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3 2004 EDITION
BY SRINIVASAN.R MFF ENGINEERING
1 Calculate the thickness for 10" pipe having internal Pressure of 18 bar, design temp= 270 deg C material
of pipe - A312 TP304 (ERW). Also find MAWP and rating of flange. Flange material - A182 GR F304
please note that 0.875 of nom thk > minimum thk for 100% - 3.4 mm
0.875 x 3.4= 2.975 > 2.74 mm for 87.5% - 0.875 x 3.4 = 2.975
c) Rating of Flange
To find Rating of flange for A312 TP304 Pr=18 bar at 270 deg C refer ANSI B16.5 group 2.1 table 2-2
Since MAWP is 22.6 kg/cm^2 which falls in 300 # group Flange rating is 300.
NOTE:- 1.SA106 GRB pipes are seamless only no ERW pipes are available.
2. For calculating thk of pipes t min = t calculated + c.a then add 12.5 % mill tolerance
tmin/0.875 = tnom
2 THICKNESS UNDER EXTERNAL PRESSURE CLAUSE 304.1.3
2 Calculate the pipe wall thickness for following design condition of jacketed pipe
Core pipe size = 8", internal pressure 50 bar at 250 deg C( 482 deg F) Jacket pipe size = 10" jacket
having saturated steamat 25 bar pressure C.A internal = 1.6 mm External = 1.0 mm
Material core pipe is A106 GR B jacketed pipe A53 GR B . L=6000 mm
= (725*8.625/2*(19098*1+725*0.4)) + 2.6/25.4
= 0.263"
add 12.5% tolerance ie 0.875 x 0.263 = 0.3"= 8.18 mm
For 8" pipe and thickness 7.62 mm nearest schedule is SCH 40 ie 8.18 mm(0.322")
using the value of factor A and temperature in deg F find factor B which is 6800 psi
Since Pa max allowable external pressure is less than actual pressure 25 kg/cm^2 (362.5 psi)
selected sch40 is not adequate. Hence repeat the procedure till Pa>P(actual pr)by increasing thk.
3 Calculate the thickness of bend after forming with the following datas
Design Pressure= 261 psi. 10" pipe design temperature = 518 deg f
long radius material of pipe is SA312 TP 304 ERW Pipe)
Thickening of the bend takes place at inside bend radius (ie intrados ) and thinning
takes place at outside bend radius (ie. Extrados)
To calculate the thickness of pipe before bending, the loss in thickness due to thinning at outer radius
shall be added to pipe thickness.
pipe thickness is determined by t = (PDO/ 2(SE+PY)) + C.A
=261*10.75/(2*(17300*0.85)+261*0.4)+0
=0.0947"
Thickness of pipe before bending = pipe thickness + loss in thickness at extrados due to thinning
= 0.0947 " + 0.0117"
= 0.1064" = 2.703 MM
ADD 12.5% TOLERANCE
= 0.1064 / 0.875 = 0.1217" = 3.09 MM
For 10" pipe and thickness 3.09 mm nearest schedule is SCH 5S ie 3.4 mm
please note that 0.875 of nom thk > minimum thk for 100% - 3.4 mm
0.875 x 3.4= 2.975 > 2.703 mm for 87.5% - 0.875 x 3.4 = 2.975
4 Calculate the thickness of bend after forming with the following datas
Design Pressure= 261 psi. 10" pipe design temperature = 518 deg f
long radius material of pipe is SA312 TP 304 ERW Pipe) ANGLE THEETA= 22.5 DEG
Pm = SEW (T-c) / r2 (( T-c) / ( (t-c) + 0.643 TAN THEETA SQRT (r2 (T-c))) ------ 1
r2 = Mean radius of pipe using nominalwall T= (OD- thk) / 2 =( 10.75 - 0.117) / 2 = 5.3165"
Assume Thk as SCH 5S = 3.4 mm = 3.4 x 0.875 = 2.975 /25.4 = 0.117"
Pm= allowable design internal pressure
Pm= 17302 x 0.85 (0.117-0) / 5.3165 ( (0.117-0) / (0.117-0) + 0.643 tan 22.5 sqrt (5.3165(0.117)))
= 1720.68 / 5.3165 ( 0.117 / 0.3270)
= 323.6497 x 0.3577 = 115. 779 psi
The lesser of equation 1 & 2 must be greater than Design pr otherwise increase the thickness
Pm = SEW (T-c) / r2 (( T-c) / ( (t-c) + 0.643 TAN THEETA SQRT (r2 (T-c))) ------ 1
