Vessel Design Calculation

BtKitangN90cumCal4.
xls
Batu Kitang
90 cum. SURGE VESSEL DESIGN 27/Oct/16 07:21 PM
Fileused C:\MainHD\Jobs\B&C\2016\BtKitang\45cum\[BtKitang45cumCal5.xls]Sheet1
I) DESIGN PARAMETERS
i) Design pressure
2
Design pressure,P = 1.4 N/mm = 14 bar
2
Test pressure = 1.82 N/mm = 14*1.3 UG-99
= 18.2 bar
2
Operating pressure = 1.2 N/mm = 12 bar
ii) Material & construction
Design code : 2013 ASME BOILER AND PRESSURE VESSEL CODE: Section VIII, Division 1
(Section II, Part D, Table 1A)
2
Use ASTM A516 grade 7 20000 psi = 137.93 N/mm
S, Allowable stress =
2
ASTM A106 grade B carb 17100 psi = 117.93 N/mm
S, Allowable stress =
Degree of radiographic examination : 100%

Fully radiographed butt joints.
From Table UW-12, joint efficiencies E = 100%
2
Young's Modulus E= 200000 N/mm
iii) Dimensions
Internal Diameter ------------------ 2882 mm = 2.882 m

Concrete lining --------------------- 0 mm = 0 m
Steel Plate thickness ---------------- 19 mm = 0.019 m
Corrosion allowance --------------- 1.5 mm = 0.0015 m
Internal dia. of vessel shell ---------- 2882 mm = 2.88 m
Mean dia. of vessel ----------------- 2901 mm = 2.90 m
Outer dia. of vessel ----------------- 2920 mm = 2.92 m
Internal Radius of vessel ------------ 1441 mm = 1.44 m
Length of vessel ---------------------- 12.90 m
LEGEND of SYMBOLS:
t - Minimum required thickness of shell, mm.
p - Internal design pressure , N/mm2 .
R - Inside radius of the shell, mm
S - Allowable stress, N/mm2 .
E - Joint efficiency, %.
D - Inside diameter of the head skirt, mm.
h - Distance nozzle projects beyond the inner surface of the vessel wall, mm
Page 1 of 22
BtKitangN90cumCal4.xls
LIST of CONSTANTS:
Density of water - 10 KN/m3

Density of steel - 79 KN/m3
Density of concrete - 24 KN/m3
Young's modulus of steel - 200,000 N/mm2
II) Vessel design
a) Minimum thickness for internal pressure (Clause UG-27)

i) Circumferential Stress
PR
t = -------------
SE - 0.6P
= 1.4*( 2882/2)/(137.93*100%-0.6* 1.4)
= 14.72 mm add 1.5 mm for corrosion allowance
therefore min. t = 16.22 mm < 19 mm OK
ii) Longitudinal Stress
PR
t = -------------
2SE + 0.4P
= 1.4*( 2882/2)/(2*137.93*100%+0.4* 1.4)
= 7.30 mm add 1.5 mm for corrosion allowance
therefore min. t = 8.80 mm < 19 mm OK

% extreme fiber elongation = 50* 19/ 1441
= 0.66 % < 5%, Heat treatment not necessary
(Ro = infinity for flat plate)
b) Minimum thickness of ellipsoidal ends (Clause UG - 32)
From MANDATORY APPENDICES h
Sect 1-4, Table 1-4.1, for D/2h = 1.81
PDk k = 0.88 D
t = ------------- h= 1441/1.81
2SE - 0.2P = 795
= 1.4* 2882/(2*137.93*100%-0.2* 1.4)*0.88
= 12.85 and add 1.5 mm for corrosion allowance
= 12.85+ 1.5
= 14.35 mm allow 15% for thinning due to forming
therefore min. t =14.35/0.85 = 16.89 mm < 19.0 mm OK
% extreme fiber elongation = 75* 19/ 1441

= 0.99 % < 5%, Heat treatment not necessary
Page 2 of 22
c) Supports (G-9 of ASME VIII:- points to BS5500)
b= 794.76 b= 794.76
A= 2000 A= 2000
L 12900
=
Length of vessel = 12.90 m
Weight of cylinder = 3.14* 2901/1000* 19/1000*79 + 3.14*(+ 2882+ 0)/1000* 0/1000*24

