VENVEL THERMAL & MECHANICLA DESIGNERS

EQP. TAG No. : - DESIGN REF No --- SHEET No. : 1 of 13

MSN : - REV No. : 0
COVER PAGE
DATED : 14/04/16

MECHANICAL DESIGN
CALCULATION REPORT
PROJECT ------

EQUIPMENT NAME ACID SEPARATOR WITH COOLER

CLIENT M/S --------

PO NO ---------------

REFERENCE DATA SHEET NO --------, Rev 0

CODE OF CONSTRUCTION ASME SECTION VIII DIV 1, EDITION 2015

EQUIPMENT TAG NO. --------

MFRS SERIAL NUMBER -------

Job No -------

0 14/04/16 First Issue

REV DATE DESCRIPTION OF REVISION PREPARED REVIEWED

NO AND APPROVED BY BY
DESIGN ENGINEER CUSTOMER
 VENVEL THERMAL & MECHANICLA DESIGNERS
EQP. TAG No. : - DESIGN REF No --- SHEET No. : 2 of 13
MSN : - REV No. : 0
INDEX
DATED : 14/04/16

SR. SHEET REVISION No.

DESCRIPTION
No. NO. 0 1 2 3
1. COVER PAGE 1 14/04/16

2. INDEX 2 14/04/16

3. DESIGN DATA 3 14/04/16

4. SHELL UG -27 & Appendix 1-1 4 14/04/16

5. MAWP FOR SHELL 4 14/04/16

6. DISH END UG-32 5-6 14/04/16

7. MAWP FOR DISH 6 14/04/16

8. NOZZLE (N1,N2) AS PER UG 45, UG 36 DN 80 7 14/04/16

9. NOZZLE (N3) AS PER UG 45, UG 36 DN 50 8 14/04/16

10. NOZZLE (N4,N5,N6) AS PER UG 45, UG 36 DN 40 9 14/04/16

11. NOZZLE (N9,N10) AS PER UG 45, UG 36 DN 50 10 14/04/16

12. NOZZLE (N7,N8) AS PER UG 45, UG 36 DN 25 11 14/04/16

13. REQUIREMENT OF STRESS RELEIVING FOR COLD FORMED 12-13 14/04/16

PLATES
 VENVEL THERMAL & MECHANICLA DESIGNERS
EQP. TAG No. : - DESIGN REF No --- SHEET No. : 3 of 13
MSN : - REV No. : 0
DESIGN DATA
DATED : 14/04/16
EQUIPMENT DESIGN DATA :
CONFIGURATION (TYPE) : VERTICAL
SERVICE ( LETHAL OR NON LETHEL) : NON LETHAL
DESIGN AND MANUFACTURING CODE : ASME SECTION VIII DIV 1, EDITION 2015
INTERNAL DESIGN PRESSURE : 0.6 MPa (g) (1.05 Kg/cm2)
MAXIMUM ALLOWABLE WORKING PRESSURE (MAWP) : 0.84 MPa (g) @ 70 Deg C
DESIGN TEMPERATURE (MAX) : 70 Deg C
MINIMUM DESIGN METAL TEMPERATUE (MDMT) : 10 Deg C @ 0.6 MPa (g)
CORROSION ALLOWANCE : 3 mm (Only for shell)
RADIOGRAPHY :NA (100% DP Test)
JOINT EFFICIENCY FOR SHELL (CIRC STRESS / LONG STRESS) : 0.7/ 0.7
OPERATING PRESSURE : 0.15 MPa(g)
OPERATING TEMPERATURE : 45 Deg C
PROCESS FLUID : H2SO4 + GAS
PROCESS FLUID DENSITY (MAX) : 890 kg / m3
HIGHEST LIQUID LEVEL FROM BOTTOM : 1670 mm
INSULATION THK : NIL
: 0.78 MPa (g) 7.95 (kg/cm2 (g))
HYDROSTATIC TEST PRESSURE (AT TOP) VERTICAL POSITION
Do not exceed 8 Kg/cm2 (g)
HYDROTEST TEMPERATURE (MIN/MAX) : 27 / 48 Deg C (Recommended)
PNEUMATIC TEST PRESSURE : N.A
POST WELD HEAT TREATMENT (PWHT) (Refer Sheet No : 28) : EXEMPTED
IMPACT TEST(Refer Sheet No : 27) : EXEMPTED
POST FORMING HEAT TREATMENT : REQUIRED FOR DISH END
RATINGS OF FLANGES : ASME B16.5, 2013 Edition
ASME CERTIFICATION MARK :NO
NATIONAL BOARD REGISTRATION : NO
OVER PRESSURE PROTECTION :-
WEIGHT DETAILS :
EMPTY WEIGHT(We ) : 662 kg
OPERATING WEIGHT(Wo ) : 893 kg
HYDRO TEST WEIGHT (Wh) : 1042 kg
MATERIAL OF CONSTRUCTION :
SHELL / DISH END : SA 516 GR 70
TUBES : SA 213 TP 316 L
TUBE SHEEET : SA 240 TP 316 L
NOZZLE PIPES : SA 106 GR B
SHELL FLANGES : SA 516 GR 70
NOZZLE FLANGES : SA 105
GUSSET,BAFFLE,IMPINGMENT,LIFITING LUG,NAME PLATE : SA 516 GR 70
BRACKET & FLAT BOTTOM PLATES, PARTITION PLATE
NAME PLATE : SA 240 TP 304
 VENVEL THERMAL & MECHANICLA DESIGNERS
EQP. TAG No. : - DESIGN REF No --- SHEET No. : 4 of 13
MSN : - REV No. : 0
SHELL UG -27 & Appendix 1-1
DATED : 14/04/16
MATERIAL : SA 516 GR 70

