Compress Verification Manual

COMPRESS Verification Manual

A06 Version www.codeware.com

Revised 03/2007

Codeware, Inc. Table of Contents

Table of Contents Section 1: Introduction 1-1 1.1 Purpose of the Application 1-1 1.2 Future Changes 1-1 1.3 Intellectual Property Statement 1-1 Section 2: Quality Assurance Procedures 2-1 2.1 COMPRESS Development Team 2-1 2.2 Automated Verification 2-1 2.3 Baseline Test Files 2-2 Section 3: Component Analysis Verification 3-1 3.1 Shell and Head Verification 3-1 3.2 Nozzle Verification 3-5 3.3 Flange Verification 3-6 3.4 Cone Verification 3-7 3.5 ASME Tubesheet Verification 3-8 3.6 TEMA Tubesheet Verification 3-9 3.7 ASME Division 2 Component Verification 3-9 Section 4: Detailed Calculations 4-1 4.1 ASME Appendix L-2.2 4-1 4.2 ASME Appendix L-2.3.1 – L-2.3.2 4-12 4.3 ASME Appendix L-2.3.3 4-19 4.4 ASME Appendix L-3.1 4-24

COMPRESS Verification Document i

Table of Contents Codeware, Inc.

4.5 ASME Appendix L-3.2 4-26 4.6 ASME Appendix L-6.1 4-29 4.7 ASME Appendix L-6.2 4-33 4.8 ASME Appendix L-7.1 4-37 4.9 ASME Appendix L-7.3 4-41 4.10 ASME Division 2 Appendix G-101 4-47

4.11 ASME Division 2 Appendix G-105 4-49

4.12 ASME Division 2 Appendix G-115 No Reinforcement 4-54 4.13 ASME Division 2 Appendix G-115 w/ Local Insert Plate 4-65 4.14 ASME Division 2 Appendix G-115 w/ Reinforcing Pad 4-76 4.15 ASME Self Directed Interactive CD Example 4-4 4-89 4.16 ASME Self Directed Interactive CD Example 4-5 4-92 4.17 ASME Self Directed Interactive CD Example 4-8 4-102 4.18 ASME Self Directed Interactive CD Example 4-11 4-106 4.19 ASME Self Directed Interactive CD Example 4-14 4-109 4.20 Taylor Forge Bulletin 502 Edition VII Example 1 4-111 4.21 Appendix 2 Slip On Full Face Gasketed Flange 4-118 4.22 ASME UHX-20.1.1 4-124 4.23 ASME UHX-20.1.4 4-161

Section 5: Reference Documents 5-1

ii COMPRESS Verification Document

Codeware, Inc. Introduction

Section 1: Introduction

This document provides an abbreviated description of the procedures and verifications performed prior to releasing new builds of the COMPRESS software application. Note that the procedures and examples presented in this document are a representative subset of the various standard operating procedures within Codeware’s Quality Management System. For a more complete description of Codeware’s Quality Management System the reader is referred to the Codeware Quality Manual. 1.1 Purpose of the Application COMPRESS is a software application that designs pressure vessels and heat exchangers in accordance with the latest Addenda of the ASME Boiler and Pressure Vessel Code. The purpose of this software program is to provide users with a powerful, accurate and user-friendly tool that will enhance engineering productivity and simplify vessel design. Because of the nature of the application, the highest levels of quality assurance must be in place to provide users with software they can rely upon. 1.2 Future Changes Codeware is committed to continuously improving the systems and procedures used in the development of COMPRESS. Accordingly, this document is subject to change as required by Codeware’s Quality Management System. 1.3 Intellectual Property Statement This document and its contents are considered to be proprietary. This material shall not be copied or distributed to other parties without the express written consent of Codeware, Inc.

COMPRESS Verification Document 1-1

Introduction Codeware, Inc.

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1-2 COMPRESS Verification Document

Codeware, Inc. Quality Assurance Procedures

Section 2: Quality Assurance Procedures This section describes the basic elements of the COMPRESS quality assurance procedures. The elements involved are Codeware’s Development Team, the automated verification system and a list of the files used in the automated verification system. 2.1 COMPRESS Development Team The Codeware Development Team is responsible for the development and maintenance of the COMPRESS software product. The team consists of the President, Vice President, Software Developers and Technical Support Engineers. All members of the Codeware Development Team have a background in mechanical engineering or computer science. 2.2 Automated Verification Codeware’s Baseline Conformity Assessment is an automated software test system that exercises the various options and functions of the COMPRESS software using a predefined series of verified examples. These examples are contained in a collection of COMPRESS files designed to test both the engineering calculation and various commonly used software functions. New examples are periodically added to the Baseline Conformity Assessment. COMPRESS calculation results are verified using this automated test system prior to releasing the software.


Quality Assurance Procedures Codeware, Inc.

2.3 Baseline Test Files Listed below are the files currently used by the automated software test system to exercise COMPRESS prior to release. They are taken from a variety of sources including the ASME Boiler and Pressure Vessel Handbook, ASME VIII-1 Appendix L, ASME VIII-2 Appendix G, Taylor Forge Bulletin 502, etc. Still others are examples that compare COMPRESS results to verified, “hand checked” or MathcadTM calculations. New files are periodically added to this list.

• 3473 EA-5331.CW6 • 99-209.cw6 • Appendix 2 Slip On Full Face

Gasketed Flange.CW6 • ASME2001 A03 L_2.3.1 And

L_2.3.2 without Rings.CW6 • ASME2001 A03 L_2.3.1 And

L_2.3.2 withRings.CW6 • ASME2001 A03 L_2.3.3.CW6 • ASME2001 A03 L_3.1.CW6 • ASME2001 A03 L_3.2.CW6 • ASME2001 A03 L_3.3 no juncture

rings.CW6 • ASME2001 A03 L_3.3.CW6 • ASME2001 A03 L_5.3.CW6 • ASME2001 A03 L_6.1.CW6 • ASME2001 A03 L_6.2.CW6 • ASME2001 A03 L_6.3.CW6 • ASME2001 A03 L_6.4.CW6 • ASME2001 A03 L_7.1.CW6 • ASME2001 A03 L_7.2.5.CW6 • ASME2001 A03 L_7.2.6.CW6 • ASME2001 A03 L_7.3.CW6 • ASME2001 A03 L_7.5.CW6 • ASME2001 A03 L_7.6.CW6 • ASME2001 A03 L_7.7

NozzleWall_0.5.CW6 • ASME2001 A03 L_7.7

NozzleWall_0.875.CW6 • ASME2001 A03 L_7.8.CW6 • ASME2001 A03 L_9.CW6 • ASME2001_A03_L_1.5.1.CW6 • ASME2001_A03_L_1.5.2.CW6 • ASME2001_A03_L_1.5.3.CW6 • ASME2001_A03_L_1.5.4.CW6 • ASME2001_A03_L_1.5.5.CW6 • ASME2001_A03_L_1.5.6.CW6 • ASME2001_A03_L_2.1.CW6 • ASME2001_A03_L_2.2.CW6 • ASME2004 A06 L_1.5.1.CW6 • ASME2004 A06 L_1.5.2.CW6 • ASME2004 A06 L_1.5.3.CW6

• ASME2004 A06 L_1.5.4.CW6 • ASME2004 A06 L_1.5.5.CW6 • ASME2004 A06 L_1.5.6.CW6 • ASME2004 A06 L_2.1.CW6 • ASME2004 A06 L_2.2.CW6 • ASME2004 A06 L_2.3.1 And

L_2.3.2 without Rings.CW6 • ASME2004 A06 L_2.3.1 And

L_2.3.2 withRings.CW6 • ASME2004 A06 L_2.3.3.CW6 • ASME2004 A06 L_3.1.CW6 • ASME2004 A06 L_3.2.CW6 • ASME2004 A06 L_3.3 no juncture

rings.CW6 • ASME2004 A06 L_3.3.CW6 • ASME2004 A06 L_5.3.CW6 • ASME2004 A06 L_6.1.CW6 • ASME2004 A06 L_6.2.CW6 • ASME2004 A06 L_6.3.CW6 • ASME2004 A06 L_6.4.CW6 • ASME2004 A06 L_7.1.CW6 • ASME2004 A06 L_7.2.5.CW6 • ASME2004 A06 L_7.2.6.CW6 • ASME2004 A06 L_7.3.CW6 • ASME2004 A06 L_7.5.CW6 • ASME2004 A06 L_7.6.CW6 • ASME2004 A06 L_7.7

NozzleWall_0.5.CW6 • ASME2004 A06 L_7.7

NozzleWall_0.875.CW6 • ASME2004 A06 L_7.8.CW6 • ASME2004 A06 L_9.CW6 • Div2 A03 Appendix G_101.CW6 • Div2 A03 Appendix G_102.CW6 • Div2 A03 Appendix G_104.CW6 • Div2 A03 Appendix G_105.CW6 • Div2 A03 Appendix G_108.CW6 • Div2 A03 Appendix G_112.CW6 • Div2 A03 Appendix G_113.CW6 • Div2 A03 Appendix G_114.CW6 • Div2 A03 Appendix G_115 No

Pad.CW6


Codeware, Inc. Quality Assurance Procedures

• Div2 A03 Appendix G_115 With Local Insert Plate.CW6

• Div2 A03 Appendix G_115 With Reinforcing Pad.CW6

• Div2 A03 Appendix G_118.CW6 • Div2 A06 Appendix G_101.CW6 • Div2 A06 Appendix G_102.CW6 • Div2 A06 Appendix G_104.CW6 • Div2 A06 Appendix G_105.CW6 • Div2 A06 Appendix G_108.CW6 • Div2 A06 Appendix G_112.CW6 • Div2 A06 Appendix G_113.CW6 • Div2 A06 Appendix G_114.CW6 • Div2 A06 Appendix G_115 No

Pad.CW6 • Div2 A06 Appendix G_115 With

Local Insert Plate.CW6 • Div2 A06 Appendix G_115 With

Reinforcing Pad.CW6 • Div2 A06 Appendix G_118.CW6 • Jawad Farr SDC EX 4.8 1998 Code

Edition.CW6 • Lap_joint_Loose.CW6 • Lap_joint_Loose_A05.CW6 • Lap_joint_Split_Loose.CW6 • Lap_joint_Split_Loose_A05.CW6 • Lap_joint_Split_Loose_Single_Split.

CW6 • Lap_joint_Split_Loose_Single_Split

_A05.CW6 • large opening-6223.CW6 • large opening-6251 A06.CW6 • LiftLug EarType.CW6 • LiftLug Horizontal Std Calc.CW6 • NozzleInternalHead.CW6 • P_609696A-1_TS2_4375in.CW6 • SDC Type b Full Face

Verification.CW6 • SDC Type b Ring Type

Verification.CW6 • SDC Type c FF Gasket Slot Bolts

Verification.CW6 • SDC Type c FF Gasket Std Bolts

Verification.CW6 • SDC Type c Ring Gasket Slot Bolts

Verification.CW6 • SDC Type c Ring Gasket Std Bolts

Verification.CW6 • SDC Type d Ring Type

Verification.CW6 • Slip_On_Full_Face.CW6 • Slip_On_Integral.CW6 • Slip_On_Integral_VIII_1_83_115_on

.CW6

• Slip_On_Loose.CW6 • Taylor Forge Welding Neck Flange

Example.CW6 • tom 1-A03-6223.CW6 • UHX 20_1_1 Example 1 2004

Edition.CW6 • UHX 20_1_1 Example 1 A06.CW6 • UHX 20_1_1 Example 1.CW6 • UHX 20_1_2 Example 2 2004



Edition.CW6 • UHX 20_1_4 Example 4 A06.CW6 • UHX 20_1_4 Example 4.CW6 • UHX 20_2_1 Example 1

Bellows.CW6 • UHX 20_2_2 Example 2 2004




Edition.CW6 • UHX 20_3_3 Example 3 A06.CW6 • UHX 20_3_3 Example 3.CW6 • UHX 20_4_3.CW6 • UHX 20_4_4.CW6 • UHX 20_4_5.CW6 • UHX 20_4_6.CW6 • UHX 20_5_3.CW6 • UHX 20_5_4.CW6 • UHX 20_5_5.CW6 • UHX 20_5_6.CW6 • V01.CW6 • V01Metric.CW6 • V01MKS.CW6 • V02.CW6 • V02Metric.CW6 • V02MKS.CW6 • V03.CW6


Quality Assurance Procedures Codeware, Inc.

• V03Metric.CW6 • V03MKS.CW6 • V04.CW6 • V04Metric.CW6 • V04MKS.CW6 • V05.CW6 • V05Metric.CW6 • V05MKS.CW6 • V06.CW6 • V06Metric.CW6 • V06MKS.CW6 • V07.CW6 • V07Metric.CW6 • V07MKS.CW6 • V08.CW6 • V08Metric.CW6 • V08MKS.CW6 • V09.CW6 • V09Metric.CW6 • V09MKS.CW6

• V10.CW6 • V10Metric.CW6 • V10MKS.CW6 • V11.CW6 • V11Metric.CW6 • V11MKS.CW6 • V12.CW6 • V12Metric.CW6 • V12MKS.CW6 • V13.CW6 • V13Metric.CW6 • V13MKS.CW6 • V14.CW6 • V14Metric.CW6 • V14MKS.CW6 • V15.CW6 • V15Metric.CW6 • V15MKS.CW6 • Weld_Neck.CW6


Codeware, Inc. Component Analysis Verification

Section 3: Component Analysis Verification This section summarizes comparisons of selected COMPRESS verification examples with industry accepted publications and verified calculations. Supporting detailed COMPRESS calculation reports can be found in Section 4 of this document. 3.1 Shell and Head Verification 1. ASME Appendix L-2.2 (COMPRESS file ASME L_2.2.CW6): Horizontal vessel under internal pressure and supplemental loadings.

Parameter COMPRESS ASME Required Shell Thickness, t 0.3063 0.306

Factor K1* 0.7903 0.7904 *The factor K1 in COMPRESS is determined using calculations from the Zick saddle analysis. ASME uses a different method to find this value. 2. ASME Self Study CD Course Example 4-4 (COMPRESS file 4-4 Design Thickness of a Cylinder Shell1.CW6): Cylindrical shell under internal pressure.

Parameters COMPRESS ASME Factor Z 3.2353 3.235

Circum. Stress Weld Joint Efficiency 1.0 1.0 Required Shell Thickness, t (in.) 14.9161 14.92

3. ASME Appendix L-3.1 (COMPRESS file ASME L_3.1.CW6): Cylindrical shell under external pressure.

Parameters COMPRESS ASME A 0.000502 0.0005 B 6041.7378* 6100

MAEP (psi) 15.0101 15.1 *COMPRESS uses logarithmic interpolation to determine the value of B whereas in the example in Appendix L, the value of B is approximated.


Component Analysis Verification Codeware, Inc.

4. ASME Self Study CD Course Example 4-5 (COMPRESS file 4-5 Design Thickness of a Spherical Shell.CW6): Spherical shell under internal pressure.

Parameters COMPRESS ASME Maximum Allowable Stress, (psi) 20000 20000

Weld Joint Efficiency, E 0.85 0.85 Required Shell Thickness, t (in.) 0.451 0.45

5. ASME Appendix L-3.2 (COMPRESS file ASME L_3.2.CW6): Spherical shell under external pressure.


MAEP (psi) 24.0522 24.4 *COMPRESS uses logarithmic interpolation to determine the value of B whereas in the example in Appendix L, the value of B is approximated. 6. ASME Self Study CD Example 4-8 (COMPRESS file Example 4-8.CW6): Ellipsoidal head under internal pressure.

Parameters COMPRESS ASME Design temperature, T (°F) 200 200

Weld joint efficiency 1 1 Required head thickness, t (in.) 0.6164 0.62



7. ASME Appendix L-6.1 (COMPRESS file ASME L_6.1.CW6): Ellipsoidal head under external pressure.

Parameters COMPRESS ASME A 0.000465* 0.000462 B 5601.829* 5100

MAEP (psi) 20.8547* 18.9 *Appendix L-6.1 has several mistakes in Codeware's opinion. (1) Ro = Ko*Do from Table UG-33.1 For an ellipsoidal head, the 2:1 ratio is not maintained for both the inner and outer surfaces. COMPRESS assumes that the inner surface maintains a 2:1 ratio, and calculates ho = hi + thead = 42.53125. Ko = Do / (2 *ho) = 169 / (2*42.53125) = 1.98677 Interpolating from Table UG-33.1, Ko = 0.89405. Ro = Ko*Do = 0.89405*169 = 151.1" A = 0.000465 (2) From Table CS-2, the B value is close to 5600 psi whereas the example states a B value of 5100 psi. It appears the value of 5600 psi is a more accurate value even using an A value of 0.000462 as listed in the example. Pa = 20.85 psi (3) Additionally, the Code example does not check the maximum external pressure per UG-33(a)(1).



8. ASME Self Study CD Example 4-11 (COMPRESS file Example 4-11.CW6): A torispherical head under internal pressure.

Parameters COMPRESS ASME L/r* 7.3286 7.5

Factor M* 1.427 1.44 Required head thickness, t (in.) 2.3897 2.41

* There is a discrepancy between COMPRESS results and the ASME Exercise results. In the COMPRESS calculation, the value for M in Appendix 1, Table 1.4. is interpolated to be 1.426 for a value of L/r of 7.3286. The ASME Exercise uses M = 1.44, which according to Table 1.4 is for L/r = 7.5, lacking interpolation. This is a fine point, but one which results in a slightly different answer. Codeware considers the COMPRESS result to be the “more exact” answer. 9. ASME Appendix L-6.2 (COMPRESS file ASME L_6.2.CW6): A torispherical head under external pressure.


MAEP (psi) 16.6296* 15.6

*For example Appendix L-6.2, the allowable compressive stress (B) listed at the stated A value of 0.00042 seems to be incorrect. COMPRESS uses a logarithmic interpolation from vacuum chart tabular values resulting in a B value of about 5000 psi. Using a B value of about 5000 psi, the MAEP of the head is 16.6296 psi. Additionally, the Code example does not check the maximum external pressure per UG-33(a)(1). 10. ASME Self Study CD Course Example 4-14 Minimum thickness of a Flat Head (COMPRESS file 4-14 Minimum Thickness of a Flat Head.CW6): Flat head on a cylindrical vessel under internal pressure.

Parameters COMPRESS ASME Design Factor C 0.2274 0.23

Required Head Thickness, t (in.) 2.6733* 2.69 *The difference between the results is due to a round-off error in the ASME calculation.



3.2 Nozzle Verification 1. ASME Appendix L-7.1 Example 1 (COMPRESS file ASME L_7.1.CW6) A nozzle attached to a shell under a specified pressure and temperature.

Parameters COMPRESS ASME Required Shell Thickness (in.) 0.2768 0.277

Required Nozzle Thickness (in.) 0.0337 0.034 Required Total Area of Reinforcement (in.2) 1.107 1.11 Available Total Area of Reinforcement (in.2) 1.8767 1.87

2. ASME Appendix L-7.3 (COMPRESS file ASME L_7.3.CW6): Insert-type nozzle lying on a longitudinal weld of a cylindrical shell.

Parameters COMPRESS ASME Required Shell Thickness (in.) 0.53 0.530

Required Nozzle Thickness (in.) 0.0893 0.0893 Reinforcement Area Required (in. 2) 6.228 6.23

Total Area available (in. 2) 6.2665 6.27 Total weld load, W (lb) 72540.04 72600

Weld load for path 1-1, W1-1 (lb) 71554.34 71600 Weld load for path 2-2, W2-2 (lb) 34854.82 34900 Weld load for path 3-3, W3-3 (lb) 82279.34 82300 Strength of failure path 1-1 (lb) 203289.6 203000 Strength of failure path 2-2 (lb) 229116.4 229000 Strength of failure path 3-3 (lb) 250441.6 250000



3.3 Flange Verification 1. Taylor Forge Bulletin 502 Edition VII Example 1 Welding Neck Flange Design (COMPRESS file TaylorForge_Bulletin502_Example_1_Welding_Neck_Design.CW6): The flange calculation results of a Taylor Forge worksheet is compared to the calculated results of COMPRESS.

Parameters COMPRESS Taylor Forge Gasket Load Reaction Dia., G (in.) 33.8876 33.888

Bolt Load, Wm1 (lb) 432268.0625 432484 Gasket Seating Force, HG (lb) 71680.06 71713

End Moment, MD (in. lb) 622976 623292 Gasket Load, MG (in. lb) 111548.5 111599

Face Pressure, MT (in. lb) 79201.36 79242 Total Moment, MO (in. lb) 813725.9 814133

Longitudinal Hub Stress, SH (psi) 22853.53 22865 Radial Flange Stress, SR (psi) 10966.97 10982

Operating

Tangential Flange Stress, ST (psi) 6843.33 6800 Bolt Load, Wm2 (lb) 120552.8203 120609

Flange Design Bolt Load, W (lb) 464084.0313 464192 Total Moment Mg (in. lb) 722207.6 722371

Longitudinal Hub Stress, SH (psi) 20283.23 20288 Radial Flange Stress, SR (psi) 9733.54 9744

Seating

Tangential Flange Stress, ST (psi) 6073.67 6033 There is a small discrepancy in the calculated values between COMPRESS and the Taylor Forge calculated worksheet because COMPRESS bases its calculations in accordance to ASME VIII-1 Appendix 2 Section 2-3.



2. Hand calculated Slip On Full Face Gasketed Flange Example (COMPRESS file Appendix 2 Slip On Full Face Gasketed Flange.CW6): The flange calculation results of a hand calculated Taylor Forge worksheet is compared to the calculated results of COMPRESS.

Parameters COMPRESS Hand Calc. Bolt Load, Wm1 (lb) 96253.64 96305.1

End Moment, MD (in. lb) 93258 93305.9 Face Pressure, MT (in. lb) 17359.73 17405.7 Total Moment, MO (in. lb) 110617.7 110712

Loose Type Flange Factor, VL* 41.997 40 Longitudinal Hub Stress, SH (psi) 431.96 449.98

Radial Flange Stress, SR (psi) 446.23 462.265 Tangential Flange Stress, ST (psi) 6360.59 6308.74

Operating

Bolt Circle Stress, SRAD (in. lb) 698.13 698.269 Bolt Load, Wm2 (lb) 71770.0625 71785.5

Flange Design Bolt Load, W (lb) 113156.82 113190 Seating Total Moment MG (in. lb) 30334.55 30340.7

*The loose type flange factor, VL, is interpolated in COMPRESS while VL for the hand calculation is an approximated value from Appendix 2 Fig. 2-7.5. This discrepancy in result affects the values of SH and SR. 3.4 Cone Verification 1. ASME Appendix L-2.3.1 and L-2.3.2 (COMPRESS file ASME L_2.3.1 and L_2.3.2 withRings.CW6): A cone-to-cylinder transition under internal pressure.

Parameters COMPRESS ASME Line Force (lb) 2750.01 2750

Reinforcement Area Req., (in. 2) 4.537 4.54 Large end Total Area available (in. 2) 0.499 0.500

Line Force (lb) 1310.1 1312.5 Reinforcement Area Req., (in. 2) 2.21 2.22 Small

end Total Area available (in. 2) 0.78 0.78



2. ASME Appendix L-2.3.3 (COMPRESS file ASME L_2.3.3.CW6): Determining the required thickness of a knuckle on a cone-to-cylinder transition under internal pressure.

Parameters COMPRESS ASME Inner Dia. Tangent to the Knuckle, Di (in.) 194.6451 194.64

Crown Radius, L (in.) 112.3652 112 Required Thickness of the Knuckle, tk (in.) 0.3418 0.340

Required Thickness of the Cone, t (in.) 0.5103 0.510 3.5 ASME Tubesheet Verification 1. ASME UHX 20.1.1 Example 1: Tubesheet Integral with Shell and Channel (COMPRESS file UHX 20_1_1 Example 1.CW6): The calculation results being compared are for loading case 3.

Parameters COMPRESS ASME Moment due to pressures, MTS (in.-lb/in) -160.13 -160 Maximum bending moment, M (in.-lb/in) 567.98 568

Tubesheet bending stress, s(psi) 35999 36000 Tubesheet average shear stress, t(psi) 3347 3350

Total axial stress in the shell, sS (psi) 17745 17700 Total axial stress in the channel, sC (psi) 26616 26600

2. ASME UHX 20.1.4 Example 4: Tubesheet Gasketed With Shell and Integral With Channel, Extended as a Flange (COMPRESS file UHX 20_1_4 Example 4.CW6): The calculation results being compared are for loading case 2.

Parameters COMPRESS ASME Moment due to pressures, MTS (in.-lb/in) 16467.24 16500 Maximum bending moment, M (in.-lb/in) 30044.91 30000

Tubesheet bending stress, s(psi) 38176 38200 Tubesheet average shear stress, t(psi) 4875 4880 Total axial stress in the channel, sC (psi) 56955 57000

Because the channel stress exceeds the allowable stress, an elastic-plastic calculation is performed.



Parameters COMPRESS ASME

Maximum bending moment, M (in.-lb/in) 31353.43 31400 Maximum bending stress, s(psi) 39838 39800

3.6 TEMA Tubesheet Verification 1. TEMA Tubesheet Example (COMPRESS file P_609696A-1_TS2_4375in.CW6): The calculated results are compared to a MathcadTM calculation file.*

Parameters COMPRESS MathcadTM

Eff. Shell side design Pres., bend. (psi) 36.93298 36.9284 Eff. Tube side design Pres., bend. (psi) 123.9039 123.8968

Req. thk. Shellside (in.) 1.1308 1.13074 Req. Thk. Tubeside (in.) 2.1486 2.148464

Equiv. Differential Exp. Pres., Pd (psi) -0.5250 -0.5273 *The detailed calculations for the TEMA Tubesheet Example is not provided in this document, but can be obtained by contacting Codeware. 3.7 ASME Division 2 Component Verification

1. ASME Division 2 Appendix G-101 Example No. 1: AD-201 (COMPRESS file Div2 Appendix G_101.CW6): A cylindrical shell subjected to internal pressure.

Parameter COMPRESS ASME Minimum wall thickness, t (in.) 5.5962 5.600

2. ASME Division 2 Appendix G-105 Example No. 5: AD-204.3 (COMPRESS file Div 2 Appendix G_105): A cylinder and a 2:1 ellipsoidal head subjected to internal pressure.

Parameter COMPRESS ASME Minimum cylinder wall thickness, t (in.) 0.9917 0.992

Minimum head thickness, t (in.) 1.1884 1.188



3. ASME Division 2 Appendix G-115 Example NO. 15 (COMPRESS files Div2 Appendix G_115 No Pad.CW6, Div2 Appendix G_115 Local Insert Plate.CW6, Div2 Appendix G_115 Reinforcing Pad.CW6): A nozzle without any additional reinforcement attached to a cylindrical shell.

Parameter COMPRESS ASME Minimum thickness tr (in.) 0.5793 0.579

Area Required, A (in.2) 3.8379 3.836 Limit of Reinforcement Parallel to the Shell, L1 (in.) 6.625 6.625 2/3 Limit of Reinforcement Parallel to the Shell (in.) 5.8928 5.893 Limit of Reinforcement Normal to the Shell, L2 (in.) 1.08 1.08

Area available for reinforcement, A1 (in.2) 0.979* 0.981 2/3 Limit of Area available for reinforcement (in.2) 0.763* 0.764

Reinforcement by a local increase in shell thickness:

Parameter COMPRESS ASME Area available for reinforcement, A1 (in.2) 1.9202* 1.918

2/3 Limit of Area available for reinforcement (in.2) 1.4958* 1.494 Reinforcement by reinforcing pad:

Parameter COMPRESS ASME Area available for reinforcement, A1 (in.2) 1.9202* 1.918

2/3 Limit of Area available for reinforcement (in.2) 1.526* 1.528 *These values represent half of the area available for reinforcement, but the COMPRESS calculations display the full area available for reinforcement.


Codeware, Inc. Detailed Calculations


Section 4: Detailed Calculations

4.1 ASME Appendix L-2.2

Cylinder #4

ASME Section VIII Division 1, 2004 Edition, A06 Addenda

Component: Cylinder Material specification: L-2.1 (user defined)

Not a UCS-66 material. Internal design pressure: P = 55.4647 psi @ 100°F

Static liquid head:

Ps = 4.5353 psi (SG=1.0525, Hs=119.3750" Operating head) Pth = 4.3091 psi (SG=1.0000, Hs=119.3750", Horizontal test head) Corrosion allowance: Inner C = 0.0000" Outer C = 0.0000" PWHT is not performed Radiography: Longitudinal joint - Spot UW-11(b) Type 1 Left circumferential joint - Full UW-11(a) Type 1 Right circumferential joint - None UW-11(c) Type 2 Estimated weight: New = 3990.3994 lb corr = 3990.3994 lb Capacity: New = 5814.1461 gal corr = 5814.1461 gal

ID = 119.3750" Length Lc = 120.0000" t = 0.3125"

Design thickness, (at 100.00°F) UG-27(c)(1)

t = P*R/(S*E - 0.60*P) + Corrosion = 60.00*59.6875/(13800*0.85 - 0.60*60.00) + 0.0000 = 0.3063"

Maximum allowable working pressure, (at 100.00°F) UG-27(c)(1)

P = S*E*t/(R + 0.60*t) - Ps = 13800*0.85*0.3125 / (59.6875 + 0.60*0.3125) - 4.5353 = 56.6860 psi

Detailed Calculations Codeware, Inc.


Maximum allowable pressure, (at 70.00°F) UG-27(c)(1)

P = S*E*t/(R + 0.60*t) = 13800*0.85*0.3125 / (59.6875 + 0.60*0.3125) = 61.2213 psi

% Extreme fiber elongation - User defined non-carbon steel material

= (50 * t / Rf) * (1 - Rf / Ro) = (50 * 0.3125 / 59.8438) * (1 - 59.8438 /∞) = 0.2611 % Allowable Compressive Stress, Hot and Corroded- ScHC, (table CS-2) A = 0.125 / (Ro / t) = 0.125 / (60.0000 / 0.3125) = 0.000651 B = 9388.3760 psi

S = 13800.0000 / 1.0000 = 13800.0000 psi

ScHC = 9388.3760 psi Allowable Compressive Stress, Hot and New- ScHN ScHN = ScHC = 9388.3760 psi Allowable Compressive Stress, Cold and New- ScCN, (table CS-2) A = 0.125 / (Ro / t) = 0.125 / (60.0000 / 0.3125) = 0.000651 B = 9388.3760 psi

S = 13800.0000 / 1.0000 = 13800.0000 psi

ScCN = 9388.3760 psi



Allowable Compressive Stress, Cold and Corroded- ScCC ScCC = ScCN = 9388.3760 psi Allowable Compressive Stress, Vacuum and Corroded- ScVC, (table CS-2) A = 0.125 / (Ro / t) = 0.125 / (60.0000 / 0.3125) = 0.000651 B = 9388.3760 psi

S = 13800.0000 / 1.0000 = 13800.0000 psi

ScVC = 9388.3760 psi



Saddle #1

Saddle material: Saddle construction is: Centered web Saddle allowable stress: Ss = 20,000.00 psi Saddle yield stress: Sy = 38,000.00 psi Saddle distance to datum: 690.0000 in Tangent to tangent length: L = 720.0000 in Saddle separation: Ls = 660.0000 in Vessel radius: R = 60.0000 in Tangent distance left: Al = 30.0000 in Tangent distance right: Ar = 30.0000 in Saddle height: Hs = 72.0000 in Saddle contact angle: θ = 120 ° Web plate thickness: ts = 0.6250 in Base plate length: E = 105.0000 in Base plate width: F = 10.0000 in Base plate thickness: tb = 0.8750 in Number of stiffener ribs: n = 6 Largest stiffener rib spacing: di = 21.4500 in Stiffener rib thickness: tw = 0.5000 in Saddle width: B = 9.0000 in Anchor bolt size & type: 2.75 inch series 8 threaded Anchor bolt material: Anchor bolt allowable shear: 15,000.00 psi Anchor bolt corrosion allowance: 0.0000 in Anchor bolts per saddle: 2 Base coefficient of friction: μ = 0.45

Weight on left saddle: operating corr = 175,005.0 lb, test new = 166,947.0 lb Weight on right saddle: operating corr = 175,005.0 lb, test new = 166,948.0 lb Weight of saddle pair = 1,640.00 lb



Notes: (1) Saddle calculations are based on the method presented in "Stresses in Large Cylindrical Pressure Vessels on Two Saddle Supports" by L.P. Zick.

