htri-compress kettle calculations
TRANSCRIPT
Codeware, Inc.
Houston, TX, USA
www.codeware.com
COMPRESS Pressure Vessel Design Calculations
Item: Split Stream DearatorVessel No: V-1234Customer: Magaladon Oil Venture
Contract: C-45490-R56Designer: John Doe
Date: April 1, 2001
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Deficiencies Summary
Deficiencies for Kettle reboilerTEMA RCB-3.13: The shell thickness is less than the required minimum thickness of 0.3125 in.TEMA RCB-4.52: The unsupported straight tube span exceeds 69 in.TEMA RCB-3.13: The front channel thickness is less than the required minimum thickness of 0.3125 in.TEMA RCB-3.2: The rear closure thickness is less than the required minimum thickness of 0.3125 in.TEMA RCB-3.2: The front channel closure thickness is less than the required minimum thickness of 0.3125 in.
Deficiencies for SaddleShell bending stress at the saddle is excessive.Circumferential stress at the wear plate horns is excessive.
Deficiencies for SS Inlet (N4)Nozzle MAWP (56.1229 psi) is less than the design pressure (60.3041 psi).The inner fillet weld (Leg41) is too small., MAP condition per UW-16
Deficiencies for SS Outlet (N3)The inner fillet weld (Leg41) is too small., MAP condition per UW-16
Deficiencies for SS Outlet 2 (N5)Nozzle MAWP (59.2441 psi) is less than the design pressure (60.3041 psi).The inner fillet weld (Leg41) is too small., MAP condition per UW-16
Deficiencies for TS Inlet (N1)Due to size or thickness limitations, SA-455 <= 3/8 is not acceptable.The inner fillet weld (Leg41) is too small., MAP condition per UW-16
Deficiencies for TS Outlet (N2)The inner fillet weld (Leg41) is too small., MAP condition per UW-16
Warnings Summary
Warnings for Kettle reboilerFront Tubesheet: UHX-12.4(c): The tubesheet corroded thickness (0.8908 in) is less than the tube diameter (1 in).The effect of the tubesheet deflection should be considered in the design. (warning)
Warnings for SaddleThe wear plate thickness should not exceed the shell thickness (Bednar Note #1, Section 6.4 (pg 171, 2nd Ed)(warning)
Warnings for Shell Side Flange (front)TEMA, Table D-5: Current bolt circle (19.25 in) does not provide sufficient wrench clearance, 19.5 in recommended.(warning)TEMA, Table D-5: Bolt washers will extend beyond the flange outer diameter. (warning)
Warnings for SS Inlet (N4)UCS-79: The extreme fiber elongation exceeds 5 percent. Heat treatment per UCS-56 may be required. SeeUCS-79(d)(4) or (5). (warning)
Warnings for SS Outlet (N3)Nozzle does not satisfy the specified minimum projection length of 6.0000" (warning)
Warnings for SS Outlet 2 (N5)UCS-79: The extreme fiber elongation exceeds 5 percent. Heat treatment per UCS-56 may be required. SeeUCS-79(d)(4) or (5). (warning)
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Warnings for TS Inlet (N1)UCS-79: The extreme fiber elongation exceeds 5 percent and the thickness exceeds 5/8 inch;. Heat treatment perUCS-56 is required if fabricated by cold forming. (warning)Appendix 1-10(d): Di / t = 17.375 / 0.125 = 139 > 100 and nozzle projection = 5.9375" < 3*(Rn*tn)2 =3*(7.0005*0.9995)1/2 = 7.9356". Strain redistribution may cause distortion (ovaling) of the nozzle neck and flange suchthat a proper seal at the bolted flange connection cannot be obtained or maintained. Division 2 Part 4.5 performed perU-2(g). Optionally, Appendix 1-7 may be used for radial nozzles by selecting the option in the Areas dialog. (warning)Nozzle thickness in excess of three times the vessel plus pad thickness (tn = 0.9995" > 3*t = 3*0.125 = 0") is notrecommended and may produce excessive secondary stresses in the welds. (warning)Nozzle thickness in excess of three times the vessel plus pad thickness (tn = 1.062" > 3*t = 3*0.1875 = 0") is notrecommended and may produce excessive secondary stresses in the welds. (warning)Nozzle does not satisfy the specified minimum projection length of 6.0000" (warning)
Warnings for Tube Side Flange (front)TEMA, Table D-5: Current bolt circle (19.25 in) does not provide sufficient wrench clearance, 19.5 in recommended.(warning)TEMA, Table D-5: Bolt washers will extend beyond the flange outer diameter. (warning)This body flange is being counted as a line of support for external pressure. (warning)
Warnings for VesselNo baffles specified. Vessel weight and weight distribution may not be correct. (warning)
ASME B16.5 / B16.47 Flange Warnings Summary
ASME B16.5 / 16.47 Flanges with Warnings
Flange Applicable Warnings
TS Inlet (N1) 1, 2
TS Outlet (N2) 1, 2
SS Outlet (N3) 1
SS Inlet (N4) 1
SS Outlet 2 (N5) 1
ASME B16.5 / 16.47 Flange Warnings
No. Warning
1 For Class 150 flanges, ASME B16.5 para. 5.4.3 recommends gaskets to be in accordance with Annex C, TableC1, Group No. I.
2 For Class 150 flanges when temperature exceeds 400°F, care should be taken to avoid imposing severeexternal loads and/or thermal gradients or leakage may develop.ASME B16.5 para. 2.5.2.
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Nozzle Schedule
Nozzlemark Service Size
Materials
Nozzle Impact Norm Fine Grain Pad Impact Norm Fine Grain Flange
N1 TS Inlet 13.88 IDx1.06 SA-455 <= 3/8 No No No N/A N/A N/A N/A WN A105 Class 150
N2 TS Outlet 8.07 IDx0.28 SA-455 <= 3/8 No No No N/A N/A N/A N/A WN A105 Class 150
N3 SS Outlet 8.00 IDx0.31 SA-455 <= 3/8 No No No N/A N/A N/A N/A WN A105 Class 150
N4 SS Inlet 4.00 IDx0.25 SA-455 <= 3/8 No No No N/A N/A N/A N/A WN A105 Class 150
N5 SS Outlet 2 7.63 IDx0.50 SA-455 ( 3/8 < t <= 0.58) No No No N/A N/A N/A N/A WN A105 Class 150
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Nozzle Summary
Nozzlemark
OD(in)
tn
(in)Req t
n(in)
A1? A2?Shell Reinforcement
Pad Corr(in)
Aa/A
r(%)
Nom t(in)
Design t(in)
User t(in)
Width(in)
tpad(in)
N1 16.00 1.0620 0.1481 Yes Yes 0.1875 0.1875 N/A N/A 0.0625 145.9
N2 8.63 0.2770 0.1329 Yes Yes 0.1875 0.1563 N/A N/A 0.0625 100.0
N3 8.63 0.3120 0.1250 Yes Yes 0.1250 0.0984 N/A N/A 0.0625 100.0
N4 4.50 0.2500 0.1250 Yes Yes 0.1250 0.0816 N/A N/A 0.0625 100.1
N5 8.63 0.5000 0.1250 Yes Yes 0.1250 0.1026 N/A N/A 0.0625 100.0
tn: Nozzle thicknessReq tn: Nozzle thickness required per UG-45/UG-16Nom t: Vessel wall thicknessDesign t: Required vessel wall thickness due to pressure + corrosion allowance per UG-37User t: Local vessel wall thickness (near opening)Aa: Area available per UG-37, governing conditionAr: Area required per UG-37, governing conditionCorr: Corrosion allowance on nozzle wall
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Pressure Summary
Pressure Summary for Tube side chamber
IdentifierP
Design( psi)
T
Design(°F)
MAWP( psi)
MAP( psi)
MAEP( psi)
Te
external(°F)
MDMT(°F)
MDMTExemption
Total Corrosion
Allowance(in)
ImpactTest
Front Head 0.0 414.5 144.58 289.44 27.86 414.5 -20.0 Note 1 0.063 No
Straight Flange on Front Head 0.0 414.5 284.73 429.18 60.54 414.5 -20.0 Note 2 0.063 No
Front Channel 0.0 414.5 284.73 429.18 60.54 414.5 -20.0 Note 2 0.063 No
Tubesheet 0.0 414.5 0.00 135.67 60.62 414.5 -20.0 Note 3 0.125 No
Tubes 0.0 414.5 2278.57 2279.14 1318.79 414.5 -155.0 Note 4 0.000 No
Tube Side Flange (front) 0.0 414.5 265.60 285.33 989.51 414.5 -26.9 Note 5 0.000 No
Tube Side Flange (front) - Flange Hub 0.0 414.5 286.78 287.36 61.21 414.5 -20.0 Note 6 0.000 No
TS Inlet (N1) 0.0 414.5 195.65 285.00 60.54 414.5 -20.0 Note 7 0.063 No
TS Outlet (N2) 0.0 414.5 160.75 248.71 29.83 414.5 -27.6 Note 8 0.063 No
Chamber design MDMT is -20.00°FChamber rated MDMT is -20.00°F @ 0.00 psi
Chamber MAWP hot & corroded is 0.00 psi @ 414.5°F
Chamber MAP cold & new is 135.67 psi @ 70.0°F
Chamber MAEP is 27.86 psi @ 414.5°FVacuum rings did not govern the external pressure rating.
Pressure Summary for Shell side chamber
IdentifierP
Design( psi)
T
Design(°F)
MAWP( psi)
MAP( psi)
MDMT(°F)
MDMTExemption
Total Corrosion
Allowance(in)
ImpactTest
Tubesheet 73.5 414.5 60.62 135.67 -20.0 Note 3 0.125 No
Port Cylinder (front) 60.3 307.6 142.34 287.36 -55.0 Note 9 0.063 No
Front Cone 60.3 307.6 88.71 179.96 -55.0 Note 10 0.063 No
Shell 60.3 307.6 91.47 185.47 -55.0 Note 11 0.063 No
Straight Flange on Rear Shell Head 60.3 307.6 91.47 185.47 -55.0 Note 11 0.063 No
Rear Shell Head 60.3 307.6 92.26 186.34 -55.0 Note 12 0.063 No
Tubes 0.0 414.5 1318.79 1318.79 N/A N/A 0.000 No
Shell Side Flange (front) 60.3 307.6 303.26 285.34 -55.0 Note 13 0.000 No
Shell Side Flange (front) - Flange Hub 60.3 307.6 286.43 287.36 -155.0 Note 14 0.000 No
Saddle 60.3 307.6 56.12 N/A N/A N/A N/A N/A
SS Outlet (N3) 60.3 307.6 62.50 129.16 -37.7 Note 15 0.063 No
SS Inlet (N4) 60.3 307.6 56.12 121.27 -20.3 Note 16 0.063 No
SS Outlet 2 (N5) 60.3 307.6 59.24 122.34 -21.2 Note 17 0.063 No
Chamber design MDMT is -20.00°FChamber rated MDMT is -20.00°F @ 56.12 psi
Chamber MAWP hot & corroded is 56.12 psi @ 307.6°F
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Chamber MAP cold & new is 121.27 psi @ 70.0°F
This pressure chamber is not designed for external pressure.
Notes for MDMT Rating:
Note # Exemption Details
1. Straight Flange governs MDMT
2. Material is impact test exempt per UG-20(f) UCS-66 governing thickness = 0.1875 in
3. Tubesheet is impact test exempt per UG-20(f) UCS-66 governing thickness = 0.254 in.
4. Material is impact test exempt per UCS-66(d) (NPS 4 or smaller pipe)
5.
UCS-66(b)(1)(b) has been applied.Flange impact test exemption temperature from Fig UCS-66 Curve B = -20 °FFig UCS-66.1 MDMT reduction = 6.9 °F, (coincident ratio = 0.9308646)UCS-66 governing thickness = 0.125 in
Bolts rated MDMT per Fig UCS-66 note (e) = -55 °F
6. Material is impact test exempt per UG-20(f) UCS-66 governing thickness = 0.125 in
7. Nozzle is impact test exempt per UG-20(f) UCS-66 governing thickness = 0.1875 in.
8. Nozzle impact test exemption temperature from Fig UCS-66 Curve A = 18 °FFig UCS-66.1 MDMT reduction = 45.6 °F, (coincident ratio = 0.56336) UCS-66 governing thickness = 0.1875 in.
9.Material impact test exemption temperature from Fig UCS-66 Curve B = -20 °FFig UCS-66.1 MDMT reduction = 105 °F, (coincident ratio = 0.3972073)Rated MDMT is governed by UCS-66(b)(2)
UCS-66 governing thickness = 0.125 in
10.Material impact test exemption temperature from Fig UCS-66 Curve B = -20 °FFig UCS-66.1 MDMT reduction = 36.4 °F, (coincident ratio = 0.6364939)Rated MDMT is governed by UCS-66(b)(2)
UCS-66 governing thickness = 0.125 in
11.Material impact test exemption temperature from Fig UCS-66 Curve B = -20 °FFig UCS-66.1 MDMT reduction = 38.3 °F, (coincident ratio = 0.6174237)Rated MDMT is governed by UCS-66(b)(2)
UCS-66 governing thickness = 0.125 in
12. Straight Flange governs MDMT
13. UCS-66(b)(1)(b) has been applied.Flange is impact test exempt to -155 °F per UCS-66(b)(3) (coincident ratio = 0.19669) Bolts rated MDMT per Fig UCS-66 note (e) = -55 °F
14. Material is impact test exempt to -155 °F per UCS-66(b)(3) (coincident ratio = 0.19717)
15. Nozzle impact test exemption temperature from Fig UCS-66 Curve A = 18 °FFig UCS-66.1 MDMT reduction = 55.7 °F, (coincident ratio = 0.516) UCS-66 governing thickness = 0.125 in.
16. Nozzle impact test exemption temperature from Fig UCS-66 Curve A = 18 °FFig UCS-66.1 MDMT reduction = 38.3 °F, (coincident ratio = 0.61744) UCS-66 governing thickness = 0.125 in.
17. Nozzle impact test exemption temperature from Fig UCS-66 Curve A = 18 °FFig UCS-66.1 MDMT reduction = 39.2 °F, (coincident ratio = 0.60784) UCS-66 governing thickness = 0.125 in.
Design notes are available on the Settings Summary page.
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Revision History
No. Date Operator Notes
0 11/25/2010 ß 363 nk � New vessel created Heat Exchanger. [Build 6258]
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Settings Summary
COMPRESS Build 6258
Units: U.S. Customary
Datum Line Location: 0.00" from right seam
Design
ASME Section VIII Division 1, 2007 Edition
Design or Rating: Get Thickness from PressureMinimum thickness: 1/16" per UG-16(b)Design for cold shut down only: NoDesign for lethal service (full radiography required): NoDesign nozzles for: Design P, find nozzle MAWP and MAPCorrosion weight loss: 100% of theoretical lossUG-23 Stress Increase: 1.20Skirt/legs stress increase: 1.0Minimum nozzle projection: 6.0000"Juncture calculations for α > 30 only: YesPreheat P-No 1 Materials > 1.25" and <= 1.50" thick: NoButt welds are tapered per Figure UCS-66.3(a).
Hydro/Pneumatic Test
Shop Hydrotest Pressure: 1.3 times vesselMAWP
Test liquid specific gravity: 1.00Maximum stress during test: 90% of yield
Required Marking - UG-116
Shell SideUG-116 (e) Radiography: RT1UG-116 (f) Postweld heat treatment: None
Tube SideUG-116 (e) Radiography: RT1UG-116 (f) Postweld heat treatment: None
Code Cases\Interpretations
Use Code Case 2547: NoApply interpretation VIII-1-83-66: YesApply interpretation VIII-1-86-175: YesApply interpretation VIII-1-83-115: YesApply interpretation VIII-1-01-37: YesDisallow UG-20(f) exemptions: No
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UG-22 Loadings
UG-22 (a) Internal or External Design Pressure : YesUG-22 (b) Weight of the vessel and normal contents under operating or test conditions: YesUG-22 (c) Superimposed static reactions from weight of attached equipment (external loads): NoUG-22 (d)(2) Vessel supports such as lugs, rings, skirts, saddles and legs: YesUG-22 (f) Wind reactions: NoUG-22 (f) Seismic reactions: NoNote: UG-22 (b),(c) and (f) loads only considered when supports are present.
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Thickness Summary
ComponentIdentifier
Material Diameter(in)
Length(in)
Nominal t(in)
Design t(in)
JointE
Load
Front Head SA-516 70 17.25 ID 4.44 0.1250* 0.1056 1.0000 External
Straight Flange on Front Head SA-516 70 17.25 ID 2.00 0.1875 0.1307 1.0000 External
Front Channel SA-516 70 17.25 ID 23.25 0.1875 0.1307 1.0000 External
Tubesheet SA-516 70 17.63 OD 1.02 1.0158 1.0125 1.0000 Unknown
Tubes SA-179 Smls tube 1.0000 OD 72.00 0.0910 0.0151 1.0000 External
Port Cylinder (front) SA-516 70 17.25 ID 6.00 0.1250 0.0892 1.0000 Internal
Front Cone SA-516 70 17.25/26.81 ID 19.12 0.1250 0.1052 1.0000 Internal
Shell SA-516 70 26.81 ID 48.11 0.1250 0.1040 1.0000 Internal
Straight Flange on Rear Shell Head SA-516 70 26.81 ID 2.00 0.1250 0.1040 1.0000 Internal
Rear Shell Head SA-516 70 26.81 ID 6.83 0.1250* 0.1036 1.0000 Internal
Nominal t: Vessel wall nominal thickness
Design t: Required vessel thickness due to governing loading + corrosion
Joint E: Longitudinal seam joint efficiency
* Head minimum thickness after forming
Load
internal: Circumferential stress due to internal pressure governs
external: External pressure governs
Wind: Combined longitudinal stress of pressure + weight + wind governs
Seismic: Combined longitudinal stress of pressure + weight + seismic governs
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Weight Summary
ComponentWeight ( lb) Contributed by Vessel Elements
MetalNew*
Metal
Corroded*Insulation &
Supports Lining Piping+ Liquid
OperatingLiquid
TestLiquid
Front Head 18.16 10.12 0.00 0.00 0.00 28.96 41.13
Front Channel 53.82 36.04 0.00 0.00 0.00 158.69 230.26
Tubesheet 43.95 38.54 0.00 0.00 0.00 0.00 0.00
Port Cylinder (front) 11.59 5.81 0.00 0.00 0.00 70.11 91.58
Front Cone 46.46 23.30 0.00 0.00 0.00 253.29 324.97
Shell 141.36 70.85 0.00 0.00 0.00 641.41 612.29
Tubes 793.86 793.86 0.00 0.00 0.00 139.28 204.77
Rear Shell Head 35.61 17.90 0.00 0.00 0.00 123.31 131.79
Saddle 108.00 108.00 0.00 0.00 0.00 0.00 0.00
TOTAL: 1,252.80 1,104.42 0.00 0.00 0.00 1,415.03 1,636.78
* Shells with attached nozzles have weight reduced by material cut out for opening.
Component
Weight ( lb) Contributed by Attachments
Body Flanges Nozzles &Flanges Packed
BedsTrays &
SupportsRings &
ClipsVerticalLoads
New Corroded New Corroded
Front Head 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Front Channel 50.75 50.75 273.85 266.58 0.00 0.00 0.00 0.00
Tubesheet 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Port Cylinder (front) 50.75 50.75 0.00 0.00 0.00 0.00 0.00 0.00
Front Cone 0.00 0.00 46.39 44.83 0.00 0.00 0.00 0.00
Shell 0.00 0.00 67.35 65.15 0.00 0.00 0.00 0.00
Rear Shell Head 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
TOTAL: 101.49 101.49 387.59 376.57 0.00 0.00 0.00 0.00
Vessel operating weight, Corroded: 2,998 lbVessel operating weight, New: 3,157 lbVessel empty weight, Corroded: 1,582 lbVessel empty weight, New: 1,742 lbVessel test weight, New: 3,379 lb
Vessel center of gravity location - from datum - lift condition
Vessel Lift Weight, New: 1,742 lbCenter of Gravity: 46.44"
Vessel Capacity
Shell side Capacity** (New): 138 US galShell side Capacity** (Corroded): 140 US galTube side Capacity** (New): 56 US galTube side Capacity** (Corroded): 57 US gal**The shell and tube capacity does not include volume of nozzle, piping or other attachments.
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Hydrostatic Test
Shop test pressure determination for Tube side chamber based on MAWP per UG-99(b)
Shop hydrostatic test gauge pressure is 36.221 psi at 70 °F (the chamber MAEP = 27.863 psi). External pressuregoverns the test pressure per UG-99(f).
The shop test is performed with the vessel in the horizontal position.
IdentifierLocal testpressure
psi
Test liquidstatic head
psi
UG-99stressratio
UG-99pressure
factor
Stressduring test
psi
Allowabletest stress
psi
Stressexcessive?
Front Head (1) 37.065 0.844 1 1.30 2,302 34,200 No
Straight Flange on Front Head 37.065 0.844 1 1.30 1,723 34,200 No
Front Channel 37.065 0.844 1 1.30 1,723 34,200 No
Tubes 37.052 0.831 1 1.30 208 23,400 No
Tube Side Flange (front) 37.065 0.844 1 1.30 5,196 51,300 No
Tubesheet 37.238 1.016 1 1.30 See tubesheet report
TS Inlet (N1) 36.436 0.214 1.0047 1.30 1,870 51,300 No
TS Outlet (N2) 37.288 1.067 1.0047 1.30 5,180 51,300 No
Notes:(1) Front Head limits the UG-99 stress ratio.(2) PL stresses at nozzle openings have been estimated using the method described in PVP-Vol. 399, pages 77-82.(3) VIII-2, AD-151.1(b) used as the basis for nozzle allowable test stress.(4) The zero degree angular position is assumed to be up, and the test liquid height is assumed to the top-mostflange.
The field test condition has not been investigated for the Tube side chamber.
Shop test pressure determination for Shell side chamber based on MAWP per UG-99(b)
Shop hydrostatic test gauge pressure is 72.96 psi at 70 °F (the chamber MAWP = 56.123 psi)
The shop test is performed with the vessel in the horizontal position.
IdentifierLocal testpressure
psi
Test liquidstatic head
psi
UG-99stressratio
UG-99pressure
factor
Stressduring test
psi
Allowabletest stress
psi
Stressexcessive?
