Attachment #4

Sample Strength Calculation for

Bellows Type Expansion Joint
 Rabigh Phase II Petrochemical Project Petrochemical-1 Package (CP1) ITEM NO.: P240-E-1023 REV. NO.: 2
P.O. NO.:P-203-1420-2091-KR PAGE 166 OF 229
------------------------------------------------------------------------------------------

SIZE : I.D 1600 SHEET : OF

ITEM No. : P240-E-1023 NORMAL OPERATING REV No. : 0
BELLOWS DESIGN ANALYSIS
ASME SECTION VIII DIVISION 1, APPENDIX 26 (2010 ED.+2011 ADD.)
REINFORCED TYPE (SINGLE)
DESIGN PRESSURE D.P= 48.000 (kg/cm2) 4.707 Mpa
DESIGN TEMPERATURE D.T= 400 ℃
BELLOWS MATERIAL SB443(N06625)
ALLOWABLE STRESS (Hot & Cold) Sabc= 22.077 (kg/mm2) 216.501 N/mm2
Sabh= 20.311 (kg/mm2) 199.181 N/mm2
MODULUS OF ELASTICITY(Hot & Cold) Eo= 21092.596 (kg/mm2) 206847.711 N/mm2
Eb= 17453.421 (kg/mm2) 171159.586 N/mm2
REINFORCING RING MATERIAL SA266-4
2
ALLOWABLE STRESS (Hot & Cold) Sarc= 14.062 (kg/mm ) 137.898 N/mm2
Sarh= 10.327 (kg/mm2) 101.273 N/mm2
MODULUS OF ELASTICITY(Hot & Cold) Erc= 20670.745 (kg/mm2) 202710.757 N/mm2
Er= 17453.421 (kg/mm2) 171159.586 N/mm2
MEAN METAL TEMPERATURE Shell= 5.00 Tube= 149.00 ℃
DIFFERENTIAL THERMAL GROWTH
= (1.152E-05*(5-21)-1.242E-05*(149-21))*4877 Ex= -8.653 mm
CROSS SECTIONAL METAL AREA OF ONE REINFORCE RING Ar= 3000.0 mm2
RATIO OF THE INTERNAL PRESSURE FORCE RESISTED BY THE BELLOWS
= A*Eb/(Ar*Er) R1 = 0.156
CONVOLUTION HEIGHT FACTOR FOR REINFORCED FACTOR
= 0.3-(100/(0.6*(D.P*14.223)^1.5+320))^2 Cr= 0.2999177
DESIGN MOVEMENT CONDITION
COND-----------------AXIAL(mm.)------------------------------LATERAL(mm.)----------------------------------ANGULAR(deg)----------CYCLES-
EXT.= 8.653 COMP.= 0.000 Y= 0.000 Z= 0.000 Θ= 0.000 1000
-(A) IS PRIMARY DESIGN CONDITION
C1= q/(2*w)= 0.5 C2=q/(2.2*(Dm*tp)0.5)= 0.4215
FACTOR 'Cp', 'Cf' & 'Cd' Cp= 0.658 Cf= 1.612 Cd= 1.773
CYLINDRICAL TANGENT INSIDE DIAMETER Db= 1686 mm
MATERIAL THICKNESS t= 3.175 mm
NOMINAL THICKNESS OF BELLOWS AFTER FORMING
(-)10% REDUCTION DUE TO LOW MATERIAL & MANUFACTURING TOLERANCE
= 0.9*t*(Db/Dm)^0.5 tp= 2.80 mm
NUMBER OF PLIES n= 1 Plies
NUMBER OF CONVOLUTIONS N= 3 corr.
PITCH OF BELLOWS CONVOLUTION q= 65 mm
HEIGHT OF BELLOWS CONVOLUTION w= 65 mm
FREE LENGTH OVER CONVOLUTIONS = (q*N) Lb= 195 mm
-EQUIVALENT AXIAL MOVEMENT PER 1(ONE) CONVOLUTION-
Δq TOTAL= 2.88 AXIAL= 2.88 LATERAL=0.00 ANGULAR=0.00 mm
REINFORCING MEMBER CIRCUMFERENTIAL MEMBRANE STRESS DUE TO PRESSURE
= D.P*Dm*q/(200*Ar)*(1/(R1+1)) S'2= 7.890 (kg/mm2) 77.378 N/mm2
S'2 <= Cwr*Sarh S'2= 77.378 <= Cwr*Sarh= 101.273 O.K!

HKR Co.,Ltd. Prg No.: HKR-BELL-A-R

 Rabigh Phase II Petrochemical Project Petrochemical-1 Package (CP1) ITEM NO.: P240-E-1023 REV. NO.: 2
P.O. NO.:P-203-1420-2091-KR PAGE 167 OF 229
------------------------------------------------------------------------------------------

