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CademPVD by CADEM Softwares

Most value for money software for the mechanical design of process equipment
Trial version available on our website www.cadem.in

Pressure Vessels
Reaction Vessels
Agitator Shafts
Heat Exchangers
Process Columns
Storage Tank
Floating Roof
Chimney

ASME Sec. VIII Div. 1


TEMA
EEUA
IS 2825
EN 13445
API 650
API 620
IS 6533

28 years of equipment design experience captured, polished, compacted and is now ready for transfer to
designers, fabricators and plant engineers

Intelligent, works with minimum inputs


For instance, in case of say a body flange, the software automatically evaluates optimum configuration of
all undefined parameters: Flange OD, Flange ID, PCD, Number and Size of bolts, Gasket OD & ID, etc.
meeting the requirements of the specified equipment design code.

Generates final design at estimation stage, saves more than 80% of your design & estimation time

Earn more as you save on costing and quotation making time

High quality documentation with all formulae and relevant code clauses

Most importantly, the user need not be a hard core designer

CADEM Softwares
Enhancing your business strengths and design capabilities.
Website:

www.cadem.in

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EXAMPLE NO. PC-01


DESIGN OF
REACTION VESSEL WITH AGITATOR SHAFT

This example covers design of a Reaction Vessel with Agitator Shaft.


This reaction vessel has dishes at the top and bottom ends. The jacketing is of plain
shell type, partially covering the main shell and extending on to the bottom dished end.
It has an agitator, with say 20 HP power and the agitator shaft RPM is 100. All the
components in contact with the internal process liquid are of SS 316 and the jacketing is
of SS 304.

NOTE:
1) Link to youtube video of this design:
https://www.youtube.com/watch?v=Szl9AE_d4pQ&list=PLPL8SPZUxm-mFqQZceyhr13QYDEruelJx&index=6
2) As you can see in the video, the inbuilt intelligence in the software generates maximum information by
itself.
Eg: For a body flange, the software evaluates all the undefined parameters Flange OD, Flange ID, PCD,
Number and Size of bolts, Gasket OD & ID, etc. meeting the requirements of specified equipment design
code.
3) In case of any changes to the interconnected shell geometry and / or design conditions (pressure /
temperature) including material of constructions, these dimensions are automatically regenerated by the
software to meet the new requirements.
4) The software can generate cost estimation and BOM in Excel.

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date


Index

/ R00 , 06-04-2015 19:23:54

Sr. No.

Description

Title page & equipment info

Design data

Material of constructions

Effective Pressures

Weight summary report

Wind load calculations

Seismic load calculations

Design of Dished End (Front)

Design of Closure Flng (Front)

10

Design of Closure Flng (Front)

11

Design of Shell Flng (Front)

12

Design of Shell Flng (Front)

13

Design of Main Shell

14

Design of Dished End (Rear)

15

Design of Jacket Closure (Top)

16

Design of Jacket Shell

17

Design of Jacket Dish (Bottom)

18

Design of Lug Support

19

Design of Lug Support

20

Design of Shaft

21

Design of Impeller (1)

22

Design of Lifting Lugs

23

Foundation load data

24

C.G. Data

Page No

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Customer
ABC Company Ltd.
Project

Soap Plant

Location

Vapi Site

Plant
EQUIPMENT INFORMATION :
Design Code

Refrigeration Plant

Equipment Name

Reactor R101

Equipment Type

Reaction Vessel

Equipment Class

N.A.

Equipment Category

N.A.

Reference Drawing No

---

Service

Chemical Services

Support Type
DESIGN & REVIEWAL :

Lug Supports

ASME VIII Div.1, 10 A11

Designed By
Design Date

06-04-2015 19:23:54

Checked By
Approved By
Revision
INSPECTION & APPROVAL :
Inspection Agency

R00

Reviewed By
EQUIPMENT DATA :

---

Front end

Dished End

Front end flanged

True

Rear end

Dished End

Rear end flanged

False

Shell ID

1600 mm

Shell OD

1628 mm

Length, Shell (W.L. to W.L) / Overall


JACKETING DATA :
Jacketing system

2400 / 3338.3 mm

Jacket type
AGITATOR DATA :

Plain Jacket

Power

20 hp (MKS)

RPM

100

Duty Factor

Diameter of shaft

101 mm

Free Length of shaft

3738.3 mm

No of impellers

Propped
OTHER DATA :
Fabricated weight

---

Shell & Bottom End

True
5065.2 kgf

Empty weight + external weights

5065.2 kgf

Estimated operating weight

11231.4 kgf

Estimated hydrotest weight

10964.4 kgf

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date

/ R00 , 06-04-2015 19:23:54

REACTION VESSEL DESIGN DATA


SHELL

SIDE

(1) PROCESS DETAILS :


MEDIA

JACKET
DENSITY

MEDIA

DENSITY

kg/m
Operating

Process

980

Design1

SIDE

kg/m
Steam

1.5

1000

1000

Design2
Startup
Shutdown
Upset
Hydrotest

Water

1000

Water

Pneumatic

Process

1.2

Steam

(2) PR. : kgf/mm g

INT.

EXT.

1000
1.2

INT.

EXT.

Input Pr

MAWP

Input Pr

Input Pr

MAWP

Input Pr

Operating

0.06

0.06

0.01055

0.04

0.04

0.01055

Design1

0.08

0.08

0.01055

0.05

0.05

0.01055

Design2
Startup
Shutdown
Upset
(3) TEST PR. : kgf/mm g
Hydrotest

Based on

Based on

Input Pr

MAWP

MAP

Input Pr

MAWP

MAP

0.106

0.106

0.106

0.07085

0.07085

0.07085

0.08976

0.08976

0.05995

0.05995

0.05995

MDMT.

MAX.

MDMT.

MAX

Pneumatic
0.08976
(4) TEMPERATURE : C
MIN.

MIN.

Operating

20

120

20

150

Design1

10

180

10

200

21.67

50

21.67

50

50

21.67

Design2
Startup
Shutdown
Upset
Hydrotest

Pneumatic
21.67
(5) ALLOWANCES : mm
INT.

EXT.

Corrosion

Polishing
0
(6) RADIOGRAPHY & JOINT EFFICIENCY :
JOINT
RADIOGRAPHY
EFFICIENCY

INT.

EXT.

0
RADIOGRAPHY

JOINT
EFFICIENCY

Shell

Spot + T Joints

0.85

Spot + T Joints

0.85

Head

Full

1.00

Full

1.00

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date


REACTION VESSEL DESIGN DATA
1. MATERIAL OF CONSTRUCTION :

/ R00 , 06-04-2015 19:23:54

Shell side

Jacket side

Shell / Channel

SA-240 GR. 316 Plt. [UNS:S31600]

SA-240 GR. 304 Plt. [UNS:S30400]

Head

SA-240 GR. 316 Plt. [UNS:S31600]

SA-240 GR. 304 Plt. [UNS:S30400]

Body flange

SA-240 GR. 316 Plt. [UNS:S31600]

SA-240 GR. 304 Plt. [UNS:S30400]

Body flange cover

SA-240 GR. 316 Plt. [UNS:S31600]

SA-240 GR. 304 Plt. [UNS:S30400]

Shell side

Jacket side

Nozzle neck <= NPS 40

SA-312 GR. TP316 Smls. Pipe


[UNS:S31600]

SA-312 GR. TP304 Smls. Pipe


[UNS:S30400]

Flange

SA-240 GR. 316 Plt. [UNS:S31600]

SA-240 GR. 304 Plt. [UNS:S30400]

Cover flange

SA-240 GR. 316 Plt. [UNS:S31600]

SA-240 GR. 304 Plt. [UNS:S30400]

Nozzle NPS > 40 & < 200

SA-312 GR. TP316 Smls. Pipe


[UNS:S31600]

SA-312 GR. TP304 Smls. Pipe


[UNS:S30400]

Flange

SA-240 GR. 316 Plt. [UNS:S31600]

SA-240 GR. 304 Plt. [UNS:S30400]

Cover flange

SA-240 GR. 316 Plt. [UNS:S31600]

SA-240 GR. 304 Plt. [UNS:S30400]

Nozzle neck >= NPS 200

SA-240 GR. 316 Plt. [UNS:S31600]

SA-240 GR. 304 Plt. [UNS:S30400]

Flange

SA-240 GR. 316 Plt. [UNS:S31600]

SA-240 GR. 304 Plt. [UNS:S30400]

Cover flange

SA-240 GR. 316 Plt. [UNS:S31600]

SA-240 GR. 304 Plt. [UNS:S30400]

Pad flange

SA-240 GR. 316 Plt. [UNS:S31600]

SA-240 GR. 304 Plt. [UNS:S30400]

Pad flange cover

SA-240 GR. 316 Plt. [UNS:S31600]

SA-240 GR. 304 Plt. [UNS:S30400]

Manhole flange

SA-240 GR. 316 Plt. [UNS:S31600]

SA-240 GR. 304 Plt. [UNS:S30400]

Manhole cover

SA-240 GR. 316 Plt. [UNS:S31600]

SA-240 GR. 304 Plt. [UNS:S30400]

Reinforcement pad

SA-240 GR. 316 Plt. [UNS:S31600]

SA-240 GR. 304 Plt. [UNS:S30400]

External bolt

SA-193 GR. B7 Bolt [UNS:G41400]

SA-193 GR. B7 Bolt [UNS:G41400]

External gasket

Spiral metal wound CAF filled (S.S.)

CAF with suitable binder (3 mm.)

Stiffener

SA-240 GR. 316 Plt. [UNS:S31600]

SA-240 GR. 304 Plt. [UNS:S30400]

Lifting lug

IS-2062 GR. A Plt.

IS-2062 GR. A Plt.

Support

IS-2062 GR. A Plt.

IS-2062 GR. A Plt.

Anchor bolt
3. AGITATOR:
Shaft

SA-36 / IS-1363,67 Bolt [UNS:K02600]

SA-36 / IS-1363,67 Bolt [UNS:K02600]

Impeller

SA-240 GR. 316 Plt. [UNS:S31600]

Internal coupling

SA-479 GR. 316 Bar [UNS:S31600]

Housing

SA-479 GR. 316 Bar [UNS:S31600]

Liner
2. NOZZLE CONNECTIONS :

SA-479 GR. 316 Bar [UNS:S31600]

Housing cover
SA-240 GR. 316 Plt. [UNS:S31600]
4. INSULATION & CLADDING:
Mat. / Density / Thk.
Rockwool (Mineral Fibre) / 136.2 kg/m / 60 mm
Mat. / Thk.

Al. sheet / 1.191 mm

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date


/ R00 , 06-04-2015 19:23:54
SUMMARY OF EFFECTIVE DESIGN PRESSURES IN kgf/mm g VS TEMPERATURE IN C
Sr.

Item name

Temp.

No.

Inside pr.
+ve

Liquid pr.

-ve

Effective pr.
+ve

-ve

Dished End (Front)

180

0.08

0.01055

0.08

0.01055

Closure Flng (Front)

180

0.08

0.01055

0.08

0.01055

Shell Flng (Front)

180

0.08

0.01055

0.08

0.01055

Main Shell

180

0.08

0.01055

0.09055

0.06055

Dished End (Rear)

180

0.08

0.01055

0.08

0.01055

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date


ITEM WISE WEIGHT SUMMARY

/ R00 , 06-04-2015 19:23:54

Sr.No.

