= HD x ( hD - hG )
= 13066.8 x ( 45 - 34.3 )
= 139760.9 kgf-mm
Component of moment due to HT [MT]
= HT x ( hT - hG )
= 811 x ( 43.9 - 34.3 )
= 7784.2 kgf-mm
Total moment acting on the flange for operating condition [MO]
= MD + MT
= 139760.9 + 7784.2
= 147545.1 kgf-mm
14. LOADS AND FORCES DURING GASKET SEATING AS PER APPENDIX 2-3
Gasket load for seating condition [HG]
= W
= 307837.2 kgf
15. MOMENT UNDER GASKET SEATING AS PER APPENDIX 2-6
Total moment acting on the flange for gasket seating [MO']
= W x hG
= 307837.2 x 34.3
= 10560086 kgf-mm
16. SHAPE CONSTANTS
17. STRESS FORMULA FACTORS
Assumed thickness [t]
= 108.9 mm
Factor [a]
= t x e + 1
= 108.9 x 0.00922 + 1
= 2.004
Factor [b]
= 1.333 x t x e + 1
= 1.333 x 108.9 x 0.00922 + 1
= 2.338
Factor [g]
= a / T
= 2.004 / 1.866
= 1.074
Factor [d]
= t 3
/ d
= 108.9 3 / 306079.1
= 4.217
Factor [l]
= g + d
= 1.074 + 4.217
= 5.29
18. FLANGE STRESSES AS PER APPENDIX 2-7 & 2-8
Equivalent moment [Mmax]
A / B K 1.131
Flange factors from Fig. 2-7.1 T 1.866
Z 8.189
Y 15.84
U 17.41
h0 93.77
F / h0 e 0.00922
Factor from Fig. 2-7.2 F 0.864
Factor from Fig. 2-7.3 V 0.261
g1 / g0 2.429
h / h0 0.32
( U / V ) x h0 x g0 2 d 306079.1
Factor from Fig. 2-7.6 f 2.935

= MAX [ MO , MO' x Sfo / Sfa ]
= MAX [ 147545.1 , 10560086 x 14.06 / 14.06 ]
= 10560086 kgf-mm
Corrected equivalent moment per unit length [M]
= Mmax x ( Cf / B )
= 10560086 x ( 1 / 1256 )
= 8407.7 kgf
Longitudinal hub stress [SH]
= f x M / ( l x g1 2
)
= 2.935 x 8407.7 / ( 5.29 x 17 2
)
Radial flange stress [SR]
= b x M / ( l x t 2
)
= 2.004 x 8407.7 / ( 5.29 x 108.9 2
)
Tangential flange stress [ST]
= ( M x Y / t 2
) - Z x SR
= ( 8407.7 x 15.84 / 108.9 2
) - 8.189 x 0.313
Average stress
= MAX [ 0.5 x ( SH + SR ) , 0.5 x ( SH + ST ) ]
= MAX [ 0.5 x ( 16.14 + 0.313 ) , 0.5 x ( 16.14 + 8.669 ) ]
19. FLANGE RIGIDITY CHECKING AS PER APPENDIX AS PER 2-14
Rigidity index [J]
= 52.14 x V x Mmax / ( l x Efo x g0 2
x KI x h0 )
= 52.14 x 0.261 x 10560086 / ( 5.29 x 19888.4 x 7 2
x 0.3 x 93.77 )
= 0.992
Since J < 1.0, design is safe
= 16.14 kgf/mm² .................................... < 1.5 x Sfo
= 0.313 kgf/mm² .................................... < Sfo
= 8.669 kgf/mm² .................................... < Sfo
= 12.4 kgf/mm² .................................... < Sfo
Modulus of elasticity for flange Efo 19888.4 kgf/mm²
Rigidity factor KI 0.3

1. DESIGN CONDITIONS ( Design Mode 1 , Corroded Condition )
2. DESIGN CALCULATION AS PER UG-27
Thickness of shell under internal pressure [ti]
= Pi x R / ( S x E - 0.6 x Pi )
= 0.12 x 628 / ( 14.06 x 0.85 - 0.6 x 0.12 )
= 6.343 mm
3. DESIGN CALCULATION OF SHELL THICKNESS UNDER EXTERNAL PRESSURE AS PER UG-28
Allowable external pressure [Pa]
= 4 x B / ( 3 x ( OD / te ) )
= 4 x 2.272 / ( 3 x 284.4 )
= 0.01065 kgf/mm² g
Since Pa > Pe, design is safe
Since available thickness is more than design thickness, design is safe.
Licensee :
Pune, India
DESIGN OF SHELL ( INTERNAL AND EXTERNAL PRESSURE ) Main Shell
Design pressure ( internal ) Pi 0.12 kgf/mm² g
Design pressure ( external ) Pe 0.01055 kgf/mm² g
Material of construction SA-516 GR. 70 Plt. [UNS:K02700]
Max. allowable stress at design temp. S 14.06 kgf/mm²
Joint efficiency long. seam Ec 0.85
Outside diameter OD 1270 mm
Inside radius ( corroded ) R 628 mm
Shell length L 1650 mm
Design length L1 1650 mm
Nominal thickness 10 mm
Nominal thickness required as per TEMA N.A. mm
Internal allowance, corrosion + polishing 3 mm
External allowance, corrosion + polishing 0 mm
Thickness undertolerance 0 mm
Available thickness 7 mm
Assumed te 4.466 mm
L1 / OD 1.299
OD / te 284.4
Factor A ( Refer to Fig. G in Subpart 3 of Sec. II, Part D ) 0.00021
Factor B ( CS-2 ) 2.272 kgf/mm²

2. DESIGN CALCULATION AS PER UG 32 d / APPENDIX 1-4 ( c ) :
Factor [K]
= 1
Thickness for internal pressure [t]
= K x Pi x ID / ( 2 x S x E - 0.2 x Pi )
= 1 x 0.12 x 1256 / ( 2 x 14.06 x 1 - 0.2 x 0.12 )
= 5.364 mm
3. DESIGN CALCULATION AS PER UG 33 d :
Thickness for equivalent external pressure [t]
= K x 1.67 x Pe x ID / ( 2 x S x 1.0 - 0.2 x 1.67 x Pe )
= 1 x 1.67 x 0.01055 x 1256 / ( 2 x 14.06 x 1.0 - 0.2 x 1.67 x 0.01055 )
= 0.787 mm
Factor [Ko]
= 0.77
Assumed head thickness, [te]
= 2.779 mm
Factor [A]
= 0.125 x te / ( Ko x OD )
= 0.125 x 2.779 / ( 0.77 x 1270 )
= 0.00036
Factor with reference to chart (CS-2) [B]
= 3.743 kgf/mm²
Allowable external pressure [Pa]
= B / ( Ko x OD / te )
= 3.743 x 2.779 / ( 0.77 x 1270 )
= 0.01064 kgf/mm²
Since Pa > Pe, design is safe
Since available thickness is more than design thickness, design is safe.
Licensee :
Pune, India
DESIGN OF ELLIPSOIDAL HEAD ( INT. & EXT. PRESSURE ) Dished End (Rear)
Material of construction SA-516 GR. 70 Plt. [UNS:K02700]
Max. allowable stress @ design temp. S 14.06 kgf/mm²
Radiography Full
Outside diameter of head OD 1270 mm
Inside diameter of shell ID 1256 mm
Head shape Elliptical D/2H = 2.0
Nominal thickness 10 mm
Nominal thickness required as per TEMA N.A mm
Internal allowance, corrosion + polishing 3 mm
External allowance, corrosion + polishing 0 mm
Thinning allowance / Under tolerance 1 mm
Available thickness 6 mm
109