Bending + pressure between saddles

(psi)

Bending + pressure at the saddle (psi) Load Vessel

condition S1 (+)

allow (+)

S1 (-)

allow(-)

S2 (+)

allow (+)

S2 (-)

allow(-)

Weight Operating 12,811 8,970 7,081 9,388 5,780 13,800 50 9,388 Weight Test 14,052 28,256 6,755 9,388 7,345 43,470 48 9,388

Tangential shear (psi)

Circumferentialstress (psi)

Stress oversaddle (psi) Splitting (psi)

Load Vessel condition

S3 allow S4 (horns)

allow(+/-) S5 allow S6 allow

Weight Operating 8,234 11,040 -44,369 20,700 57,694 19,000 5,122 13,333 Weight Test 7,855 34,776 -42,326 43,470 55,038 34,200 4,886 34,200

Load Case 1: Weight ,Operating Longitudinal stress between saddles (Weight ,Operating, right saddle loading and geometry govern) S1 = +- 3*K1*Q*(L/12) / (π*R2*t) = 3*0.7903*175,005.0*(720/12) / (π*59.843752*0.3125) = 7,080.72 psi Sp = P*R/(2*t) = 60.00002*59.6875/(2*0.3125) = 5,730.001 psi Maximum tensile stress S1t = S1 + Sp = 12,810.72 psi Maximum compressive stress (shut down) S1c = S1 = 7,080.72 psi



** WARNING Tensile stress between saddles is excessive (> 8,970 psi)** Compressive stress is acceptable (<=1*Sc = 9,388.376 psi) Longitudinal stress at the right saddle (Weight ,Operating) Le = 2*(Left head depth)/3 + L + 2*(Right head depth)/3 = 2*30.16355/3 + 720 + 2*30.16365/3 = 760.2181 in w = Wt/Le = 350,010.0/760.2181 = 460.4073 lb/in Bending moment at the right saddle: Mq = w*(2*H*Ar/3 + Ar

2/2 - (R2 - H2)/4) = 460.4073*(2*30.16365*30/3 + 302/2 - (602 - 30.163652)/4) = 175,292.9 lb-in S2 = +- Mq*K1'/ (π*R2*t) = 175,292.9*1/ (π*59.843752*0.3125) = 49.85709 psi Sp = P*R/(2*t) = 60.00002*59.6875/(2*0.3125) = 5,730.001 psi Maximum tensile stress S2t = S2 + Sp = 5,779.858 psi Maximum compressive stress (shut down) S2c = S2 = 49.85709 psi Tensile stress is acceptable (<=1*S = 13,800.00 psi) Compressive stress is acceptable (<=1*Sc = 9,388.376 psi) Tangential shear stress in the shell (left saddle, Weight ,Operating) S3 = K2.3*Q/(R*(t)) = 0.8799*175,005.0/(59.84375*(0.3125)) = 8,234.077 psi Tangential shear stress is acceptable (<= 0.8*S = 11,040.00 psi) Tangential shear stress in the left head (Weight ,Operating) S3 = K2.3*Q/(R*th) = 0.8799*175,005.0/(59.84375*0.3198) = 8,046.12 psi



Tangential shear stress is acceptable (<= 0.8*S = 11,040.00 psi)

Additional stress in the head used as a stiffener S3h = K2.4*Q/(R*th) = 0.4011*175,005.0/(59.84375*0.3198) = 3,667.802 psi Sp = P*(K*Di + 0.2*th)/(2*th) = 60.00002*(1*119.375 + 0.2*0.3198)/(2*0.3198) = 11,204.41 psi Total stress in the head = S3h + Sp = 14,872.21 psi Stress in the head is acceptable (<= 1.25*Sh = 17,250.00 psi) Circumferential stress at the right saddle horns (Weight ,Operating) S4 = -Q/(4*t*(b+1.56*Sqr(Ro*t))) - 3*K3*Q/(2*t2) = -175,005.0/(4*0.3125*(9+1.56*Sqr(60*0.3125))) - 3*0.0132*175,005.0/(2*0.31252) = -44,368.94 psi ** WARNING Circumferential stress at saddle horns is excessive (> 20,700 psi)** Ring compression in shell over right saddle (Weight ,Operating) S5 = K5*Q/((t)*(ts + 1.56*Sqr(Ro*tc))) = 0.7603*175,005.0/((0.3125)*(0.625 + 1.56*Sqr(60*0.3125))) = 57,693.80 psi ** WARNING Ring compression in shell is excessive (> 19,000 psi)** Saddle splitting load (right, Weight ,Operating) Area resisting splitting force = Web area + wear plate area Ae = Heff*ts + tp*Wp = 11.125*0.625 + 0*0 = 6.953125 in2 S6 = K8*Q / Ae = 0.2035*175,005.0 / 6.953125 = 5,121.944 psi



Stress in saddle is acceptable (<= (2/3)*Ss = 13,333.33 psi) Load Case 2: Weight ,Test Longitudinal stress between saddles (Weight ,Test, right saddle loading and geometry govern) S1 = +- 3*K1*Q*(L/12) / (π*R2*t) = 3*0.7903*166,948.0*(720/12) / (π*59.843752*0.3125) = 6,754.733 psi Sp = P*R/(2*t) = 76.41319*59.6875/(2*0.3125) = 7,297.46 psi Maximum tensile stress S1t = S1 + Sp = 14,052.19 psi Maximum compressive stress (shut down) S1c = S1 = 6,754.733 psi Tensile stress is acceptable (<= 0.9*Sy = 28,255.50 psi) Compressive stress is acceptable (<=1*Sc = 9,388.376 psi) Longitudinal stress at the right saddle (Weight ,Test) Le = 2*(Left head depth)/3 + L + 2*(Right head depth)/3 = 2*30.16355/3 + 720 + 2*30.16365/3 = 760.2181 in w = Wt/Le = 333,895.0/760.2181 = 439.2095 lb/in Bending moment at the right saddle: Mq = w*(2*H*Ar/3 + Ar

2/2 - (R2 - H2)/4) = 439.2095*(2*30.16365*30/3 + 302/2 - (602 - 30.163652)/4) = 167,222.2 lb-in S2 = +- Mq*K1'/ (π*R2*t) = 167,222.2*1/ (π*59.843752*0.3125) = 47.56159 psi Sp = P*R/(2*t) = 76.41319*59.6875/(2*0.3125) = 7,297.46 psi Maximum tensile stress S2t = S2 + Sp = 7,345.021 psi



Maximum compressive stress (shut down) S2c = S2 = 47.56159 psi Tensile stress is acceptable (<= 0.9*Sy = 43,470.00 psi) Compressive stress is acceptable (<=1*Sc = 9,388.376 psi) Tangential shear stress in the shell (right saddle, Weight ,Test) S3 = K2.3*Q/(R*(t)) = 0.8799*166,948.0/(59.84375*(0.3125)) = 7,854.991 psi Tangential shear stress is acceptable (<= 0.8*(0.9*Sy) = 34,776.00 psi) Tangential shear stress in the right head (Weight ,Test) S3 = K2.3*Q/(R*th) = 0.8799*166,948.0/(59.84375*0.3199) = 7,673.288 psi Tangential shear stress is acceptable (<= 0.8*(0.9*Sy) = 34,776.00 psi) Additional stress in the head used as a stiffener S3h = K2.4*Q/(R*th) = 0.4011*166,948.0/(59.84375*0.3199) = 3,497.847 psi Sp = P*(K*Di + 0.2*th)/(2*th) = 76.41319*(1*119.375 + 0.2*0.3198)/(2*0.3198) = 14,269.41 psi Total stress in the head = S3h + Sp = 17,762.79 psi Stress in the head is acceptable (<= 0.9*Sy = 43,470.00 psi) Circumferential stress at the right saddle horns (Weight ,Test) S4 = -Q/(4*t*(b+1.56*Sqr(Ro*t))) - 3*K3*Q/(2*t2) = -166,948.0/(4*0.3125*(9+1.56*Sqr(60*0.3125))) - 3*0.0132*166,948.0/(2*0.31252) = -42,326.25 psi Circumferential stress at saddle horns is acceptable (<= 0.9*Sy = 43,470.00 psi) Ring compression in shell over right saddle (Weight ,Test)



S5 = K5*Q/((t)*(ts + 1.56*Sqr(Ro*tc))) = 0.7603*166,948.0/((0.3125)*(0.625 + 1.56*Sqr(60*0.3125))) = 55,037.66 psi ** WARNING Ring compression in shell is excessive (> 34,200 psi)** Saddle splitting load (right, Weight ,Test) Area resisting splitting force = Web area + wear plate area Ae = Heff*ts + tp*Wp = 11.125*0.625 + 0*0 = 6.953125 in2 S6 = K8*Q / Ae = 0.2035*166,948.0 / 6.953125 = 4,886.137 psi Stress in saddle is acceptable (<= 0.9*Sy = 34,200.00 psi) Shear stress in anchor bolting, one end slotted Maximum seismic or wind base shear = 0 lb Thermal expansion base shear = W*μ = 175,825.0 * 0.45= 79,121.25 lb Corroded root area for a 2.75 inch series 8 threaded bolt = 5.259 in2 ( 2 per saddle ) Bolt shear stress = 79,121.25/(5.259* 2) = 7522.46 psi Anchor bolt stress is acceptable (<= 15,000.00 psi) Web plate buckling check (Escoe pg 251) Allowable compressive stress Sc is the lesser of 20,000.00 or 28,483.32 psi: (20,000.00) Sc = Ki*π2*E/(12*(1 - 0.32)*(di/tw)2) = 1.28*π2*29,000,000/(12*(1 - 0.32)*(21.45/0.625)2) = 28,483.32 psi Allowable compressive load on the saddle be = di*ts/(di*ts + 2*tw*(b - 1)) = 21.45*0.625/(21.45*0.625 + 2*0.5*(9 - 1))



= 0.6262773 Fb = n*(As + 2*be*tw)*Sc = 6*(4.1875 + 2*0.6262773*0.625)*20,000.00 = 596,441.6 lb Saddle loading of 175,825.0 is <= Fb; satisfactory. Primary bending + axial stress in the saddle due to end loads (assumes one saddle slotted) σ b = V * (Hs - xo)* y / I + Q / A = 0 * (72 - 49.6196)* 4.5 / 183.0129 + 175,005.0 / 90.0769 = 1,942.84 psi The primary bending + axial stress in the saddle <= 20,000 psi; satisfactory. Secondary bending + axial stress in the saddle due to end loads (includes thermal expansion, assumes one saddle slotted) σ b = V * (Hs - xo)* y / I + Q / A = 79,121.25 * (72 - 49.6196)* 4.5 / 183.0129 + 175,005.0 / 90.0769 = 45,483.17 psi The secondary bending + axial stress in the saddle < 2*Sy= 76,000 psi; satisfactory. Saddle base plate thickness check (Roark sixth edition, Table 26, case 7a) where a = 21.4500, b = 4.6875 in tb = (β1*q*b2/(1.5*Sa))0.5 = (3*167.4524*4.68752/(1.5*20,000.00))0.5 = 0.6066 in The base plate thickness of 0.8750 in is adequate. Foundation bearing check Sf = Qmax / (F*E) = 175,825.0 / (10*105) = 167.4524 psi Concrete bearing stress < 750 psi ; satisfactory.



4.2 ASME Appendix L-2.3.1 – 2.3.2

Transition #1


Component: Transition Material specification: L-2.3 (user defined)

Not a UCS-66 material. Internal design pressure: P = 50.0000 psi @ 650.00°F

Static liquid head:

Pth = 5.4146 psi (SG=1.0000, Hs=150.0000", Horizontal test head at small end)Pth = 7.2194 psi (SG=1.0000, Hs=200.0000", Horizontal test head at large end)Corrosion allowance: Inner C = 0.0000" Outer C = 0.0000" PWHT is not performed Radiography: Category A joints - Spot UW-11(b) Type 1 Circ. joint top/left - Full UW-11(a) Type 1 Circ. joint right/bottom - Full UW-11(a) Type 1 Estimated weight: New = 5861.0 lb corr = 5861.0 lb Capacity: New = 6870.4 US gal corr = 6870.4 US gal

Axial length = 86.6025" Large End ID = 200.0000" Small End ID = 100.0000" Cone tc = 0.4380"

Design thickness, (at 650.00°F) UG-32(g) (Large End)

t = P*D / (2*Cos(a)*(S*E - 0.60*P)) + C

= 50.0000*200.0000 / (2*Cos(30.000)*(17500*0.85 - 0.60*50.0000)) + 0.0000

= 0.3889"

Small End design thickness (t = 0.1945") does not govern.

MAWP, (Corroded at 650.00°F) UG-32(g) (Large End)

P = 2*S*E*t*Cos(a) / (D + 1.20*t*Cos(a) - Ps



= 2*17500*0.85*0.4380*Cos(30.000) / (200.0000 + 1.20*0.4380*Cos(30.000)) - 0.0000

= 56.30 psi

Small End MAWP (112.3361 psi) does not govern.

MAP, (New at 70.00°F) UG-32(g) (Large End)

P = 2*S*E*t*Cos(a) / (D + 1.20*t*Cos(a)) - Ps

= 2*17500*0.85*0.4380*Cos(30.000) / (200.0000 + 1.20*0.4380*Cos(30.000)) - 0.0000

= 56.30 psi

Small End MAP (112.3361 psi) does not govern.


= (50 * t / Rf) * (1 - Rf / Ro) = (50 * 0.5058 / 50.2529) * (1 - 50.2529 /∞) = 0.5032 %

Cone juncture large end calculations, P =50.000 psi Appendix 1-5(d)

Loading Area check

required (D < a)

U-2(g) analysis required

f1 (lbf /in)

QL (lbf /in)

ArL(in2)

AeL(in2)

Ring area (in2)

3/4x5.5 Flat Bar Status

Weight Corroded Yes No 250.01 2,750.01 4.54 0.50 4.13 OK

Cone large end calculations per Appendix 1-5(d), weight + pressure, corroded f1 = -Wl/(p*2*Rm) + 12*Ml/(p*Rm

2) = -3,344.614/(p*2*100.1565) + 12*670,524.8/(p*100.15652) = 250.007 lb/in P*RL/2 = 2,500.00 lb/in f1 is in tension so a U-2(g) analysis is not required. P/(Ss*E1) = 50/(17,500.00*1) = 0.002857



From table 1-5.1 D = 17.57° As D < a, a reinforcement check is required. QL = P*RL/2 + f1 = 2,500.00 + 250.007 = 2,750.007 lb/in k = Ss*Es/(Sr*Er) = 17,500.00*26,000,000/(14,500.00*26,000,000) = 1.206897 ArL = (k*QL*RL/(Ss*E1))*(1 - D/a)*tan(a) = (1.206897*2,750.007*100/(17,500.00*1))*(1 - 17.57/30)*tan(30) = 4.536859 in2 AeL = (ts - t)*(RL*ts)0.5 + (tc - tr)*(RL*tc/cos(a))0.5 = (0.313 - 0.2862049)*(100*0.313)0.5 + (0.438 - 0.388919)*(100*0.438/cos(30))0.5 = 0.4989565 in2 Additional reinforcement area required = ArL - AeL = 4.0379 in2 Area provided by a 3/4x5.5 Flat Bar = 4.1250 in2 The maximum ring centroid to juncture distance is 0.25*(RL*ts)0.5 = 1.3987 in The actual distance of ring centroid to juncture is -1.102501 in The large end is adequately reinforced per Appendix 1-5(d).



Cone juncture small end calculations P = 50.000 psi Appendix 1-5(e)

Loading Area check

required (D < a)


f2 (lbf /in)

Qs (lbf /in)

Ars(in2)

Aes(in2)

Ring area (in2)

3/8x4 Flat Bar Status

Weight Corroded Yes No 60.11 1,310.11 2.21 0.78 1.50 OK

Cone small end calculations per Appendix 1-5(e), weight + pressure, corroded f2 = -Ws/(p*2*Rm) + 12*Ms/(p*Rm

2) = -766,010.1/(p*2*50.094) + 12*1,638,344/(p*50.0942) = 60.10913 lb/in P*Rs/2 = 1,250.00 lb/in f2 is in tension so a U-2(g) analysis is not required. P/(Ss*E1) = 50/(17,500.00*1) = 0.002857 From table 1-5.2 D = 4.57° As D < a reinforcement is required. Qs = P*Rs/2 + f2 = 1,250.00 + 60.10913 = 1,310.109 lb/in k = Ss*Es/(Sr*Er) = 17,500.00*26,000,000/(14,500.00*26,000,000) = 1.206897 Ars = (k*Qs*Rs/(Ss*E1))*(1 - D/a)*tan(a) = (1.206897*1,310.109*50/(17,500.00*1))*(1 - 4.57/30)*tan(30) = 2.210926 in2 Aes = 0.78*(Rs*ts)0.5*[(ts - t) + (tc - tr)/cos(a)] = 0.78*(50*0.188)0.5*[(0.188 - 0.1431025) + (0.438 - 0.1944595)/cos(30)] = 0.77988 in2



Additional reinforcement area required = Ars - Aes = 1.43105 in2 Area provided by a 3/8x4 Flat Bar = 1.5000 in2 The maximum ring centroid to juncture distance is 0.25*(Rs*ts)0.5 = 0.7665 in The actual distance of ring centroid to juncture is 0.5 in The small end is adequately reinforced per Appendix 1-5(e).

MAP Cone juncture large end calculations, P =53.026 psi Appendix 1-5(d)

Loading Area check

required (D < a)


f1 (lbf /in)

QL (lbf /in)

ArL(in2)

AeL(in2)

Ring area (in2)


Pressure Yes No 0.00 2,651.28 4.19 0.23 4.13 OK

Cone large end calculations per Appendix 1-5(d), pressure, new f1 = -Wl/(p*2*Rm) + 12*Ml/(p*Rm

2) = -0/(p*2*100.1565) + 12*0/(p*100.15652) = 0 lb/in P*RL/2 = 2,651.277 lb/in |f1| <= P*RL/2 so a U-2(g) analysis is not required. P/(Ss*E1) = 53.02554/(17,500.00*1) = 0.00303 From table 1-5.1 D = 18.09° As D < a a reinforcement check is required. QL = P*RL/2 + f1 = 2,651.277 + 0 = 2,651.277 lb/in k = Ss*Es/(Sr*Er) = 17,500.00*29,400,000/(14,500.00*29,400,000) = 1.206897



ArL = (k*QL*RL/(Ss*E1))*(1 - D/a)*tan(a) = (1.206897*2,651.277*100/(17,500.00*1))*(1 - 18.09/30)*tan(30) = 4.190995 in2 AeL = (ts - t)*(RL*ts)0.5 + (tc - tr)*(RL*tc/cos(a))0.5 = (0.313 - 0.3035549)*(100*0.313)0.5 + (0.438 - 0.4125032)*(100*0.438/cos(30))0.5 = 0.2341663 in2 Additional reinforcement area required = ArL - AeL = 3.95683 in2 Area provided by a 3/4x5.5 Flat Bar = 4.1250 in2 The maximum ring centroid to juncture distance is 0.25*(RL*ts)0.5 = 1.3987 in The actual distance of ring centroid to juncture is -1.102501 in The large end is adequately reinforced per Appendix 1-5(d).

MAP Cone juncture small end calculations P = 53.026 psi Appendix 1-5(e)

Loading Area check

required (D < a)


f2 (lbf /in)

Qs (lbf /in)

Ars(in2)

Aes(in2)

Ring area (in2)

3/8x4 Flat Bar Status


Cone small end calculations per Appendix 1-5(e), pressure, new f2 = -Ws/(p*2*Rm) + 12*Ms/(p*Rm

2) = -0/(p*2*50.094) + 12*0/(p*50.0942) = 0 lb/in P*Rs/2 = 1,325.638 lb/in |f2| <= P*Rs/2 so a U-2(g) analysis is not required. P/(Ss*E1) = 53.02554/(17,500.00*1) = 0.00303 From table 1-5.2 D = 4.69° As D < a reinforcement is required.



Qs = P*Rs/2 + f2 = 1,325.638 + 0 = 1,325.638 lb/in k = Ss*Es/(Sr*Er) = 17,500.00*29,400,000/(14,500.00*29,400,000) = 1.206897 Ars = (k*Qs*Rs/(Ss*E1))*(1 - D/a)*tan(a) = (1.206897*1,325.638*50/(17,500.00*1))*(1 - 4.69/30)*tan(30) = 2.226576 in2 Aes = 0.78*(Rs*ts)0.5*[(ts - t) + (tc - tr)/cos(a)] = 0.78*(50*0.188)0.5*[(0.188 - 0.1517775) + (0.438 - 0.2062516)/cos(30)] = 0.7265717 in2 Additional reinforcement area required = Ars - Aes = 1.5 in2 Area provided by a 3/8x4 Flat Bar = 1.5000 in2 The maximum ring centroid to juncture distance is 0.25*(Rs*ts)0.5 = 0.7665 in The actual distance of ring centroid to juncture is 0.5 in The small end is adequately reinforced per Appendix 1-5(e).



4.3 ASME Appendix L-2.3.3

Transition #1


Component: Transition Material specification: L-2.3.3 (user defined)

Not a UCS-66 material. Internal design pressure: P = 50.0000 psi @ 650.00°F

Static liquid head:

Pth = 5.4146 psi (SG=1.0000, Hs=150.0000", Horizontal test head at small end)Pth = 7.2194 psi (SG=1.0000, Hs=200.0000", Horizontal test head at large end)Corrosion allowance: Inner C = 0.0000" Outer C = 0.0000" PWHT is not performed Radiography: Category A joints - Spot UW-11(b) Type 2 Circ. joint top/left - Spot UW-11(b) Type 2 Circ. joint right/bottom - Spot UW-11(b) Type 2 Estimated weight: New = 8131.1 lb corr = 8131.1 lb Capacity: New = 7553.2 US gal corr = 7553.2 US gal

Axial length = 92.0000" Large End ID = 200.0000" Small End ID = 100.0000" Cone tc = 0.5625" Knuckle thickness tkL = 0.3750" (Min) Knuckle radius rl = 20.0000"

Design thickness, (at 650.00°F) UG-32(h) (Large End)

Di = D - 2*r * (1 - Cos(a)) = 200.0000 - 2*20.0000 * (1- Cos(29.988)) = 194.6451"

t = P*Di / (2*Cos(a)*(S*E - 0.60*P)) + C

= 50.0000*194.6451 / (2*Cos(29.988)*(13800*0.80 - 0.60*50.0000)) + 0.0000

= 0.5103"



Design thickness, (at 650.00°F) Appendix 1-4(d) (Knuckle)

L = Di / (2*Cos(a)) = 194.6451 / (2*Cos(29.988)) = 112.3652" M = 0.25 * (3 + Sqr(L/r)) = 0.25 * (3 + Sqr(112.3652/20.0000)) = 1.34 tk = P*L*M / (2*S*E - 0.20*P) + C = 50.0000*112.3652*1.34 / (2*13800*0.80 - 0.20*50.0000) + 0.0000 = 0.3418"

Small End design thickness (t = 0.2622") does not govern.

MAWP, (Corroded at 650.00°F) UG-32(h)

P = 2*S*E*t*Cos(a) / (Di + 1.20*t*Cos(a)) - Pskl

= 2*13800*0.80*0.5625*Cos(29.988) / (194.6451 + 1.20*0.5625*Cos(29.988)) - 0.0000

= 55.1007 psi

MAWP, (Corroded at 650.00°F) App 1-4(d) (Knuckle)

P = 2*S*E*tk / (L*M + 0.20*tk) - Ps = 2*13800.0000*0.80*0.3750 / (112.3652*1.34 + 0.20*0.3750) - 0.0000 = 54.8587 psi

Small End MAWP (106.9477 psi) does not govern.

MAP, (New at 70.00°F) UG-32(h)

P = 2*S*E*t*Cos(a) / (Di + 1.20*t*Cos(a)) - Pskl

= 2*13800*0.80*0.5625*Cos(29.988) / (194.6451 + 1.20*0.5625*Cos(29.988)) - 0.0000

= 55.1007 psi



MAP, (New at 70.00°F) App 1-4(d) (Knuckle)

P = 2*S*E*tk / (L*M + 0.20*tk) - Ps = 2*13800.0000*0.80*0.3750 / (112.3652*1.34 + 0.20*0.3750) - 0.0000 = 54.8587 psi

Small End MAP (106.9477 psi) does not govern.


= (75 * t / Rf) * (1 - Rf / Ro) = (75 * 0.3750 / 20.1875) * (1 - 20.1875 /∞) = 1.3932 %

Appendix 1-5 calculations are not required for the transition large end as a knuckle is present.

Cone juncture small end calculations P = 50.429 psi Appendix 1-5(e)

Loading Area check

required (D < a)


f2 (lbf /in)

Qs (lbf /in)

Ars(in2)

Aes(in2)

Ring area (in2)


Weight Corroded Yes No -38.52 1,222.21 2.09 1.47 0.63 OK

Cone small end calculations per Appendix 1-5(e), weight + pressure, corroded f2 = -Ws/(p*2*Rm) + 12*Ms/(p*Rm

2) = -12,139.44/(p*2*50.15625) + 12*0/(p*50.156252) = -38.52066 lb/in P*Rs/2 = 1,260.733 lb/in |f2| <= P*Rs/2 so a U-2(g) analysis is not required. P/(Ss*E1) = 50.42931/(17,500.00*0.8) = 0.003602 From table 1-5.2 D = 5.07° As D < a reinforcement is required.



Qs = P*Rs/2 + f2 = 1,260.733 + -38.52066 = 1,222.212 lb/in k = Ss*Es/(Sr*Er) = 17,500.00*26,000,000/(18,800.00*26,000,000) = 1 Ars = (k*Qs*Rs/(Ss*E1))*(1 - D/a)*tan(a) = (1*1,222.212*50/(17,500.00*0.8))*(1 - 5.07/29.9884)*tan(29.9884) = 2.093105 in2 Aes = 0.78*(Rs*ts)0.5*[(ts - t) + (tc - tr)/cos(a)] = 0.78*(50*0.3125)0.5*[(0.3125 - 0.1804948) + (0.5625 - 0.26442)/cos(29.9884)] = 1.4681 in2 Additional reinforcement area required = Ars - Aes = 0.625 in2 Area provided by a 1/4x2.5 Flat Bar = 0.6250 in2 The maximum ring centroid to juncture distance is 0.25*(Rs*ts)0.5 = 0.9882 in The actual distance of ring centroid to juncture is 0.625 in The small end is adequately reinforced per Appendix 1-5(e).

MAP Cone juncture small end calculations P = 49.462 psi Appendix 1-5(e)

Loading Area check

required (D < a)


f2 (lbf /in)

Qs (lbf /in)

Ars(in2)

Aes(in2)

Ring area (in2)



Cone small end calculations per Appendix 1-5(e), pressure, new f2 = -Ws/(p*2*Rm) + 12*Ms/(p*Rm

2) = -0/(p*2*50.15625) + 12*0/(p*50.156252) = 0 lb/in P*Rs/2 = 1,236.549 lb/in



|f2| <= P*Rs/2 so a U-2(g) analysis is not required. P/(Ss*E1) = 49.46197/(17,500.00*0.8) = 0.003533 From table 1-5.2 D = 5.02° As D < a reinforcement is required. Qs = P*Rs/2 + f2 = 1,236.549 + 0 = 1,236.549 lb/in k = Ss*Es/(Sr*Er) = 17,500.00*29,400,000/(20,000.00*29,400,000) = 1 Ars = (k*Qs*Rs/(Ss*E1))*(1 - D/a)*tan(a) = (1*1,236.549*50/(17,500.00*0.8))*(1 - 5.02/29.9884)*tan(29.9884) = 2.121907 in2 Aes = 0.78*(Rs*ts)0.5*[(ts - t) + (tc - tr)/cos(a)] = 0.78*(50*0.3125)0.5*[(0.3125 - 0.1770251) + (0.5625 - 0.2593342)/cos(29.9884)] = 1.496902 in2 Additional reinforcement area required = Ars - Aes = 0.625 in2 Area provided by a 1/4x2.5 Flat Bar = 0.6250 in2 The maximum ring centroid to juncture distance is 0.25*(Rs*ts)0.5 = 0.9882 in The actual distance of ring centroid to juncture is 0.625 in The small end is adequately reinforced per Appendix 1-5(e).




Cylinder #1


Component: Cylinder Material specification: SA-285 C (II-D p. 6, ln. 3)

Material is impact test exempt per UG-20(f) UCS-66 governing thickness = 0.3142 in Internal design pressure: P = 0 psi @ 0°F External design pressure: Pe = 15 psi @ 700°F

Static liquid head:

Pth = 6.0642 psi (SG=1.0000, Hs=167.9966", Horizontal test head) Corrosion allowance: Inner C = 0.0000" Outer C = 0.0000"

Design MDMT = -20.00°F No impact test performed

Rated MDMT = -20.00°F Material is not normalized

Material is not produced to Fine Grain Practice

PWHT is not performed

Radiography: Longitudinal joint - Full UW-11(a) Type 1

Top circumferential joint - Full UW-11(a) Type 1

Bottom circumferential joint - Full UW-11(a) Type 1

Estimated weight: New = 1833.6688 lb corr = 1833.6688 lb Capacity: New = 3742.3423 gal corr = 3742.3423 gal

OD = 168.6250" Length Lc = 39.0000" t = 0.3142"

Maximum allowable working pressure, (at 0.00°F) Appendix 1-1

P = S*E*t/(Ro - 0.40*t) - Ps = 15700*1.00*0.3142 / (84.3125 - 0.40*0.3142) - 0.0000



= 58.5952 psi

Maximum allowable pressure, (at 70.00°F) Appendix 1-1

P = S*E*t/(Ro - 0.40*t) = 15700*1.00*0.3142 / (84.3125 - 0.40*0.3142) = 58.5952 psi

External Pressure, (Corroded & at 700.00°F) UG-28(c)

L/Do = 39.0000/168.6250 = 0.2313 Do/t = 168.6250/0.314114 = 536.8275 From table G: A = 0.000501 From table CS-2: B = 6039.3208 psiPa = 4*B/(3*(Do/t)) = 4*6039.3208/(3*(168.6250/0.314114)) = 15.0000 psi

Design thickness for external pressure Pa = 15.0000 psi

= t + Corrosion = 0.314114 + 0.0000 = 0.3141"

Maximum Allowable External Pressure, (Corroded & at 700.00°F) UG-28(c)

L/Do = 39.0000/168.6250 = 0.2313 Do/t = 168.6250/0.3142 = 536.6804 From table G: A = 0.000502 From table CS-2: B = 6041.7378 psiPa = 4*B/(3*(Do/t)) = 4*6041.7378/(3*(168.6250/0.3142)) = 15.0101 psi

% Extreme fiber elongation - UCS-79(d)

= (50 * t / Rf) * (1 - Rf / Ro) = (50 * 0.3142 / 84.1554) * (1 - 84.1554 /∞) = 0.1867 %




Hemi Head #1


Component: Hemi Head

Material specification: SB-209 H112 0.500 - 2.000 A93003 (II-D p. 154, ln. 7)

Rated MDMT per UNF-65 = -452 °F Internal design pressure: P = 0.0000 psi @ 0.00°F External design pressure: Pe = 20.0000 psi @ 100.00°F

Static liquid head:

Pth = 2.5990 psi (SG=1.0000, Hs=72.0000", Horizontal test head)Corrosion allowance: Inner C = 0.0000" Outer C = 0.0000"

Design MDMT = -20.00°F No impact test performed




Radiography: RT on Category A Joints - Long. Seam - Full UW-11(a) Type 1

RT on Category A Joints - Circ. Seam - Full UW-11(a) Type 1

Estimated weight: New = 408.7 lb corr = 408.7 lb Capacity: New = 423.0 US gal corr = 423.0 US gal

Inner diameter = 72.0000" Minimum head thickness = 0.5000"



Maximum allowable working pressure, (at 0.00°F) UG-32(f)

P = 2*S*E*t/(R + 0.20*t) - Ps = 2*3800.0000*1.00*0.5000 / (36.0000 + 0.20*0.5000) - 0.0000 = 105.2632 psi

Maximum allowable pressure, (at 70.00°F) UG-32(f)

P = 2*S*E*t/(R + 0.20*t) = 2*3800.0000*1.00*0.5000 / (36.0000 + 0.20*0.5000) = 105.2632 psi

External Pressure, (Corroded & at 100.00°F) UG-28(d)

A = 0.125 / (Ro / t) = 0.125 / (36.5000 / 0.4289) = 0.001469

From table NFA-1: B = 1701.9270 psi

Pa = B / (Ro / t) = 1701.9270/(36.5000/0.4289)


= t + Corrosion = 0.4289 + 0.0000 = 0.4289"

Maximum Allowable External Pressure, (Corroded @ 100.00°F)

A = 0.125 / (Ro / t) = 0.125 / (36.5000 / 0.5000) = 0.001712

From table NFA-1: B = 1755.8127 psi

Pa = B/(Ro/t) = 1755.8127 / (36.5000 / 0.5000) = 24.0522 psi

The maximum allowable external pressure is 24.0522 psi



% Forming Strain - UNF-79(a)(2)(a)

= (75 * t / Rf) * (1 - Rf / Ro) = (75 * 0.5000 / 36.2500) * (1 - 36.2500 / ∞) = 1.0345 %

Head design thickness = 0.4289"

The governing condition is due to external pressure.

The head thickness of 0.5000" is adequate.