Item name

Item size

Empty
wt

Volume

Filled wt

kgf

kgf

Dished End (Front)

Torispherical End CR = 1440,


KR = 272, 8 Nom / 7.2 Min
Thk, SF = 50

216.5

0.607

823.5

Closure Flng (Front)

Plate Ring - 1786 OD x 1619


ID x 1729 PCD, RF, 154.681
Thk, Trgv = 1.588

546.9

546.9

Shell Flng (Front)

Plate Ring - 1786 OD x 1631


ID x 1729 PCD, RF, 158.474
Thk, Trgv = 1.588

522.1

522.1

Gasket Flng (Front)

1695.2 OD x 1631 ID, 4.763


Thk

0.1

0.1

Bolt Flng (Front)

Hex Head Bolt M24 x 354.18


Lg, 68 Nos.

86.25

86.25

Main Shell

1628 OD x 14 Thk, 2400 Lg

1362.9

4.825

6188.4

Dished End (Rear)

Torispherical End CR = 1440,


KR = 272, 8 Nom / 7.2 Min
Thk, SF = 50

216.5

0.607

823.5

Jacket Closure (Top)

5296 Long x 111 Wide x 18


Thk

84.65

84.65

Jacket Shell

1744 OD x 8 Thk, 1850 Lg

645.7

0.122

767.6

10

Jacket Dish (Bottom)

Torispherical End CR = 1728,


KR = 175, 8 Nom / 7.2 Min
Thk, SF = 50

222.2

222.2

11

Gusset Plate

220 Long x 240 Wide x 16


Thk, 4 Nos.

26.75

26.75

12

Anchor Bolt

Anchor M20 x 200 Lg, 8 Nos.

3.979

3.979

13

Support Pad

330 Long x 300 Wide x 14


Thk, 4 Nos.

44.35

44.35

14

Motor

20 HP x 1450 RPM

200

200

15

Gear Box

20 HP x 14.5 Red. Ratio

200

200

16

Coupling

Flexible Coupled B5

28.38

28.38

17

Bearing Housing

222 OD x 43 Thk, 325 Lg

62.87

0.00472

67.59

18

Top Bearing

SKF Taper Roller 30216

0.163

0.163

19

Bottom Bearing

SKF Taper Roller 30217

0.209

0.209

20

Shaft Seal

Gland Packing

10

10

21

Shaft

101 OD x 4438.311 Lg

284.5

284.5

22

Impeller (1)

Propeller, Sweep Dia Propeller


x 4 Blades

27

27

23

Lifting Lugs

135 Long x 77 Wide x 28 Thk,


2 Nos.

4.608

4.608

24

Pad (Lifting Lugs)

70 Long x 180 Wide x 8 Thk, 2


Nos.

1.613

1.613

25

Insulation

5805.663 W x 5411.911 L, 60
Thk

256.7

256.7

26

Cladding

5809.404 W x 5411.911 L,
1.191 Thk

10.36

10.36

27
28
29

30

5065.2

10964.4

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date

/ R00 , 06-04-2015 19:23:54

WIND LOAD CALCULATION


CODE
1. DESIGN CONDITIONS ( Design Mode 1 , Uncorroded Condition ) :
Basic wind speed
( Section 5.2 )
Vb

Wind [IS:875, 87]

Expected life of equipment

( Section 5.3.1 )

25 Years

Probability factor (Risk coeff)

( Section 5.3.1 )

Terrain category

K1

( Section 5.3.2 )

Structure class

( Section 5.3.3 )

Force coefficient (Shape factor)


3. CALCULATION OF FORCES AND MOMENTS:

0.902
Category 2

( Section 5.3.2.2 )

Topography factor

50 m/s

Class B
K3

1.3

Cf

0.8

Equivalent diameter

De

2408 mm

Overall length of equipment

3338.3 mm

Height of C.G. of equipment

Hcg

1804.4 mm

K2

0.98

8038652.8 mm

Vz

57.44 m/s

Pz

0.0002 kgf/mm

Size and height factor

( Section 5.3.2 )

Effective transverse cross sectional area


= De x L
Effective wind speed
= K1 x K2 x K3 x Vb
Wind pressure
= 6E-08 x Vz

Longitudinal force
= Cf x A x Pz
Support elevation

1273.2 kgf

456.2 mm

1716622.5 kgf-mm

Turning moment
= F x ( Hcg - H )

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date

/ R00 , 06-04-2015 19:23:54

SEISMIC LOAD CALCULATION


CODE
1. DESIGN CONDITIONS ( Design Mode 1 , Uncorroded Condition ) :
Weight of equipment
Wo

Seismic [IS:1893, 02]

Importance factor

1.5

( Table-6 , 2002 )

11231.4 kgf

Soil profile type

Stiff Soil Profile (SD)

Foundation type

RCC footings + Tie Beams

Damping factor

Seismic zone

Zone III

Seismic zone factor

( Table-2 , 2002 )

0.16

Response reduction factor

( Table-7 , 2002 )

2.9

Sa / g

2.5, Use max value

Cf

Ah

0.103

Spectral accelerations coeff.


Damping correction factor
Seismic coefficient

( Fig. 2 , 2002 )
( Table-3 , 2002 )

( Clause-6.4.2 , 2002 )

= 0.5 x Z x I x Cf x ( Sa / g ) x ( 1 / R )
= 0.5 x 0.16 x 1.5 x 1 x
2.5 x ( 1 / 2.9 )
2. CALCULATION OF FORCES AND MOMENTS:
Elevation of support

456.2 mm

Height of C.G. of equipment

Hcg

1804.4 mm

Vb

1161.9 kgf

1566464.3 kgf-mm

Seismic base shear force


= Ah x Wo
= 0.103 x 11231.4
Seismic moment of support
= Vb x ( Hcg - H )
= 1161.9 x ( 1804.4 - 456.2 )

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date

/ R00 , 06-04-2015 19:23:54

DESIGN OF TORISPHERICAL HEAD ( INT. & EXT. PRESSURE )

Dished End (Front)

CODE
1. DESIGN CONDITIONS ( Design Mode 1 , Uncorroded Condition ) :
Design pressure ( internal )
Pi

ASME VIII Div.1, 10 A11

Design pressure ( external )

Pe

0.01055 kgf/mm g

Design temperature

180 C

13.79 kgf/mm

Material of construction
Max. allowable stress @ design temp.

0.08 kgf/mm g

SA-240 GR. 316 Plt. [UNS:S31600]

Radiography

Full

Joint efficiency

Outside diameter of head

OD

1616 mm

Crown radius

CR

1440 mm

Knuckle radius

KR

272 mm

Nominal thickness

8 mm

Nominal thickness required as per TEMA

N.A mm

Internal allowance, corrosion + polishing

0 mm

External allowance, corrosion + polishing

0 mm

Thinning allowance / Under tolerance

0.8 mm

Available thickness
2. DESIGN CALCULATION AS PER UG 32 e / APPENDIX 1-4 ( d ) :
Factor [M]
= ( 1 / 4 ) x [ 3 + SQRT [ CR / KR ] ]
= ( 1 / 4 ) x [ 3 + SQRT [ 1440 / 272 ] ]
= 1.325
Thickness for internal pressure [t]
= M x Pi x CR / ( 2 x S x E - 0.2 x Pi )
= 1.325 x 0.08 x 1440 / ( 2 x 13.79 x 1 - 0.2 x 0.08 )
= 5.54 mm
3. DESIGN CALCULATION AS PER UG 33 e :
Thickness for equivalent external pressure [t]
= M x 1.67 x Pe x CR / ( 2 x S x 1.0 - 0.2 x 1.67 x Pe )
= 1.325 x 1.67 x 0.01055 x 1440 / ( 2 x 13.79 x 1.0 - 0.2 x 1.67 x 0.01055 )
= 1.219 mm
Assumed head thickness, [te]
= 4.454 mm
Assumed outside crown radius, [CRo]
= 1448 mm
Factor [A]
= 0.125 x te / CRo
= 0.125 x 4.454 / 1448
= 0.00038
Factor with reference to chart (HA-2) [B]
= 3.455 kgf/mm
Allowable external pressure [Pa]
= B x te / CRo
= 3.455 x 4.454 / 1448
= 0.01063 kgf/mm
Since Pa > Pe, design is safe
Since available thickness is more than design thickness, design is safe.

7.2 mm

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date

/ R00 , 06-04-2015 19:23:54

FLANGE DESIGN ( INTERNAL )

Closure Flng (Front)

CODE
1. DESIGN CONDITIONS ( Design Mode 1 , Uncorroded Condition ) :
Design pressure
P

ASME VIII Div.1, 10 A11

Design temperature

180 C

Allowance

CA

0 mm

Groove allowance
2. FLANGE DATA :
M.O.C.

Tg

1.588 mm

Code allw. stress @ design temp.

Sfo

10.46 kgf/mm

0.08 kgf/mm g

SA-240 GR. 316 Plt. [UNS:S31600]

Code allw. stress @ atm. temp.

Sfa

14.06 kgf/mm

Inside diameter

1619 mm

Outside diameter

1786 mm

Hub length

0 mm

Thickness ( hub end )

g1

0 mm

Thickness ( pipe end )

g0

0 mm

Thickness provided

154.7 mm

Thickness available
3. BOLTING DATA :
M.O.C.

153.1 mm
SA-193 GR. B7 Bolt [UNS:G41400]

Code allw. stress @ design temp.

Sb

17.58 kgf/mm

Code allw. stress @ atm. temp.

Sa

17.58 kgf/mm

Bolt PCD

1729 mm

Bolt dia.

db

24 mm

No. of bolts
4. LINER DATA :

nb

68

M.O.C.
Liner ID

mm

Liner OD

mm

Liner thk.
5. GASKET DATA :
5a. Flange gasket data :
M.O.C.

mm

Gasket type

Ring Gasket

Gasket confinement type

Unconfined

Flange face type

Raised Face

Flange gakset surface finish

Serrated (Normal)

Counter flange face type

Raised Face

Counter gakset surface finish

Serrated (Normal)

Applicalbe gasket sketch in Table 2-5.2

Type 1B

Spiral metal wound CAF filled (S.S.)

Applicable gasket column in Table 2-5.2


Gasket seating stress

( refer to Note 1, Table 2-5.1 )

Gasket factor

( from Table 2-5.1 )

Inside diameter
Outside diameter

1
y

7.031 kgf/mm

Gi

1631 mm

Go

1695.2 mm

Width of gasket

( as per Table 2-5.2 )

32.1 mm

Width of gasket

( as per Table 2-5.2 )

32.1 mm

Width of raised face or gasket contact width

38.1 mm

( as per Table 2-5.2 )


Basic gasket seating width

( as per Table 2-5.2 )

b0

16.05 mm

Effective gasket width

( as per Table 2-5.2 )

10.1 mm

1675 mm

Dia. at load reaction


( see Table 2-5.2 )
5b. Partition groove gasket data (For H.E. body flange) :
M.O.C.