1. LUG DATA :
2. BOLT DATA :
3. GUSSET DATA :
4. SHELL DATA :
5. PAD DATA :
6. LOAD AND MOMENT ( Wind ) :
7. DESIGN OF ANCHOR BOLTS :
Total uplift force on bolts [T]
= [ 4 x M / ( D x N ) ] - Wt / N
= [ 4 x 940925.4 / ( 1570 x 4 ) ] - 2388.5 / 4
= 2.203 kgf
Required area of bolts [Am]
= MAX [ ( T / Fs ) , 0 ]
= MAX [ ( 2.203 / 20.88 ) , 0 ]
= 0.106 mm²
Available area of bolts [Ab]
= Ar x Nb ........................................................................................ where, Ar = 217.1 mm², is root area of bolt
= 217.1 x 1
= 217.1 mm²
Since Ab > Am, bolts provided are sufficient
8. GUSSET DESIGN :
Reaction force at each support [Q]
= [ 4 x M / ( D x N ) ] + Wt / N
Licensee :
Pune, India
LUG SUPPORT DESIGN Lug Support
CODE P V Design Manual, D.R. Moss
Condition
M.O.C IS-2062 GR. A Plt.
No. of support N 4
Base plate width b1 242 mm
Base plate depth Lb 200 mm
Thickness of base plate tb 16 mm
Allowable bending stress Sb 22.15 kgf/mm²
M.O.C Commercial CS Bolt
No. of bolt / lug Nb 1
Bolt diameter db 20 mm
PCD D 1570 mm
Diameter of bolt hole 24 mm
Allowable tensile stress Fs 20.88 kgf/mm²
Thickness tg 16 mm
Height h 190 mm
Gusset angle θ 51.71
Gusset depth at top Lc 50 mm
Number of gussets n 2
Distance between gussets b 200 mm
Material SA-516 GR. 70 Plt. [UNS:K02700]
OD diameter OD 1270 mm
Inside diameter ID 1256 mm
Thickness available ts 7 mm
Thickness tp 10 mm
Width W 270 mm
Length L 292 mm
Max. overturning moment M 940925.4 kgf-mm
Design weight of vessel Wt 2388.5 kgf

= [ 4 x 940925.4 / ( 1570 x 4 ) ] + 2388.5 / 4
= 1196.4 kgf
Maximum axial force in gusset [P1]
= Q / n
= 1196.4 / 2
= 598.2 kgf
Allowable compr. stress in gusset [Sg]
= 1800 / [ ( 1 + 12 / 18000 ) x ( h’ / tg ) 2
] ....................................... where, h’ = 242.1 mm
= 1800 / [ ( 1 + 12 / 18000 ) x ( 242.1 / 16 ) 2 ]
= 15616.8 psi
= 10.98 kgf/mm²
Required thickness of gusset [tg’]
= 2 x P1 x ( 3 x a - Lb ) / [ Sg x Lb 2 x ( sin θ ) 2 ]
= 2 x 598.2 x ( 3 x 150 - 200 ) / [ 10.98 x ( 200 ) 2
x ( sin 51.71 ) 2
]
= 1.106 mm
9. BASE PLATE DESIGN :
Bending moment [Mb]
= Q x b1 / 6
= 1196.4 x 242 / 6
= 48255.9 kgf-mm
Bearing pressure [bp]
= Q / ( w x b1 ) ............................................................................... where, w = 120 mm
= 1196.4 / ( 120 x 242 )
= 0.0412 kgf/mm²
Bending moment due to bearing pressure [Mb’]
= bp x b 2
/ 10
= 0.0412 x 200 2
/ 10
= 164.8 kgf-mm
Required thickness of base plate between chairs [tb’]
= SQRT { 6 x MAX [ Mb , Mb' ] / [ ( Lb - db ) x Sb ] }
= SQRT { 6 x MAX [ 48255.9 , 164.8 ] / [ ( 200 - 20 ) x 22.15 ] }
= 8.619 mm
10. CHECK FOR COMPRESSION PLATE :
Equivalent radial load [f]
= Q x a / h
= 1196.4 x 150 / 190
= 472.3 kgf
Angle between supports [b]
= 2 x p / N
= 2 x p / 4
= 1.571 rad
Internal bending moment coefficient [Kr]
= 0.5 x [ 1 / a - cot ( a ) ]
= 0.5 x [ 1 / 1.571 - cot ( 1.571 ) ]
= 0.318
Internal bending moment [Mc]
= 0.5 x Kr x f x OD
= 0.5 x 0.318 x 472.3 x 1270
= 95459.3 kgf-mm
Bending stress induced [fb]
= Mo / Zc
= 95459.3 / 7785.1
= 12.26 kgf/mm² ......................................................................... < Sb = 22.15 kgf/mm²
Since, induced stress fb < allow. stress Sb in shell material, design is safe.

1. LUG DATA :
2. BOLT DATA :
3. GUSSET DATA :
4. SHELL DATA :
5. PAD DATA :
6. LOAD AND MOMENT ( Seismic ) :
7. DESIGN OF ANCHOR BOLTS :
Total uplift force on bolts [T]
= [ 4 x M / ( D x N ) ] - Wt / N
= [ 4 x 288590.5 / ( 1570 x 4 ) ] - 1841.2 / 4
= -276.5 kgf
Required area of bolts [Am]
= MAX [ ( T / Fs ) , 0 ]
= MAX [ ( -276.5 / 20.88 ) , 0 ]
= 0 mm²
Available area of bolts [Ab]
= Ar x Nb ........................................................................................ where, Ar = 217.1 mm², is root area of bolt
= 217.1 x 1
= 217.1 mm²
Since Ab > Am, bolts provided are sufficient
8. GUSSET DESIGN :
Reaction force at each support [Q]
= [ 4 x M / ( D x N ) ] + Wt / N
Licensee :
Pune, India
LUG SUPPORT DESIGN Lug Support
Condition
M.O.C IS-2062 GR. A Plt.
No. of support N 4
Base plate width b1 242 mm
Base plate depth Lb 200 mm
Thickness of base plate tb 16 mm
Allowable bending stress Sb 22.15 kgf/mm²
M.O.C Commercial CS Bolt
No. of bolt / lug Nb 1
Bolt diameter db 20 mm
PCD D 1570 mm
Diameter of bolt hole 24 mm
Allowable tensile stress Fs 20.88 kgf/mm²
Thickness tg 16 mm
Height h 190 mm
Gusset angle θ 51.71
Gusset depth at top Lc 50 mm
Number of gussets n 2
Distance between gussets b 200 mm
OD diameter OD 1270 mm
Inside diameter ID 1256 mm
Thickness available ts 7 mm
Thickness tp 10 mm
Width W 270 mm
Length L 292 mm
Max. overturning moment M 288590.5 kgf-mm
Design weight of vessel Wt 1841.2 kgf

