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UNDERSTANDING CODE CALCULATIONS-

DISHED ENDS

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POINTS TO NOTE

THERE ARE DIFFERENT TYPES OF END COVERS AS SHOWN ABOVE,

SEMI ELLIPSOIDAL
TORISPHERICAL
HEMISPHERICAL
CONICAL
FLAT END COVERS
IN PRESSURE VESSELS SEMI ELLIPSOIDAL AND TORISPHERICAL END COVERS ARE
MOSTLY USED.
HEMISPHERICAL DISHED ENDS ARE USED FOR BOILER STEAM DRUMS AND MUD
DRUMS.

DISHED ENDS CALCULATIONS ARE DEFINED BY ID OF THE DISHED END- D

KNUCLE RADIUS IS WHERE STRESSES ARE MORE

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ELLIPSOIDAL DISHED END

ASSUMING ID AS 890 MM KNUCKLE RADIUS AS PER UG 37 WILL BE 0.17D = 151.3

SPHERICAL RADIUS WILL BE 0.9 D = 801. THIS WILL BE USED IN STRETCH
CALCULATIONS

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UG 32 FORMED HEADS

MOSTLY FORMULAE IN APPENDIX 1-4 IS USED FOR DISHED END CALCULATIONS

WE WILL DISCUSS ELLIPSOIDAL AND TORISPHERICAL DISHED END CALCULATIONS .
IMPORTANT DESIGN DATA REQUIRED FOR DISHED END CALCULATIONS
1. D=
INSIDE DIAMETER OF HEAD SKIRT OR
INSIDE LENGTH OF THE MAJOR AXIS OF AN ELLIPSOIDAL HEAD
2. L- INSIDE SPHERICAL OR CROWN RADIUS
3. VALUE OF L CAN BE FOR ELLIPSOIDAL HEADS CAN BE OBTAINED FROM TABLE UG
37

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UG 37 VALUES FOR CROWN RADIUS FOR

ELLIPSOIDAL HEADS

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APPENDIX 1-4 C

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ELLIPSOIDAL DISHED END

D/2h= (900-10)/2*(276-(50+5))
890/2*221
890/442=2.01
K1 FROM TABLE UG 37 = 0.9
L VALUES OF L= DK1= 890*0,9=801
THIS VALUE WILL BE USED FOR
CALCULATING FIBRE ELONGATION.
Rf- KNUCKLE RADIUS = 0.17 D =151.3

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Sample calculation- Elliposidal head

SUB CLAUSE PART NUMBER IN DRAWING 2,3

1‐4 ( b ) INTERNAL DESIGN PRESSURE P MPa 1.2
MATERIAL DESIGNATION ‐ ‐ SA 516 GR 70
1‐4 ( b ) MAXIMUM ALLOWABLE STRESS (AS PERASME SEC.II PART.D) S MPa 138.00
INSIDE DIAMETER OF INSIDE SKIRT D mm 600.00
INSIDE DIAMETER OF INSIDE SKIRTCORRODED
D’ mm 603.20
(D’ + 2 x C ) = (600+ 2 x 1.60)
1‐4 ( b ) INSIDE CROWN RADIUS CORRODED =(0.9 x 600) + 1.60 L mm 541.60
1‐4 ( b ) INSIDE KNUCKLE RADIUS CORRODED = (0.17 x 600) + 1.60 r mm 103.60
UG‐25 CORROSION ALLOWANCE CA mm 1.60
THICKNESS DESIGNATION (NOMINAL) mm 10.00
PROVIDED THICKNESS MINIMUM
ts mm 9.00
(AFTER FORMING CONSIDERING 10% THINNING ALLOWANCE)
FACTOR M
FACTORD/2h
FROM TABLE K 1.00
= 600 / 2 * 150 = 2.00
1‐4.1
UW‐12 WELD JOINT TYPE TYPE‐1
UW‐12 JOINT EFFICIENCY(AS PER UW‐12(d).SEAMLESS HEAD E ‐ 0.85
ts/L =8.00/ 540.00 ts/L 0.00148148
SINCE ts/L >=0 .002 APPENDIX 1‐4 (d) IS APPLICABLE , AND APPENDIX 1‐4(f) NEED NOT BE MET