SIZE : I.D 1600 SHEET : OF

ITEM No. : P240-E-1023 NORMAL OPERATING REV No. : 0
BELLOWS DESIGN ANALYSIS
BELLOWS TANGENT CIRCUMFERENTIAL MEMBRANE STRESS DUE TO PRESSURE
= D.P*(Db+n*t)^2*Lt*Eb*κ/(200*(n*t*Eb*Lt*(Db+n*t)+tc*κ*Ec*Lc*Dc)) S1 = 4.863 (kg/mm2) 47.689 N/mm2
S1 <= Sabh S1= 47.689 <= Sabh= 199.181 O.K!
CIRCUMFERENTIAL MEMBRANE STRESS DUE TO PRESSURE
= D.P*Dm*q/(200*A)*(R1/(R1+1)) S2= 7.890 (kg/mm2) 77.378 N/mm2
S2 <= Cwb*Sabh S2= 77.378 <= Cwb*Sabh= 199.181 O.K!
MERIDIONAL MEMBRANE STRESS DUE TO PRESSURE
2 2
= (0.85*D.P*(w-Cr*q))/(200*n*tp) S3= 3.314 (kg/mm ) 32.496 N/mm
MERIDIONAL BENDING STRESS DUE TO PRESSURE
= 0.85*D.P/(200*n)*((w-Cr*q)/tp)^2*Cp S4= 35.431 (kg/mm2) 347.457 N/mm2
S3 + S4 <= Kf*Sabh, Kf=3.0 (as formed bellows) S3+S4= 379.95 <= Kf*Sabh= 597.54 O.K!
MERIDIONAL MEMBRANE STRESS DUE TO DEFLECTION
= Eb*tp^2*Δq/(2*(w-Cr*q)^3*Cf) S5= 1.300 (kg/mm2) 12.751 N/mm2
MERIDIONAL BENDING STRESS DUE TO DEFLECTION
= 5*Eb*tp*Δq/(3*(w-Cr*q)^2*Cd) S6= 64.025 (kg/mm2) 627.868 N/mm2
CALCULATED TOTAL STRESS
= 0.7*(S3+S4)+S5+S6 St= 906.586 N/mm2
CALCULATED FATIGUE LIFE CYCLES
= [Ko /{( kg*(Eo/Eb)*St)-So}]^2 Nalw= 3570 Cycles
AXIAL STIFFNESS
= π/(2*(1-vb^2))*(n/N)*Eb*Dm*(tp/(w-Cr*q))^3*(1/Cf) Kb= 2566.476 (Kg/mm) 25168.534 N/mm
MAXIMUM DESIGN PRESSURE BASED ON COLUMN INSTABILITY
= 0.3*π*kb/(N*q)*100 Psc= 1240.434 (kg/cm2) 121.645 Mpa
EFFECTIVE DIA. OF BELLOWS
= Db+w+t*η Dm= 1754.175 mm
PRESSURE THRUST
= Dm2*π*D.P/400 Pt= 1160050.7 (Kg) 11376210.7 N

HKR Co.,Ltd. Prg No.: HKR-BELL-A-R

 Rabigh Phase II Petrochemical Project Petrochemical-1 Package (CP1) ITEM NO.: P240-E-1023 REV. NO.: 2
P.O. NO.:P-203-1420-2091-KR PAGE 168 OF 229
------------------------------------------------------------------------------------------

SIZE : I.D 1600 SHEET : OF

ITEM No. : P240-E-1023 SHELL SIDE FULL VACUUM REV No. : 0
BELLOWS DESIGN ANALYSIS
ASME SECTION VIII DIVISION 1, APPENDIX 26 (2010 ED.+2011 ADD.)
REINFORCED TYPE (SINGLE)
DESIGN PRESSURE D.P= 1.050 (kg/cm2) 0.103 Mpa
DESIGN TEMPERATURE D.T= 149 ℃
BELLOWS MATERIAL SB443(N06625)
ALLOWABLE STRESS (Hot & Cold) Sabc= 22.077 (kg/mm2) 216.501 N/mm2
Sabh= 22.076 (kg/mm2) 216.492 N/mm2
MODULUS OF ELASTICITY(Hot & Cold) Eo= 21092.596 (kg/mm2) 206847.711 N/mm2
Eb= 20318.639 (kg/mm2) 199257.779 N/mm2
REINFORCING RING MATERIAL SA266-4
2
ALLOWABLE STRESS (Hot & Cold) Sarc= 14.062 (kg/mm ) 137.898 N/mm2
Sarh= 14.062 (kg/mm2) 137.898 N/mm2
MODULUS OF ELASTICITY(Hot & Cold) Erc= 20670.745 (kg/mm2) 202710.757 N/mm2
Er= 19896.787 (kg/mm2) 195120.825 N/mm2
MEAN METAL TEMPERATURE Shell= 5.00 Tube= 149.00 ℃
DIFFERENTIAL THERMAL GROWTH
= (1.152E-05*(5-21)-1.242E-05*(149-21))*4877 Ex= -8.653 mm
CROSS SECTIONAL METAL AREA OF ONE REINFORCE RING Ar= 3000.0 mm2
RATIO OF THE INTERNAL PRESSURE FORCE RESISTED BY THE BELLOWS
= A*Eb/(Ar*Er) R1 = 0.159
CONVOLUTION HEIGHT FACTOR FOR REINFORCED FACTOR
= 0.3-(100/(0.6*(D.P*14.223)^1.5+320))^2 Cr= 0.2204839
DESIGN MOVEMENT CONDITION
COND-----------------AXIAL(mm.)------------------------------LATERAL(mm.)----------------------------------ANGULAR(deg)----------CYCLES-
EXT.= 8.653 COMP.= 0.000 Y= 0.000 Z= 0.000 Θ= 0.000 1000
-(A) IS PRIMARY DESIGN CONDITION
0.5
C1= q/(2*w)= 0.5 C2=q/(2.2*(Dm*tp) )= 0.4215
FACTOR 'Cp', 'Cf' & 'Cd' Cp= 0.663 Cf= 1.701 Cd= 1.757
CYLINDRICAL TANGENT INSIDE DIAMETER Db= 1686 mm
MATERIAL THICKNESS t= 3.175 mm
NOMINAL THICKNESS OF BELLOWS AFTER FORMING
(-)10% REDUCTION DUE TO LOW MATERIAL & MANUFACTURING TOLERANCE
= 0.9*t*(Db/Dm)^0.5 tp= 2.80 mm
NUMBER OF PLIES n= 1 Plies
NUMBER OF CONVOLUTIONS N= 3 corr.
PITCH OF BELLOWS CONVOLUTION q= 65 mm
HEIGHT OF BELLOWS CONVOLUTION w= 65 mm
FREE LENGTH OVER CONVOLUTIONS = (q*N) Lb= 195 mm
-EQUIVALENT AXIAL MOVEMENT PER 1(ONE) CONVOLUTION-
Δq TOTAL= 2.88 AXIAL= 2.88 LATERAL=0.00 ANGULAR=0.00 mm
REINFORCING MEMBER CIRCUMFERENTIAL MEMBRANE STRESS DUE TO PRESSURE
= D.P*Dm*q/(200*Ar)*(1/(R1+1)) S'2= 0.172 (kg/mm2) 1.688 N/mm2
S'2 <= Cwr*Sarh S'2= 1.688 <= Cwr*Sarh= 137.898 O.K!