= 17302 x 0.85 x 1 (0.2188-0) / 5.265 ((0.2118-0) / (0.2118 - 0) + 0.643 tan 22.5 sqrt ( 5.265 x 0.218)))
= 611.17 (0.4296)
= 262.54 psi
The lesser of equation 1 & 2 must be greater than Design pr otherwise increase the thickness
hence Pm=allowable int Pr = 262.54 psi > P Design Pr (261 psi) hence the thk Sch 20 is adequate
5 THICKNESS OF BLANK CLAUSE 304.5.3
5 Calculate the thickness of 6" branch pipe for the data mentioned below
Design Pr=18 bar Design Temperature = 270 deg C =518 deg F E=0.85 s=17302 psi C.A = 0.0
MOC of pipe = SA312 TP304 line size = 10"
= 0.0947" = 2.4054 mm
Minimum design thickness th=2.406 mm
th is the design thickness of header
add mill tolerance of 12.5%
= 0.058" =1.4828 mm
Minimum design thickness tb=1.4828 mm
th is the design thickness of header
add mill tolerance of 12.5%
A3= Area available for reinforcement from excess thickness in branch pipe
= 2 L4 (Tb-tb-c) / sin beeta
=2*6.06*(2.4237-1.4828-0)/1
= 11.403 mm^2
7) Design a weldneck flange to suit 10" pipe 300 rating for the following data
Design pr P= 18 bar = 261 psi Design temp t = 270 deg C (518 deg f)
Bolting material = SA193 GR B7 Flange material = SA 105 flat ring gasket of 1/8" thk.
Refer clause 304.5.1 of B31.3 which interm refers to appendix 2 of ASME SEC VIII DIVI
For designing a flange, the dimension of B16.5 are taken into consideration then to check
whether induced stress are within allowable limit then by iteration the dimensions are
optimised to get a optimum flange.
b = effective gasket or joint contact surface seating width Note 1 2-5 (c)(1)
bo= basic seating width from table 2-5.2
b=bo when bo< = 1/4" (6mm) and b=sqrt (bo/2) when bo > 1/4 in (6 mm)
Moment calculations
Hd = Hydrostatic end force on area inside of flange LB
Hg = Gasket load
Ht = difference between total hydrostatic end force and the hydrostatic end force
on area inside of flange
hd = radial distance from bolt circle to the circle on which Hd acts
hg = radial distance from gasket load reaction to the bolt circle
ht = radial distance from bolt circle to the circle on which Ht acts.
Md , Mg & Mt are respective moments.
Hd=pi b^2 p /4 =pi x 10.02^2 x 261 /4 =20580.97 lb
Hg= Wm1 - H = 62319.77 - 34271.05 = 28048.72 lb
Ht= H- Hd = 34271.05 - 20580.97 = 13690.08 lb
Using the governing moment = 163980.5 lb-in find the following stresses.
Longitudinal hub stress Sh= fMo / lambda x b x g1^2 = 8819.33 < 1.5 Sfa=34950psi
Radial flange stress Sr = beta x Mo / lambda x t^2 = 7929.8 < Sf0 = 19112 psi
Tangential flange stress St= Mo Y/ t^2 X B - Z x Sr =2623.23 <Sfo = 19112 psi
Combined stress shall be greater of 0.5 (Sh + Sr) & 0.5 (Sh+ St)
= greater of 8374.56 & 5721.28 ie 8374.56 < Sfo =19112 psi
8) For the above flange data find the thickness of blind flange when it is directly welded & when it is bolted.
When the head , cover or blind flange is bolted the thickness is calculated by
t = d x sqrt ( cx p / SxE + 1.9 W hg / Sed^3 ) + C.A
t operating = 12.93 x sqrt ( 0.33 x 261 / 19112 x 1 ) + ( 1.9 x 62319.77 x 1.16 ) / 19112 x 1 x (12.93)^3 )
= 1.144" = 29.06 mm
9) For the flange designed above find the torque required to tigjhten the bolt.
Pe = 16 M / PI x G^3 + 4 Pr / PI x G^2 + P
Pe = P
H= PI /4 X G^2 x Pe = PI/4 x 912.93)^2 x 261 = 34271.05 lb
Hp = 2bPI Gm Pe = 28048.72
Wm2 = PI x b x G x y = 42986.55 lb
Ag= 2xPI x b x G = 53.73 in^2
T = K W dm / 12 n n = no. of bolts
= 0.1 x 62175.14 x 0.9188 / 12 x 16
= 29.75 ft-lb