Port Cylinder (front) (1) 73.976 1.016 1 1.30 5,141 34,200 No
Front Cone 74.149 1.189 1 1.30 8,196 34,200 No
Shell 74.149 1.189 1 1.30 7,988 34,200 No
Straight Flange on Rear Shell Head 74.149 1.189 1 1.30 7,988 34,200 No
Rear Shell Head 74.149 1.189 1 1.30 7,156 34,200 No
Tubes 73.877 0.917 N/A 1.30 NI NI NI
Tubesheet 73.976 1.016 1 1.30 See tubesheet report
Shell Side Flange (front) 73.976 1.016 1 1.30 9,224 51,300 No
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SS Inlet (N4) 74.37 1.41 1 1.30 13,917 51,300 No
SS Outlet (N3) 73.262 0.303 1 1.30 16,035 51,300 No
SS Outlet 2 (N5) 73.176 0.217 1 1.30 9,555 49,950 No
Notes:(1) Port Cylinder (front) limits the UG-99 stress ratio.(2) NI indicates that test stress was not investigated.(3) PL stresses at nozzle openings have been estimated using the method described in PVP-Vol. 399, pages 77-82.(4) VIII-2, AD-151.1(b) used as the basis for nozzle allowable test stress.(5) The zero degree angular position is assumed to be up, and the test liquid height is assumed to the top-mostflange.
The field test condition has not been investigated for the Shell side chamber.
The test temperature of 70 °F is warmer than the minimum recommended temperature of 10 °F so the brittle fractureprovision of UG-99(h) has been met.
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Vacuum Summary
Component Line of SupportElevation
above Datum(in)
Length Le(in)
Front Head - 109.93 N/A
- 1/3 depth of Front Head 106.95 N/A
Straight Flange on Front Head Top - 105.49 29.71
Straight Flange on Front Head Bottom - 103.49 29.71
Front Channel Top - 103.49 29.71
Front Channel Bottom - 80.24 29.71
- Tube Side Flange (front) 77.24 N/A
Tubesheet - 77.24 N/A
- Shell Side Flange (front) 76.22 N/A
Port Cylinder (front) Top - 73.22 9.00
Port Cylinder (front) Bottom - 67.22 9.00
Front Cone Top - 67.22 N/A
- Front Cone Top 67.22 N/A
- Front Cone Bottom 48.11 N/A
Front Cone Bottom - 48.11 N/A
Shell Top - 48.11 52.36
Shell Bottom - 0.00 52.36
Straight Flange on Rear Shell Head Top - 0.00 52.36
Straight Flange on Rear Shell Head Bottom - -2.00 52.36
- 1/3 depth of Rear Shell Head -4.25 N/A
Rear Shell Head - -8.83 N/A
Note
For main components, the listed value of 'Le' is the largest unsupported length for the component.
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Front Channel
ASME Section VIII Division 1, 2007 Edition
Component: CylinderMaterial specification: SA-516 70 (II-D p. 18, ln. 22)Material is impact test exempt per UG-20(f)UCS-66 governing thickness = 0.1875 in
Internal design pressure: P = 0 psi @ 414.5°FExternal design pressure: Pe = 13.1759 psi @ 414.5°F
Static liquid head:
Ps =0.5754 psi (SG=0.6802, Hs=23.4375" Operating head)Pth =0.8438 psi (SG=1.0000, Hs=23.3750", Horizontal test head)
Corrosion allowance: Inner C = 0.0625" Outer C = 0.0000"
Design MDMT = -20.00°F No impact test performedRated MDMT = -20.00°F Material is not normalized
Material is not produced to Fine Grain PracticePWHT is not performed
Radiography: Longitudinal joint - Full UW-11(a) Type 1Left circumferential joint - Full UW-11(a) Type 1Right circumferential joint - Full UW-11(a) Type 1
Estimated weight: New = 67.5841 lb corr = 45.2176 lbCapacity: New = 23.5223 gal corr = 23.8644 galID = 17.2500"Length Lc = 23.2500"t = 0.1875"
Design thickness, (at 414.50°F) UG-27(c)(1)
t = P*R/(S*E - 0.60*P) + Corrosion= 0.58*8.6875/(20000*1.00 - 0.60*0.58) + 0.0625= 0.0628"
Maximum allowable working pressure, (at 414.50°F) UG-27(c)(1)
P = S*E*t/(R + 0.60*t) - Ps= 20000*1.00*0.1250 / (8.6875 + 0.60*0.1250) - 0.5754= 284.7313 psi
Maximum allowable pressure, (at 70.00°F) UG-27(c)(1)
P = S*E*t/(R + 0.60*t)= 20000*1.00*0.1875 / (8.6250 + 0.60*0.1875)= 429.1845 psi
External Pressure, (Corroded & at 414.50°F) UG-28(c)
L/Do = 29.7083/17.6250 = 1.6856Do/t = 17.6250/0.068219 = 258.3596
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From table G: A = 0.000187From table CS-2: B = 2553.0984 psi
Pa = 4*B/(3*(Do/t))= 4*2553.0984/(3*(17.6250/0.068219))= 13.1759 psi
Design thickness for external pressure Pa = 13.1759 psi
= t + Corrosion = 0.068219 + 0.0625 = 0.1307"
Maximum Allowable External Pressure, (Corroded & at 414.50°F) UG-28(c)
L/Do = 29.7083/17.6250 = 1.6856Do/t = 17.6250/0.1250 = 141.0000
From table G: A = 0.000466From table CS-2: B = 6402.5376 psi
Pa = 4*B/(3*(Do/t))= 4*6402.5376/(3*(17.6250/0.1250))= 60.5441 psi
% Extreme fiber elongation - UCS-79(d)
= (50 * t / Rf) * (1 - Rf / Ro)= (50 * 0.1875 / 8.7188) * (1 - 8.7188 / ∞)= 1.0753 %
Allowable Compressive Stress, Hot and Corroded- ScHC, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (8.8125 / 0.1250)= 0.001773
B = 12508.6357 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScHC = 12508.6357 psi
Allowable Compressive Stress, Hot and New- ScHN, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (8.8125 / 0.1875)= 0.002660
B = 13596.3066 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScHN = 13596.3066 psi
17/226
Allowable Compressive Stress, Cold and New- ScCN, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (8.8125 / 0.1875)= 0.002660
B = 15833.8398 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScCN = 15833.8398 psi
Allowable Compressive Stress, Cold and Corroded- ScCC, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (8.8125 / 0.1250)= 0.001773
B = 14491.5537 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScCC = 14491.5537 psi
Allowable Compressive Stress, Vacuum and Corroded- ScVC, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (8.8125 / 0.1250)= 0.001773
B = 12508.6357 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScVC = 12508.6357 psi
18/226
Port Cylinder (front)
ASME Section VIII Division 1, 2007 Edition
Component: CylinderMaterial specification: SA-516 70 (II-D p. 18, ln. 22)Material impact test exemption temperature from Fig UCS-66 Curve B = -20 °FFig UCS-66.1 MDMT reduction = 105 °F, (coincident ratio = 0.3972073)Rated MDMT is governed by UCS-66(b)(2)UCS-66 governing thickness = 0.125 in
Internal design pressure: P = 60.3041 psi @ 307.57°F
Static liquid head:
Ps =0.9314 psi (SG=0.9145, Hs=28.2167" Operating head)Pth =1.0163 psi (SG=1.0000, Hs=28.1542", Horizontal test head)
Corrosion allowance: Inner C = 0.0625" Outer C = 0.0000"
Design MDMT = -20.00°F No impact test performedRated MDMT = -55.00°F Material is not normalized
Material is not produced to Fine Grain PracticePWHT is not performed
Radiography: Longitudinal joint - Full UW-11(a) Type 1Left circumferential joint - Full UW-11(a) Type 1Right circumferential joint - Full UW-11(a) Type 1
Estimated weight: New = 11.5857 lb corr = 5.8137 lbCapacity: New = 6.0703 gal corr = 6.1586 galID = 17.2500"Length Lc = 6.0000"t = 0.1250"
Design thickness, (at 307.57°F) UG-27(c)(1)
t = P*R/(S*E - 0.60*P) + Corrosion= 61.24*8.6875/(20000*1.00 - 0.60*61.24) + 0.0625= 0.0892"
Maximum allowable working pressure, (at 307.57°F) UG-27(c)(1)
P = S*E*t/(R + 0.60*t) - Ps= 20000*1.00*0.0625 / (8.6875 + 0.60*0.0625) - 0.9314= 142.3350 psi
Maximum allowable pressure, (at 70.00°F) UG-27(c)(1)
P = S*E*t/(R + 0.60*t)= 20000*1.00*0.1250 / (8.6250 + 0.60*0.1250)= 287.3563 psi
% Extreme fiber elongation - UCS-79(d)
= (50 * t / Rf) * (1 - Rf / Ro)= (50 * 0.1250 / 8.6875) * (1 - 8.6875 / ∞)
19/226
= 0.7194 %
Allowable Compressive Stress, Hot and Corroded- ScHC, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (8.7500 / 0.0625)= 0.000893
B = 11683.4004 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScHC = 11683.4004 psi
Allowable Compressive Stress, Hot and New- ScHN, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (8.7500 / 0.1250)= 0.001786
B = 14380.1836 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScHN = 14380.1836 psi
Allowable Compressive Stress, Cold and New- ScCN, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (8.7500 / 0.1250)= 0.001786
B = 14521.1133 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScCN = 14521.1133 psi
Allowable Compressive Stress, Cold and Corroded- ScCC, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (8.7500 / 0.0625)= 0.000893
B = 11772.5020 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScCC = 11772.5020 psi
Allowable Compressive Stress, Vacuum and Corroded- ScVC, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (8.7500 / 0.0625)= 0.000893
B = 11683.4004 psi
20/226
S = 20000.0000 / 1.0000= 20000.0000 psi
ScVC = 11683.4004 psi
21/226
Front Cone
ASME Section VIII Division 1, 2007 Edition
Component: TransitionMaterial specification: SA-516 70 (II-D p. 18, ln. 22)Material impact test exemption temperature from Fig UCS-66 Curve B = -20 °FFig UCS-66.1 MDMT reduction = 36.4 °F, (coincident ratio = 0.6364939)Rated MDMT is governed by UCS-66(b)(2)UCS-66 governing thickness = 0.125 in
Internal design pressure: P = 60.3041 psi @ 307.57°F
Static liquid head:
Ps =0.9294 psi (SG=0.9145, Hs=28.1542" Operating head at small end)Ps =1.0871 psi (SG=0.9145, Hs=32.9333" Operating head at large end)Pth =1.0163 psi (SG=1.0000, Hs=28.1542", Horizontal test head at small end)Pth =1.1888 psi (SG=1.0000, Hs=32.9333", Horizontal test head at large end)
Corrosion allowance: Inner C = 0.0625" Outer C = 0.0000"
Design MDMT = -20.00°F No impact test performedRated MDMT = -55.00°F Material is not normalized
Material is not produced to Fine Grain PracticePWHT is not performed
Radiography: Category A joints - Full UW-11(a) Type 1Circ. joint top/left - Full UW-11(a) Type 1Circ. joint right/bottom - Full UW-11(a) Type 1
Estimated weight: New = 46.5 lb corr = 23.3 lbCapacity: New = 32.0 US gal corr = 32.4 US galAxial length = 19.1165"Large End ID = 26.8083"Small End ID = 17.2500"Cone tc = 0.1250"
Design thickness, (at 307.57°F) UG-32(g) (Large End)
t = P*D / (2*Cos(α)*(S*E - 0.60*P)) + C
= 61.3912*26.9371 / (2*Cos(14.036)*(20000*1.00 - 0.60*61.3912))+ 0.0625
= 0.1052"Small End design thickness (t = 0.0900") does not govern.
MAWP, (Corroded at 307.57°F) UG-32(g) (Large End)
P = 2*S*E*t*Cos(α) / (D + 1.20*t*Cos(α)) - Ps
= 2*20000*1.00*0.0625*Cos(14.036) / (26.9371 + 1.20*0.0625*Cos(14.036)) -1.0871
= 88.71 psi
Small End MAWP (138.0467 psi) does not govern.
22/226
MAP, (New at 70.00°F) UG-32(g) (Large End)
P = 2*S*E*t*Cos(α) / (D + 1.20*t*Cos(α)) - Ps
= 2*20000*1.00*0.1250*Cos(14.036) / (26.8083 + 1.20*0.1250*Cos(14.036)) -0.0000
= 179.96 psi
Small End MAP (278.8483 psi) does not govern.
% Extreme fiber elongation - UCS-79(d)
= (50 * t / Rf) * (1 - Rf / Ro)= (50 * 0.1288 / 8.6894) * (1 - 8.6894 / ∞)= 0.7414 %
23/226
Cone juncture large end calculations, P =89.797 psi (MAWP =88.708 psi)
Appendix 1-5(d)
LoadingArea check
required(∆ < α)
U-2(g)
analysisrequired
f1(lbf /in)
QL
(lbf /in)A
rL(in2)
AeL
(in2)Ring
area (in2)Status
Pressure No No 0 604.63 0 0 none OK
24/226
Cone large end calculations per Appendix 1-5(d), pressure, corroded
f1 = -Wl/(π*2*Rm) + 12*Ml/(π*R
m2)
= -0/(π*2*13.4979) + 12*0/(π*13.49792)= 0 lb/in
P*RL/2 = 604.6334 lb/in
|f1| <= P*RL/2 so a U-2(g) analysis is not required.
P/(Ss*E1) = 89.79716/(20,000.00*1) = 0.00449
From table 1-5.1 ∆ = 21.98°
As ∆ >= α no additional reinforcement is required.
Cone juncture small end calculations P = 89.637 psi (MAWP =88.708 psi)
Appendix 1-5(e)
LoadingArea check
required(∆ < α)
U-2(g)
analysisrequired
f2(lbf /in)
Qs(lbf /in)
Ars(in2)
Aes(in2)
Ringarea (in2)
Status
Pressure Yes No 0 389.36 0.03 0.03 none OK
25/226
Cone small end calculations per Appendix 1-5(e), pressure, corroded
f2 = -Ws/(π*2*Rm) + 12*Ms/(π*R
m2)
= -0/(π*2*8.7188) + 12*0/(π*8.71882)= 0 lb/in
P*Rs/2 = 389.3619 lb/in
|f2| <= P*Rs/2 so a U-2(g) analysis is not required.
P/(Ss*E1) = 89.63727/(20,000.00*1) = 0.004482
From table 1-5.2 ∆ = 5.65°
As ∆ < α reinforcement is required.
Qs = P*Rs/2 + f2= 389.3619 + 0= 389.3619 lb/in
Ars = (k*Qs*Rs/(Ss*E1))*(1 - ∆/α)*tan(α)= (1*389.3619*8.6875/(20,000*1))*(1 - 5.65/14.0363)*tan(14.0363)= 0.02526261 in2
Aes = 0.78*(Rs*ts)0.5*[(ts - t) + (tc - tr)/cos(α)]= 0.78*(8.6875*0.0625)0.5*[(0.0625 - 0.0390412) + (0.0625 - 0.0402427)/cos(14.0363)]= 0.02666922 in2
Aes >= Ars therefore the small end juncture is adequately reinforced.
MAP Cone juncture large end calculations, P =179.964 psiAppendix 1-5(d)
LoadingArea check
required(∆ < α)
U-2(g)
analysisrequired
f1(lbf /in)
QL
(lbf /in)A
rL(in2)
AeL
(in2)Ring
area (in2)Status
Pressure No No 0 1,213.43 0 0 none OK
26/226
Cone large end calculations per Appendix 1-5(d), pressure, new
f1 = -Wl/(π*2*Rm) + 12*Ml/(π*R
m2)
= -0/(π*2*13.4667) + 12*0/(π*13.46672)= 0 lb/in
P*RL/2 = 1,213.431 lb/in
|f1| <= P*RL/2 so a U-2(g) analysis is not required.
P/(Ss*E1) = 179.9638/(20,000.00*1) = 0.008998
From table 1-5.1 ∆ = 30°
As ∆ >= α no additional reinforcement is required.
MAP Cone juncture small end calculations P = 179.964 psiAppendix 1-5(e)
LoadingArea check
required(∆ < α)
U-2(g)
analysisrequired
f2(lbf /in)
Qs(lbf /in)
Ars(in2)
Aes(in2)
Ringarea (in2)
Status
Pressure Yes No 0 780.1 0.03 0.07 none OK
Cone small end calculations per Appendix 1-5(e), pressure, new
f2 = -Ws/(π*2*Rm) + 12*Ms/(π*R
m2)
= -0/(π*2*8.6875) + 12*0/(π*8.68752)= 0 lb/in
P*Rs/2 = 780.1017 lb/in
|f2| <= P*Rs/2 so a U-2(g) analysis is not required.
P/(Ss*E1) = 179.9638/(20,000.00*1) = 0.008998
From table 1-5.2 ∆ = 8.4°
As ∆ < α reinforcement is required.
Qs = P*Rs/2 + f2= 780.1017 + 0= 780.1017 lb/in
Ars = (k*Qs*Rs/(Ss*E1))*(1 - ∆/α)*tan(α)= (1*780.1017*8.625/(20,000*1))*(1 - 8.4/14.0363)*tan(14.0363)= 0.03359281 in2
Aes = 0.78*(Rs*ts)0.5*[(ts - t) + (tc - tr)/cos(α)]= 0.78*(8.625*0.125)0.5*[(0.125 - 0.0784358) + (0.125 - 0.0808498)/cos(14.0363)]= 0.07456966 in2
Aes >= Ars therefore the small end juncture is adequately reinforced.
27/226
Shell
ASME Section VIII Division 1, 2007 Edition
Component: CylinderMaterial specification: SA-516 70 (II-D p. 18, ln. 22)Material impact test exemption temperature from Fig UCS-66 Curve B = -20 °FFig UCS-66.1 MDMT reduction = 38.3 °F, (coincident ratio = 0.6174237)Rated MDMT is governed by UCS-66(b)(2)UCS-66 governing thickness = 0.125 in
Internal design pressure: P = 60.3041 psi @ 307.57°F
Static liquid head:
Ps =1.0892 psi (SG=0.9145, Hs=32.9958" Operating head)Pth =1.1888 psi (SG=1.0000, Hs=32.9333", Horizontal test head)
Corrosion allowance: Inner C = 0.0625" Outer C = 0.0000"
Design MDMT = -20.00°F No impact test performedRated MDMT = -55.00°F Material is not normalized
Material is not produced to Fine Grain PracticePWHT is not performed
Radiography: Longitudinal joint - Full UW-11(a) Type 1Left circumferential joint - Full UW-11(a) Type 1Right circumferential joint - Full UW-11(a) Type 1
Estimated weight: New = 143.9936 lb corr = 72.1639 lbCapacity: New = 82.4331 gal corr = 83.5319 galID = 26.8083"Length Lc = 48.1069"t = 0.1250"
Design thickness, (at 307.57°F) UG-27(c)(1)
t = P*R/(S*E - 0.60*P) + Corrosion= 61.39*13.4667/(20000*1.00 - 0.60*61.39) + 0.0625= 0.1040"
Maximum allowable working pressure, (at 307.57°F) UG-27(c)(1)
P = S*E*t/(R + 0.60*t) - Ps= 20000*1.00*0.0625 / (13.4667 + 0.60*0.0625) - 1.0892= 91.4749 psi
Maximum allowable pressure, (at 70.00°F) UG-27(c)(1)
P = S*E*t/(R + 0.60*t)= 20000*1.00*0.1250 / (13.4042 + 0.60*0.1250)= 185.4716 psi
% Extreme fiber elongation - UCS-79(d)
= (50 * t / Rf) * (1 - Rf / Ro)= (50 * 0.1250 / 13.4667) * (1 - 13.4667 / ∞)
28/226
= 0.4641 %
Allowable Compressive Stress, Hot and Corroded- ScHC, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (13.5292 / 0.0625)= 0.000577
B = 8298.0957 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScHC = 8298.0957 psi
Allowable Compressive Stress, Hot and New- ScHN, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (13.5292 / 0.1250)= 0.001155
B = 12711.7021 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScHN = 12711.7021 psi
Allowable Compressive Stress, Cold and New- ScCN, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (13.5292 / 0.1250)= 0.001155
B = 12817.7939 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScCN = 12817.7939 psi
Allowable Compressive Stress, Cold and Corroded- ScCC, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (13.5292 / 0.0625)= 0.000577
B = 8323.0674 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScCC = 8323.0674 psi
Allowable Compressive Stress, Vacuum and Corroded- ScVC, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (13.5292 / 0.0625)= 0.000577
B = 8298.0957 psi
29/226
S = 20000.0000 / 1.0000= 20000.0000 psi
ScVC = 8298.0957 psi
30/226
Front Head
ASME Section VIII, Division 1, 2007 Edition
Component: Ellipsoidal HeadMaterial Specification: SA-516 70 (II-D p.18, ln. 22)Straight Flange governs MDMT
External design pressure: Pe = 13.1759 psi @ 414.5 °F
Static liquid head:
Ps= 0.5754 psi (SG=0.6802, Hs=23.4375" Operating head)Pth= 0.8438 psi (SG=1, Hs=23.375" Horizontal test head)
Corrosion allowance: Inner C = 0.0625" Outer C = 0"
Design MDMT = -20°F No impact test performedRated MDMT = N/A Material is not normalized
Material is not produced to fine grain practicePWHT is not performedDo not Optimize MDMT / Find MAWP
Radiography: Category A joints - Seamless No RT Head to shell seam - Full UW-11(a) Type 1
Estimated weight*: new = 18.2 lb corr = 10.1 lbCapacity*: new = 4.9 US gal corr = 5 US gal* includes straight flange
Inner diameter = 17.25"Minimum head thickness = 0.125"Head ratio D/2h = 2 (new)Head ratio D/2h = 1.9857 (corroded)Straight flange length Lsf = 2"Nominal straight flange thickness tsf = 0.1875"Results Summary
The governing condition is UG-16.Minimum thickness per UG-16 = 0.0625" + 0.0625" = 0.125"Design thickness due to internal pressure (t) = 0.0628"Design thickness due to external pressure (te) = 0.1056"Maximum allowable working pressure (MAWP) = 144.58 psiMaximum allowable pressure (MAP) = 289.44 psiMaximum allowable external pressure (MAEP) = 27.86 psi
K (Corroded)
K=(1/6)*[2 + (D / (2*h))2]=(1/6)*[2 + (17.375 / (2*4.375))2]=0.99051
K (New)
K=(1/6)*[2 + (D / (2*h))2]=(1/6)*[2 + (17.25 / (2*4.3125))2]=1
31/226
Design thickness for internal pressure, (Corroded at 414.5 °F) Appendix 1-4(c)
t = P*D*K / (2*S*E - 0.2*P) + Corrosion= 0.58*17.375*0.99051 / (2*20,000*1 - 0.2*0.58) + 0.0625= 0.0627"
The head internal pressure design thickness is 0.0628".
Maximum allowable working pressure, (Corroded at 414.5 °F) Appendix 1-4(c)
P = 2*S*E*t / (K*D + 0.2*t) - Ps= 2*20,000*1*0.0625 / (0.99051*17.375 +0.2*0.0625) - 0.58= 144.58 psi
The maximum allowable working pressure (MAWP) is 144.58 psi.
