SYSTECH CONSULTANCY SERVICES, 21 & 22 AASRA APTS., ST. ANTHONY STREET, VAKOLA, SANTACRUZ (E), MUMBAI - 400 055.

PHONE: 91-22-2667-4506 or 2667-4787, FAX: 91-22-2667-2737, E-MAIL: systech@bom4.vsnl.net.in

REFERENCE SYSTECH CONSULTANCY SERVICES PAGE
SCS/RFPAD 1

Technical Basis for Reinforcing Pads Requirements on Nozzles

All equipment nozzles of following equipments for Reciprocating Compressor Services will require Reinforcing Pads
(R. F. Pads) on cylindrical Shell or D'end to have safe local stresses:
- Heat Exchangers (Inter Coolers / After Coolers)
- Separators
- Volume Bottles
- Suction Filters
- Discharge Dryer Vessels

Reinforcing pads of matching material and thickness are required for controlling Stress Intensification Factor (SIF) and
avoiding fatigue failure under dynamic loading (mechanical) even though ASME section VIII, Div. 1, may not need it
for internal pressure design.

Higher the SIF, higher the dynamic stress and higher the likely hood of fatigue failure due to pulsating loads.

For example 6"S40 pipe nozzle to inter cooler / volume bottle / separator shell of 12"S30 will have following SIF:

Without R.F. Pad Out of Plane (max) SIF value =6.37
With matching R.F. Pad Out of Plane (max) SIF value =3.24.

Hence, with matching R.F. Pad, SIF reduces by 51%.

Hence, we recommend R.F. Pads on all equipment nozzles for Reciprocating Compressors and so also SWRI and
others.

Small size fittings / valves on volume bottles must be rigidly fixed. Provide gussets (minimum 4 numbers) to avoid
cracks and failures.

1. IPCL (1985):
Computer Aided Piping Stress Services and analog study for 2 Nos. 'Linde' Reciprocating Oxygen
Compressors PC1 and PC2 installed in Integrated Offsites Plant [Model: 1VK 160-2P, Cylinders= 2,
Discharge Pressure=28 Kg/cm2, RPM=735].
For this study done by us for IPCL, Baroda to reduce vibration and frequent failures, we have come across
failure of cooling water inlet / outlet nozzles of intercoolers which were not provided with reinforcing pads prior
to our recommending R. F. Pads. After implementation of our recommendations, failure of nozzles on
Intercooler was eliminated.

2. RIL KURKUMBH (2005):
Computer Aided Acoustical Pulsation and Mechanical Manifold Analysis for Sulzer Ethylene Gas Mixture
Compressor [Model: 4K165-2E, Cylinders=4, Discharge Pressure=25.5 Kg/cm2, HP =1006, RPM=750].
Small bore PSV connection failures were observed [e.g. N3/1-150#Sch. 40 Vent on Separator 1st Stage
Suction. After implementation of our recommendations, failure of nozzle was eliminated.

3. India Glycols Ltd. [2007]:
Computer Aided Engineering Analysis and Pulsation Study for C-420 F Reclaim Compressor, Dresser Rand
Model No. (2) 23.5 & 18.5 & 11 x 10 4HHE FB3 NL2. Cracks / failures on 3rd stage discharge volume bottle
nozzles and small bore connections were observed due to fatigue failure resulting from high stress
concentration.

Hence our analysis +experience suggests R.F. Pads.

We hope you can make R. F. Pads as standard requirement to your equipment vendors (heat exchangers /
separators / volume bottles / Suction Filters) of reciprocating compressor.