= 13.68 + 0.00
= 13.68 KN/m
Weight of water = 3.14*( 2882/2/1000)^2*10

= 65.23 KN/m
Total W = +65.23+13.68 = 78.91 KN/m
Vol. Ellipsoidal = *d3/24

Surface area of ellipsoidal = 0.313*d2
wt. of ellipsoidal end = 0.313*3.14*2.90^2* .019*79 + 0.313*3.14*(2.882+ 0)^2* 0*24 + 3.14*2.882^3/ 24*10
(each) = 12.42 + 0.00 + 31.33

(steel) (conc.) (water)
= 43.76 KN
Total weight of the vessel (when full) = 78.91*12.90+43.76*2

= 1105.51 KN = 110551 kg
Total weight of the vessel (when empty) = 13.68*12.90+(0.00+12.42)*2
= 201.31 KN = 20131 kg
Volume of vessel = (1105.51-201.31)/10

= 90.4 cu.m.
L= 12900 mm = 12.9 m
Width of saddle, b1 = 200 mm = 0.2 m
b= 794.76 mm = 0.79 m
A= 2000 mm = 2 m
Total length = 12900 mm = 12.9 m
r/2 = 725.25 mm < 2000 mm (A)
therefore Not stiffened by vessel end
2
Cross-sectional area = 3.14* 2901* 19 = 173161 mm
4
Moment of inertia = 3.14/8* 2901^3* 19 = 1.82E+11 mm
Page 3 of 22
Reactions : Maximum supports reaction = 78.91*( 12900/2/1000)+43.76

W1 = 552.75 KN
r= 2882/2 = 1441 mm = 1.44 m

b= 794.76 mm = 0.79 m
L= 12900.00 mm = 12.90 m
A= 2000 mm = 2.00 m
1+2(r2-b2)/L2 = 1+2*(1.44^2-0.79^2)/12.90^2
= 1.017
1 + 4*b/3L = 1+4*0.79/3/12.90
= 1.082
1 - A/L+(r2-b2)/2AL = 1-2.00/12.90+(1.44^2-0.79^2)/2/2.00/12.90
= 0.873
Mid span M3 = 552.75*12.90/4*(1.017/1.082-4*2.00/12.90)

= 570.41 KNm (M3)
Support M4 = -552.75*2.00*(1-0.873/1.082)
= -213.70 KNm (M4)
i)Longitudinal stresses at mid-span : (Clause G.3.3.2.2,BS5500)

at the highest point
pm*r M3
f1 = ------------- - -------------
2t p*r2*t
= 1.4* 1441/2/ 19 - 570.41*1000000/3.14/ 1441^2/ 19
= 53.09 - 4.60
2 2
= 48.49 N/mm < 137.93 N/mm OK
at the lowest point

pm*r M3
f2 = ------------- + -------------
2t p*r2*t
= 1.4* 1441/2/ 19 + 570.41*1000000/3.14/ 1441^2/ 19
= 53.09 + 4.60
2 2
= 57.69 N/mm < 137.93 N/mm OK
Page 4 of 22
ii)Longitudinal stresses at the saddles : (Clause G.3.3.2.3,BS5500)

The shell is not stiffened proximity of the end.
and saddle angle = 140 degrees from table G.2,BS5500
at the highest point K1= 0.142
2
f3 = pmr/2t - M4/(K1*3.142*r *t) K2= 0.249
= 1.4* 1441/2/ 19 + -213.70*1000000/0.142/3.14/ 1441^2 / 19
= 53.09 - -12.17
2 2
= 65.26 N/mm < 137.93 N/mm OK
at the lowest point

f 4= pmr/2t + M4/(K2*3.142*r2*t)
= 1.4* 1441/2/ 19 + -213.70*1000000/0.249/3.14/ 1441^2 / 19
= 53.09 + -6.92
2 2
= 46.17 N/mm < 137.93 N/mm OK
iii) Tangential shearing stress (Clause G.3.3.2.3,BS5500)

Maximum shear force S1 = 552.75*( 12900-2* 2000)/( 12900+4/ 3*794.76)
= 352.41 KN
For shell not stiffened by rings adjacent to saddles.