= [ 4 x 288590.5 / ( 1570 x 4 ) ] + 1841.2 / 4
= 644.1 kgf
Maximum axial force in gusset [P1]
= Q / n
= 644.1 / 2
= 322.1 kgf
Allowable compr. stress in gusset [Sg]
= 1800 / [ ( 1 + 12 / 18000 ) x ( h’ / tg ) 2
] ....................................... where, h’ = 242.1 mm
= 1800 / [ ( 1 + 12 / 18000 ) x ( 242.1 / 16 ) 2 ]
= 15616.8 psi
= 10.98 kgf/mm²
Required thickness of gusset [tg’]
= 2 x P1 x ( 3 x a - Lb ) / [ Sg x Lb 2 x ( sin θ ) 2 ]
= 2 x 322.1 x ( 3 x 150 - 200 ) / [ 10.98 x ( 200 ) 2
x ( sin 51.71 ) 2
]
= 0.595 mm
9. BASE PLATE DESIGN :
Bending moment [Mb]
= Q x b1 / 6
= 644.1 x 242 / 6
= 25979.7 kgf-mm
Bearing pressure [bp]
= Q / ( w x b1 ) ............................................................................... where, w = 120 mm
= 644.1 / ( 120 x 242 )
= 0.02218 kgf/mm²
Bending moment due to bearing pressure [Mb’]
= bp x b 2
/ 10
= 0.02218 x 200 2
/ 10
= 88.72 kgf-mm
Required thickness of base plate between chairs [tb’]
= SQRT { 6 x MAX [ Mb , Mb' ] / [ ( Lb - db ) x Sb ] }
= SQRT { 6 x MAX [ 25979.7 , 88.72 ] / [ ( 200 - 20 ) x 22.15 ] }
= 6.324 mm
10. CHECK FOR COMPRESSION PLATE :
Equivalent radial load [f]
= Q x a / h
= 644.1 x 150 / 190
= 254.3 kgf
Angle between supports [b]
= 2 x p / N
= 2 x p / 4
= 1.571 rad
Internal bending moment coefficient [Kr]
= 0.5 x [ 1 / a - cot ( a ) ]
= 0.5 x [ 1 / 1.571 - cot ( 1.571 ) ]
= 0.318
Internal bending moment [Mc]
= 0.5 x Kr x f x OD
= 0.5 x 0.318 x 254.3 x 1270
= 51392.7 kgf-mm
Bending stress induced [fb]
= Mo / Zc
= 51392.7 / 7785.1
= 6.601 kgf/mm² ......................................................................... < Sb = 22.15 kgf/mm²
Since, induced stress fb < allow. stress Sb in shell material, design is safe.

DESIGN CONDITIONS
NOZZLE DATA
SHELL DATA ( Main Shell )
WELD DATA
CALCULATION OF NOZZLE NECK THICKNESS AS PER UG 45
Neck thickness for internal pressure as per UG 45(a)
Formula in Appendix 1-1 , [trn1]
= ( 0.5 x Pi x OD ) / ( Sn x E + 0.4 x Pi )
= ( 0.5 x 0.12 x 168.3 ) / ( 12.02 x 1.0 + 0.4 x 0.12 )
= 0.983 mm
Neck thickness for external pressure as per UG 45(a)
Neck thickness for external pressure as per UG 28
Assumed neck thickness , [trn3] = 0.512 mm
L / OD = 0.891
OD / trn3 = 328.5
Factor A = 0.00025
Factor B = 2.679 kgf/mm²
Allowable external pressure , [Pa]
= 4 x B / ( 3 x OD / trn3 )
= 4 x 2.679 / ( 3 x 328.5 )
= 0.01088 kgf/mm² g
Thickness of shell as per UG 45(b)(1)
Min. shell thickness reqd. as per UG 27 , [tr1 = trn2]
= Pi x R / ( Sv x E - 0.6 x Pi )
= 0.12 x 628 / ( 14.06 x 1.0 - 0.6 x 0.12 )
= 5.387 mm
Thickness for equivalent pressure as per UG 45(b)(2) , [trn4]
= Pe x R / ( Sv x E - 0.6 x Pe )
Licensee :
Pune, India
NOZZLE NECK THICKNESS AND REINFORCEMENT DESIGN N 01
Condition
M.O.C.
[UNS:K03006]
Allowable stress @ design temperature Sn 12.02 kgf/mm²
Outside diameter OD 168.3 mm
Inside diameter ID 152.3 mm
Maximum chord length D 152.3 mm
Neck thickness ( provided ) tnp 10.97 mm
Internal allowance , corrosion + polishing CAI 3 mm
External allowance , corrosion + polishing CAE 0
Neck thickness (tnp - CAI - CAE) tn 7.973 mm
Max. under tolerance on thickness Alw 1.372 mm
Available neck thickness ( tn - Alw ) ta 6.601 mm
Nozzle projection outward ( from vessel outer face ) Lo 150 mm
Total length of nozzle ( Lo + Addn for curvature) L 156 mm
Connection type Pipe Nozzle
Application type Process Opening
Reinforcement calculation method Isolated Opening
Design as large opening False
M.O.C. SA-516 GR. 70 Plt. [UNS:K02700]
Allowable stress @ design temperature Sv 14.06 kgf/mm²
Inside radius R 628 mm
Thickness t 7 mm
Min. thickness for external pressure tr2 4.466 mm
Nozzle outside weld W1 7 mm

= 0.01055 x 628 / ( 14.06 x 1.0 - 0.6 x 0.01055 )
= 0.471 mm
Standard wall thickness as per UG 45(b)(4) , [t3]
= 7.112 mm
Neck thk as per UG 45 , [trn]
= MAX { MAX [ trn1, trn3 ] , MIN [ MAX ( trn2 , trn4 ) , 0.875 x t3 ] } ..... for Process Nozzle
= MAX [ trn1, trn3 ] ............................................................................ for Access Opening
= 5.387 mm .................................................................................... Process Opening
Since available neck thickness, ta >= trn, selected neck thickness is adequate.

1. DESIGN CONDITION :
2. ATTACHMENT DATA :
3. EXTERNAL LOADS :
4. SHELL DATA :
5. STRESS CONCENTRATION FACTORS :
6. COMPUTING STRESSES :
Licensee :
Pune, India
LOCAL STRESS ANALYSIS (EDGE OF ATTACHMENT) N 01
CODE
D.R. MOSS (EXTRACT OF WRC
107)
Design Mode 1, Corroded
Condition
M.O.C
[UNS:K03006]
Weld size w 7 mm
Pad diameter Dp 292.7 mm
Pad thickness tp 10 mm
0.5 x OD C 84.14 mm
Radial force Fr 344.6 kgf
Long. moment ML 254724.1 kgf-mm
Circ. moment Mc 254724.1 kgf-mm
Torsional moment Mt 254724.1 kgf-mm
Total eff. shear load Q 487.4 kgf
M.O.C SA-516 GR. 70 Plt. [UNS:K02700]
Allowable stress Sv 14.06 kgf/mm²
Thickness of shell tv 7 mm
Mean radius of shell , [ Rm ]
= R + 0.5 x ( tv + tp )
= 628 + 0.5 x ( 7 + 10 )
= 636.5 mm
Thickness , [t]
= SQRT [ tv 2
+ tp 2
]
= SQRT [ 7 2
+ 10 2
]
= 12.21 mm
Calculate ratio , [ g ]
= Rm / te
= 636.5 / 12.21
= 52.14
Calculate ratio , [ b ]
= 0.875 x C / Rm
= 0.875 x 84.14 / 636.5
= 0.116
Factor , [ Kn ] = 1 Factor , [ Kb ] = 1
Shear stress due to Q , [ t1
]
= Q / ( p x Ro x t )
= 487.4 / ( p x 84.14 x 12.21 )
= 0.151 kgf/mm²
Shear stress due to Mt , [ t2
]
= Mt / ( 2 x p x Ro 2
x t )
= 254724.1 / ( 2 x p x 84.14 2
x 12.21 )
= 0.469 kgf/mm²
Total shear stress , [ t ]
= t1
+ t2
= 0.151 + 0.469
= 0.62 kgf/mm²
STRESSES FACT FIG. FORCES( kgf ) & MOMENTS( kgf-mm ) STRESS ( kgf/mm² )
Radial
load
Membrane
5-17A
7.023 x Fr
Rm
Nf 3.803
Kn x Nf
t
σf 0.312
5-17B
8.616 x Fr
Rm
Nx 4.665
Kn x Nx
t
σx 0.382
Bending
5-18A 0.117 x Fr Mf 40.25
6 x Kb x Mf
t 2 σf 1.621
6 x Kb x Mx

