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PROCEDURE 2 Genera Design 95 0) _ESTIMATING WEIGHTS OF VESSELS AND VESSEL COMPONENTS Estimating of sessel engucesing, In the conceptual plas vweights ar Lights of vessels is an important aspect oF prajeet stimated in onder to determine costs ane bud gets for equipment, fowndations, and Estimated accurate bids trom supple portation ches alsa Delp to yet more Acennate weights are necessiny for the design af the vessel itsell to determine forces and There ave a nvanber of different types of wwuights that are calelated, Bach weight s6 used far diferent parposes 1, Fabricated weight: Total » sted in the 2. Shipping weight: Fabrication weigh such as shipping saddles abrication weight plus any sseight plas any weight akled for shipping purpases 4, Erection weight installed! for ho ervetion of the equipment, such 3s ars insulation, irepeoating, piping, ladles, plattorns. 4, Empty weight: The overall weight of the wesso! sting on the fonnlation, fully c-essod, seating for aperating Tigi 5. Operating weight: Enply wight plos Tiga weight 8. Test weight: This lest weil tat #8 the ny operating ight oan be esther shop or fll ssel fll of water There age a umber of ways t0 estimate the weights 0 Vessel weights omputer design programs. These nny typieally calculate the sole of svetal far the ressel sell vl eal an vessels, depending on the ase ley expired can he estate hase aukl weights for supports, nacales trays, wid oer comnponients, Another fst and easy way 10 1 the volume of moral inthe: sell and uel isto ase the sit tor the required thickness a posmds per sqpare foot wldition to the base weight of mata sn the shel hheaks, the designer must inclode an allowance for plat werages per Table 218 The nll never roll the eset specified thickness woud he ine square feet and) multiply this by the um bs here the possibility of being below weed Vis " The The thickness. ‘The safety marg bay the sed te percentage alate average varies by the thiekiess F the material In aridition to the pl rnunactarer sure thst the soeas, Depending Un thick rnined fe fabricator tor he lowes to the head ¢ al wicets the ini also ads thir wi thickness i all on the type of heal, the daneter, ad s required. « thinning allesanee ein: be deter This ean be hhemi-heads over 4 in ws much as 1.5 in, for fa thes! ring thes forming process bal way rnost ork, (On g typical spun 2:1 8.F. head, the straight Mange sal get thicker and the knuckle will get thinner duc to cold working The creer of the low” eo lve ares of hiead shite remain about the Thesefore the completed hea the initial thickness of the material being formed Alter the weights ef a the eompanents are adddest total set, am adi ntage 's typically alder 69 iow for tli eon ling Te fr rents nd pival pesvon tages are as follows 50,000 Th aed 105 59000-7500 Weed Nee 5,090 108,000 Th del 6% 140,000 Ih sald 35, The wight of ange mdsievl component ca easly be hhasor) oi the olin: of she material times ty weight given in Table 2-18, Av ry caleuating Che surf ress tines the density. The designer need calla tonite shape can be a times the thick aly re sels of 0.2835 iin mber the densty af steel fir mast “eo de tortnine any weight, For vessels of components of other 1 the factor for torias, esther the density oF that material that material gelative to cutbon stool ean be usted "These wales are ak listed ithe fellowing tables 96 Pressure Vessel Design Manual Formulas for Calculating Vessel Weights Data Dn. =mean vessel diameter, in Jessel length, tangent to tangent, in Jessel thickness, in rea of cone, in? d=density of matarial, vin.* 1.0 Weight of shot W~xDythd WH =97.7 Drath 2.0 Weight of heads hemi — 1.57D3td 21 SE — 1.084086 100% 6% = 09508 Cone ~ Acid Calculation of Weight of Weld Neck Flange Data T = thickness of tlange (O=tlange OD D =bot hole diameter H =hub height G=hub thickness at small end W = width of hub B=ID of flange V=voluma, in? d= density of material, tin.