and saddle angle = 140 degrees
from table G.3 ,BS5500
K3*S1 K3= 0.905
Shear stress in the shell q = -----------
r*t
= 0.905*352.41*1000/ 1441/ 19
2
= 11.65 N/mm
allowable shear stress = smaller of 0.8S or 0.06Et/r
ie. = 110.34 or 158.22
2 2
= 110.34 N/mm > 11.65 N/mm OK
Page 5 of 22
iv) Circumferential stress (Clause G.3.3.2.5,BS5500)
Shell not stiffened by rings (Clause 3.3.2.5.1,BS5500)
W1 = 552.75 KN
Table G.5 , BS5500
At lowest point of the corss section: K5= 0.698
-K5*W1
f5= --------- = -0.698*552.75*1000/ 19/( 200+10*14.72)
tb2
2 2
= -58.52 N/mm < 137.93 N/mm OK
At the horn of the saddle
b2 = 200+10*14.72 = 347.16 mm, b1 = 200 mm is provided.
Stress in Vessel's shell at the edge of b1:

f6 = f61 -f62 Table G.4 , BS5500
f61 = -552.75*1000/4/(14.72)/347.16 K6= 0.03056 for A/r = 1.38
2
= -27.05 N/mm and  = 140+6+6
= 152
L/r = 12900/ 1441
= 8.95
f62 = 3*0.03056*552.75*1000/2/( 19)^2 or 12*0.03056*552.75*1000* 2901/2/ 12900/( 19)^2

= 70.19 or 63.14
2
= 70.19 N/mm , for > 8
 f6 = -27.05-70.19
2
= -97.24 N/mm
2 2
Allowable stress = 1.25f 172.41 N/mm > 97.24 N/mm OK
Page 6 of 22
Stress in Vessel's shell at edge of saddle:

f6 = f61 -f62 Table G.4 , BS5500
f61 = -552.75*1000/4/(14.72+ 12)/347.16 K6= 0.03807 for A/r = 1.38
2
= -14.90 N/mm and  = 140
= 140
L/r = 12900/ 1441
= 8.95
f62 = 3*0.03807*552.75*1000/2/( 19+ 12)^2 or 12*0.03807*552.75*1000* 2901/2/ 12900/( 19+ 12)^2
= 32.84 or 29.54
2
= 32.84 N/mm , for > 8
 f6 = -14.90-32.84
2
= -47.74 N/mm
2 2
Allowable stress = 1.25f 172.41 N/mm > 47.74 N/mm OK
v) Design of saddles (Clause G.3.3.2.6, BS5500)

Material used Grade 43 steel, design to BS449
b1 = 200 Vessel's shell
b1= 200 mm
h = 250 mm t1 = 12 h = 250
t1 = 12 mm t2= 12
t2 = 12 mm
2
Area a= 200* 12+250.00* 12 = 5400 mm
i)Horizontal component of the reaction H
H= K9*W1 clause G3.3.2.6, BS5500

o
= 0.240*552.75 K9 = 0.240 For saddle angle of 140
= 132.85 KN
r/3 = ( 2901/2)/3
= 483.50 > 250 mm  effective h = 250.00 mm
Average direct stress = H/a

= 132.85*1000/ 5400
2 2
= 24.60 N/mm < 91.95 N/mm OK
(2/ 3*137.93)
Page 7 of 22
350 x 400 base plate
450 x 500 sole plate

Concrete Support
Concrete Support
ii) Bearing stress on concrete:
Bearing stress = W1*1000/B/w2

= 552.75*1000/450/500
2
= 2.46 N/mm < allowable bearing stress of 5 N/mm2
iii) Column
h= 250 mm
b= 200 mm x 250 x
Plate
thickness = 12 mm
Area = ( 200*2+ 250)* 12 200

2
= 7800 mm
I xx = 12* 250^3/12+ 200* 12^3 /12*2+ 200* 12*( 250/2)^2 *2
4
9.07E+07 mm
Iyy = 250* 12^3 /12+ 12* 200^3 /12 *2
4
1.60E+07 mm
rxx = SQRT(9.07E+07/ 7800)
107.8 mm
ryy = SQRT(1.60E+07/ 7800)
45.3 mm
Height of column l = 2 m
l/ryy = 2*1000/45.3
= 44.109
from table 17a of BS449, allowable compressive stress = 136 N/mm2
Load on column = 552.75/2

= 276.38 KN
Compressive stress = 276.38*1000/ 7800

2
= 35.43 N/mm < allowable stress of 136 N/mm2
Page 8 of 22
vii) Base plate

6mm fillet weld
45
100
250 x 200 I'
500
20 mm thk
M.S. plate
400
Provide 500 x 400 x 20 thk base plate

Area = 400* 500 = 200,000 mm
2
Maximum axial load /column = 276.4 KN

Assume grade of concrete = 35
Permissible bearing stress = +35.00*0.25
= 8.75 N/mm2
Minimum area required = 276.4*1000/ 8.75
= 31,586 mm OK
2
bearing pressure = 276.4*1000/ 500/ 400

= 1.38 N/mm OK
2
over hang, B = ( 500- 250)/2 = 125 mm

A= ( 400- 200)/2 = 100 mm
Thickness of base plate =SQRT(3*1.38/185*(100.00^2-125.00^2/4))