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ELLIPSOIDAL HEAD CALCULATION

MINIMUM REQUIRED THICKNESS OF HEAD [REF. APPEXDIX 1‐4 ( d )]

MINIMUM REQUIRED THICKNESS
APPENDIX
t = P * D *K/ (2* S*E ‐ 0.2 * P) t mm 3.08858
1‐4 (d)
= 1.2*603.20* 1.00 / (2*138.00*0.850‐ 0.2*1.2)
MINIMUM THICKNESS + CORROSION ALLOWANCE = 3.08858 + 1.60 ‐ mm 4.68858
MINIMUM THICKNESS REQUIRE AS PER UG‐16(b)(4)
UG‐16(b)(4) ‐ mm 2.500
= 2.5 mm (3/32 inch)
MINIMUM THICKNESS REQUIRE AS PER UG‐16(b)(4) + CORROSION
t mm 4.100
ALLOWANCE = 2.500 + 1.60
GOVERNING THICKNESS GREATER OF MINIMUM REQUIRED
THICKNESS AS PER APPENDIX 1‐4 d, UG‐16(b)4 AND UG‐32 (b) ‐ mm 4.68858
(MAXIMUM OF 4.68858 , 4.100 )
GOVERNING THICKNESS INCLUDING CORROSION ALLOWANCE ‐ mm 4.68858
PROVIDED HEAD THICKNESS IS ADEQUATE

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EXTREME FIBRE ELONGATION

- EXTREME FIBER ELONGATION FOR DISHEDEND=((75xt)/Rf)x(1‐(Rf/Ro))=((75x10)/103.6)x(1‐(103.6/INFINITY))=7.24 %
PART MATERIA THICKNESS OD AFTER FINAL C/L ORIGINAL EXT.FIB ELONG S.R. REQD
L ACTUAL FORMING RADIUS (Rf) C/L RADIUS % (YES /NO)
t(mm) mm (Kr) mm (Ro) (Cr) mm
DISHED SA 516 GR 8 616 103.6 INFINITY 7.24 % NO
END 70
- PLATE THICKNESS TO BE VERIFIED WITH ACTUAL PLATE THICKNESS.
- ELONGATION IS GREATER THAN 5%.
- SO, POST FORMING HEAT TREATMENT IS NOT REQUIRED.
SR NO CONDITION CONDITION EXIT (YES/NO)
1 THE VESSEL WILL CONTAIN LETHAL SUBSTANCES EITHER NO
LIQUID OR GASEOUS.
2 THE MATERIAL IS NOT EXEMPT FROM IMPACT TESTING BY NO
THE RULES OF THIS DIVISION OR IMPACT TESTING IS
REQUIRED BY THE MATERIAL SPECIFICATION.
3 THE THICKNESS OF THE PART BEFORE COLD FORMING NO
EXCEEDS 16mm
4 THE REDUCION BY COLD FORMING FROM THE AS ROLLED NO
THICKNESS IS MORE THAN 10%
5 THE TEMPERATURE OF THE MATERIAL DURING FORMING IS NO
IN THE RANGE OF 120 DEG C TO 480 DEG C.
SINCE NONE OF THE ABOVE CONDITIONS EXIST; HEAT TREATMENT NOT REQUIRED FOR DISHED END.