HKR Co.,Ltd. Prg No.: HKR-BELL-A-R

 Rabigh Phase II Petrochemical Project Petrochemical-1 Package (CP1) ITEM NO.: P240-E-1023 REV. NO.: 2
P.O. NO.:P-203-1420-2091-KR PAGE 169 OF 229
------------------------------------------------------------------------------------------

SIZE : I.D 1600 SHEET : OF

ITEM No. : P240-E-1023 SHELL SIDE FULL VACUUM REV No. : 0
BELLOWS DESIGN ANALYSIS
BELLOWS TANGENT CIRCUMFERENTIAL MEMBRANE STRESS DUE TO PRESSURE
= D.P*(Db+n*t)^2*Lt*Eb*κ/(200*(n*t*Eb*Lt*(Db+n*t)+tc*κ*Ec*Lc*Dc)) S1 = 0.108 (kg/mm2) 1.063 N/mm2
S1 <= Sabh S1= 1.063 <= Sabh= 216.492 O.K!
CIRCUMFERENTIAL MEMBRANE STRESS DUE TO PRESSURE
= D.P*Dm*q/(200*A)*(R1/(R1+1)) S2= 0.176 (kg/mm2) 1.724 N/mm2
S2 <= Cwb*Sabh S2= 1.724 <= Cwb*Sabh= 216.492 O.K!
MERIDIONAL MEMBRANE STRESS DUE TO PRESSURE
2 2
= (0.85*D.P*(w-Cr*q))/(200*n*tp) S3= 0.081 (kg/mm ) 0.792 N/mm
MERIDIONAL BENDING STRESS DUE TO PRESSURE
= 0.85*D.P/(200*n)*((w-Cr*q)/tp)^2*Cp S4= 0.968 (kg/mm2) 9.491 N/mm2
S3 + S4 <= Kf*Sabh, Kf=3.0 (as formed bellows) S3+S4= 10.28 <= Kf*Sabh= 649.48 O.K!
MERIDIONAL MEMBRANE STRESS DUE TO DEFLECTION
= Eb*tp^2*Δq/(2*(w-Cr*q)^3*Cf) S5= 1.039 (kg/mm2) 10.190 N/mm2
MERIDIONAL BENDING STRESS DUE TO DEFLECTION
= 5*Eb*tp*Δq/(3*(w-Cr*q)^2*Cd) S6= 60.662 (kg/mm2) 594.894 N/mm2
CALCULATED TOTAL STRESS
= 0.7*(S3+S4)+S5+S6 St= 612.281 N/mm2
CALCULATED FATIGUE LIFE CYCLES
= [Ko /{( kg*(Eo/Eb)*St)-So}]^2 Nalw= 22764 Cycles
AXIAL STIFFNESS
= π/(2*(1-vb^2))*(n/N)*Eb*Dm*(tp/(w-Cr*q))^3*(1/Cf) Kb= 2050.957 (Kg/mm) 20113.014 N/mm
MAXIMUM DESIGN PRESSURE BASED ON COLUMN INSTABILITY
2
= 0.3*π*kb/(N*q)*100 Psc= 991.272 (kg/cm ) 97.211 Mpa
EFFECTIVE DIA. OF BELLOWS
= Db+w+t*η Dm= 1754.175 mm
PRESSURE THRUST
= Dm2*π*D.P/400 Pt= 25376.1 (Kg) 248854.6 N

HKR Co.,Ltd. Prg No.: HKR-BELL-A-R

 Rabigh Phase II Petrochemical Project Petrochemical-1 Package (CP1) ITEM NO.: P240-E-1023 REV. NO.: 2
P.O. NO.:P-203-1420-2091-KR PAGE 170 OF 229
------------------------------------------------------------------------------------------

