You are on page 1of 22

BtKitangN90cumCal4.

xls

Batu Kitang
90 cum. SURGE VESSEL DESIGN 27/Oct/16 07:21 PM

Fileused C:\MainHD\Jobs\B&C\2016\BtKitang\45cum\[BtKitang45cumCal5.xls]Sheet1

I) DESIGN PARAMETERS

i) Design pressure

2
Design pressure,P = 1.4 N/mm = 14 bar
2
Test pressure = 1.82 N/mm = 14*1.3 UG-99
= 18.2 bar
2
Operating pressure = 1.2 N/mm = 12 bar
ii) Material & construction

Design code : 2013 ASME BOILER AND PRESSURE VESSEL CODE: Section VIII, Division 1
(Section II, Part D, Table 1A)
2
Use ASTM A516 grade 7 20000 psi = 137.93 N/mm
S, Allowable stress =
2
ASTM A106 grade B carb 17100 psi = 117.93 N/mm
S, Allowable stress =

Degree of radiographic examination : 100%


Fully radiographed butt joints.
From Table UW-12, joint efficiencies E = 100%

2
Young's Modulus E= 200000 N/mm

iii) Dimensions

Internal Diameter ------------------ 2882 mm = 2.882 m


Concrete lining --------------------- 0 mm = 0 m
Steel Plate thickness ---------------- 19 mm = 0.019 m
Corrosion allowance --------------- 1.5 mm = 0.0015 m
Internal dia. of vessel shell ---------- 2882 mm = 2.88 m
Mean dia. of vessel ----------------- 2901 mm = 2.90 m
Outer dia. of vessel ----------------- 2920 mm = 2.92 m
Internal Radius of vessel ------------ 1441 mm = 1.44 m
Length of vessel ---------------------- 12.90 m
LEGEND of SYMBOLS:
t - Minimum required thickness of shell, mm.
p - Internal design pressure , N/mm2 .
R - Inside radius of the shell, mm
S - Allowable stress, N/mm2 .
E - Joint efficiency, %.
D - Inside diameter of the head skirt, mm.
h - Distance nozzle projects beyond the inner surface of the vessel wall, mm

Page 1 of 22
BtKitangN90cumCal4.xls

LIST of CONSTANTS:

Density of water - 10 KN/m3


Density of steel - 79 KN/m3
Density of concrete - 24 KN/m3
Young's modulus of steel - 200,000 N/mm2

II) Vessel design

a) Minimum thickness for internal pressure (Clause UG-27)


i) Circumferential Stress

PR
t = -------------
SE - 0.6P
= 1.4*( 2882/2)/(137.93*100%-0.6* 1.4)
= 14.72 mm add 1.5 mm for corrosion allowance

therefore min. t = 16.22 mm < 19 mm OK

ii) Longitudinal Stress

PR
t = -------------
2SE + 0.4P
= 1.4*( 2882/2)/(2*137.93*100%+0.4* 1.4)
= 7.30 mm add 1.5 mm for corrosion allowance

therefore min. t = 8.80 mm < 19 mm OK


% extreme fiber elongation = 50* 19/ 1441
= 0.66 % < 5%, Heat treatment not necessary
(Ro = infinity for flat plate)
b) Minimum thickness of ellipsoidal ends (Clause UG - 32)
From MANDATORY APPENDICES h
Sect 1-4, Table 1-4.1, for D/2h = 1.81
PDk k = 0.88 D
t = ------------- h= 1441/1.81
2SE - 0.2P = 795
= 1.4* 2882/(2*137.93*100%-0.2* 1.4)*0.88
= 12.85 and add 1.5 mm for corrosion allowance
= 12.85+ 1.5
= 14.35 mm allow 15% for thinning due to forming
therefore min. t =14.35/0.85 = 16.89 mm < 19.0 mm OK

% extreme fiber elongation = 75* 19/ 1441


= 0.99 % < 5%, Heat treatment not necessary

Page 2 of 22
BtKitangN90cumCal4.xls

c) Supports (G-9 of ASME VIII:- points to BS5500)

b= 794.76 b= 794.76
A= 2000 A= 2000
L 12900
=

Length of vessel = 12.90 m

Weight of cylinder = 3.14* 2901/1000* 19/1000*79 + 3.14*(+ 2882+ 0)/1000* 0/1000*24