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FIBRE ELONGATION HAPPENS HERE

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HYDROSTATIC TEST CHECK

 HYDRO TEST CHECK FOR DISH MATERIAL: LHS & RHS SIDE THICKNESS OF DISH
END:10 mm
 2 x S x E = [((P x D)/ t) + (0.2 x P)]
 2 x S x 0.85= [(1.56 x 301.6) / 10) + (0.2 x 1.56)] = 47.3616 MPa
 S = 47.3616 / (2 x 0.85 ) = 27.85 MPa
 ALLOWABLE YIELD STRENGTH OF THE MATERIAL AT ITS HYDRO TEST
TEMPERATURE (20 Deg C)= 260 MPa FROM ABOVE, THE MINIMUM YIELD
STRENGTH OF THE DISH MATERIAL IS GREATER THEN ACTUAL, SO, THE ABOVE
DESIGN IS ACCEPTABLE.
 AS PER UG 99b S SHALL BE LESS THAN 90% OF YES

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DETERMINATION OF HYDROSTATIC TEST PRESSURE

SHOP TEST PRESSURE DETERMINATION FOR VESSEL BASED ON DESIGN PRESSURE AT TOP OF VESSEL (P) AND DESIGN
TEMPERATURE (T) AS PER CLAUSE NO. UG‐99(b).

P : DESIGN PRESSURE (BOTTOM OF VESSEL) = 1.2 MPa g

MAWP : MAXIMUM ALLOWABLE WORKING PRESSURE = 1.2 MPa g (AS PER UG‐99, FOOT NOTE – 34)
Tc : DESIGN TEMPERATURE = 60 Deg C
DESIGN
STRESS @ TEST STRESS @ DESIGN STRESS RATIO
PRESSURE
SR. NO. COMPONENT TYPE TEMP. TEMP. S (MPa)
P
Sa (MPa) Sa / S
(MPa g)
1 SHELL 1.2 138.00 138.00 1.00
2 DISH END 1.2 138.00 138.00 1.00
3 NOZZLE PIPE 1.2 118.00 118.00 1.00
4 NOZZLE FLANGE 1.2 138.00 138.00 1.00

STRESS RATIO = Sa / S = 118/118 = 1.00 (TAKEN LEAST STRESS RATIO OF SR.NO. 1 to 4)

HYDROSTATIC TEST PRESSURE = 1.3 x P x Sa / S = 1.3 x 1.2 x 1 = 1.56MPa g (15.9073kg / cm²

g) AS PER THE CLIENT REQUIREMENT HYDRO TEST PRESSURE IS TAKEN 1.3 TIMES OF DESIGN
PRESSURE. SO, HYDRO TEST PRESSURE = 1.3 x 1.2
= 1.56MPa g (15.9073kg / cm²
g)

AS PER UG-99, FOOT NOTE – 34 THE MAXIMUM ALLOWABLE WORKING PRESSURE

MAY BE ASSUMED TO BE THE SAME AS THE DESIGN PRESSURE WHEN CALCULATIONS
ARE NOT MADE TO DETERMINE THE MAXIMUM ALLOWABLE WORKING PRESSURE.
HENCE, HERE IN THIS CASE DESIGN PRESSURE AND MAWP TAKEN SAME

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ELLIPSOIDAL DISHED END-ANOTHER

EXAMPLE
Max. Allowable Working Pressure at given Thickness,
corroded [MAWP]:
GIVEN THICKNESS – 5MM
CORROSION ALLOWANCE= 1,5MM
GIVEN THICKENSS UNDER CORRODED CONDITION = 3.5
MM
= (2*S*E*t)/(Kcor*Do-2*t*(Kcor-0.1)) per Appendix 1-
4 (c)
= (2*1406.14*1.00*3.5000)/(0.996*900.0-
2*3.5000*(1.00-0.1)) = 11.063 kgf/cm

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ELLIPSOIDAL DISHED END

Maximum Allowable Pressure, New and Cold [MAPNC]:

= (2*S*E*t)/(K*Do-2*t*(K-0.1)) per Appendix 1-4 (c)
= (2*1406.14*1.00*5.0)/(1.000*900.0-2*5.0*(1.0-0.1)) = 15.782 kgf/cm²
Actual stress at given pressure and thickness, corroded [Sact]: =
(P*(Kcor*Do-2*t*(Kcor-0.1)))/(2*E*t)
= (7.700*(0.996*900.0000-2*3.5000*(0.996-0.1)))/(2*1.00*3.5000) =
978.692 kgf/cm²