Ellipsoidal Head #1

ASME Section VIII, Division 1, 2004 Edition, A06 Addenda

Component: Ellipsoidal Head Material Specification: SA-516 70 (II-D p.14, ln. 20) Material is impact test exempt per UG-20(f) UCS-66 governing thickness = 0.5625 in External design pressure: Pe = 15 psi @ 700 °F

Static liquid head:

Ps= 0 psi (SG=1, Hs=0" Operating head) Pth= 6.0598 psi (SG=1, Hs=167.875" Horizontal test head) Corrosion allowance: Inner C = 0" Outer C = 0" Design MDMT = -20°F No impact test performed Rated MDMT = N/A Material is not normalized Material is not produced to fine grain practice PWHT is not performed Do not Optimize MDMT / Find MAWP

Radiography: Category A joints - Seamless No RT Head to shell seam - Full UW-11(a) Type 1

Estimated weight: new = 5,211.20 lb corr = 5,211.20 lb

Capacity: new = 2,680.90 US gal corr = 2,680.90 US gal

Outer diameter = 169" Minimum head thickness = 0.5625" Head ratio D/2h = 2 (new) Head ratio D/2h = 2 (corroded)



Insulation thk: 0" density: 0 lb/ft3 weight: 0 lb Insulation support ring spacing: 0" individual weight: 0

lb total weight: 0 lb

Lining/ref thk: 0" density: 0 lb/ft3 weight: 0 lb

Results Summary

The governing condition is external pressure. Minimum thickness per UG-16 = 0.0625" + 0" = 0.0625" Design thickness due to external pressure (te) = 0.4774" Maximum allowable external pressure (MAEP) = 20.8547 psi K (Corroded)

= (1/6)*[2 + (D / (2*h))2]

K = (1/6)*[2 + (167.875 / (2*41.9688))2] = 1 K (New)

= (1/6)*[2 + (D / (2*h))2]

K = (1/6)*[2 + (167.875 / (2*41.9688))2] = 1

Maximum allowable working pressure, (Corroded at 0 °F) Appendix 1-4(c)

P = 2*S*E*t / (K*Do - 2*t*(K - 0.1)) - Ps = 2*20000*1*0.5625 / (1*169 - 2*0.5625*(1 - 0.1)) - 0 = 133.9385 psi The maximum allowable working pressure (MAWP) is 133.9385 psi.

Maximum allowable pressure, (New at 70 °F) Appendix 1-4(c)

P = 2*S*E*t / (K*Do - 2*t*(K - 0.1)) - Ps = 2*20000*1*0.5625 / (1*169 - 2*0.5625*(1 - 0.1)) - 0 = 133.9385 psi The maximum allowable pressure (MAP) is 133.9385 psi.

Design thickness for external pressure, (Corroded at 700 °F) UG-33(d)

Equivalent outside spherical radius (Ro)



Ro = Ko*Do = 0.894 * 169 = 151.0942 in A = 0.125 / (Ro/t) = 0.125 / (151.0942/0.477373) = 0.000395 From Table CS-2: B=4,747.6733 psi

Pa = B/(Ro/t) = 4747.673/(151.0942/0.477373)

= 15 psi

t = 0.4774" + Corrosion = 0.4774" + 0" = 0.4774"

Check the external pressure per UG-33(a)(1) Appendix 1-4(c)

t = 1.67*Pe*Do*K / (2*S*E + 2*1.67*Pe*(K - 0.1)) + Corrosion = 1.67*15*169*1 / (2*18100*1 + 2*1.67*15*(1 - 0.1)) + 0 = 0.1168"

The head external pressure design thickness (te) is 0.477373".

Maximum Allowable External Pressure, (Corroded at 700 °F) UG-33(d)

Equivalent outside spherical radius (Ro) Ro = Ko*Do = 0.894 * 169 = 151.0942 in A = 0.125 / (Ro/t) = 0.125 / (151.0942/0.5625) = 0.000465 From Table CS-2: B=5,601.8286 psi

Pa = B/(Ro/t) = 5601.829/(151.0942/0.5625)

= 20.8547 psi



Check the Maximum External Pressure, UG-33(a)(1) Appendix 1-4(c)

P = 2*S*E*t / ((K*Do - 2*t*(K - 0.1))*1.67) - Ps2 = 2*18100*1*0.5625 / ((1*169 - 2*0.5625*(1 - 0.1))*1.67) - 0 = 72.5835 psi

The maximum allowable external pressure (MAEP) is 20.8547 psi.


= (75*t / Rf)*(1 - Rf / Ro) = (75*0.5625 / 28.82)*(1 - 28.82 / ∞) = 1.4638%

The extreme fiber elongation does not exceed 5%.




F&D Head #1


Component: F&D Head Material Specification: SA-516 70 (II-D p.14, ln. 20) Material impact test exemption temperature from Fig UCS-66 Curve B = -1 °F Fig UCS-66.1 MDMT reduction = 45.2 °F, (coincident ratio = 0.565316) UCS-66 governing thickness = 0.5625 in External design pressure: Pe = 15 psi @ 700 °F

Static liquid head:

Ps= 0 psi (SG=1, Hs=0" Operating head) Pth= 6.0643 psi (SG=1, Hs=168" Horizontal test head) Corrosion allowance: Inner C = 0" Outer C = 0" Design MDMT = -20°F No impact test performed Rated MDMT = N/A Material is not normalized Material is not produced to fine grain practice PWHT is not performed Do not Optimize MDMT / Find MAWP


Estimated weight: new = 4,220.90 lb corr = 4,220.90 lb Capacity: new = 1,663.10 US gal corr = 1,663.10 US gal

Inner diameter = 168" Crown radius L = 168.5625"Knuckle radius r = 10.1475" Minimum head thickness = 0.5625"



Insulation thk: 0" density: 0 lb/ft3 weight: 0 lb Insulation support ring spacing: 0" individual weight: 0


Lining/ref thk: 0" density: 0 lb/ft3 weight: 0 lb

Results Summary

The governing condition is external pressure. Minimum thickness per UG-16 = 0.0625" + 0" = 0.0625" Design thickness due to external pressure (te) = 0.5344" M (Corroded)

= 1/4*[3 + (L/r)1/2]

M = 1/4*[3 + (168.5625/10.1475)1/2] = 1.768922 M (New)

= 1/4*[3 + (L/r)1/2]

M = 1/4*[3 + (168.5625/10.1475)1/2] = 1.768922

Maximum allowable working pressure, (Corroded at 0 °F) Appendix 1-4(d)

P = 2*S*E*t / (L*M + 0.20*t) - Ps = 2*20000*1*0.5625 / (168.5625*1.7689 + 0.20*0.5625) - 0 = 75.4309 psi The maximum allowable working pressure (MAWP) is 75.4309 psi.

Maximum allowable pressure, (New at 70 °F) Appendix 1-4(d)

P = 2*S*E*t / (L*M + 0.20*t) - Ps = 2*20000*1*0.5625 / (168.5625*1.7689 + 0.20*0.5625) - 0 = 75.4309 psi The maximum allowable pressure (MAP) is 75.4309 psi.

Design thickness for external pressure, (Corroded at 700 °F) UG-33(e)

Equivalent outside spherical radius (Ro) = Outside crown radius = 169.125 in



A = 0.125 / (Ro/t) = 0.125 / (169.125/0.53434) = 0.000395 From Table CS-2: B=4,747.6733 psi

Pa = B/(Ro/t) = 4747.673/(169.125/0.53434)

= 15 psi

t = 0.5343" + Corrosion = 0.5343" + 0" = 0.5343"

Check the external pressure per UG-33(a)(1) Appendix 1-4(d)

t = 1.67*Pe*L*M / (2*S*E - 0.20*1.67*Pe) + Corrosion = 1.67*15*168.5625*1.7689 / (2*18100*1 - 0.20*1.67*15) + 0 = 0.2064"


Maximum Allowable External Pressure, (Corroded at 700 °F) UG-33(e)

Equivalent outside spherical radius (Ro) = Outside crown radius = 169.125 in A = 0.125 / (Ro/t) = 0.125 / (169.125/0.5625) = 0.000416 From Table CS-2: B=4,999.9800 psi

Pa = B/(Ro/t) = 4999.98/(169.125/0.5625)

= 16.6296 psi



Check the Maximum External Pressure, UG-33(a)(1) Appendix 1-4(d)

P = 2*S*E*t / ((L*M + 0.20*t)*1.67) - Ps2 = 2*18100*1*0.5625 / ((168.5625*1.7689 + 0.20*0.5625)*1.67) - 0 = 40.8772 psi



= (75*t / Rf)*(1 - Rf / Ro) = (75*0.5625 / 10.4288)*(1 - 10.4288 / ∞) = 4.0453%

The extreme fiber elongation does not exceed 5%.




Nozzle #1 (N1)


tw(lower) = 0.3750 in

Leg41 = 0.3750 in

Note: round inside edges per UG-76(c)

Located on: Cylinder #1 Liquid static head included: 0 psi

Nozzle material specification: L-7.1 Nozzle (user defined)

Nozzle longitudinal joint efficiency: 1.00 Nozzle orientation: 0° Local vessel minimum thickness: 0.375 in Nozzle center line offset to datum line: 18 in End of nozzle to shell center: 21.375 in Nozzle inside diameter, new: 4 in Nozzle nominal wall thickness: 0.75 in Nozzle corrosion allowance: 0 in Projection available outside vessel, Lpr: 6 in



Reinforcement Calculations for Internal Pressure

UG-37 Area Calculation Summary (in2) For P = 250 psi @ 150 °F

The opening is adequately reinforced

UG-45 Nozzle Wall Thickness Summary (in)

The nozzle passes UG-45 A

required A

available A1 A2 A3 A5 A welds treq tmin

1.1070 1.8767 0.3930 1.3431 -- -- 0.1406 0.2258 0.6563

Weld Failure Path Analysis Summary

The nozzle is exempt from weld strength calculations per UW-15(b)(1)

UW-16 Weld Sizing Summary

Weld description Required weldthroat size (in)

Actual weld throat size (in) Status

Nozzle to shell fillet (Leg41) 0.2500 0.2625 weld size is adequate

Calculations for internal pressure 250 psi @ 150 °F Limits of reinforcement per UG-40

Parallel to the vessel wall: d = 4 in Normal to the vessel wall outside: 2.5*(t - C) = 0.9375 in

Nozzle required thickness per UG-27(c)(1)

trn = P*Rn/(Sn*E - 0.6*P) = 250*2/(15000*1 - 0.6*250) = 0.0337 in



Required thickness tr from UG-37(a)

tr = P*R/(S*E - 0.6*P) = 250*15/(13700*1 - 0.6*250) = 0.2768 in

Area required per UG-37(c) Allowable stresses: Sn = 15000, Sv = 13700 psi fr1 = lesser of 1 or Sn/Sv = 1 fr2 = lesser of 1 or Sn/Sv = 1

A = d*tr*F + 2*tn*tr*F*(1 - fr1) = 4*0.2768*1 + 2*0.75*0.2768*1*(1 - 1) = 1.107 in2

Area available from FIG. UG-37.1 A1 = larger of the following= 0.393 in2

= d*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1) = 4*(1*0.375 - 1*0.2768) - 2*0.75*(1*0.375 - 1*0.2768)*(1 - 1) = 0.393 in2

= 2*(t + tn)*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1) = 2*(0.375 + 0.75)*(1*0.375 - 1*0.2768) - 2*0.75*(1*0.375 - 1*0.2768)*(1 - 1) = 0.2211 in2

A2 = smaller of the following= 1.3431 in2

= 5*(tn - trn)*fr2*t = 5*(0.75 - 0.0337)*1*0.375 = 1.3431 in2



= 5*(tn - trn)*fr2*tn = 5*(0.75 - 0.0337)*1*0.75 = 2.6861 in2 A41 = Leg2*fr2 = 0.3752*1 = 0.1406 in2 Area = A1 + A2 + A41 = 0.393 + 1.3431 + 0.1406 = 1.8767 in2

As Area >= A the reinforcement is adequate. UW-16(c) Weld Check Fillet weld: tmin = lesser of 0.75 or tn or t = 0.375 in tc(min) = lesser of 0.25 or 0.7*tmin = 0.25 in tc(actual) = 0.7*Leg = 0.7*0.375 = 0.2625 in The fillet weld size is satisfactory. Weld strength calculations are not required for this detail which conforms to Fig. UW-16.1, sketch (c-e). UG-45 Nozzle Neck Thickness Check

Wall thickness per UG-45(a): tr1 = 0.0337 in (E =1) Wall thickness per UG-45(b)(1): tr2 = 0.2768 in Wall thickness per UG-16(b): tr3 = 0.0625 in Standard wall pipe per UG-45(b)(4): tr4 = 0.2258 in The greater of tr2 or tr3: tr5 = 0.2768 in The lesser of tr4 or tr5: tr6 = 0.2258 in

Required per UG-45 is the larger of tr1 or tr6 = 0.2258 in Available nozzle wall thickness new, tn = 0.8750*0.75 = 0.6563 in The nozzle neck thickness is adequate.




Nozzle #1 (N1)



Leg41 = 0.5000 in tw(upper) = 0.0000 in

Leg42 = 0.4375 in Dp = 19.0000 in te = 0.5000 in

Note: round inside edges per UG-76(c)

Located on: Cylinder #1 Liquid static head included: 0 psi

Nozzle material specification: L-7.2 Nozzle (user defined)

Nozzle longitudinal joint efficiency: 1.00 Nozzle description: 12" X Heavy Pad material specification: L-7.3 Pad (user defined) Pad diameter: 19 in Nozzle orientation: 0° Local vessel minimum thickness: 0.75 in Nozzle center line offset to datum line: 30 in End of nozzle to shell center: 36.75 in Nozzle inside diameter, new: 11.75 in Nozzle nominal wall thickness: 0.5 in Nozzle corrosion allowance: 0 in Projection available outside vessel, Lpr: 6 in Pad is split: no



This nozzle passes through a Category A joint. Reinforcement Calculations for Internal Pressure

UG-37 Area Calculation Summary (in2) For P = 250 psi @ 700 °F

The opening is adequately reinforced

UG-45 Nozzle Wall Thickness Summary (in)

The nozzle passes UG-45 A

required A

available A1 A2 A3 A5 A welds treq tmin

6.2280 6.2665 1.2627 1.4374 -- 3.1250 0.4414 0.3281 0.4375

Weld Failure Path Analysis Summary (lbf) All failure paths are stronger than the applicable weld loads

Weld load W

Weld load W1-1

Path 1-1 strength

Weld loadW2-2

Path 2-2 strength

Weld load W3-3

Path 3-3 strength

72,540.04 71,554.34 203,289.63 34,854.82 229,116.38 82,279.34 250,441.59

UW-16 Weld Sizing Summary

Weld description Required weldthroat size (in)

Actual weld throat size (in) Status

Nozzle to pad fillet (Leg41) 0.3500 0.3500 weld size is adequate

Pad to shell fillet (Leg42) 0.2500 0.3062 weld size is adequate

Calculations for internal pressure 250 psi @ 700 °F Limits of reinforcement per UG-40

Parallel to the vessel wall: d = 11.75 in Normal to the vessel wall outside: 2.5*(tn - Cn) + te = 1.75 in



Nozzle required thickness per UG-27(c)(1)

trn = P*Rn/(Sn*E - 0.6*P) = 250*5.875/(16600*1 - 0.6*250) = 0.0893 in

Required thickness tr from UG-37(a)

tr = P*R/(S*E - 0.6*P) = 250*30/(14300*1 - 0.6*250) = 0.53 in

Area required per UG-37(c) Allowable stresses: Sn = 16600, Sv = 14300, Sp = 14300 psi fr1 = lesser of 1 or Sn/Sv = 1 fr2 = lesser of 1 or Sn/Sv = 1 fr3 = lesser of fr2 or Sp/Sv = 1 fr4 = lesser of 1 or Sp/Sv = 1

A = d*tr*F + 2*tn*tr*F*(1 - fr1) = 11.75*0.53*1 + 2*0.5*0.53*1*(1 - 1) = 6.228 in2

Area available from FIG. UG-37.1 A1 = larger of the following= 1.2627 in2

= d*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1) = 11.75*(0.85*0.75 - 1*0.53) - 2*0.5*(0.85*0.75 - 1*0.53)*(1 - 1) = 1.2627 in2

= 2*(t + tn)*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1) = 2*(0.75 + 0.5)*(0.85*0.75 - 1*0.53) - 2*0.5*(0.85*0.75 - 1*0.53)*(1 - 1) = 0.2686 in2



A2 = smaller of the following= 1.4374 in2

= 5*(tn - trn)*fr2*t = 5*(0.5 - 0.0893)*1*0.75 = 1.5401 in2 = 2*(tn - trn)*(2.5*tn + te)*fr2 = 2*(0.5 - 0.0893)*(2.5*0.5 + 0.5)*1 = 1.4374 in2 A41 = Leg2*fr3 = 0.52*1 = 0.25 in2 A42 = Leg2*fr4 = 0.43752*1 = 0.1914 in2 A5 = (Dp - d - 2*tn)*te*fr4 = (19 - 11.75 - 2*0.5)*0.5*1 = 3.125 in2 Area = A1 + A2 + A41 + A42 + A5 = 1.2627 + 1.4374 + 0.25 + 0.1914 + 3.125 = 6.2665 in2

As Area >= A the reinforcement is adequate. UW-16(c)(2) Weld Check

Inner fillet: tmin = lesser of 0.75 or tn or te = 0.5 in tw(min) = 0.7*tmin = 0.35 in tw(actual) = 0.7*Leg = 0.7*0.5 = 0.35 in Outer fillet: tmin = lesser of 0.75 or te or t = 0.5 in tw(min) = 0.5*tmin = 0.25 in tw(actual) = 0.7*Leg = 0.7*0.4375 = 0.3063 in



UG-45 Nozzle Neck Thickness Check

Wall thickness per UG-45(a): tr1 = 0.0893 in (E =1) Wall thickness per UG-45(b)(1): tr2 = 0.53 in Wall thickness per UG-16(b): tr3 = 0.0625 in Standard wall pipe per UG-45(b)(4): tr4 = 0.3281 in The greater of tr2 or tr3: tr5 = 0.53 in The lesser of tr4 or tr5: tr6 = 0.3281 in

Required per UG-45 is the larger of tr1 or tr6 = 0.3281 in Available nozzle wall thickness new, tn = 0.8750*0.5 = 0.4375 in The nozzle neck thickness is adequate. Allowable stresses in joints UG-45(c) and UW-15(c)

Groove weld in tension: 0.74*14300 = 10582 psi Nozzle wall in shear: 0.7*16600 = 11620 psi Inner fillet weld in shear: 0.49*14300 = 7007 psi Outer fillet weld in shear: 0.49*14300 = 7007 psi

Strength of welded joints: (1) Inner fillet weld in shear (p/2)*Nozzle OD*Leg*Si = (p/2)*12.75*0.5*7007 = 70166.89 lbf (2) Outer fillet weld in shear (p/2)*Pad OD*Leg*So = (p/2)*19*0.4375*7007 = 91492.12 lbf (3) Nozzle wall in shear (p/2)*Mean nozzle dia*tn*Sn = (p/2)*12.25*0.5*11620 = 111797.5 lbf (4) Groove weld in tension (p/2)*Nozzle OD*tw*Sg = (p/2)*12.75*0.75*10582 = 158949.5 lbf Loading on welds per UG-41(b)(1)

W = (A - A1 + 2*tn*fr1*(E1*t - F*tr))*Sv = (6.228 - 1.2627 + 2*0.5*1*(0.85*0.75 - 1*0.53))*14300 = 72540.04 lbf



W1-1 = (A2 + A5 + A41 + A42)*Sv = (1.4374 + 3.125 + 0.25 + 0.1914)*14300 = 71554.34 lbf

W2-2 = (A2 + A3 + A41 + A43 + 2*tn*t*fr1)*Sv = (1.4374 + 0 + 0.25 + 0 + 2*0.5*0.75*1)*14300 = 34854.82 lbf

W3-3 = (A2 + A3 + A5 + A41 + A42 + A43 + 2*tn*t*fr1)*Sv = (1.4374 + 0 + 3.125 + 0.25 + 0.1914 + 0 + 2*0.5*0.75*1)*14300 = 82279.34 lbf

Load for path 1-1 lesser of W or W1-1 = 71554.34 lbf Path 1-1 through (2) & (3) = 91492.12 + 111797.5 = 203289.6 lbf Path 1-1 is stronger than W1-1 so it is acceptable per UG-41(b)(1). Load for path 2-2 lesser of W or W2-2 = 34854.82 lbf Path 2-2 through (1), (4) = 70166.89 + 158949.5 = 229116.4 lbf Path 2-2 is stronger than W2-2 so it is acceptable per UG-41(b)(1). Load for path 3-3 lesser of W or W3-3 = 72540.04 lbf Path 3-3 through (2), (4) = 91492.12 + 158949.5 = 250441.6 lbf Path 3-3 is stronger than W so it is acceptable per UG-41(b)(2).



4.10 ASME Division 2 Appendix G-101

Cylinder #1

ASME Section VIII, Division 2, 2004 Edition, A06 Addenda AD-160: Requirement of fatigue analysis not investigated. Independent investigation required.

Component: Cylinder Material Specification: SA-266 3 (II-D p. 264, ln. 34) Material is impact tested per AM-204.1 to -50 °F AM-218.4(g) reduction of 12.2 °F applied (ratio = 0.87836).. AF-402: PWHT is required for P-No 1 , G-No 2 materials for governing thickness at weld of 5.7500 in. Internal design pressure: P = 10,000.00 psi @ 250 °F

Static liquid head:

Pth= 0.7219 psi (SG=1, Hs=20 in Horizontal test head) Corrosion allowance: Inner C = 0 in Outer C = 0 in Design MDMT = 32°F Impact test performed Rated MDMT = -62.2°F Material is not normalized Material is not produced to fine grain practice PWHT is performed Do not Optimize MDMT / Find MAWP Radiography: Longitudinal joint - Full AF-221.2 Type 1

Circ. joint right/bottom - Full AF-221.2 Type 1

Estimated weight: new = 2,632.761 lb corr = 2,632.761 lb Capacity: new = 27.1999 US gal corr = 27.1999 US gal

ID = 20 in Length Lc = 20 in t = 5.75 in

Insulation thk: 0 in density: 0 lb/ft3 weight: 0 lb Insulation support ring spacing: 0 in individual weight: 0 lb total weight: 0 lb



Lining/ref thk: 0 in density: 0 lb/ft3 weight: 0 lb

Results Summary

The governing condition is Operating, Hot & Corroded. Design thickness due to internal pressure (t) = 5.5962 in Minimum thickness per AD-104 = 0.25 in Maximum allowable working pressure (MAWP) = 10,220.74 psi Maximum allowable pressure (MAP) = 11,356.38 psi

Operating, Hot & Corroded

Design thickness @ 250 °F per AD-201(a)

P = 10,000.0000 > 0.4*S = 0.4 * 22,500.00 t = R * (e(P/S) -1) + Corrosion = 10 * (e(10,000.00/22,500.00) -1) + 0 = 5.5962 in

Maximum pressure rating @ 250 °F per AD-201(a)

P = 10,220.74 > 0.4*S = 0.4 * 22,500.00 PRating = S * LN(t/R + 1) - Ps = 22,500.00 * LN(5.75/10 + 1) - 0 = 10,220.74 psi

Empty, New


P = 11,356.38 > 0.4*S = 0.4 * 25,000.00 PRating = S * LN(t/R + 1) = 25,000.00 * LN(5.75/10 + 1) = 11,356.38 psi



4.11 ASME Division 2 Appendix G-105

Cylinder #1


Component: Cylinder Material Specification: SA-285 C <= 2 (II-D p. 256, ln. 12) Material impact test exemption temperature from Fig AM-218.1 Curve A = 67.62°F AM-218 governing thickness = 0.992". AF-402: PWHT is not required for P-No 1 , G-No 1 materials for governing thickness at weld of 0.9920 in. Internal design pressure: P = 300 psi @ 100 °F

Static liquid head:

Pth= 4.3317 psi (SG=1, Hs=120 in Horizontal test head) Corrosion allowance: Inner C = 0 in Outer C = 0 in Design MDMT = 32°F No impact test performed Rated MDMT = 67.616°F Material is not normalized

Material is not produced to fine grain practice

PWHT is not performed Do not Optimize MDMT / Find MAWP Radiography: Longitudinal joint - Full AF-221.2 Type 1

Circ. joint right/bottom - Full AF-221.2 Type 1

Estimated weight: new = 6,402.597 lb corr = 6,402.597 lb

Capacity: new = 2,937.593 US gal corr = 2,937.593 US gal



ID = 120 in Length Lc = 60 in t = 0.992 in

Insulation thk: 0 in density: 0 lb/ft3 weight: 0 lb Insulation support ring spacing: 0 in individual weight:

0 lb total weight: 0 lb

Lining/ref thk: 0 in density: 0 lb/ft3 weight: 0 lb

Results Summary

The governing condition is Operating, Hot & Corroded. Design thickness due to internal pressure (t) = 0.9917 in Minimum thickness per AD-104 = 0.25 in Maximum allowable working pressure (MAWP) = 300.0793 psi Maximum allowable pressure (MAP) = 300.0793 psi


Design thickness @ 100 °F per AD-201(a)

P = 300.0000 <= 0.4*S = 0.4 * 18,300.00 t = P*R/(S - 0.5*P) + Corrosion = 300*60/(18,300.00 - 0.5*300) + 0 = 0.9917 in


P = 300.0793 <= 0.4*S = 0.4 * 18,300.00 PRating = t*S/(R + 0.5*t) - Ps = 0.992*18,300.00/(60 + 0.5*0.992) - 0 = 300.0793 psi

Empty, New


P = 300.0793 <= 0.4*S = 0.4 * 18,300.00



PRating = t*S/(R + 0.5*t) = 0.992*18,300.00/(60 + 0.5*0.992) = 300.0793 psi

Ellipsoidal Head #1


Component: Elliptical Head Material Specification: SA-285 C <= 2 (II-D p. 256, ln. 12) Material impact test exemption temperature from Fig AM-218.1 Curve A = 77.04°F AM-218 governing thickness = 1.188429". AF-402: PWHT is not required for P-No 1 , G-No 1 materials for governing thickness at weld of 1.1884 in. Internal design pressure: P = 300 psi @ 100 °F

Static liquid head:

Pth= 4.3317 psi (SG=1, Hs=120 in Horizontal test head) Corrosion allowance: Inner C = 0 in Outer C = 0 in Design MDMT = 32°F No impact test performed Rated MDMT = 77.0446°F Material is not normalized


PWHT is not performed Do not Optimize MDMT / Find MAWP Radiography: Category A joints - Full AF-221.2 Type 1 Head to shell seam - Full AF-221.2 Type 1

Estimated weight*: new = 6,806.465 lb corr = 6,806.465 lb

Capacity*: new = 1,395.357 US gal corr = 1,395.357 US gal



* includes straight flange if applicable

ID = 120 in Head ratio D/2h = 2 Minimum head thickness = 1.1884 in Straight flange length Lsf = 8.5 in Nominal straight flange thickness tsf = 1.1884 in

Insulation thk*: 0 in density: 0 lb/ft3 weight: 0 lb

Insulation support ring spacing: 0 in individual weight: 0 lb total weight: 0 lb

Lining/ref thk*: 0 in density: 0 lb/ft3 weight: 0 lb


Results Summary

Design thickness due to internal pressure (t) = 1.1884 in Design thickness of straight flange due to internal pressure (tsf) = 0.9917 in Minimum thickness per AD-104 = 0.25 in Maximum allowable working pressure (MAWP) = 300 psi Maximum allowable pressure (MAP) = 300 psi The required length of the transition to the shell per AD-420(a) = 0.5893 in.

Design thickness @ 100 °F per AD-204

x = r/D = 20.4/120 = 0.17 y = LN(P/S) = LN(300/18,300.00) = -4.1109 A = a1 + a2*x + a3*x2 + (b1 + b2*x + b3*x2)*y + (c1 + c2*x + c3*x2)*y2 = -1.2618 - 4.5525*0.17 + 28.9332*0.172 + (0.663 - 2.2471*0.17 + 15.683*0.172)*-4.1109 + (0.000027 - 0.4226*0.17 + 1.8878*0.172)*-4.11092 = -4.5095 t = L * eA + Corrosion = 108 * e-4.5095 + 0 = 1.1884 in



Maximum allowable working pressure @ 100 °F per AD-204

x = r/D = 20.4/120 = 0.17 z1 = c1 - c2*x + c3*x2 = 0.000027 - 0.4226*0.17 + 1.8878*0.172 = -0.0173 z2 = b1 - b2*x + b3*x2 = 0.663 - 2.2471*0.17 + 15.683*0.172 = 0.7342 z3 = -a1 - a2*x + a3*x2 - LN(t/L) = -1.2618 - 4.5525*0.17 + 28.9332*0.172 - LN(1.1884/108) = 3.31 MAWP = S*e^(-z2±(z2

2-4*z1*z3)0.5/(2*z1)) - Ps = 18,300.00*e^(-0.7342±(0.73422-4*-0.0173*3.31)0.5/(2*-0.0173)) - 0 = 300 psi

Maximum allowable pressure @ 70 °F per AD-204

x = r/D = 20.4/120 = 0.17 z1 = c1 - c2*x + c3*x2 = 0.000027 - 0.4226*0.17 + 1.8878*0.172 = -0.0173 z2 = b1 - b2*x + b3*x2 = 0.663 - 2.2471*0.17 + 15.683*0.172 = 0.7342 z3 = -a1 - a2*x + a3*x2 - LN(t/L) = -1.2618 - 4.5525*0.17 + 28.9332*0.172 - LN(1.1884/108) = 3.31 MAP = S*e^(-z2±(z2

2-4*z1*z3)0.5/(2*z1)) = 18,300.00*e^(-0.7342±(0.73422-4*-0.0173*3.31)0.5/(2*-0.0173)) = 300 psi



4.12 ASME Division 2 Appendix G-115 No Reinforcement

Nozzle #1 (N1)


tw(lower) = 0.875 in Leg41 = 0.375 in Leg43 = 0.25 in Lpr(inward) = 0.25 in

Nozzle corner radius (r3) must be greater than or equal to the smaller of 0.25 in or tn/2; alternatively, smaller of 0.25 in or tn/4 chamfer at 45 degrees.

Nozzle design mode: Design P, Find Nozzle MAWP & MAP

Nozzle attachment: radial Located on: Cylinder #1 Liquid static head included: 0 psi

Nozzle material specification: SA-213 304 Appendix G-115 Example (user defined)

Nozzle description: 6" Sch 80 (XS) Nozzle orientation 0° Local vessel thickness: 0.875 in Nozzle center line offset to datum line: 30 in End of nozzle to shell center: 36.875 in Nozzle inside diameter, new: 5.761 in Nozzle nominal wall thickness: 0.432 in Nozzle corrosion allowance: 0 in



Projection outside vessel along nozzle OD, Lpr: 6 in

Results Summary

Full Area Check

The governing condition is Design P. Area required (Ar) = 3.8379 in2 Area available (Aa) = 1.9589 in2

*** Warning: Ar = 3.8379 in^2 > Aa = 1.9589 in^2 : Design P Condition ***

2/3 Area Check

The governing condition is Design P. Area required (Ar) = 2.5586 in2 Area available (Aa) = 1.526 in2

*** Warning: Ar = 2.5586 in^2 > Aa = 1.526 in^2 : Design P Condition ***

Nozzle Neck Status

Required nozzle neck thickness = 0.245 in Minimum nozzle neck thickness = (0.875*0.432) = 0.378 in.