= 13.68 + 0.00
= 13.68 KN/m

Weight of water = 3.14*( 2882/2/1000)^2*10


= 65.23 KN/m
Total W = +65.23+13.68 = 78.91 KN/m

Vol. Ellipsoidal = *d3/24


Surface area of ellipsoidal = 0.313*d2

wt. of ellipsoidal end = 0.313*3.14*2.90^2* .019*79 + 0.313*3.14*(2.882+ 0)^2* 0*24 + 3.14*2.882^3/ 24*10

(each) = 12.42 + 0.00 + 31.33


(steel) (conc.) (water)
= 43.76 KN

Total weight of the vessel (when full) = 78.91*12.90+43.76*2


= 1105.51 KN = 110551 kg
Total weight of the vessel (when empty) = 13.68*12.90+(0.00+12.42)*2
= 201.31 KN = 20131 kg

Volume of vessel = (1105.51-201.31)/10


= 90.4 cu.m.

L= 12900 mm = 12.9 m
Width of saddle, b1 = 200 mm = 0.2 m
b= 794.76 mm = 0.79 m
A= 2000 mm = 2 m
Total length = 12900 mm = 12.9 m
r/2 = 725.25 mm < 2000 mm (A)
therefore Not stiffened by vessel end
2
Cross-sectional area = 3.14* 2901* 19 = 173161 mm
4
Moment of inertia = 3.14/8* 2901^3* 19 = 1.82E+11 mm

Page 3 of 22
BtKitangN90cumCal4.xls

Reactions : Maximum supports reaction = 78.91*( 12900/2/1000)+43.76


W1 = 552.75 KN

r= 2882/2 = 1441 mm = 1.44 m


b= 794.76 mm = 0.79 m
L= 12900.00 mm = 12.90 m
A= 2000 mm = 2.00 m

1+2(r2-b2)/L2 = 1+2*(1.44^2-0.79^2)/12.90^2
= 1.017

1 + 4*b/3L = 1+4*0.79/3/12.90
= 1.082

1 - A/L+(r2-b2)/2AL = 1-2.00/12.90+(1.44^2-0.79^2)/2/2.00/12.90
= 0.873

Mid span M3 = 552.75*12.90/4*(1.017/1.082-4*2.00/12.90)


= 570.41 KNm (M3)

Support M4 = -552.75*2.00*(1-0.873/1.082)
= -213.70 KNm (M4)

i)Longitudinal stresses at mid-span : (Clause G.3.3.2.2,BS5500)


at the highest point
pm*r M3
f1 = ------------- - -------------
2t p*r2*t
= 1.4* 1441/2/ 19 - 570.41*1000000/3.14/ 1441^2/ 19
= 53.09 - 4.60
2 2
= 48.49 N/mm < 137.93 N/mm OK

at the lowest point


pm*r M3
f2 = ------------- + -------------
2t p*r2*t
= 1.4* 1441/2/ 19 + 570.41*1000000/3.14/ 1441^2/ 19
= 53.09 + 4.60
2 2
= 57.69 N/mm < 137.93 N/mm OK

Page 4 of 22
BtKitangN90cumCal4.xls

ii)Longitudinal stresses at the saddles : (Clause G.3.3.2.3,BS5500)


The shell is not stiffened proximity of the end.
and saddle angle = 140 degrees from table G.2,BS5500
at the highest point K1= 0.142
2
f3 = pmr/2t - M4/(K1*3.142*r *t) K2= 0.249
= 1.4* 1441/2/ 19 + -213.70*1000000/0.142/3.14/ 1441^2 / 19
= 53.09 - -12.17
2 2
= 65.26 N/mm < 137.93 N/mm OK

at the lowest point


f 4= pmr/2t + M4/(K2*3.142*r2*t)
= 1.4* 1441/2/ 19 + -213.70*1000000/0.249/3.14/ 1441^2 / 19
= 53.09 + -6.92
2 2
= 46.17 N/mm < 137.93 N/mm OK

iii) Tangential shearing stress (Clause G.3.3.2.3,BS5500)


Maximum shear force S1 = 552.75*( 12900-2* 2000)/( 12900+4/ 3*794.76)
= 352.41 KN

For shell not stiffened by rings adjacent to saddles.


and saddle angle = 140 degrees
from table G.3 ,BS5500
K3*S1 K3= 0.905
Shear stress in the shell q = -----------
r*t
= 0.905*352.41*1000/ 1441/ 19
2
= 11.65 N/mm
allowable shear stress = smaller of 0.8S or 0.06Et/r
ie. = 110.34 or 158.22
2 2
= 110.34 N/mm > 11.65 N/mm OK