= 11.69 mm < 20 mm, OK
Length of weld = 250*2+ 200*4

= 1300 mm
Size of weld = 6 mm, strength = 483 N/mm
Strength of weld = 483* 1300/1000
= 627.9 KN > 276.4 KN OK
viii) Hold Down Bolts:
Since there is no up lifting forces, the hold down bolts are designed for shear due to temperature stress.
Provide 4 numbers of 20 mm S.S. bolts
Shear force due to temperature changes = 64.01/2 = 32.00 KN
Shear stress on bolts = 32.00*1000/( 20^2/ 4*3.14* 4)

2 2
= 25.47 N/mm < 100 N/mm , OK
Page 9 of 22
c) Temperature stress:
Coefficient of expansion a = 0.000012 /K
o
Assume temperature change of 20 C
Length of vessel between supports = 8.9 m
elongation due to temperature change = a*T*L

= .000012*20* 8.9*1000
= 2.136 mm
If the vessel is restrained from lateral movement,
temperature srtress = 200000* .000012*20
2
= 48 N/mm
To reduce the temperature stress, one sliding support will be provided
reaction at support (when empty)= 13.68*( 2000/1000+12.90/2)+12.42+0.00 =

= 128.02 KN
Assume coefficient of friction = 0.5
Axial force in Vessel = 128.02 * 0.50 = 64.01 KN

2
or stress = 0.37 N/mm very small
Lifting hook:
Check stresses on vessel:
2Cx 2Cx
2C 2C
At Hook:
Distance of hook from end a = 900 mm
Mean dia. of vessel= 2981 mm mean rad. (ro)= 1490.5 mm
Plate thickness = 38 mm
Length of vessel = 12900 mm
Total W = 201.3 KN
Lifting force W= 201/2 = 100.66 KN
[half thk of lug] C= 19 mm ) Clause G.2.2.1

[half length of lug] Cx= 200.0 mm )
Length Le ( 12900)-4*( 12900/2- 900)^2/( 12900) = 3348.8 mm
Loaded width/2r = 19.00/(1491*2)= 0.00637
Page 10 of 22
Within acceptable range of

r/t = 1490.50/38.00 = 39.22 Fig G.1
Clause G.2.2.1.2
2*Cx 2*200.00
i) axial length of load)/length = -------- = ------- = 0.12
L 3349
ii)
circumferential length of loaded area 2*Co 2*19.00
------------ --------------------------------- = -------- = -------- = 0.095
axial length of loaded area 2*Cx 2*200.00
2
r Cx
iii)Non-dimension function= 64*---- * -- = 45.20
t r
From Fig. G.6 M/W= 0.174 therefore M= 17514.1108 Nmm/mm

From Fig. G.7 Mx/W= 0.09 therefore Mx= 9059.02283 Nmm/mm
From Fig. G.8 N*t/W= -0.126 therefore N= -333.8 N/mm
From Fig. G.9 Nx*t/W= -0.151 therefore Nx= -400.0 N/mm
Nx 6 * Mx
resultant longitudinal stress = ----- +/- - ----------
t t2
= -10.53 +/- - 37.64

2
= 27.12 or -48.17 N/mm
N 6 * M
resultant circumferential stress = ------ +/- - ----------
t t2
= -8.78 +/- - 72.77

2
= 63.99 or -81.56 N/mm
2
Both stresses are less then the allowable stress of 137.93 N/mm
therefore the arrangement is acceptable.
Page 11 of 22
At Stiffener:
Distance of hook from end a = 900 mm
Mean dia. of vessel= 2981 mm mean rad. (ro)= 1490.5 mm
Plate thickness = 19 mm
Length of vessel = 12900 mm
Total W = 201 KN
Lifting force W= 201/2 = 100.7 KN
C= 300 mm ) Clause G.2.2.1
Cx= 300 mm )
Length Le ( 12900)-4*( 12900/2- 900)^2/( 12900) = 3349 mm
Loaded width/2r = 300.00/(1491*2)= 0.1006374
Within acceptable range of
r/t = 1490.50/19.00 = 78.4 Fig G.1
Clause G.2.2.1.2
2*Cx 2*300.00
i) axial length of load)/length = -------- = ------- = 0.18
L 3349
ii)
circumferential length of loaded area Co 2*300.00
------------ --------------------------------- = -------- = -------- = 1.000
axial length of loaded area Cx 2*300.00
2
r Cx
iii)Non-dimension function= 64*---- * -- = 203.39
t r
From Fig. G.6 M/W= 0.040 therefore M= 3993 Nmm/mm
From Fig. G.7 Mx/W= 0.018 therefore Mx= 1840 Nmm/mm
From Fig. G.8 N*t/W= -0.060 therefore N= -317.9 N/mm
From Fig. G.9 Nx*t/W= -0.093 therefore Nx= -491.5 N/mm
Nx 6 * Mx
resultant longitudinal stress = ----- +/- - ----------
t t2
= -25.87 +/- - 30.58

