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# Calculations for Design Pressure

DM Feed Pump

mwc
mwc

mwc

64.6
77.520
8.05

Design Pressure
Say

4.2785
89.8485
or

42
50.4
5.6

R4

Design Pressure
Say

8.99 kg/cm2

2.8
58.8
or

5.9 kg/cm2

mwc
mwc

R4

Design Pressure
Say

33
39.6
8.05
2.3825
50.0325

or

5.03 kg/cm2

## ION EXCHANGE (INDIA) LIMITED

CLIENT
: M/s. JAIPRAKASH POWER VENTURES LTD
CONSULTANT : DEVELOPMENT CONSULTANT PRIVATE LIMITED, KOLKATA
PROJECT
: 2x 660 MW JAYPEE NIGRIE SUPER THERMAL POWER PROJECT
CONTRACT NO. : 4303100037

PAGE : 2 OF 6

## Design Calculations for Thickness Of Shell

As Per IS 2825 Code
Sr
No

Vessel
Description

No MATERIAL
Of

Di

CA

TS

MT

TS+CA
+MT

TNOM

Remarks

DM PLANT

DMF-C-A/B

2 IS-2062

3600

5.03

1400

0.7

2.0

9.262546

0.6

11.86

12

DMFA/B/C

3 IS-2062

3800

8.99

1400

0.7

2.0

17.50991

1.1

20.61

22

ACF -A/B/C

3 IS-2062

3400

8.99

1400

0.7

2.0

15.66676

18.67

20

SAC -A/B/C

3 IS-2062

2200

8.99

1400

10.13731

0.6

10.74

12

SBA -A/B/C

3 IS-2062

3400

5.9

1400

0.7
.
0.7

10.2656

0.6

10.87

12

MB-A/B/C

3 IS-2062

1600

5.9

1400

0.7

4.830868

0.3

5.13

1 IS-2062

1000

5.9

1400

0.7

3.019293

0.3

5.32

ALKALI ACF

ARV

1 IS-2062

1600

8.5

1400

0.7

6.968998

0.4

7.37

10

HWT

1 SS 316

2600

1390

0.85

8.832272

0.5

9.33

10

## DIA = Unit diameter (mm)

HOS = Vessel height (mm)
P
= Design Pressure (Kgf/cm2)
Design Pressure =( Shut Off Pressure 20 % higher than pump head + Static Head (as applicable))X 5% margin
S
= Allowable stress (Kgf/cm2)
CA = Corrosion allowance (mm)
3
Di
= Inside diameter of shell in corroded condition (mm)
E
= Joint efficiency
MATL = Material for shell
TS = Calculated shell thickness
= P * D/(2*S*E-P)
MT = Mill Tolerance (mm) = 5% OF NOMINAL THICKNESS
CA = Corrosion allowance= 2mm (For Non - Rubberlined Vessels)
T = Design Temperature = 60 deg C
TNOM = Thickness Nominal
ION EXCHANGE (INDIA) LIMITED
CLIENT
: M/s. JAIPRAKASH POWER VENTURES LTD
CONSULTANT : DEVELOPMENT CONSULTANT PRIVATE LIMITED, KOLKATA
PROJECT
: 2x 660 MW JAYPEE NIGRIE SUPER THERMAL POWER PROJECT
CONTRACT NO. : 4303100037

R5

PAGE : 3 OF 6

## Design Calculations For Thickness Of Torispherical Dished ends

As Per IS 2825 Code (1969) & IS 4049 PART II (1996)
Sr Vessel

MATERIAL

No Description

Di

Do

Ro

ro

hE

hE/Do

t/Do

CA

TA t+CA

assumed

TNOM

+MT+TA

DM PLANT
2 DMF-C-A/B

IS2002 -2B

10

3600

3628

2890

540

915.3041

1.4

1590

0.85

0.250

0.0028

9.40

13.90

14

3 DMF-A/BC

IS2002 -2B

15

3800

3840

3055

570

968.6815

1.2

8.99

1590

0.85

0.250

0.0039

15.33

19.83

20

4 ACF -A/B/C

IS2002 -2B

14

3400

3440

2734

510

867.9678

1.2

8.99

1590

0.85

0.250

0.0041

13.73

18.23

20

5 SAC-A/B/C

IS2002 -2B

8.5

2200

2224

1768.5

330

561.1234

1.2

8.99

1590

0.85

0.250

0.0038

8.88

11.38

12

6 SBA -A/B/C

IS2002 -2B

8.5

3400

3424

2728.5

510

863.845

1.25

5.9

1590

0.85

0.250

0.0025

9.34

11.74

12

7 MB -A/B/C

IS2002 -2B

1600

1616

1284

240

408.0365

1.3

5.9

1590

0.85

0.250

0.0025

4.59

6.99

8 ALAKALI ACF

IS2002 -2B

1000

1016

803

150

256.8819

1.25

5.9

1590

0.85

0.250

0.0030

2.77

7.17

9 ARV

IS2002 -2B

1600

1620

1286

240

408.9504

1.2

8.5

1590

0.85

0.250

0.0037

6.11

8.51

10

10 HWT

2600

2624

2088

390

662.1248

1.25

1390

0.250

0.0030

9.44

11.94

12

## Ro = outside crown radius (mm)

ro = Outside knuckle radius (mm)
hE = Effective ouside height of DE (mm)
=Ro-SQRT((Ro-Do/2) * (Ro+Do/2-2*ro))
c = Shape factor
t
= P *Do*c/2*f*j (mm)
MATL =Material of Dish
f
= Allowable stress (Kgf/cm2)
P = Design pressure (Kgf/cm2)
j
= Joint efficiency
MT = Mill Tolerance (mm) = 0
T = Design Temperature = 60 deg C
TA = Thinning Allowance
TNOM = Thickness Nominal
CLIENT
CONSULTANT