7. COMBINING STRESSES :
** Only absolute values of quantities in bracket shall be used while combining stresses
( 1 ) : Fr sign is (+) for outward load, & (-) for inward load.
Allowabe Stresses for various catergories:
1. Membrane only, Sm = 1.5 x Sv
2. Membrane + Bending, Sa = 3 x Sv
3. Shear only, Sh = 0.5 x Sv
DESIGN IS ACCEPTABLE ? : YES
5-18B 0.0707 x Fr Mx 24.37 t 2 σx 0.981
Long.
moment
Membrane
CL=1 5-19A
3.516 x CL x ML
Rm 2
x b
Nf 19.11
Kn x Nf
t
σf 1.566
CL=1 5-19B
1.697 x CL x ML
Rm 2
x b
Nx 9.222
Kn x Nx
t
σx 0.756
Bending
5-20A
0.03827 x ML
Rm x b
Mf 132.4
6 x Kb x Mf
t 2 σf 5.331
5-20B
0.06937 x ML
Rm x B
Mx 240
6 x Kb x Mx
t 2 σx 9.665
Circ.
moment
Membrane
Cc=1 5-21A
1.893 x Cc x Mc
Rm 2
x b
Nf 10.29
Kn x Nf
t
σf 0.843
Cc=1 5-21B
2.973 x Cc x Mc
Rm 2
x b
Nx 16.16
Kn x Nx
t
σx 1.324
Bending
5-22A
0.09066 x Mc
Rm x b
Mf 313.7
6 x Kb x Mf
t 2 σf 12.63
5-22B
0.04678 x Mc
Rm x b
Mx 161.9
6 x Kb x Mx
t 2 σx 6.518
Stress due to
σx σf
0° 90° 180° 270° 0° 90° 180° 270°
Radial
load,
Fr.(1)
Membrane
Nf 0.312 0.312 0.312 0.312
Nx 0.382 0.382 0.382 0.382
Bending
Mf 1.621 1.621 1.621 1.621
Mx 0.981 0.981 0.981 0.981
Long.
moment,
ML.
Membrane
Nf
+
( 1.566 )
-( 1.566 )
Nx
+
( 0.756 )
-( 0.756 )
Bending
Mf
+
( 5.331 )
-( 5.331 )
Mx
+
( 9.665 )
-( 9.665 )
Circ
moment,
Mc.
Membrane
Nf
+
( 0.843 )
-( 0.843 )
Nx
+
( 1.324 )
-( 1.324 )
Bending
Mf
+
( 12.63 )
-
( 12.63 )
Mx
+
( 6.518 )
-( 6.518 )
Int.
pr., P.
Pi x
Rm
t
σf
+
( 10.91 )
+
( 10.91)
+
( 10.91 )
+
( 10.91 )
Pi x
Rm
2 x t
σx
+
( 5.456 )
+
( 5.456 )
+
( 5.456 )
+
( 5.456 )
Total,
∑
Membrane 6.593 7.162 5.082 4.514 12.86 12.14 9.728 10.45
Mem+Bend 17.24 14.66 -3.601 -1.023 19.74 26.32 5.946 -0.631

3. EXTERNAL LOADS :
4. SHELL DATA :
Licensee :
Pune, India
LOCAL STRESS ANALYSIS (EDGE OF PAD) N 01
CODE
107)
Condition
M.O.C
[UNS:K03006]
Weld size w 7 mm
0.5 x OD C 146.3 mm
M.O.C SA-516 GR. 70 Plt. [UNS:K02700]
Thickness of shell t 7 mm
= R + 0.5 x t
= 628 + 0.5 x 7
= 631.5 mm
= Rm / t
= 631.5 / 7
= 90.21
= 0.875 x C / Rm
= 0.875 x 146.3 / 631.5
= 0.203
]
= Q / ( p x Ro x t )
= 487.4 / ( p x 146.3 x 7 )
= 0.151 kgf/mm²
]
= Mt / ( 2 x p x Ro 2
x t )
= 254724.1 / ( 2 x p x 146.3 2
x 7 )
= 0.27 kgf/mm²
= t1
+ t2
= 0.151 + 0.27
= 0.422 kgf/mm²
Radial
load
Membrane
5-17A
4.941 x Fr
Rm
Nf 2.696
Kn x Nf
t
σf 0.385
5-17B
11.06 x Fr
Rm
Nx 6.037
Kn x Nx
t
σx 0.862
Bending
5-18A 0.04175 x Fr Mf 14.39
6 x Kb x Mf
t 2 σf 1.762
6 x Kb x Mx

5-18B 0.01857 x Fr Mx 6.398 t 2 σx 0.783
Long.
moment
Membrane
CL=1 5-19A
6.231 x CL x ML
Rm 2
x b
Nf 19.63
Kn x Nf
t
σf 2.804
CL=1 5-19B
3.293 x CL x ML
Rm 2
x b
Nx 10.38
Kn x Nx
t
σx 1.482
Bending
5-20A
0.0128 x ML
Rm x b
Mf 25.46
6 x Kb x Mf
t 2 σf 3.117
5-20B
0.01693 x ML
Rm x B
Mx 33.68
6 x Kb x Mx
t 2 σx 4.124
Circ.
moment
Membrane
Cc=1 5-21A
3.869 x Cc x Mc
Rm 2
x b
Nf 12.19
Kn x Nf
t
σf 1.741
Cc=1 5-21B
7.986 x Cc x Mc
Rm 2
x b
Nx 25.16
Kn x Nx
t
σx 3.594
Bending
5-22A
0.06043 x Mc
Rm x b
Mf 120.2
6 x Kb x Mf
t 2 σf 14.72
5-22B
0.026 x Mc
Rm x b
Mx 51.73
6 x Kb x Mx
t 2 σx 6.334
Stress due to
σx σf
0° 90° 180° 270° 0° 90° 180° 270°
Radial
load,
Fr.(1)
Membrane
Nf ( 0.385 ) ( 0.385) ( 0.385 ) ( 0.385 )
Nx ( 0.862 ) ( 0.862 ) ( 0.862 ) ( 0.862 )
Bending
Mf ( 1.762 ) ( 1.762 ) ( 1.762 ) ( 1.762 )
Mx ( 0.783 ) ( 0.783 ) ( 0.783 ) ( 0.783 )
Long.
moment,
ML.
Membrane
Nf
+
( 2.804 )
-( 2.804 )
Nx
+
( 1.482 )
-( 1.482 )
Bending
Mf
+
( 3.117 )
-( 3.117 )
Mx
+
( 4.124 )
-( 4.124 )
Circ
moment,
Mc.
Membrane
Nf
+
( 1.741 )
-( 1.741 )
Nx
+
( 3.594 )
-( 3.594 )
Bending
Mf
+
( 14.72 )
-
( 14.72 )
Mx
+
( 6.334 )
-( 6.334 )
Int.
pr., P.
Pi x
Rm
t
σf
+
( 10.83 )
+
( 10.83)
+
( 10.83 )
+
( 10.83 )
Pi x
Rm
2 x t
σx
+
( 5.413 )
+
( 5.413 )
+
( 5.413 )
+
( 5.413 )
Total,
∑
Membrane 7.757 9.869 4.793 2.681 14.49 13.43 8.884 9.947
Mem+Bend 12.67 16.99 1.452 -2.87 18.89 29.44 7.051 -3.49