P :INTERNAL DESIGN PRESSURE : 0.6 MPa (g)

Tc :DESIGN TEMPERATURE : 70 Deg C

C :CORROSION ALLOWANCE :3 mm

Do :OUTSIDE DIAMETER OF SHELL : 590 mm

Tol :PERMISSABLE TOLERANCE FOR INSIDE DIAMETER OF SHELL : + / - 5 mm

Ro :OUTSIDE RADIUS OF SHELL : 295 mm

ts : ASSUMED THICKNESS OF SHELL : 10 mm

S : MAXIMUM ALLOWABLE STRESS VALUE AT DESIGN TEMP. : 138 MPa (g)

(AS PER ASME SEC.II PART.D)

El :JOINT EFFICIENCY FACTOR FOR CIRCUMFERENTIAL STRESS : 0.7

Ec :JOINT EFFICIENCY FACTOR FOR LONGITUDINAL STRESS : 0.7

UG-27 (a) AS PER APPENDIX 1 1 (a) (1)

ts = P * Ro / ( S*E +0.4 * P) + CA

= [ (0.6 x 295) / ( 138.00 x 0.7 + 0.4 x 0.6 )] + 3

= [ 177 / (96.6 + 0.24 )] + 3 = [177 / 96.84] + 3

= 4.827 : 4.827 mm

UG-16 (b)

t min : MINIMUM REQUIRED THICKNESS OF CYLINDRICAL SHELL : 4.5 mm

FOR PRESSURE PARTS + C = 1.5 + 3

td : DESIGN THICKNESS OF SHELL WITH CORROSION ALLOWANCE : 4.827 mm

(GREATER OF ( 4.827 , 4.5 )

ts : PROVIDED SHELL THICKNESS* : 10.00 mm

* Mill under tolerance as per UG-16 (c) ( smaller of 0.25 mm or 6 % of the order thickness )

= Smaller (0.25, 0.6) : 0.25 mm

PROVIDED THICKNESS of shell = 10 mm - 0.25 mm = 9.75 mm, 9.75 (Provided) > 4.827 mm (Required)

AS REQUIRED THICKNESS IS LESS THEN NOMINAL THICKNESS, PLATE SUPPLIED WITH ABOVE UNDER TOLERANCE MAY BE
ACCEPTED AND CAN BE USED AT RATED MAWP.

MAWP FOR SHELL

t :THICKNESS OF SHELL IN CORRODED CONDITION (10-3) : 7 mm

Ro : OUTSIDE RADIUS OF SHELL : 255 mm

P = [S*E*t/(Ro-0.4t)]

P = [138*0.7*7/(255-0.4*7)] = [676.2/252.2]

P = 2.68 Mpa : 2.68 Mpa

MAXIMUM ALLOWABLE WORKING PRESSURE = 2.68 Mpa

 VENVEL THERMAL & MECHANICLA DESIGNERS
EQP. TAG No. : - DESIGN REF No --- SHEET No. : 5 of 13
MSN : - REV No. : 0
DISHED END UG -32
DATED : 14/04/16

MATERIAL : SA 516 GR 70

TYPE OF DISHED END : 2:1 Ellipsoidal

P : INTERNAL DESIGN PRESSURE : 0.6 MPa (g)

Tc : DESIGN TEMPERATURE : 70 Deg C

C : CORROSION ALLOWANCE : 3 mm

D : INSIDE DIAMETER OF DISHED END SKIRT : 566 mm

h : DEPTH OF THE DISH END : 141.5 mm

L' : INSIDE CROWN RADIUS,D / 2h = 566 / (2 x 141.5) = 566/283 = 2,

(FROM TABLE UG -37)K1 = 0.9 =: 0.9 x 566 : 509.4 mm

L : INSIDE CROWN RADIUS CORRODED CONDITION=(L'+C) : 512.4 mm (For t/L calculations)

S.F :STRAIGHT FACE OF DISHED END : 50 mm

D : INSIDE DIAMETER OF DISHED END SKIRT (CORRODED CONDITION)