SIZE : I.D 1600 SHEET : OF

ITEM No. : P240-E-1023 TUBE SIDE FULL VACUUM REV No. : 0
BELLOWS DESIGN ANALYSIS
ASME SECTION VIII DIVISION 1, APPENDIX 26 (2010 ED.+2011 ADD.)
REINFORCED TYPE (SINGLE)
DESIGN PRESSURE D.P= 48.000 (kg/cm2) 4.707 Mpa
DESIGN TEMPERATURE D.T= 400 ℃
BELLOWS MATERIAL SB443(N06625)
ALLOWABLE STRESS (Hot & Cold) Sabc= 22.077 (kg/mm2) 216.501 N/mm2
Sabh= 20.311 (kg/mm2) 199.181 N/mm2
MODULUS OF ELASTICITY(Hot & Cold) Eo= 21092.596 (kg/mm2) 206847.711 N/mm2
Eb= 17453.421 (kg/mm2) 171159.586 N/mm2
REINFORCING RING MATERIAL SA266-4
2
ALLOWABLE STRESS (Hot & Cold) Sarc= 14.062 (kg/mm ) 137.898 N/mm2
Sarh= 10.327 (kg/mm2) 101.273 N/mm2
MODULUS OF ELASTICITY(Hot & Cold) Erc= 20670.745 (kg/mm2) 202710.757 N/mm2
Er= 17453.421 (kg/mm2) 171159.586 N/mm2
MEAN METAL TEMPERATURE Shell= 5.00 Tube= 149.00 ℃
DIFFERENTIAL THERMAL GROWTH
= (1.152E-05*(5-21)-1.242E-05*(149-21))*4877 Ex= -8.653 mm
CROSS SECTIONAL METAL AREA OF ONE REINFORCE RING Ar= 3000.0 mm2
RATIO OF THE INTERNAL PRESSURE FORCE RESISTED BY THE BELLOWS
= A*Eb/(Ar*Er) R1 = 0.156
CONVOLUTION HEIGHT FACTOR FOR REINFORCED FACTOR
= 0.3-(100/(0.6*(D.P*14.223)^1.5+320))^2 Cr= 0.2999177
DESIGN MOVEMENT CONDITION
COND-----------------AXIAL(mm.)------------------------------LATERAL(mm.)----------------------------------ANGULAR(deg)----------CYCLES-
EXT.= 8.653 COMP.= 0.000 Y= 0.000 Z= 0.000 Θ= 0.000 1000
-(A) IS PRIMARY DESIGN CONDITION
C1= q/(2*w)= 0.5 C2=q/(2.2*(Dm*tp)0.5)= 0.4215
FACTOR 'Cp', 'Cf' & 'Cd' Cp= 0.663 Cf= 1.701 Cd= 1.706
CYLINDRICAL TANGENT INSIDE DIAMETER Db= 1686 mm
MATERIAL THICKNESS t= 3.175 mm
NOMINAL THICKNESS OF BELLOWS AFTER FORMING
(-)10% REDUCTION DUE TO LOW MATERIAL & MANUFACTURING TOLERANCE
= 0.9*t*(Db/Dm)^0.5 tp= 2.80 mm
NUMBER OF PLIES n= 1 Plies
NUMBER OF CONVOLUTIONS N= 3 corr.
PITCH OF BELLOWS CONVOLUTION q= 65 mm
HEIGHT OF BELLOWS CONVOLUTION w= 65 mm
FREE LENGTH OVER CONVOLUTIONS = (q*N) Lb= 195 mm
-EQUIVALENT AXIAL MOVEMENT PER 1(ONE) CONVOLUTION-
Δq TOTAL= 2.88 AXIAL= 2.88 LATERAL=0.00 ANGULAR=0.00 mm
REINFORCING MEMBER CIRCUMFERENTIAL MEMBRANE STRESS DUE TO PRESSURE
= D.P*Dm*q/(200*Ar)*(1/(R1+1)) S'2= 7.890 (kg/mm2) 77.378 N/mm2
S'2 <= Cwr*Sarh S'2= 77.378 <= Cwr*Sarh= 101.273 O.K!

HKR Co.,Ltd. Prg No.: HKR-BELL-A-R

 Rabigh Phase II Petrochemical Project Petrochemical-1 Package (CP1) ITEM NO.: P240-E-1023 REV. NO.: 2
P.O. NO.:P-203-1420-2091-KR PAGE 171 OF 229
------------------------------------------------------------------------------------------

SIZE : I.D 1600 SHEET : OF

ITEM No. : P240-E-1023 TUBE SIDE FULL VACUUM REV No. : 0
BELLOWS DESIGN ANALYSIS
BELLOWS TANGENT CIRCUMFERENTIAL MEMBRANE STRESS DUE TO PRESSURE
= D.P*(Db+n*t)^2*Lt*Eb*κ/(200*(n*t*Eb*Lt*(Db+n*t)+tc*κ*Ec*Lc*Dc)) S1 = 4.863 (kg/mm2) 47.689 N/mm2
S1 <= Sabh S1= 47.689 <= Sabh= 199.181 O.K!
CIRCUMFERENTIAL MEMBRANE STRESS DUE TO PRESSURE
= D.P*Dm*q/(200*A)*(R1/(R1+1)) S2= 7.890 (kg/mm2) 77.378 N/mm2
S2 <= Cwb*Sabh S2= 77.378 <= Cwb*Sabh= 199.181 O.K!
MERIDIONAL MEMBRANE STRESS DUE TO PRESSURE
2 2
= (0.85*D.P*(w-Cr*q))/(200*n*tp) S3= 3.314 (kg/mm ) 32.496 N/mm
MERIDIONAL BENDING STRESS DUE TO PRESSURE
= 0.85*D.P/(200*n)*((w-Cr*q)/tp)^2*Cp S4= 35.685 (kg/mm2) 349.950 N/mm2
S3 + S4 <= Kf*Sabh, Kf=3.0 (as formed bellows) S3+S4= 382.45 <= Kf*Sabh= 597.54 O.K!
MERIDIONAL MEMBRANE STRESS DUE TO DEFLECTION
= Eb*tp^2*Δq/(2*(w-Cr*q)^3*Cf) S5= 1.232 (kg/mm2) 12.083 N/mm2
MERIDIONAL BENDING STRESS DUE TO DEFLECTION
= 5*Eb*tp*Δq/(3*(w-Cr*q)^2*Cd) S6= 66.530 (kg/mm2) 652.439 N/mm2
CALCULATED TOTAL STRESS
= 0.7*(S3+S4)+S5+S6 St= 932.235 N/mm2
CALCULATED FATIGUE LIFE CYCLES
= [Ko /{( kg*(Eo/Eb)*St)-So}]^2 Nalw= 3296 Cycles
AXIAL STIFFNESS
= π/(2*(1-vb^2))*(n/N)*Eb*Dm*(tp/(w-Cr*q))^3*(1/Cf) Kb= 2432.038 (Kg/mm) 23850.146 N/mm
MAXIMUM DESIGN PRESSURE BASED ON COLUMN INSTABILITY
= 0.3*π*kb/(N*q)*100 Psc= 1175.457 (kg/cm2) 115.273 Mpa
EFFECTIVE DIA. OF BELLOWS
= Db+w+t*η Dm= 1754.175 mm
PRESSURE THRUST
= Dm2*π*D.P/400 Pt= 1160050.7 (Kg) 11376210.7 N