DESIGN CONDITIONS
NOZZLE DATA
SHELL DATA ( Main Shell )
WELD DATA
= ( 0.5 x Pi x OD ) / ( Sn x E + 0.4 x Pi )
= ( 0.5 x 0.12 x 168.3 ) / ( 12.02 x 1.0 + 0.4 x 0.12 )
= 0.983 mm
L / OD = 0.891
OD / trn3 = 328.5
Factor A = 0.00025
= 4 x B / ( 3 x OD / trn3 )
= 4 x 2.679 / ( 3 x 328.5 )
= 0.01088 kgf/mm² g
Thickness of shell as per UG 45(b)(1)
Min. shell thickness reqd. as per UG 27 , [tr1 = trn2]
= Pi x R / ( Sv x E - 0.6 x Pi )
= 0.12 x 628 / ( 14.06 x 1.0 - 0.6 x 0.12 )
= 5.387 mm
= Pe x R / ( Sv x E - 0.6 x Pe )
Licensee :
Pune, India
Condition
M.O.C.
[UNS:K03006]
M.O.C. SA-516 GR. 70 Plt. [UNS:K02700]
Thickness t 7 mm
Nozzle outside weld W1 7 mm

3. EXTERNAL LOADS :
4. SHELL DATA :
Licensee :
Pune, India
LOCAL STRESS ANALYSIS (EDGE OF ATTACHMENT) N 02
CODE
107)
Condition
M.O.C
[UNS:K03006]
Weld size w 7 mm
0.5 x OD C 84.14 mm
M.O.C SA-516 GR. 70 Plt. [UNS:K02700]
Thickness of shell tv 7 mm
= R + 0.5 x ( tv + tp )
= 628 + 0.5 x ( 7 + 10 )
= 636.5 mm
Thickness , [t]
= SQRT [ tv 2
+ tp 2
]
= SQRT [ 7 2
+ 10 2
]
= 12.21 mm
= Rm / te
= 636.5 / 12.21
= 52.14
= 0.875 x C / Rm
= 0.875 x 84.14 / 636.5
= 0.116
]
= Q / ( p x Ro x t )
= 487.4 / ( p x 84.14 x 12.21 )
= 0.151 kgf/mm²
]
= Mt / ( 2 x p x Ro 2
x t )
= 254724.1 / ( 2 x p x 84.14 2
x 12.21 )
= 0.469 kgf/mm²
= t1
+ t2
= 0.151 + 0.469
= 0.62 kgf/mm²
Radial
load
Membrane
5-17A
7.023 x Fr
Rm
Nf 3.803
Kn x Nf
t
σf 0.312
5-17B
8.616 x Fr
Rm
Nx 4.665
Kn x Nx
t
σx 0.382
Bending
5-18A 0.117 x Fr Mf 40.25
6 x Kb x Mf
t 2 σf 1.621
6 x Kb x Mx

3. EXTERNAL LOADS :
4. SHELL DATA :
Licensee :
Pune, India
LOCAL STRESS ANALYSIS (EDGE OF PAD) N 02
CODE
107)
Condition
M.O.C
[UNS:K03006]
Weld size w 7 mm
0.5 x OD C 146.3 mm
M.O.C SA-516 GR. 70 Plt. [UNS:K02700]
Thickness of shell t 7 mm
= R + 0.5 x t
= 628 + 0.5 x 7
= 631.5 mm
= Rm / t
= 631.5 / 7
= 90.21
= 0.875 x C / Rm
= 0.875 x 146.3 / 631.5
= 0.203
]
= Q / ( p x Ro x t )
= 487.4 / ( p x 146.3 x 7 )
= 0.151 kgf/mm²
]
= Mt / ( 2 x p x Ro 2
x t )
= 254724.1 / ( 2 x p x 146.3 2
x 7 )
= 0.27 kgf/mm²
= t1
+ t2
= 0.151 + 0.27
= 0.422 kgf/mm²
Radial
load
Membrane
5-17A
4.941 x Fr
Rm
Nf 2.696
Kn x Nf
t
σf 0.385
5-17B
11.06 x Fr
Rm
Nx 6.037
Kn x Nx
t
σx 0.862
Bending
5-18A 0.04175 x Fr Mf 14.39
6 x Kb x Mf
t 2 σf 1.762
6 x Kb x Mx

DESIGN CONDITIONS
NOZZLE DATA
HEAD DATA ( Dished End (Rear) )
WELD DATA
Thickness of head as per UG 37
Min. head thickness reqd. as per UG 27(d) , [tr1]
= 0.5 x Pi x ID1 / ( 2 x Sv x E - 0.2 x Pi )
= 0.5 x 0.12 x 2260.8 / ( 2 x 14.06 x 1.0 - 0.2 x 0.12 )
= 4.828 mm
= ( 0.5 x Pi x OD ) / ( Sn x E + 0.4 x Pi )
= ( 0.5 x 0.12 x 60.33 ) / ( 12.02 x 1.0 + 0.4 x 0.12 )
= 0.353 mm
L / OD = 2.487
OD / trn3 = 216.3
Factor A = 0.00016
= 4 x B / ( 3 x OD / trn3 )
= 4 x 1.763 / ( 3 x 216.3 )
Licensee :
Pune, India
Condition
M.O.C.
[UNS:K03006]
Inside diameter of head @ head skirt Dsf 1256 mm
D / 2 H for Ellispoidal head 2
Factor from Table UG-37 K1 0.9
Inside diameter of equivalent sphere, K1 x Dsk x 2 ID1 2260.8 mm
Thickness t 7 mm
Nozzle outside weld W1 6.35 mm

= 0.01087 kgf/mm² g
Thickness of head as per UG 45(b)(1)
Min. head thickness reqd. as per UG 27(d) , [trn2 = tr1]
= 4.828 mm
= 0.5 x Pe x ID1 / ( 2 x Sv x E - 0.2 x Pe )
= 0.5 x 0.01055 x 2260.8 / ( 2 x 14.06 x 1.0 - 0.2 x 0.01055 )
= 0.424 mm
Standard wall thickness as per UG 45(b)(4) , [t3]
= 3.912 mm
Neck thk as per UG 45 , [trn]
= MAX { MAX [ trn1, trn3 ] , MIN [ MAX ( trn2 , trn4 ) , 0.875 x t3 ] } ..... for Process Nozzle
= MAX [ trn1, trn3 ] ............................................................................ for Access Opening
= 3.423 mm .................................................................................... Process Opening
Since available neck thickness, ta >= trn, selected neck thickness is adequate.