Pressure Ratings

MAWP = 264.9429 psi

MAP = 354.9683 psi

PWHT Status

Summary Tables

AD-520 Reinforcement Calculation Summary

Condition Pressure (psi)

Full or 2/3 Area Check

Area RequiredAr (in2)

Area AvailableAa (in2)

Ratio Aa / Ar

350.0000 1 3.8379 1.9589 0.5104Design P

350.0000 2/3 2.5586 1.5260 0.5964264.9429 1 2.8984 2.8984 1.0000

MAWP 285.3653 2/3 2.0824 2.0824 1.0000

MAP 354.9683 1 3.3852 3.3852 1.0000



396.9620 2/3 2.5267 2.5268 1.0000 Available Areas (in2)

Condition Full or 2/3 Area Check

A1 A2 A3 A41 A43

1 1.9589 0.0000 0.0000 0.0000 0.0000Design P

2/3 1.5260 0.0000 0.0000 0.0000 0.00001 2.8984 0.0000 0.0000 0.0000 0.0000

MAWP 2/3 2.0824 0.0000 0.0000 0.0000 0.00001 2.1522 0.8139 0.2160 0.1406 0.0625

MAP 2/3 1.3080 0.8139 0.2160 0.1406 0.0625

AD-602 Minimum Nozzle Neck Check

Condition treq (in)

tmin (in) Status

Design P 0.2450 0.3780 adequateMAWP 0.2450 0.3780 adequateMAP 0.2450 0.3780 adequate

Maximum Pressure Calculations Condition Full Area Check 2/3 Area Check Nozzle Neck CheckMAWP 264.9429 285.3653 526.0742 MAP 354.9683 396.9620 526.0742 Minimum Fillet Weld Sizes Fillet Leg RequiredLeg Size (in) ActualLeg Size (in) Status Leg41 0.3571 0.3750 weld size is adequateLeg43 0.2500 0.2500 weld size is adequate

Calculations for Design P = 350 psi @ 400 °F

AD-540 Limits of Reinforcement Parallel to vessel wall: Larger of d or r + t + tn Larger of 6.625 or 3.3125 + 0.875 + 0.432 = 4.6195 = 6.625 in Parallel to vessel wall (2/3 limit): Larger of r + 0.5*(Rm*t)0.5 or r + t + tn Larger of 3.3125 + 0.5*(30.4375*0.875)0.5 = 5.8928 or 3.3125 + 0.875 + 0.432 = 4.6195 = 5.8928 in



Normal to vessel wall: Nozzle conforms to Figure AD-540.1 Sketch (d). Larger of 0.5*(rm*tn)0.5 + te + K or 2.5*tn + te + K but not to exceed 2.5*t Larger of 0.5*(3.0965*0.432)0.5 + 0 + 0 = 0.5783 or 2.5*0.432 + 0 + 0 = 1.08 but not to exceed 2.5*0.875 = 2.1875 = 1.08 in AD-550(f) Nozzle Available Area Check ABS(aR - aV)*10-5*DT≤0.0008 ABS(0.919 - 0.674)*10-5*330 = 0.00081≤0.0008 No credit shall be taken for reinforcing potentially available in the nozzle neck or adjoining fillet weld metal Nozzle Required Thickness P = 350 <= 0.4*S = 0.4 * 18700 trn = P*R/(S - 0.5*P) = 350*2.8805/(18700 - 0.5*350) = 0.0544 in Required Thickness tr from AD-520 tr = 0.5793 in Area Required AD-551 Strength of reinforcement factors Allowable stresses: Sn = 18,700.00 psi, Sv = 18,300.00 psi AD-551 Strength of reinforcement factors fr1 = lesser of 1 or Sn/Sv = 1.0000 fr2 = lesser of 1 or Sn/Sv = 1.0000 Ar = d*tr*F + 2*tn*tr*F*(1-fr1) = 6.625*0.5793*1 + 2*0.432*0.5793*1*(1-1) = 3.8379 in2 Area Available A1 = (2*Limit - d)*(t - F*tr) - 2*tn*(t - F*tr)*(1-fr1) = (2*6.625 - 6.625)*(0.875 - 1*0.5793) - 2*0.432*(0.875 - 1*0.5793)*(1-1) = 1.9589 in2



A2 = 0 per AD-550 A3 = 2*Limit*tn*fr2 A41 = 0 per AD-550 A43 = 0 per AD-550 Aa = A1 + A2 + A3 = 1.9589 + 0 + 0 = 1.9589 in2 As Aa < Ar the reinforcement IS NOT adequate. 2/3 Area Check Area Required Ar = 2/3*(d*tr*F + 2*tn*tr*F*(1-fr1)) = 2/3*(6.625*0.5793*1 + 2*0.432*0.5793*1*(1-1)) = 2.5586 in2 Area Available A1 = (2*Limit - d)*(t - F*tr) - 2*tn*(t - F*tr)*(1-fr1) = (2*5.8928 - 6.625)*(0.875 - 1*0.5793) - 2*0.432*(0.875 - 1*0.5793)*(1-1) = 1.526 in2 A2 = 0 per AD-550 A3 = 0 per AD-550 A41 = 0 per AD-550 A43 = 0 per AD-550 Aa = A1 + A2 + A3 = 1.526 + 0 + 0 = 1.526 in2 As Aa < Ar the reinforcement IS NOT adequate for the 2/3 area check.. Minimum Weld Size Check Required throat weld size of fillet 41 (tc) = 0.25 in Required leg weld size = 0.25/0.7 = 0.3571 in



Required throat weld size of fillet 43 (tc) = 0.175 in Required leg weld size = 0.175/0.7 = 0.25 in AD-602 Nozzle Neck Thickness Check Required thickness (tr1) = 0.0544 in Required thickness per AD-602(a) (tr2) = 0.5793 in Required thickness per AD-602(b) (tr3) = 0.245 in Required thickness equal to larger of (tr1, Smaller of (tr2, tr3))= 0.245 in Available thickness, tn = 0.875*0.432 = 0.378 in The nozzle neck thickness is adequate.

Calculations for MAWP = 264.9429 psi @ 400 °F

AD-550(f) Nozzle Available Area Check ABS(aR - aV)*10-5*DT≤0.0008 ABS(0.919 - 0.674)*10-5*330 = 0.00081≤0.0008 No credit shall be taken for reinforcing potentially available in the nozzle neck or adjoining fillet weld metal Nozzle Required Thickness P = 264.9429 <= 0.4*S = 0.4 * 18700 trn = P*R/(S - 0.5*P) = 264.9429*2.8805/(18700 - 0.5*264.9429) = 0.0411 in Required Thickness tr from AD-520 tr = 0.4375 in Area Required AD-551 Strength of reinforcement factors Allowable stresses: Sn = 18,700.00 psi, Sv = 18,300.00 psi AD-551 Strength of reinforcement factors fr1 = lesser of 1 or Sn/Sv = 1.0000 fr2 = lesser of 1 or Sn/Sv = 1.0000



Ar = d*tr*F + 2*tn*tr*F*(1-fr1) = 6.625*0.4375*1 + 2*0.432*0.4375*1*(1-1) = 2.8984 in2 Area Available A1 = (2*Limit - d)*(t - F*tr) - 2*tn*(t - F*tr)*(1-fr1) = (2*6.625 - 6.625)*(0.875 - 1*0.4375) - 2*0.432*(0.875 - 1*0.4375)*(1-1) = 2.8984 in2 A2 = 0 per AD-550 A3 = 2*Limit*tn*fr2 A41 = 0 per AD-550 A43 = 0 per AD-550 Aa = A1 + A2 + A3 = 2.8984 + 0 + 0 = 2.8984 in2 As Aa >= Ar the reinforcement is adequate.


2/3 Area Check Nozzle Required Thickness P = 285.3653 <= 0.4*S = 0.4 * 18700 trn = P*R/(S - 0.5*P) = 285.3653*2.8805/(18700 - 0.5*285.3653) = 0.0443 in Required Thickness tr from AD-520 tr = 0.4715 in Area Required Ar = 2/3*(d*tr*F + 2*tn*tr*F*(1-fr1)) = 2/3*(6.625*0.4715*1 + 2*0.432*0.4715*1*(1-1)) = 2.0824 in2



Area Available A1 = (2*Limit - d)*(t - F*tr) - 2*tn*(t - F*tr)*(1-fr1) = (2*5.8928 - 6.625)*(0.875 - 1*0.4715) - 2*0.432*(0.875 - 1*0.4715)*(1-1) = 2.0824 in2 A2 = 0 per AD-550 A3 = 0 per AD-550 A41 = 0 per AD-550 A43 = 0 per AD-550 Aa = A1 + A2 + A3 = 2.0824 + 0 + 0 = 2.0824 in2 As Aa >= Ar the reinforcement is adequate for the 2/3 area check..


AD-602 Nozzle Neck Thickness Check Required thickness (tr1) = 0.0822 in Required thickness per AD-602(a) (tr2) = 0.875 in Required thickness per AD-602(b) (tr3) = 0.245 in Required thickness equal to larger of (tr1, Smaller of (tr2, tr3))= 0.245 in Available thickness, tn = 0.875*0.432 = 0.378 in The nozzle neck thickness is adequate.

Calculations for MAP = 354.9683 psi @ 70 °F

AD-540 Limits of Reinforcement Parallel to vessel wall: Larger of d or r + t + tn Larger of 5.761 or 2.8805 + 0.875 + 0.432 = 4.1875 = 6.625 in Parallel to vessel wall (2/3 limit): Larger of r + 0.5*(Rm*t)0.5 or r + t + tn Larger of 2.8805 + 0.5*(30.4375*0.875)0.5 = 5.4608 or 2.8805 + 0.875 + 0.432 =



4.1875 = 5.8928 in Normal to vessel wall: Nozzle conforms to Figure AD-540.1 Sketch (d). Larger of 0.5*(rm*tn)0.5 + te + K or 2.5*tn + te + K but not to exceed 2.5*t Larger of 0.5*(3.0965*0.432)0.5 + 0 + 0 = 0.5783 or 2.5*0.432 + 0 + 0 = 1.08 but not to exceed 2.5*0.875 = 2.1875 = 1.08 in Nozzle Required Thickness P = 354.9683 <= 0.4*S = 0.4 * 18700 trn = P*R/(S - 0.5*P) = 354.9683*2.8805/(18700 - 0.5*354.9683) = 0.0552 in Required Thickness tr from AD-520 tr = 0.5876 in Area Required AD-551 Strength of reinforcement factors Allowable stresses: Sn = 18,700.00 psi, Sv = 18,300.00 psi AD-551 Strength of reinforcement factors fr1 = lesser of 1 or Sn/Sv = 1.0000 fr2 = lesser of 1 or Sn/Sv = 1.0000 Ar = d*tr*F + 2*tn*tr*F*(1-fr1) = 5.761*0.5876*1 + 2*0.432*0.5876*1*(1-1) = 3.3852 in2 Area Available A1 = (2*Limit - d)*(t - F*tr) - 2*tn*(t - F*tr)*(1-fr1) = (2*6.625 - 5.761)*(0.875 - 1*0.5876) - 2*0.432*(0.875 - 1*0.5876)*(1-1) = 2.1522 in2 A2 = 2*Limit*(tn - trn)*fr2 = 2*1.08*(0.432 - 0.0552)*1 = 0.8139 in2 A3 = 2*Limit*tn*fr2



= 2*0.25*0.432*1 = 0.216 in2 A41 = Leg2*fr2 = 0.3752*1 = 0.1406 in2 A43 = Leg2*fr2 = 0.0625 (Reduced area calculated as part of weld is outside of limits) Aa = A1 + A2 + A3 + A41 + A43 = 2.1522 + 0.8139 + 0.216 + 0.1406 + 0.0625 = 3.3852 in2 As Aa >= Ar the reinforcement is adequate.


2/3 Area Check Nozzle Required Thickness P = 396.9620 <= 0.4*S = 0.4 * 18700 trn = P*R/(S - 0.5*P) = 396.962*2.8805/(18700 - 0.5*396.962) = 0.0618 in Required Thickness tr from AD-520 tr = 0.6579 in Area Required Ar = 2/3*(d*tr*F + 2*tn*tr*F*(1-fr1)) = 2/3*(5.761*0.6579*1 + 2*0.432*0.6579*1*(1-1)) = 2.5267 in2 Area Available A1 = (2*Limit - d)*(t - F*tr) - 2*tn*(t - F*tr)*(1-fr1) = (2*5.8928 - 5.761)*(0.875 - 1*0.6579) - 2*0.432*(0.875 - 1*0.6579)*(1-1) = 1.308 in2 A2 = 2*Limit*(tn - trn)*fr2 = 2*1.08*(0.432 - 0.0552)*1 = 0.8139 in2



A3 = 2*Limit*tn*fr2 = 2*0.25*0.432*1 = 0.216 in2 A41 = Leg2*fr2 = 0.3752*1 = 0.1406 in2 A43 = Leg2*fr2 = 0.0625 (Reduced area calculated as part of weld is outside of limits) Aa = A1 + A2 + A3 + A41 + A43 = 1.308 + 0.8139 + 0.216 + 0.1406 + 0.0625 = 2.5268 in2 As Aa >= Ar the reinforcement is adequate for the 2/3 area check.. Minimum Weld Size Check Required throat weld size of fillet 41 (tc) = 0.25 in Required leg weld size = 0.25/0.7 = 0.3571 in Required throat weld size of fillet 43 (tc) = 0.175 in Required leg weld size = 0.175/0.7 = 0.25 in





4.13 ASME Division 2 Appendix G-115 With Local Insert Plate

Nozzle #1 (N1)


tw(lower) = 1.159 in Leg41 = 0.375 in Leg43 = 0.25 in Lpr(inward) = 0.25 in

Nozzle corner radius (r3) must be greater than or equal to the smaller of 0.25 in or tn/2; alternatively, smaller of 0.25 in or tn/4 chamfer at 45 degrees.




Nozzle description: 6" Sch 80 (XS) Nozzle orientation 0° Local vessel thickness: 1.159 in Nozzle center line offset to datum line: 30 in End of nozzle to shell center: 36.875 in Nozzle inside diameter, new: 5.761 in Nozzle nominal wall thickness: 0.432 in Nozzle corrosion allowance: 0 in Projection outside vessel along nozzle OD, Lpr: 6 in



Results Summary Full Area Check The governing condition is Design P. Area required (Ar) = 3.8379 in2 Area available (Aa) = 3.8404 in2

2/3 Area Check The governing condition is Design P. Area required (Ar) = 2.5586 in2 Area available (Aa) = 2.9916 in2

Nozzle Neck Status Required nozzle neck thickness = 0.245 in Minimum nozzle neck thickness = (0.875*0.432) = 0.378 in. Pressure Ratings MAWP = 350.1137 psi MAP = 458.3565 psi PWHT Status

Summary Tables

AD-520 Reinforcement Calculation Summary



Area Required

Ar (in2)


RatioAa / Ar

350.0000 1 3.8379 3.8404 1.0007Design P

350.0000 2/3 2.5586 2.9916 1.1692350.1137 1 3.8392 3.8392 1.0000

MAWP 377.0325 2/3 2.7583 2.7583 1.0000458.3565 1 4.3837 4.3837 1.0000

MAP 509.9014 2/3 3.2558 3.2558 1.0000

Available Areas (in2)

Condition Full or

2/3 Area Check

A1 A2 A3 A41 A43

1 3.8404 0.0000 0.0000 0.0000 0.0000Design P

2/3 2.9916 0.0000 0.0000 0.0000 0.00001 3.8392 0.0000 0.0000 0.0000 0.0000

MAWP 2/3 2.7583 0.0000 0.0000 0.0000 0.00001 2.9811 0.9835 0.2160 0.1406 0.0625

MAP 2/3 1.8754 0.9835 0.2160 0.1406 0.0625



AD-602 Minimum Nozzle

Neck Check

Condition treq (in)

tmin (in) Status


Maximum Pressure Calculations Condition Full Area Check 2/3 Area Check Nozzle Neck CheckMAWP 350.1137 377.0325 693.5913 MAP 458.3565 509.9014 693.5913

Minimum Fillet Weld Sizes Fillet Leg RequiredLeg Size (in) ActualLeg Size (in) Status Leg41 0.3571 0.3750 weld size is adequate Leg43 0.2500 0.2500 weld size is adequate


AD-540 Limits of Reinforcement Parallel to vessel wall: Larger of d or r + t + tn Larger of 6.625 or 3.3125 + 0.875 + 0.432 = 4.6195 = 6.625 in Parallel to vessel wall (2/3 limit): Larger of r + 0.5*(Rm*t)0.5 or r + t + tn Larger of 3.3125 + 0.5*(30.4375*0.875)0.5 = 5.8928 or 3.3125 + 0.875 + 0.432 = 4.6195 = 5.8928 in Normal to vessel wall: Nozzle conforms to Figure AD-540.1 Sketch (d). Larger of 0.5*(rm*tn)0.5 + te + K or 2.5*tn + te + K but not to exceed 2.5*t Larger of 0.5*(3.0965*0.432)0.5 + 0.284 + 0 = 0.8623 or 2.5*0.432 + 0.284 + 0 = 1.364 but not to exceed 2.5*0.875 = 2.1875 = 1.364 in



AD-550(f) Nozzle Available Area Check ABS(aR - aV)*10-5*DT≤0.0008 ABS(0.919 - 0.674)*10-5*330 = 0.00081≤0.0008 No credit shall be taken for reinforcing potentially available in the nozzle neck or adjoining fillet weld metal Nozzle Required Thickness P = 350 <= 0.4*S = 0.4 * 18700 trn = P*R/(S - 0.5*P) = 350*2.8805/(18700 - 0.5*350) = 0.0544 in Required Thickness tr from AD-520 tr = 0.5793 in Area Required AD-551 Strength of reinforcement factors Allowable stresses: Sn = 18,700.00 psi, Sv = 18,300.00 psi AD-551 Strength of reinforcement factors fr1 = lesser of 1 or Sn/Sv = 1.0000 fr2 = lesser of 1 or Sn/Sv = 1.0000 Ar = d*tr*F + 2*tn*tr*F*(1-fr1) = 6.625*0.5793*1 + 2*0.432*0.5793*1*(1-1) = 3.8379 in2 Area Available A1 = (2*Limit - d)*(t - F*tr) - 2*tn*(t - F*tr)*(1-fr1) = (2*6.625 - 6.625)*(1.159 - 1*0.5793) - 2*0.432*(1.159 - 1*0.5793)*(1-1) = 3.8404 in2 A2 = 0 per AD-550 A3 = 2*Limit*tn*fr2 A41 = 0 per AD-550 A43 = 0 per AD-550



Aa = A1 + A2 + A3 = 3.8404 + 0 + 0 = 3.8404 in2 As Aa >= Ar the reinforcement is adequate. 2/3 Area Check Area Required Ar = 2/3*(d*tr*F + 2*tn*tr*F*(1-fr1)) = 2/3*(6.625*0.5793*1 + 2*0.432*0.5793*1*(1-1)) = 2.5586 in2 Area Available A1 = (2*Limit - d)*(t - F*tr) - 2*tn*(t - F*tr)*(1-fr1) = (2*5.8928 - 6.625)*(1.159 - 1*0.5793) - 2*0.432*(1.159 - 1*0.5793)*(1-1) = 2.9916 in2 A2 = 0 per AD-550 A3 = 0 per AD-550 A41 = 0 per AD-550 A43 = 0 per AD-550 Aa = A1 + A2 + A3 = 2.9916 + 0 + 0 = 2.9916 in2 As Aa >= Ar the reinforcement is adequate for the 2/3 area check.. Minimum Weld Size Check Required throat weld size of fillet 41 (tc) = 0.25 in Required leg weld size = 0.25/0.7 = 0.3571 in Required throat weld size of fillet 43 (tc) = 0.175 in Required leg weld size = 0.175/0.7 = 0.25 in AD-602 Nozzle Neck Thickness Check Required thickness (tr1) = 0.0544 in



Required thickness per AD-602(a) (tr2) = 0.5793 in Required thickness per AD-602(b) (tr3) = 0.245 in Required thickness equal to larger of (tr1, Smaller of (tr2, tr3))= 0.245 in Available thickness, tn = 0.875*0.432 = 0.378 in The nozzle neck thickness is adequate.


AD-550(f) Nozzle Available Area Check ABS(aR - aV)*10-5*DT≤0.0008 ABS(0.919 - 0.674)*10-5*330 = 0.00081≤0.0008 No credit shall be taken for reinforcing potentially available in the nozzle neck or adjoining fillet weld metal Nozzle Required Thickness P = 350.1137 <= 0.4*S = 0.4 * 18700 trn = P*R/(S - 0.5*P) = 350.1137*2.8805/(18700 - 0.5*350.1137) = 0.0544 in Required Thickness tr from AD-520 tr = 0.5795 in Area Required AD-551 Strength of reinforcement factors Allowable stresses: Sn = 18,700.00 psi, Sv = 18,300.00 psi AD-551 Strength of reinforcement factors fr1 = lesser of 1 or Sn/Sv = 1.0000 fr2 = lesser of 1 or Sn/Sv = 1.0000 Ar = d*tr*F + 2*tn*tr*F*(1-fr1) = 6.625*0.5795*1 + 2*0.432*0.5795*1*(1-1) = 3.8392 in2



Area Available A1 = (2*Limit - d)*(t - F*tr) - 2*tn*(t - F*tr)*(1-fr1) = (2*6.625 - 6.625)*(1.159 - 1*0.5795) - 2*0.432*(1.159 - 1*0.5795)*(1-1) = 3.8392 in2 A2 = 0 per AD-550 A3 = 2*Limit*tn*fr2 A41 = 0 per AD-550 A43 = 0 per AD-550 Aa = A1 + A2 + A3 = 3.8392 + 0 + 0 = 3.8392 in2 As Aa >= Ar the reinforcement is adequate.


2/3 Area Check Nozzle Required Thickness P = 377.0325 <= 0.4*S = 0.4 * 18700 trn = P*R/(S - 0.5*P) = 377.0325*2.8805/(18700 - 0.5*377.0325) = 0.0587 in Required Thickness tr from AD-520 tr = 0.6245 in Area Required Ar = 2/3*(d*tr*F + 2*tn*tr*F*(1-fr1)) = 2/3*(6.625*0.6245*1 + 2*0.432*0.6245*1*(1-1)) = 2.7583 in2 Area Available A1 = (2*Limit - d)*(t - F*tr) - 2*tn*(t - F*tr)*(1-fr1) = (2*5.8928 - 6.625)*(1.159 - 1*0.6245) - 2*0.432*(1.159 - 1*0.6245)*(1-1) = 2.7583 in2



A2 = 0 per AD-550 A3 = 0 per AD-550 A41 = 0 per AD-550 A43 = 0 per AD-550 Aa = A1 + A2 + A3 = 2.7583 + 0 + 0 = 2.7583 in2 As Aa >= Ar the reinforcement is adequate for the 2/3 area check..




AD-540 Limits of Reinforcement Parallel to vessel wall: Larger of d or r + t + tn Larger of 5.761 or 2.8805 + 0.875 + 0.432 = 4.1875 = 6.625 in Parallel to vessel wall (2/3 limit): Larger of r + 0.5*(Rm*t)0.5 or r + t + tn Larger of 2.8805 + 0.5*(30.4375*0.875)0.5 = 5.4608 or 2.8805 + 0.875 + 0.432 = 4.1875 = 5.8928 in Normal to vessel wall: Nozzle conforms to Figure AD-540.1 Sketch (d). Larger of 0.5*(rm*tn)0.5 + te + K or 2.5*tn + te + K but not to exceed 2.5*t Larger of 0.5*(3.0965*0.432)0.5 + 0.284 + 0 = 0.8623 or 2.5*0.432 + 0.284 + 0 = 1.364



but not to exceed 2.5*0.875 = 2.1875 = 1.364 in Nozzle Required Thickness P = 458.3565 <= 0.4*S = 0.4 * 18700 trn = P*R/(S - 0.5*P) = 458.3565*2.8805/(18700 - 0.5*458.3565) = 0.0715 in Required Thickness tr from AD-520 tr = 0.7609 in Area Required AD-551 Strength of reinforcement factors Allowable stresses: Sn = 18,700.00 psi, Sv = 18,300.00 psi AD-551 Strength of reinforcement factors fr1 = lesser of 1 or Sn/Sv = 1.0000 fr2 = lesser of 1 or Sn/Sv = 1.0000 Ar = d*tr*F + 2*tn*tr*F*(1-fr1) = 5.761*0.7609*1 + 2*0.432*0.7609*1*(1-1) = 4.3837 in2 Area Available A1 = (2*Limit - d)*(t - F*tr) - 2*tn*(t - F*tr)*(1-fr1) = (2*6.625 - 5.761)*(1.159 - 1*0.7609) - 2*0.432*(1.159 - 1*0.7609)*(1-1) = 2.9811 in2 A2 = 2*Limit*(tn - trn)*fr2 = 2*1.364*(0.432 - 0.0715)*1 = 0.9835 in2 A3 = 2*Limit*tn*fr2 = 2*0.25*0.432*1 = 0.216 in2 A41 = Leg2*fr2 = 0.3752*1 = 0.1406 in2



A43 = Leg2*fr2 = 0.0625 (Reduced area calculated as part of weld is outside of limits) Aa = A1 + A2 + A3 + A41 + A43 = 2.9811 + 0.9835 + 0.216 + 0.1406 + 0.0625 = 4.3837 in2 As Aa >= Ar the reinforcement is adequate.


2/3 Area Check Nozzle Required Thickness P = 509.9014 <= 0.4*S = 0.4 * 18700 trn = P*R/(S - 0.5*P) = 509.9014*2.8805/(18700 - 0.5*509.9014) = 0.0796 in Required Thickness tr from AD-520 tr = 0.8477 in Area Required Ar = 2/3*(d*tr*F + 2*tn*tr*F*(1-fr1)) = 2/3*(5.761*0.8477*1 + 2*0.432*0.8477*1*(1-1)) = 3.2558 in2 Area Available A1 = (2*Limit - d)*(t - F*tr) - 2*tn*(t - F*tr)*(1-fr1) = (2*5.8928 - 5.761)*(1.159 - 1*0.8477) - 2*0.432*(1.159 - 1*0.8477)*(1-1) = 1.8754 in2 A2 = 2*Limit*(tn - trn)*fr2 = 2*1.364*(0.432 - 0.0715)*1 = 0.9835 in2 A3 = 2*Limit*tn*fr2 = 2*0.25*0.432*1 = 0.216 in2 A41 = Leg2*fr2



= 0.3752*1 = 0.1406 in2 A43 = Leg2*fr2 = 0.0625 (Reduced area calculated as part of weld is outside of limits) Aa = A1 + A2 + A3 + A41 + A43 = 1.8754 + 0.9835 + 0.216 + 0.1406 + 0.0625 = 3.2558 in2 As Aa >= Ar the reinforcement is adequate for the 2/3 area check.. Minimum Weld Size Check Required throat weld size of fillet 41 (tc) = 0.25 in Required leg weld size = 0.25/0.7 = 0.3571 in Required throat weld size of fillet 43 (tc) = 0.175 in Required leg weld size = 0.175/0.7 = 0.25 in





4.14 ASME Division 2 Appendix G-115 With Reinforcing Pad

Nozzle #1 (N1)



Leg41 = 0.3571 in tw(upper) = 0.296 in

Leg42 = 0.296 in Wp = 3.017 in te = 0.296 in

Nozzle inside corner radius (r1) must be greater than or equal to 0.125*0.875 = 0.1094 in. Nozzle inside corner radius (r1) must be less than or equal to 0.5*0.875 = 0.4375 in.




Nozzle description: 6" Sch 80 (XS)

Pad material specification: SA-515 60 Appendix G-115 Example (user defined)

Pad width: 3.017 in Nozzle orientation 0° Local vessel thickness: 0.875 in Nozzle center line offset to datum line: 30 in End of nozzle to shell center: 36.875 in



Nozzle inside diameter, new: 5.761 in Nozzle nominal wall thickness: 0.432 in Nozzle corrosion allowance: 0 in Projection outside vessel along nozzle OD, Lpr: 6 in Results Summary Full Area Check The governing condition is Design P. Area required (Ar) = 3.8379 in2 Area available (Aa) = 3.8288 in2 *** Warning: Ar = 3.8379 in^2 > Aa = 3.8288 in^2 : Design P Condition *** 2/3 Area Check The governing condition is Design P. Area required (Ar) = 2.5586 in2 Area available (Aa) = 3.0535 in2 Nozzle Neck Status Required nozzle neck thickness = 0.245 in Minimum nozzle neck thickness = (0.875*0.432) = 0.378 in. Pressure Ratings MAWP = 349.5888 psi MAP = 434.5673 psi PWHT Status Nozzle Advisory Per AD-570(a), Nozzle material shall conform to Section IX, QW-422. Per AD-570(c), minimum elongation is 12 percent in 2 inches. Per AD-570(e), requirements of AD-160 for pads in cylic service must be met. Per AD-570(a), Pad material shall conform to Section IX, QW-422. Minimum Design Metal Temperature Vessel coincident ratio used per ASME Interpretation VIII-1-01-37. Pad: Material impact test exemption temperature from Fig AM-218.1 Curve B = -20°F Fig AM-218.3 MDMT reduction = 33.9°F, (coincident ratio = 0.66128) AM-218 governing thickness = 0.296". Nozzle assembly MDMT = Larger(MDMT of nozzle, MDMT of pad) = Larger(0 °F, -53.9 °F) = -53.9 °F



Summary Tables AD-520 Reinforcement Calculation Summary



Area RequiredAr (in2)


RatioAa / Ar

350.0000 1 3.8379 3.8288 0.9976Design P

350.0000 2/3 2.5586 3.0535 1.1934349.5888 1 3.8334 3.8334 1.0000

MAWP 380.8960 2/3 2.7869 2.7868 1.0000434.5673 1 4.1535 4.1535 1.0000

MAP 482.5470 2/3 3.0788 3.0788 1.0000

Available Areas (in2)

Condition Full or 2/3 Area Check

A1 A2 A41 A42 A5

1 1.9589 0.0000 0.0000 0.0838 1.7861Design P

2/3 1.5260 0.0000 0.0000 0.0000 1.52761 1.9635 0.0000 0.0000 0.0838 1.7861

MAWP 2/3 1.2593 0.0000 0.0000 0.0000 1.52761 1.1536 1.0025 0.1276 0.0838 1.7861

MAP 2/3 0.4420 1.0025 0.1276 0.0000 1.5276

AD-602 Minimum Nozzle Neck Check

Condition treq (in)

tmin (in) Status


Maximum Pressure Calculations Condition Full Area Check 2/3 Area Check Nozzle Neck CheckMAWP 349.5888 380.8960 526.0742 MAP 434.5673 482.5470 526.0742 Minimum Fillet Weld Sizes Fillet Leg RequiredLeg Size (in) ActualLeg Size (in) Status Leg41 0.3571 0.3571 weld size is adequate Leg42 0.2537 0.2960 weld size is adequate




AD-540 Limits of Reinforcement Parallel to vessel wall: Larger of d or r + t + tn Larger of 6.625 or 3.3125 + 0.875 + 0.432 = 4.6195 = 6.625 in Parallel to vessel wall (2/3 limit): Larger of r + 0.5*(Rm*t)0.5 or r + t + tn Larger of 3.3125 + 0.5*(30.4375*0.875)0.5 = 5.8928 or 3.3125 + 0.875 + 0.432 = 4.6195 = 5.8928 in Normal to vessel wall: Nozzle conforms to Figure AD-540.1 Sketch (d). Larger of 0.5*(rm*tn)0.5 + te + K or 2.5*tn + te + K but not to exceed 2.5*t Larger of 0.5*(3.0965*0.432)0.5 + 0.296 + 0 = 0.8743 or 2.5*0.432 + 0.296 + 0 = 1.376 but not to exceed 2.5*0.875 = 2.1875 = 1.376 in AD-550(f) Nozzle Available Area Check ABS(aR - aV)*10-5*DT≤0.0008 ABS(0.919 - 0.674)*10-5*330 = 0.00081≤0.0008 No credit shall be taken for reinforcing potentially available in the nozzle neck or adjoining fillet weld metal AD-550(f) Pad Available Area Check ABS(aR - aV)*10-5*DT≤0.0008 ABS(0.674 - 0.674)*10-5*330 = 0≤0.0008 Credit will be taken for reinforcing potentially available in the pad and adjoining fillet weld metal Nozzle Required Thickness P = 350 <= 0.4*S = 0.4 * 18700 trn = P*R/(S - 0.5*P) = 350*2.8805/(18700 - 0.5*350) = 0.0544 in



Required Thickness tr from AD-520 tr = 0.5793 in Area Required AD-551 Strength of reinforcement factors Allowable stresses: Sn = 18,700.00 psi, Sv = 18,300.00 psi, Sp = 18,300.00 psi AD-551 Strength of reinforcement factors fr1 = lesser of 1 or Sn/Sv = 1.0000 fr2 = lesser of 1 or Sn/Sv = 1.0000 fr3 = lesser of fr2 or Sp/Sv = 1.0000 fr4 = lesser of 1 or Sp/Sv = 1.0000 Ar = d*tr*F + 2*tn*tr*F*(1-fr1) = 6.625*0.5793*1 + 2*0.432*0.5793*1*(1-1) = 3.8379 in2 Area Available A1 = (2*Limit - d)*(t - F*tr) - 2*tn*(t - F*tr)*(1-fr1) = (2*6.625 - 6.625)*(0.875 - 1*0.5793) - 2*0.432*(0.875 - 1*0.5793)*(1-1) = 1.9589 in2 A2 = 0 per AD-550 A41 = 0 per AD-550 A42 = Leg2*fr2 = 0.0838 (Reduced area calculated as part of weld is outside of limits) A5 = 2*W*te*fr4 = 2*3.017*0.296*1 = 1.7861 in2 Aa = A1 + A2 + A3 + A42 + A5 = 1.9589 + 0 + 0 + 0.0838 + 1.7861 = 3.8288 in2 As Aa < Ar the reinforcement IS NOT adequate.



2/3 Area Check Area Required Ar = 2/3*(d*tr*F + 2*tn*tr*F*(1-fr1)) = 2/3*(6.625*0.5793*1 + 2*0.432*0.5793*1*(1-1)) = 2.5586 in2 Area Available A1 = (2*Limit - d)*(t - F*tr) - 2*tn*(t - F*tr)*(1-fr1) = (2*5.8928 - 6.625)*(0.875 - 1*0.5793) - 2*0.432*(0.875 - 1*0.5793)*(1-1) = 1.526 in2 A2 = 0 per AD-550 A41 = 0 per AD-550 A42 = Leg2*fr2 = 0 (Reduced area calculated as part of weld is outside of limits) A5 = 2*(Limit - r - tn)*te*fr4 = 2*(5.8928 - 2.8805 - 0.432)*0.296*1 = 1.5276 in2 Aa = A1 + A2 + A3 + A42 + A5 = 1.526 + 0 + 0 + 0 + 1.5276 = 3.0535 in2 As Aa >= Ar the reinforcement is adequate for the 2/3 area check.. Minimum Weld Size Check Required throat weld size of fillet 41 (tc) = 0.25 in Required leg weld size = 0.25/0.7 = 0.3571 in Required throat weld size of fillet 42 (tc) = 0.1776 in Required leg weld size = 0.1776/0.7 = 0.2537 in AD-602 Nozzle Neck Thickness Check Required thickness (tr1) = 0.0544 in Required thickness per AD-602(a) (tr2) = 0.5793 in Required thickness per AD-602(b) (tr3) = 0.245 in Required thickness equal to larger of (tr1, Smaller of (tr2, tr3))= 0.245 in



Available thickness, tn = 0.875*0.432 = 0.378 in The nozzle neck thickness is adequate.