® N-number of bolts‘noles Ox Br 1 [Era 3. 0.5{(B | 2G +W)xWH)=(+) “2 5.Va1+243-4= 6. woight =V xd For carbon stool =O89DRLt 10.68 Dat = 0.44508 0.30708 = 0.26908 0.2833 Act /® General Design 97 Table 2-18 is of Carbor Steel Plate ard Stainless Sto! Shot, PSF - | west oe Weight we Faw Woot | Srerweaht | overoigt | im | eww | Sverre | Overeist oa a] See 10% or =? zest [ae wee em 125 ses Fi au [ Tetoce dve seat woot wren a8 oy vs eck a 2h a8 “Ga | 28 2aGR 0686 wes) asa oats 1508 [os oe: % Overweight = bead on suarded n oetnce add me Padres alee gunaree ninmm mars 98 Pressure Vessel Design Manual Table 2-19 Wight of Flanges, 2. 241. (by ‘S20 in) Fain ° 38 2 e a 2 i = 8 7 1 1 0 r ea 90 nD 5t 1075 3 10 25 2 2 28 — u 120 ae fe ™0. vat oD 2 8 120 i 1 “08 St “aa 2s 20 = 0 20 “re SS ve neck te mht ofa wee ex ange 2 uate ate back hag be tae Taple 2-20 Dbenersions and Weighs of Lane ameter Flanges, 269.9 6010, ASME 16.47, Soins A Seen) T ~omensions 0 son 1s ‘37% ‘eet ion a) seo 1 ao ‘3 0 18 206 62 a9 r 1s ory 22 we ~T ee 23 335 =u 0 30% 208 30 oom 0 wat 2st ‘sa 335 r 160 “aa 26 coe se 0 Ta 2 ai ae Cy 50 9: 204 es 5008 Te ato: 3 708 eet = so 075 ee General Design 40 50 aS 405 130 99 400 Preseure Vessel Design Maru Table 221 Wiegnis of Noles and Manways, 1. ta 60in T i pop pop eo Ef ese Le « | « a ses 2 a * ee mf = | 2 a Ey a ‘92 zor ES “eo | we 0 1088 fee ea fee 1 ‘07 158 8 a8 310, 380 2 78 { sop 287 4600 «| 7 m=) we = Ea we s[#[e|[a[e “ » [s[s|sis « [2 2 ee ee a0 © to S| ss | i = 1. Weghe naude pps ane Ne General Design 101 Table 2-22 Wilghts of Vale Trays, PSF |p es «| Atoy - es. ‘aor cs ‘Moy roe sieve The soarecme® seas campansit she wear cowreamire nares Table 2-28 osteo Tay Suge a Domeamer Ba) tas ea hey] my [es iy) Bm) es soy z % a Te re a a =] “a a B [we 16 12 os ze 4 t 3 o ve 202 ve 26 386 208 | [ee 2 2 18 2 1s 2 | ae ae ® ee 2 awe eae ae % ie ® a 7 e a i me Tay sua tgs nt cocoa ting Bae 88 Csi? Shiny Se" 3 Table 2-24 “Thien owen for Hoss cary @ oe LC ie 102 Proscure Yee! Design Marval Table 2-25 Wiahts a Fie (=UF) cmon _Behedte , [>= ]* [> «fe | os [ » [1m | wm | | w | os om | owe a ae a [ies Teme we [a Se ee General Design 103, Tonle 2.26 wn arty sual ots Me Fer to0Pecue ae o wwe [ew fo Tw ie [oe] fo Dw wm Don > fe fel] f-]-tt 1. 2] = ie [ws i » [» |=! ele}, >| Pt I - = [oe i ope tm fat t = foe = Sh te 4 —f too} yy a ee ve tow [ap ame — ea ~ = Dw pep awe pe poe) fp LC a foe) wee | w]e | me | el ow me = Tt Se mf te [om [mf oe fe | oe : L eee ee Ce J] ms - SSC] ep epee eee] = a os ! or oo) te 20 Ce fe | we [eee fa | oe |e T = Te se a D =m re E I pee = | 404 Prossure Vessel Docign Manuat “able 227 lg of Saton ad Bases (0) wae a8 | kes a8 oem satin Sante | tn) Ske supe 0 - Bo x 0 a { 400 #0 EJ ® i ves 20 wae 7st ‘0 ms = 78 ase me eo 0 0 te re 2 = ne esto ero 2 8 700 360, ~ 240, +7500, 600 1360 se i 220 1 t Tablo 2:28 Dons of Varous Matos co din vor Weis Adee we 400 SST 0283 | 0.93 | Peal one a ua tos 0 oar oe sos Hustetioy 630 0287 513 105 Cast iron 0288 46 ‘ost } General Design 105 Ladder and Platform (L&P) Estimating “The following is a isting of average breakdowns, both cost and weight, for ladders and platforms (LAPS) for refinery-type projects. Note that LAPS include pipe supports, guides, and davits as well as ladders and platforms case this data is “average,” its meant to be averaged over an enlire project and not to ind the cost or weight of any individual tem or vessel 1. Estimated Price Breakdown: «Platforms 30PSF @ $2.80! = $75Isq tt | + Ladders: Caged 2éibiht @ $3.00" = $72 Uneaged Alby @ $2.35" — Seam = Mise, 2.50!16 Handrail) Straight saat Cireular seaitt 2. Estimated Weight Breakdown (as a breakdown of the total quantity) Item Percentage (%) Cast (Sib) Plattorms: Creular 30-35% $2.50 Rectangular 50-55% 32.00 Ladders: Caged 79% $3.00 Uncaged 23% 32.25, Mise. 510% $2.50 Total 100% 