## ION EXCHANGE (INDIA) LIMITED

: M/s. JAIPRAKASH POWER VENTURES LTD
: DEVELOPMENT CONSULTANT PRIVATE LIMITED, KOLKATA

R5

PROJECT
: 2x 660 MW JAYPEE NIGRIE SUPER THERMAL POWER PROJECT
CONTRACT NO. : 4303100037

PAGE : 4 OF 6

## Design Calculations for Thickness Of Shell - TANKS

As Per IS 2825 Code
Sr
No

Vessel
Description

Qty.

BAT

BCT

BAT CW

MATERIAL

Di

P
(max)

CA

TS

MT

TS+CA +MT

THK

THK PROVIDED

IS-2062

3400

1400

0.7

5.2121

0.5

5.71

10

IS-2062

3200

1400

0.7

4.9055

0.5

5.41

10

IS-2062

2000

1400

0.7

3.0659

0.5

3.57

10

As per Calculations the thickness is much lower but , minimum Thickness of 10 mm has been provided as per Tender Specs for Bulk Storage Tanks.
BAT : BULK ACID STORAGE TANK
BCT: BULK CAUSTIC STORAGE TANK
BAT CW : BULK ACID STORAGE TANK CW TREATMENT

Notes :

S
CA

## = Allowable stress (Kgf/cm2)

= Corrosion allowance (mm)

Di
E

## = Inside diameter of shell in corroded condition (mm)

= Joint efficiency

## MATL = Material for shell

TS = Calculated shell thickness
= P * D/(2*S*E-P)
MT = Mill Tolerance (mm) = 5 % 0f Nominal Thickness.
CA = Corrosion allowance= 2.0mm (For Non - Rubberlined Vessels) & 0 mm (for Rubberlined Vessels)
T

## TNOM = Thickness Nominal

ION EXCHANGE (INDIA) LIMITED
CLIENT
: M/s. JAIPRAKASH POWER VENTURES LTD
CONSULTANT : DEVELOPMENT CONSULTANT PRIVATE LIMITED, KOLKATA
PROJECT
: 2x 660 MW JAYPEE NIGRIE SUPER THERMAL POWER PROJECT
CONTRACT NO. : 4303100037

PAGE : 5 OF 6

## Design Calculations For Thickness Of Torispherical Dished ends - TANKS

As Per IS 2825 Code (1969) & IS 4049 PART II (1996)
Sr Vessel
No Description

MATERIAL
t
assumed

Di

Do

Ro

ro

hE

hE/Do

t/Do

CA

TA

t+CA
REQD.
+MT+TA THICK.

1 BAT

IS2062

3400

3420

2726

510

863.03

1.25

1400

0.7

0.2523 0.0018

6.54

9.04

10

2 BCT

IS2062

3200

3220

2566

480

812.576 1.25

1400

0.7

0.2524 0.0019

6.16

8.66

10

3 BAT CW

IS2062

2000

2020

1604

300

510.238 1.25

1400

0.7

0.2526 0.0019

3.86

8.36

10

As per Calculations the thickness is much lower but , minimum Thickness of 10 mm has been provided as per Tender Specs.
Hence the calculation is submitted only for ref and information
Notes :
D - Inside Diameter of Shell in Corroded Condition (mm)
BAT : BULK ACID STORAGE TANK
L - Crown Radius in Corroded Condition (mm)
BCT: BULK CAUSTIC STORAGE TANK
R - Knuckle Radius in Corroded Condition (mm)
BAT CW : BULK ACID STORAGE TANK CW TREATMENT
NOTE :
Do = Outside diameter of dish (mm)
Ro = outside crown radius (mm)
ro = Outside knuckle radius (mm)
hE = Effective ouside height of DE (mm)
=Ro-SQRT((Ro-Do/2) * (Ro+Do/2-2*ro))
c = Shape factor
t
= P *Do*c/2*f*j (mm)
MATL =Material of Dish
f
= Allowable stress (Kgf/cm2)
P = Design pressure (Kgf/cm2)
j
= Joint efficiency
TD= Calculated D.E.Thickness
MT = Mill Tolerance (mm) = 0.3 mm for plate upto 6 mm
= 0.5 mm for plates 8 mm & above.
T = Design Temperature = 60 Degrees C (MAX)
ION EXCHANGE (INDIA) LIMITED
CLIENT
: M/s. JAIPRAKASH POWER VENTURES LTD
CONSULTANT : DEVELOPMENT CONSULTANT PRIVATE LIMITED, KOLKATA
PROJECT
: 2x 660 MW JAYPEE NIGRIE SUPER THERMAL POWER PROJECT
CONTRACT NO. : 4303100037

PAGE : 6 OF 6