KNM PROCESS SYSTEMS SDN. BHD.

(200140-X) page 1
(Formerly known as KNM steel Sdn. Bhd.)

UIL PROJECT NO.: 66 - 6259 - 700

KNM DOC. NO.: K02309-E-DC-007 TOTAL PAGE :

PROJECT NAME : AMMONIA & UREA PLANT

REVAMP PROJECT

DESIGN CALCULATION FOR

SKIMMING DRUM (ITEM NO:13-D005)

DESIGN APPROVED BY : ABS

CONFIDENTIAL INFORMATION
THIS INFORMATION IS THE PROPERTY OF THE KNM GROUP AND ITS ASSOCIATED COMPANIES.
REPRODUCTION, DISCLOSURE AND/OR USE, IN WHOLE OR
PART WITHOUT THE WRITTEN PERMISSION OF KNM IS FORBIDDEN.

2 Issued for FINAL ESWARAN YFCHUA KWA

1 Issued for Approval ESWARAN / 29-01-03 YFCHUA / 29-01-03 KWA / 29-01-03
0 Issued for Approval ESWARAN - 22-11-02 YFCHUA - 22-11-02 KWA 23-11-02
REV. DESCRIPTION PREPARED BY / DATE CHECKED BY / DATE APPROVED BY / DATE

KNM Project No . K02309

CLIENT: ASEAN BINTULU FERTILIZER, MALAYSIA

 Page no.: 2

TABLE OF CONTENTS
Page
1.0 Design Condition

2.0 Shell Thickness Calculation

3.0 Head Thickness Calculation

4.0 Nozzle thk & Compensation Calculation

5.0 MDMT summary (Pressure summary)

6.0 Hydrotest

7.0 Weight Summary

8.0 Leg support & Base plate design

9.0 Lifting Lug Calculation

 Page no.: 3

1.0 DESIGN CONDITION :

Item SKIMMING DRUM

Quantity required 1
Design Code ASME SECT. VIII DIV 1, EDITION 2001
Medium SOLUTION
Design Pressure 9 bar g
Design Temperature 100 °C
Max. Allow. Working Pressure (MAWP) 9 bar g
MDMT (CET) -29 °C
Operating Pressure 3.79 bar a
Operating Temperature 66.09 °C
Hydrostatic Test Pressure (Horizontal) 12.01 bar g
Corrosion Allowance 0.0 mm
Radiography (Shell & Head) SPOT
Joint Efficiency (Shell & Head) 0.85
Postweld Heat Treatment No
Insulation Yes
Impact Testing No

Capacity 2.30 M³
Surface Area ( Vessel only) 10.54 M²

Weight, Fabricated (Shipping) 1,500 Kg

Empty (Field) 1,540 Kg
Operating (Field) 3,880 Kg
Full of Water (Field) 3,840 Kg

Material Specification
Shell : A 240 316L
Head : A 240 316L
Reinforcement pad : A 240 316L
Nozzle neck Plate : A 240 316L - 100% RT ON NECK LS SEAM
Pipe : A 312 TP 316L -SEAMLESS
Fittings : A 403 WP 316L - SEAMLESS
Flange/Forging : A 182 F316L

Stud bolting & Nut (Ext.) : A 193 B7 & A 194 2H

Stud bolting & Nut (Int.) :-

Pad / Leg sup & Base plate : A 240 316L / A36 OR EQ

Name Plate and Bracket : SS 304L / A 240 316L
Lifting Lug / Pad : A 516 GR 70 / A 240 316 L
Gasket : SS 316L spiral wound Graphite filled with SS316L inner
: ring and CS outer ring.

Internal (Welded) : A 240 316L

Internal (Removable) :-
 Page no.: 4

2.0 THICKNESS CALCULATION FOR SHELL UNDER INTERNAL PRESSURE

[UG-27(c), FOR VERTICAL VESSEL]

2.1 CIRCUMFERENTIAL TENSILE STRESS [PER UG-27(c), (1)]

[ P = 9 kPa < 0.385× SE = 48766.795 kPa ]

tc = P × R / (SE - 0.6P) + CA

= 9 × 500 / (149020 × 0.85 - 0.6 ×9) + 0

Required shell thickness, tc = 0.03553 mm

2.2 LONGITUDINAL TENSILE STRESS AS PER UG - 27 (c), (2)

[ P = 9 kPa < 1.25*SE = 158333.75 kPa]

tL = P×R / 2SE + 0.4P + CA

= 9 × 500 / ( 2 × 149020 × 0.85 + 0.4 × 9 ) + 0

Required shell thickness, tL = 0.01776 mm

2.3 COMPARE THICKNESS TO THE REQUIREMENTS OF UG 16 (b)(4)

tmin = 1.6 + Corrosion Allow.

= 1.6 + 0

= 1.6 mm

Required thickness = Max. of tc, tL or tmin = 1.6 mm

Provided Thickness, t = 8 mm OK

2.4 SHELL THICKNESS UNDER HYDROTEST CONDITION

tht = Pht × R / (Sht E - 0.6Pht) + CA

= 40.95 × 500 / (198576 × 0.85 - 0.6 ×40.95) + 0

Required shell thickness, tht = 0.12 mm

Since, provided shell thickness, t > tht, Shell thickness is sufficient

Where,
Pht = Hydrotest Pressure including Static Head, kPa = 12.01 + (2950 × 0.036093)
= 40.95 kPa
 Page no.: 5