3. Average Cost of L&Ps (assuming 100 tons) Item Weight (tons) Cost ($1000), % (cost) Platt Cire 31 188 34 Platt Rect 5 204 45 Lagder Caged 8 48 " Ladder (uncaged) 25 11.25 2 Misc. 78 378 8 1007 $455.75, +00% | Average Silb ~455,75/100 x 2 = $2.28 4. Average % Detailed Weight Breakdown for Trayed Column: Item Large: Mediuin Ladders 13.1% 9.3% Framing 33.3 44.2 Grating 253 235 Handrailing 132 97 Pipe supports 30 Baiting 25 Davits at Mise. os 100% 5, If no estimate of LAPs is available, an ROM weight estimate can be determined by taking 5% of the overall ‘vessel weights for the project as a total LAP weight. A percentage breakdown may be made of this overall value as noted. 106 Prossure Vessel Design Manual ‘Notes 1. Miscellaneous woights: a, Concrete 144 PCF b. Waler 62.4 PCF © Gunnite 125 POF 6 Refractory 65-135 POF Calcium silicate insulation 18.8 PCF 2. Estimate weight of liquid holdup in random packed columns as 13% of volume. 3. Weights of demistor pads and support grids is as follows: Type Density (PCE ai 5 826 72 431 9 221 10,8 (mutipioce) 12 (single piece) 1 Gnd 3 PSF Estimate weights of platforming as follows Type Weight Circular platform 30 PSF Rectangular piatform 20PSF Ladder witn cage 2e PLE Ladder without cage 10PLF Weight of anchor chairs per anchor bolt | ( each, lo): Anichor Bott Dia (in 1 1.25 12 150 15 175 20 20 38 2.25 48, 25 6a __| REFERENCES ASME Boller and Pressure Vessel Code, Seetion VIEL Division 1, 1995 Edition America Society of Mechanical Frigneers 2 Maer, J. Bs Theory and Design of Moder Pressure Vesely, 2unl Futon, Vann Nosteand Reinbol 3. Bednar HI. Pressure Vessel Desiga Ha Rostrnd Reinhold Co, 198 4. Modern Flange Design, Tih Edition, Bulletin 502, ‘Tavlor Forge International, Ine 5. Brownell, LF. amd Youn, B, HL, Process Eguipn Design, Joly Wiley and Sons, Inc, 1959, Soction 62, pp. IS7-159 5. Mats, GoW. and Lang. He AL “The Stresses in a Pressure Vessel with a Blut Head Closage,” ASME Paper No. 5L-A-146, 1951 FT Burgreen, D., Design Methods reer Plant Strnctures, C S Bladyett OW un af Weld J. F Lincoln Are Welding Posindation, 19 33 . Manual of St Press, 1 Constmetian, Sth Felton, Institute of Stee] Constrvetion, Ine, 1980, 10 ASME: Hoilor and Prossire Vessel Cade, Section VII Division 2, 1995 Eelition, Aerean Society of Mechanica) Engineers 19 Radvinowly, Bo 1, "Bolt Design for Repeat Loading.” Mochine Design (Noveanber 1952), pp. 1354 Meyer, G. ancl Strelow, D., “Simple Diagrams Nid in Awilysing Forces in Bolted Joints Engineering (Jannary 1972}, pp. 25-35 Horsch, 1 "Solve Complicated! Barc: Problems with Simple Dis Avweinhly. Enginorring (December 1972), pp Levinson, L$ States and Strength of Motertals Prentice Hall, Ine, 1971, Chapter 16, Twoitsky, M.S. Pubulur Steel Structures, Theory and Design, 2nd KSition, James F. Lincoln Are Welding Foundation, 1990, Chapter 2 Dambssi | Tnteraetion Analysis of Cylindrical sels tor Estersal Pressure and Imposed Lou, ASME. ‘Technical’ Paper S@-C2PVP-2, American Society of Mechanical Engineres, 199 Haney. | F. Theory and Design of Pressure Vessels fan Nostrand Reinhold Co, 1985, Chapter 8 AWWA D-10096, Welded Stor? Tanks fir Wate Storage, American Water Works Association, 6568 W ‘Quiney Ave, Denver, CO $1235, Soetion 40 MoH, and Fare, J. Ha Strectural analysts Design of Process Riuipmient 2nd kedition, John Wey and Sons, 1989, Chapter 5 Bednar, HH. Vessel Handbook, 2nd Edition, Vian Nostrand Reinhold Co., 1886, yp. 45-55 Kems, GD, "New charts speed dni sizing Petraeus Refiner, Jule 1960. Jowadekar SP "Consider corrosion aa 1D caleulatien,” Chemiea! Engineering, December 15 13st Genera! Design 107. Abakians, K., “Nomographs eve optinonny vessel size Hydrocarbon Brocessine aul Petsolown Befiner, Jane 1983 Gonunda, A, “How t0 sae liguid-vapor separators, Chemica! Engineering, May 4, 108 Brownell, Lo E. wad Younyg. EH. Pr Design, Join Woley & Sons, Ine sy Eipuipnient 9, Chapter 5