[566 + (3 x2)] = [566 + 6] : 578 mm

tnom : ASSUMED NOMINAL DISH THICKNESS BEFORE FORMING (BLANK) : 12 mm

x : FORMING THICKNESS TOLERANCE (THINING ) : 2 mm

ts : ASSUMED DISH THICKNESS AFTER FORMING = ( tnom x ) = (12 2.0) : 10 mm

S :MAXIMUM ALLOWABLE STRESS VALUE AT DESIGN TEMP : 138 MPa (g)

(AS PER ASME SEC.II PART D)

E:JOINT EFFIRNCY FACTOR FOR CIRCUMFERENTIAL STRESS : 0.7

(SHELL TO DISH END JOINT)

As per UG 32 (d)

(ts-C)/L=(7)/440.4: 0.002 < 0.015

AS(ts-C)/L>=0.002,THE RULES OF 1-4(f) SHALL NOT REQUIRED OK

t req1 : MINIMUM REQUIRED THICKNESS OF HEAD AFTER FORMING

= [(P x D ) / ((2 x S x El)(0.2 x P))] +C

= [(0.6 x 578)/((2 x 138 x 0.7) (0.2 x 0.6))]+ 3

= [ 346.8/ (193.2 0.12)] +3 = [346.8 / 193.08] + 3 = 1.796 + 3 : 4.796 mm

UG-16(b)(2)

t req2 :MINIMUM REQUIRED THICKNESS OF DISHED END : 4.5

FOR PRESSURE PARTS + C = 1.5 + 3

td : DESIGN THICKNESS OF SHELL WITH CORROSION ALLOWANCE : 4.796 mm

(GREATER OF ( 4.796, 4.5 )

 VENVEL THERMAL & MECHANICLA DESIGNERS
EQP. TAG No. : - DESIGN REF No --- SHEET No. : 6 of 13
MSN : - REV No. : 0
DISHED END UG -32
DATED : 22/02/16

td : MINIMUM DESIGN THICKNESS OF DISHED END AFTER FORMING : 4.796 mm

th : PROVIDED DISHED END NOMINAL THICKNESS* : 12 mm

* Mill Under tolerance as per UG-16( c ) : 0.25 mm

(Smaller of 0.25mm or 6% of the order thickness = Smaller ( 0.25, 0.72)

NOMINAL THICKNESS OF PLATE IN UNDER TOLARANCE COND ITION = 12 0.25 : 11.75 mm (9.75 mm After forming)

Ts:MINIMUM SPECIFIED THICKNESS OF DISHED END AFTER FORMING : 9.75 mm

9.75 > 4.796(Inclusive of corrosion allowance) ACCEPTABLE *

* Note : After forming actual thickness shall be inspected before use.

MAWP FOR DISH ENDS

S : MAXIMUM ALLOWABLE STRESS VALUE AT DESIGN TEMP. : 138 MPa (g)

(AS PER ASME SEC.II PART.D)

El :JOINT EFFICIENCY FACTOR FOR CIRCUMFERENTIAL STRESS : 0.7

t :THICKNESS OF SHELL IN CORRODED CONDITION (12-3) : 9 mm

D : INSIDE DIAMETER OF DISHED END SKIRT (CORRODED CONDITION) : 492 mm

P = [2*S*E*t/(D+0.2t)]

P = [2*138*0.7*7(492+0.2*7)]

P = 2.74 Mpa : 2.74 Mpa

MAXIMUM ALLOWABLE WORKING PRESSURE = 2.74 Mpa

 VENVEL THERMAL & MECHANICLA DESIGNERS
EQP. TAG No. : - DESIGN REF No --- SHEET No. : 7 of 13
MSN : - NOZZLE (N1,N2) AS PER UG 45, UG 36 REV No. : 0
DN 80 SCH 80 DATED : 14/04/16
NOZZLE
.SUB CLAUSE NOZZLE MARK :N1,N2 ON SHELL
LOCATION:
UG-45 IS NOZZLE TYPE = ACCESS OPENING OR USED ONLY FOR INSPECTION NO
INTERNAL DESIGN PRESSURE P MPa (g) 0.6
MAXIMUM ALLOWABLE WORKING PRESSURE P Mpa (g) 0.840
EXTERNAL DESIGN PRESSURE Pe MPa (g) NIL
NOZZLE PARAMETERS