Page 5 of 22
BtKitangN90cumCal4.xls

iv) Circumferential stress (Clause G.3.3.2.5,BS5500)

Shell not stiffened by rings (Clause 3.3.2.5.1,BS5500)

W1 = 552.75 KN
Table G.5 , BS5500
At lowest point of the corss section: K5= 0.698
-K5*W1
f5= --------- = -0.698*552.75*1000/ 19/( 200+10*14.72)
tb2
2 2
= -58.52 N/mm < 137.93 N/mm OK

At the horn of the saddle

b2 = 200+10*14.72 = 347.16 mm, b1 = 200 mm is provided.

Stress in Vessel's shell at the edge of b1:


f6 = f61 -f62 Table G.4 , BS5500
f61 = -552.75*1000/4/(14.72)/347.16 K6= 0.03056 for A/r = 1.38
2
= -27.05 N/mm and  = 140+6+6
= 152
L/r = 12900/ 1441
= 8.95

f62 = 3*0.03056*552.75*1000/2/( 19)^2 or 12*0.03056*552.75*1000* 2901/2/ 12900/( 19)^2


= 70.19 or 63.14
2
= 70.19 N/mm , for > 8

 f6 = -27.05-70.19
2
= -97.24 N/mm

2 2
Allowable stress = 1.25f 172.41 N/mm > 97.24 N/mm OK

Page 6 of 22
BtKitangN90cumCal4.xls

Stress in Vessel's shell at edge of saddle:


f6 = f61 -f62 Table G.4 , BS5500
f61 = -552.75*1000/4/(14.72+ 12)/347.16 K6= 0.03807 for A/r = 1.38
2
= -14.90 N/mm and  = 140
= 140
L/r = 12900/ 1441
= 8.95

f62 = 3*0.03807*552.75*1000/2/( 19+ 12)^2 or 12*0.03807*552.75*1000* 2901/2/ 12900/( 19+ 12)^2

= 32.84 or 29.54
2
= 32.84 N/mm , for > 8

 f6 = -14.90-32.84
2
= -47.74 N/mm

2 2
Allowable stress = 1.25f 172.41 N/mm > 47.74 N/mm OK

v) Design of saddles (Clause G.3.3.2.6, BS5500)


Material used Grade 43 steel, design to BS449
b1 = 200 Vessel's shell

b1= 200 mm
h = 250 mm t1 = 12 h = 250
t1 = 12 mm t2= 12
t2 = 12 mm

2
Area a= 200* 12+250.00* 12 = 5400 mm

i)Horizontal component of the reaction H

H= K9*W1 clause G3.3.2.6, BS5500


o
= 0.240*552.75 K9 = 0.240 For saddle angle of 140
= 132.85 KN

r/3 = ( 2901/2)/3

= 483.50 > 250 mm  effective h = 250.00 mm

Average direct stress = H/a


= 132.85*1000/ 5400
2 2
= 24.60 N/mm < 91.95 N/mm OK
(2/ 3*137.93)

Page 7 of 22
BtKitangN90cumCal4.xls

350 x 400 base plate

450 x 500 sole plate


Concrete Support
Concrete Support

ii) Bearing stress on concrete:

Bearing stress = W1*1000/B/w2


= 552.75*1000/450/500
2
= 2.46 N/mm < allowable bearing stress of 5 N/mm2
iii) Column
h= 250 mm
b= 200 mm x 250 x
Plate
thickness = 12 mm

Area = ( 200*2+ 250)* 12 200


2
= 7800 mm
I xx = 12* 250^3/12+ 200* 12^3 /12*2+ 200* 12*( 250/2)^2 *2
4
9.07E+07 mm
Iyy = 250* 12^3 /12+ 12* 200^3 /12 *2

4
1.60E+07 mm
rxx = SQRT(9.07E+07/ 7800)
107.8 mm
ryy = SQRT(1.60E+07/ 7800)
45.3 mm
Height of column l = 2 m
l/ryy = 2*1000/45.3
= 44.109
from table 17a of BS449, allowable compressive stress = 136 N/mm2