Sht = Allowable Stress, kPa, = 0.9 × s = 0.9 × 220640

= 198,576 kPa
tc = Minimum required thickness of shell , mm., (Circumferential tensile stress)
tL = Minimum required thickness of shell , mm., (Longitudmmal tensile stress)
tht = Minimum required thickness of shell during Hydrotest Condition, mm.
P= Design pressure (UG - 12) = 9 kPa
R= Inside radius of shell (Corroded cond.), in., (UG-16(e)) = 500 mm
E= Joint efficiency (UW - 12), FULL RT = 0.9
CA = Corrosion allowance (UG - 25) = 0.0 mm
S= Max. allowable stress : A 240 316L = 149,020 kPa
s= Min. Yield stress : A 240 316L = 220,640 kPa

2.5 THICKNESS CALCULATION OF 2:1 ELLIPSOIDAL HEAD

UNDER PRESSURE ON THE CONCAVE SIDE (APPENDIX 1-4 (C))

th = (PDK / 2SE - 0.2P) +CA

= ( 9 × 1000 × 1 ) / ( 2 × 137900 × 0.85 - 0.2 × 9 ) + 0

Required Head thickness, th = 0.04 mm

Provided head nom. Thickness, tH = 8 mm

2.6 THICKNESS CALCULATION OF 2:1 ELLIPSOIDAL HEAD UNDER

HYDROTEST CONDITION

thht = (PhtDK / 2ShtE - 0.2Pht) +CA

= ( 40.95 × 1000 × 1 ) / ( 2 × 198576 × 0.85 - 0.2 × 40.95 ) + 0

= 0.12 mm

Since, provided head thickness, tH > thht, head thickness is sufficient

Where,
Pht = Hydrotest Pressure including Static Head, kPa = 12.01 + (2950 × 0.036093)
= 40.95 kPa
Sht = Allowable Stress, kPa, = 0.9 × s = 0.9 × 220640
= 198,576 kPa
th = Min. thickness of formed head, in
thht = Minimum required thickness of head during Hydrotest Condition, in.
P = Design pressure (UG - 12) = 9 kPa
D = Inside length of major axis of ellipsoidal head (corroded cond.)
1000 mm
S = Max. allowable stress : A 240 316L = 137,900 kPa
K = Factor in formula for ellipsoidal heads depending on the head
proportion D/2h, See Table 1-4.1 = 1.0
E = Joint efficiency (UW - 12), () = 0.9
CA = Corrosion allowance (UG - 25) = 0.0 mm
 Page no.: 124

6.0 DESIGN OF LIFTING LUG

R38

88.0 Dia. 25
50.0

16 thk 90.0

Weight of empty vessel (Wt) = 689 kg = 6,759 N

Lug dimension :
thickness (t) = 16.0 mm
width at base (w) = 90.0 mm
height (h) = 88.0 mm
Radius (R) = 38 mm
hole diameter (f) = 25.0 mm
hole CL to base (k) = 50.0 mm
Impact factor (IF) = 1.5
Lifting angle (a) = 60 o
Lug Quantity (QTY) = 4
Load per lug = (Wt × IF) / QTY = 2,534 N

Lifting Lug Loading :

Vertical load (VL) = 2,534 N
Horizontal load (HL) = 15,083 N
Resultant /load (RL) = 5,069 N
Moment (M) = HL × k = 754,144 Nmm

Lifting Lug material = SA 516 Gr. 70

Material yield strength (sy) = 262.10 N/mm² = 38,000 psi

Lug allowable stress (AISC) :

FB1 (Bearing) = 0.66 × sy = 172.99 N/mm²
FT1 (Tensile) = 0.6 × sy = 157.26 N/mm²
FS1 (Shear) = 0.4 × sy = 104.84 N/mm²

Stress of lifting lug :

FB = RL / (f × t) = 12.67 N/mm²
FT = RL / [ (R×2 - f) × t ] = 6.21 N/mm²
FS = RL / [ R - f/2 ] × t] = 12.42 N/mm²

Allowable safety factor = 2.00

Safety factor for :
Bearing = FB1 / FB = 13.65 > 2.00
Tensile = FT1 / FT = 25.32 > 2.00
Shear = FS1 / FS = 8.44 > 2.00
Conclusion : Lifting lug size is adequate for the required loading.
 Page no.: 125

Check Weld Size For Lug to Attachment (Pad) :

Weld size = 6 mm
Weld throat thickness (tr) = 4.2 mm b =24.4
Welded witdh (b) = 24.4 mm
Welded length (d) = 98.4 mm
Welded area (A) = 960.96 mm² d =98.4
Lug area
Linear section modulus of attachment (Z) = [(b×d³)-(t×w³)] /6d
= 19619.65 mm³ Welded area

Allowable weld stress (sw) = 0.49 × Sa = 57.79 N/mm² lug t = 16.0 mm

lug w = 90.0 mm
Stress of vertical load (sv) = VL / A = 2.64 N/mm² Sa = 117.9455 N/mm²
Stress of horizontal load (s h) = HL / A = 15.70 N/mm²
Bending stress (sM) = M / Z = 38.44 N/mm²

Maximum Combined Stress = [(sv + sM)2 + sh2]0.5

= 43.97 N/mm² < 57.79 N/mm²

Conclusion : Weld size is adequate.