2
= 4.71 or -56.45 N/mm
N 6 * M
resultant circumferential stress = ------ +/- - ----------
t t2
= -16.73 +/- - 66.36

2
= 49.63 or -83.09 N/mm
2
Both stresses are less then the allowable stress of 137.93 N/mm
therefore the arrangement is acceptable.
Page 12 of 22
d) BRANCHES
i) DESIGN of BRANCH or OPENINGS (UG - 37)
600mm Manhole:
Rn
tn
d A5
trn
Lp
A2 te
h+te tr
h t
A1 A4 D
larger of d or Rn+tn+t A3
A
INPUT PARAMETERS :
Dia. of shell D = 2882 mm
2
Design pressure P= 1.4 N/mm
Branch dia. d = 600 mm
2
Allowable stress S = 137.93 N/mm
E= 1.00
Actual thickness of shell = 19 mm
Corrosion allowance c = 1.5 mm
therefore t = 19- 1.5 = 17.5 mm
Thickness of shell due to pressure tr = 1.4* 2882/2/(137.93*1.00-0.6* 1.4)
= 14.72 mm
Thickness of branch due to pressure trn = 1.4* 600/2/(137.93*1.00-0.6* 1.4)
= 3.06 mm
Actual thickness of branch provided = 10 mm
tn = 10- 1.5 = 8.5 mm
Leg length of weld for branch = 10 mm
Thickness of reinforcing plate te = 19 mm (external only)
Leg length of weld for reinforcing plate = 10 mm
Area of replacement required A = dtrF + 2tntrF(1-fr1) [fr1=1]
= +600.00*14.72*1.00
2
= 8829.46 mm
COMPUTE REPLACEMENT AREA:
i) Area A1 (Area available in shell)
d = 600 mm
2(t + tn) = 2*( 17.5+ 8.5)= 52 mm
therefore A1 = MAX( 600, 52)*(1.00* 17.5-1*14.72)

2
= 1670.54 mm
Page 13 of 22
ii) Area A2 (Area available in nozzle projecting outward)
A2 = smaller of 5*( 8.5-3.06)*1* 17.5

or 2*( 8.5-3.06)*(2.5* 8.5+ 19)*1
= 475.68 or 437.63
2
therefore A2 = 437.63 mm
iii) Area A3 (Area available in nozzle projecting inward)
h = smaller of 2.5* 17.5 or 2.5*( 8.5+ 19)

= 43.75 or 68.75
= 43.75 mm
A3 = 0
2
= 0 mm
iv) Area A4 (Area available welds)
A4 (A41 & A43) = 2* 10^2*1

2
= 200 mm
A4 (A42) = 10^2*1
2
= 100 mm
2
Total A4 = 100+ 200 = 300 mm
max. Dp = greater of 2*d or 2*(Rn + tn + t)

= 1200 or 2*(( 600- 1.5*2)/2+ 8.5+ 17.5) = 649
= 1200 mm
Diameter of compensation plate provided = 1229 mm
Width of compensation plate = 291.5 mm wide , 19 mm thick
Dp = 291.5*2+ 8.5*2+ 600 = 1200 mm
A5 = (MIN( 1200, 1200)- 600-2* 8.5)* 19* 1

2
= 11077 mm
Total Replacement area = A1+A2+A3+A4+A5

= 300+ 0+437.63+1670.54+ 11077
2 2
= 13485.16 mm > 8829 mm OK
Page 14 of 22
ii) DESIGN of BRANCH or OPENINGS (UG - 37)

350mm I/O
Rn
tn
d A5
trn
Lp A2 te
h+te tr
h t
A1 A4 D
INPUT PARAMETERS :
2
2
E= 1.00
therefore t = 19- 1.5 = 17.5 mm
= 14.72 mm
= 1.79 mm
Actual thickness of branch provided = 6.3 mm
tn = 6.3- 1.5 = 4.8 mm
Leg length of weld for branch = 6.3 mm
Leg length of weld for reinforcing plate = 6.3 mm
= +350.00*14.72*1.00
2
= 5150.52 mm
d = 350 mm
2(t + tn) = 2*( 17.5+ 4.8)= 44.6 mm
therefore A1 = MAX( 350, 44.6)*(1.00* 17.5-1*14.72)