--

Gasket seating stress

( refer to Note 1, Table 2-5.1 )

Gasket factor

( from Table 2-5.1 )

y'

0 kgf/mm

m'

Pass partition gasket width

Wp

0 mm

Pass partition gasket length

Lp

0 mm

Effective pass partition gasket width


b'
0 mm
6. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b1)
Total joint - contact surface compression load [Hp]
= 2 x ( x b x G x m + b' x Lp x m' ) x P
= 2 x ( x 10.1 x 1675 x 3 + 0 x 0 x 0 ) x 0.08
= 25499.6 kgf
Total hydrostatic end force [H]
= 0.25 x x G x P
= 0.25 x x 1675 x 0.08
= 176284.5 kgf
Minimum required bolt load for operating condition [Wm1a]
= Hp + H
= 25499.6 + 176284.5
= 201784.1 kgf
Minimum required bolt load for operating condition [Wm1b]
( from mating flange )
= 201784.1 kgf
Governing bolt load for operating condition [Wm1]
= MAX [ Wm1a , Wm1b ]
= MAX [ 201784.1 , 201784.1 ]
= 201784.1 kgf
7. BOLT LOAD CALCULATION AS PER APPENDIX 2-5 (b2)
Minimum required bolt load for gasket seating [Wm2]
= ( x b x G x y + b' x Lp x y' )
= ( x 10.1 x 1675 x 7.031 + 0 x 0 x 0 )
= 373499.5 kgf
8. BOLT AREAS AS PER APPENDIX 2-5 (d)
Total required cross-sectional area of bolts [Am]
= MAX [ Wm2 / Sa , Wm1 / Sb ] ........ For Internal '+' Pr Design
= Wm2 / Sa ..................................... For External Pr & Self Sealing Design
= 21249.6 mm
Actual bolt area using root diameter [Ab]
= 21266.9 mm
Flange design bolt load for the gasket seating [W]
= 0.5 x ( Am + Ab ) x Sa x 1 .................... average bolt area
= Ab x Sa x 1 ..........................................full bolt area
= 373650.9 kgf ( Avg. bolt area and margin factor of 1 )
9. CHECK FOR GASKET CRUSHING
Minimum gasket width required [Nmin]
= Ab x Sb / ( 2 x x y x G )
= 21266.9 x 17.58 / ( 2 x x 7.031 x 1675 )
= 5.052 mm
10. BOLT SPACING CORRECTION FACTOR
As per Brownell & Young or IS 2825,
= SQRT [ Bolt spacing / ( 2 x db + t ) ]
As per TEMA or BS 5500,
= SQRT [ Bolt spacing / Bmax ] ................... where,
Bmax = maximum recommended bolt spacing = 2 x db + 6 x t / ( m + 0.5 )
Brownell & Young, Cf = 1 ( min. equal to 1 )
RING FLANGE DESIGN
Closure Flng (Front)
11. LOADS AND FORCES DURING OPERATING CONDITION AS PER APPENDIX 2-3
Hydrostatic end force on area inside of flange [HD]
= 0.25 x x B 2 x P
= 0.25 x x 1619 2 x 0.08
= 164692.4 kgf
Gasket load (difference between flange design bolt load and total hydrostatic end force) [HG]
= Wm1 - H
= 201784.1 - 176284.5
= 25499.6 kgf
Difference between total hydrostatic end force and hydrostatic end force on area inside of flange [HT]
= H - HD
= 176284.5 - 164692.4
= 11592.1 kgf
12. MOMENT ARMS FOR FLANGE LOADS AS PER TABLE 2-6
Radial distance from the bolt circle to intersection of hub and back of flange, as per Appendix 2-3 [R]
= 0.5 x ( C - B ) - g1
= 0.5 x ( 1729 - 1619 ) - 0

= 55
Radial distance from the bolt circle to the circle on which HD acts [hD]
= R + 0.5 x g1
= 55 + 0.5 x 0
= 55 mm
Radial distance from gasket load reaction to the bolt circle [hG]
= 0.5 x ( C - G )
= 0.5 x ( 1729 - 1675 )
= 27 mm
Radial distance from the bolt circle to the circle on which HT acts [hT]
= 0.5 x ( R + g1 + hG )
= 0.5 x ( 55 + 0 + 27 )
= 41 mm
13. FLANGE MOMENTS UNDER OPERATING CONDITION AS PER APPENDIX 2-6
Component of moment due to HD [MD]
= HD x hD
= 164692.4 x 55
= 9058082.2 kgf-mm
Component of moment due to HG [MG]
= HG x hG
= 25499.6 x 27
= 688371.3 kgf-mm
Component of moment due to HT [MT]
= HT x hT
= 11592.1 x 41
= 475251.3 kgf-mm
Total moment acting on the flange for operating condition [MO]
= MD + MG + MT
= 9058082.2 + 688371.3 + 475251.3
= 10221704.8 kgf-mm
14. LOADS AND FORCES DURING GASKET SEATING AS PER APPENDIX 2-3
Gasket load for seating condition [HG]
=W
= 373650.9 kgf
15. MOMENT UNDER GASKET SEATING AS PER APPENDIX 2-6
Total moment acting on the flange for gasket seating [MO']
= W x hG
= 373650.9 x 27
= 10086863.4 kgf-mm
16. SHAPE CONSTANTS
Factor [K]
=A/B
= 1786 / 1619
= 1.103
Flange factor from Fig. 2-7.1 [Y]
= 19.74
17. FLANGE THICKNESS REQUIRED AS PER APPENDIX 2-7
Equivalent moment [Mmax]
= MAX [ MO , MO' x Sfo / Sfa ]
= MAX [ 10221704.8 , 10086863.4 x 10.46 / 14.06 ]
= 10221704.8 kgf-mm
Corrected equivalent moment per unit length [M]
= Mmax x Cf / B
= 10221704.8 x 1 / 1619
= 6313.6 kgf
Required thickness of flange [t]
= SQRT [ M x Y / Sfo ]
= SQRT [ 6313.6 x 19.74 / 10.46 ]
= 109.2 mm
18. FLANGE RIGIDITY CHECKING AS PER APPENDIX 2-14
Assumed flange thickness
tr
144.8 mm
Modulus of elasticity for flange

Efo

18786 kgf/mm

Rigidity factor
Rigidity index [J]
= 109.4 x Mmax / ( Efo x tr 3 x KL x ln ( K ) )
= 109.4 x 10221704.8 / ( 18786 x 144.8 3 x 0.2 x ln ( 1.103 ) )
= 0.999
Since J < 1.0, design is safe

KL

0.2

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date

/ R00 , 06-04-2015 19:23:54

FLANGE DESIGN ( EXTERNAL )

Closure Flng (Front)

CODE
1. DESIGN CONDITIONS ( Design Mode 1 , Uncorroded Condition ) :
Design pressure
P

ASME VIII Div.1, 10 A11

Design temperature

180 C

Allowance

CA

0 mm

Groove allowance
2. FLANGE DATA :
M.O.C.

Tg

1.588 mm

Code allw. stress @ design temp.

Sfo

10.46 kgf/mm

0.01055 kgf/mm g

SA-240 GR. 316 Plt. [UNS:S31600]

Code allw. stress @ atm. temp.

Sfa

14.06 kgf/mm

Inside diameter

1619 mm

Outside diameter

1786 mm

Hub length

0 mm

Thickness ( hub end )

g1

0 mm

Thickness ( pipe end )

g0

0 mm

Thickness provided

154.7 mm

Thickness available
3. BOLTING DATA :
M.O.C.

153.1 mm
SA-193 GR. B7 Bolt [UNS:G41400]

Code allw. stress @ design temp.

Sb

17.58 kgf/mm

Code allw. stress @ atm. temp.

Sa

17.58 kgf/mm

Bolt PCD

1729 mm

Bolt dia.

db

24 mm

No. of bolts
4. LINER DATA :

nb

68

M.O.C.
Liner ID

mm

Liner OD

mm

Liner thk.
5. GASKET DATA :
5a. Flange gasket data :
M.O.C.

mm

Gasket type

Ring Gasket

Gasket confinement type

Unconfined

Flange face type

Raised Face

Flange gakset surface finish

Serrated (Normal)

Counter flange face type

Raised Face

Counter gakset surface finish

Serrated (Normal)

Applicalbe gasket sketch in Table 2-5.2

Type 1B

Spiral metal wound CAF filled (S.S.)

Applicable gasket column in Table 2-5.2


Gasket seating stress

( refer to Note 1, Table 2-5.1 )

Gasket factor

( from Table 2-5.1 )

Inside diameter
Outside diameter

1
y

7.031 kgf/mm

Gi

1631 mm

Go

1695.2 mm

Width of gasket

( as per Table 2-5.2 )

32.1 mm

Width of gasket

( as per Table 2-5.2 )

32.1 mm

Width of raised face or gasket contact width

38.1 mm

( as per Table 2-5.2 )


Basic gasket seating width

( as per Table 2-5.2 )

b0

16.05 mm

Effective gasket width

( as per Table 2-5.2 )

10.1 mm

1675 mm

Dia. at load reaction


( see Table 2-5.2 )
5b. Partition groove gasket data (For H.E. body flange) :
M.O.C.

--

Gasket seating stress

( refer to Note 1, Table 2-5.1 )

Gasket factor

( from Table 2-5.1 )

y'

0 kgf/mm

m'

Pass partition gasket width

Wp

0 mm

Pass partition gasket length

Lp

0 mm

Effective pass partition gasket width


b'
0 mm
6. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b1)
Total joint - contact surface compression load [Hp]
= 2 x ( x b x G x m + b' x Lp x m' ) x P
= 2 x ( x 10.1 x 1675 x 3 + 0 x 0 x 0 ) x 0.01055
= 3361.6 kgf
Total hydrostatic end force [H]
= 0.25 x x G x P
= 0.25 x x 1675 x 0.01055
= 23239.4 kgf
Minimum required bolt load for operating condition [Wm1a]
= Hp + H
= 3361.6 + 23239.4
= 26600.9 kgf
Minimum required bolt load for operating condition [Wm1b]
( from mating flange )
= 26600.9 kgf
Governing bolt load for operating condition [Wm1]
= MAX [ Wm1a , Wm1b ]
= MAX [ 26600.9 , 26600.9 ]
= 26600.9 kgf
7. BOLT LOAD CALCULATION AS PER APPENDIX 2-5 (b2)
Minimum required bolt load for gasket seating [Wm2]
= ( x b x G x y + b' x Lp x y' )
= ( x 10.1 x 1675 x 7.031 + 0 x 0 x 0 )
= 373499.5 kgf
8. BOLT AREAS AS PER APPENDIX 2-5 (d)
Total required cross-sectional area of bolts [Am]
= MAX [ Wm2 / Sa , Wm1 / Sb ] ........ For Internal '+' Pr Design
= Wm2 / Sa ..................................... For External Pr & Self Sealing Design
= 21249.6 mm
Actual bolt area using root diameter [Ab]
= 21266.9 mm
Flange design bolt load for the gasket seating [W]
= 0.5 x ( Am + Ab ) x Sa x 1 .................... average bolt area
= Ab x Sa x 1 ..........................................full bolt area
= 373650.9 kgf ( Avg. bolt area and margin factor of 1 )
9. CHECK FOR GASKET CRUSHING
Minimum gasket width required [Nmin]
= Ab x Sb / ( 2 x x y x G )
= 21266.9 x 17.58 / ( 2 x x 7.031 x 1675 )
= 5.052 mm
10. BOLT SPACING CORRECTION FACTOR
As per Brownell & Young or IS 2825,
= SQRT [ Bolt spacing / ( 2 x db + t ) ]
As per TEMA or BS 5500,
= SQRT [ Bolt spacing / Bmax ] ................... where,
Bmax = maximum recommended bolt spacing = 2 x db + 6 x t / ( m + 0.5 )
Brownell & Young, Cf = 1 ( min. equal to 1 )
RING FLANGE DESIGN
Closure Flng (Front)
11. LOADS AND FORCES DURING OPERATING CONDITION AS PER APPENDIX 2-3
Hydrostatic end force on area inside of flange [HD]
= 0.25 x x B 2 x P
= 0.25 x x 1619 2 x 0.01055
= 21711.2 kgf
Difference between total hydrostatic end force and hydrostatic end force on area inside of flange [HT]
= H - HD
= 23239.4 - 21711.2
= 1528.2 kgf
12. MOMENT ARMS FOR FLANGE LOADS AS PER TABLE 2-6
Radial distance from the bolt circle to intersection of hub and back of flange, as per Appendix 2-3 [R]
= 0.5 x ( C - B ) - g1
= 0.5 x ( 1729 - 1619 ) - 0
= 55
Radial distance from the bolt circle to the circle on which HD acts [hD]
= R + 0.5 x g1
= 55 + 0.5 x 0