Load on column = 552.75/2


= 276.38 KN

Compressive stress = 276.38*1000/ 7800


2
= 35.43 N/mm < allowable stress of 136 N/mm2

Page 8 of 22
BtKitangN90cumCal4.xls

vii) Base plate


6mm fillet weld
45

100
250 x 200 I'
500
20 mm thk
M.S. plate
400

Provide 500 x 400 x 20 thk base plate


Area = 400* 500 = 200,000 mm
2

Maximum axial load /column = 276.4 KN


Assume grade of concrete = 35
Permissible bearing stress = +35.00*0.25
= 8.75 N/mm2
Minimum area required = 276.4*1000/ 8.75
= 31,586 mm OK
2

bearing pressure = 276.4*1000/ 500/ 400


= 1.38 N/mm OK
2

over hang, B = ( 500- 250)/2 = 125 mm


A= ( 400- 200)/2 = 100 mm

Thickness of base plate =SQRT(3*1.38/185*(100.00^2-125.00^2/4))


= 11.69 mm < 20 mm, OK

Length of weld = 250*2+ 200*4


= 1300 mm
Size of weld = 6 mm, strength = 483 N/mm
Strength of weld = 483* 1300/1000
= 627.9 KN > 276.4 KN OK

viii) Hold Down Bolts:

Since there is no up lifting forces, the hold down bolts are designed for shear due to temperature stress.

Provide 4 numbers of 20 mm S.S. bolts

Shear force due to temperature changes = 64.01/2 = 32.00 KN

Shear stress on bolts = 32.00*1000/( 20^2/ 4*3.14* 4)


2 2
= 25.47 N/mm < 100 N/mm , OK

Page 9 of 22
BtKitangN90cumCal4.xls

c) Temperature stress:
Coefficient of expansion a = 0.000012 /K
o
Assume temperature change of 20 C
Length of vessel between supports = 8.9 m

elongation due to temperature change = a*T*L


= .000012*20* 8.9*1000
= 2.136 mm
If the vessel is restrained from lateral movement,
temperature srtress = 200000* .000012*20
2
= 48 N/mm

To reduce the temperature stress, one sliding support will be provided

reaction at support (when empty)= 13.68*( 2000/1000+12.90/2)+12.42+0.00 =


= 128.02 KN
Assume coefficient of friction = 0.5

Axial force in Vessel = 128.02 * 0.50 = 64.01 KN


2
or stress = 0.37 N/mm very small

Lifting hook:
Check stresses on vessel:

2Cx 2Cx

2C 2C

At Hook:
Distance of hook from end a = 900 mm
Mean dia. of vessel= 2981 mm mean rad. (ro)= 1490.5 mm
Plate thickness = 38 mm
Length of vessel = 12900 mm

Total W = 201.3 KN
Lifting force W= 201/2 = 100.66 KN

[half thk of lug] C= 19 mm ) Clause G.2.2.1


[half length of lug] Cx= 200.0 mm )
Length Le ( 12900)-4*( 12900/2- 900)^2/( 12900) = 3348.8 mm
Loaded width/2r = 19.00/(1491*2)= 0.00637

Page 10 of 22
BtKitangN90cumCal4.xls

Within acceptable range of


r/t = 1490.50/38.00 = 39.22 Fig G.1

Clause G.2.2.1.2
2*Cx 2*200.00
i) axial length of load)/length = -------- = ------- = 0.12
L 3349

ii)
circumferential length of loaded area 2*Co 2*19.00
------------ --------------------------------- = -------- = -------- = 0.095
axial length of loaded area 2*Cx 2*200.00

2
r Cx
iii)Non-dimension function= 64*---- * -- = 45.20
t r

From Fig. G.6 M/W= 0.174 therefore M= 17514.1108 Nmm/mm


From Fig. G.7 Mx/W= 0.09 therefore Mx= 9059.02283 Nmm/mm
From Fig. G.8 N*t/W= -0.126 therefore N= -333.8 N/mm
From Fig. G.9 Nx*t/W= -0.151 therefore Nx= -400.0 N/mm

Nx 6 * Mx
resultant longitudinal stress = ----- +/- - ----------
t t2

= -10.53 +/- - 37.64


2
= 27.12 or -48.17 N/mm

N 6 * M
resultant circumferential stress = ------ +/- - ----------
t t2

= -8.78 +/- - 72.77


2
= 63.99 or -81.56 N/mm

2
Both stresses are less then the allowable stress of 137.93 N/mm
therefore the arrangement is acceptable.

Page 11 of 22
BtKitangN90cumCal4.xls

At Stiffener:
Distance of hook from end a = 900 mm
Mean dia. of vessel= 2981 mm mean rad. (ro)= 1490.5 mm
Plate thickness = 19 mm
Length of vessel = 12900 mm
Total W = 201 KN
Lifting force W= 201/2 = 100.7 KN
C= 300 mm ) Clause G.2.2.1
Cx= 300 mm )
Length Le ( 12900)-4*( 12900/2- 900)^2/( 12900) = 3349 mm
Loaded width/2r = 300.00/(1491*2)= 0.1006374
Within acceptable range of
r/t = 1490.50/19.00 = 78.4 Fig G.1
Clause G.2.2.1.2
2*Cx 2*300.00
i) axial length of load)/length = -------- = ------- = 0.18
L 3349