Check Weld Size For Attachment (Pad) to Shell :

Pad material = SA 516 Gr. 60N

Min. yield strength (sy) = 262.10 N/mm² = 32000 psi
b=98.4
Weld size = 6 mm
Weld throat thickness (tr) = 4.2 mm
Welded witdh (b) = 98.4 mm d=148.4
Welded length (d) = 148.4 mm Pad area
Welded area (A) = 2002.56 mm²
Welded area
Linear section modulus of attachment (Z) = [(b×d3)-(t×w3)] /6d
= 83,811 mm³ Pad width = 90 mm
Pad length = 140 mm
Allowable weld stress (sw) = 0.49 × Sa = 57.79 N/mm²

Stress of vertical load (sv) = VL / A = 1.27 N/mm²

Stress of horizontal load (sh) = HL / A = 7.53 N/mm²
Bending stress (sM) = M / Z = 9.00 N/mm²

Maximum Combined Stress = [(sv + sM)2 + sh2]0.5

= 12.73 N/mm² < 57.79 N/mm²

Conclusion : Weld size is adequate.

 LAMPIRAN UPV
MAKLUMAT- MAKLUMAT YANG DIPERLUKAN
1. Nama dan Alamat Pemohon Kwa Teck Chuan
(Sila sertakan nama pegawai teknical KNM Steel Sdn. Bhd.
yang patut dihubungi) 15, Jalan Dagang SB 4/1, Taman Sungai Besi Indah,
Name & Address of Applicant 43300 Seri Kembangan, Selangor D.E.
2. Nama dan Alamat Pemilik Sarawak Shell Berhad
(Kedudukan) Locked Bag No.1,
Name & Address of Owner 98009 Miri, Sarawak, Malaysia.
3. Nama dan Alamat Pembuat EPMI
Name & Address of Manufacturer Bintang A & B Topsides

4. No. Rujukan Surat/Tarikh memohon KNM/K01372/E/DOSH/L-001 dated

Letter ref. No. / Date

5. Nama Pengandung Tekanan (Item) SKIMMING DRUM

Item Name & No.
6. Model ( jika ada) -
Model ( if applicable)
7. No. Siri Later
Serial No.
8. No. Pelan (lukisan) K01372-E-D-001,002,003
Drawing No.
9. Ukuran [Outside Dia x Shell 1240 mm OD × 4400 mm T/T
Length / Overall Length (mm)]
10. Kod Rekabentuk dan Kelas ASME SECT. VIII DIV 1, EDITION 2001
Design Code
Shell/Head Jacket/Lain-lain
Tube/Lain Tube/Lain-lain
( ) ( )
11. Tekanan Kerja Selamat (kPa) 9 kPa - - -
Design Pressure
12. Tekanan Ujian (kPa) 12.01 kPa - - -
H.T. Pressure
13. Suhu Rekabentuk (Celsius) 100 °C - - -
Design Temperature
14. Media Kerja SOLUTION - - -
Working Medium
15. Bahan-bahan Binaan Utama A516 Gr. 70 - - -
Material
16. Allowable Stress (kPa) 137895 kPa - - -
- -
17. Ketebalan (mm) 10 mm - - -
Thickness
18. Ujian Tanpa Musnah (NDT) RT - - -
RT / MPI / UT / PT / NIL
19. Joint Efficiency (%) 100% - - -

20. Corrosion Allowance (mm) 0 mm - - -

21. Isipadu (m³) 5.62 m³ - - -

Volume
UNTUK KEGUNAAN PEJABAT
Initial JKKP/KSM-UD Tempat
Ujian
Tarikh Lulus Tarikh Luput Tempat
Dipasang
Impot/ JKKP/KSM-BT Tarikh
Tempatan Terima
2 LIFTING LUG DESIGN CALCULATION
2.1 GEOMETRIC DATA

d rL

tL

hL
wL

Weight of Component, We = 689 kg

= 6,756 N
Number of lifting lug, N = 4
Lifting angle, ß° = 60.00 °

Lug radius, rL = 38 mm
Lug base width, wL = 90 mm
Lug thickness, tL = 16 mm
Distance between lug base to hole centre, hL = 50 mm
Diameter of hole, d = 25 mm
Pin size, Dp = 35 mm

2.2 MATERIAL & MECHANICAL PROPERTIES

Material used = A 516 GR 70
Specified yield stress, Sy = 262.01 N/mm²
Specified tensile stress, Sm = 482.64 N/mm²
Impact load factor, p = 1.2

2.3 ALLOWABLE STRESSES

Allowable tensile stress, St.all ( = 0.42 Sy ) = 110.04 N/mm²
Allowable bearing stress, Sbr.all ( = 0.9 Sy ) = 235.81 N/mm²
Allowable bending stress, Sbn.all ( = 0.66 Sy ) = 172.92 N/mm²
Allowable shear stress, Ss.all ( = 0.4 Sy ) = 104.80 N/mm²

2.4 LIFTING LUG DESIGN

2.4.1 FORCE DIAGRAM
Design load , Wt ( = p.We ) = 8108 N
Design load per lug, W ( = Wt / N ) = 2027 N

Horizontal component force, Fy = 1170 N

Component force, Fx ( = Fc ) = 2340 N

Maximum component force, Fz = 0 N
2.4.2 STRESS CHECK AT PIN HOLE
(a) Tensile Stress
Fc Fc
Fc

Resultant force, Fc = 2340 N

Cross sectional area of lug eye, Ae ( = 2 * [ rL - d/2 ] x tL ) = 816 mm²
Tensile stress, St ( = Fc.max / Ae ) = 2.87 N/mm²
Since St < St.all, therefore the lifting lug size is satisfactory.

(b) Bearing Stress

Resultant force, Fc = 2340 N
Cross sectional area of lug eye, Ae ( = Dp x tL ) = 560 mm²
Bearing stress, Sbr ( = Fc / Ae ) = 4.18 N/mm²
Since Sbr < Sbr.all,therefore the lifting lug size is satisfactory.