2
= 974.48 mm
Page 15 of 22
A2 = smaller of 5*( 4.8-1.79)*1* 17.5

or 2*( 4.8-1.79)*(2.5* 4.8+ 19)*1
= 263.63 or 186.80
therefore A2 = MIN(263.63,186.80)*117.93/137.93
2
= 159.71 mm
h = smaller of 2.5* 17.5 or 2.5*( 4.8+ 19)

= 43.75 or 59.5
= 43.75 mm
A3 = 0
2
= 0 mm
A4 (A41 & A43) = 2* 6.3^2*1

2
= 79.38 mm
A4 (A42) = 6.3^2*1
2
= 39.69 mm
2
Total A4 = 39.69+ 79.38 = 119.07 mm

= 700 or 2*(( 350- 1.5*2)/2+ 4.8 391.6
= 700 mm
Diameter of compensation plate provided = 725.6 mm
Dp = 171.5*2+ 4.8*2+ 350 = 702.6 mm
A5 = (MIN( 700, 702.6)- 350-2* 4.8)* 19* 1

2
= 6467.6 mm

= 119.07+ 0+159.71+974.48+ 6467.6
2 2
= 7720.86 mm > 5150.52 mm OK
Page 16 of 22
iii) DESIGN of BRANCH or OPENINGS (UG - 37)

80mm Pressure relief
Rn
tn
d A5
trn
Lp A2 te
h+te tr
h t
A1 A4 D
INPUT PARAMETERS :
2
2
E= 1.00
therefore t = 19- 1.5 = 17.5 mm
= 14.72 mm
= 0.41 mm
tn = 3.5- 1.5 = 2 mm
Leg length of weld for branch = 3.5 mm
Leg length of weld for reinforcing plate = 3.5 mm
= +80.00*14.72*1.00
2
= 1177.26 mm
d = 80 mm
2(t + tn) = 2*( 17.5+ 2)= 39 mm
Page 17 of 22
therefore A1 = MAX( 80, 39)*(1.00* 17.5-1*14.72)

2
= 222.74 mm
A2 = smaller of 5*( 2-0.41)*1* 17.5

or 2*( 2-0.41)*(2.5* 2+ 19)*1
= 139.26 or 76.39
therefore A2 = MIN(139.26,76.39)*117.93/137.93
2
= 65.32 mm
h = smaller of 2.5* 17.5 or 2.5*( 2+ 19)

= 43.75 or 52.5
= 43.75 mm
A3 = 0
2
= 0 mm
A4 (A41 & A43) = 2* 3.5^2*1

2
= 24.5 mm
A4 (A42) = 3.5^2*1
2
= 12.25 mm
2
Total A4 = 12.25+ 24.5 = 36.75 mm

= 160 or 2*(( 80- 1.5*2)/2+ 2+ 17116
= 160 mm
Diameter of compensation plate provided = 201 mm
Width of compensation plate = 57 mm wide , 19 mm thick
Dp = 57*2+ 2*2+ 80 = 198 mm
A5 = (MIN( 160, 198)- 80-2* 2)* 19* 1

2
= 1444 mm

= 36.75+ 0+65.32+222.74+ 1444
2 2
= 1768.80 mm > 1177.26 mm OK
Page 18 of 22
iv) DESIGN of BRANCH or OPENINGS (UG - 37)

50mm Air Inlet
d A5
trn
Lp
A2 te
h+te tr
h t
A1 A4 D
INPUT PARAMETERS :
2
2
E= 1.00
therefore t = 19- 1.5 = 17.5 mm
= 14.72 mm
= 0.26 mm
tn = 2.77- 1.5 = 1.27 mm
= +50.00*14.72*1.00
2
= 735.79 mm
d = 50 mm
2(t + tn) = 2*( 17.5+ 1.27)= 37.54 mm
therefore A1 = MAX( 50, 37.54)*(1.00* 17.5-1*14.72)
Page 19 of 22
2
= 139.21 mm
A2 = smaller of 5*( 1.27-0.26)*1* 17.5

or 2*( 1.27-0.26)*(2.5* 1.27+ 19)*1
= 88.79 or 45.00
therefore A2 = MIN(88.79,45.00)*117.93/137.93
2
= 38.48 mm
h = smaller of 2.5* 17.5 or 2.5*( 1.27+ 19)

