GP-QM-7.

3-2 R1

GP-839

GRAND PRIX

1
0
Rev. No.
DATE

DESIGN CALCULATION

SHT. 1 OF 12

Client

: M/s. Bharat Pumps & Compressors Ltd.

Project

: MSQU / IOCL

P.O. No.

: 461-16430421-1533 Dtd. 14.02.2005

Item

: Discharge Volume Bottles - D2A( 6510418/D )

Drg. No.

: 2-GP839-1324

Inspection

: BPCL/ EIL

G.P. Job No.

: GP-839

Revised as per clients comment.

Issued for Approval
Description

GRAND PRIX

1.04.04
02.03.05
Date

A.S.
N.J.
Prepared By

FARIDABAD

Checked By
Approved By
Doc. No.
Rev.

GP-QM-7.3-2 R1

GRAND PRIX

02.03.05

FARIDABAD

GP839-DC-01

GP-839

GRAND PRIX

DESIGN CALCULATION

SHT. 2 OF 12

DESIGN DATA
Design Code

: ASME SEC VIII, DIV. 1 - 2004

Design Pressure

56.2

Kg/Cm2g

Design Temp.

204

Flange Rating.

600

Radiography

100

Joint Efficiency

1.0

Corrosion Allowance

Vessel OD, D

mm

: 450.0 mm

Vessel Outer Radius, R :

Name of Part

3.2

225.0 mm

Material of Construction

Stress Value at Design Temp.

Shell

SA 516 Gr. 60

1202.47

Kg/Cm2

Dish End

SA 516 Gr. 60

1202.47

Kg/Cm2

Nozzle

SA 106 Gr. B

1202.47

Kg/Cm2

GP-QM-7.3-2 R1
DATE

GRAND PRIX

02.03.05

FARIDABAD

Doc. No.

Rev.

GP839-DC-01

GP-839

GRAND PRIX

DESIGN CALCULATION

SHT. 3 OF 12

DESIGN SUMMARY
S. No.

Description

Size

Calculated Minimum
Thickness

Actual
Thickness
Provided

Shell

OD 450 x 14 Thk.

13.52 mm

14.0 mm

Dish End

OD 450x13.3 Thk(min).

13.29 mm

16.0 mm(nom)

S3

6" NB x Sch. 80

7.06 mm

10.972 mm

S1,S2

4"NB x Sch. 120

5.82 mm

11.12 mm

S4,S5,S8,S9

1"NB x Sch. XX

4.31 mm

10.16 mm

GP-QM-7.3-2 R1

DATE

GRAND PRIX

02.03.05

FARIDABAD

Doc. No.

Rev.

GP839-DC-01

GP-839

GRAND PRIX

DESIGN CALCULATION

SHT. 4 OF 12

Shell Thickness :t =

P.R
(SE + 0.4P)

10.32 mm

10.32 + 3.2

13.52

Adding 3.2 mm Corrosion Allownace

Used Plate 14 mm Thick

Dish End Tickness :Type of D/End, Semi-Elliptical , 2 : 1

t =

K =1.0

P.D.K
2SE + 2P(K - 0.1)

10.09 mm

10.09 + 3.2

13.29 mm

Adding 3.2 mm Corrosion Allownace

Used Plate 16 mm Thick

GP-QM-7.3-2 R1

DATE

GRAND PRIX

02.03.05

FARIDABAD

Doc. No.

Rev.