HKR Co.,Ltd. Prg No.: HKR-BELL-A-R

 Rabigh Phase II Petrochemical Project Petrochemical-1 Package (CP1) ITEM NO.: P240-E-1023 REV. NO.: 2
P.O. NO.:P-203-1420-2091-KR PAGE 172 OF 229
------------------------------------------------------------------------------------------

SIZE : I.D 1600 SHEET : OF

ITEM No. : P240-E-1023 TUBE SIDE STEAM OUT REV No. : 0
BELLOWS DESIGN ANALYSIS
ASME SECTION VIII DIVISION 1, APPENDIX 26 (2010 ED.+2011 ADD.)
REINFORCED TYPE (SINGLE)
DESIGN PRESSURE D.P= 0.000 (kg/cm2) 0.000 Mpa
DESIGN TEMPERATURE D.T= 21 ℃
BELLOWS MATERIAL SB443(N06625)
ALLOWABLE STRESS (Hot & Cold) Sabc= 22.077 (kg/mm2) 216.501 N/mm2
Sabh= 22.077 (kg/mm2) 216.501 N/mm2
MODULUS OF ELASTICITY(Hot & Cold) Eo= 21092.596 (kg/mm2) 206847.711 N/mm2
Eb= 21093.341 (kg/mm2) 206855.012 N/mm2
REINFORCING RING MATERIAL SA266-4
2
ALLOWABLE STRESS (Hot & Cold) Sarc= 14.062 (kg/mm ) 137.898 N/mm2
Sarh= 14.062 (kg/mm2) 137.898 N/mm2
MODULUS OF ELASTICITY(Hot & Cold) Erc= 20670.745 (kg/mm2) 202710.757 N/mm2
Er= 20671.489 (kg/mm2) 202718.058 N/mm2
MEAN METAL TEMPERATURE Shell= 5.00 Tube= 149.00 ℃
DIFFERENTIAL THERMAL GROWTH
= (1.152E-05*(5-21)-1.242E-05*(149-21))*4877 Ex= -8.653 mm
CROSS SECTIONAL METAL AREA OF ONE REINFORCE RING Ar= 3000.0 mm2
RATIO OF THE INTERNAL PRESSURE FORCE RESISTED BY THE BELLOWS
= A*Eb/(Ar*Er) R1 = 0.159
CONVOLUTION HEIGHT FACTOR FOR REINFORCED FACTOR
= 0.3-(100/(0.6*(D.P*14.223)^1.5+320))^2 Cr= 0.2023438
DESIGN MOVEMENT CONDITION
COND-----------------AXIAL(mm.)------------------------------LATERAL(mm.)----------------------------------ANGULAR(deg)----------CYCLES-
EXT.= 8.653 COMP.= 0.000 Y= 0.000 Z= 0.000 Θ= 0.000 1000
-(A) IS PRIMARY DESIGN CONDITION
C1= q/(2*w)= 0.5 C2=q/(2.2*(Dm*tp)0.5)= 0.4215
FACTOR 'Cp', 'Cf' & 'Cd' Cp= 0.663 Cf= 1.701 Cd= 1.706
CYLINDRICAL TANGENT INSIDE DIAMETER Db= 1686 mm
MATERIAL THICKNESS t= 3.175 mm
NOMINAL THICKNESS OF BELLOWS AFTER FORMING
(-)10% REDUCTION DUE TO LOW MATERIAL & MANUFACTURING TOLERANCE
= 0.9*t*(Db/Dm)^0.5 tp= 2.80 mm
NUMBER OF PLIES n= 1 Plies
NUMBER OF CONVOLUTIONS N= 3 corr.
PITCH OF BELLOWS CONVOLUTION q= 65 mm
HEIGHT OF BELLOWS CONVOLUTION w= 65 mm
FREE LENGTH OVER CONVOLUTIONS = (q*N) Lb= 195 mm
-EQUIVALENT AXIAL MOVEMENT PER 1(ONE) CONVOLUTION-
Δq TOTAL= 2.88 AXIAL= 2.88 LATERAL=0.00 ANGULAR=0.00 mm
REINFORCING MEMBER CIRCUMFERENTIAL MEMBRANE STRESS DUE TO PRESSURE
= D.P*Dm*q/(200*Ar)*(1/(R1+1)) S'2= 0.000 (kg/mm2) 0.000 N/mm2
S'2 <= Cwr*Sarh S'2= 0.000 <= Cwr*Sarh= 137.898 O.K!

HKR Co.,Ltd. Prg No.: HKR-BELL-A-R

 Rabigh Phase II Petrochemical Project Petrochemical-1 Package (CP1) ITEM NO.: P240-E-1023 REV. NO.: 2
P.O. NO.:P-203-1420-2091-KR PAGE 173 OF 229
------------------------------------------------------------------------------------------