= 55 mm
Radial distance from gasket load reaction to the bolt circle [hG]
= 0.5 x ( C - G )
= 0.5 x ( 1729 - 1675 )
= 27 mm
Radial distance from the bolt circle to the circle on which HT acts [hT]
= 0.5 x ( R + g1 + hG )
= 0.5 x ( 55 + 0 + 27 )
= 41 mm
13. FLANGE MOMENTS UNDER OPERATING CONDITION AS PER APPENDIX 2-6
Component of moment due to HD [MD]
= HD x ( hD - hG )
= 21711.2 x ( 55 - 27 )
= 608012.7 kgf-mm
Component of moment due to HT [MT]
= HT x ( hT - hG )
= 1528.2 x ( 41 - 27 )
= 21398 kgf-mm
Total moment acting on the flange for operating condition [MO]
= MD + MT
= 608012.7 + 21398
= 629410.7 kgf-mm
14. LOADS AND FORCES DURING GASKET SEATING AS PER APPENDIX 2-3
Gasket load for seating condition [HG]
=W
= 373650.9 kgf
15. MOMENT UNDER GASKET SEATING AS PER APPENDIX 2-6
Total moment acting on the flange for gasket seating [MO']
= W x hG
= 373650.9 x 27
= 10086863.4 kgf-mm
16. SHAPE CONSTANTS
Factor [K]
=A/B
= 1786 / 1619
= 1.103
Flange factor from Fig. 2-7.1 [Y]
= 19.74
17. FLANGE THICKNESS REQUIRED AS PER APPENDIX 2-7
Equivalent moment [Mmax]
= MAX [ MO , MO' x Sfo / Sfa ]
= MAX [ 629410.7 , 10086863.4 x 10.46 / 14.06 ]
= 7500591.6 kgf-mm
Corrected equivalent moment per unit length [M]
= Mmax x Cf / B
= 7500591.6 x 1 / 1619
= 4632.9 kgf
Required thickness of flange [t]
= SQRT [ M x Y / Sfo ]
= SQRT [ 4632.9 x 19.74 / 10.46 ]
= 93.51 mm
18. FLANGE RIGIDITY CHECKING AS PER APPENDIX 2-14
Assumed flange thickness
tr
144.3 mm
Modulus of elasticity for flange

Efo

18786 kgf/mm

Rigidity factor
Rigidity index [J]
= 109.4 x Mmax / ( Efo x tr 3 x KL x ln ( K ) )
= 109.4 x 7500591.6 / ( 18786 x 144.3 3 x 0.2 x ln ( 1.103 ) )
= 0.997
Since J < 1.0, design is safe

KL

0.2

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date

/ R00 , 06-04-2015 19:23:54

FLANGE DESIGN ( INTERNAL )

Shell Flng (Front)

CODE
1. DESIGN CONDITIONS ( Design Mode 1 , Uncorroded Condition ) :
Design pressure
P

ASME VIII Div.1, 10 A11

Design temperature

180 C

Allowance

CA

0 mm

Groove allowance
2. FLANGE DATA :
M.O.C.

Tg

1.588 mm

Code allw. stress @ design temp.

Sfo

10.46 kgf/mm

0.08 kgf/mm g

SA-240 GR. 316 Plt. [UNS:S31600]

Code allw. stress @ atm. temp.

Sfa

14.06 kgf/mm

Inside diameter

1631 mm

Outside diameter

1786 mm

Hub length

0 mm

Thickness ( hub end )

g1

0 mm

Thickness ( pipe end )

g0

0 mm

Thickness provided

158.5 mm

Thickness available
3. BOLTING DATA :
M.O.C.

156.9 mm
SA-193 GR. B7 Bolt [UNS:G41400]

Code allw. stress @ design temp.

Sb

17.58 kgf/mm

Code allw. stress @ atm. temp.

Sa

17.58 kgf/mm

Bolt PCD

1729 mm

Bolt dia.

db

24 mm

No. of bolts
4. LINER DATA :

nb

68

M.O.C.
Liner ID

mm

Liner OD

mm

Liner thk.
5. GASKET DATA :
5a. Flange gasket data :
M.O.C.

mm

Gasket type

Ring Gasket

Gasket confinement type

Unconfined

Flange face type

Raised Face

Flange gakset surface finish

Serrated (Normal)

Counter flange face type

Raised Face

Counter gakset surface finish

Serrated (Normal)

Applicalbe gasket sketch in Table 2-5.2

Type 1B

Spiral metal wound CAF filled (S.S.)

Applicable gasket column in Table 2-5.2


Gasket seating stress

( refer to Note 1, Table 2-5.1 )

Gasket factor

( from Table 2-5.1 )

Inside diameter
Outside diameter

1
y

7.031 kgf/mm

Gi

1631 mm

Go

1695.2 mm

Width of gasket

( as per Table 2-5.2 )

32.1 mm

Width of gasket

( as per Table 2-5.2 )

32.1 mm

Width of raised face or gasket contact width

38.1 mm

( as per Table 2-5.2 )


Basic gasket seating width

( as per Table 2-5.2 )

b0

16.05 mm

Effective gasket width

( as per Table 2-5.2 )

10.1 mm

1675 mm

Dia. at load reaction


( see Table 2-5.2 )
5b. Partition groove gasket data (For H.E. body flange) :
M.O.C.

--

Gasket seating stress

( refer to Note 1, Table 2-5.1 )

Gasket factor

( from Table 2-5.1 )

y'

0 kgf/mm

m'

Pass partition gasket width

Wp

0 mm

Pass partition gasket length

Lp

0 mm

Effective pass partition gasket width


b'
0 mm
6. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b1)
Total joint - contact surface compression load [Hp]
= 2 x ( x b x G x m + b' x Lp x m' ) x P
= 2 x ( x 10.1 x 1675 x 3 + 0 x 0 x 0 ) x 0.08
= 25499.6 kgf
Total hydrostatic end force [H]
= 0.25 x x G x P
= 0.25 x x 1675 x 0.08
= 176284.5 kgf
Minimum required bolt load for operating condition [Wm1a]
= Hp + H
= 25499.6 + 176284.5
= 201784.1 kgf
Minimum required bolt load for operating condition [Wm1b]
( from mating flange )
= 201784.1 kgf
Governing bolt load for operating condition [Wm1]
= MAX [ Wm1a , Wm1b ]
= MAX [ 201784.1 , 201784.1 ]
= 201784.1 kgf
7. BOLT LOAD CALCULATION AS PER APPENDIX 2-5 (b2)
Minimum required bolt load for gasket seating [Wm2]
= ( x b x G x y + b' x Lp x y' )
= ( x 10.1 x 1675 x 7.031 + 0 x 0 x 0 )
= 373499.5 kgf
8. BOLT AREAS AS PER APPENDIX 2-5 (d)
Total required cross-sectional area of bolts [Am]
= MAX [ Wm2 / Sa , Wm1 / Sb ] ........ For Internal '+' Pr Design
= Wm2 / Sa ..................................... For External Pr & Self Sealing Design
= 21249.6 mm
Actual bolt area using root diameter [Ab]
= 21266.9 mm
Flange design bolt load for the gasket seating [W]
= 0.5 x ( Am + Ab ) x Sa x 1 .................... average bolt area
= Ab x Sa x 1 ..........................................full bolt area
= 373650.9 kgf ( Avg. bolt area and margin factor of 1 )
9. CHECK FOR GASKET CRUSHING
Minimum gasket width required [Nmin]
= Ab x Sb / ( 2 x x y x G )
= 21266.9 x 17.58 / ( 2 x x 7.031 x 1675 )
= 5.052 mm
10. BOLT SPACING CORRECTION FACTOR
As per Brownell & Young or IS 2825,
= SQRT [ Bolt spacing / ( 2 x db + t ) ]
As per TEMA or BS 5500,
= SQRT [ Bolt spacing / Bmax ] ................... where,
Bmax = maximum recommended bolt spacing = 2 x db + 6 x t / ( m + 0.5 )
Brownell & Young, Cf = 1 ( min. equal to 1 )
RING FLANGE DESIGN
Shell Flng (Front)
11. LOADS AND FORCES DURING OPERATING CONDITION AS PER APPENDIX 2-3
Hydrostatic end force on area inside of flange [HD]
= 0.25 x x B 2 x P
= 0.25 x x 1631 2 x 0.08
= 167142.8 kgf
Gasket load (difference between flange design bolt load and total hydrostatic end force) [HG]
= Wm1 - H
= 201784.1 - 176284.5
= 25499.6 kgf
Difference between total hydrostatic end force and hydrostatic end force on area inside of flange [HT]
= H - HD
= 176284.5 - 167142.8
= 9141.7 kgf
12. MOMENT ARMS FOR FLANGE LOADS AS PER TABLE 2-6
Radial distance from the bolt circle to intersection of hub and back of flange, as per Appendix 2-3 [R]
= 0.5 x ( C - B ) - g1
= 0.5 x ( 1729 - 1631 ) - 0