Maximum allowable pressure, (New at 70 °F) Appendix 1-4(c)
P = 2*S*E*t / (K*D + 0.2*t) - Ps= 2*20,000*1*0.125 / (1*17.25 +0.2*0.125) - 0= 289.44 psi
The maximum allowable pressure (MAP) is 289.44 psi.
Design thickness for external pressure, (Corroded at 414.5 °F) UG-33(d)
Equivalent outside spherical radius (Ro)Ro = Ko*Do
= 0.8873 * 17.5= 15.5282 in
A = 0.125 / (Ro/t)= 0.125 / (15.5282/0.043038)= 0.000346
From Table CS-2: B=4,753.9014 psi
Pa = B/(Ro/t)= 4,753.901/(15.5282/0.043038)= 13.1759 psi
t = 0.043" + Corrosion = 0.043" + 0.0625" = 0.1055"Check the external pressure per UG-33(a)(1) Appendix 1-4(c)
t = 1.67*Pe*D*K / (2*S*E - 0.2*1.67*Pe) + Corrosion= 1.67*13.18*17.375*0.99051 / (2*20,000*1 - 0.2*1.67*13.18) + 0.0625= 0.072"
The head external pressure design thickness (te) is 0.1055".
Maximum Allowable External Pressure, (Corroded at 414.5 °F) UG-33(d)
Equivalent outside spherical radius (Ro)Ro = Ko*Do
= 0.8873 * 17.5= 15.5282 in
32/226
A = 0.125 / (Ro/t)= 0.125 / (15.5282/0.0625)= 0.000503
From Table CS-2: B=6,922.457 psi
Pa = B/(Ro/t)= 6,922.457/(15.5282/0.0625)= 27.8625 psi
Check the Maximum External Pressure, UG-33(a)(1) Appendix 1-4(c)
P = 2*S*E*t / ((K*D + 0.2*t)*1.67) - Ps2= 2*20,000*1*0.0625 / ((0.99051*17.375 +0.2*0.0625)*1.67) - 0= 86.92 psi
The maximum allowable external pressure (MAEP) is 27.86 psi.
% Extreme fiber elongation - UCS-79(d)
= (75*t / Rf)*(1 - Rf / Ro)= (75*0.1875 / 3.0263)*(1 - 3.0263 / ∞)= 4.6468%
The extreme fiber elongation does not exceed 5%.
33/226
Straight Flange on Front Head
ASME Section VIII Division 1, 2007 Edition
Component: Straight FlangeMaterial specification: SA-516 70 (II-D p. 18, ln. 22)Material is impact test exempt per UG-20(f)UCS-66 governing thickness = 0.1875 in
Internal design pressure: P = 0 psi @ 414.5°FExternal design pressure: Pe = 13.1759 psi @ 414.5°F
Static liquid head:
Ps =0.5754 psi (SG=0.6802, Hs=23.4375" Operating head)Pth =0.8438 psi (SG=1.0000, Hs=23.3750", Horizontal test head)
Corrosion allowance: Inner C = 0.0625" Outer C = 0.0000"
Design MDMT = -20.00°F No impact test performedRated MDMT = -20.00°F Material is not normalized
Material is not produced to Fine Grain PracticePWHT is not performed
Radiography: Longitudinal joint - Seamless No RTCircumferential joint - Full UW-11(a) Type 1
Estimated weight: New = 5.8137 lb corr = 3.8897 lbCapacity: New = 2.0234 gal corr = 2.0529 galID = 17.2500"Length Lc = 2.0000"t = 0.1875"
Design thickness, (at 414.50°F) UG-27(c)(1)
t = P*R/(S*E - 0.60*P) + Corrosion= 0.58*8.6875/(20000*1.00 - 0.60*0.58) + 0.0625= 0.0628"
Maximum allowable working pressure, (at 414.50°F) UG-27(c)(1)
P = S*E*t/(R + 0.60*t) - Ps= 20000*1.00*0.1250 / (8.6875 + 0.60*0.1250) - 0.5754= 284.7313 psi
Maximum allowable pressure, (at 70.00°F) UG-27(c)(1)
P = S*E*t/(R + 0.60*t)= 20000*1.00*0.1875 / (8.6250 + 0.60*0.1875)= 429.1845 psi
External Pressure, (Corroded & at 414.50°F) UG-28(c)
L/Do = 29.7083/17.6250 = 1.6856Do/t = 17.6250/0.068219 = 258.3596
From table G: A = 0.000187
34/226
From table CS-2: B = 2553.0984 psi
Pa = 4*B/(3*(Do/t))= 4*2553.0984/(3*(17.6250/0.068219))= 13.1759 psi
Design thickness for external pressure Pa = 13.1759 psi
= t + Corrosion = 0.068219 + 0.0625 = 0.1307"
Maximum Allowable External Pressure, (Corroded & at 414.50°F) UG-28(c)
L/Do = 29.7083/17.6250 = 1.6856Do/t = 17.6250/0.1250 = 141.0000
From table G: A = 0.000466From table CS-2: B = 6402.5376 psi
Pa = 4*B/(3*(Do/t))= 4*6402.5376/(3*(17.6250/0.1250))= 60.5441 psi
% Extreme fiber elongation - UCS-79(d)
= (50 * t / Rf) * (1 - Rf / Ro)= (50 * 0.1875 / 8.7188) * (1 - 8.7188 / ∞)= 1.0753 %
Allowable Compressive Stress, Hot and Corroded- ScHC, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (8.8125 / 0.1250)= 0.001773
B = 12508.6357 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScHC = 12508.6357 psi
Allowable Compressive Stress, Hot and New- ScHN, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (8.8125 / 0.1875)= 0.002660
B = 13596.3066 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScHN = 13596.3066 psi
35/226
Allowable Compressive Stress, Cold and New- ScCN, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (8.8125 / 0.1875)= 0.002660
B = 15833.8398 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScCN = 15833.8398 psi
Allowable Compressive Stress, Cold and Corroded- ScCC, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (8.8125 / 0.1250)= 0.001773
B = 14491.5537 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScCC = 14491.5537 psi
Allowable Compressive Stress, Vacuum and Corroded- ScVC, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (8.8125 / 0.1250)= 0.001773
B = 12508.6357 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScVC = 12508.6357 psi
36/226
Straight Flange on Rear Shell Head
ASME Section VIII Division 1, 2007 Edition
Component: Straight FlangeMaterial specification: SA-516 70 (II-D p. 18, ln. 22)Material impact test exemption temperature from Fig UCS-66 Curve B = -20 °FFig UCS-66.1 MDMT reduction = 38.3 °F, (coincident ratio = 0.6174237)Rated MDMT is governed by UCS-66(b)(2)UCS-66 governing thickness = 0.125 in
Internal design pressure: P = 60.3041 psi @ 307.57°F
Static liquid head:
Ps =1.0892 psi (SG=0.9145, Hs=32.9958" Operating head)Pth =1.1888 psi (SG=1.0000, Hs=32.9333", Horizontal test head)
Corrosion allowance: Inner C = 0.0625" Outer C = 0.0000"
Design MDMT = -20.00°F No impact test performedRated MDMT = -55.00°F Material is not normalized
Material is not produced to Fine Grain PracticePWHT is not performed
Radiography: Longitudinal joint - Seamless No RTCircumferential joint - Full UW-11(a) Type 1
Estimated weight: New = 5.9864 lb corr = 3.0001 lbCapacity: New = 4.8870 gal corr = 4.9327 galID = 26.8083"Length Lc = 2.0000"t = 0.1250"
Design thickness, (at 307.57°F) UG-27(c)(1)
t = P*R/(S*E - 0.60*P) + Corrosion= 61.39*13.4667/(20000*1.00 - 0.60*61.39) + 0.0625= 0.1040"
Maximum allowable working pressure, (at 307.57°F) UG-27(c)(1)
P = S*E*t/(R + 0.60*t) - Ps= 20000*1.00*0.0625 / (13.4667 + 0.60*0.0625) - 1.0892= 91.4749 psi
Maximum allowable pressure, (at 70.00°F) UG-27(c)(1)
P = S*E*t/(R + 0.60*t)= 20000*1.00*0.1250 / (13.4042 + 0.60*0.1250)= 185.4716 psi
% Extreme fiber elongation - UCS-79(d)
= (50 * t / Rf) * (1 - Rf / Ro)= (50 * 0.1250 / 13.4667) * (1 - 13.4667 / ∞)= 0.4641 %
37/226
Allowable Compressive Stress, Hot and Corroded- ScHC, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (13.5292 / 0.0625)= 0.000577
B = 8298.0957 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScHC = 8298.0957 psi
Allowable Compressive Stress, Hot and New- ScHN, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (13.5292 / 0.1250)= 0.001155
B = 12711.7021 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScHN = 12711.7021 psi
Allowable Compressive Stress, Cold and New- ScCN, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (13.5292 / 0.1250)= 0.001155
B = 12817.7939 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScCN = 12817.7939 psi
Allowable Compressive Stress, Cold and Corroded- ScCC, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (13.5292 / 0.0625)= 0.000577
B = 8323.0674 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScCC = 8323.0674 psi
Allowable Compressive Stress, Vacuum and Corroded- ScVC, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (13.5292 / 0.0625)= 0.000577
B = 8298.0957 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
38/226
ScVC = 8298.0957 psi
39/226
Rear Shell Head
ASME Section VIII, Division 1, 2007 Edition
Component: Ellipsoidal HeadMaterial Specification: SA-516 70 (II-D p.18, ln. 22)Straight Flange governs MDMT
Internal design pressure: P = 60.3041 psi @ 307.57 °F
Static liquid head:
Ps= 1.0892 psi (SG=0.9145, Hs=32.9958" Operating head)Pth= 1.1888 psi (SG=1, Hs=32.9333" Horizontal test head)
Corrosion allowance: Inner C = 0.0625" Outer C = 0"
Design MDMT = -20°F No impact test performedRated MDMT = -55°F Material is not normalized
Material is not produced to fine grain practicePWHT is not performedDo not Optimize MDMT / Find MAWP
Radiography: Category A joints - Seamless No RT Head to shell seam - Full UW-11(a) Type 1
Estimated weight*: new = 35.6 lb corr = 17.9 lbCapacity*: new = 15.8 US gal corr = 16.1 US gal* includes straight flange
Inner diameter = 26.8083"Minimum head thickness = 0.125"Head ratio D/2h = 2 (new)Head ratio D/2h = 1.9908 (corroded)Straight flange length Lsf = 2"Nominal straight flange thickness tsf = 0.125"Results Summary
The governing condition is UG-16.Minimum thickness per UG-16 = 0.0625" + 0.0625" = 0.125"Design thickness due to internal pressure (t) = 0.1036"Maximum allowable working pressure (MAWP) = 92.26 psiMaximum allowable pressure (MAP) = 186.34 psi
K (Corroded)
K=(1/6)*[2 + (D / (2*h))2]=(1/6)*[2 + (26.9333 / (2*6.7646))2]=0.993855
K (New)
K=(1/6)*[2 + (D / (2*h))2]=(1/6)*[2 + (26.8083 / (2*6.7021))2]=1
40/226
Design thickness for internal pressure, (Corroded at 307.57 °F) Appendix 1-4(c)
t = P*D*K / (2*S*E - 0.2*P) + Corrosion= 61.39*26.9333*0.993855 / (2*20,000*1 - 0.2*61.39) + 0.0625= 0.1036"
The head internal pressure design thickness is 0.1036".
Maximum allowable working pressure, (Corroded at 307.57 °F) Appendix 1-4(c)
P = 2*S*E*t / (K*D + 0.2*t) - Ps= 2*20,000*1*0.0625 / (0.993855*26.9333 +0.2*0.0625) - 1.09= 92.26 psi
The maximum allowable working pressure (MAWP) is 92.26 psi.
Maximum allowable pressure, (New at 70 °F) Appendix 1-4(c)
P = 2*S*E*t / (K*D + 0.2*t) - Ps= 2*20,000*1*0.125 / (1*26.8083 +0.2*0.125) - 0= 186.34 psi
The maximum allowable pressure (MAP) is 186.34 psi.
% Extreme fiber elongation - UCS-79(d)
= (75*t / Rf)*(1 - Rf / Ro)= (75*0.125 / 4.6199)*(1 - 4.6199 / ∞)= 2.0293%
The extreme fiber elongation does not exceed 5%.
41/226
Shell Side Flange (front)
ASME VIII-1, 2007 Edition, Appendix 2 Flange Calculations
Flange is attached to: Port Cylinder (front) (Left)Flange type: Weld neck integralFlange material specification: SA-516 70 (II-D p. 18, ln. 22)
Bolt material specification: SA-193 B7 Bolt <= 2 1/2 (II-D p. 348,ln. 33)
Internal design pressure, P: 60.3 psi @ 307.57 °FLiquid static head acting on flange: 0.9294 psiRequired flange thickness: tr= 1.7279 inMaximum allowable working pressure,MAWP: 303.26 psi @ 307.57 °F
Maximum allowable pressure, MAP: 285.34 psi @ 70 °FCorrosion allowance: Bore = 0 in Flange = 0 inBolt corrosion (root), Cbolt: 0 inDesign MDMT: -20 °F No impact test performedRated MDMT: -55 °F Flange material is not normalized
Material is not produced to fine grainpracticePWHT is not performed
Estimated weight: New = 50.7 lb corroded = 50.7 lb
Flange dimensions, new
flange OD A = 20.5 inbolt circle C = 19.25 ingasket OD = 18.125 ingasket ID = 17.25 inflange ID B = 17.25 inthickness t = 1.75 inbolting = 24- 0.625 in diahub thickness g1 = 0.1875 inhub thickness g0 = 0.125 inhub length h = 1.25 inlength e = 3 ingasket factor m = 3seating stress y = 5,000.00 psi
Note: this flange is calculated as an integral type.
42/226
Determination of Flange MDMT
UCS-66(b)(1)(b) has been applied.Flange is impact test exempt to -155 °F per UCS-66(b)(3) (coincident ratio = 0.19669)Bolts rated MDMT per Fig UCS-66 note (e) = -55 °F
The rated flange MDMT is -55 °F
Flange calculations for Internal Pressure + Weight Only
43/226
Gasket details from facing sketch 1(a) or (b), Column II
Gasket width N = 0.4375 in
b0 = N/2 = 0.2188 in
Effective gasket seating width, b = b0 = 0.2188 in
G = (OD of contact face + gasket ID) / 2 = 17.6875 in
hG = (C - G)/2 = (19.25 - 17.6875)/2 = 0.7813 in
hD = R + g1/2 = 0.8125 + 0.1875/2 = 0.9063 in
hT = (R + g1 + hG)/2 = (0.8125 + 0.1875 + 0.7813)/2 = 0.8906 in
Hp = 2*b*3.14*G*m*P= 2*0.2188*3.14*17.6875*3*61.2335= 4,463.59 lbf
H = 0.785*G2*P= 0.785*17.68752*61.2335= 15,038.05 lbf
HD = 0.785*B2*P= 0.785*17.252*61.2335= 14,303.32 lbf
HT = H - HD= 15,038.05 - 14,303.32= 734.73 lbf
Wm1 = H + Hp= 15,038.05 + 4,463.59= 19,501.65 lbf
Wm2 = 3.14*b*G*y= 3.14*0.2188*17.6875*5,000= 60,745.51 lbf
Per VIII-1, Appendix 2-5(a)(2): Wm2 from the mating flange governs so Wm2 = 97,800.2 lbf
Required bolt area, Am = greater of Am1, Am2 = 3.912008 in2
Am1 = Wm1/Sb = 19,501.65/25,000 = 0.7801 in2
Am2 = Wm2/Sa = 97,800.2/25,000 = 3.912 in2
Total area for 24- 0.625 in dia bolts, corroded, Ab = 4.848 in2
W = (Am + Ab)*Sa/2= (3.912 + 4.848)*25,000/2= 109,500.1 lbf
MD = HD*hD = 14,303.32*0.9063 = 12,962.4 lb-inMT = HT*hT = 734.73*0.8906 = 654.4 lb-in
44/226
HG = Wm1 - H = 19,501.65 - 15,038.05 = 4,463.59 lbf
MG = HG*hG = 4,463.59*0.7813 = 3,487.2 lb-in
Mo = MD + MT + MG = 12,962.4 + 654.4 + 3,487.2 = 17,103.9 lb-in
Mg = W*hG = 109,500.1*0.7813 = 85,547 lb-in
The bolts are adequately spaced so the TEMA RCB-11.23 load concentration factor does not apply.
Hub and Flange Factors
h0 = (B*g0)1/2 = (17.25*0.125)1/2 = 1.4684 in
From FIG. 2-7.1, where K = A/B = 20.5/17.25 = 1.1884
T = 1.8436 Z = 5.8507 Y = 11.3396 U =12.4611
h/h0 = 0.8513 g1/g0 = 1.5
F = 0.8078 V = 0.2647 e = F/h0 = 0.5501
d = (U/V)*h0*g02= (12.46108/0.2647)*1.4684*0.1252
= 1.0802 in3
Stresses at operating conditions - VIII-1, Appendix 2-7
f = 1
L = (t*e + 1)/T + t3/d= (1.75*0.5501 + 1)/1.843613 + 1.753/1.0802= 6.026093
SH = f*Mo/(L*g12*B)
= 1*17,103.9/(6.026093*0.18752*17.25)= 4,680 psi
SR = (1.33*t*e + 1)*Mo/(L*t2*B)= (1.33*1.75*0.5501 + 1)*17,103.9/(6.026093*1.752*17.25)= 123 psi
ST = Y*Mo/(t2*B) - Z*SR= 11.3396*17,103.9/(1.752*17.25) - 5.8507*123= 2,955 psi
Allowable stress Sfo = 20,000 psiAllowable stress Sno = 20,000 psi
ST does not exceed SfoSH does not exceed Min[ 1.5*Sfo, 2.5*Sno ] = 30,000 psiSR does not exceed Sfo0.5(SH + SR) = 2,401 psi does not exceed Sfo0.5(SH + ST) = 3,817 psi does not exceed Sfo
Stresses at gasket seating - VIII-1, Appendix 2-7
SH = f*Mg/(L*g12*B)
= 1*85,547/(6.026093*0.18752*17.25)
45/226
= 23,409 psi
SR = (1.33*t*e + 1)*Mg/(L*t2*B)= (1.33*1.75*0.5501 + 1)*85,547/(6.026093*1.752*17.25)= 613 psi
ST = Y*Mg/(t2*B) - Z*SR= 11.3396*85,547/(1.752*17.25) - 5.8507*613= 14,777 psi
Allowable stress Sfa = 20,000 psiAllowable stress Sna = 20,000 psi
ST does not exceed SfaSH does not exceed Min[ 1.5*Sfa, 2.5*Sna ] = 30,000 psiSR does not exceed Sfa0.5(SH + SR) = 12,011 psi does not exceed Sfa0.5(SH + ST) = 19,093 psi does not exceed Sfa
Flange rigidity per VIII-1, Appendix 2-14
J = 52.14*V*Mo/(L*E*g02*KI*h0)
= 52.14*0.2647*85,547/(6.0261*29,400,000*0.1252*0.3*1.4684)= 0.9681055
The flange rigidity index J does not exceed 1; satisfactory.
Flange calculations for External Pressure + Weight Only per VIII-1, Appendix 2-11
46/226
Gasket details from facing sketch 1(a) or (b), Column II
Gasket width N = 0.4375 in
b0 = N/2 = 0.2188 in
Effective gasket seating width, b = b0 = 0.2188 in
G = (OD of contact face + gasket ID) / 2 = 17.6875 in
hG = (C - G)/2 = (19.25 - 17.6875)/2 = 0.7813 in
hD = R + g1/2 = 0.8125 + 0.1875/2 = 0.9063 in
hT = (R + g1 + hG)/2 = (0.8125 + 0.1875 + 0.7813)/2 = 0.8906 in
Hp = 2*b*3.14*G*m*P= 2*0.2188*3.14*17.6875*3*0= 0 lbf
H = 0.785*G2*P= 0.785*17.68752*0= 0 lbf
HD = 0.785*B2*P= 0.785*17.252*0= 0 lbf
HT = H - HD= 0 - 0= 0 lbf
Wm1 = H + Hp= 0 + 0= 0 lbf
Per VIII-1, Appendix 2-5(a)(2): Wm1 from the mating flange governs so Wm1 = 4,782.14 lbf
Wm2 = 3.14*b*G*y= 3.14*0.2188*17.6875*5,000= 60,745.51 lbf
Per VIII-1, Appendix 2-5(a)(2): Wm2 from the mating flange governs so Wm2 = 97,800.2 lbf
Required bolt area, Am = greater of Am1, Am2 = 3.912008 in2
Am1 = 0.785*G2*(Pm - Pr)/Sb = 0/25,000 = 0 in2
Am2 = Wm2/Sa = 97,800.2/25,000 = 3.912 in2
Total area for 24- 0.625 in dia bolts, corroded, Ab = 4.848 in2
W = (Am2 + Ab)*Sa/2= (3.912 + 4.848)*25,000/2= 109,500.1 lbf
Mo = HD*(hD - hG) + HT*(hT - hG)
47/226
= 0*(0.9063 - 0.7813) + 0*(0.8906 - 0.7813)= 0 lb-in
Mg = W*hG = 109,500.1*0.7813 = 85,547 lb-in
The bolts are adequately spaced so the TEMA RCB-11.23 load concentration factor does not apply.
Hub and Flange Factors
h0 = (B*g0)1/2 = (17.25*0.125)1/2 = 1.4684 in
From FIG. 2-7.1, where K = A/B = 20.5/17.25 = 1.1884
T = 1.8436 Z = 5.8507 Y = 11.3396 U =12.4611
h/h0 = 0.8513 g1/g0 = 1.5
F = 0.8078 V = 0.2647 e = F/h0 = 0.5501
d = (U/V)*h0*g02= (12.46108/0.2647)*1.4684*0.1252
= 1.0802 in3
Stresses at operating conditions - VIII-1, Appendix 2-7
f = 1
L = (t*e + 1)/T + t3/d= (1.75*0.5501 + 1)/1.843613 + 1.753/1.0802= 6.026093
SH = f*Mo/(L*g12*B)
= 1*0/(6.026093*0.18752*17.25)= 0 psi
SR = (1.33*t*e + 1)*Mo/(L*t2*B)= (1.33*1.75*0.5501 + 1)*0/(6.026093*1.752*17.25)= 0 psi
ST = Y*Mo/(t2*B) - Z*SR= 11.3396*0/(1.752*17.25) - 5.8507*0= 0 psi
Allowable stress Sfo = 20,000 psiAllowable stress Sno = 20,000 psi
ST does not exceed SfoSH does not exceed Min[ 1.5*Sfo, 2.5*Sno ] = 30,000 psiSR does not exceed Sfo0.5(SH + SR) = 0 psi does not exceed Sfo0.5(SH + ST) = 0 psi does not exceed Sfo
Stresses at gasket seating - VIII-1, Appendix 2-7
SH = f*Mg/(L*g12*B)
= 1*85,547/(6.026093*0.18752*17.25)= 23,409 psi
SR = (1.33*t*e + 1)*Mg/(L*t2*B)
48/226
= (1.33*1.75*0.5501 + 1)*85,547/(6.026093*1.752*17.25)= 613 psi
ST = Y*Mg/(t2*B) - Z*SR= 11.3396*85,547/(1.752*17.25) - 5.8507*613= 14,777 psi
Allowable stress Sfa = 20,000 psiAllowable stress Sna = 20,000 psi
ST does not exceed SfaSH does not exceed Min[ 1.5*Sfa, 2.5*Sna ] = 30,000 psiSR does not exceed Sfa0.5(SH + SR) = 12,011 psi does not exceed Sfa0.5(SH + ST) = 19,093 psi does not exceed Sfa
Flange rigidity per VIII-1, Appendix 2-14
J = 52.14*V*Mo/(L*E*g02*KI*h0)
= 52.14*0.2647*85,547/(6.0261*29,400,000*0.1252*0.3*1.4684)= 0.9681055
The flange rigidity index J does not exceed 1; satisfactory.