MATERIAL DESIGNATION SA 106 GR B

MAXIMUM ALLOWABLE STRESS S MPa 118
OUTSIDE DIAMETER OF PIPE Do mm 88.9
OUTSIDE RADIUS OF PIPE = Do / 2 = 610 / 2 Ro mm 44.45
NOMINAL PIPE SIZE DN 80
CORROSION ALLOWANCE CA mm 0
LONGITUDINAL JOINT TYPE SEAMLESS
JOINT EFFICIENCY FOR NECK PIPE E 0.7
UG-27 (a) AS PER APPENDIX 1 1 (a)
t = P * Ro / ( S*E +0.4 * P) + CA
ta = 0.6 x 44.45 / ( 118 x 0.7 + 0.4 x 0.6 ) 0.322
(a) REQUIRED THICKNESS OF SHELL (USING E = 0.7) AT NOZZLE
LOCATION (From Sheet No 17) = 4.827
tb1 MINIMUM REQUIRED THICKNESS FOR COMPRESSED AIR tb1 mm 4.827
APPLICATION AS PER UG (16)(b) = 1.5
Max of (a,b) = Max (4.827, 1.5 ) = 4.827 mm
tb2 THICKNESS REQUIRED FOR EXTERNAL PRESSURE tb2 mm 0
tb3 THICKNESS REQUIRED AS PER TABLE UG-45 + CA = (4.80+ 0) tb3 mm 4.8
tb = Min (tb3, max (tb1,tb2) = Min ( 4.8, max (4.827, 0 )
UG -45 Tb mm 4.8
= Min (4.8, 4.827 )
GOVERNING THICKNESS FOR ABOVE tn mm 4.8
PROVIDED NOMINAL THICKNESS t mm 7.62
PIPE THICKNESS DURING UNDER TOLARENCE CASE = 7.62 x 0.875 = 6.67
AS REQUIRED THK. (4.8 mm) <= PROVIDED THK. (6.67 mm), PROVIDED THICKNESS IS ADEQUATE.
FINISHED OPENING SIZE
= do -2 x tn (UNDER TOLERANCE) + 2 x C
=(88.9 2 x 6.67) + (2 x 3) D mm 81.56
AS PER UG -36(c)(3)(a) and UW-15(b) (2), FINISHED OPENING SIZE LARGER THAN 89 MM DIAMETER IN VESSEL SHELLS OR HEADS WITH A REQUIRED
MINIMUM THICKNESS 10MM OR MORE, ARE NOT EXEMPTED FROM REINFORCEMENT AND WELD STRENGTH CALCULATION .
FINISHED OPENING SIZE D mm 81.56
REQUIRED MINIMUM THICKNESS OF NOZZLE tn mm 7.62
HENCE , REINFORCEMENT REQUIRED AND WELD STRENGTH CHECKING CALCULATIONS ARE NOT REQUIRED FOR THIS NOZZLE.
FILLET WELD REQUIRED AT NOZZLE TO SHELL JUNCTION:
tn : NORMAL THICKNESS OF NOZZLE NECK tn = 7.62 : 7.62 Mm
ts : NOMINAL THICKNESS OF SHELL ts = 10 : 10.00 Mm
t min : SMALLER OF 19 mm OR LESSER OF tn& t = SMALLER (19.00, 7.62, 10.00) : 7.62 Mm
(tn) : REQUIRED THROAT NOT LESS THAN SMALLER OF 6 mm OR (0.7 x tmin )= 0.7 x 7.62 = SMALLER (6.00,5.334) : 5.334 Mm
tleg (req) : REQUIRED LEG SIZE = 5.334 / 0.7 : 7.62 Mm
Leg : PROVIDED LEG SIZE : 8.00 Mm
 VENVEL THERMAL & MECHANICLA DESIGNERS
EQP. TAG No. : - DESIGN REF No --- SHEET No. : 8 of 13
MSN : - NOZZLE (N3) AS PER UG 45, UG 36 REV No. : 0
DN 50 SCH 80 DATED : 14/04/16

NOZZLE
.SUB CLAUSE NOZZLE MARK :N3 ON SHELL
LOCATION:
UG-45 IS NOZZLE TYPE = ACCESS OPENING OR USED ONLY FOR INSPECTION NO
INTERNAL DESIGN PRESSURE P MPa (g) 0.6
MAXIMUM ALLOWABLE WORKING PRESSURE P Mpa (g) 0.840
EXTERNAL DESIGN PRESSURE Pe MPa (g) NIL
MATERIAL DESIGNATION SA 106 GR B
NOZZLE PARAMETERS