= 49
Radial distance from the bolt circle to the circle on which HD acts [hD]
= R + 0.5 x g1
= 49 + 0.5 x 0
= 49 mm
Radial distance from gasket load reaction to the bolt circle [hG]
= 0.5 x ( C - G )
= 0.5 x ( 1729 - 1675 )
= 27 mm
Radial distance from the bolt circle to the circle on which HT acts [hT]
= 0.5 x ( R + g1 + hG )
= 0.5 x ( 49 + 0 + 27 )
= 38 mm
13. FLANGE MOMENTS UNDER OPERATING CONDITION AS PER APPENDIX 2-6
Component of moment due to HD [MD]
= HD x hD
= 167142.8 x 49
= 8189999.4 kgf-mm
Component of moment due to HG [MG]
= HG x hG
= 25499.6 x 27
= 688371.3 kgf-mm
Component of moment due to HT [MT]
= HT x hT
= 9141.7 x 38
= 347363.7 kgf-mm
Total moment acting on the flange for operating condition [MO]
= MD + MG + MT
= 8189999.4 + 688371.3 + 347363.7
= 9225734.4 kgf-mm
14. LOADS AND FORCES DURING GASKET SEATING AS PER APPENDIX 2-3
Gasket load for seating condition [HG]
=W
= 373650.9 kgf
15. MOMENT UNDER GASKET SEATING AS PER APPENDIX 2-6
Total moment acting on the flange for gasket seating [MO']
= W x hG
= 373650.9 x 27
= 10086863.4 kgf-mm
16. SHAPE CONSTANTS
Factor [K]
=A/B
= 1786 / 1631
= 1.095
Flange factor from Fig. 2-7.1 [Y]
= 21.32
17. FLANGE THICKNESS REQUIRED AS PER APPENDIX 2-7
Equivalent moment [Mmax]
= MAX [ MO , MO' x Sfo / Sfa ]
= MAX [ 9225734.4 , 10086863.4 x 10.46 / 14.06 ]
= 9225734.4 kgf-mm
Corrected equivalent moment per unit length [M]
= Mmax x Cf / B
= 9225734.4 x 1 / 1631
= 5656.5 kgf
Required thickness of flange [t]
= SQRT [ M x Y / Sfo ]
= SQRT [ 5656.5 x 21.32 / 10.46 ]
= 107.4 mm
18. FLANGE RIGIDITY CHECKING AS PER APPENDIX 2-14
Assumed flange thickness
tr
148.1 mm
Modulus of elasticity for flange

Efo

18786 kgf/mm

Rigidity factor
Rigidity index [J]
= 109.4 x Mmax / ( Efo x tr 3 x KL x ln ( K ) )
= 109.4 x 9225734.4 / ( 18786 x 148.1 3 x 0.2 x ln ( 1.095 ) )
= 0.996
Since J < 1.0, design is safe

KL

0.2

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date

/ R00 , 06-04-2015 19:23:54

FLANGE DESIGN ( EXTERNAL )

Shell Flng (Front)

CODE
1. DESIGN CONDITIONS ( Design Mode 1 , Uncorroded Condition ) :
Design pressure
P

ASME VIII Div.1, 10 A11

Design temperature

180 C

Allowance

CA

0 mm

Groove allowance
2. FLANGE DATA :
M.O.C.

Tg

1.588 mm

Code allw. stress @ design temp.

Sfo

10.46 kgf/mm

0.01055 kgf/mm g

SA-240 GR. 316 Plt. [UNS:S31600]

Code allw. stress @ atm. temp.

Sfa

14.06 kgf/mm

Inside diameter

1631 mm

Outside diameter

1786 mm

Hub length

0 mm

Thickness ( hub end )

g1

0 mm

Thickness ( pipe end )

g0

0 mm

Thickness provided

158.5 mm

Thickness available
3. BOLTING DATA :
M.O.C.

156.9 mm
SA-193 GR. B7 Bolt [UNS:G41400]

Code allw. stress @ design temp.

Sb

17.58 kgf/mm

Code allw. stress @ atm. temp.

Sa

17.58 kgf/mm

Bolt PCD

1729 mm

Bolt dia.

db

24 mm

No. of bolts
4. LINER DATA :

nb

68

M.O.C.
Liner ID

mm

Liner OD

mm

Liner thk.
5. GASKET DATA :
5a. Flange gasket data :
M.O.C.

mm

Gasket type

Ring Gasket

Gasket confinement type

Unconfined

Flange face type

Raised Face

Flange gakset surface finish

Serrated (Normal)

Counter flange face type

Raised Face

Counter gakset surface finish

Serrated (Normal)

Applicalbe gasket sketch in Table 2-5.2

Type 1B

Spiral metal wound CAF filled (S.S.)

Applicable gasket column in Table 2-5.2


Gasket seating stress

( refer to Note 1, Table 2-5.1 )

Gasket factor

( from Table 2-5.1 )

Inside diameter
Outside diameter

1
y

7.031 kgf/mm

Gi

1631 mm

Go

1695.2 mm

Width of gasket

( as per Table 2-5.2 )

32.1 mm

Width of gasket

( as per Table 2-5.2 )

32.1 mm

Width of raised face or gasket contact width

38.1 mm

( as per Table 2-5.2 )


Basic gasket seating width

( as per Table 2-5.2 )

b0

16.05 mm

Effective gasket width

( as per Table 2-5.2 )

10.1 mm

1675 mm

Dia. at load reaction


( see Table 2-5.2 )
5b. Partition groove gasket data (For H.E. body flange) :
M.O.C.

--

Gasket seating stress

( refer to Note 1, Table 2-5.1 )

Gasket factor

( from Table 2-5.1 )

y'

0 kgf/mm

m'

Pass partition gasket width

Wp

0 mm

Pass partition gasket length

Lp

0 mm

Effective pass partition gasket width


b'
0 mm
6. BOLT LOAD CALCULATIONS AS PER APPENDIX 2-5 (b1)
Total joint - contact surface compression load [Hp]
= 2 x ( p x b x G x m + b' x Lp x m' ) x P
= 2 x ( p x 10.1 x 1675 x 3 + 0 x 0 x 0 ) x 0.01055
= 3361.6 kgf
Total hydrostatic end force [H]
= 0.25 x p x G x P
= 0.25 x p x 1675 x 0.01055
= 23239.4 kgf
Minimum required bolt load for operating condition [Wm1a]
= Hp + H
= 3361.6 + 23239.4
= 26600.9 kgf
Minimum required bolt load for operating condition [Wm1b]
( from mating flange )
= 26600.9 kgf
Governing bolt load for operating condition [Wm1]
= MAX [ Wm1a , Wm1b ]
= MAX [ 26600.9 , 26600.9 ]
= 26600.9 kgf
7. BOLT LOAD CALCULATION AS PER APPENDIX 2-5 (b2)
Minimum required bolt load for gasket seating [Wm2]
= ( p x b x G x y + b' x Lp x y' )
= ( p x 10.1 x 1675 x 7.031 + 0 x 0 x 0 )
= 373499.5 kgf
8. BOLT AREAS AS PER APPENDIX 2-5 (d)
Total required cross-sectional area of bolts [Am]
= MAX [ Wm2 / Sa , Wm1 / Sb ] ........ For Internal '+' Pr Design
= Wm2 / Sa ..................................... For External Pr & Self Sealing Design
= 21249.6 mm
Actual bolt area using root diameter [Ab]
= 21266.9 mm
Flange design bolt load for the gasket seating [W]
= 0.5 x ( Am + Ab ) x Sa x 1 .................... average bolt area
= Ab x Sa x 1 ..........................................full bolt area
= 373650.9 kgf ( Avg. bolt area and margin factor of 1 )
9. CHECK FOR GASKET CRUSHING
Minimum gasket width required [Nmin]
= Ab x Sb / ( 2 x p x y x G )
= 21266.9 x 17.58 / ( 2 x p x 7.031 x 1675 )
= 5.052 mm
10. BOLT SPACING CORRECTION FACTOR
As per Brownell & Young or IS 2825,
= SQRT [ Bolt spacing / ( 2 x db + t ) ]
As per TEMA or BS 5500,
= SQRT [ Bolt spacing / Bmax ] ................... where,
Bmax = maximum recommended bolt spacing = 2 x db + 6 x t / ( m + 0.5 )
Brownell & Young, Cf = 1 ( min. equal to 1 )
RING FLANGE DESIGN
Shell Flng (Front)
11. LOADS AND FORCES DURING OPERATING CONDITION AS PER APPENDIX 2-3
Hydrostatic end force on area inside of flange [HD]
= 0.25 x p x B 2 x P
= 0.25 x p x 1631 2 x 0.01055
= 22034.2 kgf
Difference between total hydrostatic end force and hydrostatic end force on area inside of flange [HT]
= H - HD
= 23239.4 - 22034.2
= 1205.1 kgf
12. MOMENT ARMS FOR FLANGE LOADS AS PER TABLE 2-6
Radial distance from the bolt circle to intersection of hub and back of flange, as per Appendix 2-3 [R]
= 0.5 x ( C - B ) - g1
= 0.5 x ( 1729 - 1631 ) - 0
= 49
Radial distance from the bolt circle to the circle on which HD acts [hD]
= R + 0.5 x g1
= 49 + 0.5 x 0

= 49 mm
Radial distance from gasket load reaction to the bolt circle [hG]
= 0.5 x ( C - G )
= 0.5 x ( 1729 - 1675 )
= 27 mm
Radial distance from the bolt circle to the circle on which HT acts [hT]
= 0.5 x ( R + g1 + hG )
= 0.5 x ( 49 + 0 + 27 )
= 38 mm
13. FLANGE MOMENTS UNDER OPERATING CONDITION AS PER APPENDIX 2-6
Component of moment due to HD [MD]
= HD x ( hD - hG )
= 22034.2 x ( 49 - 27 )
= 484853.9 kgf-mm
Component of moment due to HT [MT]
= HT x ( hT - hG )
= 1205.1 x ( 38 - 27 )
= 13259.3 kgf-mm
Total moment acting on the flange for operating condition [MO]
= MD + MT
= 484853.9 + 13259.3
= 498113.2 kgf-mm
14. LOADS AND FORCES DURING GASKET SEATING AS PER APPENDIX 2-3
Gasket load for seating condition [HG]
=W
= 373650.9 kgf
15. MOMENT UNDER GASKET SEATING AS PER APPENDIX 2-6
Total moment acting on the flange for gasket seating [MO']
= W x hG
= 373650.9 x 27
= 10086863.4 kgf-mm
16. SHAPE CONSTANTS
Factor [K]
=A/B
= 1786 / 1631
= 1.095
Flange factor from Fig. 2-7.1 [Y]
= 21.32
17. FLANGE THICKNESS REQUIRED AS PER APPENDIX 2-7
Equivalent moment [Mmax]
= MAX [ MO , MO' x Sfo / Sfa ]
= MAX [ 498113.2 , 10086863.4 x 10.46 / 14.06 ]
= 7500591.6 kgf-mm
Corrected equivalent moment per unit length [M]
= Mmax x Cf / B
= 7500591.6 x 1 / 1631
= 4598.8 kgf
Required thickness of flange [t]
= SQRT [ M x Y / Sfo ]
= SQRT [ 4598.8 x 21.32 / 10.46 ]
= 96.83 mm
18. FLANGE RIGIDITY CHECKING AS PER APPENDIX 2-14
Assumed flange thickness
tr
148.4 mm
Modulus of elasticity for flange

Efo

18786 kgf/mm

Rigidity factor
Rigidity index [J]
= 109.4 x Mmax / ( Efo x tr 3 x KL x ln ( K ) )
= 109.4 x 7500591.6 / ( 18786 x 148.4 3 x 0.2 x ln ( 1.095 ) )
= 0.99
Since J < 1.0, design is safe

KL

0.2

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date

/ R00 , 06-04-2015 19:23:54

DESIGN OF SHELL ( INTERNAL AND EXTERNAL PRESSURE )

Main Shell

CODE
1. DESIGN CONDITIONS ( Design Mode 1 , Uncorroded Condition )
Design pressure ( internal )
Pi

ASME VIII Div.1, 10 A11

Design pressure ( external )

Pe

0.06055 kgf/mm g

Design temperature

180 C

13.79 kgf/mm

Material of construction
Max. allowable stress at design temp.