AD-550(f) Nozzle Available Area Check ABS(aR - aV)*10-5*DT≤0.0008 ABS(0.919 - 0.674)*10-5*330 = 0.00081≤0.0008 No credit shall be taken for reinforcing potentially available in the nozzle neck or adjoining fillet weld metal AD-550(f) Pad Available Area Check ABS(aR - aV)*10-5*DT≤0.0008 ABS(0.674 - 0.674)*10-5*330 = 0≤0.0008 Credit will be taken for reinforcing potentially available in the pad and adjoining fillet weld metal Nozzle Required Thickness P = 349.5888 <= 0.4*S = 0.4 * 18700 trn = P*R/(S - 0.5*P) = 349.5888*2.8805/(18700 - 0.5*349.5888) = 0.0544 in Required Thickness tr from AD-520 tr = 0.5786 in Area Required AD-551 Strength of reinforcement factors Allowable stresses: Sn = 18,700.00 psi, Sv = 18,300.00 psi, Sp = 18,300.00 psi AD-551 Strength of reinforcement factors fr1 = lesser of 1 or Sn/Sv = 1.0000 fr2 = lesser of 1 or Sn/Sv = 1.0000 fr3 = lesser of fr2 or Sp/Sv = 1.0000 fr4 = lesser of 1 or Sp/Sv = 1.0000



Ar = d*tr*F + 2*tn*tr*F*(1-fr1) = 6.625*0.5786*1 + 2*0.432*0.5786*1*(1-1) = 3.8334 in2 Area Available A1 = (2*Limit - d)*(t - F*tr) - 2*tn*(t - F*tr)*(1-fr1) = (2*6.625 - 6.625)*(0.875 - 1*0.5786) - 2*0.432*(0.875 - 1*0.5786)*(1-1) = 1.9635 in2 A2 = 0 per AD-550 A41 = 0 per AD-550 A42 = Leg2*fr2 = 0.0838 (Reduced area calculated as part of weld is outside of limits) A5 = 2*W*te*fr4 = 2*3.017*0.296*1 = 1.7861 in2 Aa = A1 + A2 + A3 + A42 + A5 = 1.9635 + 0 + 0 + 0.0838 + 1.7861 = 3.8334 in2 As Aa >= Ar the reinforcement is adequate.


2/3 Area Check Nozzle Required Thickness P = 380.8960 <= 0.4*S = 0.4 * 18700 trn = P*R/(S - 0.5*P) = 380.896*2.8805/(18700 - 0.5*380.896) = 0.0593 in Required Thickness tr from AD-520 tr = 0.631 in



Area Required Ar = 2/3*(d*tr*F + 2*tn*tr*F*(1-fr1)) = 2/3*(6.625*0.631*1 + 2*0.432*0.631*1*(1-1)) = 2.7869 in2 Area Available A1 = (2*Limit - d)*(t - F*tr) - 2*tn*(t - F*tr)*(1-fr1) = (2*5.8928 - 6.625)*(0.875 - 1*0.631) - 2*0.432*(0.875 - 1*0.631)*(1-1) = 1.2593 in2 A2 = 0 per AD-550 A41 = 0 per AD-550 A42 = Leg2*fr2 = 0 (Reduced area calculated as part of weld is outside of limits) A5 = 2*(Limit - r - tn)*te*fr4 = 2*(5.8928 - 2.8805 - 0.432)*0.296*1 = 1.5276 in2 Aa = A1 + A2 + A3 + A42 + A5 = 1.2593 + 0 + 0 + 0 + 1.5276 = 2.7868 in2 As Aa >= Ar the reinforcement is adequate for the 2/3 area check..




AD-540 Limits of Reinforcement



Parallel to vessel wall: Larger of d or r + t + tn Larger of 5.761 or 2.8805 + 0.875 + 0.432 = 4.1875 = 6.625 in Parallel to vessel wall (2/3 limit): Larger of r + 0.5*(Rm*t)0.5 or r + t + tn Larger of 2.8805 + 0.5*(30.4375*0.875)0.5 = 5.4608 or 2.8805 + 0.875 + 0.432 = 4.1875 = 5.8928 in Normal to vessel wall: Nozzle conforms to Figure AD-540.1 Sketch (d). Larger of 0.5*(rm*tn)0.5 + te + K or 2.5*tn + te + K but not to exceed 2.5*t Larger of 0.5*(3.0965*0.432)0.5 + 0.296 + 0 = 0.8743 or 2.5*0.432 + 0.296 + 0 = 1.376 but not to exceed 2.5*0.875 = 2.1875 = 1.376 in AD-550(f) Pad Available Area Check ABS(aR - aV)*10-5*DT≤0.0008 ABS(0.674 - 0.674)*10-5*330 = 0≤0.0008 Credit will be taken for reinforcing potentially available in the pad and adjoining fillet weld metal Nozzle Required Thickness P = 434.5673 <= 0.4*S = 0.4 * 18700 trn = P*R/(S - 0.5*P) = 434.5673*2.8805/(18700 - 0.5*434.5673) = 0.0677 in Required Thickness tr from AD-520 tr = 0.721 in Area Required AD-551 Strength of reinforcement factors Allowable stresses: Sn = 18,700.00 psi, Sv = 18,300.00 psi, Sp = 18,300.00 psi AD-551 Strength of reinforcement factors fr1 = lesser of 1 or Sn/Sv = 1.0000 fr2 = lesser of 1 or Sn/Sv = 1.0000 fr3 = lesser of fr2 or Sp/Sv = 1.0000



fr4 = lesser of 1 or Sp/Sv = 1.0000 Ar = d*tr*F + 2*tn*tr*F*(1-fr1) = 5.761*0.721*1 + 2*0.432*0.721*1*(1-1) = 4.1535 in2 Area Available A1 = (2*Limit - d)*(t - F*tr) - 2*tn*(t - F*tr)*(1-fr1) = (2*6.625 - 5.761)*(0.875 - 1*0.721) - 2*0.432*(0.875 - 1*0.721)*(1-1) = 1.1536 in2 A2 = 2*Limit*(tn - trn)*fr2 = 2*1.376*(0.432 - 0.0677)*1 = 1.0025 in2 A41 = Leg2*fr3 = 0.35712*1 = 0.1276 in2 A42 = Leg2*fr2 = 0.0838 (Reduced area calculated as part of weld is outside of limits) A5 = 2*W*te*fr4 = 2*3.017*0.296*1 = 1.7861 in2 Aa = A1 + A2 + A3 + A41 + A42 + A5 = 1.1536 + 1.0025 + 0 + 0.1276 + 0.0838 + 1.7861 = 4.1535 in2 As Aa >= Ar the reinforcement is adequate.




2/3 Area Check Nozzle Required Thickness P = 482.5470 <= 0.4*S = 0.4 * 18700 trn = P*R/(S - 0.5*P) = 482.547*2.8805/(18700 - 0.5*482.547) = 0.0753 in Required Thickness tr from AD-520 tr = 0.8016 in Area Required Ar = 2/3*(d*tr*F + 2*tn*tr*F*(1-fr1)) = 2/3*(5.761*0.8016*1 + 2*0.432*0.8016*1*(1-1)) = 3.0788 in2 Area Available A1 = (2*Limit - d)*(t - F*tr) - 2*tn*(t - F*tr)*(1-fr1) = (2*5.8928 - 5.761)*(0.875 - 1*0.8016) - 2*0.432*(0.875 - 1*0.8016)*(1-1) = 0.442 in2 A2 = 2*Limit*(tn - trn)*fr2 = 2*1.376*(0.432 - 0.0677)*1 = 1.0025 in2 A41 = Leg2*fr3 = 0.35712*1 = 0.1276 in2 A42 = Leg2*fr2 = 0 (Reduced area calculated as part of weld is outside of limits) A5 = 2*(Limit - r - tn)*te*fr4 = 2*(5.8928 - 2.8805 - 0.432)*0.296*1 = 1.5276 in2 Aa = A1 + A2 + A3 + A41 + A42 + A5 = 0.442 + 1.0025 + 0 + 0.1276 + 0 + 1.5276 = 3.0788 in2



As Aa >= Ar the reinforcement is adequate for the 2/3 area check.. Minimum Weld Size Check Required throat weld size of fillet 41 (tc) = 0.25 in Required leg weld size = 0.25/0.7 = 0.3571 in Required throat weld size of fillet 42 (tc) = 0.1776 in Required leg weld size = 0.1776/0.7 = 0.2537 in





4.15 ASME Self Study CD Example 4-4

Cylinder #1


Component: Cylinder Material specification: User Defined (user defined)

Material is impact tested per UG-84 to -50 °F UCS-66(i) reduction of 140 °F applied (ratio = 6.082239E-02). Internal design pressure: P = 9500 psi @ 650°F External design pressure: Pe = 15 psi @ 650°F

Static liquid head:

Pt

h =1.2995 psi (SG=1.0000, Hs=36.0000", Horizontal test head)

Corrosion allowance: Inner C = 0.3000" Outer C = 0.0000" Design MDMT = -20.00°F Impact test performed



PWHT is performed Radiography: Longitudinal joint - Full UW-11(a) Type 1 Top circumferential joint - Full UW-11(a) Type 1 Bottom circumferential joint - Full UW-11(a) Type 1 Estimated weight: New = 65293.3555 lb corr = 64363.8867 lb

Capacity: New = 423.0134 gal corr = 437.2313 gal

ID = 36.0000" Length Lc = 96.0000" t = 15.0000"

Design thickness, (at 650.00°F) Appendix 1-2

Z = (S*E + P) / (S*E - P) = (18000*1.00 + 9500.00) / (18000*1.00 - 9500.00) = 3.2353 t = R * (Z1/2 - 1) + Corrosion



= 18.3000 * (3.23531/2 - 1) + 0.3000 = 14.9161"

Maximum allowable working pressure, (at 650.00°F) Appendix 1-2

Z = ((R + t) / R)2 = ((18.3000 + 14.7000) / 18.3000)2 = 3.2518

P=S * E * (Z-1) / (Z+1) - Ps=18000 * 1.00 * (3.2518-1) / (3.2518+1) - 0.0000=9533.0264 psi

Maximum allowable pressure, (at 70.00°F) Appendix 1-3

Z = ((R + t) / R)2 = ((18.0000 + 15.0000) / 18.0000)2 = 3.3611 P = S*E*(Z-1)/(Z+1) = 200000*1.00*(3.3611-1)/(3.3611+1) = 108280.2578 psi

External Pressure, (Corroded & at 650.00°F) UG-28(c)

L/Do = 96.0000/66.0000 = 1.4545 Do/t = 66.0000/0.274642 = 240.3130 From table G: A = 0.000244 From table CD-1: B = 2703.5193 psi

Pa

= 4*B/(3*(Do/t))

= 4*2703.5193/(3*(66.0000/0.274642)) = 15.0000 psi


= t + Corrosion = 0.274642 + 0.3000 = 0.5746"

Maximum Allowable External Pressure, (Corroded & at 650.00°F) UG-28(c)

L/Do = 96.0000/66.0000 = 1.4545 Do/t = 66.0000/14.7000 = 4.4898 From table G: A = 0.094648



From table CD-1: B = 16900.0000 psi

S1 = 2*Se = 2*18000.0000 = 36000.0000 psi S2 = 0.90*Sy = 0.90*33800.0000 = 30420.0000 psi S = lesser of S1 or S2 = 30420.0000 psi

Pa

1 = [2.167/(Do/t)-0.08333]*B

= [2.167/4.4898-0.08333]*16900.0000 = 6749.0146 psi Pa

2 = (2*S/(Do/t))*[1-1/(Do/t)]

= (2*30420.0000/4.4898)*[1-1/4.4898] = 10532.6104 psi

Allowable external pressure = lesser of Pa1 or Pa2 = 6749.0146 psi


= (50 * t / Rf) * (1 - Rf / Ro) = (50 * 15.0000 / 25.5000) * (1 - 25.5000 / ∞) = 29.4118 %



4.16 ASME Self Study CD Example 4-5

Hemi Head #2


Component: Hemi Head Material specification: SA-516 70 (II-D p. 14, ln. 20)

Material impact test exemption temperature from Fig UCS-66 Curve B = -7 °F Fig UCS-66.1 MDMT reduction = 26.1 °F, (coincident ratio = 0.7389164) UCS-66 governing thickness = 0.5 in Internal design pressure: P = 230.0000 psi @ 400.00°F External design pressure: Pe = 15.0000 psi @ 400.00°F

Static liquid head:

Pt

h =3.4653 psi (SG=1.0000, Hs=96.0000", Horizontal test head)

Corrosion allowance: Inner C = 0.1250" Outer C = 0.0000" Design MDMT = -20.00°F No impact test performed



PWHT is not performed Radiography: RT on Category A Joints - Long. Seam - Spot UW-11(b) Type 1 RT on Category A Joints - Circ. Seam - Full UW-11(a) Type 1 Estimated weight: New = 2069.8 lb corr = 1556.4 lb Capacity: New = 1002.7 US gal corr = 1010.6 US gal

Inner diameter = 96.0000" Minimum head thickness = 0.5000"

Design thickness, (at 400.00°F) UG-32(f)

t = P*R/(2*S*E - 0.20*P) + Corrosion = 230.0000*48.1250/(2*20000.0000*0.85 - 0.20*230.0000) + 0.1250 = 0.4510"

Maximum allowable working pressure, (at 400.00°F) UG-32(f)

P = 2*S*E*t/(R + 0.20*t) - Ps



= 2*20000.0000*0.85*0.3750 / (48.1250 + 0.20*0.3750) - 0.0000 = 264.5228 psi

Maximum allowable pressure, (at 70.00°F) UG-32(f)

P = 2*S*E*t/(R + 0.20*t) = 2*20000.0000*0.85*0.5000 / (48.0000 + 0.20*0.5000) = 353.4304 psi

External Pressure, (Corroded & at 400.00°F) UG-28(d)

A = 0.125 / (Ro / t) = 0.125 / (48.5000 / 0.1430) = 0.000368

From table CS-2: B = 5088.5718 psi

Pa = B / (Ro / t) = 5088.5718/(48.5000/0.1430)


= t + Corrosion = 0.1430 + 0.1250 = 0.2680"

Maximum Allowable External Pressure, (Corroded @ 400.00°F)

A = 0.125 / (Ro / t) = 0.125 / (48.5000 / 0.3750) = 0.000966

From table CS-2: B = 10953.0615 psi

Pa = B/(Ro/t) = 10953.0615 / (48.5000 / 0.3750) = 84.6886 psi

The maximum allowable external pressure is 84.6886 psi


= (75 * t / Rf) * (1 - Rf / Ro) = (75 * 0.5000 / 48.2500) * (1 - 48.2500 / ∞) = 0.7772 %



Required thickness, largest of the following + corrosion = 0.4513"

The governing condition is due to weight at the top seam in condition Operating, Hot & Corroded

The head thickness of 0.5000" is adequate.

Thickness Required Due to Pressure + External Loads

Allowable Stress Before UG-23

Stress Increase ( psi)

Condition Pressure P ( psi)

St Sc

Temperature (°F)

Corrosion C (in) Load

Req'd Thk

Due to Tension

(in)

Req'd Thk Due to

Compression (in)


230.00 20000.00 10953.06 400.00 0.1250 Weight 0.3263 0.3263

Operating, Hot & New

230.00 20000.00 11794.41 400.00 0.0000 Weight 0.3255 0.3255

Hot Shut Down, Corroded

0.00 20000.00 10953.06 400.00 0.1250 Weight 0.0003 0.0003

Hot Shut Down, New

0.00 20000.00 11794.41 400.00 0.0000 Weight 0.0004 0.0004

Empty, Corroded 0.00 20000.00 12136.00 0.00 0.1250 Weight 0.0003 0.0003

Empty, New 0.00 20000.00 13226.29 0.00 0.0000 Weight 0.0004 0.0004

Vacuum -15.00 20000.00 10953.06 400.00 0.1250 Weight 0.0325 0.0325 Hot Shut Down, Corroded, Weight & Eccentric Moments Only

0.00 20000.00 10953.06 400.00 0.1250 Weight 0.0003 0.0003

Allowable Compressive Stress, Hot and Corroded- ScHC, (table CS-2) A = 0.125 / (Ro / t) = 0.125 / (48.5000 / 0.3750) = 0.000966 B = 10953.0615 psi



S = 20000.0000 / 1.0000 = 20000.0000 psi

ScHC = 10953.0615 psi Allowable Compressive Stress, Hot and New- ScHN, (table CS-2) A = 0.125 / (Ro / t) = 0.125 / (48.5000 / 0.5000) = 0.001289 B = 11794.4111 psi

S = 20000.0000 / 1.0000 = 20000.0000 psi

ScHN = 11794.4111 psi Allowable Compressive Stress, Cold and New- ScCN, (table CS-2) A = 0.125 / (Ro / t) = 0.125 / (48.5000 / 0.5000) = 0.001289 B = 13226.2939 psi

S = 20000.0000 / 1.0000 = 20000.0000 psi

ScCN = 13226.2939 psi Allowable Compressive Stress, Cold and Corroded- ScCC, (table CS-2) A = 0.125 / (Ro / t) = 0.125 / (48.5000 / 0.3750) = 0.000966 B = 12135.9971 psi

S = 20000.0000 / 1.0000



= 20000.0000 psi

ScCC = 12135.9971 psi Allowable Compressive Stress, Vacuum and Corroded- ScVC, (table CS-2) A = 0.125 / (Ro / t) = 0.125 / (48.5000 / 0.3750) = 0.000966 B = 10953.0615 psi

S = 20000.0000 / 1.0000 = 20000.0000 psi

ScVC = 10953.0615 psi

Operating, Hot & Corroded, Top Seam

tp = P*R/(2*St*Ks*Ec - 0.20*|P|) (Pressure)

= 230.00*48.1250/(2*20000*1.0000*0.85 - 0.20*|230.0000|)

= 0.3260"

tm = M/(p*Rm2*St*Ks*Ec) (bending)

= 0/(p*48.31252*20000*1.0000*0.85) = 0.0000"

tw = W/(2*p*Rm*St*Ks*Ec) (Weight) = -1556/(2*p*48.3125*20000*1.0000*0.85) = -0.0003"

tt = tp + tm - tw (total required, tensile)

= 0.325993 + 0.000000 - (-0.000302) = 0.3263"



tc = |tmc + twc - tpc| (total, net tensile) = |0.000000 + (-0.000302) - (0.325993)| = 0.3263"

Maximum allowable working pressure, Longitudinal Stress

P = 2*St*Ks*Ec*(t-tm+tw) / (R + 0.20*(t-tm+tw))

= 2*20000*1.0000*0.85*(0.3750-0.000000+(-0.000302)) / (48.1250 + 0.20*(0.3750-0.000000+(-0.000302)))

= 264.31 psi

Operating, Hot & New, Top Seam

tp = P*R/(2*St*Ks*Ec - 0.20*|P|) (Pressure)

= 230.00*48.0000/(2*20000*1.0000*0.85 - 0.20*|230.0000|)

= 0.3251"

tm = M/(p*Rm2*St*Ks*Ec) (bending)

= 0/(p*48.25002*20000*1.0000*0.85) = 0.0000"


tt = tp + tm - tw (total required, tensile)

= 0.325146 + 0.000000 - (-0.000402) = 0.3255"


Maximum allowable working pressure, Longitudinal Stress

P = 2*St*Ks*Ec*(t-tm+tw) / (R + 0.20*(t-tm+tw))



= 2*20000*1.0000*0.85*(0.5000-0.000000+(-0.000402)) / (48.0000 + 0.20*(0.5000-0.000000+(-0.000402)))

= 353.15 psi

Hot Shut Down, Corroded, Top Seam

tp = 0.0000" (Pressure) tm = M/(p*Rm

2*St*Ks*Ec) (bending) = 0/(p*48.31252*20000*1.0000*0.85) = 0.0000"


tt = tp + tm - tw (total required, tensile) = 0.000000 + 0.000000 - (-0.000302) = 0.0003"


Hot Shut Down, New, Top Seam


2*St*Ks*Ec) (bending) = 0/(p*48.25002*20000*1.0000*0.85) = 0.0000"


tt = tp + tm - tw (total required, tensile) = 0.000000 + 0.000000 - (-0.000402)



= 0.0004"


Empty, Corroded, Top Seam


2*St*Ks*Ec) (bending) = 0/(p*48.31252*20000*1.0000*0.85) = 0.0000"




Empty, New, Top Seam


2*St*Ks*Ec) (bending) = 0/(p*48.25002*20000*1.0000*0.85) = 0.0000"






Vacuum, Top Seam

tp = P*R/(2*Sc*Ks - 0.20*|P|) (Pressure)

= -15.00*48.1250/(2*10953*1.0000 - 0.20*|15.0000|)

= -0.0330"

tm = M/(p*Rm2*Sc*Ks) (bending)

= 0/(p*48.31252*10953*1.0000) = 0.0000"

tw = W/(2*p*Rm*Sc*Ks) (Weight) = -1556/(2*p*48.3125*10953*1.0000) = -0.0005"

tt = |tp + tm - tw| (total, net compressive) = |-0.032958 + 0.000000 - (-0.000468)| = 0.0325"

tc = tmc + twc - tpc (total required, compressive)

= 0.000000 + (-0.000468) - (-0.032958) = 0.0325"



Hot Shut Down, Corroded, Weight & Eccentric Moments Only, Top Seam


2*St*Ks*Ec) (bending) = 0/(p*48.31252*20000*1.0000*0.85) = 0.0000"






4.17 ASME Self Study CD Course Example 4-8

Ellipsoidal Head #1


Component: Ellipsoidal Head Material Specification: SA-516 70 (II-D p.14, ln. 20) Straight Flange governs MDMT Internal design pressure: P = 430 psi @ 200 °F External design pressure: Pe = 15 psi @ 200 °F

Static liquid head:

Ps= 0 psi (SG=1, Hs=0" Operating head) Pth= 1.9763 psi (SG=1, Hs=54.75" Horizontal test head) Corrosion allowance: Inner C = 0.1" Outer C = 0" Design MDMT = -20°F No impact test performed Rated MDMT = -20°F Material is not normalized Material is not produced to fine grain practice PWHT is not performed Do not Optimize MDMT / Find MAWP Radiography: Category A joints - Seamless No RT Head to shell seam - Full UW-11(a) Type 1 Estimated weight*: new = 532.1 lb corr = 448.1 lb

Capacity*: new = 78.3 US gal corr = 79.5 US gal

* includes straight flange

Inner diameter = 48" Minimum head thickness = 0.6165" Head ratio D/2h = 2 (new)

Head ratio D/2h = 1.9917 (corroded)

Straight flange length Lsf = 2" Nominal straight flange thickness tsf

= 0.625"



Insulation thk*: 0" density: 0 lb/ft3 weight: 0 lb Insulation support ring spacing: 0" individual weight: 0


Lining/ref thk*: 0" density: 0 lb/ft3 weight: 0 lb


Results Summary

The governing condition is internal pressure. Minimum thickness per UG-16 = 0.0625" + 0.1" = 0.1625"Design thickness due to internal pressure (t) = 0.6165" Design thickness due to external pressure (te) = 0.2249" Maximum allowable working pressure (MAWP) = 430.0736 psi Maximum allowable pressure (MAP) = 512.4337 psi Maximum allowable external pressure (MAEP) = 164.8543 psi K (Corroded)

=(1/6)*[2 + (D / (2*h))2]

K =(1/6)*[2 + (48.2 / (2*12.1))2] =0.994502 K (New)

= (1/6)*[2 + (D / (2*h))2]

K = (1/6)*[2 + (48 / (2*12))2] = 1

Design thickness for internal pressure, (Corroded at 200 °F) Appendix 1-4(c)

t = P*D*K / (2*S*E - 0.20*P) + Corrosion = 430*48.2*0.994502 / (2*20000*1 - 0.20*430) + 0.1 = 0.6164" The head internal pressure design thickness is 0.6165".

Maximum allowable working pressure, (Corroded at 200 °F) Appendix 1-4(c)

P = 2*S*E*t / (K*D + 0.20*t) - Ps = 2*20000*1*0.5165 / (0.994502*48.2 +0.20*0.5165) - 0 = 430.0736 psi



The maximum allowable working pressure (MAWP) is 430.0736 psi.

Maximum allowable pressure, (New at 70 °F) Appendix 1-4(c)

P = 2*S*E*t / (K*D + 0.20*t) - Ps = 2*20000*1*0.6165 / (1*48 +0.20*0.6165) - 0 = 512.4337 psi The maximum allowable pressure (MAP) is 512.4337 psi.

Design thickness for external pressure, (Corroded at 200 °F) UG-33(d)

Equivalent outside spherical radius (Ro) Ro = Ko*Do = 0.878 * 49.233 = 43.2271 in A = 0.125 / (Ro/t) = 0.125 / (43.2271/0.124851) = 0.000361 From Table CS-2: B=5,193.4546 psi

Pa = B/(Ro/t) = 5193.455/(43.2271/0.124851)

= 15 psi

t = 0.1249" + Corrosion = 0.1249" + 0.1" = 0.2249"

Check the external pressure per UG-33(a)(1) Appendix 1-4(c)

t = 1.67*Pe*D*K / (2*S*E - 0.20*1.67*Pe) + Corrosion = 1.67*15*48.2*0.994502 / (2*20000*1 - 0.20*1.67*15) + 0.1 = 0.13"


Maximum Allowable External Pressure, (Corroded at 200 °F) UG-33(d)

Equivalent outside spherical radius (Ro) Ro = Ko*Do



= 0.878 * 49.233 = 43.2271 in A = 0.125 / (Ro/t) = 0.125 / (43.2271/0.5165) = 0.001494 From Table CS-2: B=13,797.0488 psi

Pa = B/(Ro/t) = 13797.05/(43.2271/0.5165)

= 164.8543 psi

Check the Maximum External Pressure, UG-33(a)(1) Appendix 1-4(c)

P = 2*S*E*t / ((K*D + 0.20*t)*1.67) - Ps2 = 2*20000*1*0.5165 / ((0.994502*48.2 +0.20*0.5165)*1.67) - 0 = 257.5291 psi



= (75*t / Rf)*(1 - Rf / Ro) = (75*0.625 / 8.4725)*(1 - 8.4725 / ∞) = 5.5326% The extreme fiber elongation exceeds 5 percent. Heat treatment per UCS-56 may be required. See UCS-79(d)(4) or (5).




F&D Head #1


Component: F&D Head Material Specification: SA-516 70 (II-D p.14, ln. 20) Straight Flange governs MDMT Internal design pressure: P = 825 psi @ 775 °F

Static liquid head:

Ps= 0 psi (SG=1, Hs=0" Operating head) Pth= 2.1533 psi (SG=1, Hs=59.6537" Horizontal test head) Corrosion allowance: Inner C = 0.125" Outer C = 0" Design MDMT = 30°F No impact test performed Rated MDMT = 15.21°F Material is not normalized


PWHT is performed Do not Optimize MDMT / Find MAWP


Estimated weight*: new = 2,991.80 lb corr = 2,870.10 lb

Capacity*: new = 125.8 US gal corr = 129.2 US gal

* includes straight flange

Outer diameter = 64.1" Crown radius L = 51.3" Knuckle radius r = 7" Minimum head thickness = 2.3963"



Straight flange length Lsf = 2" Nominal straight flange thickness tsf

= 2.5"

Insulation thk*: 0" density: 0 lb/ft3 weight: 0 lb Insulation support ring spacing: 0" individual weight: 0


Lining/ref thk*: 0" density: 0 lb/ft3 weight: 0 lb


Results Summary

The governing condition is internal pressure. Minimum thickness per UG-16 = 0.0625" + 0.125" = 0.1875"Design thickness due to internal pressure (t) = 2.3898" Maximum allowable working pressure (MAWP) = 827.4772 psi Maximum allowable pressure (MAP) = 1301.042 psi M (Corroded)

= 1/4*[3 + (L/r)1/2]

M = 1/4*[3 + (51.425/7.125)1/2] = 1.421637 M (New)

= 1/4*[3 + (L/r)1/2]

M = 1/4*[3 + (51.3/7)1/2] = 1.426783

Design thickness for internal pressure, (Corroded at 775 °F) Appendix 1-4(d)

t = P*Lo*M / (2*S*E + P*(M - 0.2)) + Corrosion = 825*53.6963*1.4216 / (2*13400*1 + 825*(1.4216 - 0.2)) + 0.125 = 2.3897" The head internal pressure design thickness is 2.3898".

Maximum allowable working pressure, (Corroded at 775 °F) Appendix 1-4(d)

P = 2*S*E*t / (M*Lo - t*(M - 0.2)) - Ps = 2*13400*1*2.2713 / (1.4216*53.6963 - 2.2713*(1.4216 - 0.2)) - 0 = 827.4772 psi



The maximum allowable working pressure (MAWP) is 827.4772 psi.

Maximum allowable pressure, (New at 70 °F) Appendix 1-4(d)

P = 2*S*E*t / (M*Lo - t*(M - 0.2)) - Ps = 2*20000*1*2.3963 / (1.4268*53.6963 - 2.3963*(1.4268 - 0.2)) - 0 = 1301.042 psi The maximum allowable pressure (MAP) is 1301.042 psi.


= (75*t / Rf)*(1 - Rf / Ro) = (75*2.5 / 8.25)*(1 - 8.25 / ∞) = 22.7273%




Welded Cover #2


Component: Welded Cover Material specification: SA-516 70 (II-D p. 14, ln. 20)

Head impact test exemption temperature from Fig UCS-66 Curve B = 31 °F Fig UCS-66.1 MDMT reduction = 9.5 °F, (coincident ratio = 0.905) UCS-66 governing thickness = 1 in.