Shell Side Flange (front) - Flange hub
ASME Section VIII Division 1, 2007 Edition
Component: Flange hubMaterial specification: SA-516 70 (II-D p. 18, ln. 22)Material is impact test exempt to -155 °F per UCS-66(b)(3) (coincident ratio = 0.19717)
Internal design pressure: P = 60.3041 psi @ 307.57°F
Static liquid head:
Not Considered
Corrosion allowance: Inner C = 0.0000" Outer C = 0.0000"
Design MDMT = -20.00°F No impact test performedRated MDMT = -155.00°F Material is not normalized
Material is not produced to Fine Grain PracticePWHT is not performed
Radiography: Longitudinal joint - Seamless No RTLeft circumferential joint - N/ARight circumferential joint - Full UW-11(a) Type 1
Estimated weight: New = 2.3963 lb corr = 2.3963 lbCapacity: New = 1.2646 gal corr = 1.2646 galID = 17.2500"Length Lc = 1.2500"t = 0.1250"
49/226
Design thickness, (at 307.57°F) UG-27(c)(1)
t = P*R/(S*E - 0.60*P) + Corrosion= 61.23*8.6250/(20000*1.00 - 0.60*61.23) + 0.0000= 0.0265"
Maximum allowable working pressure, (at 307.57°F) UG-27(c)(1)
P = S*E*t/(R + 0.60*t) - Ps= 20000*1.00*0.1250 / (8.6250 + 0.60*0.1250) - 0.9294= 286.4269 psi
Maximum allowable pressure, (at 70.00°F) UG-27(c)(1)
P = S*E*t/(R + 0.60*t)= 20000*1.00*0.1250 / (8.6250 + 0.60*0.1250)= 287.3563 psi
% Extreme fiber elongation - UCS-79(d)
= (50 * t / Rf) * (1 - Rf / Ro)= (50 * 0.1250 / 8.6875) * (1 - 8.6875 / ∞)= 0.7194 %
Allowable Compressive Stress, Hot and Corroded- ScHC, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (8.7500 / 0.1250)= 0.001786
B = 14380.1836 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScHC = 14380.1836 psi
Allowable Compressive Stress, Hot and New- ScHN
ScHN = ScHC
= 14380.1836 psi
Allowable Compressive Stress, Cold and New- ScCN, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (8.7500 / 0.1250)= 0.001786
B = 14521.1133 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScCN = 14521.1133 psi
50/226
Allowable Compressive Stress, Cold and Corroded- ScCC
ScCC = ScCN
= 14521.1133 psi
Allowable Compressive Stress, Vacuum and Corroded- ScVC, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (8.7500 / 0.1250)= 0.001786
B = 14380.1836 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScVC = 14380.1836 psi
51/226
SS Inlet (N4)
ASME Section VIII Division 1, 2007 Edition
tw(lower) = 0.125 inLeg41 = 0.0625 in
Note: round inside edges per UG-76(c)
Located on: ShellLiquid static head included: 1.0913 psiNozzle material specification: SA-455 <= 3/8 (II-D p. 22, ln. 14)Nozzle longitudinal joint efficiency: 1Flange description: 4 inch Class 150 WN A105Bolt Material: SA-193 B7 Bolt <= 2 1/2 (II-D p. 348, ln. 33)Flange rated MDMT: -55°F(UCS-66(b)(3): Coincident ratio = 0.2014462)(Flange rated MDMT = -155 °FBolts rated MDMT per Fig UCS-66 note (e) = -55 °F)Liquid static head on flange: 1.2893 psiASME B16.5 flange rating MAWP: 227.73 psi @ 307.57°FASME B16.5 flange rating MAP: 285 psi @ 70°FASME B16.5 flange hydro test: 450 psi @ 70°FNozzle orientation: 180°Local vessel minimum thickness: 0.125 inNozzle center line offset to datum line: 24.0535 inEnd of nozzle to shell center: 19.5292 inNozzle inside diameter, new: 4 inNozzle nominal wall thickness: 0.25 inNozzle corrosion allowance: 0.0625 inProjection available outside vessel, Lpr: 5.06 inProjection available outside vessel to flange face, Lf: 6 in
52/226
Reinforcement Calculations for Internal Pressure
Available reinforcement per UG-37 governs the MAWP of this nozzle.
UG-37 Area Calculation Summary (in2)For P = 57.21 psi @ 307.57 °F
The opening is adequately reinforced
UG-45Nozzle WallThicknessSummary
(in)The nozzle
passes UG-45
Arequired
Aavailable A1 A2 A3 A5
Awelds treq tmin
0.1592 0.1594 0.0986 0.0569 -- -- 0.0039 0.125 0.25
Weld Failure Path Analysis Summary
The nozzle is exempt from weld strengthcalculations per UW-15(b)(1)
UW-16 Weld Sizing Summary
Weld description Required weldthroat size (in)
Actual weldthroat size (in) Status
Nozzle to shell fillet (Leg41) 0.0438 0.0438 weld size is adequate
Calculations for internal pressure 57.21 psi @ 307.57 °F
Nozzle impact test exemption temperature from Fig UCS-66 Curve A = 18 °FFig UCS-66.1 MDMT reduction = 38.3 °F, (coincident ratio = 0.61744).
Nozzle UCS-66 governing thk: 0.125 inNozzle rated MDMT: -20.3 °F
Limits of reinforcement per UG-40
Parallel to the vessel wall: d = 4.125 inNormal to the vessel wall outside: 2.5*(t - C) = 0.1563 in
Nozzle required thickness per UG-27(c)(1)
trn = P*Rn/(Sn*E - 0.6*P)= 57.2142*2.0625/(21,400*1 - 0.6*57.2142)= 0.0055 in
Required thickness tr from UG-37(a)
tr = P*R/(S*E - 0.6*P)= 57.2142*13.4667/(20,000*1 - 0.6*57.2142)= 0.0386 in
53/226
Area required per UG-37(c)
Allowable stresses: Sn = 21,400, Sv = 20,000 psi
fr1 = lesser of 1 or Sn/Sv = 1fr2 = lesser of 1 or Sn/Sv = 1
A = d*tr*F + 2*tn*tr*F*(1 - fr1)= 4.125*0.0386*1 + 2*0.1875*0.0386*1*(1 - 1)= 0.1592 in2
Area available from FIG. UG-37.1
A1 = larger of the following= 0.0986 in2
= d*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1)= 4.125*(1*0.0625 - 1*0.0386) - 2*0.1875*(1*0.0625 - 1*0.0386)*(1 - 1)= 0.0986 in2
= 2*(t + tn)*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1)= 2*(0.0625 + 0.1875)*(1*0.0625 - 1*0.0386) - 2*0.1875*(1*0.0625 - 1*0.0386)*(1 - 1)= 0.012 in2
A2 = smaller of the following= 0.0569 in2
= 5*(tn - trn)*fr2*t= 5*(0.1875 - 0.0055)*1*0.0625= 0.0569 in2
= 5*(tn - trn)*fr2*tn= 5*(0.1875 - 0.0055)*1*0.1875= 0.1706 in2
A41 = Leg2*fr2= 0.06252*1= 0.0039 in2
Area = A1 + A2 + A41
= 0.0986 + 0.0569 + 0.0039= 0.1594 in2
As Area >= A the reinforcement is adequate.
UW-16(c) Weld Check
Fillet weld: tmin = lesser of 0.75 or tn or t = 0.0625 intc(min) = lesser of 0.25 or 0.7*tmin = 0.0438 intc(actual) = 0.7*Leg = 0.7*0.0625 = 0.0438 in
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The fillet weld size is satisfactory.
Weld strength calculations are not required for this detail which conforms to Fig. UW-16.1, sketch (c-e).
UG-45 Nozzle Neck Thickness Check
Wall thickness per UG-45(a): tr1 = 0.068 in (E =1)Wall thickness per UG-45(b)(1): tr2 = 0.1011 inWall thickness per UG-16(b): tr3 = 0.125 inStandard wall pipe per UG-45(b)(4): tr4 = 0.2699 inThe greater of tr2 or tr3: tr5 = 0.125 inThe lesser of tr4 or tr5: tr6 = 0.125 in
Required per UG-45 is the larger of tr1 or tr6 = 0.125 in
Available nozzle wall thickness new, tn = 0.25 in
The nozzle neck thickness is adequate.
% Extreme fiber elongation - UCS-79(d)
= (50*t / Rf)*(1 - Rf / Ro)= (50*0.25 / 2.125)*(1 - 2.125 / ∞)= 5.8824%
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The extreme fiber elongation exceeds 5 percent. Heat treatment per UCS-56 may be required. See UCS-79(d)(4) or(5).
Reinforcement Calculations for MAP
Available reinforcement per UG-37 governs the MAP of this nozzle.
UG-37 Area Calculation Summary (in2)For P = 121.27 psi @ 70 °F
The opening is adequately reinforced
UG-45Nozzle WallThicknessSummary
(in)The nozzle
passes UG-45
Arequired
Aavailable A1 A2 A3 A5
Awelds treq tmin
0.3263 0.3267 0.1737 0.1491 -- -- 0.0039 0.0816 0.25
Weld Failure Path Analysis Summary
The nozzle is exempt from weld strengthcalculations per UW-15(b)(1)
UW-16 Weld Sizing Summary
Weld description Required weldthroat size (in)
Actual weldthroat size (in) Status
Nozzle to shell fillet (Leg41) 0.0875 0.0438 weld size is NOT adequate
Calculations for internal pressure 121.27 psi @ 70 °F
Limits of reinforcement per UG-40
Parallel to the vessel wall: d = 4 inNormal to the vessel wall outside: 2.5*(t - C) = 0.3125 in
Nozzle required thickness per UG-27(c)(1)
trn = P*Rn/(Sn*E - 0.6*P)= 121.2745*2/(21,400*1 - 0.6*121.2745)= 0.0114 in
Required thickness tr from UG-37(a)
tr = P*R/(S*E - 0.6*P)= 121.2745*13.4042/(20,000*1 - 0.6*121.2745)= 0.0816 in
Area required per UG-37(c)
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Allowable stresses: Sn = 21,400, Sv = 20,000 psi
fr1 = lesser of 1 or Sn/Sv = 1fr2 = lesser of 1 or Sn/Sv = 1
A = d*tr*F + 2*tn*tr*F*(1 - fr1)= 4*0.0816*1 + 2*0.25*0.0816*1*(1 - 1)= 0.3263 in2
Area available from FIG. UG-37.1
A1 = larger of the following= 0.1737 in2
= d*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1)= 4*(1*0.125 - 1*0.0816) - 2*0.25*(1*0.125 - 1*0.0816)*(1 - 1)= 0.1737 in2
= 2*(t + tn)*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1)= 2*(0.125 + 0.25)*(1*0.125 - 1*0.0816) - 2*0.25*(1*0.125 - 1*0.0816)*(1 - 1)= 0.0326 in2
A2 = smaller of the following= 0.1491 in2
= 5*(tn - trn)*fr2*t= 5*(0.25 - 0.0114)*1*0.125= 0.1491 in2
= 5*(tn - trn)*fr2*tn= 5*(0.25 - 0.0114)*1*0.25= 0.2983 in2
A41 = Leg2*fr2= 0.06252*1= 0.0039 in2
Area = A1 + A2 + A41
= 0.1737 + 0.1491 + 0.0039= 0.3267 in2
As Area >= A the reinforcement is adequate.
UW-16(c) Weld Check
Fillet weld: tmin = lesser of 0.75 or tn or t = 0.125 intc(min) = lesser of 0.25 or 0.7*tmin = 0.0875 intc(actual) = 0.7*Leg = 0.7*0.0625 = 0.0438 in
** The fillet weld size IS NOT satisfactory. **UG-45 Nozzle Neck Thickness Check
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Wall thickness per UG-45(a): tr1 = 0.0114 in (E =1)Wall thickness per UG-45(b)(1): tr2 = 0.0816 inWall thickness per UG-16(b): tr3 = 0.0625 inStandard wall pipe per UG-45(b)(4): tr4 = 0.2074 inThe greater of tr2 or tr3: tr5 = 0.0816 inThe lesser of tr4 or tr5: tr6 = 0.0816 in
Required per UG-45 is the larger of tr1 or tr6 = 0.0816 in
Available nozzle wall thickness new, tn = 0.25 in
The nozzle neck thickness is adequate.
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Tabular Results
Results were generated with the finite element program FE/Pipe®. Stress results are post-processed inaccordance with the rules specified in ASME Section III and ASME Section VIII, Division 2.
Analysis Time Stamp: Thu Nov 25 14:30:55 2010.
Model Notes• Load Case Report• Solution Data• ASME Code Stress Output Plots• ASME Overstressed Areas• Highest Primary Stress Ratios• Highest Secondary Stress Ratios• Highest Fatigue Stress Ratios• Stress Intensification Factors• Allowable Loads• Flexibilities• Graphical Results•
Model Notes
Input Echo:
Model Type : Cylindrical Shell
Parent Outside Diameter : 27.058 in.Thickness : 0.063 in.Fillet Along Shell : 0.063 in.
Parent Properties:Cold Allowable : 20000.0 psiHot Allowable : 20000.0 psiMaterial ID #2 : Low Alloy SteelUltimate Tensile (Amb) : 70000.0 psiYield Strength (Amb) : 38000.0 psiYield Strength (Hot) : 33500.0 psiElastic Modulus (Amb) : 29400000.0 psiPoissons Ratio : 0.300Weight Density : 0.283 lb./cu.in.(NOT USED)
Nozzle Outside Diameter : 4.500 in.Thickness : 0.188 in.Length : 6.031 in.Nozzle Weld Length : 0.063 in.Nozzle Tilt Angle : 0.000 deg.Distance from Top : 24.053 in.Distance from Bottom : 24.053 in.
Nozzle Properties
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Cold Allowable : 21400.0 psiHot Allowable : 21400.0 psiMaterial ID #2 : Low Alloy SteelUltimate Tensile (Amb) : 75000.0 psiYield Strength (Amb) : 38000.0 psiYield Strength (Hot) : 33500.0 psiElastic Modulus (Amb) : 29200000.0 psiPoissons Ratio : 0.300Weight Density : 0.283 lb./cu.in. (NOT USED)
Design Operating Cycles : 0.Ambient Temperature (Deg.) : 70.00Nozzle Pressure : 61.4 psiVessel Pressure : 61.4 psi
No external forces or bending moments were included in this analysis.
Both ends of the model are "fixed," except that one endis free axially so that longitudinal pressure stressesmay be developed in the geometry.
Stresses are NOT averaged.
Unstructured Mesh Generation used for this model.
Vessel Centerline Vector : 0.000 0.000 1.000Nozzle Orientation Vector : 0.000 -1.000 0.000
Table of Contents
Load Case Report
Inner and outer element temperatures are the samethroughout the model. No thermal ratchetingcalculations will be performed.
THE 9 LOAD CASES ANALYZED ARE:
1 Weight ONLY
Weight ONLY case run to get the stress rangebetween the installed and the operating states.It is assumed that the weight only case accuratelyrepresents the installed stress state.
/-------- Loads in Case 1Forces due to Weight
2 Sustained
Sustained case run to satisfy Pl Qb, the bending stress due to primary loads mustbe less than 3Smh as per Note 3 of Fig. NB-3222-1,and Table 4-120.1
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/-------- Loads in Case 2Forces due to WeightPressure Case 1
3 Operating
Operating case run to compute the extreme operatingstress state to be used in the shakedown and peakstress calculations.
/-------- Loads in Case 3Pressure Case 1Force Case (Operating)
4 Expansion (Fatigue Calc Performed)
Expansion case run to get the RANGE of stressesas described in NB-3222.2, or Note 1 of 4-130.1.The allowable is 3Smavg.
/-------- Combinations in Expansion Case 4Plus Stress Results from CASE 3Minus Stress Results from CASE 1
5 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 5Force Case (Axial)
6 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 6Force Case (Inplane)
7 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 7Force Case (Outplane)
8 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 8Force Case (Torsion)
9 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 9
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Pressure Case 1
Table of Contents
Solution Data
Maximum Solution Row Size = 924Number of Nodes = 2339Number of Elements = 756Number of Solution Cases = 8
Largest On-Diagonal Stiffness = 643712797181.Smallest On-Diagonal Stiffness = 2.
Largest Off-Diagonal Stiffness = 317150669168.Smallest Off-Diagonal Stiffness = 1.
Summation of Loads per Case
Case # FX FY FZ
1 0. -76. 0.2 0. -1. 34978.3 0. -1. 34978.4 0. -29821. 0.5 0. 0. 0.6 0. 0. 0.7 0. 0. 0.8 0. 76. 34978.
Equation Coefficient (Stiffness) Distribution)
OnDiagonal Number of AveragePercentile Coefficients Stiffness
90-to-100% 24 639233579164.70-to-90% 0 0.50-to-70% 0 0.30-to-50% 96 231105249849.10-to-30% 144 92060611835.1-to-10% 96 56146602265..1-to- 1% 100 1256696747..01-to-.1% 368 269908248..001-to-.01% 3727 16628457..0001-TO-.001% 9479 1915116.
OFF Diagonal Number of AveragePercentile Coefficients Stiffness
90-to-100% 48 314868703720.70-to-90% 0 0.50-to-70% 0 0.
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30-to-50% 144 125099360394.10-to-30% 424 52317133205.1-to-10% 2292 10867263975..1-to- 1% 5428 1097279174..01-to-.1% 7052 129612138..001-to-.01% 13079 9355474..0001-TO-.001% 609241 161456.
Table of Contents
ASME Code Stress Output Plots
1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
2) Qb < 3(Smh) (SUS,Bending) Case 2
3) Pl+Pb+Q < 3(Smavg) (OPE,Inside) Case 3
4) Pl+Pb+Q < 3(Smavg) (OPE,Outside) Case 3
5) Pl+Pb+Q+F < Sa (SIF,Outside) Case 5
6) Pl+Pb+Q+F < Sa (SIF,Outside) Case 6
7) Pl+Pb+Q+F < Sa (SIF,Outside) Case 7
8) Pl+Pb+Q+F < Sa (SIF,Outside) Case 8
9) Pl+Pb+Q+F < Sa (SIF,Outside) Case 9
10) Pl+Pb+Q < 3(Smavg) (EXP,Inside) Case 4
11) Pl+Pb+Q < 3(Smavg) (EXP,Outside) Case 4
12) Pl+Pb+Q+F < Sa (EXP,Inside) Case 4
13) Pl+Pb+Q+F < Sa (EXP,Outside) Case 4
Table of Contents
ASME Overstressed Areas
*** NO OVERSTRESSED NODES IN THIS MODEL ***
Table of Contents
Highest Primary Stress Ratios
Header Next to Nozzle Weld
Pl 1.5(k)Smh Primary Membrane Load Case 2
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20,675 30,000 Plot Reference:psi psi 1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
68%
Branch Next to Header Weld
Pl 1.5(k)Smh Primary Membrane Load Case 215,793 32,100 Plot Reference:psi psi 1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
49%
Branch Transition
Pl 1.5(k)Smh Primary Membrane Load Case 21,590 32,100 Plot Reference:psi psi 1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
4%
Header away from Junction
Pl 1.5(k)Smh Primary Membrane Load Case 219,640 30,000 Plot Reference:psi psi 1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
65%
Branch away from Junction
Qb 3(Smh) Primary Bending Load Case 24,183 64,200 Plot Reference:psi psi 2) Qb < 3(Smh) (SUS,Bending) Case 2
6%
Table of Contents
Highest Secondary Stress Ratios
Header Next to Nozzle Weld
Pl+Pb+Q 3(Smavg) Primary+Secondary (Outer) Load Case 327,824 60,000 Plot Reference:psi psi 4) Pl+Pb+Q < 3(Smavg) (OPE,Outside) Case 3
46%
Branch Next to Header Weld
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Pl+Pb+Q 3(Smavg) Primary+Secondary (Inner) Load Case 318,765 64,200 Plot Reference:psi psi 3) Pl+Pb+Q < 3(Smavg) (OPE,Inside) Case 3
29%
Branch Transition
Pl+Pb+Q 3(Smavg) Primary+Secondary (Inner) Load Case 42,945 64,200 Plot Reference:psi psi 10) Pl+Pb+Q < 3(Smavg) (EXP,Inside) Case 4
4%
Header away from Junction
Pl+Pb+Q 3(Smavg) Primary+Secondary (Outer) Load Case 323,071 60,000 Plot Reference:psi psi 4) Pl+Pb+Q < 3(Smavg) (OPE,Outside) Case 3
38%
Branch away from Junction
Pl+Pb+Q 3(Smavg) Primary+Secondary (Inner) Load Case 35,483 64,200 Plot Reference:psi psi 3) Pl+Pb+Q < 3(Smavg) (OPE,Inside) Case 3
8%
Table of Contents
Highest Fatigue Stress Ratios
Header Next to Nozzle Weld
Pl+Pb+Q+F Sa Primary+Secondary+Peak (Outer) Load Case 418,741 568,400 Stress Concentration Factor = 1.350psi psi Strain Concentration Factor = 1.000Cycles Allowed for this Stress = 117527.03% "B31" Fatigue Stress Allowable = 50000.0Markl Fatigue Stress Allowable = 245000.0WRC 474 Mean Cycles to Failure = 2874399.WRC 474 99% Probability Cycles = 667762.WRC 474 95% Probability Cycles = 927116.BS5500 Allowed Cycles(Curve F) = 98781.Membrane-to-Bending Ratio = 1.585Bending-to-PL+PB+Q Ratio = 0.387Plot Reference:13) Pl+Pb+Q+F < Sa (EXP,Outside) Case 4
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Branch Next to Header Weld
Pl+Pb+Q+F Sa Primary+Secondary+Peak (Inner) Load Case 412,653 564,533 Stress Concentration Factor = 1.350psi psi Strain Concentration Factor = 1.000Cycles Allowed for this Stress = 702353.42% "B31" Fatigue Stress Allowable = 53500.0Markl Fatigue Stress Allowable = 245000.0WRC 474 Mean Cycles to Failure = 4336082.WRC 474 99% Probability Cycles = 1007330.WRC 474 95% Probability Cycles = 1398571.BS5500 Allowed Cycles(Curve F) = 327575.Membrane-to-Bending Ratio = 3.568Bending-to-PL+PB+Q Ratio = 0.219Plot Reference:12) Pl+Pb+Q+F < Sa (EXP,Inside) Case 4
Branch Transition
Pl+Pb+Q+F Sa Primary+Secondary+Peak (Inner) Load Case 41,988 564,533 Stress Concentration Factor = 1.350psi psi Strain Concentration Factor = 1.000Cycles Allowed for this Stress = 1000000.00% "B31" Fatigue Stress Allowable = 53500.0Markl Fatigue Stress Allowable = 245000.0WRC 474 Mean Cycles to Failure = 1596255872.WRC 474 99% Probability Cycles = 370831808.WRC 474 95% Probability Cycles = 514860608.BS5500 Allowed Cycles(Curve F) = 355817888.Membrane-to-Bending Ratio = 0.635Bending-to-PL+PB+Q Ratio = 0.612Plot Reference:12) Pl+Pb+Q+F < Sa (EXP,Inside) Case 4
Header away from Junction
Pl+Pb+Q+F Sa Primary+Secondary+Peak (Outer) Load Case 411,511 568,400 Stress Concentration Factor = 1.000psi psi Strain Concentration Factor = 1.000Cycles Allowed for this Stress = 1000000.02% "B31" Fatigue Stress Allowable = 50000.0Markl Fatigue Stress Allowable = 245000.0WRC 474 Mean Cycles to Failure = 5025799.WRC 474 99% Probability Cycles = 1167561.WRC 474 95% Probability Cycles = 1621034.BS5500 Allowed Cycles(Curve F) = 173270.Membrane-to-Bending Ratio = 2.927Bending-to-PL+PB+Q Ratio = 0.255Plot Reference:13) Pl+Pb+Q+F < Sa (EXP,Outside) Case 4
Branch away from Junction
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Pl+Pb+Q+F Sa Primary+Secondary+Peak (Inner) Load Case 42,739 564,533 Stress Concentration Factor = 1.000psi psi Strain Concentration Factor = 1.000Cycles Allowed for this Stress = 1000000.00% "B31" Fatigue Stress Allowable = 53500.0Markl Fatigue Stress Allowable = 245000.0WRC 474 Mean Cycles to Failure = 227633072.WRC 474 99% Probability Cycles = 52882236.WRC 474 95% Probability Cycles = 73421376.BS5500 Allowed Cycles(Curve F) = 15968436.Membrane-to-Bending Ratio = 0.372Bending-to-PL+PB+Q Ratio = 0.729Plot Reference:12) Pl+Pb+Q+F < Sa (EXP,Inside) Case 4
Table of Contents
Stress Intensification Factors
Branch/Nozzle Sif Summary
Peak Primary SecondaryAxial : 188.875 33.459 279.815Inplane : 34.961 17.668 51.794Outplane: 125.957 18.058 186.602Torsion : 5.765 7.344 8.697Pressure: 1.410 1.554 2.089
The above stress intensification factors are to be usedin a beam-type analysis of the piping system. Inplane,Outplane and Torsional sif's should be used with thematching branch pipe whose diameter and thickness is givenbelow. The axial sif should be used to intensify theaxial stress in the branch pipe calculated by F/A. Thepressure sif should be used to intensify the nominalpressure stress in the PARENT or HEADER, calculatedfrom PD/2T.