(c) Shear Stress

Resultant force, Fc = 2340 N
Cross sectional area of lug eye, Ae ( = 2.(rL-d/2).tL ) = 816 mm²
Bearing stress, Sbr ( = Fc / Ae ) = 2.87 N/mm²
Since Sbr < Sbr.all,therefore the lifting lug size is satisfactory.

2.4.3 STRESS CHECK AT LUG BASE

(a) Tensile Stress In X - Direction
Fx

tL
Fy.max Fz.max

hL

wL

Bending in Y - direction Bending in Z - direction

Vertical force, Fx = 2340 N

Cross sectional area of lug, At ( = 2.rL.t ) = 1216 mm²
Tensile stress, ft ( = Fx / At ) = 1.92 N/mm²

(b) Bending Stress In Y - Direction

Component force, Fy = 1170 N
Bending moment at Z-axis, Mx ( = Fy .hL ) = 58511 Nmm
Section modulus, Zz-z ( = tL.wL²/6) = 21600 mm³
Bending Stress, fy ( = My / Zz-z ) = 2.71 N/mm²
 (c) Bending Stress In Z - Direction
Component force, Fz.max = 0 N
Bending moment at X-axis, Mz ( = Fz.max . hL ) = 0 Nmm
Section modulus, Zx-x ( = ( wL.tL² )/6 ) = 3840 mm³
Bending Stress, fz ( = Mz / Zx-x ) = 0.00 N/mm²

Combined stress,
ft fx fz
+ + = 0.033
St.all Sbn.all Sbn.all < 1.00

Therefore, the lifting lug size is satisfactory.

2.5 DESIGN OF WELD SIZE AT LUG TO SHELL JOINT

Lug to shell welding
z

Top View of Lug

x x X
z

Z
2.5.1 GENERAL
Weld leg , w = 6 mm
Weld throat thickness, tr = 4.2 mm
Allowable welding stress for steel A 36 ( = 0.6 * Sy ) = 157 N/mm²

2.5.2 CRITICAL WELD CROSS-SECTIONAL PROPERTIES

Area of weld, Aw ( = 2 tr ( wL + tL ) ) = 899 mm²
Section modulus at Z axis, Zz-z ( = tr.wL² /3 + tL.tr.wL ) = 17562 mm³
Section modulus at X axis, Zx-x ( = tr.tL² /3 + tL.tr.wL ) = 6470 mm³

2.5.3 STRESS DUE TO FORCE Fy

Component force, Fy = 1170 N
Shear stress, Ssx ( = Fy / Aw ) = 1.30 N/mm²
Bending stress, Sbx ( = Fy.hL / Zz-z ) = 3.33 N/mm²

2.5.4 STRESS DUE TO FORCE Fx

Component force, Fx = 2340 N
Tensile stress, Sty ( = Fx / Aw ) = 2.60 N/mm²

2.5.5 STRESS DUE TO FORCE Fz

Transverse component force, Fz = 0 N
Shear stress, Ssz ( = Fz / Aw ) = 0.00 N/mm²
Bending stress, Sbz ( = Fz.hL / Zx-x ) = 0.00 N/mm²

2.5.6 COMBINED STRESSES

Sm = (Sbx + Sty + Sbz)² + Ssx² + Ssz² = 6.08 N/mm²
Allowable welding stress, Sa = 157.20 N/mm²
Since Sm < Sa, therefore the selected weld size is satisfactory .
 Page no.: 1

9.0 OPENING & REINFORCEMENT ON HEAD

9.1 NOZZLE DESCRIPTION :

N1 8" NB × Sch 80 , 150# WNRF FLANGE

DESIGN DATA :
Nozzle Neck Mataterial : A 312 TP 316L -SEAMLESS
Nozzle allowable Stress, Sn 117,905 Psi
Design Pressure, P 9 Psi
Design Temp. 100 °F
Corr. Allowance 0 in
Reinf. Element Material : A 240 316L
Reinf. Element allowable Stress, Sp 15,000 Psi

Vessel data: New Cond. Corroded Cond.

Shell, I.D. 1000 in. 1000 in.
t 0 in. 0 in.
Head, I.D. 1000 in. 1000 in.
t (after forming) 0 in. 0.0000 in.

Nozzle Neck data:

Nominal Thickness, tn 0.500 in. 0.5 in.
Inside Diameter, d 7.625 in. 7.625 in.
Outside Diameter, do 8.625 in. - in.
Mean Diameter, dm 8.125 in. 8.125 in.
Inside Vessel Ext.,h - in. - in.
Sch. Std wall thk. 0.322 in. - in.

NOMENCLATURE UG-37(a):
t = nom. thk. of vessel wall, in.
tr = req'd thk. of shell or formed head, in.
tn = nom. thk. of nozzle wall, irrespective of product form, in.
trn = req'd thk. Of nozzle wall, in.
te = thickness of reinforcing element, in.
d = finished diameter of circular opening, in.
F = correction factor, 1.0
fr = strength reduction factor, not greater than 1.0

Wall Thickness Required : UG - 27(c)(1)

Shell, tr = PR/SE-0.6P

= (9 × 500) / (15000 ×1.0 - 0.6 ×9)

tr = 0.0302 in. = 0.77 mm

 Page no.: 2

Nozzle Thickness Required

Nozzle trn = P×Rn/Sn×E-0.6P

= (9 × 3.8125) / (117904.5 × 1.0 - 0.6 × 9)

trn = 0 in. = 0 mm

Nozzle thickness required as per UG - 45

Wall thickness as per UG-45(a): tr1 = 0 in = 0 mm (E=1)