SIZE : I.D 1600 SHEET : OF

ITEM No. : P240-E-1023 TUBE SIDE STEAM OUT REV No. : 0
BELLOWS DESIGN ANALYSIS
BELLOWS TANGENT CIRCUMFERENTIAL MEMBRANE STRESS DUE TO PRESSURE
= D.P*(Db+n*t)^2*Lt*Eb*κ/(200*(n*t*Eb*Lt*(Db+n*t)+tc*κ*Ec*Lc*Dc)) S1 = 0.000 (kg/mm2) 0.000 N/mm2
S1 <= Sabh S1= 0.000 <= Sabh= 216.501 O.K!
CIRCUMFERENTIAL MEMBRANE STRESS DUE TO PRESSURE
= D.P*Dm*q/(200*A)*(R1/(R1+1)) S2= 0.000 (kg/mm2) 0.000 N/mm2
S2 <= Cwb*Sabh S2= 0.000 <= Cwb*Sabh= 216.501 O.K!
MERIDIONAL MEMBRANE STRESS DUE TO PRESSURE
2 2
= (0.85*D.P*(w-Cr*q))/(200*n*tp) S3= 0.000 (kg/mm ) 0.000 N/mm
MERIDIONAL BENDING STRESS DUE TO PRESSURE
= 0.85*D.P/(200*n)*((w-Cr*q)/tp)^2*Cp S4= 0.000 (kg/mm2) 0.000 N/mm2
S3 + S4 <= Kf*Sabh, Kf=3.0 (as formed bellows) S3+S4= 0.00 <= Kf*Sabh= 649.50 O.K!
MERIDIONAL MEMBRANE STRESS DUE TO DEFLECTION
= Eb*tp^2*Δq/(2*(w-Cr*q)^3*Cf) S5= 1.007 (kg/mm2) 9.873 N/mm2
MERIDIONAL BENDING STRESS DUE TO DEFLECTION
= 5*Eb*tp*Δq/(3*(w-Cr*q)^2*Cd) S6= 61.937 (kg/mm2) 607.395 N/mm2
CALCULATED TOTAL STRESS
= 0.7*(S3+S4)+S5+S6 St= 617.268 N/mm2
CALCULATED FATIGUE LIFE CYCLES
= [Ko /{( kg*(Eo/Eb)*St)-So}]^2 Nalw= 25810 Cycles
AXIAL STIFFNESS
= π/(2*(1-vb^2))*(n/N)*Eb*Dm*(tp/(w-Cr*q))^3*(1/Cf) Kb= 1987.171 (Kg/mm) 19487.487 N/mm
MAXIMUM DESIGN PRESSURE BASED ON COLUMN INSTABILITY
2
= 0.3*π*kb/(N*q)*100 Psc= 960.443 (kg/cm ) 94.187 Mpa
EFFECTIVE DIA. OF BELLOWS
= Db+w+t*η Dm= 1754.175 mm
PRESSURE THRUST
= Dm2*π*D.P/400 Pt= 0.0 (Kg) 0.0 N

HKR Co.,Ltd. Prg No.: HKR-BELL-A-R

 Rabigh Phase II Petrochemical Project Petrochemical-1 Package (CP1) ITEM NO.: P240-E-1023 REV. NO.: 2
P.O. NO.:P-203-1420-2091-KR PAGE 174 OF 229
------------------------------------------------------------------------------------------

SIZE : I.D 1600 SHEET : OF

ITEM No. : P240-E-1023 MAWP REV No. : 0
BELLOWS DESIGN ANALYSIS
ASME SECTION VIII DIVISION 1, APPENDIX 26 (2010 ED.+2011 ADD.)
REINFORCED TYPE (SINGLE)
DESIGN PRESSURE D.P= 49.400 (kg/cm2) 4.844 Mpa
DESIGN TEMPERATURE D.T= 400 ℃
BELLOWS MATERIAL SB443(N06625)
ALLOWABLE STRESS (Hot & Cold) Sabc= 22.077 (kg/mm2) 216.501 N/mm2
Sabh= 20.311 (kg/mm2) 199.181 N/mm2
MODULUS OF ELASTICITY(Hot & Cold) Eo= 21092.596 (kg/mm2) 206847.711 N/mm2
Eb= 17453.421 (kg/mm2) 171159.586 N/mm2
REINFORCING RING MATERIAL SA266-4
2
ALLOWABLE STRESS (Hot & Cold) Sarc= 14.062 (kg/mm ) 137.898 N/mm2
Sarh= 10.327 (kg/mm2) 101.273 N/mm2
MODULUS OF ELASTICITY(Hot & Cold) Erc= 20670.745 (kg/mm2) 202710.757 N/mm2
Er= 17453.421 (kg/mm2) 171159.586 N/mm2
MEAN METAL TEMPERATURE Shell= 5.00 Tube= 149.00 ℃
DIFFERENTIAL THERMAL GROWTH
= (1.152E-05*(5-21)-1.242E-05*(149-21))*4877 Ex= -8.653 mm
CROSS SECTIONAL METAL AREA OF ONE REINFORCE RING Ar= 3000.0 mm2
RATIO OF THE INTERNAL PRESSURE FORCE RESISTED BY THE BELLOWS
= A*Eb/(Ar*Er) R1= 0.156
CONVOLUTION HEIGHT FACTOR FOR REINFORCED FACTOR
= 0.3-(100/(0.6*(D.P*14.223)^1.5+320))^2 Cr= 0.2999243
DESIGN MOVEMENT CONDITION
COND-----------------AXIAL(mm.)------------------------------LATERAL(mm.)----------------------------------ANGULAR(deg)----------CYCLES-
EXT.= 8.653 COMP.= 0.000 Y= 0.000 Z= 0.000 Θ= 0.000 1000
-(A) IS PRIMARY DESIGN CONDITION
C1= q/(2*w)= 0.5 C2=q/(2.2*(Dm*tp)0.5)= 0.4215
FACTOR 'Cp', 'Cf' & 'Cd' Cp= 0.658 Cf= 1.612 Cd= 1.773
CYLINDRICAL TANGENT INSIDE DIAMETER Db= 1686 mm
MATERIAL THICKNESS t= 3.175 mm
NOMINAL THICKNESS OF BELLOWS AFTER FORMING
(-)10% REDUCTION DUE TO LOW MATERIAL & MANUFACTURING TOLERANCE
= 0.9*t*(Db/Dm)^0.5 tp= 2.80 mm
NUMBER OF PLIES n= 1 Plies
NUMBER OF CONVOLUTIONS N= 3 corr.
PITCH OF BELLOWS CONVOLUTION q= 65 mm
HEIGHT OF BELLOWS CONVOLUTION w= 65 mm
FREE LENGTH OVER CONVOLUTIONS = (q*N) Lb= 195 mm
-EQUIVALENT AXIAL MOVEMENT PER 1(ONE) CONVOLUTION-
Δq TOTAL= 2.88 AXIAL= 2.88 LATERAL= 0.00 ANGULAR=0.00 mm
REINFORCING MEMBER CIRCUMFERENTIAL MEMBRANE STRESS DUE TO PRESSURE
= D.P*Dm*q/(200*Ar)*(1/(R1+1)) S'2= 8.121 (kg/mm2) 79.635 N/mm2
S'2 <= Cwr*Sarh S'2= 79.635 <= Cwr*Sarh= 101.273 O.K!