MAXIMUM ALLOWABLE STRESS S MPa 118

OUTSIDE DIAMETER OF PIPE Do mm 60.3
OUTSIDE RADIUS OF PIPE = Do / 2 = 610 / 2 Ro mm 30.15
NOMINAL PIPE SIZE DN 50
CORROSION ALLOWANCE CA mm 0
LONGITUDINAL JOINT TYPE SEAMLESS
JOINT EFFICIENCY FOR NECK PIPE E 0.7
UG-27 (a) AS PER APPENDIX 1 1 (a)
t = P * Ro / ( S*E +0.4 * P) + CA
ta = 0.6 x 30.15 / ( 118 x 0.7 + 0.4 x 0.6 ) + 0 0.218
(a) REQUIRED THICKNESS OF SHELL (USING E = 0.7) AT NOZZLE
LOCATION (From Sheet No 17) = 4.827
tb1 MINIMUM REQUIRED THICKNESS FOR COMPRESSED AIR tb1 mm 4.827
APPLICATION AS PER UG (16)(b) = 1.5 + 0
Max of (a,b) = Max (4.827, 1.5 ) = 4.827 mm
tb2 THICKNESS REQUIRED FOR EXTERNAL PRESSURE tb2 mm 0
tb3 THICKNESS REQUIRED AS PER TABLE UG-45 + CA = (3.42 + 0) tb3 mm 3.42
tb = Min (tb3, max (tb1,tb2) = Min ( 3.42, max (4.827, 0 )
UG -45 Tb mm 3.42
= Min (3.42, 4.827 )
GOVERNING THICKNESS FOR ABOVE tn mm 3.42
PROVIDED NOMINAL THICKNESS t mm 5.54
PIPE THICKNESS DURING UNDER TOLARENCE CASE = 5.54 x 0.875 = 4.85
AS REQUIRED THK. (4.827 mm) <= PROVIDED THK. (4.85 mm), PROVIDED THICKNESS IS ADEQUATE.
FINISHED OPENING SIZE
= do -2 x tn (UNDER TOLERANCE) + 2 x C
=(60.3 2 x 4.85) + (2 x 3) D mm 56.6
AS PER UG -36(c)(3)(a) and UW-15(b) (2), FINISHED OPENING SIZE LARGER THAN 89 MM DIAMETER IN VESSEL SHELLS OR HEADS WITH A REQUIRED
MINIMUM THICKNESS 10MM OR MORE, ARE NOT EXEMPTED FROM REINFORCEMENT AND WELD STRENGTH CALCULATION .
FINISHED OPENING SIZE D mm 56.6
REQUIRED MINIMUM THICKNESS OF NOZZLE tn mm 5.54
HENCE , REINFORCEMENT REQUIRED AND WELD STRENGTH CHECKING CALCULATIONS ARE NOT REQUIRED FOR THIS NOZZLE.
FILLET WELD REQUIRED AT NOZZLE TO SHELL JUNCTION:

tn : NORMAL THICKNESS OF NOZZLE NECK tn = 7.62 : 5.54 Mm

ts : NOMINAL THICKNESS OF SHELL ts = 10 : 10.00 Mm
t min : SMALLER OF 19 mm OR LESSER OF tn& t = SMALLER (19.00, 5.54, 10.00) : 5.54 Mm
(tn) : REQUIRED THROAT NOT LESS THAN SMALLER OF 6 mm OR (0.7 x tmin )= 0.7 x 5.54 = SMALLER (6.00,3.878) : 3.878 Mm
tleg (req) : REQUIRED LEG SIZE = 3.878 / 0.7 : 5.54 Mm
Leg : PROVIDED LEG SIZE : 6.00 Mm
 VENVEL THERMAL & MECHANICLA DESIGNERS
EQP. TAG No. : - DESIGN REF No --- SHEET No. : 9 of 13
MSN : - NOZZLE (N4,N5,N6) AS PER UG 45, UG 36 REV No. : 0
DN 40 SCH 80 DATED : 14/04/16

NOZZLE
.SUB CLAUSE NOZZLE MARK :N4,N5,N6 ON SHELL
LOCATION:
UG-45 IS NOZZLE TYPE = ACCESS OPENING OR USED ONLY FOR INSPECTION NO
INTERNAL DESIGN PRESSURE P MPa (g) 0.6
MAXIMUM ALLOWABLE WORKING PRESSURE P Mpa (g) 0.840
EXTERNAL DESIGN PRESSURE Pe MPa (g) NIL
MATERIAL DESIGNATION SA 106 GR B
NOZZLE PARAMETERS