Wall thickness as per UG-45(b)(1): tr2 = 0.0302 in = 0.8 mm
Wall thickness as per UG-16(b): tr3 = 0.0625 in = 1.6 mm
Std. pipe wall thk. as per UG-45(b)(4): tr4 = 0.2818 in = 7.2 mm
The greater of tr2 or tr3: tr5 = 0.0625 in = 1.6 mm
The lesser of tr4 or tr5: tr6 = 0.0625 in = 1.6 mm

Required as per UG-45 is the larger of tr1 or tr6: = 0.0625 in = 1.6 mm

Available nozzle wall thickness new, tn = 0.875 × 0.5 = 0.438 in = 11.1 mm

Hence, NOZZLE THICKNESS PROVIDED IS SUFFICIENT

Size of weld required [UW - 16 (c) & Fig. UW - 16.1 d]

tc = not less than the smaller of 1/4 in. or 0.7 × tmin

where :
tmin = lesser of 0.25 in. or tn or te =

leg = 0.472441 in.

tc(min) = 0.354331 in.
tc (actual) = 0.354331 in.

Strength calculation for attachment welds are not required for this detail
which conforms with Figure UW - 16.1 (d) & UW - 15(b)

Page no.: 3
 NOZZLE WALL THICKNESS UNDER EXTERNAL PRESSURE

Wall Thickness Required : UG - 37(d)(1)

Shell, tr = 0.0302 in.

Nozzle Thickness Required

Assumed nozzle thikckness, t = 3 mm

Outside diameter , Do = 508 mm
L= 146 mm
L/Do = 0.287

Do/t = 169.33

From figure G: A = 0.0025

From Figure CS-2 : B = 14000 PSI

Pa = 4B/(3Do/t) = 110.2384 PSI

7.752 KG/cm²

Since Pa is greater than the external design pressure P of 1.033 kg/cm²g, the assumed
thickness of nozzle is satisfactory.
 Page no.: 4

CHECK WITHOUT REINFORCEMENT ELEMENT :

Calculate the strength reduction factor :

fr1 = fr2 = Sn/Sv = 0.8 where ; Sn = 117,905 Psi
.
.. fr = 1.0 Sv = 149,020 Psi

Area of reinforcement required, A - Fig. UG-37.1

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

= (7.625 × 0.0302 × 1.0)+(2 × 0.5 × 0.0302 ×1.0) × (1 -1.0)

= 0.2303 in²

Area available in shell :

A1 = larger of the following :

A1 = d(E1t-Ftr)-2tn(E1t - Ftr)(1 - fr1)

= (7.625×(1.0×0 - 1.0×0.0302) - 2×0.5*(1.0×0 - 1.0×0.0302)(1.0 - 1.0)

= -0.2303 mm²

Or

A1 = 2(t + tn)(E1t - Ftr) - 2tn(E1t - Ftr)(1 - fr1)

= 2(0 + 0.5)(1.0×0 - 1.0×0.0302) - 2×0.5×(1.0×0 - 1.0×0.0302)(1.0 - 1.0)

= -0.0302 in²
Therefore, A1 = -0.0302 in²

Area Available in Nozzle

A2 = smaller of the following

A2 = 5(tn - trn)fr2t Or A2 = 5(tn - trn)fr2 tn

= 5(0.5 - 0)(1.0)(0) = 5(0.5 - 0)(1.0)(0.5)

= 0 in² = 1.25 in²

Therefore, A2 = 0 in²

Page no.: 5
Area Available in outside fillet welds

A41 = 2 x 1/2(leg)²fr2

= 2 * 1/2(0.354330708661417)²(1.0)

= 0.1256 in²

Area provided by A1 + A2 + A41 = AT

AT = -0.0302 + 0 + 0.1256

= 0.1 in² < 0.2303 in²

Therefore reinforcing element is required

CHECK WITH REINFORCING ELEMENT (PLATE ADDED) :

SIZE OF WELDS REQUIRED UW-16 (c) ; a

Figure UW-16.1 Sketch (h)

Weld Sizes :

Nozzle to pad 0.472441 in leg

Pad to shell 0.472441 in leg

INNER REINFORCING ELEMENT FILLET WELD

tmin = lesser of 3/4 in. or the thickness less corr. Allowance of

the thinner part joined.

= 0.472441 in

tw = 0.7 tmin.

= 0.330709 in (min. throat required)

twa = 0.7 x weld size

= 0.330709 in (min. throat required)

Therefore, tw(min) < tw(actual)

Page no.: 6
OUTER REINFORCING ELEMENT FILLET WELD

tmin, = 0.3543 in

throat = 1/2(tmin)

= 0.5 * 0.3543

= 0.1772 in (min. throat required)

throat = 0.7 x weld size

= 0.7 * 0.3543

= 0.248 in (actual throat)

throat (min) < throat (actual) SATISFACTORY

AREA OF REINFORCEMENT REQUIRED :

A = 0.2303 in² Reinf. Pad size

O.D (Dp) = 15.748 in
THK (te) = 0.3937 in
Area available in shell, A1 = -0.0302 in²

Area available in outer nozzle

A2 = smaller of the following

= 5(tn - trn)fr2t

= 5(0.5 - 0)(1.0)(0)

= 0 in²

Or

A2 = 2(tn - trn)(2.5tn + te)fr2

= 2(0.5 - 0)(2.5*0.5 + 0.3937)(1.0)

= 1.6437 in² Therefore, A2 = 0 in²

Page no.: 7

Area available in outward nozzle to plate fillet weld, A41

 A41 = (leg)² fr3 where, fr3 = Sn/Sv = 1.0

= (0.3543)²(1.0)