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ELLIPSOIDAL DISHED END

MDMT Calculations in the Knuckle Portion:

Govrn. thk, tg = 5.000 , tr = 2.494 , c = 1.5000 mm , E* = 1.00
Stress Ratio = tr * (E*)/(tg - c) = 0.713 , Temp. Reduction = 16 °C
Min Metal Temp. w/o impact per UCS-66, Curve B -29 °C
Min Metal Temp. at Required thickness (UCS 66.1) -45 °C

IT MEANS FOR DESIGN METAL TEMPERATURE UPTO -45, THERE IS NO NEED FOR
IMPACT TEST.
BUT WHEN IT GOES BELOW -45 DEG.C, THEN IMPACT TEST IS REQUIRED.
WHY THIS IS CALCULATED?
KNUCKLE PORTION WILL HAVE A DIFFERENT THICKNESS THAN THE REST OF THE
DISHED END. STRESS RATIO WILL BE DIFFERENT.

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ELLIPSOIDAL DISHED END

MDMT Calculations in the Head Straight Flange:

Govrn. thk, tg = 8.000 , tr = 2.512 , c = 1.5000 mm , E* = 1.00
Stress Ratio = tr * (E*)/(tg - c) = 0.386 ,
Temp. Reduction = 63 °C
Min Metal Temp. w/o impact per UCS-66, Curve B -29 °C
Min Metal Temp. at Required thickness (UCS 66.1) -48 °C

WHAT IS TEMPERATURE REDUCTION -63 °C?

THIS IS THE REDUCTION YOU CAN TAKE CREDIT FOR AVOIDING IMPACT TEST.
IF YOUR MINIMUM DESIGN METAL TEMPERATURE IS SAY, 25 DEG.C THEN YOU CAN
GO UPTO 25+(-63)= -38 DEG.C

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THE SAME COMMENT APPLIES FOR TOP DISHED END ALSO

DESIGN ISSUES WITH DISHED ENDS

REFER CALCULATION PAGE NO.11. BOTTOM DISHED

END CROWN RADIUS IS GIVEN AS 410 MM AND
KNUCKLE RADIUS AS 51 MM. DRAWING INDICATES
10% KR. PLEASE CLARIFY. SHOW CROWN RADIUS
ALSO IN THE DRG.
AS PER DRAWING DISHED END HEIGHT IS 137 MM FOR
TOP BOTTOM DISHED END AND 172 MM FOR TOP
DISHED END. EXCLUDING SF AND THICKNESS THE
INTERNAL HEIGHT IS 97 MM. IN CALCULATIONS

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THE SAME COMMENT APPLIES FOR TOP DISHED END ALSO

DESIGN ISSUES WITH DISHED ENDS

• INSIDE CORRODED HEAD DEPTH IS SHOWN AS

110.9MM.PLEASE CHECK VALUES TAKEN IN
CALCULTIONS AND DRG. AND CORRECT AS
REQUIRED. THE SAME APPLIES FOR TOP DISHED
END ALSO.
• CALCULATION SHEET 35 FOR TOP DISHED AND
PAGE 31 FOR BOTTOM DISHED END INDICATES
15.789% . AS THIS IS GREATER THAN 5% POST
FORMING HEAT TREATMENT IS REQUIRED. THIS IS
NOT INDICATD IN THE DISHED END DRAWINGS
• DESIGN CALCULATION SHEET 5 INDICATES TORI
HEAD CROWN RADIUS AS 2016MM
DRAWING INDICATES ICR 2020.

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QUESTIONS

1. A 2: 1 ellipsoidal head of P1 Gr 2 is cold formed. The internal diameter is

1000mm and the thickness is 50mm.The knucke radius is 170mm What is the fiber elongation?
a) 12
b) 14
c) 19 You can use the following link
d) 22 Calculation of forming strain of cylinders according to
ASME Code Section VIII Division 1

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