GP839-DC-01

GP-839

GRAND PRIX

DESIGN CALCULATION

Nozzle Thickness :t =

SHT. 5 OF 12

(6"NB Size)
P.Ro
(SE + 0.4P)

3.86

3.86 + 3.2

7.06

Do =

168.27

mm

Ro =
E=

84.135
1.0

mm

mm
Adding 3.2 mm Corrosion Allownace

mm
Used 6" NB x Sch. 80 Pipe (10.972 mm)

Nozzle Thickness :t =

(4" NB Size)
P.Ro
(SE + 0.4P)

2.62

2.62 + 3.2

5.82

Do =
Ro =
E=

114.3
57.15
1.0

mm
mm

mm
Adding 3.2 mm Corrosion Allownace

mm
Used 4" NB x Sch. 120 Pipe (11.12 mm)

Nozzle Thickness :t =

(1" NB Size)
P.Ro
(SE + 0.4P)

1.11

1.11 + 3.2

Do =
Ro =
E=

48.26
24.13
1.0

mm
mm

mm
Adding 3.2 mm Corrosion Allownace

GP-QM-7.3-2 R1

4.31

mm
Used 1" NB x Sch. XX Pipe (10.16 mm)

DATE

GRAND PRIX

02.03.05

FARIDABAD

Doc. No.

Rev.

GP839-DC-01

GP-839

GRAND PRIX

DESIGN CALCULATION

SHT. 6 OF 12

Table 1
Nozzle

Size (NB)

S3

150

13.29

9.42

7.06

9.42

10.77

S1

100

13.52

8.46

5.82

8.46

9.67

11.12

S2

100

13.29

8.46

5.82

8.46

9.67

11.12

S4,S5,S
8, S9

40

Shell/ D.End Std. Wall Cal. Nozzle Smaller of T1 & T2

Thk.+C.A. (T1) Thk. Less Thk.+C.A.
(T4)
12.5% +
(T3)
C.A. (T2)

13.52

6.42

4.31

6.42

Greater of T3 Provided
& T4 / 0.875
Thk. /
for (Pipes)
Sch.

7.34

10.972
Sch. 80
Sch. 120
Sch. 120

10.16
Sch. XX

GP-QM-7.3-2 R1

DATE

GRAND PRIX

02.03.05

FARIDABAD

Doc. No.

Rev.

GP839-DC-01

GP-839

GRAND PRIX

DESIGN CALCULATION

SHT. 7 OF 12

Nozzle Reinforcement
1.0
2.0
3.0
4.0
5.0

Nozzle No.
Size (NB)
tr = Required Shell Thk.
t = Provied Shell Thk. - C.A.
tm= Required Nozzle Thk.

150

100

10.09
10.8

10.09
10.8

3.86

2.62

7.772
149.52

7.92
95.24

8.0

tn = Provied Nozzle Thk. - C.A.

d = Inside Dia of Nozzle + C.A.
Sn = Allowable Stress in Nozzle (Kg/Cm2)

1202.47

1202.47

9.0

Sv = Allowable Stress in Vessel (Kg/Cm2)

1202.47

1202.47

1202.47

1202.47

1.0

1.0

1.0

1.0

1.0
1.0

1.0
1.0

14.0

14.0

Dr = Dia. of RF. Pad (Available)

299.04

190.48

Dp = Dia. of RF. Pad (Provided)

250.0

200.0

1508.86

961.10

1.0

1.0

105.95

67.49

152.02

209.88

100.0

100.0

1189.104

1244.88

6.0
7.0

2
10.0 Sp = Allowable Stress in RF. Pad (Kg/Cm )
11.0 fr1 = Sn/Sv (1.0 Max.)

12.0 fr2 = Sn/Sv (1.0 Max.)

13.0 fr3 , fr4= Sp/Sv (1.0 Max.)
14.0 F = Correction Factor
15.0 te = Thickness of RF. Pad
16.0

17.0 Area Required, A = dtrF+2tntrF(1-fr1)

18.0 Value , E1
Area Available in Shell, A1 = Larger of
19.0 d(E1t-Ftr)-2tn(E1t-Ftr)(1-fr1) OR
2(t+tn)(E1t-Ftr)-2tn(E1t-Ftr)(1-fr1)
20.0

Area Available in Nozzle, A2 = Smaller of

5(tn-tm)t.fr2 OR 5(tn-tm)tn.fr2

2
21.0 Welding Area, A41 = (LEG) .fr2
22.0 Area in RF. Pad, A5 = (Dp-d-2tn)te.fr3

GP-QM-7.3-2 R1

23.0 Welding Area, A42 = (LEG) .fr4

24.0 Total Area Available = A1+A2+A41+A5+A42
2

100.0

100.0

1647.08

1722.25

Remarks :- 1. Reinforcement Provided is OK

2. No Reinforcement Required.

DATE

GRAND PRIX

02.03.05

FARIDABAD

Doc. No.