ii)
circumferential length of loaded area Co 2*300.00
------------ --------------------------------- = -------- = -------- = 1.000
axial length of loaded area Cx 2*300.00

2
r Cx
iii)Non-dimension function= 64*---- * -- = 203.39
t r
From Fig. G.6 M/W= 0.040 therefore M= 3993 Nmm/mm
From Fig. G.7 Mx/W= 0.018 therefore Mx= 1840 Nmm/mm
From Fig. G.8 N*t/W= -0.060 therefore N= -317.9 N/mm
From Fig. G.9 Nx*t/W= -0.093 therefore Nx= -491.5 N/mm

Nx 6 * Mx
resultant longitudinal stress = ----- +/- - ----------
t t2

= -25.87 +/- - 30.58


2
= 4.71 or -56.45 N/mm

N 6 * M
resultant circumferential stress = ------ +/- - ----------
t t2

= -16.73 +/- - 66.36


2
= 49.63 or -83.09 N/mm

2
Both stresses are less then the allowable stress of 137.93 N/mm
therefore the arrangement is acceptable.

Page 12 of 22
BtKitangN90cumCal4.xls

d) BRANCHES
i) DESIGN of BRANCH or OPENINGS (UG - 37)
600mm Manhole:

Rn

tn
d A5
trn
Lp
A2 te
h+te tr

h t
A1 A4 D

larger of d or Rn+tn+t A3

A
INPUT PARAMETERS :
Dia. of shell D = 2882 mm
2
Design pressure P= 1.4 N/mm
Branch dia. d = 600 mm
2
Allowable stress S = 137.93 N/mm
E= 1.00
Actual thickness of shell = 19 mm
Corrosion allowance c = 1.5 mm
therefore t = 19- 1.5 = 17.5 mm
Thickness of shell due to pressure tr = 1.4* 2882/2/(137.93*1.00-0.6* 1.4)
= 14.72 mm
Thickness of branch due to pressure trn = 1.4* 600/2/(137.93*1.00-0.6* 1.4)
= 3.06 mm
Actual thickness of branch provided = 10 mm
tn = 10- 1.5 = 8.5 mm
Leg length of weld for branch = 10 mm
Thickness of reinforcing plate te = 19 mm (external only)
Leg length of weld for reinforcing plate = 10 mm
Area of replacement required A = dtrF + 2tntrF(1-fr1) [fr1=1]
= +600.00*14.72*1.00
2
= 8829.46 mm

COMPUTE REPLACEMENT AREA:

i) Area A1 (Area available in shell)

d = 600 mm
2(t + tn) = 2*( 17.5+ 8.5)= 52 mm

therefore A1 = MAX( 600, 52)*(1.00* 17.5-1*14.72)


2
= 1670.54 mm

Page 13 of 22
BtKitangN90cumCal4.xls

ii) Area A2 (Area available in nozzle projecting outward)

A2 = smaller of 5*( 8.5-3.06)*1* 17.5


or 2*( 8.5-3.06)*(2.5* 8.5+ 19)*1
= 475.68 or 437.63
2
therefore A2 = 437.63 mm

iii) Area A3 (Area available in nozzle projecting inward)

h = smaller of 2.5* 17.5 or 2.5*( 8.5+ 19)


= 43.75 or 68.75
= 43.75 mm

A3 = 0
2
= 0 mm

iv) Area A4 (Area available welds)

A4 (A41 & A43) = 2* 10^2*1


2
= 200 mm

A4 (A42) = 10^2*1
2
= 100 mm

2
Total A4 = 100+ 200 = 300 mm

max. Dp = greater of 2*d or 2*(Rn + tn + t)


= 1200 or 2*(( 600- 1.5*2)/2+ 8.5+ 17.5) = 649
= 1200 mm
Diameter of compensation plate provided = 1229 mm
Width of compensation plate = 291.5 mm wide , 19 mm thick