= 0.1255 in²

Area Available in Outer Plate Fillet Weld :

A42 = (leg)² fr4 where, fr4=Sp/Sv=15000/149020 = 0.1

= (0.3543)²(0.1)

= 0.0126 in²

Area Available in Reinforcing Plate

A5 = (Dp - d - 2tn) (te) (fr4)

= (15.748 - 7.625 -2*0.5)(0.3937)(0.1)

= 0.2804 in²

Total Area Provided by, A1 + A2 + A41 + A42 + A5 =A T

AT = -0.0302 + 0 + 0.1255 + 0.0126 + 0.2804

AT = 0.39 in² > 0.2303 in²

#REF!
 Page no.: 1

9.0 OPENING & REINFORCEMENT ON HEAD

9.1 NOZZLE DESCRIPTION :

N2 6" NB × Sch 120 , 300# WNRF FLANGE

DESIGN DATA :
Nozzle Neck Mataterial : A 312 TP 316L -SEAMLESS
Nozzle allowable Stress, Sn 117,905 Psi
Design Pressure, P 9 Psi
Design Temp. 100 °F
Corr. Allowance 0 in
Reinf. Element Material : A 240 316L
Reinf. Element allowable Stress, Sp 15,000 Psi

Vessel data: New Cond. Corroded Cond.

Shell, I.D. 1000 in. 1000 in.
t 0 in. 0 in.
Head, I.D. 1000 in. 1000 in.
t (after forming) 0 in. 0.0000 in.

Nozzle Neck data:

Nominal Thickness, tn 0.562 in. 0.562 in.
Inside Diameter, d 5.501 in. 5.501 in.
Outside Diameter, do 6.625 in. - in.
Mean Diameter, dm 6.063 in. 6.063 in.
Inside Vessel Ext.,h - in. - in.
Sch. Std wall thk. 0.280 in. - in.

NOMENCLATURE UG-37(a):
t = nom. thk. of vessel wall, in.
tr = req'd thk. of shell or formed head, in.
tn = nom. thk. of nozzle wall, irrespective of product form, in.
trn = req'd thk. Of nozzle wall, in.
te = thickness of reinforcing element, in.
d = finished diameter of circular opening, in.
F = correction factor, 1.0
fr = strength reduction factor, not greater than 1.0

Wall Thickness Required : UG - 27(c)(1)

Shell, tr = PR/SE-0.6P

= (9 × 500) / (15000 ×1.0 - 0.6 ×9)

tr = 0.0302 in. = 0.77 mm

 Page no.: 2

Nozzle Thickness Required

Nozzle trn = P×Rn/Sn×E-0.6P

= (9 × 2.7505) / (117904.5 × 1.0 - 0.6 × 9)

trn = 0 in. = 0 mm

Nozzle thickness required as per UG - 45

Wall thickness as per UG-45(a): tr1 = 0 in = 0 mm (E=1)

Wall thickness as per UG-45(b)(1): tr2 = 0.0302 in = 0.8 mm
Wall thickness as per UG-16(b): tr3 = 0.0625 in = 1.6 mm
Std. pipe wall thk. as per UG-45(b)(4): tr4 = 0.245 in = 6.2 mm
The greater of tr2 or tr3: tr5 = 0.0625 in = 1.6 mm
The lesser of tr4 or tr5: tr6 = 0.0625 in = 1.6 mm

Required as per UG-45 is the larger of tr1 or tr6: = 0.0625 in = 1.6 mm

Available nozzle wall thickness new, tn = 0.875 × 0.562 = 0.492 in = 12.5 mm

Hence, NOZZLE THICKNESS PROVIDED IS SUFFICIENT

Size of weld required [UW - 16 (c) & Fig. UW - 16.1 d]

tc = not less than the smaller of 1/4 in. or 0.7 × tmin

where :
tmin = lesser of 0.25 in. or tn or te =

leg = 0.472441 in.

tc(min) = 0.354331 in.
tc (actual) = 0.354331 in.

Strength calculation for attachment welds are not required for this detail
which conforms with Figure UW - 16.1 (d) & UW - 15(b)

Page no.: 3
 NOZZLE WALL THICKNESS UNDER EXTERNAL PRESSURE

Wall Thickness Required : UG - 37(d)(1)

Shell, tr = 0.0302 in.

Nozzle Thickness Required

Assumed nozzle thikckness, t = 3 mm

Outside diameter , Do = 508 mm
L= 146 mm
L/Do = 0.287

Do/t = 169.33

From figure G: A = 0.0025

From Figure CS-2 : B = 14000 PSI

Pa = 4B/(3Do/t) = 110.2384 PSI

7.752 KG/cm²

Since Pa is greater than the external design pressure P of 1.033 kg/cm²g, the assumed
thickness of nozzle is satisfactory.
 Page no.: 4

CHECK WITHOUT REINFORCEMENT ELEMENT :

Calculate the strength reduction factor :

fr1 = fr2 = Sn/Sv = 0.8 where ; Sn = 117,905 Psi
.
.. fr = 1.0 Sv = 149,020 Psi

Area of reinforcement required, A - Fig. UG-37.1

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

= (5.501 × 0.0302 × 1.0)+(2 × 0.562 × 0.0302 ×1.0) × (1 -1.0)

= 0.1661 in²

Area available in shell :

A1 = larger of the following :

A1 = d(E1t-Ftr)-2tn(E1t - Ftr)(1 - fr1)

= (5.501×(1.0×0 - 1.0×0.0302) - 2×0.562*(1.0×0 - 1.0×0.0302)(1.0 - 1.0)