0.09055 kgf/mm g

SA-240 GR. 316 Plt. [UNS:S31600]

Radiography

Spot + T Joints

Joint efficiency long. seam

Ec

0.85

Outside diameter

OD

1628 mm

Inside radius ( corroded )

800 mm

Shell length

2400 mm

Design length

L1

2400 mm

Nominal thickness

14 mm

Nominal thickness required as per TEMA

N.A. mm

Internal allowance, corrosion + polishing

0 mm

External allowance, corrosion + polishing

0 mm

Thickness undertolerance

0 mm

Available thickness

14 mm

2. DESIGN CALCULATION AS PER UG-27


Thickness of shell under internal pressure [ti]
= Pi x R / ( S x E - 0.6 x Pi )
= 0.09055 x 800 / ( 13.79 x 0.85 - 0.6 x 0.09055 )
= 6.211 mm
3. DESIGN CALCULATION OF SHELL THICKNESS UNDER EXTERNAL PRESSURE AS PER UG-28
Assumed te

13.47 mm

L1 / OD

1.474

OD / te

120.9

Factor A ( Refer to Fig. G in Subpart 3 of Sec. II, Part D )

0.00067

Factor B ( HA-2 )

5.516 kgf/mm

Allowable external pressure [Pa]


= 4 x B / ( 3 x ( OD / te ) )
= 4 x 5.516 / ( 3 x 120.9 )
= 0.06086 kgf/mm g
Since Pa > Pe, design is safe
Since available thickness is more than design thickness, design is safe.

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date

/ R00 , 06-04-2015 19:23:54

DESIGN OF TORISPHERICAL HEAD ( INT. & EXT. PRESSURE )

Dished End (Rear)

CODE
1. DESIGN CONDITIONS ( Design Mode 1 , Uncorroded Condition ) :
Design pressure ( internal )
Pi

ASME VIII Div.1, 10 A11

Design pressure ( external )

Pe

0.01055 kgf/mm g

Design temperature

180 C

13.79 kgf/mm

Material of construction
Max. allowable stress @ design temp.

0.08 kgf/mm g

SA-240 GR. 316 Plt. [UNS:S31600]

Radiography

Full

Joint efficiency

Outside diameter of head

OD

1616 mm

Crown radius

CR

1440 mm

Knuckle radius

KR

272 mm

Nominal thickness

8 mm

Nominal thickness required as per TEMA

N.A mm

Internal allowance, corrosion + polishing

0 mm

External allowance, corrosion + polishing

0 mm

Thinning allowance / Under tolerance

0.8 mm

Available thickness
2. DESIGN CALCULATION AS PER UG 32 e / APPENDIX 1-4 ( d ) :
Factor [M]
= ( 1 / 4 ) x [ 3 + SQRT [ CR / KR ] ]
= ( 1 / 4 ) x [ 3 + SQRT [ 1440 / 272 ] ]
= 1.325
Thickness for internal pressure [t]
= M x Pi x CR / ( 2 x S x E - 0.2 x Pi )
= 1.325 x 0.08 x 1440 / ( 2 x 13.79 x 1 - 0.2 x 0.08 )
= 5.54 mm
3. DESIGN CALCULATION AS PER UG 33 e :
Thickness for equivalent external pressure [t]
= M x 1.67 x Pe x CR / ( 2 x S x 1.0 - 0.2 x 1.67 x Pe )
= 1.325 x 1.67 x 0.01055 x 1440 / ( 2 x 13.79 x 1.0 - 0.2 x 1.67 x 0.01055 )
= 1.219 mm
Assumed head thickness, [te]
= 4.454 mm
Assumed outside crown radius, [CRo]
= 1448 mm
Factor [A]
= 0.125 x te / CRo
= 0.125 x 4.454 / 1448
= 0.00038
Factor with reference to chart (HA-2) [B]
= 3.455 kgf/mm
Allowable external pressure [Pa]
= B x te / CRo
= 3.455 x 4.454 / 1448
= 0.01063 kgf/mm
Since Pa > Pe, design is safe
Since available thickness is more than design thickness, design is safe.

7.2 mm

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date

/ R00 , 06-04-2015 19:23:54

DESIGN OF JACKET CLOSURE


1. DESIGN CONDITIONS :
Code

Jacket Closure (Top)


ASME VIII Div.1, 10 A11

Design pressure ( INTERNAL )

Pi

0.05 kgf/mm g

Design temperature

200 C

Material of construction
Max. allowable stress @ design temp.

SA-240 GR. 304 Plt. [UNS:S30400]


S

12.9 kgf/mm

0.85

Radiography
Joint efficiency

Spot + T Joints

Jacketing type

Shell & Bottom End

Closure type

Figure (f2)

Jacket spacing

50 mm

Nominal closure thickness

18 mm

Internal allowance, corrosion + polishing

0 mm

External allowance, corrosion + polishing


Available thickness
2. SHELL DATA :
Material of construction

0 mm
tc

18 mm
SA-240 GR. 316 Plt. [UNS:S31600]

Outside diameter

OD1

1628 mm

Inside diameter

ID1

1600 mm

Provided thickness

14 mm

Nominal thickness
3. JACKET DATA :
Material of construction

ts

14 mm

Outside diameter

OD

1744 mm

Inside diameter

ID

1728 mm

tj

8 mm

SA-240 GR. 304 Plt. [UNS:S30400]

Provided thickness
Nominal thickness

8 mm

Required minimum thickness of outer jacket wall


trj
3.951 mm
4. MAX. ALLOWABLE WIDTH OF JACKET SPACE
Maximum allowed jacket spacing [Jmax]
= [ 4 x S x ts 2 / ( Pi x ID ) ] - 0.5 x ( ts + tj )
= [ 4 x 12.9 x 14 2 / ( 0.05 x 1728 ) ] - 0.5 x ( 14 + 8 )
= 106.1 mm.
In this case J < Jmax , \ jacket width is acceptable.
5. DESIGN CALCULATION AS PER 9.5 (c)(5) :
Calculated thickness of closure member for pressure [t1]
= 1.414 x SQRT [ 0.5 x OD1 x Pi x J / S ]
= 1.414 x SQRT [ 0.5 x 1628 x 0.05 x 50 / 12.9 ]
= 17.76 mm
Required minimum thickness of closure member [tr]
= MAX [ t1 , trj ]
= MAX [ 17.76 , 3.951 ]
= 17.76 mm
Since required minimum thickness of closure (tr) < available thickness of jacket closure (tc) , design is safe.

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date

/ R00 , 06-04-2015 19:23:54

DESIGN OF SHELL ( INTERNAL AND EXTERNAL PRESSURE )

Jacket Shell

CODE
1. DESIGN CONDITIONS ( Design Mode 1 , Uncorroded Condition )
Design pressure ( internal )
Pi

ASME VIII Div.1, 10 A11

Design pressure ( external )

Pe

0.01055 kgf/mm g

Design temperature

200 C

12.9 kgf/mm

Material of construction
Max. allowable stress at design temp.

0.05 kgf/mm g

SA-240 GR. 304 Plt. [UNS:S30400]

Radiography

Spot + T Joints

Joint efficiency long. seam

Ec

0.85

Outside diameter

OD

1744 mm

Inside radius ( corroded )

864 mm

Shell length

1850 mm

Design length

L1

1850 mm

Nominal thickness

8 mm

Nominal thickness required as per TEMA

N.A. mm

Internal allowance, corrosion + polishing

0 mm

External allowance, corrosion + polishing

0 mm

Thickness undertolerance

0 mm

Available thickness

8 mm

2. DESIGN CALCULATION AS PER UG-27


Thickness of shell under internal pressure [ti]
= Pi x R / ( S x E - 0.6 x Pi )
= 0.05 x 864 / ( 12.9 x 0.85 - 0.6 x 0.05 )
= 3.951 mm
3. DESIGN CALCULATION OF SHELL THICKNESS UNDER EXTERNAL PRESSURE AS PER UG-28
Assumed te

6.128 mm

L1 / OD

1.061

OD / te

284.6

Factor A ( Refer to Fig. G in Subpart 3 of Sec. II, Part D )

0.00026

Factor B ( HA-1 )

2.272 kgf/mm

Allowable external pressure [Pa]


= 4 x B / ( 3 x ( OD / te ) )
= 4 x 2.272 / ( 3 x 284.6 )
= 0.01064 kgf/mm g
Since Pa > Pe, design is safe
Since available thickness is more than design thickness, design is safe.

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date

/ R00 , 06-04-2015 19:23:54

DESIGN OF TORISPHERICAL HEAD ( INT. & EXT. PRESSURE )

Jacket Dish (Bottom)

CODE
1. DESIGN CONDITIONS ( Design Mode 1 , Uncorroded Condition ) :
Design pressure ( internal )
Pi

ASME VIII Div.1, 10 A11

Design pressure ( external )

Pe

0.01055 kgf/mm g

Design temperature

200 C

12.9 kgf/mm

Material of construction
Max. allowable stress @ design temp.

0.05 kgf/mm g

SA-240 GR. 304 Plt. [UNS:S30400]

Radiography

Full

Joint efficiency

Outside diameter of head

OD

1744 mm

Crown radius

CR

1728 mm

Knuckle radius

KR

175 mm

Nominal thickness

8 mm

Nominal thickness required as per TEMA

N.A mm

Internal allowance, corrosion + polishing

0 mm

External allowance, corrosion + polishing

0 mm

Thinning allowance / Under tolerance

0.8 mm

Available thickness
2. DESIGN CALCULATION AS PER UG 32 e / APPENDIX 1-4 ( d ) :
Factor [M]
= ( 1 / 4 ) x [ 3 + SQRT [ CR / KR ] ]
= ( 1 / 4 ) x [ 3 + SQRT [ 1728 / 175 ] ]
= 1.536
Thickness for internal pressure [t]
= M x Pi x CR / ( 2 x S x E - 0.2 x Pi )
= 1.536 x 0.05 x 1728 / ( 2 x 12.9 x 1 - 0.2 x 0.05 )
= 5.144 mm
3. DESIGN CALCULATION AS PER UG 33 e :
Thickness for equivalent external pressure [t]
= M x 1.67 x Pe x CR / ( 2 x S x 1.0 - 0.2 x 1.67 x Pe )
= 1.536 x 1.67 x 0.01055 x 1728 / ( 2 x 12.9 x 1.0 - 0.2 x 1.67 x 0.01055 )
= 1.812 mm
Assumed head thickness, [te]
= 5.337 mm
Assumed outside crown radius, [CRo]
= 1736 mm
Factor [A]
= 0.125 x te / CRo
= 0.125 x 5.337 / 1736
= 0.00038
Factor with reference to chart (HA-1) [B]
= 3.456 kgf/mm
Allowable external pressure [Pa]
= B x te / CRo
= 3.456 x 5.337 / 1736
= 0.01062 kgf/mm
Since Pa > Pe, design is safe
Since available thickness is more than design thickness, design is safe.

7.2 mm

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date

/ R00 , 06-04-2015 19:23:54

LUG SUPPORT DESIGN

Lug Support

CODE

P V Design Manual, D.R. Moss


Design Mode 1 , Uncorroded
Condition

1. LUG DATA :
M.O.C

IS-2062 GR. A Plt.