MAXIMUM ALLOWABLE STRESS S MPa 118

OUTSIDE DIAMETER OF PIPE Do mm 48.3
OUTSIDE RADIUS OF PIPE = Do / 2 = 610 / 2 Ro mm 24.15
NOMINAL PIPE SIZE DN 40
CORROSION ALLOWANCE CA mm 0
LONGITUDINAL JOINT TYPE SEAMLESS
JOINT EFFICIENCY FOR NECK PIPE E 0.7
UG-27 (a) AS PER APPENDIX 1 1 (a)
t = P * Ro / ( S*E +0.4 * P) + CA
ta = 0.6 x 24.15 / ( 118 x 0.7 + 0.4 x 0.6 ) + 0 0.175
(a) REQUIRED THICKNESS OF SHELL (USING E = 0.7) AT NOZZLE
LOCATION (From Sheet No 17) = 4.827
tb1 MINIMUM REQUIRED THICKNESS FOR COMPRESSED AIR tb1 mm 4.827
APPLICATION AS PER UG (16)(b) = 1.5 + 0
Max of (a,b) = Max (4.827, 1.5 ) = 4.827 mm
tb2 THICKNESS REQUIRED FOR EXTERNAL PRESSURE tb2 mm 0
tb3 THICKNESS REQUIRED AS PER TABLE UG-45 + CA = (3.22 + 0) tb3 mm 3.22
UG -45 tb = Min (tb3, max (tb1,tb2) = Min ( 3.22, max (4.827, 0 ) Tb mm 3.22
GOVERNING THICKNESS FOR ABOVE tn mm 3.22
PROVIDED NOMINAL THICKNESS t mm 4.445
PIPE THICKNESS DURING UNDER TOLARENCE CASE = 5.08 x 0.875 = 4.445
AS REQUIRED THK. (3.22 mm) <= PROVIDED THK. (4.445 mm), PROVIDED THICKNESS IS ADEQUATE.
FINISHED OPENING SIZE
= do -2 x tn (UNDER TOLERANCE) + 2 x C
=(48.3 2 x 4.445) + (2 x 0) D mm 39.41
AS PER UG -36(c)(3)(a) and UW-15(b) (2), FINISHED OPENING SIZE LARGER THAN 89 MM DIAMETER IN VESSEL SHELLS OR HEADS WITH A REQUIRED
MINIMUM THICKNESS 10MM OR MORE, ARE NOT EXEMPTED FROM REINFORCEMENT AND WELD STRENGTH CALCULATION .
FINISHED OPENING SIZE D mm 39.41
REQUIRED MINIMUM THICKNESS OF NOZZLE tn mm 4.445
HENCE , REINFORCEMENT REQUIRED AND WELD STRENGTH CHECKING CALCULATIONS ARE NOT REQUIRED FOR THIS NOZZLE.
 VENVEL THERMAL & MECHANICLA DESIGNERS
EQP. TAG No. : - DESIGN REF No --- SHEET No. : 10 of 13
MSN : - NOZZLE (N7,N8) AS PER UG 45, UG 36 REV No. : 0
DN 25 SCH 80 DATED : 14/04/16

NOZZLE
.SUB CLAUSE NOZZLE MARK :N7,N8 ON SHELL
LOCATION:
UG-45 IS NOZZLE TYPE = ACCESS OPENING OR USED ONLY FOR INSPECTION NO
INTERNAL DESIGN PRESSURE P MPa (g) 0.6
MAXIMUM ALLOWABLE WORKING PRESSURE P Mpa (g) 0.840
EXTERNAL DESIGN PRESSURE Pe MPa (g) NIL
MATERIAL DESIGNATION SA 106 GR B
NOZZLE PARAMETERS

MAXIMUM ALLOWABLE STRESS S MPa 118

OUTSIDE DIAMETER OF PIPE Do mm 33.4
OUTSIDE RADIUS OF PIPE = Do / 2 = 610 / 2 Ro mm 16.7
NOMINAL PIPE SIZE DN 25
CORROSION ALLOWANCE CA mm 0
LONGITUDINAL JOINT TYPE SEAMLESS
JOINT EFFICIENCY FOR NECK PIPE E 0.7
UG-27 (a) AS PER APPENDIX 1 1 (a)
t = P * Ro / ( S*E +0.4 * P) + CA
Ta = 0.6 x 16.7/ ( 118 x 0.7 + 0.4 x 0.6 ) + 0 0.121
(a) REQUIRED THICKNESS OF SHELL(USING E = 0.7) AT NOZZLE
LOCATION (From Sheet No 17) = 4.827
tb1 MINIMUM REQUIRED THICKNESS FOR COMPRESSED AIR tb1 mm 4.827
APPLICATION AS PER UG (16)(b) = 1.5 + 0
Max of (a,b) = Max (4.827, 1.5 ) = 4.827 mm
tb2 THICKNESS REQUIRED FOR EXTERNAL PRESSURE tb2 mm 0
tb3 THICKNESS REQUIRED AS PER TABLE UG-45 + CA = (2.96 + 0) tb3 mm 2.96
UG -45 tb = Min (tb3, max (tb1,tb2) = Min ( 2.96, max (4.827, 0 ) Tb mm 2.96
GOVERNING THICKNESS FOR ABOVE tn mm 2.96
PROVIDED NOMINAL THICKNESS t mm 3.98
PIPE THICKNESS DURING UNDER TOLARENCE CASE = 4.55 x 0.875 = 3.98
AS REQUIRED THK. (2.96 mm) <= PROVIDED THK. (3.98 mm), PROVIDED THICKNESS IS ADEQUATE.
FINISHED OPENING SIZE
= do -2 x tn (UNDER TOLERANCE) + 2 x C
=(33.4 2 x 3.98) + 0 D mm 25.44
AS PER UG -36(c)(3)(a) and UW-15(b) (2), FINISHED OPENING SIZE LARGER THAN 89 MM DIAMETER IN VESSEL SHELLS OR HEADS WITH A REQUIRED
MINIMUM THICKNESS 10MM OR MORE, ARE NOT EXEMPTED FROM REINFORCEMENT AND WELD STRENGTH CALCULATION .
FINISHED OPENING SIZE D mm 25.44
REQUIRED MINIMUM THICKNESS OF NOZZLE tn mm 4.55
HENCE , REINFORCEMENT REQUIRED AND WELD STRENGTH CHECKING CALCULATIONS ARE NOT REQUIRED FOR THIS NOZZLE.
 VENVEL THERMAL & MECHANICLA DESIGNERS
EQP. TAG No. : - DESIGN REF No --- SHEET No. : 11 of 13
MSN : - NOZZLE (N9,N10) AS PER UG 45, UG 36 REV No. : 0
DN 50 SCH 80 DATED : 14/04/16