Rev.

GP839-DC-01

GP-839

GRAND PRIX

DESIGN CALCULATION

SHT. 8 OF 12

Nozzle Reinforcement
1.0
2.0
3.0
4.0
5.0

Nozzle No.
Size (NB)
tr = Required Shell Thk.
t = Provied Shell Thk. - C.A.
tm= Required Nozzle Thk.

100
10.32
10.8
2.62

8.0

tn = Provied Nozzle Thk. - C.A.

d = Inside Dia of Nozzle + C.A.
Sn = Allowable Stress in Nozzle (Kg/Cm2)

1202.47

9.0

Sv = Allowable Stress in Vessel (Kg/Cm2)

1202.47

6.0
7.0

2
10.0 Sp = Allowable Stress in RF. Pad (Kg/Cm )
11.0 fr1 = Sn/Sv (1.0 Max.)

12.0 fr2 = Sn/Sv (1.0 Max.)

13.0 fr3 , fr4= Sp/Sv (1.0 Max.)
14.0 F = Correction Factor
15.0 te = Thickness of RF. Pad
16.0

1202.47
1.0
1.0
1.0
1.0
10.8

Dr = Dia. of RF. Pad (Available)

190.48

Dp = Dia. of RF. Pad (Provided)

200.0

17.0 Area Required, A = dtrF+2tntrF(1-fr1)

18.0 Value , E1
Area Available in Shell, A1 = Larger of
19.0 d(E1t-Ftr)-2tn(E1t-Ftr)(1-fr1) OR
2(t+tn)(E1t-Ftr)-2tn(E1t-Ftr)(1-fr1)
20.0

7.92
95.24

Area Available in Nozzle, A2 = Smaller of

5(tn-tm)t.fr2 OR 5(tn-tm)tn.fr2

2
21.0 Welding Area, A41 = (LEG) .fr2

983.15
1.0
45.44

198
100.0

GP-QM-7.3-2 R1

22.0 Area in RF. Pad, A5 = (Dp-d-2tn)te.fr3

2
23.0 Welding Area, A42 = (LEG) .fr4

960.336

24.0 Total Area Available = A1+A2+A41+A5+A42

1403.78

100.0

Remarks :- 1. Reinforcement Provided is OK

2. No Reinforcement Required.

DATE

GRAND PRIX

02.03.05

FARIDABAD

Doc. No.

Rev.

GP839-DC-01

GP-839

GRAND PRIX

DESIGN CALCULATION

SHT. 9 OF 12

Calculation for Nozzle Loads

( Code used : BSI-PD 5500 :2000)
(a) Calculation for Nozzles S1 & S2 ( 4" NB ) :-

Inside Diametre of Shell , Di

422.4

mm

Nozzle Flange bolt ( PCD ) , do

200.15

mm

Corrosion Allowance , CA

3.2

mm

Shell Thickness, ts

14.0

mm

Reinforcing Pad Thickness, tp

14.0

mm

Nozzle Thickness , tn

11.12

mm

28

mm

Shell, Calculation Thickness, tcs

=
AllowableStress of Shell Material,Sa =

12.0247

Kg/mm2

AllowableStress of Pad Material ,Sp

12.0247

Kg/mm2

Constant ,S

GP-QM-7.3-2 R1

Polynomial Coeffecients ,a0 to a4

(As per Table 1)

Calculation Factors , C2 to C4

(As per PD 5500)

C2

2.9076014796

C3

5.3396426797

C4

13.81

DATE

GRAND PRIX

Doc. No.