3. EXTERNAL LOADS :
4. HEAD DATA :
Licensee :
Pune, India
LOCAL STRESS ANALYSIS ( ROUND ATTACHMENT ) N 03
CODE
107)
Condition
M.O.C
[UNS:K03006]
Weld size w 7 mm
0.5 x OD
Ro =
C
30.16 mm
Latitudinal moment ML 29967.5 kgf-mm
Meridional moment Mc 29967.5 kgf-mm
Total eff. moment, [ ML 2
+ Mc 2
] 0.5 M 42380.5 kgf-mm
Shear load Q 106 kgf
M.O.C SA-516 GR. 70 Plt. [UNS:K02700]
Inside radius R 1130.4 mm
Thickness ( corroded ) t 7 mm
= R + 0.5 x t
= 1130.4 + 0.5 x 7
= 1133.9 mm
Calculate factor , [ U ]
= 1.82 x 30.16 / SQRT [ 1133.9 x 7 ]]
= 0.616
Calculate factor , [ S ]
= 1.82 x 0.5 x Dp / SQRT [ Rm x t ]
= 1.82 x 0.5 x / SQRT [ 1133.9 x 7 ]
= 0.616
]
= Q / ( p x Ro x t )
= 106 / ( p x 30.16 x 7 )
= 0.16 kgf/mm²
]
= Mt / ( 2 x p x Ro 2
x t )
= 29967.5 / ( 2 x p x 30.16 2 x 7 )
= 0.749 kgf/mm²
= t1
+ t2
= 0.16 + 0.749
= 0.909 kgf/mm²
STRESS FIGURE VALUE FROM FIGURE STRESS ( kgf/mm² )
Radial
load
Membrane
5-25A
Nx x t
Fr
-
0.06044
Kn x Fr
t 2 σx
-
0.09241
5-25B
Nf x t
Fr
-0.179
Kn x Fr
t 2 σf -0.274
Bending 5-26A
Mx
Fr
0.0621
6 x Kb x Fr
t 2 σx 0.57

5-26B
Mf
Fr
0.131
6 x Kb x Fr
t 2 σf 1.203
Moment ,
M
Membrane
5-27A
Nx x t x SQRT [ Rm x t ]
M
-
0.05621
Kn x M
t 2
x SQRT [ Rm x t ]
σx -0.546
5-27B
Nf x t x SQRT [ Rm x t ]
M
-0.159
Kn x M
t 2
x SQRT [ Rm x t ]
σf -1.541
Bending
5-28A
Mx x SQRT [ Rm x t ]
M
0.117
6 x Kb x M
t 2
x SQRT [ Rm x t ]
σx 6.794
5-28B
Mf x SQRT [ Rm x t ]
M
0.43
6 x Kb x M
t 2
x SQRT [ Rm x t ]
σf 25.07
Stress due to
σx σf
0° 90° 180° 270° 0° 90° 180° 270°
Radial
load,
Fr.(1)
Memberane
Nx
+( -
0.274 )
+( -
0.274 )
+( -
0.274 )
+( -
0.274 )
Nf
+( -
0.09241 )
+( -
0.09241 )
+( -
0.09241 )
+( -
0.09241 )
Bending
Mx
+
( 1.203 )
+
( 1.203 )
+
( 1.203 )
+
( 1.203 )
Mf +( 0.57 ) +( 0.57 ) +( 0.57 ) +( 0.57 )
Moment,
M.
Memberane
Nx
+( -
1.541 )
-( -
1.541 )
Nf
+( -
0.546 )
-( -
0.546 )
Bending
Mx
+
( 25.07 )
-
( 25.07 )
Mf
+
( 6.794 )
-( 6.794 )
Int.
pr., P.
Pi x
Rm
t
σf
+
( 9.719 )
+
( 9.719)
+
( 9.719 )
+
( 9.719 )
+
( 9.719 )
+( 9.719)
+
( 9.719 )
+
( 9.719 )
Total,
∑
Membrane 1.815 0.274 -1.267 0.274 0.82 0.274 -0.272 0.274
Mem+Bend 28.09 1.477 -25.14 1.477 8.002 0.662 -6.678 0.662

1. LIFTING LUG DATA :
2. DESIGN LOADS :
3. CALCULATION OF REFERENCE DIMENSIONS :
4. DESIGN OF LUG PLATE :
5. CALCULATION OF STRESSES IN LUG PLATE WELDS :
Licensee :
Pune, India
DESIGN OF LIFTING LUG Lifting Lugs
Design Mode 1 , Uncorroded
Condition
Material IS-2062 GR. A Plt.
Length of lug LL 70 mm
Width of lug A 120 mm
Thickness of lug plate TL 12 mm
Straight length B1 10 mm
Radius at tip R3 35 mm
Pin Hole diameter D1 40 mm
Lug to vessel weld size W1 8 mm
Min yield stress Sy 24.61 kgf/mm²
Allowable tensile stress ( 2 / 3 x Sy ) St 16.4 kgf/mm²
Allowable bending stress ( 1.5 x St ) Sb 22.15 kgf/mm²
Allowable shear stress (0.6 x St ) Ss 9.843 kgf/mm²
Empty weight of equipment Wt 2149.7 kgf
Number of lifting lugs N 2
Jirk load factor j 1.5
Dimension [ L1 ]
= LL - B1 - R3
= 70 - 10 - 35
= 25 mm
Dimension [ L2 ]
= L1 / SIN ( q1 )
= 25 / SIN ( 0.395 )
= 65 mm
Dimension [ LT ]
= LL - R3
= 70 - 35
= 35 mm
Angle [ q2 ]
= ASIN ( R3 / L2 )
= ASIN ( 35 / 65 )
= 0.569 radians
Angle [ q1 ]
= ATAN ( 2 x L1 / A )
= ATAN ( 2 x 25 / 120 )
= 0.395 radians
Angle [ q3 ]
= q1 + q2
= 0.395 + 0.569
= 0.963 radians
Dimension [ L3 ]
= R3 / SIN ( q3 )
= 35 / SIN ( 0.963 )
= 42.62 mm
Effective design load on each lug [ P ]
= j x Wt / N
= 1.5 x 2149.7 / 2
= 1633 kgf
Required min. thickness of lug plate for shear [ t2 ]
= P / [ ( R3 - 0.5 x D1) x ss ]
= 1633 / [ ( 35 - 0.5 x 40 ) x 9.843 ]
= 11.06 mm
Required min. thickness of lug plate for bending [ t1 ]
= 6 x P x LT / ( A 2
x Sb )
= 6 x 1633 x 35 / ( 120 2 x 22.15 )
= 1.075 mm
Required min. thickness of lug plate for shear [ t3 ]
= P / [ ( 2 x L3 - D1 ) x ss ]
= 1633 / [ ( 2 x 42.62 - 40 ) x 9.843 ]
= 2.2 mm
Bending stress in weld [ f1 ]
= 6 x P x LT / [ 2 x LL2
]
= 6 x 1633 x 35 / ( 2 x 70 2 )
= 34.99 kgf/mm
Max. shear stress in weld [ f2 ]
= P / [ 2 x A ]
= 1633 / ( 2 x 120 )
= 6.804 kgf/mm
Min. Size of lug plate weld [ w1 ]
= MAX ( f1 , 2 x f2 ) / ( 0.707 x Ss )
= MAX ( 34.99 , 2 x 6.804 ) / ( 0.707 x 9.843 )