NOZZLE
.SUB CLAUSE NOZZLE MARK :N9,N10 ON DISH END
LOCATION:
UG-45 IS NOZZLE TYPE = ACCESS OPENING OR USED ONLY FOR INSPECTION NO
INTERNAL DESIGN PRESSURE P MPa (g) 0.6
MAXIMUM ALLOWABLE WORKING PRESSURE P Mpa (g) 0.840
EXTERNAL DESIGN PRESSURE Pe MPa (g) NIL
MATERIAL DESIGNATION SA 106 GR B
NOZZLE PARAMETERS

MAXIMUM ALLOWABLE STRESS S MPa 118

OUTSIDE DIAMETER OF PIPE Do mm 60.3
OUTSIDE RADIUS OF PIPE = Do / 2 = 610 / 2 Ro mm 30.15
NOMINAL PIPE SIZE DN 50
CORROSION ALLOWANCE CA mm 3
LONGITUDINAL JOINT TYPE SEAMLESS
JOINT EFFICIENCY FOR NECK PIPE E 0.7
UG-27 (a) AS PER APPENDIX 1 1 (a)
t = P * Ro / ( S*E +0.4 * P) + CA
ta = 0.6 x 30.15 / ( 118 x 0.7 + 0.4 x 0.6 ) + 3 3.218
(a) REQUIRED THICKNESS OF DISH END (USING E = 0.7) AT
NOZZLE LOCATION (From Sheet No 17) = 4.796
tb1 MINIMUM REQUIRED THICKNESS FOR COMPRESSED AIR tb1 mm 4.796
APPLICATION AS PER UG (16)(b) = 1.5 + 3
Max of (a,b) = Max (4.796, 4.5 ) = 4.796 mm
tb2 THICKNESS REQUIRED FOR EXTERNAL PRESSURE tb2 mm 0
tb3 THICKNESS REQUIRED AS PER TABLE UG-45 + CA = (3.42 + 3) tb3 mm 6.42
UG -45 tb = Min (tb3, max (tb1,tb2) = Min ( 6.42, max (4.529, 0 ) Tb mm 4.796
GOVERNING THICKNESS FOR ABOVE tn mm 4.796
PROVIDED NOMINAL THICKNESS t mm 5.54
PIPE THICKNESS DURING UNDER TOLARENCE CASE = 5.54 x 0.875 = 4.85
AS REQUIRED THK. (4.796 mm) <= PROVIDED THK. (4.85 mm), PROVIDED THICKNESS IS ADEQUATE.
FINISHED OPENING SIZE
= do -2 x tn (UNDER TOLERANCE) + 2 x C
=(60.3 2 x 4.85) + (2 x 3) D mm 56.6
AS PER UG -36(c)(3)(a) and UW-15(b) (2), FINISHED OPENING SIZE LARGER THAN 89 MM DIAMETER IN VESSEL SHELLS OR HEADS WITH A REQUIRED
MINIMUM THICKNESS 10MM OR MORE, ARE NOT EXEMPTED FROM REINFORCEMENT AND WELD STRENGTH CALCULATION .
FINISHED OPENING SIZE D mm 56.6
REQUIRED MINIMUM THICKNESS OF NOZZLE tn mm 5.54
HENCE , REINFORCEMENT REQUIRED AND WELD STRENGTH CHECKING CALCULATIONS ARE NOT REQUIRED FOR THIS NOZZLE.
FILLET WELD REQUIRED AT NOZZLE TO SHELL JUNCTION:

tn : NORMAL THICKNESS OF NOZZLE NECK tn = 7.62 : 5.54 Mm

ts : NOMINAL THICKNESS OF DISH END ts = 12 : 12.00 Mm
t min : SMALLER OF 19 mm OR LESSER OF tn& t = SMALLER (19.00, 5.54, 10.00) : 5.54 Mm
(tn) : REQUIRED THROAT NOT LESS THAN SMALLER OF 6 mm OR (0.7 x tmin )= 0.7 x 5.54 = SMALLER (6.00,3.878) : 3.878 Mm
tleg (req) : REQUIRED LEG SIZE = 3.878 / 0.7 : 5.54 Mm
Leg : PROVIDED LEG SIZE : 6.00 Mm
 VENVEL THERMAL & MECHANICLA DESIGNERS
EQP. TAG No. : - DESIGN REF No --- SHEET No. : 12 of 13
MSN : - REV No. : 0
REQUIREMENT OF UG-79, UCS-79
DATED : 14/04/16

FORMING PRESSURE PARTS : .