Dp = 291.5*2+ 8.5*2+ 600 = 1200 mm

A5 = (MIN( 1200, 1200)- 600-2* 8.5)* 19* 1


2
= 11077 mm

Total Replacement area = A1+A2+A3+A4+A5


= 300+ 0+437.63+1670.54+ 11077
2 2
= 13485.16 mm > 8829 mm OK

Page 14 of 22
BtKitangN90cumCal4.xls

ii) DESIGN of BRANCH or OPENINGS (UG - 37)


350mm I/O

Rn

tn
d A5
trn
Lp A2 te
h+te tr

h t
A1 A4 D

larger of d or Rn+tn+t A3

INPUT PARAMETERS :
Dia. of shell D = 2882 mm
2
Design pressure P= 1.4 N/mm
Branch dia. d = 350 mm
2
Allowable stress S = 137.93 N/mm
E= 1.00
Actual thickness of shell = 19 mm
Corrosion allowance c = 1.5 mm
therefore t = 19- 1.5 = 17.5 mm
Thickness of shell due to pressure tr = 1.4* 2882/2/(137.93*1.00-0.6* 1.4)
= 14.72 mm
Thickness of branch due to pressure trn = 1.4* 350/2/(137.93*1.00-0.6* 1.4)
= 1.79 mm
Actual thickness of branch provided = 6.3 mm
tn = 6.3- 1.5 = 4.8 mm
Leg length of weld for branch = 6.3 mm
Thickness of reinforcing plate te = 19 mm (external only)
Leg length of weld for reinforcing plate = 6.3 mm
Area of replacement required A = dtrF + 2tntrF(1-fr1) [fr1=1]
= +350.00*14.72*1.00
2
= 5150.52 mm

COMPUTE REPLACEMENT AREA:

i) Area A1 (Area available in shell)

d = 350 mm
2(t + tn) = 2*( 17.5+ 4.8)= 44.6 mm

therefore A1 = MAX( 350, 44.6)*(1.00* 17.5-1*14.72)


2
= 974.48 mm

Page 15 of 22
BtKitangN90cumCal4.xls

ii) Area A2 (Area available in nozzle projecting outward)

A2 = smaller of 5*( 4.8-1.79)*1* 17.5


or 2*( 4.8-1.79)*(2.5* 4.8+ 19)*1
= 263.63 or 186.80
therefore A2 = MIN(263.63,186.80)*117.93/137.93
2
= 159.71 mm
iii) Area A3 (Area available in nozzle projecting inward)

h = smaller of 2.5* 17.5 or 2.5*( 4.8+ 19)


= 43.75 or 59.5
= 43.75 mm

A3 = 0
2
= 0 mm

iv) Area A4 (Area available welds)

A4 (A41 & A43) = 2* 6.3^2*1


2
= 79.38 mm

A4 (A42) = 6.3^2*1
2
= 39.69 mm

2
Total A4 = 39.69+ 79.38 = 119.07 mm

max. Dp = greater of 2*d or 2*(Rn + tn + t)


= 700 or 2*(( 350- 1.5*2)/2+ 4.8 391.6
= 700 mm
Diameter of compensation plate provided = 725.6 mm
Width of compensation plate = 171.5 mm wide , 19 mm thick

Dp = 171.5*2+ 4.8*2+ 350 = 702.6 mm

A5 = (MIN( 700, 702.6)- 350-2* 4.8)* 19* 1


2
= 6467.6 mm

Total Replacement area = A1+A2+A3+A4+A5


= 119.07+ 0+159.71+974.48+ 6467.6
2 2
= 7720.86 mm > 5150.52 mm OK

Page 16 of 22
BtKitangN90cumCal4.xls

iii) DESIGN of BRANCH or OPENINGS (UG - 37)


80mm Pressure relief

Rn

tn
d A5
trn
Lp A2 te
h+te tr

h t
A1 A4 D

larger of d or Rn+tn+t A3

INPUT PARAMETERS :
Dia. of shell D = 2882 mm
2
Design pressure P= 1.4 N/mm
Branch dia. d = 80 mm
2
Allowable stress S = 137.93 N/mm
E= 1.00
Actual thickness of shell = 19 mm
Corrosion allowance c = 1.5 mm
therefore t = 19- 1.5 = 17.5 mm
Thickness of shell due to pressure tr = 1.4* 2882/2/(137.93*1.00-0.6* 1.4)
= 14.72 mm
Thickness of branch due to pressure trn = 1.4* 80/2/(137.93*1.00-0.6* 1.4)
= 0.41 mm
Actual thickness of branch provided = 3.5 mm
tn = 3.5- 1.5 = 2 mm
Leg length of weld for branch = 3.5 mm
Thickness of reinforcing plate te = 19 mm (external only)
Leg length of weld for reinforcing plate = 3.5 mm
Area of replacement required A = dtrF + 2tntrF(1-fr1) [fr1=1]
= +80.00*14.72*1.00
2
= 1177.26 mm