Rev.

GP839-DC-01

FARIDABAD

02.03.05

GP-839

GRAND PRIX

DESIGN CALCULATION

SHT. 10 OF 12

Shell effective mean Diametre, De

453.6

mm

Nozzle Mean Diametre, dm

192.23

mm

Geometric Parametre for shells C

Maximum allowable Axial Force

on the Nozzle ,FX Max

Maximum allowable Circumferential

Forceon the Nozzle ,FY Max =

Maximum allowable Longitudinal Force

on the Nozzle ,FZ Max =

Maximum allowable Axial Moment

on the Nozzle ,M X Max =
Maximum Allowable Circumferential
moment on the Nozzle , MY Max =

Maximum Allowable Longitudinal

2.412265711

27411.0198409225 Kg
268902.10463945 N

50338.7594431687 Kg
493823.230137485 N

130167.342017879 Kg
1276941.62519539 N

1317318.79151505 Kg-mm
12922.8973447627 Nm
2419180.1013198 Kg-mm
23732.1567939472 Nm

GP-QM-7.3-2 R1

moment on the Nozzle , MZ Max

TABLE 1
Factor
C2
C3
C4 with
tp / ts 0.2
C4 with
tp / ts 0.5

6255582.12269522 Kg-mm
61367.2606236401 Nm

Coefficients to define factore C2 , C3 or C4

a0
a1
a2
a3
a4
0.60072181
0.95196257
0.00520
-0.0014064
0
4.526315
0.064021889
0.15888
-0.0214193 0.00104
4.8844124 -0.07138921
6.3178075

0.79991

-3.6618209

-0.0241557

4.51454

DATE

GRAND PRIX

-0.8309484 0.0507
Doc. No.

Rev.

GP839-DC-01

FARIDABAD

02.03.05

GP-839

GRAND PRIX

CALCULATED
MAX ALLOWABLE
LOAD N / Nm
ALLOWABLE
LOAD N / Nm

DESIGN CALCULATION

FX

FY

FZ

SHT. 11 OF 12

MX

268902.1 493823.2 1276941.6

12922.90

2700.00 3350.00 3350.00

1250.00

MY

MZ

23732.157 61367.26

850.00

The forces and Moments are on the safer Side.

850.00

GP-QM-7.3-2 R1

DATE

GRAND PRIX

02.03.05

FARIDABAD

Doc. No.

Rev.

GP839-DC-01

GP-839

GRAND PRIX

DESIGN CALCULATION
Calculation for Saddle Support.
( Code used : BS- PD 5500 )

Allowable Stress of Saddle Mat. =

9.80

Design Stress of the web section =

Kg/mm2

6.533 Kg/mm2

( Considered 2/3rd of the allowable stress )

Outer Dia of Vessel , D

450

mm

Outer radius of Vessel , R

225

mm

Test Weight of the Vessel , W

640.00 Kg.

The load on one Saddle , Q =

640.00 Kg.

Numerical Constant , k9 =
Web Plate Thickness , T =
Horizontal Force F =

0.204 ( From Table 1)

10.00

mm

130.56 Kg.

SHT. 12 OF 12

GP-QM-7.3-2 R1
VALUE OF CONSTANT K9 (As per PD 5500:2000 Annex. G)
CONTACT ANGLE
120
K9
0.204

130

140

150

160

170

180

0.222

0.241

0.259

0.279

0.298

0.318

R/3

75

mm.

To Resist this Force The effective area of Web Plate =

Stress due to Horizontal Force, F =

750 mm2

0.17408 kg/mm2

Since the allowable Stress is 6.533 Kg/mm2 , The Selected size is satisfactory

DATE
02.03.05

GRAND PRIX

FARIDABAD

Doc. No.

Rev.

GP839-DC-01

Approved By