Internal design pressure: P = 900.0000 psi @ 700.00°F External design pressure: Pe = 15.0000 psi @ 700.00°F

Static liquid head:

Pt

h =0.3971 psi (SG=1.0000, Hs=11.0000",Horizontal test head)

Corrosion allowance: Inner C = 0.1000" Outer C = 0.0000" Design MDMT = -20.00°F No impact test

performed

Rated MDMT = 21.50°F Material is not normalized


PWHT is performed Radiography: Category A joints - Full UW-11(a) Type 1 Estimated weight: New = 318.2 lb corr = 306.3 lb

Head outside diameter = 24.0000" Cover thickness = 2.6733"

Factor C from Fig. UG-34, sketch (b-2), (e through g) C = 0.33*tr/ts = 0.33*0.6202/0.9 = 0.2274 Design thickness, (at 700.00 °F) UG-34 (c)(2) t = d*Sqr(C*P/(S*E)) + Corrosion = 24.2*Sqr(0.2274*900/(18,100.00*1)) + 0.1



= 2.6733 in Maximum allowable working pressure, (at 700.00 °F ) C = 0.33*tr/ts = 0.33*0.6202/0.9 = 0.2274 P = (S*E/C)*(t/d)2 - Ps = (18,100.00*1/0.2274)*(2.5733/24.2)2 - 0 = 899.991 psi Maximum allowable pressure, (At 70.00 °F ) C = 0.33*tr/ts = 0.33*0.6831/1 = 0.2254 P = (S*E/C)*(t/d)2 = (20,000.00*1/0.2254)*(2.6733/24)2 = 1,100.903 psi Design thickness for external pressure, (at 700.00 °F) UG-34(c)(2) t = d*Sqr(C*Pe/(S*E)) + Corrosion = 24.2*Sqr(0.33*15/(18,100.00*1)) + 0.1 = 0.5002 in Maximum allowable external pressure, (At 700.00 °F ) P = (S*E/C)*(t/d)2 = (18,100.00*1/0.33)*(2.5733/24.2)2 = 620.176 psi



4.20 Taylor Forge Bulletin 502 Edition VII Example 1

Welding Neck Flange

ASME VIII-1, 2004 Edition, A06 Addenda, Appendix 2 Flange Calculations

Flange type: Weld neck integral Flange material specification: SA-105 (II-D p. 14, ln. 6)

Bolt material specification: SA-193 B7 Bolt <= 2 1/2 (II-D p. 382, ln. 33)

Internal design pressure, P: 400 psi @ 500 °F Required flange thickness: tr= 1.8688 in

Maximum allowable working pressure, MAWP: 417.1184 psi @ 500 °F

Maximum allowable pressure, MAP: 458.881 psi @ 70 °F (bolting limits)

Corrosion allowance: Bore = 0.0000 in Flange = 0.0000 in Bolt corrosion (root), Cbolt: 0.0000 in

Design MDMT: -20.00 °F No impact test performed

Rated MDMT: -43.10 °F Flange material is normalized

Material is produced to fine grain practice

PWHT is not performed Estimated weight: New = 308.8 lb corroded = 308.8 lb



Flange dimensions, new

flange OD A = 39.1250 in bolt circle C = 37.0000 in raised face OD = 34.5000 in

gasket OD = 36.0000 in gasket ID = 33.0000 in flange ID B = 32.0000 in thickness t = 2.0000 in bolting = 36- 1 in dia

hub thickness g1

= 1.1250 in

hub thickness g0

= 0.5000 in

hub length h = 2.7500 in length e = 6.0000 in

gasket factor m = 2.75

seating stress y = 3,700.00 psi

gasket description

Asbestos with binder 1/16 in. thick

Note: this flange is calculated as an integral type. Determination of Flange MDMT UCS-66(b)(1)(b) has been applied. Flange impact test exemption temperature from Fig UCS-66 Curve C = -34 °F Fig UCS-66.1 MDMT reduction = 9.1 °F, (coincident ratio = 0.9089903) UCS-66 governing thickness = 0.5 in Bolts rated MDMT per Fig UCS-66 note (e) = -55 °F The rated flange MDMT is -43.10 °F Gasket details from facing sketch 1(a) or (b), Column II



Gasket width N = 0.7500 in b0 = N/2 = 0.375 in Effective gasket seating width, b = 0.5*b0

1/2 = 0.3062 in G = (OD of contact face) - 2b = 33.8876 in hG = (C - G)/2 = (37 - 33.8876)/2 = 1.5562 in hD = R + g1/2 = 1.375 + 1.125/2 = 1.9375 in hT = (R + g1 + hG)/2 = (1.375 + 1.125 + 1.5562)/2 = 2.0281 in Hp = 2*b*3.14*G*m*P = 2*0.3062*3.14*33.8876*2.75*400 = 71,680.0547 lb H = 0.785*G2*P = 0.785*33.88762*400 = 360,588.0000 lb HD = 0.785*B2*P = 0.785*322*400 = 321,536.0000 lb HT = H - HD = 360,588.0 - 321,536.0 = 39,052.0000 lb Wm1 = H + Hp = 360,588.0 + 71,680.05 = 432,268.0625 lb Wm2 = 3.14*b*G*y = 3.14*0.3062*33.8876*3,700.00 = 120,552.8203 lb Required bolt area, Am = greater of Am1, Am2 = 17.29072 in2 Am1 = Wm1/Sb = 432,268.1/25,000.00 = 17.29072 in2 Am2 = Wm2/Sa = 120,552.8/25,000.00 = 4.822113 in2 Total area for 36- 1 in dia bolts, corroded, Ab = 19.836 in2



W = (Am + Ab)*Sa/2 = (17.29072 + 19.836)*25,000.00/2 = 464,084.0313 lb MD = HD*hD = 321,536.0*1.9375 = 622,976.0 lb-in MT = HT*hT = 39,052.00*2.0281 = 79,201.36 lb-in HG = Wm1 - H = 432,268.1 - 360,588.0 = 71,680.06 lb MG = HG*hG = 71,680.06*1.5562 = 111,548.5 lb-in Mo = MD + MT + MG = 622,976.0 + 79,201.36 + 111,548.5 = 813,725.9 lb-in Mg = W*hG = 464,084.0*1.5562 = 722,207.6 lb-in

Hub and Flange Factors h0 = (B*g0)1/2 = (32*0.5)1/2 = 4 in From FIG. 2-7.1, where K = A/B = 39.125/32 = 1.222656

T = 1.829756 Z = 5.041316 Y = 9.773324 U = 10.73989

h/h0 = 0.6875 g1/g0 = 2.25

F = 0.7769334 V = 0.1615516 e = F/h0 = 0.1942334

d = (U/V)*h0*g0

2= (10.73989/0.1615516)*4*0.52 = 66.47967 Stresses at operating conditions - VIII-1, Appendix 2-7 f = 1 L = (t*e + 1)/T + t3/d = (2*0.1942334 + 1)/1.829756 + 23/66.47967 = 0.8791639 SH = f*Mo/(L*g1

2*B) = 1*813,725.9/(0.8791639*1.1252*32) = 22,853.53 psi



SR = (1.33*t*e + 1)*Mo/(L*t2*B) = (1.33*2*0.1942334 + 1)*813,725.9/(0.8791639*22*32) = 10,966.97 psi ST = Y*Mo/(t2*B) - Z*SR = 9.773324*813,725.9/(22*32) - 5.041316*10,966.97 = 6,843.33 psi Allowable stress Sfo = 19,600.00 psi ST does not exceed Sfo SH does not exceed 1.5*Sfo = 29,400.00 psi SR does not exceed Sfo 0.5(SH + SR) = 16,910.25 psi does not exceed Sfo 0.5(SH + ST) = 14,848.43 psi does not exceed Sfo

Stresses at gasket seating - VIII-1, Appendix 2-7 SH = f*Mg/(L*g1

2*B) = 1*722,207.6/(0.8791639*1.1252*32) = 20,283.23 psi SR = (1.33*t*e + 1)*Mg/(L*t2*B) = (1.33*2*0.1942334 + 1)*722,207.6/(0.8791639*22*32) = 9,733.54 psi ST = Y*Mg/(t2*B) - Z*SR = 9.773324*722,207.6/(22*32) - 5.041316*9,733.537 = 6,073.67 psi Allowable stress Sfa = 20,000.00 psi ST does not exceed Sfa SH does not exceed 1.5*Sfa = 30,000.00 psi SR does not exceed Sfa 0.5(SH + SR) = 15,008.38 psi does not exceed Sfa 0.5(SH + ST) = 13,178.45 psi does not exceed Sfa Flange rigidity per VIII-1, Appendix 2-14 J = 52.14*V*Mo/(L*E*g0

2*Kl*h0) = 52.14*0.1615516*813,725.9/(0.8791639*27,100,000*0.52*0.3*4) = 0.9589587 The flange rigidity index J does not exceed 1; satisfactory.



Welding Neck Flange - Flange hub


Component: Flange hub Material specification: SA-105 (II-D p. 14, ln. 6)

Material impact test exemption temperature from Fig UCS-66 Curve B = -7 °F Fig UCS-66.1 MDMT reduction = 32.4 °F, (coincident ratio = 0.6758467) UCS-66 governing thickness = 0.5 in Internal design pressure: P = 400 psi @ 500°F

Static liquid head:

Not Considered Corrosion allowance: Inner C = 0.0000" Outer C = 0.0000" Design MDMT = -20.00°F No impact test

performed

Rated MDMT = -39.40°F Material is normalized



Radiography: Longitudinal joint - N/A

Top circumferential joint - Full UW-11(a) Type 1

Bottom circumferential joint - Full UW-11(a) Type 1

Estimated weight: New = 39.1191 lb corr = 39.1191 lb

Capacity: New = 9.5744 gal corr = 9.5744 gal

ID = 32.0000" Length Lc = 2.7500" t = 0.5000"

Design thickness, (at 500.00°F) UG-27(c)(1)

t = P*R/(S*E - 0.60*P) + Corrosion = 400.00*16.0000/(19600*1.00 - 0.60*400.00) + 0.0000 = 0.3306"



Maximum allowable working pressure, (at 500.00°F) UG-27(c)(1)

P = S*E*t/(R + 0.60*t) - Ps = 19600*1.00*0.5000 / (16.0000 + 0.60*0.5000) - 0.0000 = 601.2270 psi

Maximum allowable pressure, (at 70.00°F) UG-27(c)(1)

P = S*E*t/(R + 0.60*t) = 20000*1.00*0.5000 / (16.0000 + 0.60*0.5000) = 613.4969 psi


= (50 * t / Rf) * (1 - Rf / Ro) = (50 * 0.5000 / 16.2500) * (1 - 16.2500 / ∞) = 1.5385 %



4.21 Appendix 2 Slip On Full Face Gasketed Flange

Slip On Full Faced Flange

ASME VIII-1, 2004 Edition, A06 Addenda, Appendix 2 Flange Calculations

Flange type: Slip on full face gasket

Flange material specification: SA-181 60 (II-D p. 6, ln. 20)

Bolt material specification: SA-307 B Bolt (II-D p. 382, ln. 1)

Internal design pressure, P: 75 psi @ 300 °F Required flange thickness: tr= 1.8321 in Maximum allowable working pressure, MAWP:

93.76088 psi @ 300 °F

Maximum allowable pressure, MAP:

101.3416 psi @ 70 °F (bolting limits)

Corrosion allowance: Bore = 0.0000 in Flange = 0.0000 in Bolt corrosion (root), Cbolt: 0.0000 in

Design MDMT: -20.00 °F No impact test performed

Rated MDMT: -20.00 °F Flange material is not normalized


PWHT is not performed Estimated weight: New = 216.9 lb corroded = 216.9 lb



Flange dimensions, new

flange OD A = 32.0000 in bolt circle C = 29.5000 in flange ID B = 24.0000 in thickness t = 2.0000 in

bolting = 20- 1.25 in dia

hub thickness g1 = 1.0625 in

hub thickness g0 = 1.0625 in

hub length h = 0.7500 in

upper fillet weld h1 = 0.2500 in

lower fillet weld h2 = 0.2500 in

length e = 0.2500 in gasket factor m = 1

seating stress y = 200 psi

gasket description

Elastomers without fabric 75A or higher Shore Durometer

Note: this flange is calculated as a loose type. Determination of Flange MDMT UCS-66(b)(1)(b) has been applied. Flange impact test exemption temperature from Fig UCS-66 Curve B = -20 °F Fig UCS-66.1 MDMT reduction = 7.5 °F, (coincident ratio = 0.9251962) UCS-66 governing thickness = 0.25 in



Bolts rated MDMT per Fig UCS-66 note (e) = -20 °F The rated flange MDMT is -20.00 °F Full face gasketed flange calculated per TAYLOR Bulletin 502. b = (C - B)/4 = (29.5 - 24)/4 = 1.375 in hg = (C - B)*(2*B + C)/(6*(B + C)) = (29.5 - 24)*(2*24 + 29.5)/(6*(24 + 29.5)) = 1.3279 hg' = (A - C)*(2*A + C)/(6*(C + A)) = (32 - 29.5)*(2*32 + 29.5)/(6*(29.5 + 32)) = 0.6335 hg" = hg*hg'/(hg + hg') = 1.327882*0.6334688/(1.327882 + 0.6334688) = 0.4289 G = C - 2*hg = 29.5 - 2*1.327882 = 26.8442 HG = b*3.14*G*y = 1.375*3.14*26.84424*200 = 23,179.9980 lb Hp = 2*b*3.14*G*m*P = 2*1.375*3.14*26.84424*1*75 = 17,385.0000 lb H = 0.785*G2*P = 0.785*26.844242*75 = 42,426.0898 lb HD = 0.785*B2*P = 0.785*242*75 = 33,912.0000 lb HT = H - HD = 42,426.09 - 33,912.00 = 8,514.0898 lb HG' = (hg/hg')*HG = (1.327882/0.6334688)*23,180.00



= 48,590.0664 lb Hp' = (hg/hg')*Hp = (1.327882/0.6334688)*17,385.00 = 36,442.5547 lb Wm1 = H + Hp + Hp' = 42,426.09 + 17,385.00 + 36,442.55 = 96,253.6406 lb Wm2 = HG + HG' = 23,180.00 + 48,590.07 = 71,770.0625 lb Required bolt area, Am = greater of Am1, Am2 = 13.75052 in2 Am1 = Wm1/Sb = 96,253.64/7,000.00 = 13.75052 in2 Am2 = Wm2/Sa = 71,770.06/7,000.00 = 10.25287 in2 Total area for 20- 1.25 in dia bolts, corroded, Ab = 18.58 in2 W = (Am + Ab)*Sa/2 = (13.75052 + 18.58)*7,000.00/2 = 113,156.8203 lb hD = (C - B)/2 = (29.5 - 24)/2 = 2.75 in hT = (R + g1 + hG)/2 = (1.6875 + 1.0625 + 1.327882)/2 = 2.0389 MD = HD*hD = 33,912.00*2.75 = 93,258.00 lb-in MT = HT*hT = 8,514.09*2.038941 = 17,359.73 lb-in Mo = MD + MT = 93,258.00 + 17,359.73 = 110,617.7 lb-in Mg = (W - H)*hG" = (113,156.8 - 42,426.09)*0.4288737 = 30,334.55 lb-in



Hub and Flange Factors h0 = (B*g0)1/2 = (24*1.0625)1/2 = 5.049752 in From FIG. 2-7.1, where K = A/B = 32/24 = 1.333333

T = 1.783097 Z = 3.571428 Y = 6.903148 U = 7.58586

h/h0 = 0.14852 g1/g0 = 1

FL = 5.050434 VL = 41.99714 e = FL/h0 = 1.000135

d = (U/VL)*h0*g0

2 = (7.58586/41.99714)*5.049752*1.06252 = 1.029706 Stresses at operating conditions - VIII-1, Appendix 2-7 f = 1 L = (t*e + 1)/T + t3/d = (2*1.000135 + 1)/1.783097 + 23/1.029706 = 9.451828 SH = f*Mo/(L*g1

2*B) = 1*110,617.7/(9.451828*1.06252*24) = 431.96 psi SR = (1.33*t*e + 1)*Mo/(L*t2*B) = (1.33*2*1.000135 + 1)*110,617.7/(9.451828*22*24) = 446.23 psi ST = Y*Mo/(t2*B) - Z*SR = 6.903148*110,617.7/(22*24) - 3.571428*446.2327 = 6,360.59 psi Allowable stress Sfo = 17,100.00 psi ST does not exceed Sfo SH does not exceed 1.5*Sfo = 25,650.00 psi SR does not exceed Sfo 0.5(SH + SR) = 439.0945 psi does not exceed Sfo 0.5(SH + ST) = 3,396.272 psi does not exceed Sfo



Radial stress at the bolt circle (gasket seating) SRad = 6*Mg/(t2*(p*C - n*d1)) = 6*30,334.55/(22*(p*29.5 - 20*1.375)) = 698.13 psi Allowable stress Sfa = 17,100.00 psi SRad does not exceed Sfa Flange rigidity per VIII-1, Appendix 2-14 J = 52.14*VL*Mo/(L*E*g0

2*KL*h0) = 52.14*41.99714*110,617.7/(9.451828*28,100,000*1.06252*0.2*5.049752) = 0.7998994 The flange rigidity index J does not exceed 1; satisfactory.



4.22 ASME UHX-20.1.1

Front Tubesheet -- ASME


Tubesheet Type of heat exchanger: U-Tube

Type of construction: Fig. UHX-12.1 Configuration a: tubesheet integral with shell and channel

Tubesheet material specification: SA-240 316 (II-D p. 66, ln. 37) Tube layout: Square Tubesheet outer diameter, A: 12.9390 in Tubesheet thickness, h: 0.5210 in (tdesign = 0.5210 in) Number of tubes, Nt: 76 Tube pitch, p: 1.0000 in Radius to outer tube center, ro: 5.4380 in Total area of untubed lanes, AL: 26.1000 in2 Pass partition groove depth, hg: 0.0000 in Corrosion allowance shell side , cs: 0.0000 in Corrosion allowance tube side , ct: 0.0000 in Tubesheet poisson's ratio, n: 0.3000 Shell

Shell material specification: SA-312 TP316 Wld pipe (II-D p. 70, ln. 7)

Shell inner diameter, Ds: 12.3900 in Shell thickness, ts: 0.1800 in Shell inner corrosion allowance: 0.0000 in Shell outer corrosion allowance: 0.0000 in Shell poisson's ratio, ns: 0.3000 Channel Channel material specification: SA-240 316 (II-D p. 66, ln. 37) Channel inner diameter, Dc: 12.3130 in Channel thickness, tc: 0.3130 in Channel inner corrosion allowance: 0.0000 in Channel outer corrosion allowance: 0.0000 in Channel poisson's ratio, nc: 0.3000



Tubes

Tube material specification: SA-249 TP316 Wld tube (II-D p. 70, ln. 3)

Tube outer diameter, dt: 0.7500 in Tube nominal thickness, tt: 0.0650 in Tube inner corrosion allowance: 0.0000 in Tube outer corrosion allowance: 0.0000 in Tube expansion depth ratio, r: 0 Tube poisson's ratio, nt: 0.3000 Tube Supports Tube supports present: Yes Support all tubes: No Maximum distance from tubesheet to first support: 35.0000 in

Maximum distance between tube supports: 35.0000 in

Summary Tables

Tubesheet Design Thickness Summary

Condition tdesign (in)

Operating 0.5054808

Tube side vacuum 0.3789492

Shell side vacuum 0.5210419

Tube side hydrotest 0.4791050

Shell side hydrotest 0.3229532



Pressures and Temperatures

Condition

Shell side design

pressure Ps

(psi)

Tube side design

pressure Pt

(psi)

Tubesheet design temp

T (°F)

Shell design temp

Ts (°F)

Channel design temp

Tc (°F)

Tube design temp

Tt (°F)

Operating 60 140 500 500 500 500

Tube side vacuum 60 -15 500 500 500 500

Shell side vacuum -10 140 500 500 500 500

Tube side hydrotest 0 186.38 70 70 70 70

Shell side hydrotest 80.26 0 70 70 70 70

Material Properties

Condition Component Material Modulus of Elasticity

(psi)

Allowable Stress (psi)

Yield Stress (psi)

Shell SA-312 TP316 Wld pipe

Es = 25.8E+06

Ss = 18,000*

Sy,s =20,000

Channel SA-240 316 Ec =25.8E+06 Sc =18,000 Sy,c

=20,000

Tubesheet SA-240 316 E =25.8E+06 S =18,000 S =20,000

Operating

Tubes SA-249 TP316 Wld tube

Et =25.8E+06 St =18,000* Sy,t

=20,000


Es = 25.8E+06

Ss = 18,000*

Sy,s =20,000


=20,000


Tube side vacuum


Et =25.8E+06 St =18,000* Sy,t

=20,000

Shell side vacuum Shell SA-312 TP316

Wld pipe Es =

25.8E+06 Ss =

18,000* Sy,s

=20,000




=20,000



Et =25.8E+06 St =18,000* Sy,t

=20,000


Es = 28.3E+06

Ss = 31,765*

Sy,s =30,000


=30,000


Tube side hydrotest


Et =28.3E+06 St =31,765* Sy,t

=30,000


Es = 28.3E+06

Ss = 31,765*

Sy,s =30,000


=30,000


Shell side hydrotest


Et =28.3E+06 St =31,765* Sy,t

=30,000*The allowable tensile stress from Section II-D has been divided by 0.85 as the calculated stresses are longitudinal. Calculations for Operating Condition

UHX-12.5.1 Step 1

Do = 2*ro + dt

m = (p - dt) / p

d* = MAX{[dt - 2*tt*(Et / E)*(St / S)*r], [dt - 2*tt]}

p* = p /(1 - 4*MIN(AL, 4*Do*p) /(p*Do2))0.5

m* = (p* - d*)/p*

hg' = MAX[(hg - ct), 0]

Condition Operating

New or corroded Do = 2*5.4380 + 0.7500 = 11.6260



New or corroded m = (1.0000 - 0.7500) /1.0000 = 0.2500

New or corroded

d* = MAX{[0.7500 - 2*0.0650*(25.8E+06 / 25.8E+06)*(18,000 / 18,000)*0.0000],

[0.7500 - 2*0.0650]} = 0.7500000

New or corroded

p* = 1.0000 /(1 - 4*MIN(26.1000, 4*11.6260*1.0000) /(p*11.62602))0.5 = 1.1515

New or corroded m* = (1.1515276 - 0.7500000)/1.1515276 = 0.348691

hg' = 0.0000



UHX-12.5.2 Step 2

rs = Ds / Do

rc = Dc / Do

MTS = Do2 / 16 *[(rs -1)*(rs

2 + 1)*Ps - (rc - 1)*(rc2 + 1)*Pt]

Condition Operating

New or corroded

All load cases rs = 12.3900 / 11.6260 = 1.0657

New or corroded

All load cases rc = 12.3130 / 11.6260 = 1.0591

Load case 1

MTS = 11.62602 / 16 *[(1.0657148 -1)*(1.06571482 + 1)*0 - (1.0590916 - 1)*(1.05909162 + 1)*140] = -148.28

Load case 2

MTS = 11.62602 / 16 *[(1.0657148 -1)*(1.06571482 + 1)*60 - (1.0590916 - 1)*(1.05909162 + 1)*0] = 71.14

New or corroded

Load case 3

MTS = 11.62602 / 16 *[(1.0657148 -1)*(1.06571482 + 1)*60 - (1.0590916 - 1)*(1.05909162 + 1)*140] = -77.14

UHX-12.5.3 Step 3

E* / E = a0 + a1*m* + a2*m*2 + a3*m*3 + a4*m*4

n* = b0 + b1*m* + b2*m*2 + b3*m*3 + b4*m*4

Condition Operating

New or corroded h/p = 0.5210/1.0000 = 0.5210

New or corroded

- from Fig. UHX-11.4(a) E*/E = 0.4449

New or corroded E* = 0.4448859*25.8E+06 = 11,478,057

New or corroded - from Fig. UHX-11.4(b) n* = 0.2539



UHX-12.5.4 Step 4

bs = (12*(1 - ns2))0.25 / ((Ds + ts)*ts)0.5

ks = bs*Es*ts3 / (6*(1 - ns2))

ls = 6*Ds*ks / h3*[1 + h*bs + h2*bs2/ 2]

ds = Ds2 / (4*Es*ts) * (1 - ns / 2)

ws = rs*ks*bs*ds*(1 + h*bs)

bc = (12*(1 - nc2))0.25 / ((Dc + tc)*tc)0.5

kc = bc*Ec*tc3 / (6*(1 - nc2))

lc = 6*Dc*kc / h3*[1 + h*bc + h2*bc2/ 2]

dc = Dc2 / (4*Ec*tc) * (1 - nc / 2)

wc = rc*kc*bc*dc*(1 + h*bc)

Condition Operating

New or corroded

bs = (12*(1 - 0.30002))0.25 / ((12.3900 + 0.1800)*0.1800)0.5 = 1.2085142

New or corrode

d

All load

cases ks = 1.2085142*25.8E+06*0.18003 / (6*(1 - 0.30002)) = 33,304.00

New or corrode

d

All load

cases

ls = (6*12.3900 / 0.52103)*33,304.0000*(1 + 0.5210*1.2085142 + 0.52102*1.20851422 / 2) = 31,993,576

New or corrode

d

All load

cases

ds = 12.39002 / (4*25.8E+06*0.1800) * (1 - 0.3000 / 2) = 7.0244E-06

New or corrode

d

All load

cases

ws = 1.0657148*33,304.0000*1.2085142*7.024402E-06*(1 + 0.5210*1.2085142) = 0.4910

New or corroded

bc = (12*(1 - 0.30002))0.25 / ((12.3130 + 0.3130)*0.3130)0.5 = 0.9144303

New or corrode

d

All load

cases kc = 0.9144303*25.8E+06*0.31303 / (6*(1 - 0.30002)) = 132,498.41

New or corrode

d

All load

cases

lc = (6*12.3130 / 0.52103)*132,498.4063*(1 + 0.5210*0.9144303 + 0.52102*0.91443032 / 2) = 110,025,816



New or corrode

d

All load

cases

dc = 12.31302 / (4*25.8E+06*0.3130) * (1 - 0.3000 / 2) = 3.9895E-06

New or corrode

d

All load

cases

wc = 1.0590916*132,498.4063*0.9144303*3.989538E-06*(1 + 0.5210*0.9144303) = 0.7559

UHX-12.5.5 Step 5

K = A / Do

F = ((1 - n*) / E*)*(ls + lc + E*ln(K))

Condition Operating

New or corroded

All load cases K = 12.9390 / 11.6260 = 1.1129

New or corroded

All load cases

F = ((1 - 0.2539405) / 11,478,057)*(31,993,576 + 110,025,816 + 25.8E+06*ln(1.1129)) = 9.4105

UHX-12.5.6 Step 6

M* = MTS + wc*Pt - ws*Ps

Condition Operating

Load case 1 M* = -148.28 + 0.7558543*140 - 0.4910238*0 = -42.46

Load case 2 M* = 71.14 + 0.7558543*0 - 0.4910238*60 = 41.68

New or corroded

Load case 3 M* = -77.14 + 0.7558543*140 - 0.4910238*60 = -0.78



UHX-12.5.7 Step 7

Mp = (M* - (Do2 / 32)*F*(Ps - Pt)) / (1 + F)

Mo = Mp + (Do2 / 64)*(3 + n*)*(Ps - Pt)

M = Max[Abs(Mp),Abs(Mo)]

Condition Operating

Load case 1

Mp = (-42.46 - (11.62602 / 32)*9.4105*(0 - 140)) / (1 + 9.4105) = 530.46

Load case 2

Mp = (41.68 - (11.62602 / 32)*9.4105*(60 - 0)) / (1 + 9.4105) = -225.09

New or corroded

Load case 3

Mp = (-0.78 - (11.62602 / 32)*9.4105*(60 - 140)) / (1 + 9.4105) = 305.38

Load case 1

Mo = 530.4614 + (11.62602 / 64)*(3 + 0.2539405)*(0 - 140) = -431.63

Load case 2

Mo = -225.0851 + (11.62602 / 64)*(3 + 0.2539405)*(60 - 0) = 187.24

New or corroded

Load case 3

Mo = 305.3763 + (11.62602 / 64)*(3 + 0.2539405)*(60 - 140) = -244.39

Load case 1 M = Max[Abs(530.4614),Abs(-431.63)] = 530.46

Load case 2 M = Max[Abs(-225.0851),Abs(187.24)] = 225.09

New or corroded




UHX-12.5.8 Step 8

s = 6*M / (m**(h - hg')2)

Condition Operating Stress(psi)

Allowable

2*S (psi)

Over- stressed

?

Load case 1

s = 6*530.4614 / (0.3486913*(0.5210 - 0.0000)2) = 33,622 36,000 No

Load case 2

s = 6*225.0851 / (0.3486913*(0.5210 - 0.0000)2) = 14,266 36,000 No

New or corroded

Load case 3

s = 6*305.3763 / (0.3486913*(0.5210 - 0.0000)2) = 19,355 36,000 No

UHX-12.5.9 Step 9

t = (1 / (4*m))*(Do / h)*ABS(Ps - Pt)

Condition Operating

Tubesheet Shear Stress Stres

s (psi)

Allowable

(psi)

Over- stressed

?

Load case 1

t = (1 / (4*0.2500))*(11.6260 / 0.5210)*ABS(0 - 140) = 3,124 14,400 No

Load case 2

t = (1 / (4*0.2500))*(11.6260 / 0.5210)*ABS(60 - 0) = 1,339 14,400 No

New or corroded

Load case 3

t = (1 / (4*0.2500))*(11.6260 / 0.5210)*ABS(60 - 140) = 1,785 14,400 No



UHX-12.5.10 Step 10

ssm = Ds2*Ps / (4*ts*(Ds + ts))

ssb = (6 / ts2)*ks*[bs*ds*Ps + 6*((1 - n*) / E*)*(Do / h3)*(1 + h*bs / 2)*(Mp + (Do2 / 32)*(Ps -

Pt))]

ss = ABS(ssm) + ABS(ssb)

scm = Dc2*Pt / (4*tc*(Dc + tc))

scb = (6 / tc2)*kc*[bc*dc*Pt - 6*((1 - n*) / E*)*(Do / h3)*(1 + h*bc / 2)*(Mp + (Do2 / 32)*(Ps - Pt))]

sc = ABS(scm) + ABS(scb)

Shell Evaluation Stress(psi)

Allowable

1.5*Ss (psi)

Allowable

SPS,s (psi)

Over-stressed?

ssm = 12.39002*0 / (4*0.1800*(12.3900 + 0.1800)) = 0

ssb = (6 / 0.18002)*33,304.0000*[1.2085142*7.02

4402E-06*0 + 6*((1 - 0.2539405) / 11,478,057)*(11.6260 / 0.52103)*(1 +

0.5210*1.2085142 / 2)*(530.4614 + (11.62602 / 32)*(0 - 140))] =

-15,824

Load case 1

ss = ABS(0) + ABS(-15,824) = 15,824

27,000 54,000 No

ssm = 12.39002*60 / (4*0.1800*(12.3900 + 0.1800)) = 1,018

ssb = (6 / 0.18002)*33,304.0000*[1.2085142*7.02

4402E-06*60 + 6*((1 - 0.2539405) / 11,478,057)*(11.6260 / 0.52103)*(1 + 0.5210*1.2085142 / 2)*(-225.0851 +

(11.62602 / 32)*(60 - 0))] =

10,509

Load case 2

ss = ABS(1,018) + ABS(10,509) = 11,527

27,000 54,000 No

New or

corroded

Lod

ssm = 12.39002*60 / (4*0.1800*(12.3900 + 0.1800)) = 1,018 27,000 54,000 N

o



ssb = (6 / 0.18002)*33,304.0000*[1.2085142*7.02

4402E-06*60 + 6*((1 - 0.2539405) / 11,478,057)*(11.6260 / 0.52103)*(1 +

0.5210*1.2085142 / 2)*(305.3763 + (11.62602 / 32)*(60 - 140))] =

-5,315

ad case 3

ss = ABS(1,018) + ABS(-5,315) = 6,333

Channel Evaluation Stress(psi)

Allowable

1.5*Sc (psi)

Allowable

SPS,c (psi)

Over-stressed?

scm = 12.31302*140 / (4*0.3130*(12.3130 + 0.3130)) = 1,343

scb = (6 / 0.31302)*132,498.4063*[0.9144303*3.9

89538E-06*140 - 6*((1 - 0.2539405) / 11,478,057)*(11.6260 / 0.52103)*(1 +

0.5210*0.9144303 / 2)*(530.4614 + (11.62602 / 32)*(0 - 140))] =

23,752

Load case 1

sc = ABS(1,343) + ABS(23,752) = 25,095

27,000 54,000 No

scm = 12.31302*0 / (4*0.3130*(12.3130 + 0.3130)) = 0

scb = (6 / 0.31302)*132,498.4063*[0.9144303*3.9

89538E-06*0 - 6*((1 - 0.2539405) / 11,478,057)*(11.6260 / 0.52103)*(1 + 0.5210*0.9144303 / 2)*(-225.0851 +

(11.62602 / 32)*(60 - 0))] =

-9,130

Load case 2

sc = ABS(0) + ABS(-9,130) = 9,130

27,000 54,000 No

scm = 12.31302*140 / (4*0.3130*(12.3130 + 0.3130)) = 1,343

scb = (6 / 0.31302)*132,498.4063*[0.9144303*3.9

89538E-06*140 - 6*((1 - 0.2539405) / 11,478,057)*(11.6260 / 0.52103)*(1 +

0.5210*0.9144303 / 2)*(305.3763 + (11.62602 / 32)*(60 - 140))] =

14,622

New or

corroded

Load case 3

sc = ABS(1,343) + ABS(14,622) = 15,965

27,000 54,000 No



Calculations for Tube side vacuum Condition

UHX-12.5.1 Step 1

Do = 2*ro + dt

m = (p - dt) / p


p* = p /(1 - 4*MIN(AL, 4*Do*p) /(p*Do2))0.5

m* = (p* - d*)/p*

hg' = MAX[(hg - ct), 0]

Condition Tube side vacuum


New or corroded m = (1.0000 - 0.7500) /1.0000 = 0.2500

New or corroded

d* = MAX{[0.7500 - 2*0.0650*(25.8E+06 / 25.8E+06)*(18,000 / 18,000)*0.0000],

[0.7500 - 2*0.0650]} = 0.7500000

New or corroded

p* = 1.0000 /(1 - 4*MIN(26.1000, 4*11.6260*1.0000) /(p*11.62602))0.5 = 1.1515

New or corroded m* = (1.1515276 - 0.7500000)/1.1515276 = 0.348691

hg' = 0.0000



UHX-12.5.2 Step 2

rs = Ds / Do

rc = Dc / Do

MTS = Do2 / 16 *[(rs -1)*(rs

2 + 1)*Ps - (rc - 1)*(rc2 + 1)*Pt]


New or corroded

All load cases rs = 12.3900 / 11.6260 = 1.0657

New or corroded

All load cases rc = 12.3130 / 11.6260 = 1.0591

Load case 1

MTS = 11.62602 / 16 *[(1.0657148 -1)*(1.06571482 + 1)*0 - (1.0590916 - 1)*(1.05909162 + 1)*-15] = 15.89

Load case 2

MTS = 11.62602 / 16 *[(1.0657148 -1)*(1.06571482 + 1)*60 - (1.0590916 - 1)*(1.05909162 + 1)*0] = 71.14

New or corroded

Load case 3

MTS = 11.62602 / 16 *[(1.0657148 -1)*(1.06571482 + 1)*60 - (1.0590916 - 1)*(1.05909162 + 1)*-15] = 87.03

UHX-12.5.3 Step 3

E* / E = a0 + a1*m* + a2*m*2 + a3*m*3 + a4*m*4

n* = b0 + b1*m* + b2*m*2 + b3*m*3 + b4*m*4



New or corroded

- from Fig. UHX-11.4(a) E*/E = 0.4449





UHX-12.5.4 Step 4

bs = (12*(1 - ns2))0.25 / ((Ds + ts)*ts)0.5

ks = bs*Es*ts3 / (6*(1 - ns2))

ls = 6*Ds*ks / h3*[1 + h*bs + h2*bs2/ 2]

ds = Ds2 / (4*Es*ts) * (1 - ns / 2)


bc = (12*(1 - nc2))0.25 / ((Dc + tc)*tc)0.5

kc = bc*Ec*tc3 / (6*(1 - nc2))

lc = 6*Dc*kc / h3*[1 + h*bc + h2*bc2/ 2]

dc = Dc2 / (4*Ec*tc) * (1 - nc / 2)



New or corroded

bs = (12*(1 - 0.30002))0.25 / ((12.3900 + 0.1800)*0.1800)0.5 = 1.2085142

New or corrode

d

All load

cases ks = 1.2085142*25.8E+06*0.18003 / (6*(1 - 0.30002)) = 33,304.00

New or corrode

d

All load

cases

ls = (6*12.3900 / 0.52103)*33,304.0000*(1 + 0.5210*1.2085142 + 0.52102*1.20851422 / 2) = 31,993,576

New or corrode

d

All load

cases

ds = 12.39002 / (4*25.8E+06*0.1800) * (1 - 0.3000 / 2) = 7.0244E-06

New or corrode

d

All load

cases

ws = 1.0657148*33,304.0000*1.2085142*7.024402E-06*(1 + 0.5210*1.2085142) = 0.4910

New or corroded

bc = (12*(1 - 0.30002))0.25 / ((12.3130 + 0.3130)*0.3130)0.5 = 0.9144303

New or corrode

d

All load

cases kc = 0.9144303*25.8E+06*0.31303 / (6*(1 - 0.30002)) = 132,498.41

New or corrode

d

All load

cases

lc = (6*12.3130 / 0.52103)*132,498.4063*(1 + 0.5210*0.9144303 + 0.52102*0.91443032 / 2) = 110,025,816



New or corrode

d

All load

cases

dc = 12.31302 / (4*25.8E+06*0.3130) * (1 - 0.3000 / 2) = 3.9895E-06

New or corrode

d

All load

cases

wc = 1.0590916*132,498.4063*0.9144303*3.989538E-06*(1 + 0.5210*0.9144303) = 0.7559

UHX-12.5.5 Step 5

K = A / Do

F = ((1 - n*) / E*)*(ls + lc + E*ln(K))


New or corroded

All load cases K = 12.9390 / 11.6260 = 1.1129

New or corroded

All load cases

F = ((1 - 0.2539405) / 11,478,057)*(31,993,576 + 110,025,816 + 25.8E+06*ln(1.1129)) = 9.4105

UHX-12.5.6 Step 6



Load case 1 M* = 15.89 + 0.7558543*-15 - 0.4910238*0 = 4.55

Load case 2 M* = 71.14 + 0.7558543*0 - 0.4910238*60 = 41.68

New or corroded

Load case 3 M* = 87.03 + 0.7558543*-15 - 0.4910238*60 = 46.23



UHX-12.5.7 Step 7

Mp = (M* - (Do2 / 32)*F*(Ps - Pt)) / (1 + F)

Mo = Mp + (Do2 / 64)*(3 + n*)*(Ps - Pt)



Load case 1

Mp = (4.55 - (11.62602 / 32)*9.4105*(0 - -15)) / (1 + 9.4105) = -56.84

Load case 2

Mp = (41.68 - (11.62602 / 32)*9.4105*(60 - 0)) / (1 + 9.4105) = -225.09

New or corroded

Load case 3

Mp = (46.23 - (11.62602 / 32)*9.4105*(60 - -15)) / (1 + 9.4105) = -281.92

Load case 1

Mo = -56.8351 + (11.62602 / 64)*(3 + 0.2539405)*(0 - -15) = 46.25

Load case 2

Mo = -225.0851 + (11.62602 / 64)*(3 + 0.2539405)*(60 - 0) = 187.24

New or corroded

Load case 3

Mo = -281.9202 + (11.62602 / 64)*(3 + 0.2539405)*(60 - -15) = 233.49



New or corroded




UHX-12.5.8 Step 8

s = 6*M / (m**(h - hg')2)

Condition Tube side vacuum Stress(psi)

Allowable

2*S (psi)

Over- stressed

?