COMPUTE REPLACEMENT AREA:

i) Area A1 (Area available in shell)

d = 80 mm
2(t + tn) = 2*( 17.5+ 2)= 39 mm

Page 17 of 22
BtKitangN90cumCal4.xls

therefore A1 = MAX( 80, 39)*(1.00* 17.5-1*14.72)


2
= 222.74 mm

ii) Area A2 (Area available in nozzle projecting outward)

A2 = smaller of 5*( 2-0.41)*1* 17.5


or 2*( 2-0.41)*(2.5* 2+ 19)*1
= 139.26 or 76.39
therefore A2 = MIN(139.26,76.39)*117.93/137.93
2
= 65.32 mm
iii) Area A3 (Area available in nozzle projecting inward)

h = smaller of 2.5* 17.5 or 2.5*( 2+ 19)


= 43.75 or 52.5
= 43.75 mm

A3 = 0
2
= 0 mm

iv) Area A4 (Area available welds)

A4 (A41 & A43) = 2* 3.5^2*1


2
= 24.5 mm

A4 (A42) = 3.5^2*1
2
= 12.25 mm

2
Total A4 = 12.25+ 24.5 = 36.75 mm

max. Dp = greater of 2*d or 2*(Rn + tn + t)


= 160 or 2*(( 80- 1.5*2)/2+ 2+ 17116
= 160 mm
Diameter of compensation plate provided = 201 mm
Width of compensation plate = 57 mm wide , 19 mm thick

Dp = 57*2+ 2*2+ 80 = 198 mm

A5 = (MIN( 160, 198)- 80-2* 2)* 19* 1


2
= 1444 mm

Total Replacement area = A1+A2+A3+A4+A5


= 36.75+ 0+65.32+222.74+ 1444
2 2
= 1768.80 mm > 1177.26 mm OK

Page 18 of 22
BtKitangN90cumCal4.xls

iv) DESIGN of BRANCH or OPENINGS (UG - 37)


50mm Air Inlet

d A5
trn
Lp
A2 te
h+te tr

h t
A1 A4 D

larger of d or Rn+tn+t A3

INPUT PARAMETERS :
Dia. of shell D = 2882 mm
2
Design pressure P= 1.4 N/mm
Branch dia. d = 50 mm
2
Allowable stress S = 137.93 N/mm
E= 1.00
Actual thickness of shell = 19 mm
Corrosion allowance c = 1.5 mm
therefore t = 19- 1.5 = 17.5 mm
Thickness of shell due to pressure tr = 1.4* 2882/2/(137.93*1.00-0.6* 1.4)
= 14.72 mm
Thickness of branch due to pressure trn = 1.4* 50/2/(137.93*1.00-0.6* 1.4)
= 0.26 mm
Actual thickness of branch provided = 2.77 mm
tn = 2.77- 1.5 = 1.27 mm
Leg length of weld for branch = 3 mm
Thickness of reinforcing plate te = 19 mm (external only)
Leg length of weld for reinforcing plate = 3 mm
Area of replacement required A = dtrF + 2tntrF(1-fr1) [fr1=1]
= +50.00*14.72*1.00
2
= 735.79 mm

COMPUTE REPLACEMENT AREA:

i) Area A1 (Area available in shell)

d = 50 mm
2(t + tn) = 2*( 17.5+ 1.27)= 37.54 mm

therefore A1 = MAX( 50, 37.54)*(1.00* 17.5-1*14.72)

Page 19 of 22
BtKitangN90cumCal4.xls

2
= 139.21 mm

ii) Area A2 (Area available in nozzle projecting outward)

A2 = smaller of 5*( 1.27-0.26)*1* 17.5


or 2*( 1.27-0.26)*(2.5* 1.27+ 19)*1
= 88.79 or 45.00
therefore A2 = MIN(88.79,45.00)*117.93/137.93
2
= 38.48 mm
iii) Area A3 (Area available in nozzle projecting inward)

h = smaller of 2.5* 17.5 or 2.5*( 1.27+ 19)