= 43.75 or 50.675
= 43.75 mm
A3 = 0
2
= 0 mm
A4 (A41 & A43) = 2* 3^2*1

2
= 18 mm
A4 (A42) = 3^2*1
2
= 9 mm
2
Total A4 = 9+ 18 = 27 mm

= 100 or 2*(( 50- 1.5*2)/2+ 1.27+ 17.5) = 84.54
= 100 mm
Dp = 42.9*2+ 1.27*2+ 50 = 138.34 mm
A5 = (MIN( 100, 138.34)- 50-2* 1.27)* 19* 1

2
= 901.74 mm

= 27+ 0+38.48+139.21+ 901.74
2 2
= 1106.43 mm > 735.79 mm OK
Page 20 of 22
v) DESIGN of BRANCH or OPENINGS (UG - 37)

25mm Sight Glass
Rn
tn
d A5
trn
Lp
A2 te
h+te tr
h t
A1 A4 D
INPUT PARAMETERS :
2
2
E= 1.00
therefore t = 19- 1.5 = 17.5 mm
= 14.72 mm
= 0.13 mm
tn = 2.77- 1.5 = 1.27 mm
= +25.00*14.72*1.00
2
= 367.89 mm
d = 25 mm
2(t + tn) = 2*( 17.5+ 1.27)= 37.54 mm
Page 21 of 22
therefore A1 = MAX( 25, 37.54)*(1.00* 17.5-1*14.72)

2
= 104.52 mm
A2 = smaller of 5*( 1.27-0.13)*1* 17.5

or 2*( 1.27-0.13)*(2.5* 1.27+ 16)*1
= 99.96 or 43.81
therefore A2 = MIN(99.96,43.81)*117.93/137.93
2
= 37.46 mm
h = smaller of 2.5* 17.5 or 2.5*( 1.27+ 16)

= 43.75 or 43.175
= 43.175 mm
A3 = 2*( 1.27- 1.5)*1* 43.175

2
= -19.8605 mm
A4 (A41 & A43) = 2* 3^2*1

2
= 18 mm
A4 (A42) = 3^2*1
2
= 9 mm
2
Total A4 = 9+ 18 = 27 mm
Dp = greater of 2*d or 2*(Rn + tn + t)

= 50 or 2*(( 25- 1.5*2)/2+ 1.27+ 17.5) = 59.54
= 59.54 mm
Say provide compensation plate of 35.4 mm wide , 16 mm thick
Dp = 35.4*2+ 1.27*2+ 25 = 98.34 mm
A5 = (MIN( 59.54, 98.34)- 25-2* 1.27)* 16* 1

2
= 512 mm

= 27+-19.8605+37.46+104.52+ 512
2 2
= 661.12 mm > 367.89 mm OK
Page 22 of 22

Vessel Design Calculation

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Vessel Design Calculation

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BtKitangN90cumCal4.

Degree of radiographic examination : 100%

Internal Diameter ------------------ 2882 mm = 2.882 m

Density of water - 10 KN/m3

II) Vessel design

a) Minimum thickness for internal pressure (Clause UG-27)

therefore min. t = 16.22 mm < 19 mm OK

ii) Longitudinal Stress

therefore min. t = 8.80 mm < 19 mm OK

% extreme fiber elongation = 75* 19/ 1441

c) Supports (G-9 of ASME VIII:- points to BS5500)

Length of vessel = 12.90 m

Weight of cylinder = 3.14* 2901/1000* 19/1000*79 + 3.14*(+ 2882+ 0)/1000* 0/1000*24

Weight of water = 3.14*( 2882/2/1000)^2*10

Vol. Ellipsoidal = *d3/24

(each) = 12.42 + 0.00 + 31.33

Total weight of the vessel (when full) = 78.91*12.90+43.76*2

Volume of vessel = (1105.51-201.31)/10

Reactions : Maximum supports reaction = 78.91*( 12900/2/1000)+43.76

r= 2882/2 = 1441 mm = 1.44 m

Mid span M3 = 552.75*12.90/4*(1.017/1.082-4*2.00/12.90)

i)Longitudinal stresses at mid-span : (Clause G.3.3.2.2,BS5500)

at the lowest point

ii)Longitudinal stresses at the saddles : (Clause G.3.3.2.3,BS5500)

at the lowest point

iii) Tangential shearing stress (Clause G.3.3.2.3,BS5500)

For shell not stiffened by rings adjacent to saddles.

iv) Circumferential stress (Clause G.3.3.2.5,BS5500)

Shell not stiffened by rings (Clause 3.3.2.5.1,BS5500)

At the horn of the saddle

b2 = 200+10*14.72 = 347.16 mm, b1 = 200 mm is provided.