Load case 1

s = 6*56.8351 / (0.3486913*(0.5210 - 0.0000)2) = 3,602 36,000 No

Load case 2

s = 6*225.0851 / (0.3486913*(0.5210 - 0.0000)2) = 14,266 36,000 No

New or corroded

Load case 3

s = 6*281.9202 / (0.3486913*(0.5210 - 0.0000)2) = 17,869 36,000 No

UHX-12.5.9 Step 9



s (psi)

Allowable

(psi)

Over- stressed

?

Load case 1

t = (1 / (4*0.2500))*(11.6260 / 0.5210)*ABS(0 - -15) = 335 14,400 No

Load case 2

t = (1 / (4*0.2500))*(11.6260 / 0.5210)*ABS(60 - 0) = 1,339 14,400 No

New or corroded

Load case 3

t = (1 / (4*0.2500))*(11.6260 / 0.5210)*ABS(60 - -15) = 1,673 14,400 No



UHX-12.5.10 Step 10


ssb = (6 / ts2)*ks*[bs*ds*Ps + 6*((1 - n*) / E*)*(Do / h3)*(1 + h*bs / 2)*(Mp + (Do2 / 32)*(Ps - Pt))]






Allowable

1.5*Ss (psi)

Allowable

SPS,s (psi)

Over-

stressed?

ssm = 12.39002*0 / (4*0.1800*(12.3900 + 0.1800)) = 0

ssb = (6 / 0.18002)*33,304.0000*[1.2085142*7.02440

2E-06*0 + 6*((1 - 0.2539405) / 11,478,057)*(11.6260 / 0.52103)*(1 +

0.5210*1.2085142 / 2)*(-56.8351 + (11.62602 / 32)*(0 - -15))] =

1,695

Load

case 1

ss = ABS(0) + ABS(1,695) = 1,695

27,000 54,000 No

ssm = 12.39002*60 / (4*0.1800*(12.3900 + 0.1800)) = 1,018

ssb = (6 / 0.18002)*33,304.0000*[1.2085142*7.02440

2E-06*60 + 6*((1 - 0.2539405) / 11,478,057)*(11.6260 / 0.52103)*(1 + 0.5210*1.2085142 / 2)*(-225.0851 +

(11.62602 / 32)*(60 - 0))] =

10,509

Load

case 2

ss = ABS(1,018) + ABS(10,509) = 11,527

27,000 54,000 No

ssm = 12.39002*60 / (4*0.1800*(12.3900 + 0.1800)) = 1,018

New or corrode

d

Load

case 3 ssb = (6 /

0.18002)*33,304.0000*[1.2085142*7.024402E-06*60 + 6*((1 - 0.2539405) /

11,478,057)*(11.6260 / 0.52103)*(1 + 0.5210*1.2085142 / 2)*(-281.9202 +

(11.62602 / 32)*(60 - -15))] =

12,205

27,000 54,000 No



ss = ABS(1,018) + ABS(12,205) = 13,223


Allowable

1.5*Sc (psi)

Allowable

SPS,c (psi)

Over-

stressed?

scm = 12.31302*-15 / (4*0.3130*(12.3130 + 0.3130)) = -144

scb = (6 / 0.31302)*132,498.4063*[0.9144303*3.9895

38E-06*-15 - 6*((1 - 0.2539405) / 11,478,057)*(11.6260 / 0.52103)*(1 +

0.5210*0.9144303 / 2)*(-56.8351 + (11.62602 / 32)*(0 - -15))] =

-2,545

Load

case 1

sc = ABS(-144) + ABS(-2,545) = 2,689

27,000 54,000 No

scm = 12.31302*0 / (4*0.3130*(12.3130 + 0.3130)) = 0

scb = (6 / 0.31302)*132,498.4063*[0.9144303*3.9895

38E-06*0 - 6*((1 - 0.2539405) / 11,478,057)*(11.6260 / 0.52103)*(1 + 0.5210*0.9144303 / 2)*(-225.0851 +

(11.62602 / 32)*(60 - 0))] =

-9,130

Load

case 2

sc = ABS(0) + ABS(-9,130) = 9,130

27,000 54,000 No

scm = 12.31302*-15 / (4*0.3130*(12.3130 + 0.3130)) = -144

scb = (6 / 0.31302)*132,498.4063*[0.9144303*3.9895

38E-06*-15 - 6*((1 - 0.2539405) / 11,478,057)*(11.6260 / 0.52103)*(1 + 0.5210*0.9144303 / 2)*(-281.9202 +

(11.62602 / 32)*(60 - -15))] =

-11,674

New or corrode

d

Load

case 3

sc = ABS(-144) + ABS(-11,674) = 11,818

27,000 54,000 No



Calculations for Shell side vacuum Condition

UHX-12.5.1 Step 1

Do = 2*ro + dt

m = (p - dt) / p


p* = p /(1 - 4*MIN(AL, 4*Do*p) /(p*Do2))0.5

m* = (p* - d*)/p*

hg' = MAX[(hg - ct), 0]

Condition Shell side vacuum


New or corroded m = (1.0000 - 0.7500) /1.0000 = 0.2500

New or corroded

d* = MAX{[0.7500 - 2*0.0650*(25.8E+06 / 25.8E+06)*(18,000 / 18,000)*0.0000],

[0.7500 - 2*0.0650]} = 0.7500000

New or corroded

p* = 1.0000 /(1 - 4*MIN(26.1000, 4*11.6260*1.0000) /(p*11.62602))0.5 = 1.1515

New or corroded m* = (1.1515276 - 0.7500000)/1.1515276 = 0.348691

hg' = 0.0000



UHX-12.5.2 Step 2

rs = Ds / Do

rc = Dc / Do

MTS = Do2 / 16 *[(rs -1)*(rs

2 + 1)*Ps - (rc - 1)*(rc2 + 1)*Pt]


New or corroded

All load cases rs = 12.3900 / 11.6260 = 1.0657

New or corroded

All load cases rc = 12.3130 / 11.6260 = 1.0591

Load case 1

MTS = 11.62602 / 16 *[(1.0657148 -1)*(1.06571482 + 1)*0 - (1.0590916 - 1)*(1.05909162 + 1)*140] =

-148.28

Load case 2

MTS = 11.62602 / 16 *[(1.0657148 -1)*(1.06571482 + 1)*-10 - (1.0590916 - 1)*(1.05909162 + 1)*0] = -11.86

New or corroded

Load case 3

MTS = 11.62602 / 16 *[(1.0657148 -1)*(1.06571482 + 1)*-10 - (1.0590916 - 1)*(1.05909162 + 1)*140] =

-160.13

UHX-12.5.3 Step 3

E* / E = a0 + a1*m* + a2*m*2 + a3*m*3 + a4*m*4

n* = b0 + b1*m* + b2*m*2 + b3*m*3 + b4*m*4



New or corroded

- from Fig. UHX-11.4(a) E*/E = 0.4449





UHX-12.5.4 Step 4

bs = (12*(1 - ns2))0.25 / ((Ds + ts)*ts)0.5

ks = bs*Es*ts3 / (6*(1 - ns2))

ls = 6*Ds*ks / h3*[1 + h*bs + h2*bs2/ 2]

ds = Ds2 / (4*Es*ts) * (1 - ns / 2)


bc = (12*(1 - nc2))0.25 / ((Dc + tc)*tc)0.5

kc = bc*Ec*tc3 / (6*(1 - nc2))

lc = 6*Dc*kc / h3*[1 + h*bc + h2*bc2/ 2]

dc = Dc2 / (4*Ec*tc) * (1 - nc / 2)



New or corroded

bs = (12*(1 - 0.30002))0.25 / ((12.3900 + 0.1800)*0.1800)0.5 = 1.2085142

New or corrode

d

All load

cases ks = 1.2085142*25.8E+06*0.18003 / (6*(1 - 0.30002)) = 33,304.00

New or corrode

d

All load

cases

ls = (6*12.3900 / 0.52103)*33,304.0000*(1 + 0.5210*1.2085142 + 0.52102*1.20851422 / 2) = 31,993,576

New or corrode

d

All load

cases

ds = 12.39002 / (4*25.8E+06*0.1800) * (1 - 0.3000 / 2) = 7.0244E-06

New or corrode

d

All load

cases

ws = 1.0657148*33,304.0000*1.2085142*7.024402E-06*(1 + 0.5210*1.2085142) = 0.4910

New or corroded

bc = (12*(1 - 0.30002))0.25 / ((12.3130 + 0.3130)*0.3130)0.5 = 0.9144303

New or corrode

d

All load

cases kc = 0.9144303*25.8E+06*0.31303 / (6*(1 - 0.30002)) = 132,498.41

New or corrode

d

All load

cases

lc = (6*12.3130 / 0.52103)*132,498.4063*(1 + 0.5210*0.9144303 + 0.52102*0.91443032 / 2) = 110,025,816



New or corrode

d

All load

cases

dc = 12.31302 / (4*25.8E+06*0.3130) * (1 - 0.3000 / 2) = 3.9895E-06

New or corrode

d

All load

cases

wc = 1.0590916*132,498.4063*0.9144303*3.989538E-06*(1 + 0.5210*0.9144303) = 0.7559

UHX-12.5.5 Step 5

K = A / Do

F = ((1 - n*) / E*)*(ls + lc + E*ln(K))


New or corroded

All load cases K = 12.9390 / 11.6260 = 1.1129

New or corroded

All load cases

F = ((1 - 0.2539405) / 11,478,057)*(31,993,576 + 110,025,816 + 25.8E+06*ln(1.1129)) = 9.4105

UHX-12.5.6 Step 6



Load case 1 M* = -148.28 + 0.7558543*140 - 0.4910238*0 = -42.46

Load case 2 M* = -11.86 + 0.7558543*0 - 0.4910238*-10 = -6.95

New or corroded

Load case 3 M* = -160.13 + 0.7558543*140 - 0.4910238*-10 = -49.40



UHX-12.5.7 Step 7

Mp = (M* - (Do2 / 32)*F*(Ps - Pt)) / (1 + F)

Mo = Mp + (Do2 / 64)*(3 + n*)*(Ps - Pt)



Load case 1

Mp = (-42.46 - (11.62602 / 32)*9.4105*(0 - 140)) / (1 + 9.4105) = 530.46

Load case 2

Mp = (-6.95 - (11.62602 / 32)*9.4105*(-10 - 0)) / (1 + 9.4105) = 37.51

New or corroded

Load case 3

Mp = (-49.40 - (11.62602 / 32)*9.4105*(-10 - 140)) / (1 + 9.4105) = 567.98

Load case 1

Mo = 530.4614 + (11.62602 / 64)*(3 + 0.2539405)*(0 - 140) = -431.63

Load case 2

Mo = 37.5142 + (11.62602 / 64)*(3 + 0.2539405)*(-10 - 0) = -31.21

New or corroded

Load case 3

Mo = 567.9755 + (11.62602 / 64)*(3 + 0.2539405)*(-10 - 140) = -462.84



New or corroded




UHX-12.5.8 Step 8

s = 6*M / (m**(h - hg')2)

Condition Shell side vacuum Stress(psi)

Allowable

2*S (psi)

Over- stressed

?

Load case 1

s = 6*530.4614 / (0.3486913*(0.5210 - 0.0000)2) = 33,622 36,000 No

Load case 2

s = 6*37.5142 / (0.3486913*(0.5210 - 0.0000)2) = 2,378 36,000 No

New or corroded

Load case 3

s = 6*567.9755 / (0.3486913*(0.5210 - 0.0000)2) = 35,999 36,000 No

UHX-12.5.9 Step 9



s (psi)

Allowable

(psi)

Over- stressed

?

Load case 1

t = (1 / (4*0.2500))*(11.6260 / 0.5210)*ABS(0 - 140) = 3,124 14,400 No

Load case 2

t = (1 / (4*0.2500))*(11.6260 / 0.5210)*ABS(-10 - 0) = 223 14,400 No

New or corroded

Load case 3

t = (1 / (4*0.2500))*(11.6260 / 0.5210)*ABS(-10 - 140) = 3,347 14,400 No



UHX-12.5.10 Step 10








Allowable

1.5*Ss (psi)

Allowable

SPS,s (psi)

Over-stressed?

ssm = 12.39002*0 / (4*0.1800*(12.3900 + 0.1800)) = 0

ssb = (6 / 0.18002)*33,304.0000*[1.2085142*7.02440

2E-06*0 + 6*((1 - 0.2539405) / 11,478,057)*(11.6260 / 0.52103)*(1 +

0.5210*1.2085142 / 2)*(530.4614 + (11.62602 / 32)*(0 - 140))] =

-15,824

Load

case 1

ss = ABS(0) + ABS(-15,824) = 15,824

27,000 54,000 No

ssm = 12.39002*-10 / (4*0.1800*(12.3900 + 0.1800)) = -170

ssb = (6 / 0.18002)*33,304.0000*[1.2085142*7.02440

2E-06*-10 + 6*((1 - 0.2539405) / 11,478,057)*(11.6260 / 0.52103)*(1 +

0.5210*1.2085142 / 2)*(37.5142 + (11.62602 / 32)*(-10 - 0))] =

-1,752

Load

case 2

ss = ABS(-170) + ABS(-1,752) = 1,921

27,000 54,000 No

New or corrode

d

Load

ssm = 12.39002*-10 / (4*0.1800*(12.3900 + 0.1800)) = -170 27,000 54,000 No



ssb = (6 / 0.18002)*33,304.0000*[1.2085142*7.02440

2E-06*-10 + 6*((1 - 0.2539405) / 11,478,057)*(11.6260 / 0.52103)*(1 +

0.5210*1.2085142 / 2)*(567.9755 + (11.62602 / 32)*(-10 - 140))] =

-17,576

d case 3

ss = ABS(-170) + ABS(-17,576) = 17,745


Allowable

1.5*Sc (psi)

Allowable

SPS,c (psi)

Over-stressed?

scm = 12.31302*140 / (4*0.3130*(12.3130 + 0.3130)) = 1,343

scb = (6 / 0.31302)*132,498.4063*[0.9144303*3.9895

38E-06*140 - 6*((1 - 0.2539405) / 11,478,057)*(11.6260 / 0.52103)*(1 +

0.5210*0.9144303 / 2)*(530.4614 + (11.62602 / 32)*(0 - 140))] =

23,752

Load

case 1

sc = ABS(1,343) + ABS(23,752) = 25,095

27,000 54,000 No

scm = 12.31302*0 / (4*0.3130*(12.3130 + 0.3130)) = 0

scb = (6 / 0.31302)*132,498.4063*[0.9144303*3.9895

38E-06*0 - 6*((1 - 0.2539405) / 11,478,057)*(11.6260 / 0.52103)*(1 +

0.5210*0.9144303 / 2)*(37.5142 + (11.62602 / 32)*(-10 - 0))] =

1,522

Load

case 2

sc = ABS(0) + ABS(1,522) = 1,522

27,000 54,000 No

scm = 12.31302*140 / (4*0.3130*(12.3130 + 0.3130)) = 1,343

scb = (6 / 0.31302)*132,498.4063*[0.9144303*3.9895

38E-06*140 - 6*((1 - 0.2539405) / 11,478,057)*(11.6260 / 0.52103)*(1 +

0.5210*0.9144303 / 2)*(567.9755 + (11.62602 / 32)*(-10 - 140))] =

25,274

New or corrode

d

Load

case 3

sc = ABS(1,343) + ABS(25,274) = 26,616

27,000 54,000 No

Calculations for Tube side hydrotest Condition



UHX-12.5.1 Step 1

Do = 2*ro + dt

m = (p - dt) / p


p* = p /(1 - 4*MIN(AL, 4*Do*p) /(p*Do2))0.5

m* = (p* - d*)/p*

hg' = MAX[(hg - ct), 0]

Condition Tube side hydrotest

New Do = 2*5.4380 + 0.7500 = 11.6260

New m = (1.0000 - 0.7500) /1.0000 = 0.2500

New d* = MAX{[0.7500 - 2*0.0650*(28.3E+06 / 28.3E+06)*(31,765 /

40,000)*0.0000], [0.7500 - 2*0.0650]} =

0.7500000

New p* = 1.0000 /(1 - 4*MIN(26.1000, 4*11.6260*1.0000) /(p*11.62602))0.5 = 1.1515

New m* = (1.1515276 - 0.7500000)/1.1515276 = 0.348691

hg' = 0.0000

UHX-12.5.2 Step 2

rs = Ds / Do

rc = Dc / Do

MTS = Do2 / 16 *[(rs -1)*(rs

2 + 1)*Ps - (rc - 1)*(rc2 + 1)*Pt]


New

All load cases rs = 12.3900 / 11.6260 = 1.0657

New

All load cases rc = 12.3130 / 11.6260 = 1.0591

New

Load case 1

MTS = 11.62602 / 16 *[(1.0657148 -1)*(1.06571482 + 1)*0 - (1.0590916 - 1)*(1.05909162 + 1)*186.38] = -197.40



UHX-12.5.3 Step 3

E* / E = a0 + a1*m* + a2*m*2 + a3*m*3 + a4*m*4

n* = b0 + b1*m* + b2*m*2 + b3*m*3 + b4*m*4


New h/p = 0.5210/1.0000 = 0.5210

New

- from Fig. UHX-11.4(a) E*/E = 0.4449

New E* = 0.4448859*28.3E+06 = 12,590,272

New - from Fig. UHX-11.4(b) n* = 0.2539

UHX-12.5.4 Step 4

bs = (12*(1 - ns2))0.25 / ((Ds + ts)*ts)0.5

ks = bs*Es*ts3 / (6*(1 - ns2))

ls = 6*Ds*ks / h3*[1 + h*bs + h2*bs2/ 2]

ds = Ds2 / (4*Es*ts) * (1 - ns / 2)


bc = (12*(1 - nc2))0.25 / ((Dc + tc)*tc)0.5

kc = bc*Ec*tc3 / (6*(1 - nc2))

lc = 6*Dc*kc / h3*[1 + h*bc + h2*bc2/ 2]

dc = Dc2 / (4*Ec*tc) * (1 - nc / 2)



New bs = (12*(1 - 0.30002))0.25 / ((12.3900 + 0.1800)*0.1800)0.5 = 1.2085142

New

Load case

1 ks = 1.2085142*28.3E+06*0.18003 / (6*(1 - 0.30002)) = 36,531.13

New

Load case

ls = (6*12.3900 / 0.52103)*36,531.1289*(1 + 0.5210*1.2085142 + 0.52102*1.20851422 / 2) = 35,093,728



1

New

Load case

1 ds = 12.39002 / (4*28.3E+06*0.1800) * (1 - 0.3000 / 2) = 6.4039E-06

New

Load case

1

ws = 1.0657148*36,531.1289*1.2085142*6.403871E-06*(1 + 0.5210*1.2085142) = 0.4910

New bc = (12*(1 - 0.30002))0.25 / ((12.3130 + 0.3130)*0.3130)0.5 = 0.9144303

New

Load case

1 kc = 0.9144303*28.3E+06*0.31303 / (6*(1 - 0.30002)) = 145,337.41

New

Load case

1

lc = (6*12.3130 / 0.52103)*145,337.4063*(1 + 0.5210*0.9144303 + 0.52102*0.91443032 / 2) = 120,687,240

New

Load case

1 dc = 12.31302 / (4*28.3E+06*0.3130) * (1 - 0.3000 / 2) = 3.6371E-06

New

Load case

1

wc = 1.0590916*145,337.4063*0.9144303*3.637105E-06*(1 + 0.5210*0.9144303) = 0.7559

UHX-12.5.5 Step 5

K = A / Do

F = ((1 - n*) / E*)*(ls + lc + E*ln(K))


New

All load cases K = 12.9390 / 11.6260 = 1.1129

New

All load cases

F = ((1 - 0.2539405) / 12,590,272)*(35,093,728 + 120,687,240 + 28.3E+06*ln(1.1129)) = 9.4105



UHX-12.5.6 Step 6



New

Load case 1 M* = -197.40 + 0.7558543*186.38 - 0.4910238*0 = -56.52

UHX-12.5.7 Step 7

Mp = (M* - (Do2 / 32)*F*(Ps - Pt)) / (1 + F)

Mo = Mp + (Do2 / 64)*(3 + n*)*(Ps - Pt)



New

Load case 1

Mp = (-56.52 - (11.62602 / 32)*9.4105*(0 - 186.3831)) / (1 + 9.4105) = 706.21

New

Load case 1

Mo = 706.2075 + (11.62602 / 64)*(3 + 0.2539405)*(0 - 186.3831) = -574.64

New


UHX-12.5.8 Step 8

s = 6*M / (m**(h - hg')2)

Condition Tube side hydrotest Stress(psi)

Allowable

(psi)

Over- stressed

?

New

Load case 1

s = 6*706.2075 / (0.3486913*(0.5210 - 0.0000)2) = 44,761 54,000 No

UHX-12.5.9 Step 9



s (psi)

Allowable

(psi)

Over- stressed

?



New

Load case 1

t = (1 / (4*0.2500))*(11.6260 / 0.5210)*ABS(0 - 186.38) = 4,159 24,000 No

UHX-12.5.10 Step 10







Shell Evaluation Stress (psi)

Allowable

1.5*Ss (psi)

Allowabl

e SPS,s(psi)

Over-stress

ed?

ssm = 12.39002*0 / (4*0.1800*(12.3900 + 0.1800)) = 0

ssb = (6 / 0.18002)*36,531.1289*[1.2085142*6.403871

E-06*0 + 6*((1 - 0.2539405) / 12,590,272)*(11.6260 / 0.52103)*(1 +

0.5210*1.2085142 / 2)*(706.2075 + (11.62602 / 32)*(0 - 186.38))] =

-21,067 New

Load

case 1

ss = ABS(0) + ABS(-21,067) = 21,067

40,500 63,529 No

Channel Evaluation Stress (psi)

Allowable

1.5*Sc (psi)

Allowabl

e SPS,c(psi)

Over-stress

ed?

scm = 12.31302*186.38 / (4*0.3130*(12.3130 + 0.3130)) = 1,788

scb = (6 / 0.31302)*145,337.4063*[0.9144303*3.63710

5E-06*186.38 - 6*((1 - 0.2539405) / 12,590,272)*(11.6260 / 0.52103)*(1 +

0.5210*0.9144303 / 2)*(706.2075 + (11.62602 / 32)*(0 - 186.38))] =

31,621 New

Load

case 1

sc = ABS(1,788) + ABS(31,621) = 33,409

40,500 60,000 No



Calculations for Shell side hydrotest Condition

UHX-12.5.1 Step 1

Do = 2*ro + dt

m = (p - dt) / p


p* = p /(1 - 4*MIN(AL, 4*Do*p) /(p*Do2))0.5

m* = (p* - d*)/p*

hg' = MAX[(hg - ct), 0]

Condition Shell side hydrotest

New Do = 2*5.4380 + 0.7500 = 11.6260

New m = (1.0000 - 0.7500) /1.0000 = 0.2500

New d* = MAX{[0.7500 - 2*0.0650*(28.3E+06 / 28.3E+06)*(31,765 /

40,000)*0.0000], [0.7500 - 2*0.0650]} =

0.7500000

New p* = 1.0000 /(1 - 4*MIN(26.1000, 4*11.6260*1.0000) /(p*11.62602))0.5 = 1.1515

New m* = (1.1515276 - 0.7500000)/1.1515276 = 0.348691

hg' = 0.0000

UHX-12.5.2 Step 2

rs = Ds / Do

rc = Dc / Do

MTS = Do2 / 16 *[(rs -1)*(rs

2 + 1)*Ps - (rc - 1)*(rc2 + 1)*Pt]


New

All load cases rs = 12.3900 / 11.6260 = 1.0657

New

All load cases rc = 12.3130 / 11.6260 = 1.0591

New

Load case 2

MTS = 11.62602 / 16 *[(1.0657148 -1)*(1.06571482 + 1)*80.26 - (1.0590916 - 1)*(1.05909162 + 1)*0] = 95.16



UHX-12.5.3 Step 3

E* / E = a0 + a1*m* + a2*m*2 + a3*m*3 + a4*m*4

n* = b0 + b1*m* + b2*m*2 + b3*m*3 + b4*m*4


New h/p = 0.5210/1.0000 = 0.5210

New

- from Fig. UHX-11.4(a) E*/E = 0.4449

New E* = 0.4448859*28.3E+06 = 12,590,272


UHX-12.5.4 Step 4

bs = (12*(1 - ns2))0.25 / ((Ds + ts)*ts)0.5

ks = bs*Es*ts3 / (6*(1 - ns2))

ls = 6*Ds*ks / h3*[1 + h*bs + h2*bs2/ 2]

ds = Ds2 / (4*Es*ts) * (1 - ns / 2)


bc = (12*(1 - nc2))0.25 / ((Dc + tc)*tc)0.5

kc = bc*Ec*tc3 / (6*(1 - nc2))

lc = 6*Dc*kc / h3*[1 + h*bc + h2*bc2/ 2]

dc = Dc2 / (4*Ec*tc) * (1 - nc / 2)



New bs = (12*(1 - 0.30002))0.25 / ((12.3900 + 0.1800)*0.1800)0.5 = 1.2085142

New

Load case

2 ks = 1.2085142*28.3E+06*0.18003 / (6*(1 - 0.30002)) = 36,531.13

New

Load case

ls = (6*12.3900 / 0.52103)*36,531.1289*(1 + 0.5210*1.2085142 + 0.52102*1.20851422 / 2) = 35,093,728



2

New

Load case

2 ds = 12.39002 / (4*28.3E+06*0.1800) * (1 - 0.3000 / 2) = 6.4039E-06

New

Load case

2

ws = 1.0657148*36,531.1289*1.2085142*6.403871E-06*(1 + 0.5210*1.2085142) = 0.4910

New bc = (12*(1 - 0.30002))0.25 / ((12.3130 + 0.3130)*0.3130)0.5 = 0.9144303

New

Load case

2 kc = 0.9144303*28.3E+06*0.31303 / (6*(1 - 0.30002)) = 145,337.41

New

Load case

2

lc = (6*12.3130 / 0.52103)*145,337.4063*(1 + 0.5210*0.9144303 + 0.52102*0.91443032 / 2) = 120,687,240

New

Load case

2 dc = 12.31302 / (4*28.3E+06*0.3130) * (1 - 0.3000 / 2) = 3.6371E-06

New

Load case

2

wc = 1.0590916*145,337.4063*0.9144303*3.637105E-06*(1 + 0.5210*0.9144303) = 0.7559

UHX-12.5.5 Step 5

K = A / Do

F = ((1 - n*) / E*)*(ls + lc + E*ln(K))


New

All load cases K = 12.9390 / 11.6260 = 1.1129

New

All load cases

F = ((1 - 0.2539405) / 12,590,272)*(35,093,728 + 120,687,240 + 28.3E+06*ln(1.1129)) = 9.4105

UHX-12.5.6 Step 6



New

Load case 2 M* = 95.16 + 0.7558543*0 - 0.4910238*80.26 = 55.75



UHX-12.5.7 Step 7

Mp = (M* - (Do2 / 32)*F*(Ps - Pt)) / (1 + F)

Mo = Mp + (Do2 / 64)*(3 + n*)*(Ps - Pt)



New

Load case 2

Mp = (55.75 - (11.62602 / 32)*9.4105*(80.2615 - 0)) / (1 + 9.4105) = -301.09

New

Load case 2

Mo = -301.0945 + (11.62602 / 64)*(3 + 0.2539405)*(80.2615 - 0) = 250.47

New


UHX-12.5.8 Step 8

s = 6*M / (m**(h - hg')2)

Condition Shell side hydrotest Stress(psi)

Allowable

(psi)

Over- stressed

?

New

Load case 2

s = 6*301.0945 / (0.3486913*(0.5210 - 0.0000)2) = 19,084 54,000 No

UHX-12.5.9 Step 9



s (psi)

Allowable

(psi)

Over- stressed

?