No. of support

Base plate width

b1

42 mm

Base plate depth

Lb

220 mm

Thickness of base plate

tb

16 mm

Allowable bending stress


2. BOLT DATA :
M.O.C

Sb

22.15 kgf/mm

No. of bolt / lug

Nb

SA-36 / IS-1363,67 Bolt [UNS:K02600]

Bolt diameter

db

20 mm

PCD

1928 mm

Fs

20.88 kgf/mm

Diameter of bolt hole

24 mm

Allowable tensile stress


3. GUSSET DATA :
Thickness

tg

16 mm

Height

240 mm

Gusset angle

54.69

Gusset depth at top

Lc

50 mm

Number of gussets

Distance between gussets


4. SHELL DATA :

0 mm

Material

SA-240 GR. 316 Plt. [UNS:S31600]

OD diameter

OD

1628 mm

Inside diameter

ID

1600 mm

Thickness available
5. PAD DATA :

ts

14 mm

tp

14 mm

Material
Thickness

SA-240 GR. 316 Plt. [UNS:S31600]

Width

330 mm

Length
6. LOAD AND MOMENT ( Wind ) :

300 mm

Max. overturning moment

2107478.2 kgf-mm

Design weight of vessel


7. DESIGN OF ANCHOR BOLTS :
Total uplift force on bolts [T]

Wt

6175 kgf

= [ 4 x M / ( D x N ) ] - Wt / N
= [ 4 x 2107478.2 / ( 1928 x 4 ) ] - 6175 / 4
= -450.7 kgf
Required area of bolts [Am]
= MAX [ ( T / Fs ) , 0 ]
= MAX [ ( -450.7 / 20.88 ) , 0 ]
= 0 mm
Available area of bolts [Ab]
= Ar x Nb ........................................................................................ where, Ar = 217.1 mm, is root area of bolt
= 217.1 x 2
= 434.1 mm
Since Ab > Am, bolts provided are sufficient
8. GUSSET DESIGN :
Reaction force at each support [Q]

= [ 4 x M / ( D x N ) ] + Wt / N
= [ 4 x 2107478.2 / ( 1928 x 4 ) ] + 6175 / 4
= 2636.8 kgf
Maximum axial force in gusset [P1]
=Q
= 2636.8
= 2636.8 kgf
Allowable compr. stress in gusset [Sg]
= 1800 / [ ( 1 + 12 / 18000 ) x ( h / tg )

] ....................................... where, h = 294.1 mm


2

= 2 x P1 x ( 3 x a - Lb ) / [ Sg x Lb 2 x ( sin )

= 1800 / [ ( 1 + 12 / 18000 ) x ( 294.1 / 16 )


= 14690.8 psi
= 10.33 kgf/mm
Required thickness of gusset [tg]

= 2 x 2636.8 x ( 3 x 150 - 220 ) / [ 10.33 x ( 220 ) 2 x ( sin 54.69 )


= 3.644 mm
9. BASE PLATE DESIGN :
Bending moment [Mb]

= Q x b1 / 4
= 2636.8 x 42 / 4
= 27686.9 kgf-mm
Bearing pressure [bp]
= Q / ( w x b1 ) ............................................................................... where, w = 132 mm
= 2636.8 / ( 132 x 42 )
= 0.476 kgf/mm
Bending moment due to bearing pressure [Mb]
= bp x b

/2

= 0.476 x 0 2 / 2
= 40.19 kgf-mm
Required thickness of base plate between chairs [tb]
= SQRT { 6 x MAX [ Mb , Mb' ] / [ ( Lb - db ) x Sb ] }
= SQRT { 6 x MAX [ 27686.9 , 40.19 ] / [ ( 220 - 20 ) x 22.15 ] }
= 6.186 mm
10. CHECK FOR COMPRESSION PLATE :
Equivalent radial load [f]
=Qxa/h
= 2636.8 x 150 / 240
= 1648 kgf
Angle between supports [b]
=2xp/N
=2xp/4
= 1.571 rad
Internal bending moment coefficient [Kr]
= 0.5 x [ 1 / a - cot ( a ) ]
= 0.5 x [ 1 / 1.571 - cot ( 1.571 ) ]
= 0.318
Internal bending moment [Mc]
= 0.5 x Kr x f x OD
= 0.5 x 0.318 x 1648 x 1628
= 427011.1 kgf-mm
Bending stress induced [fb]
= Mo / Zc
= 427011.1 / 30687.7
= 13.91 kgf/mm ......................................................................... < Sb = 22.15 kgf/mm
Since, induced stress fb < allow. stress Sb in shell material, design is safe.

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date

/ R00 , 06-04-2015 19:23:54

LUG SUPPORT DESIGN

Lug Support

CODE

P V Design Manual, D.R. Moss


Design Mode 1 , Uncorroded
Condition

1. LUG DATA :
M.O.C

IS-2062 GR. A Plt.

No. of support

Base plate width

b1

42 mm

Base plate depth

Lb

220 mm

Thickness of base plate

tb

16 mm

Allowable bending stress


2. BOLT DATA :
M.O.C

Sb

22.15 kgf/mm

No. of bolt / lug

Nb

SA-36 / IS-1363,67 Bolt [UNS:K02600]

Bolt diameter

db

20 mm

PCD

1928 mm

Fs

20.88 kgf/mm

Diameter of bolt hole

24 mm

Allowable tensile stress


3. GUSSET DATA :
Thickness

tg

16 mm

Height

240 mm

Gusset angle

54.69

Gusset depth at top

Lc

50 mm

Number of gussets

Distance between gussets


4. SHELL DATA :

0 mm

Material

SA-240 GR. 316 Plt. [UNS:S31600]

OD diameter

OD

1628 mm

Inside diameter

ID

1600 mm

Thickness available
5. PAD DATA :

ts

14 mm

tp

14 mm

Material
Thickness

SA-240 GR. 316 Plt. [UNS:S31600]

Width

330 mm

Length
6. LOAD AND MOMENT ( Seismic ) :

300 mm

Max. overturning moment

1923130.8 kgf-mm

Design weight of vessel


7. DESIGN OF ANCHOR BOLTS :
Total uplift force on bolts [T]

Wt

4385.1 kgf

= [ 4 x M / ( D x N ) ] - Wt / N
= [ 4 x 1923130.8 / ( 1928 x 4 ) ] - 4385.1 / 4
= -98.79 kgf
Required area of bolts [Am]
= MAX [ ( T / Fs ) , 0 ]
= MAX [ ( -98.79 / 20.88 ) , 0 ]
= 0 mm
Available area of bolts [Ab]
= Ar x Nb ........................................................................................ where, Ar = 217.1 mm, is root area of bolt
= 217.1 x 2
= 434.1 mm
Since Ab > Am, bolts provided are sufficient
8. GUSSET DESIGN :
Reaction force at each support [Q]

= [ 4 x M / ( D x N ) ] + Wt / N
= [ 4 x 1923130.8 / ( 1928 x 4 ) ] + 4385.1 / 4
= 2093.7 kgf
Maximum axial force in gusset [P1]
=Q
= 2093.7
= 2093.7 kgf
Allowable compr. stress in gusset [Sg]
= 1800 / [ ( 1 + 12 / 18000 ) x ( h / tg )

] ....................................... where, h = 294.1 mm


2

= 2 x P1 x ( 3 x a - Lb ) / [ Sg x Lb 2 x ( sin )

= 1800 / [ ( 1 + 12 / 18000 ) x ( 294.1 / 16 )


= 14690.8 psi
= 10.33 kgf/mm
Required thickness of gusset [tg]

= 2 x 2093.7 x ( 3 x 150 - 220 ) / [ 10.33 x ( 220 ) 2 x ( sin 54.69 )


= 2.893 mm
9. BASE PLATE DESIGN :
Bending moment [Mb]

= Q x b1 / 4
= 2093.7 x 42 / 4
= 21984.3 kgf-mm
Bearing pressure [bp]
= Q / ( w x b1 ) ............................................................................... where, w = 132 mm
= 2093.7 / ( 132 x 42 )
= 0.378 kgf/mm
Bending moment due to bearing pressure [Mb]
= bp x b

/2

= 0.378 x 0 2 / 2
= 31.91 kgf-mm
Required thickness of base plate between chairs [tb]
= SQRT { 6 x MAX [ Mb , Mb' ] / [ ( Lb - db ) x Sb ] }
= SQRT { 6 x MAX [ 21984.3 , 31.91 ] / [ ( 220 - 20 ) x 22.15 ] }
= 5.513 mm
10. CHECK FOR COMPRESSION PLATE :
Equivalent radial load [f]
=Qxa/h
= 2093.7 x 150 / 240
= 1308.6 kgf
Angle between supports [b]
=2xp/N
=2xp/4
= 1.571 rad
Internal bending moment coefficient [Kr]
= 0.5 x [ 1 / a - cot ( a ) ]
= 0.5 x [ 1 / 1.571 - cot ( 1.571 ) ]
= 0.318
Internal bending moment [Mc]
= 0.5 x Kr x f x OD
= 0.5 x 0.318 x 1308.6 x 1628
= 339060.9 kgf-mm
Bending stress induced [fb]
= Mo / Zc
= 339060.9 / 30687.7
= 11.05 kgf/mm ......................................................................... < Sb = 22.15 kgf/mm
Since, induced stress fb < allow. stress Sb in shell material, design is safe.

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date

/ R00 , 06-04-2015 19:23:54

AGITATOR SHAFT WITH INTERMEDIATE BEARING HOUSING


1. SHAFT DATA :
Power

Shaft
P

20 hp (MKS)

Pumping capacity (RPM)

RPM

100

Service (Duty) factor

sf

Material of impeller

SA-479 GR. 316 Bar [UNS:S31600]

0.2% Proof stress

Sy

21.09 kgf/mm

Allowable stress

Sa

14.05 kgf/mm

Youngs modulus

Es

18786 kgf/mm

Weight density

rho

7999.5 kg/m

Shaft OD

OD

101 mm

Shaft ID

ID

0 mm

Total length

4438.3 mm

Allowance

CA

0 mm

Distance between bearings

250 mm

Overhanging length

3738.3 mm

300 mm

Shaft is propped at bottom

True

Type of shaft seal

Gland Packing

Distance of packing /seal


Allowable deflection at packing
2. IMPELLER TORQUE, FORCES AND MOMENTS :
Impeller Length,

Power,

Hub
No

L(i) mm

P(i) hp
(MKS)

3150

20

P = 20

0.5 mm

Radius,

Torque,

Rb(i) mm

Tm(i) kgfmm

F(i) kgf

143288.1

Tm =
143288.1

265

Force,

Moment,

Moment,

Moment,

M(i) kgf-mm

M'(i) kgf-mm

M''(i) kgfmm3

720.9

2270981.5

424140.7

146.8E09

F = 720.9

M=
2270981.5

M' =
424140.7

M" =
146.8E09

2
3
4
5

Formulae used in the above table :