Pipe OD : 4.500 in.Pipe Thk: 0.188 in.Z approx: 2.739 cu.in.Z exact : 2.630 cu.in.
B31.3Peak Stress Sif .... 0.000 Axial73.642 Inplane97.189 Outplane1.000 TorsionalB31.1Peak Stress Sif .... 0.000 Axial62.044 Inplane62.044 Outplane62.044 TorsionalWRC 330Peak Stress Sif .... 0.000 Axial
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41.880 Inplane41.880 Outplane6.690 Torsional
Table of Contents
Allowable Loads
SECONDARY Maximum Conservative RealisticLoad Type (Range): Individual Simultaneous SimultaneousOccuring Occuring OccuringAxial Force (lb. ) 545. 98. 146.Inplane Moment (in. lb.) 3046. 386. 818.Outplane Moment (in. lb.) 846. 107. 227.Torsional Moment (in. lb.) 18141. 3476. 5213.Pressure (psi ) 132.68 61.40 61.40
PRIMARY Maximum Conservative RealisticLoad Type: Individual Simultaneous SimultaneousOccuring Occuring OccuringAxial Force (lb. ) 2278. 237. 355.Inplane Moment (in. lb.) 4465. 328. 695.Outplane Moment (in. lb.) 4368. 321. 680.Torsional Moment (in. lb.) 10742. 1115. 1673.Pressure (psi ) 89.17 61.40 61.40
NOTES:
1) Maximum Individual Occuring Loads are the maximumallowed values of the respective loads if all otherload components are zero, i.e. the listed axial forcemay be applied if the inplane, outplane and torsionalmoments, and the pressure are zero.
2) The Conservative Allowable Simultaneous loads arethe maximum loads that can be applied simultaneously.A conservative stress combination equation is usedthat typically produces stresses within 50-70% of theallowable stress.
3) The Realistic Allowable Simultaneous loads are themaximum loads that can be applied simultaneously. Amore realistic stress combination equation is usedbased on experience at Paulin Research. Stresses aretypically produced within 80-105% of the allowable.
4) Secondary allowable loads are limits for expansionand operating piping loads.
5) Primary allowable loads are limits for weight,primary and sustained type piping loads.
Table of Contents
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Flexibilities
The following stiffnesses should be used in a piping,"beam-type" analysis of the intersection. The stiff-nesses should be inserted at the surface of thebranch/header or nozzle/vessel junction. The generalcharacteristics used for the branch pipe should be:
Outside Diameter = 4.500 in.Wall Thickness = 0.188 in.
Axial Translational Stiffness = 13086. lb./in.Inplane Rotational Stiffness = 5592. in.lb./degOutplane Rotational Stiffness = 884. in.lb./degTorsional Rotational Stiffness = 449356. in.lb./deg
Table of Contents
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Finite Element Model
Finite Element Model•
Elements at Discontinuity
1) Pl < 1.5(k)Smh (SUS Membrane) Case 2• 2) Qb < 3(Smh) (SUS Bending) Case 2• 3) Pl+Pb+Q < 3(Smavg) (OPE Inside) Case 3• 4) Pl+Pb+Q < 3(Smavg) (OPE Outside) Case 3• 10) Pl+Pb+Q < 3(Smavg) (EXP Inside) Case 4• 11) Pl+Pb+Q < 3(Smavg) (EXP Outside) Case 4• 12) Pl+Pb+Q+F < Sa (EXP Inside) Case 4• 13) Pl+Pb+Q+F < Sa (EXP Outside) Case 4• 5) Pl+Pb+Q+F < Sa (SIF Outside) Case 5• 6) Pl+Pb+Q+F < Sa (SIF Outside) Case 6• 7) Pl+Pb+Q+F < Sa (SIF Outside) Case 7• 8) Pl+Pb+Q+F < Sa (SIF Outside) Case 8• 9) Pl+Pb+Q+F < Sa (SIF Outside) Case 9•
Tabular Results
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SS Outlet (N3)
ASME Section VIII Division 1, 2007 Edition
tw(lower) = 0.125 inLeg41 = 0.0625 in
Note: round inside edges per UG-76(c)
Located on: Front ConeLiquid static head included: 0.2768 psiNozzle material specification: SA-455 <= 3/8 (II-D p. 22, ln. 14)Nozzle longitudinal joint efficiency: 1Flange description: 8 inch Class 150 WN A105Bolt Material: SA-193 B7 Bolt <= 2 1/2 (II-D p. 348, ln. 33)Flange rated MDMT: -55°F(UCS-66(b)(3): Coincident ratio = 0.1971988)(Flange rated MDMT = -155 °FBolts rated MDMT per Fig UCS-66 note (e) = -55 °F)Liquid static head on flange: 0.0788 psiASME B16.5 flange rating MAWP: 227.73 psi @ 307.57°FASME B16.5 flange rating MAP: 285 psi @ 70°FASME B16.5 flange hydro test: 450 psi @ 70°FNozzle orientation: 0°Local vessel minimum thickness: 0.125 inNozzle center line offset to datum line: 57.6652 inEnd of nozzle to shell center: 17.1434 inNozzle inside diameter, new: 8.001 inNozzle nominal wall thickness: 0.312 inNozzle corrosion allowance: 0.0625 inProjection available outside vessel, Lpr: 3.8019 inProjection available outside vessel to flange face, Lf: 4.9219 inNozzle longitudinal axis is: perpendicular to the vessel longitudinal axisOpening chord length: 8.3761 in
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Reinforcement Calculations for Internal Pressure
Available reinforcement per UG-37 governs the MAWP of this nozzle.
UG-37 Area Calculation Summary (in2)For P = 62.78 psi @ 307.57 °F
The opening is adequately reinforced
UG-45Nozzle WallThicknessSummary
(in)The nozzle
passes UG-45
Arequired
Aavailable A1 A2 A3 A5
Awelds treq tmin
0.3008 0.3008 0.2227 0.0742 -- -- 0.0039 0.125 0.312
Weld Failure Path Analysis Summary
The nozzle is exempt from weld strengthcalculations per UW-15(b)(1)
UW-16 Weld Sizing Summary
Weld description Required weldthroat size (in)
Actual weldthroat size (in) Status
Nozzle to shell fillet (Leg41) 0.0438 0.0438 weld size is adequate
Calculations for internal pressure 62.78 psi @ 307.57 °F
Nozzle impact test exemption temperature from Fig UCS-66 Curve A = 18 °FFig UCS-66.1 MDMT reduction = 55.7 °F, (coincident ratio = 0.516).
Nozzle UCS-66 governing thk: 0.125 inNozzle rated MDMT: -37.7 °F
Limits of reinforcement per UG-40
Parallel to the vessel wall: d = 8.3761 inNormal to the vessel wall outside: 2.5*(t - C) = 0.1563 in
Nozzle required thickness per UG-27(c)(1)
trn = P*Rn/(Sn*E - 0.6*P)= 62.7801*4.063/(21,400*1 - 0.6*62.7801)= 0.0119 in
Required thickness tr from UG-37(a)(b)
tr = P*Di/(2*cos(α)*(S*E - 0.6*P))= 62.7801*22.1542/(2*cos(14.04)*(20,000*1 - 0.6*62.7801))= 0.0359 in
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Area required per UG-37(c)
Allowable stresses: Sn = 21,400, Sv = 20,000 psi
fr1 = lesser of 1 or Sn/Sv = 1fr2 = lesser of 1 or Sn/Sv = 1
A = d*tr*F + (2*tn/Cos(14.0363))*tr*F*(1 - fr1)= 8.3761*0.0359*1 + (2*0.2495/Cos(14.0363))*0.0359*1*(1 - 1)= 0.3008 in2
Area available from FIG. UG-37.1
A1 = larger of the following= 0.2227 in2
= d*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1)= 8.3761*(1*0.0625 - 1*0.0359) - 2*0.2495*(1*0.0625 - 1*0.0359)*(1 - 1)= 0.2227 in2
= 2*(t + tn)*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1)= 2*(0.0625 + 0.2495)*(1*0.0625 - 1*0.0359) - 2*0.2495*(1*0.0625 - 1*0.0359)*(1 - 1)= 0.0166 in2
A2 = smaller of the following= 0.0742 in2
= 5*(tn - trn)*fr2*t= 5*(0.2495 - 0.0119)*1*0.0625= 0.0742 in2
= 5*(tn - trn)*fr2*tn= 5*(0.2495 - 0.0119)*1*0.2495= 0.2964 in2
A41 = Leg2*fr2= 0.06252*1= 0.0039 in2
Area = A1 + A2 + A41
= 0.2227 + 0.0742 + 0.0039= 0.3008 in2
As Area >= A the reinforcement is adequate.
UW-16(c) Weld Check
Fillet weld: tmin = lesser of 0.75 or tn or t = 0.0625 intc(min) = lesser of 0.25 or 0.7*tmin = 0.0438 intc(actual) = 0.7*Leg = 0.7*0.0625 = 0.0438 in
80/226
The fillet weld size is satisfactory.
Weld strength calculations are not required for this detail which conforms to Fig. UW-16.1, sketch (c-e).
UG-45 Nozzle Neck Thickness Check
Wall thickness per UG-45(a): tr1 = 0.0744 in (E =1)Wall thickness per UG-45(b)(1): tr2 = 0.0984 inWall thickness per UG-16(b): tr3 = 0.125 inStandard wall pipe per UG-45(b)(4): tr4 = 0.3443 inThe greater of tr2 or tr3: tr5 = 0.125 inThe lesser of tr4 or tr5: tr6 = 0.125 in
Required per UG-45 is the larger of tr1 or tr6 = 0.125 in
Available nozzle wall thickness new, tn = 0.312 in
The nozzle neck thickness is adequate.
% Extreme fiber elongation - UCS-79(d)
= (50*t / Rf)*(1 - Rf / Ro)= (50*0.312 / 4.1565)*(1 - 4.1565 / ∞)= 3.7532%
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The extreme fiber elongation does not exceed 5%.
Reinforcement Calculations for MAP
Available reinforcement per UG-37 governs the MAP of this nozzle.
UG-37 Area Calculation Summary (in2)For P = 129.16 psi @ 70 °F
The opening is adequately reinforced
UG-45 NozzleWall
ThicknessSummary (in)The nozzle passes
UG-45
Arequired
Aavailable A1 A2 A3 A5
Awelds treq tmin
0.6071 0.6076 0.4238 0.1799 -- -- 0.0039 0.0736 0.312
Weld Failure Path Analysis Summary
The nozzle is exempt from weld strengthcalculations per UW-15(b)(1)
UW-16 Weld Sizing Summary
Weld description Required weldthroat size (in)
Actual weldthroat size (in) Status
Nozzle to shell fillet (Leg41) 0.0875 0.0438 weld size is NOT adequate
Calculations for internal pressure 129.16 psi @ 70 °F
Limits of reinforcement per UG-40
Parallel to the vessel wall: d = 8.2472 inNormal to the vessel wall outside: 2.5*(t - C) = 0.3125 in
Nozzle required thickness per UG-27(c)(1)
trn = P*Rn/(Sn*E - 0.6*P)= 129.1612*4.0005/(21,400*1 - 0.6*129.1612)= 0.0242 in
Required thickness tr from UG-37(a)(b)
tr = P*Di/(2*cos(α)*(S*E - 0.6*P))= 129.1612*22.0292/(2*cos(14.04)*(20,000*1 - 0.6*129.1612))= 0.0736 in
Area required per UG-37(c)
Allowable stresses: Sn = 21,400, Sv = 20,000 psi
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fr1 = lesser of 1 or Sn/Sv = 1fr2 = lesser of 1 or Sn/Sv = 1
A = d*tr*F + (2*tn/Cos(14.0363))*tr*F*(1 - fr1)= 8.2472*0.0736*1 + (2*0.312/Cos(14.0363))*0.0736*1*(1 - 1)= 0.6071 in2
Area available from FIG. UG-37.1
A1 = larger of the following= 0.4238 in2
= d*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1)= 8.2472*(1*0.125 - 1*0.0736) - 2*0.312*(1*0.125 - 1*0.0736)*(1 - 1)= 0.4238 in2
= 2*(t + tn)*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1)= 2*(0.125 + 0.312)*(1*0.125 - 1*0.0736) - 2*0.312*(1*0.125 - 1*0.0736)*(1 - 1)= 0.0449 in2
A2 = smaller of the following= 0.1799 in2
= 5*(tn - trn)*fr2*t= 5*(0.312 - 0.0242)*1*0.125= 0.1799 in2
= 5*(tn - trn)*fr2*tn= 5*(0.312 - 0.0242)*1*0.312= 0.449 in2
A41 = Leg2*fr2= 0.06252*1= 0.0039 in2
Area = A1 + A2 + A41
= 0.4238 + 0.1799 + 0.0039= 0.6076 in2
As Area >= A the reinforcement is adequate.
UW-16(c) Weld Check
Fillet weld: tmin = lesser of 0.75 or tn or t = 0.125 intc(min) = lesser of 0.25 or 0.7*tmin = 0.0875 intc(actual) = 0.7*Leg = 0.7*0.0625 = 0.0438 in
** The fillet weld size IS NOT satisfactory. **UG-45 Nozzle Neck Thickness Check
Wall thickness per UG-45(a): tr1 = 0.0242 in (E =1)Wall thickness per UG-45(b)(1): tr2 = 0.0736 in
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Wall thickness per UG-16(b): tr3 = 0.0625 inStandard wall pipe per UG-45(b)(4): tr4 = 0.2818 inThe greater of tr2 or tr3: tr5 = 0.0736 inThe lesser of tr4 or tr5: tr6 = 0.0736 in
Required per UG-45 is the larger of tr1 or tr6 = 0.0736 in
Available nozzle wall thickness new, tn = 0.312 in
The nozzle neck thickness is adequate.
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Tabular Results
Results were generated with the finite element program FE/Pipe®. Stress results are post-processed inaccordance with the rules specified in ASME Section III and ASME Section VIII, Division 2.
Analysis Time Stamp: Thu Nov 25 14:30:52 2010.
Model Notes• Load Case Report• Solution Data• ASME Code Stress Output Plots• ASME Overstressed Areas• Highest Primary Stress Ratios• Highest Secondary Stress Ratios• Highest Fatigue Stress Ratios• Stress Intensification Factors• Allowable Loads• Flexibilities• Graphical Results•
Model Notes
Input Echo:
Model Type : Conical Shell
Parent Outside Diameter : 27.066 in.Thickness : 0.063 in.Cone Length : 19.117 in.Cone OD at Top : 17.508 in.Knuckle Radius @ Top : 0.000 in.Knuckle Radius @ Bottom: 0.000 in.Fillet Along Shell : 0.063 in.
Parent Properties:Cold Allowable : 20000.0 psiHot Allowable : 20000.0 psiMaterial ID #2 : Low Alloy SteelUltimate Tensile (Amb) : 70000.0 psiYield Strength (Amb) : 38000.0 psiYield Strength (Hot) : 33500.0 psiElastic Modulus (Amb) : 29400000.0 psiPoissons Ratio : 0.300Weight Density : 0.283 lb./cu.in.(NOT USED)
Nozzle Outside Diameter : 8.625 in.Thickness : 0.250 in.Length : 6.031 in.Nozzle Weld Length : 0.063 in.Nozzle Tilt Angle : 90.000 deg.
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Distance from Top : 11.143 in.Distance from Bottom : 7.973 in.
Nozzle PropertiesCold Allowable : 21400.0 psiHot Allowable : 21400.0 psiMaterial ID #2 : Low Alloy SteelUltimate Tensile (Amb) : 75000.0 psiYield Strength (Amb) : 38000.0 psiYield Strength (Hot) : 33500.0 psiElastic Modulus (Amb) : 29200000.0 psiPoissons Ratio : 0.300Weight Density : 0.283 lb./cu.in. (NOT USED)
Design Operating Cycles : 0.Ambient Temperature (Deg.) : 70.00Nozzle Pressure : 60.6 psiVessel Pressure : 60.6 psi
No external forces or bending moments were included in this analysis.
Both ends of the model are "fixed," except that one endis free axially so that longitudinal pressure stressesmay be developed in the geometry.
Stresses are NOT averaged.
Unstructured Mesh Generation used for this model.
Vessel Centerline Vector: 0.000 0.000 1.000Nozzle Centerline Vector: 0.000 0.000 1.000Zero Degree Orientation Vector: 0.000 1.000 0.000
Table of Contents
Load Case Report
Inner and outer element temperatures are the samethroughout the model. No thermal ratchetingcalculations will be performed.
THE 9 LOAD CASES ANALYZED ARE:
1 Weight ONLY
Weight ONLY case run to get the stress rangebetween the installed and the operating states.It is assumed that the weight only case accuratelyrepresents the installed stress state.
/-------- Loads in Case 1Forces due to Weight
2 Sustained
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Sustained case run to satisfy Pl Qb, the bending stress due to primary loads mustbe less than 3Smh as per Note 3 of Fig. NB-3222-1,and Table 4-120.1
/-------- Loads in Case 2Forces due to WeightPressure Case 1
3 Operating
Operating case run to compute the extreme operatingstress state to be used in the shakedown and peakstress calculations.
/-------- Loads in Case 3Pressure Case 1Force Case (Operating)
4 Expansion (Fatigue Calc Performed)
Expansion case run to get the RANGE of stressesas described in NB-3222.2, or Note 1 of 4-130.1.The allowable is 3Smavg.
/-------- Combinations in Expansion Case 4Plus Stress Results from CASE 3Minus Stress Results from CASE 1
5 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 5Force Case (Axial)
6 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 6Force Case (Inplane)
7 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 7Force Case (Outplane)
8 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 8Force Case (Torsion)
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9 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 9Pressure Case 1
Table of Contents
Solution Data
Maximum Solution Row Size = 708Number of Nodes = 2380Number of Elements = 780Number of Solution Cases = 8
Largest On-Diagonal Stiffness = 42801518806782.Smallest On-Diagonal Stiffness = 2.
Largest Off-Diagonal Stiffness = 1613771282605.Smallest Off-Diagonal Stiffness = 1.
Summation of Loads per Case
Case # FX FY FZ
1 0. -36. 0.2 0. -36. 20214.3 0. -36. 20214.4 0. 131295. 0.5 0. 0. 0.6 0. 0. 0.7 0. 0. 0.8 0. 0. 20214.
Equation Coefficient (Stiffness) Distribution)
OnDiagonal Number of AveragePercentile Coefficients Stiffness
90-to-100% 1 42801518806782.70-to-90% 0 0.50-to-70% 0 0.30-to-50% 0 0.10-to-30% 0 0.1-to-10% 354 1556163368744..1-to- 1% 191 128388370436..01-to-.1% 4 42393908159..001-to-.01% 0 0..0001-TO-.001% 13730 9014652.
OFF Diagonal Number of Average
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Percentile Coefficients Stiffness
90-to-100% 48 1574057434559.70-to-90% 48 1293470424615.50-to-70% 60 952290798143.30-to-50% 268 628588640003.10-to-30% 420 298259837402.1-to-10% 2352 54218383466..1-to- 1% 1888 7489744863..01-to-.1% 456 715467004..001-to-.01% 2091 34498721..0001-TO-.001% 633676 276057.