FOUNDATION LOAD DATA
Licensee :
Pune, India
Sr.
No.
Mode Condition
Weight ( kgf ) Wind Seismic
Empty Filled
Shear ( kgf ) Moment ( kgf-m ) Shear Moment
Tran. Long. Tran. Long. ( kgf )
( kgf-
m )
1 Operating Corroded 1898.3 1922.1 649.9 649.9 940.9 940.9 198.8 285.7
2 Design1 Corroded 1898.3 1926.8 649.9 649.9 940.9 940.9 199.3 286
3 Hydro Corroded 1841.1 4212.7 649.9 649.9 940.9 940.9 435.8 436.7
4 Pneumatic Corroded 1841.1 1843.9 649.9 649.9 940.9 940.9 190.8 275.9
5 Operating Uncorroded 2149.7 2173.2 649.9 649.9 882.1 882.1 224.8 303.3
6 Design1 Uncorroded 2149.7 2177.9 649.9 649.9 882.1 882.1 225.3 303.6
7 Hydro Uncorroded 2092.5 4439.8 649.9 649.9 882.1 882.1 459.3 454.2
8 Pneumatic Uncorroded 2092.5 2095.3 649.9 649.9 882.1 882.1 216.8 294

CENTER OF GRAVITY DATA
Licensee :
Pune, India
Sr.
No.
Mode Condition
Empty Operating / Filled
Wt ( kgf ) C.G. ( mm ) Wt ( kgf ) C.G. ( mm )
1 Operating Corroded 1898.3 1820.2 1922.1 1809.6
2 Design1 Corroded 1898.3 1820.2 1926.8 1807.5
3 Hydro Corroded 1841.1 1820.2 4212.7 1374.5
4 Pneumatic Corroded 1841.1 1820.2 1843.9 1818.9
5 Operating Uncorroded 2149.7 1729.8 2173.2 1721.7
6 Design1 Uncorroded 2149.7 1729.8 2177.9 1720.1
7 Hydro Uncorroded 2092.5 1729.8 4439.8 1361.3
8 Pneumatic Uncorroded 2092.5 1729.8 2095.3 1728.8

Index
Licensee :
Pune, India
Sr. No. Description Page No
1 Title page & equipment info
2 Design data
3 Material of constructions
4 Effective Pressures
5 Weight summary report
6 Test pressure calculations (shell side)
7 Wind load calculations
8 Seismic load calculations
11 Design of Main Shell
12 Design of Dished End (Rear)
15 Design of N 01
16 Design of N 01
17 Design of N 01
18 Design of N 02
19 Design of N 02
20 Design of N 02
21 Design of N 03
22 Design of N 03
23 Design of Lifting Lugs
24 Foundation load data
25 C.G. Data

EQUIPMENT INFORMATION :
DESIGN & REVIEWAL :
INSPECTION & APPROVAL :
EQUIPMENT DATA :
OTHER DATA :
Project Soap Plant
Location Vapi Site
Plant Refrigeration Plant
Design Code ASME VIII Div.1, 10 A11
Equipment Name Gas Filter
Equipment Type Pressure Vessel
Equipment Class N.A.
Equipment Category N.A.
Reference Drawing No ---
Service Compressed Gas Services
Support Type Lug Supports
Designed By
Design Date 31-03-2015 00:25:14
Checked By
Approved By
Revision R00
Inspection Agency ---
Reviewed By ---
Front end Flat End
Front end flanged True
Rear end Dished End
Rear end flanged False
Shell ID 1250 mm
Shell OD 1270 mm
Length, Shell (W.L. to W.L) / Overall 1650 / 2254.6 mm
Fabricated weight 1841.1 kgf
Empty weight + external weights 1841.1 kgf
Estimated operating weight 4212.7 kgf
Estimated hydrotest weight 4439.8 kgf

SUMMARY OF EFFECTIVE DESIGN PRESSURES IN kgf/mm² g VS TEMPERATURE IN °C
Licensee :
Pune, India
Sr. Item name Temp. Inside pr. Liquid pr. Effective pr.
No. +ve -ve +ve -ve
1 Cover (Front) 50 0.12 0 0.00007 0.12 0
2 Shell Flng (Front) 50 0.12 0 0.00023 0.12 0
3 Main Shell 50 0.12 0 0.00188 0.122 0
4 Dished End (Rear) 50 0.12 0 0.00225 0.122 0
5

ITEM WISE WEIGHT SUMMARY
Licensee :
Pune, India
Sr.No. Item name Item size
Empty
wt
Volume Filled wt
kgf m³ kgf
1 Cover (Front)
Blind Flange - 1420 OD x
73.411 Thk, RF, 1363 PCD,
Tgrv = 1.588
900.5 0 900.5
2 Shell Flng (Front)
Fabricated WN - 1420 OD x
1250 ID x 1363 PCD, RF,
128.692 Thk, Trgv = 1.588,
G1 = 20, G0 = 10, hf = 30
312.3 0 312.3
3 Gasket Flng (Front)
1313.5 OD x 1250 ID, 4.763
Thk
0.1 0 0.1
4 Bolt Flng (Front)
Lg, 56 Nos.
48.76 0 48.76
5 Main Shell 1270 OD x 10 Thk, 1650 Lg 517.1 2.025 2541.9
6 Dished End (Rear)
Elliptical D/2H = 2.0, 1270 OD
x 10 Nom / 9 Min Thk, SF =
50
181.7 0.317 498.7
7 Gusset Plate
Thk, 8 Nos.
38.51 0 38.51
8 Anchor Bolt Anchor M20 x 200 Lg, 4 Nos. 1.99 0 1.99
9 Support Pad
Thk, 4 Nos.
24.97 0 24.97
10 N 01
156 Lg
6.697 0.00262 9.32
11 Flange [N 01]
8.08 0 8.08
12 Gasket [N 01]
166.329 OD x 146.329 ID,
4.763 Thk
0.1 0 0.1
13 Bolt [N 01]
Lg, 8 Nos.
1.714 0 1.714
8.08 0 8.08
15 Reinf [N 01]
292.659 OD x 171.275 ID x 10
Thk
3.501 0 3.501
16 N 02
156 Lg
6.697 0.00262 9.32
17 Flange [N 02]
8.08 0 8.08
18 Gasket [N 02]
166.329 OD x 146.329 ID,
4.763 Thk
0.1 0 0.1
19 Bolt [N 02]
Lg, 8 Nos.
1.714 0 1.714
8.08 0 8.08
21 Reinf [N 02]
292.659 OD x 171.275 ID x 10
Thk
3.501 0 3.501
22 N 03
150 Lg
1.682 0.00022 1.898
23 Flange [N 03]
2.428 0 2.428
24 Gasket [N 03]
62.85 OD x 42.85 ID, 4.763
Thk
0.1 0 0.1
25 Bolt [N 03]
Lg, 4 Nos.
0.431 0 0.431
26 Bolted Cover [N 03]
150# for 50 160 NPS Pipe
2.522 0 2.522
120 Long x 70 Wide x 12 Thk,

27 Lifting Lugs 2 Nos. 1.596 0 1.596
28 Pad (Lifting Lugs)
70 Long x 170 Wide x 8 Thk, 2
Nos.
1.507 0 1.507
29
30
31
32
33
34
35
∑ 2092.5 ∑ 4439.8