Tm(i) = [ 736 x 60 x HP(i) / ( 9.81 x 2 x p x RPM ) ] kgf-m = [ 716440.6 x P(i) / RPM ] kgf-mm
F(i) = Tm(i) / ( 0.75 x Rb ) kgf
M(i) = F(i) x L(i) kgf-mm
M'(i) = F(i) x ( L - L(i) ) kgf-mm
M"(i) = F(i) x ( L - L(i) ) 3 kgf-mm 3
3. CHECK FOR EQUIVALENT BENDING MOMENT
Reaction at top bearing [R1]
= [ M" - M' x L 2 ] / [ 2 x A x L x ( A + L ) ]
= [ 146.8E09 - 424140.7 x 3738.3 2 ] / [ 2 x 250 x 3738.3 x ( 250 + 3738.3 ) ]
= -775.4 kgf
Reaction at bottom bearing [R2]
= [ - M' - R1 x ( A + L ) ] / L
= [ - 424140.7 - -775.4 x ( 250 + 3738.3 ) ] / 3738.3
= 713.8 kgf
Reaction at bush [R3]
= - [ R1 + R2 + F ]
= - [ -775.4 + 713.8 + 720.9 ]
= -659.3 kgf
Bending moment at the bottom bearing [Mt]
= M + R3 x L
= 2270981.5 + -659.3 x 3738.3
= -193854.1 kgf-mm
Induced equivalent moment in shaft [Me]
= ( Mt 2 + 0.75 x Tm 2 ) 0.5
= ( -193854.1 2 + 0.75 x 143288.1 2 ) 0.5
= 230169.6 kgf-mm
Stress induced in shaft [Fy]

= ( 32 x sf x Me x D1 ) / [ p x ( D1 4 - ID 4 ) ] .......................... where, assumed D1 = 60.58 mm


= ( 32 x 2 x 230169.6 x 60.58 ) / [ p x ( 60.58 4 - 0 4 ) ]
= 21.09 kgf/mm
Since induced stress (Fy) <= yield stress (Sy), shaft diameter required for equivalent bending is D1 = 60.58 mm.
4. CHECK FOR CONTINUOUS WORKING STRESS
Stress assumed in shaft [Fq]
= ( 16 x sf x Tm x D2 ) / [ p x ( D2 4 - ID 4 ) ] .......................... where, assumed D2 = 47.01 mm
= ( 16 x 2 x 143288.1 x 47.01 ) / [ p x ( 47.01 4 - 0 4 ) ]
= 14.05 kgf/mm
Since induced stress (Fq) <= allowable stress (Sa), shaft diameter required for torsion is D2 = 47.01 mm.
5. SHAFT DEFLECTION AT IMPELLERS
M.I. of shaft [MI]
= p x ( OD 4 - ID 4 ) / 64
= p x ( 101 4 - 0 4 ) / 64
= 661070.1 mm 4
Impeller

Deflection of shaft center, mm

Deflection at edge of blade,


mm

Ds(i)

7 x Ds(i) / 3

107.5

250.9

2
3
4
Formula used in the above table :
Formula used in the above table :
Ds(i) = { R1 x [ ( A + L(i) ) 3 - A x ( A + L(i) ) ] + R2 x L(i) 3 - [

j=i

j = no. of hubs

F(j) x ( L - L(j) ) 3 ] } / ( 6 x Es x MI )

6 (a). CRITICAL SPEED OF SHAFT


Critical speed of shaft [Ns]
= [ 60 / ( 2 x p ) ] x SQRT [ 384 x Es x MI x g / ( 5 x ws x L 4 ) ] ... where, g = 9810 mm/s & ws = 0.02306 kgf/mm
= [ 60 / ( 2 x p ) ] x SQRT [ 8 x 18786 x 661070.1 x 9810 / (0.02306 x 3738.3 4 ) ]
= 435.3 rpm
6 (b). CRITICAL SPEED OF ATTACHMENTS ( BLADES, CPLGS ETC. )
Sr. No.
Wt(i), kgf
L(i), mm
Nc(i), rpm
1

27

3150

18.96

2
3
4
5
Formula used in the above table :
Nc(i) = [ 60 / ( 2 x p ) ] x SQRT{ 3 x Es x MI x g / [ Wt( < / x ( L - L(i) ) ] }
6 (c). CRITICAL SPEED OF THE SYSTEM
Critical speed of the entire shaft system [Nc]
= 1 / SQRT { [ 1 / Ns 2 ] + [ 1 / Nc(1) 2 ] + [ 1 / Nc(2) 2 ] + [ 1 / Nc(3) 2 ] + [ 1 / Nc(4) 2 ] + [ 1 / Nc(5) 2 ] }
= 18.94 rpm
7. PROVIDED SHAFT DIAMETER 101 mm
Provided shaft diameter should be atleast equal to MAX [ D1, D2 ] + CA i.e., MAX [ 60.58, 47.01 ] + 0 mm.

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date

/ R00 , 06-04-2015 19:23:54

DESIGN OF IMPELLER BLADE WITH STIFFENER :


1. DESIGN DATA :
Power

Impeller (1)
P

20 hp (MKS)

Pumping capacity (RPM)

RPM

100

Service (Duty) factor

sf

Material of impeller

SA-240 GR. 316 Plt. [UNS:S31600]

0.2% Proof stress

Sy

21.09 kgf/mm

Youngs modulus

Es

18786 kgf/mm

Weight density

7999.5 kg/m

Allowance
2. SHAFT DATA :
Shaft OD at Impeller

CA

0 mm

Total length
3. BLADE DATA :
Type of impeller

OD

101 mm

3150 mm

Impellar radius

265 mm

Distance of impeller from bottom bearing

3150 mm

No of blades

Nb

4 mm

Width of blade

125 mm

Blade thickness

tb

14 mm

Blade angle
a
0
4. CALCULATION OF BLADE THICKNESS
Torsional moment on shaft [Tm]
= 736 x 60 x H.P. / ( 9.81 x 2 x p x RPM ) kg-m
= 716440.6 x P / RPM kgf-mm
= 716440.6 x 20 / 100
= 143288.1 kgf-mm
Effective force on blade [Fm]
= Tm / ( 0.75 x Rb )
= 143288.1 / ( 0.75 x 265 )
= 720.9 kgf
Minimum blade thickness required [tb]
= SQRT [ 6 x sf x Tm / ( Nb x d x Sa ) ]
= SQRT [ 6 x 2 x 143288.1 / ( 4 x 125 x 21.09 ) ]
= 12.77 mm
Since the calculated thickness 12.77 mm is less that provided thickness 14 mm of blade, blade thickness is adequate.

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date

/ R00 , 06-04-2015 19:23:54

DESIGN OF LIFTING LUG

Lifting Lugs

CODE

P V Design Manual, D.R. Moss


Design Mode 1 , Uncorroded
Condition

1. LIFTING LUG DATA :


Material

IS-2062 GR. A Plt.

Length of lug

LL

77 mm

Width of lug

135 mm

Thickness of lug plate

TL

28 mm

Straight length

B1

10 mm

Radius at tip

R3

40 mm

Pin Hole diameter

D1

50 mm

Lug to vessel weld size

W1

10.22 mm

Min yield stress

Sy

24.61 kgf/mm

Allowable tensile stress ( 2 / 3 x Sy )

St

16.4 kgf/mm

Allowable bending stress ( 1.5 x St )

Sb

22.15 kgf/mm

Allowable shear stress (0.6 x St )


2. DESIGN LOADS :
Empty weight of equipment

Ss

9.843 kgf/mm

Wt

5065.2 kgf

Number of lifting lugs

Jirk load factor


3. CALCULATION OF REFERENCE DIMENSIONS :

1.5

Dimension [ L1 ]
= LL - B1 - R3
= 77 - 10 - 40
= 27 mm

Dimension [ L2 ]
= L1 / SIN ( q1 )
= 27 / SIN ( 0.381 )
= 72.7 mm

Dimension [ LT ]
= LL - R3
= 77 - 40
= 37 mm

Angle [ q2 ]
= ASIN ( R3 / L2 )
= ASIN ( 40 / 72.7 )
= 0.583 radians

Angle [ q1 ]
= ATAN ( 2 x L1 / A )
= ATAN ( 2 x 27 / 135 )
= 0.381 radians

Angle [ q3 ]
= q1 + q2
= 0.381 + 0.583
= 0.963 radians
Dimension [ L3 ]
= R3 / SIN ( q3 )
= 40 / SIN ( 0.963 )
= 48.72 mm

4. DESIGN OF LUG PLATE :


Effective design load on each lug [ P ]
= j x Wt / N
= 1.5 x 5065.2 / 2
= 3798.9 kgf

Required min. thickness of lug plate for shear [ t2 ]


= P / [ ( R3 - 0.5 x D1) x ss ]
= 3798.9 / [ ( 40 - 0.5 x 50 ) x 9.843 ]
= 25.73 mm

Required min. thickness of lug plate for bending [ t1 ]

Required min. thickness of lug plate for shear [ t3 ]


= P / [ ( 2 x L3 - D1 ) x ss ]
= 3798.9 / [ ( 2 x 48.72 - 50 ) x 9.843 ]
= 4.881 mm

= 6 x P x LT / ( A x Sb )
= 6 x 3798.9 x 37 / ( 135 2 x 22.15 )
= 2.089 mm
5. CALCULATION OF STRESSES IN LUG PLATE WELDS :
Bending stress in weld [ f1 ]
= 6 x P x LT / [ 2 x LL2 ]
= 6 x 3798.9 x 37 / ( 2 x 77
= 71.12 kgf/mm

Min. Size of lug plate weld [ w1 ]


= MAX ( f1 , 2 x f2 ) / ( 0.707 x Ss )
= MAX ( 71.12 , 2 x 14.07 ) / ( 0.707 x 9.843 )

Max. shear stress in weld [ f2 ]


=P/[2xA]
= 3798.9 / ( 2 x 135 )
= 14.07 kgf/mm

= 10.22 mm

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date


FOUNDATION LOAD DATA

/ R00 , 06-04-2015 19:23:54


Weight ( kgf )

Sr.
No.

Mode

Condition

Wind
Shear ( kgf )

Empty

Filled

Seismic

Moment ( kgf-m )

Shear

Moment

Tran.

Long.

Tran.

Long.

( kgf )

( kgfm)

Operating

Uncorroded

5065.2

10988.8

1273.2

1273.2

2107.5

2107.5

1136.8

1534.9

Design1

Uncorroded

5065.2

11231.4

1273.2

1273.2

2107.5

2107.5

1161.9

1566.5

Hydro

Uncorroded

4798.1

10964.4

1273.2

1273.2

2107.5

2107.5

1134.2

1529.2

Pneumatic

Uncorroded

4798.1

4805.5

1273.2

1273.2

2107.5

2107.5

497.1

822.3

'CademPVD' Version 14.91 by CADEM Softwares , Pune , Website www.cadem.in


Sunay Wagle, CADEM Services,
Licensee :
Pune, India
Customer

ABC Company Ltd.

Project / Equipment

Soap Plant / Reactor R101

Designed By / Revision and Date


CENTER OF GRAVITY DATA

/ R00 , 06-04-2015 19:23:54

Sr.
No.

Empty

Operating / Filled

Mode

Condition

Operating

Uncorroded

5065.2

2111.4

10988.8

1806.4

Design1

Uncorroded

5065.2

2111.4

11231.4

1804.4

Hydro

Uncorroded

4798.1

2111.4

10964.4

1804.4

Pneumatic

Uncorroded

4798.1

2111.4

4805.5

2110.2

Wt ( kgf )

C.G. ( mm )

Wt ( kgf )

C.G. ( mm )

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