New

Load case 2

t = (1 / (4*0.2500))*(11.6260 / 0.5210)*ABS(80.26 - 0) = 1,791 24,000 No



UHX-12.5.10 Step 10







Shell Evaluation Stress (psi)

Allowable

1.5*Ss (psi)

Allowable

SPS,s (psi)

Over-stressed?

ssm = 12.39002*80.26 / (4*0.1800*(12.3900 + 0.1800)) = 1,361

ssb = (6 / 0.18002)*36,531.1289*[1.2085142*6.403871

E-06*80.26 + 6*((1 - 0.2539405) / 12,590,272)*(11.6260 / 0.52103)*(1 + 0.5210*1.2085142 / 2)*(-301.0945 +

(11.62602 / 32)*(80.26 - 0))] =

14,058 New

Load

case 2

ss = ABS(1,361) + ABS(14,058) = 15,420

40,500 63,529 No


Allowable

1.5*Sc (psi)

Allowable

SPS,c (psi)

Over-stressed?

scm = 12.31302*0 / (4*0.3130*(12.3130 + 0.3130)) = 0

scb = (6 / 0.31302)*145,337.4063*[0.9144303*3.63710

5E-06*0 - 6*((1 - 0.2539405) / 12,590,272)*(11.6260 / 0.52103)*(1 + 0.5210*0.9144303 / 2)*(-301.0945 +

(11.62602 / 32)*(80.26 - 0))] =

-12,213 New

Load

case 2

sc = ABS(0) + ABS(-12,213) = 12,213

40,500 60,000 No



4.22 ASME UHX-20.1.4

Front Tubesheet -- ASME


Tubesheet Type of heat exchanger: U-Tube

Type of construction: Fig. UHX-12.1 Configuration e: tubesheet gasketed with shell and integral with channel, with tubesheet extended as a flange

Tubesheet material specification: SA-516 70 (II-D p. 14, ln. 20) Tube layout: Square Tubesheet outer diameter, A: 37.2500 in Tubesheet thickness, h: 3.6250 in (tdesign = 3.6176 in) Number of tubes, Nt: 496 Tube pitch, p: 1.0000 in Radius to outer tube center, ro: 12.7500 in Total area of untubed lanes, AL: 36.0938 in2 Pass partition groove depth, hg: 0.0000 in Corrosion allowance shell side , cs: 0.0000 in Corrosion allowance tube side , ct: 0.1250 in Tubesheet poisson's ratio, n: 0.3000 Gasket groove depth shell side: 0.0000 in Gasket groove depth tube side: 0.0000 in Shell

Shell material specification: SA-516 70 (II-D p. 14, ln. 20) Shell inner diameter, Ds: 31.0000 in Shell thickness, ts: 0.6250 in Shell inner corrosion allowance: 0.0000 in Shell outer corrosion allowance: 0.0000 in Shell poisson's ratio, ns: 0.3000 Channel

Channel material specification: SA-516 70 (II-D p. 14, ln. 20) Channel inner diameter, Dc: 31.0000 in Channel thickness, tc: 0.6250 in



Channel inner corrosion allowance: 0.0000 in Channel outer corrosion allowance: 0.0000 in Channel poisson's ratio, nc: 0.3000 Tubes

Tube material specification: SA-179 Smls tube (II-D p. 2, ln. 11) Tube outer diameter, dt: 0.7500 in Tube nominal thickness, tt: 0.0850 in Tube inner corrosion allowance: 0.0000 in Tube outer corrosion allowance: 0.0000 in Tube expansion depth ratio, r: 1.0000 Tube poisson's ratio, nt: 0.3000 Flange

Bolt circle diameter, C: 35.0000 in Shell side gasket load reaction diameter, Gs:

32.3750 in

Tube Supports

Tube supports present: Yes Support all tubes: No Maximum distance from tubesheet to first support: 35.0000 in

Maximum distance between tube supports: 35.0000 in

Summary Tables

Tubesheet Design Thickness Summary

Condition tdesign (in)

Operating 3.6175632

Tube side hydrotest 3.7043009

Shell side hydrotest 3.6370516



Bolt Load Summary

Condition Load Case Shell design bolt

load Ws (lbf)

Load case 1 452,505.94

Load case 2 655,999.88Operating

Load case 3 655,999.88

Tube side hydrotest

Load case 1 452,505.94

Shell side hydrotest

Load case 2 748,061.56

Pressures and Temperatures

Condition

Shell side design

pressure Ps

(psi)

Tube side design

pressure Pt

(psi)

Tubesheet design temp

T (°F)

Shell design temp

Ts (°F)

Channel design temp

Tc (°F)

Tube design temp

Tt (°F)

Operating 650 650 400 400 400 400

Tube side hydrotest 0 846.36 70 70 70 70

Shell side hydrotest 846.36 0 70 70 70 70

Material Properties

Condition Component Material Modulus of Elasticity

(psi)

Allowable Stress (psi)

Yield Stress (psi)

Shell SA-516 70 Es = 27.9E+06 Ss = 20,000 Sy,s =32,500 Channel SA-516 70 Ec =27.7E+06 Sc =20,000 Sy,c =32,500

Tubesheet SA-516 70 E =27.7E+06 S =20,000 S =32,500 Operating

Tubes SA-179 Smls tube Et =27.7E+06 St =13,400 Sy,t =22,200

Shell SA-516 70 Es = 29.4E+06 Ss = 34,200 Sy,s =38,000 Tube side hydrotest

Channel SA-516 70 Ec =29.4E+06 Sc =34,200 Sy,c =38,000





Shell SA-516 70 Es = 29.4E+06 Ss = 34,200 Sy,s =38,000 Channel SA-516 70 Ec =29.4E+06 Sc =34,200 Sy,c =38,000

Tubesheet SA-516 70 E =29.4E+06 S =34,200 S =38,000 Shell side hydrotest


Calculations for Operating Condition

UHX-9.5

hr = (1.9*W*hg / (S*G))0.5

Condition Operating

Operating

Load case 1

hr = (1.9*0.00*1.3125 / (20,000*32.3750))0.5 = 0.0000

New or corroded

Load case 2, 3

hr = (1.9*609,499.75*1.3125 / (20,000*32.3750))0.5 = 1.5321

Gasket Seating

Load case 1

hr = (1.9*452,505.94*1.3125 / (20,000*32.3750))0.5 = 1.3201

New or corroded

Load case 2, 3

hr = (1.9*655,999.88*1.3125 / (20,000*32.3750))0.5 = 1.5895

Tubesheet Flanged Extension Design Thickness = 1.5895 + 0 + 0 = 1.5895 in

UHX-12.5.1 Step 1

Do = 2*ro + dt

m = (p - dt) / p


p* = p /(1 - 4*MIN(AL, 4*Do*p) /(p*Do2))0.5



m* = (p* - d*)/p*

hg' = MAX[(hg - ct), 0]

Condition Operating


New or corroded m = (1.0000 - 0.7500) /1.0000 = 0.2500

New or corroded

d* = MAX{[0.7500 - 2*0.0850*(27.7E+06 / 27.7E+06)*(13,400 / 20,000)*1.0000],

[0.7500 - 2*0.0850]} = 0.6361000

New or corroded

p* = 1.0000 /(1 - 4*MIN(36.0938, 4*26.2500*1.0000) /(p*26.25002))0.5 = 1.0351

New or corroded m* = (1.0351132 - 0.6361000)/1.0351132 = 0.385478

hg' = 0.0000

UHX-12.5.2 Step 2

rs = Gs / Do

rc = Dc / Do

MTS = Do2 / 16 *[(rs -1)*(rs

2 + 1)*Ps - (rc - 1)*(rc2 + 1)*Pt]

Condition Operating

New or corroded

All load cases rs = 32.3750 / 26.2500 = 1.2333

New or corroded

All load cases rc = 31.0000 / 26.2500 = 1.1810

Load case 1

MTS = 26.25002 / 16 *[(1.2333333 -1)*(1.23333332 + 1)*0 - (1.1809524 -

1)*(1.18095242 + 1)*650] = -12,129.92

Load case 2

MTS = 26.25002 / 16 *[(1.2333333 -1)*(1.23333332 + 1)*650 - (1.1809524 -

1)*(1.18095242 + 1)*0] = 16,467.24

New or corroded

Load case 3

MTS = 26.25002 / 16 *[(1.2333333 -1)*(1.23333332 + 1)*650 - (1.1809524 -

1)*(1.18095242 + 1)*650] = 4,337.31



UHX-12.5.3 Step 3

E* / E = a0 + a1*m* + a2*m*2 + a3*m*3 + a4*m*4

n* = b0 + b1*m* + b2*m*2 + b3*m*3 + b4*m*4

Condition Operating

New h/p = 3.6250/1.0000 = 3.6250

Corroded h/p = 3.5000/1.0000 = 3.5000

New or corroded

- from Fig. UHX-11.4(a) E*/E = 0.4413



UHX-12.5.4 Step 4

bc = (12*(1 - nc2))0.25 / ((Dc + tc)*tc)0.5

kc = bc*Ec*tc3 / (6*(1 - nc2))

lc = 6*Dc*kc / h3*[1 + h*bc + h2*bc2/ 2]

dc = Dc2 / (4*Ec*tc) * (1 - nc / 2)


Condition Operating

New or corroded bc = (12*(1 - 0.30002))0.25 / ((31.0000 + 0.6250)*0.6250)0.5 = 0.4088843

New or corroded

All load case

s

kc = 0.4088843*27.7E+06*0.62503 / (6*(1 - 0.30002)) = 506,439.50

New All

load case

s

lc = (6*31.0000 / 3.62503)*506,439.5000*(1 + 3.6250*0.4088843 + 3.62502*0.40888432 / 2) = 7,080,779

Corroded

All load case

s

lc = (6*31.0000 / 3.50003)*506,439.5000*(1 + 3.5000*0.4088843 + 3.50002*0.40888432 / 2) = 7,590,990



New or corroded

All load case

s

dc = 31.00002 / (4*27.7E+06*0.6250) * (1 - 0.3000 / 2) = 1.1796E-05

New All

load case

s

wc = 1.1809524*506,439.5000*0.4088843*1.179567E-

05*(1 + 3.6250*0.4088843) = 7.1601

Corroded

All load case

s

wc = 1.1809524*506,439.5000*0.4088843*1.179567E-

05*(1 + 3.5000*0.4088843) = 7.0127

UHX-12.5.5 Step 5

K = A / Do

F = ((1 - n*) / E*)*(lc + E*ln(K))

Condition Operating

New or corroded

All load cases K = 37.2500 / 26.2500 = 1.4190

New All load cases

F = ((1 - 0.3179100) / 12,224,318)*(7,080,779 + 27.7E+06*ln(1.4190)) = 0.9360

Corroded All load cases

F = ((1 - 0.3179100) / 12,224,318)*(7,590,990 + 27.7E+06*ln(1.4190)) = 0.9645

UHX-12.5.6 Step 6

M* = MTS + wc*Pt + Ws*(C - Gs) / (2*p*Do)

Condition Operating

Load case 1

M* = -12,129.92 + 7.1601248*650 + 452,505.94*(35.0000 - 32.3750) / (2*p*26.2500) = -273.99

Load case 2

M* = 16,467.24 + 7.1601248*0 + 655,999.88*(35.0000 - 32.3750) / (2*p*26.2500) = 26,907.80 New

Load case 3

M* = 4,337.31 + 7.1601248*650 + 655,999.88*(35.0000 - 32.3750) / (2*p*26.2500) = 19,431.96

Corroded

Load case 1

M* = -12,129.92 + 7.0126920*650 + 452,505.94*(35.0000 - 32.3750) / (2*p*26.2500) = -369.82



Load case 2

M* = 16,467.24 + 7.0126920*0 + 655,999.88*(35.0000 - 32.3750) / (2*p*26.2500) = 26,907.80

Load case 3

M* = 4,337.31 + 7.0126920*650 + 655,999.88*(35.0000 - 32.3750) / (2*p*26.2500) = 19,336.13

UHX-12.5.7 Step 7

Mp = (M* - (Do2 / 32)*F*(Ps - Pt)) / (1 + F)

Mo = Mp + (Do2 / 64)*(3 + n*)*(Ps - Pt)


Condition Operating

Load case 1

Mp = (-273.99 - (26.25002 / 32)*0.9360*(0 - 650)) / (1 + 0.9360) = 6,625.53

Load case 2

Mp = (26,907.80 - (26.25002 / 32)*0.9360*(650 - 0)) / (1 + 0.9360) = 7,131.39 New

Load case 3

Mp = (19,431.96 - (26.25002 / 32)*0.9360*(650 - 650)) / (1 + 0.9360) = 10,037.01

Load case 1

Mp = (-369.82 - (26.25002 / 32)*0.9645*(0 - 650)) / (1 + 0.9645) = 6,683.57

Load case 2

Mp = (26,907.80 - (26.25002 / 32)*0.9645*(650 - 0)) / (1 + 0.9645) = 6,825.21

Corroded

Load case 3

Mp = (19,336.13 - (26.25002 / 32)*0.9645*(650 - 650)) / (1 + 0.9645) = 9,842.78

Load case 1

Mo = 6,625.5337 + (26.25002 / 64)*(3 + 0.3179100)*(0 - 650) = -16,594.17

Load case 2

Mo = 7,131.3896 + (26.25002 / 64)*(3 + 0.3179100)*(650 - 0) = 30,351.09 New

Load case 3

Mo = 10,037.0137 + (26.25002 / 64)*(3 + 0.3179100)*(650 - 650) = 10,037.01

Load case 1

Mo = 6,683.5703 + (26.25002 / 64)*(3 + 0.3179100)*(0 - 650) = -16,536.13

Corroded

Load case 2

Mo = 6,825.2119 + (26.25002 / 64)*(3 + 0.3179100)*(650 - 0) = 30,044.91



Load case 3

Mo = 9,842.7803 + (26.25002 / 64)*(3 + 0.3179100)*(650 - 650) = 9,842.78

Load case 1 M = Max[Abs(6,625.5337),Abs(-16,594.17)] = 16,594.17

Load case 2 M = Max[Abs(7,131.3896),Abs(30,351.09)] = 30,351.09 New

Load case 3 M = Max[Abs(10,037.0137),Abs(10,037.01)] = 10,037.01



Corroded


UHX-12.5.8 Step 8

s = 6*M / (m**(h - hg')2)

Condition Operating Stress (psi)

Allowable

2*S (psi)

Over- stressed

?

Load case 1

s = 6*16,594.1660 / (0.3854779*(3.6250 - 0.0000)2) = 19,656 40,000 No

Load case 2

s = 6*30,351.0898 / (0.3854779*(3.6250 - 0.0000)2) = 35,951 40,000 No New

Load case 3

s = 6*10,037.0137 / (0.3854779*(3.6250 - 0.0000)2) = 11,889 40,000 No

Load case 1

s = 6*16,536.1289 / (0.3854779*(3.5000 - 0.0000)2) = 21,011 40,000 No

Load case 2

s = 6*30,044.9121 / (0.3854779*(3.5000 - 0.0000)2) = 38,176 40,000 No

Corroded

Load case 3

s = 6*9,842.7803 / (0.3854779*(3.5000 - 0.0000)2) = 12,506 40,000 No



UHX-12.5.9 Step 9

t = (1 / (4*m))*(Do / h)*ABS(Ps - Pt)

Condition Operating

Tubesheet Shear Stress Stress(psi)

Allowable

(psi)

Over- stressed

? Load

case 1, 2

t = (1 / (4*0.2500))*(26.2500 / 3.6250)*ABS(0 - 650) = 4,707 16,000 No

New Load

case 3 t = (1 / (4*0.2500))*(26.2500 /

3.6250)*ABS(650 - 650) = 0 16,000 No

Load case 1,

2 t = (1 / (4*0.2500))*(26.2500 /

3.5000)*ABS(0 - 650) = 4,875 16,000 No Corrode

d Load

case 3 t = (1 / (4*0.2500))*(26.2500 /

3.5000)*ABS(650 - 650) = 0 16,000 No

UHX-12.5.10 Step 10





Allowable

1.5*Sc (psi)

Allowable

SPS,c (psi)

Over-stressed?

scm = 31.00002*650 / (4*0.6250*(31.0000 + 0.6250)) = 7,901

scb = (6 / 0.62502)*506,439.5000*[0.4088843*1.179567E-05*650 - 6*((1 - 0.3179100)

/ 12,224,318)*(26.2500 / 3.62503)*(1 + 3.6250*0.4088843 / 2)*(6,625.5337 +

(26.25002 / 32)*(0 - 650))] =

42,805

New

Load case 1

sc = ABS(7,901) + ABS(42,805) = 50,706

30,000 65,000 See EP



scm = 31.00002*0 / (4*0.6250*(31.0000 + 0.6250)) = 0

scb = (6 / 0.62502)*506,439.5000*[0.4088843*1.

179567E-05*0 - 6*((1 - 0.3179100) / 12,224,318)*(26.2500 / 3.62503)*(1 + 3.6250*0.4088843 / 2)*(7,131.3896 +

(26.25002 / 32)*(650 - 0))] =

-52,793 Load

case 2

sc = ABS(0) + ABS(-52,793) = 52,793

30,000 65,000 See EP

scm = 31.00002*650 / (4*0.6250*(31.0000 + 0.6250)) = 7,901

scb = (6 / 0.62502)*506,439.5000*[0.4088843*1.179567E-05*650 - 6*((1 - 0.3179100)

/ 12,224,318)*(26.2500 / 3.62503)*(1 + 3.6250*0.4088843 / 2)*(10,037.0137 +

(26.25002 / 32)*(650 - 650))] =

-693

Load case 3

sc = ABS(7,901) + ABS(-693) = 8,594

30,000 65,000 No

scm = 31.00002*650 / (4*0.6250*(31.0000 + 0.6250)) = 7,901

scb = (6 / 0.62502)*506,439.5000*[0.4088843*1.179567E-05*650 - 6*((1 - 0.3179100)

/ 12,224,318)*(26.2500 / 3.50003)*(1 + 3.5000*0.4088843 / 2)*(6,683.5703 +

(26.25002 / 32)*(0 - 650))] =

44,391 Load

case 1

sc = ABS(7,901) + ABS(44,391) = 52,291

30,000 65,000 See EP

scm = 31.00002*0 / (4*0.6250*(31.0000 + 0.6250)) = 0

scb = (6 / 0.62502)*506,439.5000*[0.4088843*1.

179567E-05*0 - 6*((1 - 0.3179100) / 12,224,318)*(26.2500 / 3.50003)*(1 + 3.5000*0.4088843 / 2)*(6,825.2119 +

(26.25002 / 32)*(650 - 0))] =

-56,955 Load

case 2

sc = ABS(0) + ABS(-56,955) = 56,955

30,000 65,000 See EP

Corroded

Load case 3

scm = 31.00002*650 / (4*0.6250*(31.0000 + 0.6250)) = 7,901 30,000 65,000 No



scb = (6 / 0.62502)*506,439.5000*[0.4088843*1.179567E-05*650 - 6*((1 - 0.3179100)

/ 12,224,318)*(26.2500 / 3.50003)*(1 + 3.5000*0.4088843 / 2)*(9,842.7803 +

(26.25002 / 32)*(650 - 650))] =

-2,537

sc = ABS(7,901) + ABS(-2,537) = 10,437

UHX-12.5.11 Option 3 Elastic-Plastic Analysis

Ec,ep = Ec*(1.5*Sc / sc)0.5

Load case 1 Ec,ep = 27.7E+06*(1.5*20,000 / 50,706)0.5 = 21,306,500

New Load

case 2 Ec,ep = 27.7E+06*(1.5*20,000 / 52,793)0.5 = 20,881,088

Load case 1 Ec,ep = 27.7E+06*(1.5*20,000 / 52,291)0.5 = 20,980,982

Corroded Load

case 2 Ec,ep = 27.7E+06*(1.5*20,000 / 56,955)0.5 = 20,103,600

UHX-12.5.4 Step 4

Load case 1

kc = 0.4088843*21,306,500*0.62503 / (6*(1 - 0.30002)) = 389,547.03

New Load

case 2 kc = 0.4088843*20,881,088*0.62503 / (6*(1 -

0.30002)) = 381,769.22

Load case 1

kc = 0.4088843*20,980,982*0.62503 / (6*(1 - 0.30002)) = 383,595.59

Corroded Load

case 2 kc = 0.4088843*20,103,600*0.62503 / (6*(1 -

0.30002)) = 367,554.41

Load case 1

lc = (6*31.0000 / 3.62503)*389,547.0313*(1 + 3.6250*0.4088843 + 3.62502*0.40888432 / 2) = 5,446,448

New Load

case 2 lc = (6*31.0000 / 3.62503)*381,769.2188*(1 +

3.6250*0.4088843 + 3.62502*0.40888432 / 2) = 5,337,703

Load case 1

lc = (6*31.0000 / 3.50003)*383,595.5938*(1 + 3.5000*0.4088843 + 3.50002*0.40888432 / 2) = 5,749,690

Corroded Load

case 2 lc = (6*31.0000 / 3.50003)*367,554.4063*(1 +

3.5000*0.4088843 + 3.50002*0.40888432 / 2) = 5,509,250



UHX-12.5.5 Step 5

New or corroded

All load

cases K = 37.2500 / 26.2500 = 1.4190

Load case 1

F = ((1 - 0.3179100) / 12,224,318)*(5,446,448 + 27.7E+06*ln(1.4190)) = 0.8448

New Load

case 2 F = ((1 - 0.3179100) / 12,224,318)*(5,337,703 +

27.7E+06*ln(1.4190)) = 0.8388

Load case 1

F = ((1 - 0.3179100) / 12,224,318)*(5,749,690 + 27.7E+06*ln(1.4190)) = 0.8618

Corroded Load

case 2 F = ((1 - 0.3179100) / 12,224,318)*(5,509,250 +

27.7E+06*ln(1.4190)) = 0.8483

UHX-12.5.7 Step 7

Load case 1

Mp = (-273.99 - (26.25002 / 32)*0.8448*(0 - 650)) / (1 + 0.8448) = 6,261.18

New Load

case 2 Mp = (26,907.80 - (26.25002 / 32)*0.8388*(650 -

0)) / (1 + 0.8388) = 8,248.93

Load case 1

Mp = (-369.82 - (26.25002 / 32)*0.8618*(0 - 650)) / (1 + 0.8618) = 6,280.00

Corroded Load

case 2 Mp = (26,907.80 - (26.25002 / 32)*0.8483*(650 -

0)) / (1 + 0.8483) = 8,133.73

Load case 1

Mo = 6,261.1758 + (26.25002 / 64)*(3 + 0.3179100)*(0 - 650) = -16,958.52

New Load

case 2 Mo = 8,248.9316 + (26.25002 / 64)*(3 +

0.3179100)*(650 - 0) = 31,468.63

Load case 1

Mo = 6,280.0044 + (26.25002 / 64)*(3 + 0.3179100)*(0 - 650) = -16,939.70

Corroded Load

case 2 Mo = 8,133.7290 + (26.25002 / 64)*(3 +

0.3179100)*(650 - 0) = 31,353.43


New Load

case 2 M = Max[Abs(8,248.9316),Abs(31,468.63)] = 31,468.63

Corroded Load case 1 M = Max[Abs(6,280.0044),Abs(-16,939.70)] = 16,939.70




UHX-12.5.8 Step 8

Condition Operating Stress(psi)

Allowable 2*S (psi)

Over- stressed?

Load case 1

s = 6*16,958.5234 / (0.3854779*(3.6250 -

0.0000)2) = 20,087 40,000 No

New

Load case 2

s = 6*31,468.6309 / (0.3854779*(3.6250 -

0.0000)2) = 37,275 40,000 No

Load case 1

s = 6*16,939.6953 / (0.3854779*(3.5000 -

0.0000)2) = 21,524 40,000 No

Corroded

Load case 2

s = 6*31,353.4277 / (0.3854779*(3.5000 -

0.0000)2) = 39,838 40,000 No

Calculations for Tube side hydrotest Condition

UHX-9.5


Operating

New All load cases hr = (1.9*0.00*1.3125 / (51,300*32.3750))0.5 = 0.0000

Tubesheet Flanged Extension Design Thickness = 0 + 0 + 0 = 0 in



UHX-12.5.1 Step 1

Do = 2*ro + dt

m = (p - dt) / p


p* = p /(1 - 4*MIN(AL, 4*Do*p) /(p*Do2))0.5

m* = (p* - d*)/p*

hg' = MAX[(hg - ct), 0]


New Do = 2*12.7500 + 0.7500 = 26.2500

New m = (1.0000 - 0.7500) /1.0000 = 0.2500

New

d* = MAX{[0.7500 - 2*0.0850*(29.4E+06 / 29.4E+06)*(23,400 / 45,600)*1.0000],

[0.7500 - 2*0.0850]} = 0.6627632

New

p* = 1.0000 /(1 - 4*MIN(36.0938, 4*26.2500*1.0000) /(p*26.25002))0.5 = 1.0351

New m* = (1.0351132 - 0.6627632)/1.0351132 = 0.359719

hg' = 0.0000

UHX-12.5.2 Step 2

rs = Gs / Do

rc = Dc / Do

MTS = Do2 / 16 *[(rs -1)*(rs

2 + 1)*Ps - (rc - 1)*(rc2 + 1)*Pt]


New

All load cases rs = 32.3750 / 26.2500 = 1.2333

New

All load cases rc = 31.0000 / 26.2500 = 1.1810

New

Load case 1 MTS = 26.25002 / 16 *[(1.2333333 -1)*(1.23333332 +

2-15,794.25



1)*0 - (1.1809524 - 1)*(1.18095242 + 1)*846.36] =

UHX-12.5.3 Step 3

E* / E = a0 + a1*m* + a2*m*2 + a3*m*3 + a4*m*4

n* = b0 + b1*m* + b2*m*2 + b3*m*3 + b4*m*4


New h/p = 3.6250/1.0000 = 3.6250

New

- from Fig. UHX-11.4(a) E*/E = 0.4106

New E* = 0.4106138*29.4E+06 = 12,072,047


UHX-12.5.4 Step 4

bc = (12*(1 - nc2))0.25 / ((Dc + tc)*tc)0.5

kc = bc*Ec*tc3 / (6*(1 - nc2))

lc = 6*Dc*kc / h3*[1 + h*bc + h2*bc2/ 2]

dc = Dc2 / (4*Ec*tc) * (1 - nc / 2)



New bc = (12*(1 - 0.30002))0.25 / ((31.0000 + 0.6250)*0.6250)0.5 = 0.4088843

New

Load case

1 kc = 0.4088843*29.4E+06*0.62503 / (6*(1 - 0.30002)) = 537,520.63

New

Load case

1 lc = (6*31.0000 / 3.62503)*537,520.6250*(1 +

3.6250*0.4088843 + 3.62502*0.40888432 / 2) = 7,515,339

New

Load case

1 dc = 31.00002 / (4*29.4E+06*0.6250) * (1 - 0.3000 / 2) = 1.1114E-05



New

Load case

1 wc = 1.1809524*537,520.6250*0.4088843*1.111361E-

05*(1 + 3.6250*0.4088843) = 7.1601

UHX-12.5.5 Step 5

K = A / Do

F = ((1 - n*) / E*)*(lc + E*ln(K))


New

All load cases K = 37.2500 / 26.2500 = 1.4190

New

All load cases

F = ((1 - 0.3208870) / 12,072,047)*(7,515,339 + 29.4E+06*ln(1.4190)) = 1.0016

UHX-12.5.6 Step 6



New

Load case 1

M* = -15,794.25 + 7.1601248*846.36 + 452,505.94*(35.0000 - 32.3750) / (2*p*26.2500) = -2,532.36

UHX-12.5.7 Step 7

Mp = (M* - (Do2 / 32)*F*(Ps - Pt)) / (1 + F)

Mo = Mp + (Do2 / 64)*(3 + n*)*(Ps - Pt)



New

Load case 1

Mp = (-2,532.36 - (26.25002 / 32)*1.0016*(0 - 846.3581)) / (1 + 1.0016) = 7,854.60

New

Load case 1

Mo = 7,854.6006 + (26.25002 / 64)*(3 + 0.3208870)*(0 - 846.3581) = -22,406.65

New




UHX-12.5.8 Step 8

s = 6*M / (m**(h - hg')2)

Condition Tube side hydrotest Stress (psi)

Allowable

(psi)

Over- stressed

?

New

Load case 1

s = 6*22,406.6504 / (0.3597192*(3.6250 - 0.0000)2) = 28,441 68,400 No

UHX-12.5.9 Step 9



Allowable

(psi)

Over- stressed

?

New

Load case 1

t = (1 / (4*0.2500))*(26.2500 / 3.6250)*ABS(0 - 846.36) = 6,129 27,360 No

UHX-12.5.10 Step 10





Allowable

1.5*Sc (psi)

Allowable

SPS,c (psi)

Over-stressed?

scm = 31.00002*846.36 / (4*0.6250*(31.0000 + 0.6250)) = 10,287

scb = (6 / 0.62502)*537,520.6250*[0.4088843*1.1113

61E-05*846.36 - 6*((1 - 0.3208870) / 12,072,047)*(26.2500 / 3.62503)*(1 + 3.6250*0.4088843 / 2)*(7,854.6006 +

(26.25002 / 32)*(0 - 846.36))] =

59,482 New

Load

case 1

sc = ABS(10,287) + ABS(59,482) = 69,769

51,300 68,400 Yes



Calculations for Shell side hydrotest Condition

UHX-9.5


Operating

New Load case 2

hr = (1.9*793,623.19*1.3125 / (51,300*32.3750))0.5 = 1.0916

Tubesheet Flanged Extension Design Thickness = 1.0916 + 0 + 0 = 1.0916 in

UHX-12.5.1 Step 1

Do = 2*ro + dt

m = (p - dt) / p


p* = p /(1 - 4*MIN(AL, 4*Do*p) /(p*Do2))0.5

m* = (p* - d*)/p*

hg' = MAX[(hg - ct), 0]


New Do = 2*12.7500 + 0.7500 = 26.2500

New m = (1.0000 - 0.7500) /1.0000 = 0.2500

New

d* = MAX{[0.7500 - 2*0.0850*(29.4E+06 / 29.4E+06)*(23,400 / 45,600)*1.0000],

[0.7500 - 2*0.0850]} = 0.6627632

New

p* = 1.0000 /(1 - 4*MIN(36.0938, 4*26.2500*1.0000) /(p*26.25002))0.5 = 1.0351

New m* = (1.0351132 - 0.6627632)/1.0351132 = 0.359719

hg' = 0.0000



UHX-12.5.2 Step 2

rs = Gs / Do

rc = Dc / Do

MTS = Do2 / 16 *[(rs -1)*(rs

2 + 1)*Ps - (rc - 1)*(rc2 + 1)*Pt]


New

All load cases rs = 32.3750 / 26.2500 = 1.2333

New

All load cases rc = 31.0000 / 26.2500 = 1.1810

New

Load case 2

MTS = 26.25002 / 16 *[(1.2333333 -1)*(1.23333332 + 1)*846.36 - (1.1809524 - 1)*(1.18095242 + 1)*0] = 21,441.82

UHX-12.5.3 Step 3

E* / E = a0 + a1*m* + a2*m*2 + a3*m*3 + a4*m*4

n* = b0 + b1*m* + b2*m*2 + b3*m*3 + b4*m*4


New h/p = 3.6250/1.0000 = 3.6250

New

- from Fig. UHX-11.4(a) E*/E = 0.4106

New E* = 0.4106138*29.4E+06 = 12,072,047


UHX-12.5.4 Step 4

bc = (12*(1 - nc2))0.25 / ((Dc + tc)*tc)0.5

kc = bc*Ec*tc3 / (6*(1 - nc2))

lc = 6*Dc*kc / h3*[1 + h*bc + h2*bc2/ 2]

dc = Dc2 / (4*Ec*tc) * (1 - nc / 2)





New bc = (12*(1 - 0.30002))0.25 / ((31.0000 + 0.6250)*0.6250)0.5 = 0.4088843

New

Load case

2 kc = 0.4088843*29.4E+06*0.62503 / (6*(1 - 0.30002)) = 537,520.63

New

Load case

2 lc = (6*31.0000 / 3.62503)*537,520.6250*(1 +

3.6250*0.4088843 + 3.62502*0.40888432 / 2) = 7,515,339

New

Load case

2 dc = 31.00002 / (4*29.4E+06*0.6250) * (1 - 0.3000 / 2) = 1.1114E-05

New

Load case

2 wc = 1.1809524*537,520.6250*0.4088843*1.111361E-

05*(1 + 3.6250*0.4088843) = 7.1601

UHX-12.5.5 Step 5

K = A / Do

F = ((1 - n*) / E*)*(lc + E*ln(K))


New

All load cases K = 37.2500 / 26.2500 = 1.4190

New

All load cases

F = ((1 - 0.3208870) / 12,072,047)*(7,515,339 + 29.4E+06*ln(1.4190)) = 1.0016

UHX-12.5.6 Step 6



New

Load case 2

M* = 21,441.82 + 7.1601248*0 + 748,061.56*(35.0000 - 32.3750) / (2*p*26.2500) = 33,347.59



UHX-12.5.7 Step 7

Mp = (M* - (Do2 / 32)*F*(Ps - Pt)) / (1 + F)

Mo = Mp + (Do2 / 64)*(3 + n*)*(Ps - Pt)



New

Load case 2

Mp = (33,347.59 - (26.25002 / 32)*1.0016*(846.3581 - 0)) / (1 + 1.0016) = 7,540.57

New

Load case 2

Mo = 7,540.5718 + (26.25002 / 64)*(3 + 0.3208870)*(846.3581 - 0) = 37,801.82

New


UHX-12.5.8 Step 8

s = 6*M / (m**(h - hg')2)

Condition Shell side hydrotest Stress (psi)

Allowable

(psi)

Over- stressed

?

New

Load case 2

s = 6*37,801.8242 / (0.3597192*(3.6250 - 0.0000)2) = 47,983 68,400 No

UHX-12.5.9 Step 9



Allowable

(psi)

Over- stressed

?

New

Load case 2

t = (1 / (4*0.2500))*(26.2500 / 3.6250)*ABS(846.36 - 0) = 6,129 27,360 No



UHX-12.5.10 Step 10





Allowable

1.5*Sc (psi)

Allowable

SPS,c (psi)

Over-stressed?

scm = 31.00002*0 / (4*0.6250*(31.0000 + 0.6250)) = 0

scb = (6 / 0.62502)*537,520.6250*[0.4088843*1.111

361E-05*0 - 6*((1 - 0.3208870) / 12,072,047)*(26.2500 / 3.62503)*(1 + 3.6250*0.4088843 / 2)*(7,540.5718 +

(26.25002 / 32)*(846.36 - 0))] =

-68,891 New

Load

case 2

sc = ABS(0) + ABS(-68,891) = 68,891

51,300 68,400 Yes

Codeware, Inc. Reference Documents


Section 5: Reference Documents 1. 2004 ASME Boiler and Pressure Vessel Code, A06 Edition 2. 2004 ASME Boiler and Pressure Vessel Code Section 8 Division 1: Self Directed Interactive CD-ROM Training Program 3. Codeware’s Quality Manual 4. Codeware’s Quality Plan 5. ISO 9001:2000, Quality management systems – Requirements 6. ISO/TR 10013, Guidelines for quality management system documentation 7. ISO 19011, Guidelines for quality and/or environmental management systems auditing 8. ISO/IEC 90003, Software engineering – Guidelines for the application of ISO: 9001:2000 to computer software 9. Taylor Forge Bulletin 502 Edition VII