Table of Contents
ASME Code Stress Output Plots
1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
2) Qb < 3(Smh) (SUS,Bending) Case 2
3) Pl+Pb+Q < 3(Smavg) (OPE,Inside) Case 3
4) Pl+Pb+Q < 3(Smavg) (OPE,Outside) Case 3
5) Pl+Pb+Q+F < Sa (SIF,Outside) Case 5
6) Pl+Pb+Q+F < Sa (SIF,Outside) Case 6
7) Pl+Pb+Q+F < Sa (SIF,Outside) Case 7
8) Pl+Pb+Q+F < Sa (SIF,Outside) Case 8
9) Pl+Pb+Q+F < Sa (SIF,Outside) Case 9
10) Pl+Pb+Q < 3(Smavg) (EXP,Inside) Case 4
11) Pl+Pb+Q < 3(Smavg) (EXP,Outside) Case 4
12) Pl+Pb+Q+F < Sa (EXP,Inside) Case 4
13) Pl+Pb+Q+F < Sa (EXP,Outside) Case 4
Table of Contents
ASME Overstressed Areas
*** NO OVERSTRESSED NODES IN THIS MODEL ***
Table of Contents
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Highest Primary Stress Ratios
Shell Next to Nozzle 1
Pl 1.5(k)Smh Primary Membrane Load Case 224,512 30,000 Plot Reference:psi psi 1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
81%
Nozzle 1 Next to Shell
Pl 1.5(k)Smh Primary Membrane Load Case 213,791 32,100 Plot Reference:psi psi 1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
42%
Shell In Nozzle 1 Vicinity
Pl 1.5(k)Smh Primary Membrane Load Case 223,027 30,000 Plot Reference:psi psi 1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
76%
Nozzle 1
Pl 1.5(k)Smh Primary Membrane Load Case 25,879 32,100 Plot Reference:psi psi 1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
18%
Table of Contents
Highest Secondary Stress Ratios
Shell Next to Nozzle 1
Pl+Pb+Q 3(Smavg) Primary+Secondary (Outer) Load Case 438,518 60,000 Plot Reference:psi psi 11) Pl+Pb+Q < 3(Smavg) (EXP,Outside) Case 4
64%
Nozzle 1 Next to Shell
Pl+Pb+Q 3(Smavg) Primary+Secondary (Inner) Load Case 414,825 64,200 Plot Reference:psi psi 10) Pl+Pb+Q < 3(Smavg) (EXP,Inside) Case 4
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23%
Shell In Nozzle 1 Vicinity
Pl+Pb+Q 3(Smavg) Primary+Secondary (Inner) Load Case 428,301 60,000 Plot Reference:psi psi 10) Pl+Pb+Q < 3(Smavg) (EXP,Inside) Case 4
47%
Nozzle 1
Pl+Pb+Q 3(Smavg) Primary+Secondary (Inner) Load Case 49,315 64,200 Plot Reference:psi psi 10) Pl+Pb+Q < 3(Smavg) (EXP,Inside) Case 4
14%
Table of Contents
Highest Fatigue Stress Ratios
Shell Next to Nozzle 1
Pl+Pb+Q+F Sa Primary+Secondary+Peak (Outer) Load Case 426,000 568,400 Stress Concentration Factor = 1.350psi psi Strain Concentration Factor = 1.000Cycles Allowed for this Stress = 32255.74% "B31" Fatigue Stress Allowable = 50000.0Markl Fatigue Stress Allowable = 245000.0WRC 474 Mean Cycles to Failure = 1086101.WRC 474 99% Probability Cycles = 252316.WRC 474 95% Probability Cycles = 350314.BS5500 Allowed Cycles(Curve F) = 36995.Membrane-to-Bending Ratio = 0.948Bending-to-PL+PB+Q Ratio = 0.513Plot Reference:13) Pl+Pb+Q+F < Sa (EXP,Outside) Case 4
Nozzle 1 Next to Shell
Pl+Pb+Q+F Sa Primary+Secondary+Peak (Inner) Load Case 410,007 564,533 Stress Concentration Factor = 1.350psi psi Strain Concentration Factor = 1.000Cycles Allowed for this Stress = 1000000.01% "B31" Fatigue Stress Allowable = 53500.0Markl Fatigue Stress Allowable = 245000.0WRC 474 Mean Cycles to Failure = 7360944.WRC 474 99% Probability Cycles = 1710047.WRC 474 95% Probability Cycles = 2374218.BS5500 Allowed Cycles(Curve F) = 662329.
91/226
Membrane-to-Bending Ratio = 5.669Bending-to-PL+PB+Q Ratio = 0.150Plot Reference:12) Pl+Pb+Q+F < Sa (EXP,Inside) Case 4
Shell In Nozzle 1 Vicinity
Pl+Pb+Q+F Sa Primary+Secondary+Peak (Inner) Load Case 414,151 568,400 Stress Concentration Factor = 1.000psi psi Strain Concentration Factor = 1.000Cycles Allowed for this Stress = 367752.82% "B31" Fatigue Stress Allowable = 50000.0Markl Fatigue Stress Allowable = 245000.0WRC 474 Mean Cycles to Failure = 2743425.WRC 474 99% Probability Cycles = 637335.WRC 474 95% Probability Cycles = 884872.BS5500 Allowed Cycles(Curve F) = 93263.Membrane-to-Bending Ratio = 1.488Bending-to-PL+PB+Q Ratio = 0.402Plot Reference:12) Pl+Pb+Q+F < Sa (EXP,Inside) Case 4
Nozzle 1
Pl+Pb+Q+F Sa Primary+Secondary+Peak (Inner) Load Case 44,658 564,533 Stress Concentration Factor = 1.000psi psi Strain Concentration Factor = 1.000Cycles Allowed for this Stress = 1000000.00% "B31" Fatigue Stress Allowable = 53500.0Markl Fatigue Stress Allowable = 245000.0WRC 474 Mean Cycles to Failure = 35122520.WRC 474 99% Probability Cycles = 8159435.WRC 474 95% Probability Cycles = 11328510.BS5500 Allowed Cycles(Curve F) = 2669660.Membrane-to-Bending Ratio = 0.715Bending-to-PL+PB+Q Ratio = 0.583Plot Reference:12) Pl+Pb+Q+F < Sa (EXP,Inside) Case 4
Table of Contents
Stress Intensification Factors
Branch/Nozzle Sif Summary
Peak Primary SecondaryAxial : 137.593 45.339 203.841Inplane : 61.875 26.439 91.666Outplane: 158.511 53.637 234.831Torsion : 39.121 14.327 57.956Pressure: 1.982 1.873 2.936
The above stress intensification factors are to be used
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in a beam-type analysis of the piping system. Inplane,Outplane and Torsional sif's should be used with thematching branch pipe whose diameter and thickness is givenbelow. The axial sif should be used to intensify theaxial stress in the branch pipe calculated by F/A. Thepressure sif should be used to intensify the nominalpressure stress in the PARENT or HEADER, calculatedfrom PD/2T.
Pipe OD : 8.625 in.Pipe Thk: 0.250 in.Z approx: 13.746 cu.in.Z exact : 13.360 cu.in.
B31.3Peak Stress Sif .... 0.000 Axial98.012 Inplane129.352 Outplane1.000 TorsionalB31.1Peak Stress Sif .... 0.000 Axial116.592 Inplane116.592 Outplane116.592 TorsionalWRC 330Peak Stress Sif .... 0.000 Axial78.700 Inplane78.700 Outplane24.410 Torsional
Table of Contents
Allowable Loads
SECONDARY Maximum Conservative RealisticLoad Type (Range): Individual Simultaneous SimultaneousOccuring Occuring OccuringAxial Force (lb. ) 1932. 231. 346.Inplane Moment (in. lb.) 8745. 738. 1566.Outplane Moment (in. lb.) 3414. 288. 611.Torsional Moment (in. lb.) 13831. 1651. 2476.Pressure (psi ) 94.37 60.58 60.58
PRIMARY Maximum Conservative RealisticLoad Type: Individual Simultaneous SimultaneousOccuring Occuring OccuringAxial Force (lb. ) 4344. 262. 393.Inplane Moment (in. lb.) 15160. 646. 1371.Outplane Moment (in. lb.) 7473. 319. 676.Torsional Moment (in. lb.) 27975. 1687. 2530.Pressure (psi ) 73.96 60.58 60.58
NOTES:
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1) Maximum Individual Occuring Loads are the maximumallowed values of the respective loads if all otherload components are zero, i.e. the listed axial forcemay be applied if the inplane, outplane and torsionalmoments, and the pressure are zero.
2) The Conservative Allowable Simultaneous loads arethe maximum loads that can be applied simultaneously.A conservative stress combination equation is usedthat typically produces stresses within 50-70% of theallowable stress.
3) The Realistic Allowable Simultaneous loads are themaximum loads that can be applied simultaneously. Amore realistic stress combination equation is usedbased on experience at Paulin Research. Stresses aretypically produced within 80-105% of the allowable.
4) Secondary allowable loads are limits for expansionand operating piping loads.
5) Primary allowable loads are limits for weight,primary and sustained type piping loads.
Table of Contents
Flexibilities
The following stiffnesses should be used in a piping,"beam-type" analysis of the intersection. The stiff-nesses should be inserted at the surface of thebranch/header or nozzle/vessel junction. The generalcharacteristics used for the branch pipe should be:
Outside Diameter = 8.625 in.Wall Thickness = 0.250 in.
Axial Translational Stiffness = 91188. lb./in.Inplane Rotational Stiffness = 36029. in.lb./degOutplane Rotational Stiffness = 9584. in.lb./degTorsional Rotational Stiffness = 148373. in.lb./deg
Table of Contents
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Finite Element Model
Finite Element Model•
Area of Discontinuity at Nozzle
1) Pl < 1.5(k)Smh (SUS Membrane) Case 2• 2) Qb < 3(Smh) (SUS Bending) Case 2• 3) Pl+Pb+Q < 3(Smavg) (OPE Inside) Case 3• 4) Pl+Pb+Q < 3(Smavg) (OPE Outside) Case 3• 10) Pl+Pb+Q < 3(Smavg) (EXP Inside) Case 4• 11) Pl+Pb+Q < 3(Smavg) (EXP Outside) Case 4• 12) Pl+Pb+Q+F < Sa (EXP Inside) Case 4• 13) Pl+Pb+Q+F < Sa (EXP Outside) Case 4• 5) Pl+Pb+Q+F < Sa (SIF Outside) Case 5• 6) Pl+Pb+Q+F < Sa (SIF Outside) Case 6• 7) Pl+Pb+Q+F < Sa (SIF Outside) Case 7• 8) Pl+Pb+Q+F < Sa (SIF Outside) Case 8• 9) Pl+Pb+Q+F < Sa (SIF Outside) Case 9•
Tabular Results
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SS Outlet 2 (N5)
ASME Section VIII Division 1, 2007 Edition
tw(lower) = 0.125 inLeg41 = 0.0625 in
Note: round inside edges per UG-76(c)
Located on: ShellLiquid static head included: 0.1981 psiNozzle material specification: SA-455 ( 3/8 < t <= 0.58) (II-D p. 22, ln. 12)Nozzle longitudinal joint efficiency: 1Flange description: 8 inch Class 150 WN A105Bolt Material: SA-193 B7 Bolt <= 2 1/2 (II-D p. 348, ln. 33)Flange rated MDMT: -55°F(UCS-66(b)(3): Coincident ratio = 0.1969223)(Flange rated MDMT = -155 °FBolts rated MDMT per Fig UCS-66 note (e) = -55 °F)Liquid static head on flange: 0 psiASME B16.5 flange rating MAWP: 227.73 psi @ 307.57°FASME B16.5 flange rating MAP: 285 psi @ 70°FASME B16.5 flange hydro test: 450 psi @ 70°FNozzle orientation: 0°Local vessel minimum thickness: 0.125 inNozzle center line offset to datum line: 16 inEnd of nozzle to shell center: 19.5292 inNozzle inside diameter, new: 7.625 inNozzle nominal wall thickness: 0.5 inNozzle corrosion allowance: 0.0625 inProjection available outside vessel, Lpr: 4.88 inProjection available outside vessel to flange face, Lf: 6 in
103/226
Reinforcement Calculations for Internal Pressure
Available reinforcement per UG-37 governs the MAWP of this nozzle.
UG-37 Area Calculation Summary (in2)For P = 59.44 psi @ 307.57 °F
The opening is adequately reinforced
UG-45Nozzle WallThicknessSummary
(in)The nozzle
passes UG-45
Arequired
Aavailable A1 A2 A3 A5
Awelds treq tmin
0.3108 0.3108 0.1736 0.1333 -- -- 0.0039 0.125 0.5
Weld Failure Path Analysis Summary
The nozzle is exempt from weld strengthcalculations per UW-15(b)(1)
UW-16 Weld Sizing Summary
Weld description Required weldthroat size (in)
Actual weldthroat size (in) Status
Nozzle to shell fillet (Leg41) 0.0438 0.0438 weld size is adequate
Calculations for internal pressure 59.44 psi @ 307.57 °F
Nozzle impact test exemption temperature from Fig UCS-66 Curve A = 18 °FFig UCS-66.1 MDMT reduction = 39.2 °F, (coincident ratio = 0.60784).
Nozzle UCS-66 governing thk: 0.125 inNozzle rated MDMT: -21.2 °F
Limits of reinforcement per UG-40
Parallel to the vessel wall: d = 7.75 inNormal to the vessel wall outside: 2.5*(t - C) = 0.1563 in
Nozzle required thickness per UG-27(c)(1)
trn = P*Rn/(Sn*E - 0.6*P)= 59.4422*3.875/(20,900*1 - 0.6*59.4422)= 0.011 in
Required thickness tr from UG-37(a)
tr = P*R/(S*E - 0.6*P)= 59.4422*13.4667/(20,000*1 - 0.6*59.4422)= 0.0401 in
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Area required per UG-37(c)
Allowable stresses: Sn = 20,900, Sv = 20,000 psi
fr1 = lesser of 1 or Sn/Sv = 1fr2 = lesser of 1 or Sn/Sv = 1
A = d*tr*F + 2*tn*tr*F*(1 - fr1)= 7.75*0.0401*1 + 2*0.4375*0.0401*1*(1 - 1)= 0.3108 in2
Area available from FIG. UG-37.1
A1 = larger of the following= 0.1736 in2
= d*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1)= 7.75*(1*0.0625 - 1*0.0401) - 2*0.4375*(1*0.0625 - 1*0.0401)*(1 - 1)= 0.1736 in2
= 2*(t + tn)*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1)= 2*(0.0625 + 0.4375)*(1*0.0625 - 1*0.0401) - 2*0.4375*(1*0.0625 - 1*0.0401)*(1 - 1)= 0.0224 in2
A2 = smaller of the following= 0.1333 in2
= 5*(tn - trn)*fr2*t= 5*(0.4375 - 0.011)*1*0.0625= 0.1333 in2
= 5*(tn - trn)*fr2*tn= 5*(0.4375 - 0.011)*1*0.4375= 0.933 in2
A41 = Leg2*fr2= 0.06252*1= 0.0039 in2
Area = A1 + A2 + A41
= 0.1736 + 0.1333 + 0.0039= 0.3108 in2
As Area >= A the reinforcement is adequate.
UW-16(c) Weld Check
Fillet weld: tmin = lesser of 0.75 or tn or t = 0.0625 intc(min) = lesser of 0.25 or 0.7*tmin = 0.0438 intc(actual) = 0.7*Leg = 0.7*0.0625 = 0.0438 in
105/226
The fillet weld size is satisfactory.
Weld strength calculations are not required for this detail which conforms to Fig. UW-16.1, sketch (c-e).
UG-45 Nozzle Neck Thickness Check
Wall thickness per UG-45(a): tr1 = 0.0735 in (E =1)Wall thickness per UG-45(b)(1): tr2 = 0.1026 inWall thickness per UG-16(b): tr3 = 0.125 inStandard wall pipe per UG-45(b)(4): tr4 = 0.3443 inThe greater of tr2 or tr3: tr5 = 0.125 inThe lesser of tr4 or tr5: tr6 = 0.125 in
Required per UG-45 is the larger of tr1 or tr6 = 0.125 in
Available nozzle wall thickness new, tn = 0.5 in
The nozzle neck thickness is adequate.
% Extreme fiber elongation - UCS-79(d)
= (50*t / Rf)*(1 - Rf / Ro)= (50*0.5 / 4.0625)*(1 - 4.0625 / ∞)= 6.1538%
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The extreme fiber elongation exceeds 5 percent. Heat treatment per UCS-56 may be required. See UCS-79(d)(4) or(5).
Reinforcement Calculations for MAP
Available reinforcement per UG-37 governs the MAP of this nozzle.
UG-37 Area Calculation Summary (in2)For P = 122.34 psi @ 70 °F
The opening is adequately reinforced
UG-45Nozzle WallThicknessSummary
(in)The nozzle
passes UG-45
Arequired
Aavailable A1 A2 A3 A5
Awelds treq tmin
0.6275 0.6281 0.3257 0.2985 -- -- 0.0039 0.0823 0.5
Weld Failure Path Analysis Summary
The nozzle is exempt from weld strengthcalculations per UW-15(b)(1)
UW-16 Weld Sizing Summary
Weld description Required weldthroat size (in)
Actual weldthroat size (in) Status
Nozzle to shell fillet (Leg41) 0.0875 0.0438 weld size is NOT adequate
Calculations for internal pressure 122.34 psi @ 70 °F
Limits of reinforcement per UG-40
Parallel to the vessel wall: d = 7.625 inNormal to the vessel wall outside: 2.5*(t - C) = 0.3125 in
Nozzle required thickness per UG-27(c)(1)
trn = P*Rn/(Sn*E - 0.6*P)= 122.3362*3.8125/(20,900*1 - 0.6*122.3362)= 0.0224 in
Required thickness tr from UG-37(a)
tr = P*R/(S*E - 0.6*P)= 122.3362*13.4042/(20,000*1 - 0.6*122.3362)= 0.0823 in
Area required per UG-37(c)
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Allowable stresses: Sn = 20,900, Sv = 20,000 psi
fr1 = lesser of 1 or Sn/Sv = 1fr2 = lesser of 1 or Sn/Sv = 1
A = d*tr*F + 2*tn*tr*F*(1 - fr1)= 7.625*0.0823*1 + 2*0.5*0.0823*1*(1 - 1)= 0.6275 in2
Area available from FIG. UG-37.1
A1 = larger of the following= 0.3257 in2
= d*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1)= 7.625*(1*0.125 - 1*0.0823) - 2*0.5*(1*0.125 - 1*0.0823)*(1 - 1)= 0.3257 in2
= 2*(t + tn)*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1)= 2*(0.125 + 0.5)*(1*0.125 - 1*0.0823) - 2*0.5*(1*0.125 - 1*0.0823)*(1 - 1)= 0.0534 in2
A2 = smaller of the following= 0.2985 in2
= 5*(tn - trn)*fr2*t= 5*(0.5 - 0.0224)*1*0.125= 0.2985 in2
= 5*(tn - trn)*fr2*tn= 5*(0.5 - 0.0224)*1*0.5= 1.194 in2
A41 = Leg2*fr2= 0.06252*1= 0.0039 in2
Area = A1 + A2 + A41
= 0.3257 + 0.2985 + 0.0039= 0.6281 in2
As Area >= A the reinforcement is adequate.
UW-16(c) Weld Check
Fillet weld: tmin = lesser of 0.75 or tn or t = 0.125 intc(min) = lesser of 0.25 or 0.7*tmin = 0.0875 intc(actual) = 0.7*Leg = 0.7*0.0625 = 0.0438 in
** The fillet weld size IS NOT satisfactory. **UG-45 Nozzle Neck Thickness Check
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Wall thickness per UG-45(a): tr1 = 0.0224 in (E =1)Wall thickness per UG-45(b)(1): tr2 = 0.0823 inWall thickness per UG-16(b): tr3 = 0.0625 inStandard wall pipe per UG-45(b)(4): tr4 = 0.2818 inThe greater of tr2 or tr3: tr5 = 0.0823 inThe lesser of tr4 or tr5: tr6 = 0.0823 in
Required per UG-45 is the larger of tr1 or tr6 = 0.0823 in
Available nozzle wall thickness new, tn = 0.5 in
The nozzle neck thickness is adequate.
109/226
Tabular Results
Results were generated with the finite element program FE/Pipe®. Stress results are post-processed inaccordance with the rules specified in ASME Section III and ASME Section VIII, Division 2.
Analysis Time Stamp: Thu Nov 25 14:30:40 2010.
Model Notes• Load Case Report• Solution Data• ASME Code Stress Output Plots• ASME Overstressed Areas• Highest Primary Stress Ratios• Highest Secondary Stress Ratios• Highest Fatigue Stress Ratios• Stress Intensification Factors• Allowable Loads• Flexibilities• Graphical Results•
Model Notes
Input Echo:
Model Type : Cylindrical Shell
Parent Outside Diameter : 27.058 in.Thickness : 0.063 in.Fillet Along Shell : 0.063 in.
Parent Properties:Cold Allowable : 20000.0 psiHot Allowable : 20000.0 psiMaterial ID #2 : Low Alloy SteelUltimate Tensile (Amb) : 70000.0 psiYield Strength (Amb) : 38000.0 psiYield Strength (Hot) : 33500.0 psiElastic Modulus (Amb) : 29400000.0 psiPoissons Ratio : 0.300Weight Density : 0.283 lb./cu.in.(NOT USED)
Nozzle Outside Diameter : 8.625 in.Thickness : 0.438 in.Length : 6.031 in.Nozzle Weld Length : 0.063 in.Nozzle Tilt Angle : 0.000 deg.Distance from Top : 32.107 in.Distance from Bottom : 16.000 in.
Nozzle Properties
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Cold Allowable : 20900.0 psiHot Allowable : 20900.0 psiMaterial ID #2 : Low Alloy SteelUltimate Tensile (Amb) : 73000.0 psiYield Strength (Amb) : 37000.0 psiYield Strength (Hot) : 32600.0 psiElastic Modulus (Amb) : 29200000.0 psiPoissons Ratio : 0.300Weight Density : 0.283 lb./cu.in. (NOT USED)
Design Operating Cycles : 0.Ambient Temperature (Deg.) : 70.00Nozzle Pressure : 60.5 psiVessel Pressure : 60.5 psi
No external forces or bending moments were included in this analysis.
Both ends of the model are "fixed," except that one endis free axially so that longitudinal pressure stressesmay be developed in the geometry.
Stresses are NOT averaged.
Unstructured Mesh Generation used for this model.
Vessel Centerline Vector : 0.000 0.000 1.000Nozzle Orientation Vector : 0.000 1.000 0.000
Table of Contents
Load Case Report
Inner and outer element temperatures are the samethroughout the model. No thermal ratchetingcalculations will be performed.