= -0.1661 mm²

Or

A1 = 2(t + tn)(E1t - Ftr) - 2tn(E1t - Ftr)(1 - fr1)

= 2(0 + 0.562)(1.0×0 - 1.0×0.0302) - 2×0.562×(1.0×0 - 1.0×0.0302)(1.0 - 1.0)

= -0.0339 in²
Therefore, A1 = -0.0339 in²

Area Available in Nozzle

A2 = smaller of the following

A2 = 5(tn - trn)fr2t Or A2 = 5(tn - trn)fr2 tn

= 5(0.562 - 0)(1.0)(0) = 5(0.562 - 0)(1.0)(0.562)

= 0 in² = 1.5792 in²

Therefore, A2 = 0 in²

Page no.: 5
Area Available in outside fillet welds

A41 = 2 x 1/2(leg)²fr2

= 2 * 1/2(0.354330708661417)²(1.0)

= 0.1256 in²

Area provided by A1 + A2 + A41 = AT

AT = -0.0339 + 0 + 0.1256

= 0.09 in² < 0.1661 in²

Therefore reinforcing element is required

CHECK WITH REINFORCING ELEMENT (PLATE ADDED) :

SIZE OF WELDS REQUIRED UW-16 (c) ; a

Figure UW-16.1 Sketch (h)

Weld Sizes :

Nozzle to pad 0.472441 in leg

Pad to shell 0.472441 in leg

INNER REINFORCING ELEMENT FILLET WELD

tmin = lesser of 3/4 in. or the thickness less corr. Allowance of

the thinner part joined.

= 0.472441 in

tw = 0.7 tmin.

= 0.330709 in (min. throat required)

twa = 0.7 x weld size

= 0.330709 in (min. throat required)

Therefore, tw(min) < tw(actual)

Page no.: 6
OUTER REINFORCING ELEMENT FILLET WELD

tmin, = 0.3543 in

throat = 1/2(tmin)

= 0.5 * 0.3543

= 0.1772 in (min. throat required)

throat = 0.7 x weld size

= 0.7 * 0.3543

= 0.248 in (actual throat)

throat (min) < throat (actual) SATISFACTORY

AREA OF REINFORCEMENT REQUIRED :

A = 0.1661 in² Reinf. Pad size

O.D (Dp) = 15.748 in
THK (te) = 0.3937 in
Area available in shell, A1 = -0.0339 in²

Area available in outer nozzle

A2 = smaller of the following

= 5(tn - trn)fr2t

= 5(0.562 - 0)(1.0)(0)

= 0 in²

Or

A2 = 2(tn - trn)(2.5tn + te)fr2

= 2(0.562 - 0)(2.5*0.562 + 0.3937)(1.0)

= 2.0217 in² Therefore, A2 = 0 in²

Page no.: 7

Area available in outward nozzle to plate fillet weld, A41

 A41 = (leg)² fr3 where, fr3 = Sn/Sv = 1.0

= (0.3543)²(1.0)

= 0.1255 in²

Area Available in Outer Plate Fillet Weld :

A42 = (leg)² fr4 where, fr4=Sp/Sv=15000/149020 = 0.1

= (0.3543)²(0.1)

= 0.0126 in²

Area Available in Reinforcing Plate

A5 = (Dp - d - 2tn) (te) (fr4)

= (15.748 - 5.501 -2*0.562)(0.3937)(0.1)

= 0.3592 in²

Total Area Provided by, A1 + A2 + A41 + A42 + A5 =A T

AT = -0.0339 + 0 + 0.1255 + 0.0126 + 0.3592

AT = 0.46 in² > 0.1661 in²

#REF!
 Page no.: 1

9.0 OPENING & REINFORCEMENT ON HEAD

9.1 NOZZLE DESCRIPTION :

N3, N4 2" NB × Sch 160 , 150# WNRF FLANGE

DESIGN DATA :
Nozzle Neck Mataterial : A 312 TP 316L -SEAMLESS
Nozzle allowable Stress, Sn 117,905 Psi
Design Pressure, P 9 Psi
Design Temp. 100 °F
Corr. Allowance 0 in
Reinf. Element Material : A 240 316L
Reinf. Element allowable Stress, Sp 15,000 Psi
Vessel data: New Cond. Corroded Cond.
Shell, I.D. 1000 in. 1000 in.
t 0 in. 0 in.
Head, I.D. 1000 in. 1000 in.
t (after forming) 0 in. 0.0000 in.

Nozzle Neck data:

Nominal Thickness, tn 0.344 in. 0.344 in.
Inside Diameter, d 1.687 in. 1.687 in.
Outside Diameter, do 2.375 in. - in.
Mean Diameter, dm 2.031 in. 2.031 in.
Inside Vessel Ext.,h - in. - in.
Sch. Std wall thk. 0.154 in. - in.