Stress in Vessel's shell at the edge of b1:

f62 = 3*0.03056*552.75*1000/2/( 19)^2 or 12*0.03056*552.75*1000* 2901/2/ 12900/( 19)^2

Stress in Vessel's shell at edge of saddle:

f62 = 3*0.03807*552.75*1000/2/( 19+ 12)^2 or 12*0.03807*552.75*1000* 2901/2/ 12900/( 19+ 12)^2

v) Design of saddles (Clause G.3.3.2.6, BS5500)

i)Horizontal component of the reaction H

H= K9*W1 clause G3.3.2.6, BS5500

= 483.50 > 250 mm  effective h = 250.00 mm

Average direct stress = H/a

350 x 400 base plate

450 x 500 sole plate

ii) Bearing stress on concrete:

Bearing stress = W1*1000/B/w2

Area = ( 200*2+ 250)* 12 200

Load on column = 552.75/2

Compressive stress = 276.38*1000/ 7800

vii) Base plate

Provide 500 x 400 x 20 thk base plate

Maximum axial load /column = 276.4 KN

bearing pressure = 276.4*1000/ 500/ 400

over hang, B = ( 500- 250)/2 = 125 mm

Thickness of base plate =SQRT(3*1.38/185*(100.00^2-125.00^2/4))

Length of weld = 250*2+ 200*4

viii) Hold Down Bolts:

Provide 4 numbers of 20 mm S.S. bolts

Shear force due to temperature changes = 64.01/2 = 32.00 KN

Shear stress on bolts = 32.00*1000/( 20^2/ 4*3.14* 4)

elongation due to temperature change = a*T*L

To reduce the temperature stress, one sliding support will be provided

reaction at support (when empty)= 13.68*( 2000/1000+12.90/2)+12.42+0.00 =

Axial force in Vessel = 128.02 * 0.50 = 64.01 KN

[half thk of lug] C= 19 mm ) Clause G.2.2.1

Within acceptable range of

Weight of cylinder = 3.14* 2901/1000* 19/100079 + 3.14(+ 2882+ 0)/1000* 0/1000*24

Weight of water = 3.14( 2882/2/1000)^210

Total weight of the vessel (when full) = 78.9112.90+43.762

Mid span M3 = 552.7512.90/4(1.017/1.082-4*2.00/12.90)

f62 = 30.03056552.751000/2/( 19)^2 or 120.03056552.751000* 2901/2/ 12900/( 19)^2

f62 = 30.03807552.751000/2/( 19+ 12)^2 or 120.03807552.751000* 2901/2/ 12900/( 19+ 12)^2

Area = ( 2002+ 250) 12 200

Thickness of base plate =SQRT(31.38/185(100.00^2-125.00^2/4))

Length of weld = 2502+ 2004

Shear stress on bolts = 32.001000/( 20^2/ 43.14* 4)

elongation due to temperature change = aTL

therefore A1 = MAX( 600, 52)(1.00 17.5-1*14.72)

A2 = smaller of 5( 8.5-3.06)1* 17.5

max. Dp = greater of 2d or 2(Rn + tn + t)

Dp = 291.52+ 8.52+ 600 = 1200 mm

therefore A1 = MAX( 350, 44.6)(1.00 17.5-1*14.72)

A2 = smaller of 5( 4.8-1.79)1* 17.5

max. Dp = greater of 2d or 2(Rn + tn + t)

Dp = 171.52+ 4.82+ 350 = 702.6 mm

therefore A1 = MAX( 80, 39)(1.00 17.5-1*14.72)

A2 = smaller of 5( 2-0.41)1* 17.5

max. Dp = greater of 2d or 2(Rn + tn + t)

Dp = 572+ 22+ 80 = 198 mm

therefore A1 = MAX( 50, 37.54)(1.00 17.5-1*14.72)

A2 = smaller of 5( 1.27-0.26)1* 17.5

max. Dp = greater of 2d or 2(Rn + tn + t)

Dp = 42.92+ 1.272+ 50 = 138.34 mm

therefore A1 = MAX( 25, 37.54)(1.00 17.5-1*14.72)

A2 = smaller of 5( 1.27-0.13)1* 17.5

A3 = 2( 1.27- 1.5)1* 43.175

Dp = greater of 2d or 2(Rn + tn + t)

Dp = 35.42+ 1.272+ 25 = 98.34 mm