TEST PRESSURES CALCULATION AS PER UG-99 / UG-100 : Vessel Inside
Legend :
Test Pressure Calculations
Pressure due to hydro liquid column, [ Plh ]
= Lh x h x 1E-09
= 0.00225 kgf/mm² g
Hydrotest pressure, [ Ph ]
= 1.3 x Pt - Plh
= 1.3 x 0.122 - 0.00225
= 0.157 kgf/mm² g
Pneumatic test pressure, [ Pn ]
= 1.1 x Pt
= 1.1 x 0.122
= 0.134 kgf/mm² g
Licensee :
Pune, India
Operating Liquid Density  1000 kg/m³
Hydrotest Liquid Density h 1000 kg/m³
Hydrotest Liquid Column Lh 2254.6 mm
Sr.
No.
Item Name
Pressure ( kgf/mm² g ) Stress Correction ( kgf/mm² )
Pt
Pi Pl Pc Pe Peff Sfo Sfa
Sfa
Sfo
1 Cover (Front) 0.12 0.00007 0 0 0.12 14.06 14.06 1 0.12
2 Shell Flng (Front) 0.12 0.00023 0 0 0.12 14.06 14.06 1 0.12
3 Main Shell 0.12 0.00188 0 0 0.122 14.06 14.06 1 0.122
4 Dished End (Rear) 0.12 0.00225 0 0 0.122 14.06 14.06 1 0.122
5
Min. Pr., Pt 0.122
Pi = Internal positive pressure
Pl = Pressure due to design liquid column
Pe = Internal vacuum pressure
Pc = External negative pressure
Peff = Pi + Pl + Pc
Sfo = Allowabe stress at design temperature
Sfa = Allowable stress at ambient temperature
Pt = MAX [ Peff + Pc, Pe ] x ( Sfa / Sfo )

Vessel Inside
Legend :
Licensee :
Pune, India
CALC. OF MIN. DESIGN METAL TEMPERATURE
Hydrotest Mode , Corroded
Condition
Design Pressure Pi 0.12 kgf/mm² g
Sr.
No.
Item Name / Material /
Group
Stress (kgf/mm²) Thickness (mm) MDMT (°C)
Smt Sdt tn tg tr Tm Tc MDMT
1
Cover (Front)
SA-516 GR. 70 Plt.
[UNS:K02700]
Curve : B
14.06 14.06 70.41 17.6 17.6 -11.98 40.56 -52.53
2
Shell Flng (Front)
SA-105 Frg. [UNS:K03504]
Curve : B
14.06 14.06 125.7 7 6.443 -28.89 -17.32 -11.57
3
Main Shell
SA-516 GR. 70 Plt.
[UNS:K02700]
Curve : B
14.06 14.06 7 7 6.443 -28.89 -15.08 -13.81
4
Dished End (Rear)
SA-516 GR. 70 Plt.
[UNS:K02700]
Curve : B
14.06 14.06 7 7 5.465 -28.89 -15.04 -13.85
5
Max, MDMT -11.57
Smt = Stress at minimum design metal temperature.
Sdt = Pressure due to design liquid column
tn = Stress at design metal temperature.
tg = Nominal item thickness excluding corrosion and thinning.
tr = Governing metal thickness for the item.
Tg = Required minimum thickness of the item.
Tm = Minimum metal temperature for the the item.
Tc = MDMT Correction
MDMT = Final MDMT for the item = Tm - Tc.

1. DESIGN CONDITIONS ( Hydrotest Mode , Corroded Condition ) :
Licensee :
Pune, India
WIND LOAD CALCULATION
CODE Wind [IS:875, 87]
Basic wind speed ( Section 5.2 ) Vb 50 m/s
Expected life of equipment ( Section 5.3.1 ) 25 Years
Probability factor (Risk coeff) ( Section 5.3.1 ) K1 0.902
Terrain category ( Section 5.3.2 ) Category 2
Structure class ( Section 5.3.2.2 ) Class B
Topography factor ( Section 5.3.3 ) K3 1.3
Force coefficient (Shape factor) Cf 0.8
Equivalent diameter De 1820 mm
Overall length of equipment L 2254.6 mm
Size and height factor ( Section 5.3.2 ) K2 0.98
Effective transverse cross sectional area
= De x L A 4103343.3 mm²
Effective wind speed
= K1 x K2 x K3 x Vb Vz 57.44 m/s
Wind pressure
= 6E-08 x Vz 2 Pz 0.0002 kgf/mm²
Longitudinal force
= Cf x A x Pz F 649.9 kgf
Support elevation H 372.5 mm
Turning moment
= F x ( Hcg - H ) M 651245.2 kgf-mm

Licensee :
Pune, India
SEISMIC LOAD CALCULATION
CODE Seismic [IS:1893, 02]
Weight of equipment Wo 4212.7 kgf
Importance factor ( Table-6 , 2002 ) I 1.5
Soil profile type Stiff Soil Profile (SD)
Foundation type RCC footings + Tie Beams
Damping factor 5
Seismic zone Zone III
Seismic zone factor ( Table-2 , 2002 ) Z 0.16
Response reduction factor ( Table-7 , 2002 ) R 2.9
Spectral accelerations coeff. ( Fig. 2 , 2002 ) Sa / g 2.5, Use max value
Damping correction factor ( Table-3 , 2002 ) Cf 1
Seismic coefficient ( Clause-6.4.2 , 2002 )
= 0.5 x Z x I x Cf x ( Sa / g ) x ( 1 / R )
= 0.5 x 0.16 x 1.5 x 1 x
2.5 x ( 1 / 2.9 ) Ah 0.103
Elevation of support H 372.5 mm
Seismic base shear force
= Ah x Wo
= 0.103 x 4212.7 Vb 435.8 kgf
Seismic moment of support
= Vb x ( Hcg - H )
= 435.8 x ( 1374.5 - 372.5 ) M 436679.3 kgf-mm

2. COVER DATA :
3. BOLTING DATA :
4. LINER DATA :
5. GASKET DATA :
= 2 x (  x b x G + b' x Lp ) x m x P
= 2 x (  x 9.554 x 1294.4 + 0 x 0 ) x 3 x 0.12
= 28027.1 kgf
= 0.25 x  x G 2
x P
= 0.25 x  x 1294.4 2
x 0.12
= 158212.8 kgf
= Hp + H
Licensee :
Pune, India
DESIGN OF FLAT BOLTED HEAD ( INTERNAL ) Cover (Front)
Allowance CA 3 mm
M.O.C. SA-516 GR. 70 Plt. [UNS:K02700]
Flange OD A 1420 mm
Bolt dia. db 24 mm
No. of bolts nb 56
M.O.C.
Liner ID mm
Liner OD mm
Liner thk. mm
Gasket factor m 3

= 28027.1 + 158212.8
= 186239.9 kgf
= (  x b x G + b' x Lp ) x y
= (  x 9.554 x 1294.4 + 0 x 0 ) x 7.031
= 273152.4 kgf
= 10360.4 mm²
= 17513.9 mm²
= Ab x Sb / ( 2 x  x y x G )
= 17513.9 x 26.37 / ( 2 x  x 7.031 x 1294.4 )
= 8.075 mm
= 1294.4 x SQRT [ 1.9 x 461755.8 x 0.5 x ( 1363 - 1294.4 ) / ( 14.06 x 1 x 1294.4 3
) ]
= 40.66 mm
) }
= 1294.4 x SQRT { [ 0.3 x 0.12 / ( 14.06 x 1 ) ] + 1.9 x 186239.9 x 0.5 x ( 1363 - 1294.4 ) /
( 14.06 x 1 x 1294.4 3 ) }
= 70.67 mm

2. FLANGE DATA :
3. BOLTING DATA :
4. LINER DATA :
5. GASKET DATA :
Licensee :
Pune, India
FLANGE DESIGN ( INTERNAL ) Shell Flng (Front)
Allowance CA 3 mm
M.O.C. SA-105 Frg. [UNS:K03504]
Hub length h 30 mm
Bolt PCD C 1363 mm
Bolt dia. db 24 mm
No. of bolts nb 56
M.O.C.
Liner ID mm
Liner OD mm
Liner thk. mm
M.O.C. --

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