THE 9 LOAD CASES ANALYZED ARE:
1 Weight ONLY
Weight ONLY case run to get the stress rangebetween the installed and the operating states.It is assumed that the weight only case accuratelyrepresents the installed stress state.
/-------- Loads in Case 1Forces due to Weight
2 Sustained
Sustained case run to satisfy Pl Qb, the bending stress due to primary loads mustbe less than 3Smh as per Note 3 of Fig. NB-3222-1,and Table 4-120.1
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/-------- Loads in Case 2Forces due to WeightPressure Case 1
3 Operating
Operating case run to compute the extreme operatingstress state to be used in the shakedown and peakstress calculations.
/-------- Loads in Case 3Pressure Case 1Force Case (Operating)
4 Expansion (Fatigue Calc Performed)
Expansion case run to get the RANGE of stressesas described in NB-3222.2, or Note 1 of 4-130.1.The allowable is 3Smavg.
/-------- Combinations in Expansion Case 4Plus Stress Results from CASE 3Minus Stress Results from CASE 1
5 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 5Force Case (Axial)
6 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 6Force Case (Inplane)
7 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 7Force Case (Outplane)
8 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 8Force Case (Torsion)
9 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 9
112/226
Pressure Case 1
Table of Contents
Solution Data
Maximum Solution Row Size = 780Number of Nodes = 1563Number of Elements = 500Number of Solution Cases = 8
Largest On-Diagonal Stiffness = 931597451368.Smallest On-Diagonal Stiffness = 2.
Largest Off-Diagonal Stiffness = 447788344659.Smallest Off-Diagonal Stiffness = 1.
Summation of Loads per Case
Case # FX FY FZ
1 0. -92. 0.2 0. -429. 34469.3 0. -429. 34469.4 0. 255615. 0.5 0. 0. 1.6 -1. 0. 0.7 0. 0. 0.8 0. -337. 34469.
Equation Coefficient (Stiffness) Distribution)
OnDiagonal Number of AveragePercentile Coefficients Stiffness
90-to-100% 24 925263166085.70-to-90% 0 0.50-to-70% 0 0.30-to-50% 96 353944070642.10-to-30% 240 156796948878.1-to-10% 52 18615367883..1-to- 1% 264 5149901501..01-to-.1% 408 207083244..001-to-.01% 1586 37090300..0001-TO-.001% 6708 2960926.
OFF Diagonal Number of AveragePercentile Coefficients Stiffness
90-to-100% 48 444468332268.70-to-90% 0 0.50-to-70% 0 0.
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30-to-50% 144 172642992909.10-to-30% 616 67661296735.1-to-10% 4216 14647990355..1-to- 1% 8208 1786531066..01-to-.1% 5910 190162875..001-to-.01% 11014 12751559..0001-TO-.001% 392695 261894.
Table of Contents
ASME Code Stress Output Plots
1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
2) Qb < 3(Smh) (SUS,Bending) Case 2
3) Pl+Pb+Q < 3(Smavg) (OPE,Inside) Case 3
4) Pl+Pb+Q < 3(Smavg) (OPE,Outside) Case 3
5) Pl+Pb+Q+F < Sa (SIF,Outside) Case 5
6) Pl+Pb+Q+F < Sa (SIF,Outside) Case 6
7) Pl+Pb+Q+F < Sa (SIF,Outside) Case 7
8) Pl+Pb+Q+F < Sa (SIF,Outside) Case 8
9) Pl+Pb+Q+F < Sa (SIF,Outside) Case 9
10) Pl+Pb+Q < 3(Smavg) (EXP,Inside) Case 4
11) Pl+Pb+Q < 3(Smavg) (EXP,Outside) Case 4
12) Pl+Pb+Q+F < Sa (EXP,Inside) Case 4
13) Pl+Pb+Q+F < Sa (EXP,Outside) Case 4
Table of Contents
ASME Overstressed Areas
*** NO OVERSTRESSED NODES IN THIS MODEL ***
Table of Contents
Highest Primary Stress Ratios
Header Next to Nozzle Weld
Pl 1.5(k)Smh Primary Membrane Load Case 2
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16,052 30,000 Plot Reference:psi psi 1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
53%
Branch Next to Header Weld
Pl 1.5(k)Smh Primary Membrane Load Case 28,068 31,350 Plot Reference:psi psi 1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
25%
Branch Transition
Pl 1.5(k)Smh Primary Membrane Load Case 22,134 31,350 Plot Reference:psi psi 1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
6%
Header away from Junction
Pl 1.5(k)Smh Primary Membrane Load Case 215,557 30,000 Plot Reference:psi psi 1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
51%
Table of Contents
Highest Secondary Stress Ratios
Header Next to Nozzle Weld
Pl+Pb+Q 3(Smavg) Primary+Secondary (Inner) Load Case 321,985 60,000 Plot Reference:psi psi 3) Pl+Pb+Q < 3(Smavg) (OPE,Inside) Case 3
36%
Branch Next to Header Weld
Pl+Pb+Q 3(Smavg) Primary+Secondary (Inner) Load Case 49,683 62,700 Plot Reference:psi psi 10) Pl+Pb+Q < 3(Smavg) (EXP,Inside) Case 4
15%
Branch Transition
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Pl+Pb+Q 3(Smavg) Primary+Secondary (Outer) Load Case 33,682 62,700 Plot Reference:psi psi 4) Pl+Pb+Q < 3(Smavg) (OPE,Outside) Case 3
5%
Header away from Junction
Pl+Pb+Q 3(Smavg) Primary+Secondary (Inner) Load Case 319,091 60,000 Plot Reference:psi psi 3) Pl+Pb+Q < 3(Smavg) (OPE,Inside) Case 3
31%
Table of Contents
Highest Fatigue Stress Ratios
Header Next to Nozzle Weld
Pl+Pb+Q+F Sa Primary+Secondary+Peak (Inner) Load Case 414,414 568,400 Stress Concentration Factor = 1.350psi psi Strain Concentration Factor = 1.000Cycles Allowed for this Stress = 338035.42% "B31" Fatigue Stress Allowable = 50000.0Markl Fatigue Stress Allowable = 245000.0WRC 474 Mean Cycles to Failure = 6675118.WRC 474 99% Probability Cycles = 1550720.WRC 474 95% Probability Cycles = 2153010.BS5500 Allowed Cycles(Curve F) = 217104.Membrane-to-Bending Ratio = 0.847Bending-to-PL+PB+Q Ratio = 0.541Plot Reference:12) Pl+Pb+Q+F < Sa (EXP,Inside) Case 4
Branch Next to Header Weld
Pl+Pb+Q+F Sa Primary+Secondary+Peak (Inner) Load Case 46,536 564,533 Stress Concentration Factor = 1.350psi psi Strain Concentration Factor = 1.000Cycles Allowed for this Stress = 1000000.01% "B31" Fatigue Stress Allowable = 52250.0Markl Fatigue Stress Allowable = 245000.0WRC 474 Mean Cycles to Failure = 18910530.WRC 474 99% Probability Cycles = 4393171.WRC 474 95% Probability Cycles = 6099452.BS5500 Allowed Cycles(Curve F) = 2377162.Membrane-to-Bending Ratio = 4.204Bending-to-PL+PB+Q Ratio = 0.192Plot Reference:12) Pl+Pb+Q+F < Sa (EXP,Inside) Case 4
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Branch Transition
Pl+Pb+Q+F Sa Primary+Secondary+Peak (Outer) Load Case 42,481 564,533 Stress Concentration Factor = 1.350psi psi Strain Concentration Factor = 1.000Cycles Allowed for this Stress = 1000000.00% "B31" Fatigue Stress Allowable = 52250.0Markl Fatigue Stress Allowable = 245000.0WRC 474 Mean Cycles to Failure = 411231168.WRC 474 99% Probability Cycles = 95534552.WRC 474 95% Probability Cycles = 132639592.BS5500 Allowed Cycles(Curve F) = 117344832.Membrane-to-Bending Ratio = 0.845Bending-to-PL+PB+Q Ratio = 0.542Plot Reference:13) Pl+Pb+Q+F < Sa (EXP,Outside) Case 4
Header away from Junction
Pl+Pb+Q+F Sa Primary+Secondary+Peak (Inner) Load Case 49,350 568,400 Stress Concentration Factor = 1.000psi psi Strain Concentration Factor = 1.000Cycles Allowed for this Stress = 1000000.01% "B31" Fatigue Stress Allowable = 50000.0Markl Fatigue Stress Allowable = 245000.0WRC 474 Mean Cycles to Failure = 9613735.WRC 474 99% Probability Cycles = 2233400.WRC 474 95% Probability Cycles = 3100840.BS5500 Allowed Cycles(Curve F) = 323268.Membrane-to-Bending Ratio = 2.667Bending-to-PL+PB+Q Ratio = 0.273Plot Reference:12) Pl+Pb+Q+F < Sa (EXP,Inside) Case 4
Table of Contents
Stress Intensification Factors
Branch/Nozzle Sif Summary
Peak Primary SecondaryAxial : 296.400 63.261 439.111Inplane : 69.156 48.408 102.453Outplane: 319.826 60.389 473.817Torsion : 15.498 19.666 23.427Pressure: 1.101 1.228 1.631
The above stress intensification factors are to be usedin a beam-type analysis of the piping system. Inplane,Outplane and Torsional sif's should be used with thematching branch pipe whose diameter and thickness is givenbelow. The axial sif should be used to intensify theaxial stress in the branch pipe calculated by F/A. The
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pressure sif should be used to intensify the nominalpressure stress in the PARENT or HEADER, calculatedfrom PD/2T.
Pipe OD : 8.625 in.Pipe Thk: 0.438 in.Z approx: 23.034 cu.in.Z exact : 21.928 cu.in.
B31.3Peak Stress Sif .... 0.000 Axial171.831 Inplane226.775 Outplane1.000 TorsionalB31.1Peak Stress Sif .... 0.000 Axial197.590 Inplane197.590 Outplane197.590 TorsionalWRC 330Peak Stress Sif .... 0.000 Axial133.374 Inplane133.374 Outplane40.451 Torsional
Table of Contents
Allowable Loads
SECONDARY Maximum Conservative RealisticLoad Type (Range): Individual Simultaneous SimultaneousOccuring Occuring OccuringAxial Force (lb. ) 1538. 368. 552.Inplane Moment (in. lb.) 12842. 2173. 4609.Outplane Moment (in. lb.) 2777. 470. 997.Torsional Moment (in. lb.) 56161. 12303. 18454.Pressure (psi ) 169.99 60.50 60.50
PRIMARY Maximum Conservative RealisticLoad Type: Individual Simultaneous SimultaneousOccuring Occuring OccuringAxial Force (lb. ) 5337. 855. 1282.Inplane Moment (in. lb.) 13590. 1486. 3153.Outplane Moment (in. lb.) 10893. 1191. 2527.Torsional Moment (in. lb.) 33451. 5174. 7761.Pressure (psi ) 112.88 60.50 60.50
NOTES:
1) Maximum Individual Occuring Loads are the maximumallowed values of the respective loads if all otherload components are zero, i.e. the listed axial forcemay be applied if the inplane, outplane and torsionalmoments, and the pressure are zero.
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2) The Conservative Allowable Simultaneous loads arethe maximum loads that can be applied simultaneously.A conservative stress combination equation is usedthat typically produces stresses within 50-70% of theallowable stress.
3) The Realistic Allowable Simultaneous loads are themaximum loads that can be applied simultaneously. Amore realistic stress combination equation is usedbased on experience at Paulin Research. Stresses aretypically produced within 80-105% of the allowable.
4) Secondary allowable loads are limits for expansionand operating piping loads.
5) Primary allowable loads are limits for weight,primary and sustained type piping loads.
Table of Contents
Flexibilities
The following stiffnesses should be used in a piping,"beam-type" analysis of the intersection. The stiff-nesses should be inserted at the surface of thebranch/header or nozzle/vessel junction. The generalcharacteristics used for the branch pipe should be:
Outside Diameter = 8.625 in.Wall Thickness = 0.438 in.
Axial Translational Stiffness = 49637. lb./in.Inplane Rotational Stiffness = 40836. in.lb./degOutplane Rotational Stiffness = 5643. in.lb./degTorsional Rotational Stiffness = 1172469. in.lb./deg
Table of Contents
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Finite Element Model
Finite Element Model•
Elements at Discontinuity
1) Pl < 1.5(k)Smh (SUS Membrane) Case 2• 2) Qb < 3(Smh) (SUS Bending) Case 2• 3) Pl+Pb+Q < 3(Smavg) (OPE Inside) Case 3• 4) Pl+Pb+Q < 3(Smavg) (OPE Outside) Case 3• 10) Pl+Pb+Q < 3(Smavg) (EXP Inside) Case 4• 11) Pl+Pb+Q < 3(Smavg) (EXP Outside) Case 4• 12) Pl+Pb+Q+F < Sa (EXP Inside) Case 4• 13) Pl+Pb+Q+F < Sa (EXP Outside) Case 4• 5) Pl+Pb+Q+F < Sa (SIF Outside) Case 5• 6) Pl+Pb+Q+F < Sa (SIF Outside) Case 6• 7) Pl+Pb+Q+F < Sa (SIF Outside) Case 7• 8) Pl+Pb+Q+F < Sa (SIF Outside) Case 8• 9) Pl+Pb+Q+F < Sa (SIF Outside) Case 9•
Tabular Results
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TS Inlet (N1)
ASME Section VIII Division 1, 2007 Edition
tw(lower) = 0.1875 inLeg41 = 0.125 in
Note: round inside edges per UG-76(c)
Located on: Front ChannelLiquid static head included: 0.1458 psiNozzle material specification: SA-455 <= 3/8 (II-D p. 22, ln. 14)Nozzle longitudinal joint efficiency: 1Flange description: 16 inch Class 150 WN A105Bolt Material: SA-193 B7 Bolt <= 2 1/2 (II-D p. 348, ln. 33)Flange rated MDMT: -51.4°F(UCS-66(b)(1)(b))Liquid static head on flange: 0 psiASME B16.5 flange rating MAWP: 195.65 psi @ 414.5°FASME B16.5 flange rating MAP: 285 psi @ 70°FASME B16.5 flange hydro test: 450 psi @ 70°FNozzle orientation: 0°Local vessel minimum thickness: 0.1875 inNozzle center line offset to datum line: 91.8642 inEnd of nozzle to shell center: 14.75 inNozzle inside diameter, new: 13.876 inNozzle nominal wall thickness: 1.062 inNozzle corrosion allowance: 0.0625 inProjection available outside vessel, Lpr: 4.4975 inProjection available outside vessel to flange face, Lf: 5.9375 in
128/226
Reinforcement Calculations for Internal Pressure
The attached ASME B16.5 flange limits the nozzle MAWP.
Division 2 Part 4.5 Maximum Local PrimaryMembrane Stress
For P = 195.8 psi @ 414.5 °FThe opening is adequately reinforced
UG-45 NozzleWall
ThicknessSummary (in)The nozzle passes
UG-45
PL(psi)
Sallow(psi)
A1(in2)
A2(in2)
A3(in2)
A5(in2)
Awelds(in2)
treq(in)
tmin(in)
13,705 30,000 0.2376 0.9995 -- -- 0.0078 0.1481 1.062
Division 2 Part 4.5 Strength of Nozzle Attachment Welds SummaryAverage Shear Stress in Weld
kyLτ
(in)L41T(in)
L42T(in)
L43T(in)
fwelds(lbf)
τ(psi)
S(psi)
Overstressed
1.1428 12.5664 0.0884 0 0 13,705.47 9,219 20,000 No
UW-16 Weld Sizing Summary
Weld description Required weldthroat size (in)
Actual weldthroat size (in) Status
Nozzle to shell fillet (Leg41) 0.0875 0.0875 weld size is adequate
Calculations for internal pressure 195.8 psi @ 414.5 °F
Nozzle is impact test exempt per UG-20(f).
Nozzle UCS-66 governing thk: 0.1875 inNozzle rated MDMT: -20 °FDivision 2 Part 4.5 Design Rules for Openings in Shells and Heads (U-2(g) analysis)
Effective radius of the vessel
Reff = 0.5*Di= 0.5*17.375= 8.6875 in
Limit of reinforcement along the vessel wall
LR = min[ (Reff*t)0.5, 2*Rn]= min[ (8.6875*0.125)0.5, 2*7.0005]= 1.0421 in
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Limit of reinforcement along the nozzle wall projecting outside the vessel surface
LH1 = t + te + (Rn*tn)0.5
= 0.125 + 0 + (7.0005*0.9995)0.5
= 2.7702 in
LH2 = Lpr1 + t= 4.4975 + 0.125= 4.6225 in
LH3 = 8*(t + te)= 8*(0.125 + 0)= 1 in
LH = min[ LH1, LH2, LH3]= min[ 2.7702, 4.6225, 1]= 1 in
Effective thickness
teff = t= 0.125 in
Total available area near the nozzle opening
λ = min[ (dn + tn) / ((Di + teff)*teff)0.5, 12]= min[ (14.001 + 0.9995) / ((17.375 + 0.125)*0.125)0.5, 12]= 10.1422
A1 = t*LR*max[ (λ / 5)0.85 , 1]= 0.125*1.0421*max[ (10.1422 / 5)0.85 , 1]= 0.125*1.0421*1.8243= 0.2376 in2
A2 = tn*LH= 0.9995*1= 0.9995 in2
A41 = 0.5*L412
= 0.5*0.1252
= 0.0078 in2
frn = Sn / S= 21,300 / 20,000= 1.065
AT = A1 + frn*A2 + A41= 0.2376 + 1.065*0.9995 + 0.0078= 1.3099 in2
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Forces at nozzle to vessel intersection
Rxn = tn / ln[(Rn + tn) / Rn]= 0.9995 / ln[(7.0005 + 0.9995) / 7.0005]= 7.4891 in
Rxs = teff / ln[(Reff + teff) / Reff]= 0.125 / ln[(8.6875 + 0.125) / 8.6875]= 8.7499 in
fN = P*Rxn*(LH - t)= 195.8*7.4891*(1 - 0.125)= 1,283.05 lbf
fS = P*Rxs*(LR + tn)= 195.8*8.7499*(1.0421 + 0.9995)= 3,497.61 lbf
fY = P*Rxs*Rnc= 195.8*8.7499*7.0005= 11,993.14 lbf
Average local primary membrane stress
σavg = (fN + fS + fY) / AT= (1,283.05 + 3,497.61 + 11,993.14) / 1.3099= 12,805 psi
General primary membrane stress
σcirc = P*Rxs / teff= 195.8*8.7499 / 0.125= 13,705 psi
Maximum local primary membrane stress at the nozzle intersection
PL = max[ (2*σavg - σcirc) , σcirc]= max[ (2*12,805 - 13,705) , 13,705]= 13,705 psi
Allowable stress
Sallow = 1.5*S*E= 1.5*20,000*1= 30,000 psi
PL = 13,705 psi ≤ Sallow = 30,000 psi satisfactory
Maximum allowable working pressure
Ap = Rxn*(LH - t) + Rxs*(LR + tn + Rnc)
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= (7.4891*(1 - 0.125) + 8.7499*(1.0421 + 0.9995 + 7.0005))= 85.6699 in2
Pmax1 = Sallow / (2*Ap/ AT - Rxs / teff)= 30,000 / (2*85.6699/ 1.3099 - 8.7499 / 0.125)= 493.3889 psi
Pmax2 = S*(t / Rxs)= 20,000*(0.125 / 8.7499)= 285.7191 psi
Pmax = min[ Pmax1, Pmax2]= min[ 493.39, 285.72]= 285.7191 psi
Strength of Nozzle Attachment Welds
Discontinuity force factor
ky = (Rnc + tn) / Rnc= (7.0005 + 0.9995) / 7.0005= 1.1428
Weld length resisting discontinuity force
Lτ = π / 2 * (Rn + tn)= π / 2 * (7.0005 + 0.9995)= 12.5664 in
Weld throat dimensions
L41T = 0.7071*L41= 0.7071*0.125= 0.0884 in
Average shear stress in weld
fwelds = min[ fY*ky, 1.5*Sn*(A2 + A3) ]= min[ 11,993.14*1.1428, 1.5*21,300*(0.9995 + 0) ]= 13,705.47 lbf
τ = fwelds / [Lτ*(0.49*L41T + 0.6*tw1 + 0.49*L43T)]= 13,705.47 / [12.5664*(0.49*0.0884 + 0.6*0.125 + 0.49*0)]= 9,219 psi
τ = 9,219 psi ≤ S = 20,000 psi satisfactory
132/226
UW-16(c) Weld Check
Fillet weld: tmin = lesser of 0.75 or tn or t = 0.125 intc(min) = lesser of 0.25 or 0.7*tmin = 0.0875 intc(actual) = 0.7*Leg = 0.7*0.125 = 0.0875 in
The fillet weld size is satisfactory.
Weld strength calculations are not required for this detail which conforms to Fig. UW-16.1, sketch (c-e).
UG-45 Nozzle Neck Thickness Check
Wall thickness per UG-45(a): tr1 = 0.1272 in (E =1)Wall thickness per UG-45(b)(1): tr2 = 0.1481 inWall thickness per UG-16(b): tr3 = 0.125 inStandard wall pipe per UG-45(b)(4): tr4 = 0.3906 inThe greater of tr2 or tr3: tr5 = 0.1481 inThe lesser of tr4 or tr5: tr6 = 0.1481 in
Required per UG-45 is the larger of tr1 or tr6 = 0.1481 in
Available nozzle wall thickness new, tn = 1.062 in
The nozzle neck thickness is adequate.
% Extreme fiber elongation - UCS-79(d)
= (50*t / Rf)*(1 - Rf / Ro)= (50*1.062 / 7.469)*(1 - 7.469 / ∞)= 7.1094%
133/226
The extreme fiber elongation exceeds 5 percent and the thickness exceeds 5/8 inch;. Heat treatment per UCS-56 isrequired if fabricated by cold forming.
Reinforcement Calculations for MAP
The attached ASME B16.5 flange limits the nozzle MAP.