= 43.75 or 50.675
= 43.75 mm

A3 = 0
2
= 0 mm

iv) Area A4 (Area available welds)

A4 (A41 & A43) = 2* 3^2*1


2
= 18 mm

A4 (A42) = 3^2*1
2
= 9 mm

2
Total A4 = 9+ 18 = 27 mm

max. Dp = greater of 2*d or 2*(Rn + tn + t)


= 100 or 2*(( 50- 1.5*2)/2+ 1.27+ 17.5) = 84.54
= 100 mm
Diameter of compensation plate provided = 141.34 mm
Width of compensation plate = 42.9 mm wide , 19 mm thick

Dp = 42.9*2+ 1.27*2+ 50 = 138.34 mm

A5 = (MIN( 100, 138.34)- 50-2* 1.27)* 19* 1


2
= 901.74 mm

Total Replacement area = A1+A2+A3+A4+A5


= 27+ 0+38.48+139.21+ 901.74
2 2
= 1106.43 mm > 735.79 mm OK

Page 20 of 22
BtKitangN90cumCal4.xls

v) DESIGN of BRANCH or OPENINGS (UG - 37)


25mm Sight Glass

Rn

tn
d A5
trn
Lp
A2 te
h+te tr

h t
A1 A4 D

larger of d or Rn+tn+t A3

INPUT PARAMETERS :
Dia. of shell D = 2882 mm
2
Design pressure P= 1.4 N/mm
Branch dia. d = 25 mm
2
Allowable stress S = 137.93 N/mm
E= 1.00
Actual thickness of shell = 19 mm
Corrosion allowance c = 1.5 mm
therefore t = 19- 1.5 = 17.5 mm
Thickness of shell due to pressure tr = 1.4* 2882/2/(137.93*1.00-0.6* 1.4)
= 14.72 mm
Thickness of branch due to pressure trn = 1.4* 25/2/(137.93*1.00-0.6* 1.4)
= 0.13 mm
Actual thickness of branch provided = 2.77 mm
tn = 2.77- 1.5 = 1.27 mm
Leg length of weld for branch = 3 mm
Thickness of reinforcing plate te = 16 mm (external only)
Leg length of weld for reinforcing plate = 3 mm
Area of replacement required A = dtrF + 2tntrF(1-fr1) [fr1=1]
= +25.00*14.72*1.00
2
= 367.89 mm

COMPUTE REPLACEMENT AREA:

i) Area A1 (Area available in shell)

d = 25 mm
2(t + tn) = 2*( 17.5+ 1.27)= 37.54 mm

Page 21 of 22
BtKitangN90cumCal4.xls

therefore A1 = MAX( 25, 37.54)*(1.00* 17.5-1*14.72)


2
= 104.52 mm

ii) Area A2 (Area available in nozzle projecting outward)

A2 = smaller of 5*( 1.27-0.13)*1* 17.5


or 2*( 1.27-0.13)*(2.5* 1.27+ 16)*1
= 99.96 or 43.81
therefore A2 = MIN(99.96,43.81)*117.93/137.93
2
= 37.46 mm
iii) Area A3 (Area available in nozzle projecting inward)

h = smaller of 2.5* 17.5 or 2.5*( 1.27+ 16)


= 43.75 or 43.175
= 43.175 mm

A3 = 2*( 1.27- 1.5)*1* 43.175


2
= -19.8605 mm

iv) Area A4 (Area available welds)

A4 (A41 & A43) = 2* 3^2*1


2
= 18 mm

A4 (A42) = 3^2*1
2
= 9 mm

2
Total A4 = 9+ 18 = 27 mm

Dp = greater of 2*d or 2*(Rn + tn + t)


= 50 or 2*(( 25- 1.5*2)/2+ 1.27+ 17.5) = 59.54
= 59.54 mm
Diameter of compensation plate provided = 101.34 mm
Say provide compensation plate of 35.4 mm wide , 16 mm thick

Dp = 35.4*2+ 1.27*2+ 25 = 98.34 mm

A5 = (MIN( 59.54, 98.34)- 25-2* 1.27)* 16* 1


2
= 512 mm

Total Replacement area = A1+A2+A3+A4+A5


= 27+-19.8605+37.46+104.52+ 512
2 2
= 661.12 mm > 367.89 mm OK

Page 22 of 22