HKR Co.,LTD. Prg No.: HKE-BELL-A-R

 Rabigh Phase II Petrochemical Project Petrochemical-1 Package (CP1) ITEM NO.: P240-E-1023 REV. NO.: 2
P.O. NO.:P-203-1420-2091-KR PAGE 175 OF 229
------------------------------------------------------------------------------------------

SIZE : I.D 1600 SHEET : OF

ITEM No. : P240-E-1023 MAWP REV No. : 0
BELLOWS DESIGN ANALYSIS
BELLOWS TANGENT CIRCUMFERENTIAL MEMBRANE STRESS DUE TO PRESSURE
= D.P*(Db+n*t)^2*Lt*Eb*κ/(200*(n*t*Eb*Lt*(Db+n*t)+tc*κ*Ec*Lc*Dc)) S1 = 5.005 (kg/mm2) 49.080 N/mm2
S1 <= Sabh S1= 49.080 <= Sabh= 199.181 O.K!
CIRCUMFERENTIAL MEMBRANE STRESS DUE TO PRESSURE
= D.P*Dm*q/(200*A)*(R1/(R1+1)) S2= 8.121 (kg/mm2) 79.635 N/mm2
S2 <= Cwb*Sabh S2= 79.635 <= Cwb*Sabh= 199.181 O.K!
MERIDIONAL MEMBRANE STRESS DUE TO PRESSURE
2 2
= (0.85*D.P*(w-Cr*q))/(200*n*tp) S3= 3.410 (kg/mm ) 33.444 N/mm
MERIDIONAL BENDING STRESS DUE TO PRESSURE
= 0.85*D.P/(200*n)*((w-Cr*q)/tp)^2*Cp S4= 36.463 (kg/mm2) 357.585 N/mm2
S3 + S4 <= Kf*Sabh, Kf=3.0 (as formed bellows) S3+S4= 391.03 <= Kf*Sabh= 597.54 O.K!
MERIDIONAL MEMBRANE STRESS DUE TO DEFLECTION
= Eb*tp^2*Δq/(2*(w-Cr*q)^3*Cf) S5= 1.300 (kg/mm2) 12.751 N/mm2
MERIDIONAL BENDING STRESS DUE TO DEFLECTION
= 5*Eb*tp*Δq/(3*(w-Cr*q)^2*Cd) S6= 64.026 (kg/mm2) 627.880 N/mm2
CALCULATED TOTAL STRESS
= 0.7*(S3+S4)+S5+S6 St= 914.351 N/mm2
CALCULATED FATIGUE LIFE CYCLES
= [Ko /{( kg*(Eo/Eb)*St)-So}]^2 Nalw= 3487 Cycles
AXIAL STIFFNESS
= π/(2*(1-vb^2))*(n/N)*Eb*Dm*(tp/(w-Cr*q))^3*(1/Cf) Kb= 2566.549 (Kg/mm) 25169.247 N/mm
MAXIMUM DESIGN PRESSURE BASED ON COLUMN INSTABILITY
= 0.3*π*kb/(N*q)*100 Psc= 1240.469 (kg/cm2) 121.649 Mpa
EFFECTIVE DIA. OF BELLOWS
= Db+w+t*η Dm= 1754.175 mm
PRESSURE THRUST
= Dm2*π*D.P/400 Pt= 1193885.5 (Kg) 11708016.9 N