NOMENCLATURE UG-37(a):
t = nom. thk. of vessel wall, in.
tr = req'd thk. of shell or formed head, in.
tn = nom. thk. of nozzle wall, irrespective of product form, in.
trn = req'd thk. Of nozzle wall, in.
te = thickness of reinforcing element, in.
d = finished diameter of circular opening, in.
F = correction factor, 1.0
fr = strength reduction factor, not greater than 1.0

Wall Thickness Required : UG - 27(c)(1)

Head, tr = PD/2SE-0.2P

= (9 × 1000) / (2 × 15000 ×1.0 - 0.2 ×9)

tr = 0.0302 in. = 0.77 mm

 Page no.: 2

Nozzle Thickness Required

Nozzle trn = P×Rn/Sn×E-0.6P

= (9×0.8435) / (117904.5 × 1.0 - 0.6 × 9)

trn = 0.0001 in. = 0 mm

Nozzle thickness required as per UG - 45

Wall thickness as per UG-45(a): tr1 = 0.0001 in = 0 mm (E=1)

Wall thickness as per UG-45(b)(1): tr2 = 0.0302 in = 0.8 mm
Wall thickness as per UG-16(b): tr3 = 0.0625 in = 1.6 mm
Std. pipe wall thk. as per UG-45(b)(4): tr4 = 0.1348 in = 3.4 mm
The greater of tr2 or tr3: tr5 = 0.0625 in = 1.6 mm
The lesser of tr4 or tr5: tr6 = 0.0625 in = 1.6 mm

Required as per UG-45 is the larger of tr1 or tr6: = 0.0625 in = 1.6 mm

Available nozzle wall thickness new, tn = 0.875 × 0.344 = 0.301 in = 7.6 mm

Hence, NOZZLE THICKNESS PROVIDED IS SUFFICIENT

Size of weld required [UW - 16 (c) & Fig. UW - 16.1 d]

tc = not less than the smaller of 1/4 in. or 0.7 × tmin

where :
tmin = lesser of 0.25 in. or tn or te =

leg = 0.314961 in.

tc(min) = 0.354331 in.
tc (actual) = 0.354331 in.

Strength calculation for attachment welds are not required for this detail
which conforms with Figure UW - 16.1 (d) & UW - 15(b)
 Page no. 1

ESTABLISHMENT LIST OF M.D.M.T. ACCORDING TO ASME SECT. VIII DIV. 1 UG - 20, UCS - 66
( LOWEST PERMISSIBLE TEMPERATURE )

Part Name Material Governing Ttk. Lowest Permissible Remarks Impact Test
( mm ) Temperature (Base ) Requirement

Shell SA516 - 70 10 - 20oF ( -28.8oC ) UG-20(f), Thickness < 1 inch No

Head SA516 - 70 13 - 20oF ( -28.8oC ) UG-20(f), Thickness < 1 inch No

Reinforcing Pad
for Nozzle & Hand-
Hole SA516 - 70 10 - 20oF ( -28.8oC ) UG-20(f), Thickness < 1 inch No

Pad for Lug & Leg SA516 - 70 10 - 20oF ( -28.8oC ) UG-20(f), Thickness < 1 inch No

Nozzle Neck(Pipe) SA106 - B 12.7 - 20oF ( -28.8oC ) UG-20(f), Thickness < 1 inch No

Nozzle Neck
(Forging) (Max) SA 105 - 20oF ( -28.8oC ) UG-20(f), Thickness < 1 inch No

Bolts SA193-B7 - - 20oF ( -28.8oC ) UG-20(f), Thickness < 1 inch No

Nuts SA194-2H - - 20oF ( -28.8oC ) UG-20(f), Thickness < 1 inch No

*M.D.M.T. - 20oF ( -28.8oC )

 Page no.: 14

6.0 WEIGHT ESTIMATION

All weights calculated in pounds (lbs)

CONDITIONS
Operating Testing Erected
Cylindrical shell 0 0 0
Heads (2x) 0 0 0
Nozzles 694 694 694
Misc. attachments 220 220 220
Operating Liquid
Shell 0 0 0
Head 0 0 0

Testing Liquid
Shell 0 4502 0
Head 0 578 0

Weight supported by
Leg Support 914 5994 914

Leg Support Weight 1360 1360 1360

Total weight 2274 7354 2274

Shop empty weight, Wi = 2274 lb

Shop hydrotest weight, Wst = 7354 lb
Field Erected weight, We = 2274 lb
Field Operating weight, Wo = 2274 lb
Field hydrotest weight, Wht = 7354 lb
 Page no.: 14

HEAT TREATMENT AFTER FORMING [ UCS - 79 ]

Item Head Shell

P - No. 1 1
Gr.- No. 2 2
Plate Thickness, t in. in.
Forming Method Cold Forming Cold Forming
Original Center Line
Radius, RO Infinity Infinity
Final Center Line
Radius, Rf 172 in. 500 in.
Fibre Elongation
For Double Curvature
E1 = 75 t ( 1 - Rf/Ro) 0% -
Rf
Fibre Elongation
For Single Curvature
E1 = 50 t ( 1 - Rf / Ro ) - 0%
Rf
(1) Lethal Substances No No
(2) Necessity of Impact Test No No
(3) Th'k Before Form > 5/8" (16mm) No No
(4) Reduction in Th'k > 10% No No
(5) Forming Temp. Range
withinn 250oF to 900oF
(121oC to 483oC) No No

Necessity of Heat Treatment* Exempted Exempted

* Necessity of Heat Treatment After Cold Forming

E1 > 5% and any of (1) to (5) condition --- Required

E1 <= 5% ( or E1 > 5% and None of (1) to (5) --- Exempted

For P - No. 1 and Group Nos. 1 and 2 , extreme fibre elongation may be great as
40% when none of the condition (1) through (5) exist.
NECESSITY OF POSTWELD HEAT TREATMENT [ UCS - 56 ]

Item Material P - No Gr. - No Th'k of Exempted Necessity

Weld Th'kness of PWHT
Portion (te, mm)
(TW, mm)

Shell SA516-70 1 1 10 38..1 Exempted

Head SA516-70 1 1 13 38.1 Exempted

Nozzle
Neck SA106-B 1 1 8 38.1 Exempted
Flange SA105 1 1 10.97 38.1 Exempted