UCS- 79 (d): VESSEL SHELL SECTIONS, HEADS, AND OTHER PRESSURE BOUNDARY PARTS OF CARBON AND
LOW ALLOY STEEL PLATES FABRICATED BY COLD FORMING SHALL BE HEAT TREATED
SUBSEQUENTLY WHEN THE RESULTING EXTREME FIBER ELONGATION IS MORE THAN 5%
FROM THE AS-ROLLED CONDITION.

CYLINDRICAL SHELL :

- % EXTREME FIBER ELONGATION FOR SHELL = [((50 x t)/Rf) x (1-(Rf/Ro))] = [((50x6)/310) x (1-(310/INFINITY))]

- PLATE THICKNESS TO BE VERIFIED WITH ACTUAL PLATE THICKNESS.

PART MATERIAL THICKNESS OD AFTER FINAL C/L ORIGINAL
EXTREME S.R. REQD
NOMINAL FORMING RADIUS C/L RADIUS
FIBRE (YES /No)
t(mm) mm (Rf) mm (Ro) mm
ELONGATION
%
SHELL SA 516 GR 70 10 610 310 INFINITY 1.612% No
SINCE EXTREME FIBRE ELONGATION IS LESS THEN 5%. STRESS RELEIVING MAY NOT REQUIRED AND AS PER UG-79,
UCS-79 (d) CONDITIONS NEED NOT BE VERIFIED.
 VENVEL THERMAL & MECHANICLA DESIGNERS
EQP. TAG No. : - DESIGN REF No --- SHEET No. : 13 of 13
MSN : - REV No. : 0
REQUIREMENT OF UG-79 & UCS-79
DATED : 09/01/16

DISHED END: (TOP )

Rf :INSIDE KNUCKLE RADIUS (Approximately- For Fibre Elongation)= 0.17 x 590: 100.3 mm

UCS-79 (d) VESSEL SHELL SECTIONS, HEADS, AND OTHER PRESSURE BOUNDARY PARTS OF CARBON) AND LOW ALLOY
STEEL PLATES FABRICATED BY COLD FORMING SHALL BE HEAT TREATED SUBSEQUENTLY (UCS 56), WHEN THE
RESULTING EXTREME FIBER ELONGATION IS MORE THEN 5% FROM THE AS ROLLED CONDITION.

% EXTREME FIBER ELONGATION FOR DISHED END =[((75xt)/Rf)x(1-(Rf/Ro))]=[((75x 12)/106.3) x(1-(106.3/INFINITY)

- PLATE THICKNESS TO BE VERIFIED WITH ACTUAL PLATE THICKNESS.

PART MATERIAL THICKNESS OD AFTER FINAL C/L ORIGINAL EXT.FIB S.R. REQD
NOMINAL FORMING RADIUS (Rf) C/L RADIUS ELONG % (YES /No)
t(mm) mm (Kr) mm (Ro) (Cr) mm
DISHED SA 516 GR 70 12 610 106.3 INFINITY
8.466% Yes
END
SINCE EXTREME FIBRE ELONGATION IS MORE THEN 5%. STRESS RELEIVING IS REQUIRED AND AS PER UG-79, UCS-79 (d)
CONDITIONS NEED TO BE VERIFIED.
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 YES
THICKNESS IS MORE THAN 10% AT ANY LOCATION WHERE = [(12 10 ) /10 ] * 100 = 20%
THE EXTREME FIBER ELOGNATION EXCEEDS 5%
5 THE TEMPERATURE OF THE MATERIAL DURING FORMING IS NO (As per Dish manufacturer
IN THE RANGE OF 120 DEG C TO 480 DEG C. confirmation)
EXTREME FIBER ELONGATION IS GREATER THAN 5%, AND ABOVE CONDITIONS FROM TABLE SR NO: 4 ALSO NOT
SATISFING. HENCESTRESS RELEIVING IS REQUIRED FOR THE DISHED ENDS (BOTH).

STRESS RELIEVING IS TO BE DONE, AS PER BELOW CHART.

HEAT TREATMENT CYCLE AS PER UCS-56
(STRESS RELEIVING FOR TOP AND BOTTOM DISH ENDS)
LOADING TEMPERATURE 300 Deg C (Max)
HEATING RATE 150 Deg C/ hr ( Max)
HOLDING TEMPERATURE 610 +/- 10 Deg C
SOAKING TIME 20 minutes (Min)
COOLING RATE 200 Deg C/ hr (Max)
UNLOADING TEMPERATURE 300 Deg C

ABOVE POST FORMING HEAT TREATMENT CYCLE FOR HEADS SHALL BE SPECIFIED IN THE DRAWING.