HKR Co.,LTD. Prg No.: HKE-BELL-A-R

 Rabigh Phase II Petrochemical Project Petrochemical-1 Package (CP1) ITEM NO.: P240-E-1023 REV. NO.: 2
P.O. NO.:P-203-1420-2091-KR PAGE 176 OF 229
SIZE ------------------------------------------------------------------------------------------
: I.D 1600 SHEET : OF
ITEM No. : P240-E-1023 HY'D TEST REV No. : 0
BELLOWS DESIGN ANALYSIS
ASME SECTION VIII DIVISION 1, APPENDIX 26 (2010 ED.+2011 ADD.)
REINFORCED TYPE (SINGLE)
TEST PRESSURE T.P= 70.040 (kg/cm2) 6.869 Mpa
TEST TEMPERATURE T.T= 21 ℃
BELLOWS MATERIAL SB443(N06625)
YIELD STRESS (Hot & Cold) Sybc= 38.670 (kg/mm2) 379.221 N/mm2
Sybh= 38.670 (kg/mm2) 379.221 N/mm2
MODULUS OF ELASTICITY(Hot & Cold) Eo= 21092.596 (kg/mm2) 206847.711 N/mm2
Eb= 21796.427 (kg/mm2) 213749.936 N/mm2
REINFORCING RING MATERIAL A266-4
2
YIELD STRESS (Hot & Cold) Syrc= 26.717 (kg/mm ) 262.007 N/mm2
Syrh= 26.717 (kg/mm2) 262.007 N/mm2
MODULUS OF ELASTICITY(Hot & Cold) Erc= 20670.745 (kg/mm2) 202710.757 N/mm2
Er= 20671.489 (kg/mm2) 202718.058 N/mm2
MEAN METAL TEMPERATURE Shell= - Tube= - ℃
DIFFERENTIAL THERMAL GROWTH
= Ex= 0.000 mm
CROSS SECTIONAL METAL AREA OF ONE REINFORCE RING Ar= 3000.0 mm2
RATIO OF THE INTERNAL PRESSURE FORCE RESISTED BY THE BELLOWS
= A*Eb/(Ar*Er) R1= 0.165
CONVOLUTION HEIGHT FACTOR FOR REINFORCED FACTOR
= 0.3-(100/(0.6*(D.P*14.223)^1.5+320))^2 Cr= 0.2999728
DESIGN MOVEMENT CONDITION
COND-----------------AXIAL(mm.)------------------------------LATERAL(mm.)----------------------------------ANGULAR(deg)----------CYCLES-
EXT.= 0.000 COMP.= 0.000 Y= 0.000 Z= 0.000 Θ= 0.000 1000
-(A) IS PRIMARY DESIGN CONDITION
C1= q/(2*w)= 0.5 C2=q/(2.2*(Dm*tp)0.5)= 0.4215
FACTOR 'Cp', 'Cf' & 'Cd' Cp= 0.658 Cf= 1.612 Cd= 1.773
CYLINDRICAL TANGENT INSIDE DIAMETER Db= 1686 mm
MATERIAL THICKNESS t= 3.175 mm
NOMINAL THICKNESS OF BELLOWS AFTER FORMING
(-)10% REDUCTION DUE TO LOW MATERIAL & MANUFACTURING TOLERANCE
= 0.9*t*(Db/Dm)^0.5 tp= 2.80 mm
NUMBER OF PLIES n= 1 Plies
NUMBER OF CONVOLUTIONS N= 3 corr.
PITCH OF BELLOWS CONVOLUTION q= 65 mm
HEIGHT OF BELLOWS CONVOLUTION w= 65 mm
FREE LENGTH OVER CONVOLUTIONS = (q*N) Lb= 195 mm
-EQUIVALENT AXIAL MOVEMENT PER 1(ONE) CONVOLUTION-
Δq TOTAL= 0.00 AXIAL= 0.00 LATERAL= 0.00 ANGULAR=0.00 mm
REINFORCING MEMBER CIRCUMFERENTIAL MEMBRANE STRESS DUE TO PRESSURE
= D.P*Dm*q/(200*Ar)*(1/(R1+1)) S'2= 11.429 (kg/mm2) 112.084 N/mm2
S'2 <= Cwr*Syrh*0.9 S'2= 112.084 <= Cwr*Syrh*0.9= 235.806 O.K!

HKR Co.,Ltd. Prg No.: HKR-BELL-A-R

 Rabigh Phase II Petrochemical Project Petrochemical-1 Package (CP1) ITEM NO.: P240-E-1023 REV. NO.: 2
P.O. NO.:P-203-1420-2091-KR PAGE 177 OF 229
------------------------------------------------------------------------------------------
SIZE : I.D 1600 SHEET : OF
ITEM No. : P240-E-1023 HY'D TEST REV No. : 0
BELLOWS DESIGN ANALYSIS
BELLOWS TANGENT CIRCUMFERENTIAL MEMBRANE STRESS DUE TO PRESSURE
= D.P*(Db+n*t)^2*Lt*Eb*κ/(200*(n*t*Eb*Lt*(Db+n*t)+tc*κ*Ec*Lc*Dc)) S1 = 7.435 (kg/mm2) 72.913 N/mm2
S1 <= Sybh*0.9 S1= 72.913 <= Sybh*0.9= 341.299 O.K!
CIRCUMFERENTIAL MEMBRANE STRESS DUE TO PRESSURE
= D.P*Dm*q/(200*A)*(R1/(R1+1)) S2= 12.051 (kg/mm2) 118.184 N/mm2
S2 <= Cwb*Sybh*0.9 S2= 118.184 <= Cwb*Sybh*0.9= 341.299 O.K!
MERIDIONAL MEMBRANE STRESS DUE TO PRESSURE
2 2
= (0.85*D.P*(w-Cr*q))/(200*n*tp) S3= 4.835 (kg/mm ) 47.414 N/mm
MERIDIONAL BENDING STRESS DUE TO PRESSURE
= 0.85*D.P/(200*n)*((w-Cr*q)/tp)^2*Cp S4= 51.691 (kg/mm2) 506.918 N/mm2
S3 + S4 <= Kf*Sybh*0.9, Kf=3.0 (as formed bellows) S3+S4= 554.332 <= Kf*Sybh*0.9= 1023.896 O.K!
MERIDIONAL MEMBRANE STRESS DUE TO DEFLECTION
= Eb*tp^2*Δq/(2*(w-Cr*q)^3*Cf) S5= 0.000 (kg/mm2) 0.000 N/mm2
MERIDIONAL BENDING STRESS DUE TO DEFLECTION
= 5*Eb*tp*Δq/(3*(w-Cr*q)^2*Cd) S6= 0.000 (kg/mm2) 0.000 N/mm2
CALCULATED TOTAL STRESS
= 0.7*(S3+S4)+S5+S6 St= 388.032 N/mm2
CALCULATED FATIGUE LIFE CYCLES
= [Ko /{( kg*(Eo/Eb)*St)-So}]^2 Nalw= 294589 Cycles
AXIAL STIFFNESS
= π/(2*(1-vb^2))*(n/N)*Eb*Dm*(tp/(w-Cr*q))^3*(1/Cf) Kb= 3205.860 (Kg/mm) 31438.752 N/mm
MAXIMUM DESIGN PRESSURE BASED ON COLUMN INSTABILITY
= 0.3*π*kb/(N*q)*100 Psc= 1549.463 (kg/cm2) 151.950 Mpa
EFFECTIVE DIA. OF BELLOWS
= Db+w+t*η Dm= 1754.175 mm
PRESSURE THRUST
= Dm2*π*D.P/400 Pt= 1692707.2 (Kg) 16599787.5 N

HKR Co.,Ltd. Prg No.: HKR-BELL-A-R