Appendix 1-10 Maximum Local PrimaryMembrane StressFor P = 285 psi @ 70 °F
The opening is adequately reinforced
UG-45Nozzle WallThicknessSummary
(in)The nozzle
passes UG-45
PL(psi)
Sallow(psi)
A1(in2)
A2(in2)
A3(in2)
A5(in2)
Awelds(in2)
treq(in)
tmin(in)
13,110 30,000 0.5809 1.593 -- -- 0.0078 0.124 1.062
Division 2 Part 4.5 Strength of Nozzle Attachment Welds SummaryAverage Shear Stress in Weld
kyLτ
(in)L41T(in)
L42T(in)
L43T(in)
fwelds(lbf)
τ(psi)
S(psi)
Overstressed
1.1531 12.5664 0.0884 0 0 19,665 10,044 20,000 No
UW-16 Weld Sizing Summary
Weld description Required weldthroat size (in)
Actual weldthroat size (in) Status
Nozzle to shell fillet (Leg41) 0.1312 0.0875 weld size is NOT adequate
Calculations for internal pressure 285 psi @ 70 °F
Appendix 1-10
Effective radius of the vessel
Reff = 0.5*Di= 0.5*17.25= 8.625 in
Limit of reinforcement along the vessel wall
LR = 8*t= 8*0.1875= 1.5 in
134/226
Limit of reinforcement along the nozzle wall projecting outside the vessel surface
LH1 = t + 0.78*(Rn*tn)0.5
= 0.1875 + 0.78*(6.938*1.062)0.5
= 2.3048 in
LH2 = Lpr1 + t= 4.4975 + 0.1875= 4.685 in
LH3 = 8*(t + te)= 8*(0.1875 + 0)= 1.5 in
LH = min[ LH1, LH2, LH3]= min[ 2.3048, 4.685, 1.5]= 1.5 in
Effective thickness
teff = t= 0.1875 in
Total available area near the nozzle opening
λ = min[ (dn + tn) / ((Di + teff)*teff)0.5, 10]= min[ (13.876 + 1.062) / ((17.25 + 0.1875)*0.1875)0.5, 10]= 8.2613
A1 = t*LR*max[ (λ / 4) , 1]= 0.1875*1.5*max[ (8.2613 / 4) , 1]= 0.1875*1.5*2.0653= 0.5809 in2
A2 = tn*LH= 1.062*1.5= 1.593 in2
A41 = 0.5*L412
= 0.5*0.1252
= 0.0078 in2
AT = A1 + A2 + A41= 0.5809 + 1.593 + 0.0078= 2.1817 in2
Forces at nozzle to vessel intersection
fN = P*Rn*(LH - t)= 285*6.938*(1.5 - 0.1875)= 2,595.25 lbf
135/226
fS = P*Reff*(LR + tn)= 285*8.625*(1.5 + 1.062)= 6,297.72 lbf
fY = P*Reff*Rnc= 285*8.625*6.938= 17,054.47 lbf
Average local primary membrane stress
σavg = (fN + fS + fY) / AT= (2,595.25 + 6,297.72 + 17,054.47) / 2.1817= 11,893 psi
General primary membrane stress
σcirc = P*Reff / teff= 285*8.625 / 0.1875= 13,110 psi
Maximum local primary membrane stress at the nozzle intersection
PL = max[ (2*σavg - σcirc) , σcirc]= max[ (2*11,893 - 13,110) , 13,110]= 13,110 psi
Allowable stress
Sallow = 1.5*S*E= 1.5*20,000*1= 30,000 psi
PL = 13,110 psi ≤ Sallow = 30,000 psi satisfactory
Maximum allowable pressure
Ap = Rn*(LH - t) + Reff*(LR + tn + Rnc)= (6.938*(1.5 - 0.1875) + 8.625*(1.5 + 1.062 + 6.938))= 91.0436 in2
Pmax1 = Sallow / (2*Ap/ AT - Reff / teff)= 30,000 / (2*91.0436/ 2.1817 - 8.625 / 0.1875)= 800.8184 psi
Pmax2 = S*(t / Reff)= 20,000*(0.1875 / 8.625)= 434.7826 psi
Pmax = min[ Pmax1, Pmax2]= min[ 800.82, 434.78]
136/226
= 434.7826 psi
Division 2 Part 4.5 Strength of Nozzle Attachment Welds (U-2(g) analysis)
Discontinuity force factor
ky = (Rnc + tn) / Rnc= (6.938 + 1.062) / 6.938= 1.1531
Weld length resisting discontinuity force
Lτ = π / 2 * (Rn + tn)= π / 2 * (6.938 + 1.062)= 12.5664 in
Weld throat dimensions
L41T = 0.7071*L41= 0.7071*0.125= 0.0884 in
Average shear stress in weld
fwelds = min[ fY*ky, 1.5*Sn*(A2 + A3) ]= min[ 17,054.47*1.1531, 1.5*21,400*(1.593 + 0) ]= 19,665 lbf
τ = fwelds / [Lτ*(0.49*L41T + 0.6*tw1 + 0.49*L43T)]= 19,665 / [12.5664*(0.49*0.0884 + 0.6*0.1875 + 0.49*0)]= 10,044 psi
τ = 10,044 psi ≤ S = 20,000 psi satisfactory
UW-16(c) Weld Check
Fillet weld: tmin = lesser of 0.75 or tn or t = 0.1875 intc(min) = lesser of 0.25 or 0.7*tmin = 0.1312 intc(actual) = 0.7*Leg = 0.7*0.125 = 0.0875 in
** The fillet weld size IS NOT satisfactory. **UG-45 Nozzle Neck Thickness Check
Wall thickness per UG-45(a): tr1 = 0.0931 in (E =1)Wall thickness per UG-45(b)(1): tr2 = 0.124 inWall thickness per UG-16(b): tr3 = 0.0625 in
137/226
Standard wall pipe per UG-45(b)(4): tr4 = 0.3281 inThe greater of tr2 or tr3: tr5 = 0.124 inThe lesser of tr4 or tr5: tr6 = 0.124 in
138/226
Required per UG-45 is the larger of tr1 or tr6 = 0.124 in
Available nozzle wall thickness new, tn = 1.062 in
The nozzle neck thickness is adequate.
Reinforcement Calculations for External Pressure
Division 2 Part 4.5 Maximum Local PrimaryMembrane Stress
For Pe = 60.54 psi @ 414.5 °FThe opening is adequately reinforced
UG-45 NozzleWall
ThicknessSummary (in)The nozzle passes
UG-45
PL(psi)
Sallow(psi)
A1(in2)
A2(in2)
A3(in2)
A5(in2)
Awelds(in2)
treq(in)
tmin(in)
4,388 6,403 0.1303 0.9995 -- -- 0.0078 0.1407 1.062
Division 2 Part 4.5 Strength of Nozzle Attachment Welds SummaryAverage Shear Stress in Weld
kyLτ
(in)L41T(in)
L42T(in)
L43T(in)
fwelds(lbf)
τ(psi)
S(psi)
Overstressed
1.1428 12.5664 0.0884 0 0 4,238.01 2,851 20,000 No
UW-16 Weld Sizing Summary
Weld description Required weldthroat size (in)
Actual weldthroat size (in) Status
Nozzle to shell fillet (Leg41) 0.0875 0.0875 weld size is adequate
Calculations for external pressure 60.54 psi @ 414.5 °F
Division 2 Part 4.5 Design Rules for Openings in Shells and Heads (U-2(g) analysis)
Effective radius of the vessel
Reff = 0.5*Di= 0.5*17.375= 8.6875 in
Limit of reinforcement along the vessel wall
LR = min[ (Reff*t)0.5, 2*Rn]= min[ (8.6875*0.125)0.5, 2*7.0005]= 1.0421 in
139/226
Limit of reinforcement along the nozzle wall projecting outside the vessel surface
LH1 = t + te + (Rn*tn)0.5
= 0.125 + 0 + (7.0005*0.9995)0.5
= 2.7702 in
LH2 = Lpr1 + t= 4.4975 + 0.125= 4.6225 in
LH3 = 8*(t + te)= 8*(0.125 + 0)= 1 in
LH = min[ LH1, LH2, LH3]= min[ 2.7702, 4.6225, 1]= 1 in
Effective thickness
teff = t= 0.125 in
Total available area near the nozzle opening
λ = 0 (for external pressure design)
A1 = t*LR*max[ (λ / 5)0.85 , 1]= 0.125*1.0421*max[ (0 / 5)0.85 , 1]= 0.125*1.0421*1= 0.1303 in2
A2 = tn*LH= 0.9995*1= 0.9995 in2
A41 = 0.5*L412
= 0.5*0.1252
= 0.0078 in2
frn = Sn / S= 21,300 / 20,000= 1.065
AT = A1 + frn*A2 + A41= 0.1303 + 1.065*0.9995 + 0.0078= 1.2025 in2
Forces at nozzle to vessel intersection
Rxn = tn / ln[(Rn + tn) / Rn]
140/226
= 0.9995 / ln[(7.0005 + 0.9995) / 7.0005]= 7.4891 in
Rxs = teff / ln[(Reff + teff) / Reff]= 0.125 / ln[(8.6875 + 0.125) / 8.6875]= 8.7499 in
fN = P*Rxn*(LH - t)= 60.54*7.4891*(1 - 0.125)= 396.75 lbf
fS = P*Rxs*(LR + tn)= 60.54*8.7499*(1.0421 + 0.9995)= 1,081.53 lbf
fY = P*Rxs*Rnc= 60.54*8.7499*7.0005= 3,708.53 lbf
Average local primary membrane stress
σavg = (fN + fS + fY) / AT= (396.75 + 1,081.53 + 3,708.53) / 1.2025= 4,313 psi
General primary membrane stress
σcirc = P*Rxs / teff= 60.54*8.7499 / 0.125= 4,238 psi
Maximum local primary membrane stress at the nozzle intersection
PL = max[ (2*σavg - σcirc) , σcirc]= max[ (2*4,313 - 4,238) , 4,238]= 4,388 psi
Allowable stress
Sallow = min[ Sc, S]= min[ 6,403, 20,000]= 6,403 psi
PL = 4,388 psi ≤ Sallow = 6,403 psi satisfactory
Maximum allowable external pressure
Ap = Rxn*(LH - t) + Rxs*(LR + tn + Rnc)= (7.4891*(1 - 0.125) + 8.7499*(1.0421 + 0.9995 + 7.0005))= 85.6699 in2
141/226
Pmax1 = Sallow / (2*Ap/ AT - Rxs / teff)= 6,403 / (2*85.6699/ 1.2025 - 8.7499 / 0.125)= 88.332 psi
Pmax2 = S*(t / Rxs)= 20,000*(0.125 / 8.7499)= 285.7191 psi
Pmax = min[ Pmax1, Pmax2]= min[ 88.33, 285.72]= 88.332 psi
Strength of Nozzle Attachment Welds
Discontinuity force factor
ky = (Rnc + tn) / Rnc= (7.0005 + 0.9995) / 7.0005= 1.1428
Weld length resisting discontinuity force
Lτ = π / 2 * (Rn + tn)= π / 2 * (7.0005 + 0.9995)= 12.5664 in
Weld throat dimensions
L41T = 0.7071*L41= 0.7071*0.125= 0.0884 in
Average shear stress in weld
fwelds = min[ fY*ky, 1.5*Sn*(A2 + A3) ]= min[ 3,708.53*1.1428, 1.5*21,300*(0.9995 + 0) ]= 4,238.01 lbf
τ = fwelds / [Lτ*(0.49*L41T + 0.6*tw1 + 0.49*L43T)]= 4,238.01 / [12.5664*(0.49*0.0884 + 0.6*0.125 + 0.49*0)]= 2,851 psi
τ = 2,851 psi ≤ S = 20,000 psi satisfactory
UW-16(c) Weld Check
Fillet weld: tmin = lesser of 0.75 or tn or t = 0.125 in
142/226
tc(min) = lesser of 0.25 or 0.7*tmin = 0.0875 intc(actual) = 0.7*Leg = 0.7*0.125 = 0.0875 in
The fillet weld size is satisfactory.
Weld strength calculations are not required for this detail which conforms to Fig. UW-16.1, sketch (c-e).
UG-45 Nozzle Neck Thickness Check
Wall thickness per UG-45(a): tr1 = 0.1407 inWall thickness per UG-45(b)(2): tr2 = 0.0888 inWall thickness per UG-16(b): tr3 = 0.125 inStandard wall pipe per UG-45(b)(4): tr4 = 0.3906 inThe greater of tr2 or tr3: tr5 = 0.125 inThe lesser of tr4 or tr5: tr6 = 0.125 in
Required per UG-45 is the larger of tr1 or tr6 = 0.1407 in
Available nozzle wall thickness new, tn = 1.062 in
The nozzle neck thickness is adequate.
External Pressure, (Corroded & at 414.50°F) UG-28(c)
L/Do = 11.0540/16.0000 = 0.6909Do/t = 16.0000/0.078211 = 204.5757
From table G: A = 0.000674From table CS-2: B = 9289.4531 psi
Pa = 4*B/(3*(Do/t))= 4*9289.4531/(3*(16.0000/0.078211))= 60.5445 psi
Design thickness for external pressure Pa = 60.5445 psi
= t + Corrosion = 0.078211 + 0.0625 = 0.1407"
143/226
Tabular Results
Results were generated with the finite element program FE/Pipe®. Stress results are post-processed inaccordance with the rules specified in ASME Section III and ASME Section VIII, Division 2.
Analysis Time Stamp: Thu Nov 25 14:30:52 2010.
Model Notes• Load Case Report• Solution Data• ASME Code Stress Output Plots• ASME Overstressed Areas• Highest Primary Stress Ratios• Highest Secondary Stress Ratios• Highest Fatigue Stress Ratios• Stress Intensification Factors• Allowable Loads• Flexibilities• Graphical Results•
Model Notes
Input Echo:
Model Type : Cylindrical Shell
Parent Outside Diameter : 17.625 in.Thickness : 0.125 in.Fillet Along Shell : 0.125 in.
Parent Properties:Cold Allowable : 20000.0 psiHot Allowable : 20000.0 psiMaterial ID #2 : Low Alloy SteelUltimate Tensile (Amb) : 70000.0 psiYield Strength (Amb) : 38000.0 psiYield Strength (Hot) : 32300.0 psiElastic Modulus (Amb) : 29400000.0 psiPoissons Ratio : 0.300Weight Density : 0.283 lb./cu.in.(NOT USED)
Nozzle Outside Diameter : 16.000 in.Thickness : 1.000 in.Length : 6.000 in.Nozzle Weld Length : 0.125 in.Nozzle Tilt Angle : 0.000 deg.Distance from Top : 11.625 in.Distance from Bottom : 11.625 in.
Nozzle Properties
144/226
Cold Allowable : 21400.0 psiHot Allowable : 21300.0 psiMaterial ID #2 : Low Alloy SteelUltimate Tensile (Amb) : 75000.0 psiYield Strength (Amb) : 38000.0 psiYield Strength (Hot) : 32300.0 psiElastic Modulus (Amb) : 29200000.0 psiPoissons Ratio : 0.300Weight Density : 0.283 lb./cu.in. (NOT USED)
Design Operating Cycles : 0.Ambient Temperature (Deg.) : 70.00Nozzle Pressure : 0.1 psiVessel Pressure : 0.1 psi
No external forces or bending moments were included in this analysis.
Both ends of the model are "fixed," except that one endis free axially so that longitudinal pressure stressesmay be developed in the geometry.
Stresses are NOT averaged.
Unstructured Mesh Generation used for this model.
Vessel Centerline Vector : 0.000 0.000 1.000Nozzle Orientation Vector : 0.000 1.000 0.000
Table of Contents
Load Case Report
Inner and outer element temperatures are the samethroughout the model. No thermal ratchetingcalculations will be performed.
THE 9 LOAD CASES ANALYZED ARE:
1 Weight ONLY
Weight ONLY case run to get the stress rangebetween the installed and the operating states.It is assumed that the weight only case accuratelyrepresents the installed stress state.
/-------- Loads in Case 1Forces due to Weight
2 Sustained
Sustained case run to satisfy Pl Qb, the bending stress due to primary loads mustbe less than 3Smh as per Note 3 of Fig. NB-3222-1,and Table 4-120.1
145/226
/-------- Loads in Case 2Forces due to WeightPressure Case 1
3 Operating
Operating case run to compute the extreme operatingstress state to be used in the shakedown and peakstress calculations.
/-------- Loads in Case 3Pressure Case 1Force Case (Operating)
4 Expansion (Fatigue Calc Performed)
Expansion case run to get the RANGE of stressesas described in NB-3222.2, or Note 1 of 4-130.1.The allowable is 3Smavg.
/-------- Combinations in Expansion Case 4Plus Stress Results from CASE 3Minus Stress Results from CASE 1
5 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 5Force Case (Axial)
6 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 6Force Case (Inplane)
7 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 7Force Case (Outplane)
8 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 8Force Case (Torsion)
9 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 9
146/226
Pressure Case 1
Table of Contents
Solution Data
Maximum Solution Row Size = 1014Number of Nodes = 2355Number of Elements = 760Number of Solution Cases = 8
Largest On-Diagonal Stiffness = 2381148381049.Smallest On-Diagonal Stiffness = 2.
Largest Off-Diagonal Stiffness = 1153967166297.Smallest Off-Diagonal Stiffness = 1.
Summation of Loads per Case
Case # FX FY FZ
1 0. -151. 0.2 0. -154. 35.3 0. -154. 35.4 0. 2009614. 0.5 0. 0. 0.6 0. 0. 0.7 0. 0. 0.8 0. -3. 35.
Equation Coefficient (Stiffness) Distribution)
OnDiagonal Number of AveragePercentile Coefficients Stiffness
90-to-100% 40 2360063001927.70-to-90% 0 0.50-to-70% 0 0.30-to-50% 160 886725194314.10-to-30% 400 363252103024.1-to-10% 428 64311099006..1-to- 1% 128 12355396064..01-to-.1% 410 484258060..001-to-.01% 3520 91318297..0001-TO-.001% 9044 6987867.
OFF Diagonal Number of AveragePercentile Coefficients Stiffness
90-to-100% 80 1143045757771.70-to-90% 0 0.50-to-70% 0 0.
147/226
30-to-50% 240 447337846266.10-to-30% 840 181341141920.1-to-10% 8224 35080453750..1-to- 1% 15764 4622162155..01-to-.1% 7096 506163982..001-to-.01% 19964 31609910..0001-TO-.001% 589104 765281.
Table of Contents
ASME Code Stress Output Plots
1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
2) Qb < 3(Smh) (SUS,Bending) Case 2
3) Pl+Pb+Q < 3(Smavg) (OPE,Inside) Case 3
4) Pl+Pb+Q < 3(Smavg) (OPE,Outside) Case 3
5) Pl+Pb+Q+F < Sa (SIF,Outside) Case 5
6) Pl+Pb+Q+F < Sa (SIF,Outside) Case 6
7) Pl+Pb+Q+F < Sa (SIF,Outside) Case 7
8) Pl+Pb+Q+F < Sa (SIF,Outside) Case 8
9) Pl+Pb+Q+F < Sa (SIF,Outside) Case 9
10) Pl+Pb+Q < 3(Smavg) (EXP,Inside) Case 4
11) Pl+Pb+Q < 3(Smavg) (EXP,Outside) Case 4
12) Pl+Pb+Q+F < Sa (EXP,Inside) Case 4
13) Pl+Pb+Q+F < Sa (EXP,Outside) Case 4
Table of Contents
ASME Overstressed Areas
*** NO OVERSTRESSED NODES IN THIS MODEL ***
Table of Contents
Highest Primary Stress Ratios
Header Next to Nozzle Weld
Qb 3(Smh) Primary Bending Load Case 2
148/226
184 60,000 Plot Reference:psi psi 2) Qb < 3(Smh) (SUS,Bending) Case 2
0%
Branch Next to Header Weld
Pl 1.5(k)Smh Primary Membrane Load Case 215 31,950 Plot Reference:psi psi 1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
0%
Branch Transition
Pl 1.5(k)Smh Primary Membrane Load Case 25 31,950 Plot Reference:psi psi 1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
0%
Header away from Junction
Pl 1.5(k)Smh Primary Membrane Load Case 291 30,000 Plot Reference:psi psi 1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
0%
Table of Contents
Highest Secondary Stress Ratios
Header Next to Nozzle Weld
Pl+Pb+Q 3(Smavg) Primary+Secondary (Outer) Load Case 3198 60,000 Plot Reference:psi psi 4) Pl+Pb+Q < 3(Smavg) (OPE,Outside) Case 3
0%
Branch Next to Header Weld
Pl+Pb+Q 3(Smavg) Primary+Secondary (Inner) Load Case 319 64,050 Plot Reference:psi psi 3) Pl+Pb+Q < 3(Smavg) (OPE,Inside) Case 3
0%
Branch Transition
149/226
Pl+Pb+Q 3(Smavg) Primary+Secondary (Outer) Load Case 312 64,050 Plot Reference:psi psi 4) Pl+Pb+Q < 3(Smavg) (OPE,Outside) Case 3
0%
Header away from Junction
Pl+Pb+Q 3(Smavg) Primary+Secondary (Outer) Load Case 3150 60,000 Plot Reference:psi psi 4) Pl+Pb+Q < 3(Smavg) (OPE,Outside) Case 3
0%
Table of Contents
Highest Fatigue Stress Ratios
Header Next to Nozzle Weld
Pl+Pb+Q+F Sa Primary+Secondary+Peak (Inner) Load Case 410 568,400 Stress Concentration Factor = 1.350psi psi Strain Concentration Factor = 1.000Cycles Allowed for this Stress = 1000000.00% "B31" Fatigue Stress Allowable = 50000.0Markl Fatigue Stress Allowable = 245000.0WRC 474 Mean Cycles to Failure = 352740638908WRC 474 99% Probability Cycles = 819464137133WRC 474 95% Probability Cycles = 113773898419BS5500 Allowed Cycles(Curve F) =*************Membrane-to-Bending Ratio = 0.815Bending-to-PL+PB+Q Ratio = 0.551Plot Reference:12) Pl+Pb+Q+F < Sa (EXP,Inside) Case 4
Branch Next to Header Weld
Pl+Pb+Q+F Sa Primary+Secondary+Peak (Inner) Load Case 45 564,533 Stress Concentration Factor = 1.350psi psi Strain Concentration Factor = 1.000Cycles Allowed for this Stress = 1000000.00% "B31" Fatigue Stress Allowable = 53375.0Markl Fatigue Stress Allowable = 245000.0WRC 474 Mean Cycles to Failure = 740499692370WRC 474 99% Probability Cycles = 172028086043WRC 474 95% Probability Cycles = 238842744783BS5500 Allowed Cycles(Curve F) =*************Membrane-to-Bending Ratio = 5.511Bending-to-PL+PB+Q Ratio = 0.154Plot Reference:12) Pl+Pb+Q+F < Sa (EXP,Inside) Case 4
150/226
Branch Transition
Pl+Pb+Q+F Sa Primary+Secondary+Peak (Outer) Load Case 43 564,533 Stress Concentration Factor = 1.350psi psi Strain Concentration Factor = 1.000Cycles Allowed for this Stress = 1000000.00% "B31" Fatigue Stress Allowable = 53375.0Markl Fatigue Stress Allowable = 245000.0WRC 474 Mean Cycles to Failure = 540823484503WRC 474 99% Probability Cycles = 125640601000WRC 474 95% Probability Cycles = 174438636438BS5500 Allowed Cycles(Curve F) =*************Membrane-to-Bending Ratio = 0.428Bending-to-PL+PB+Q Ratio = 0.700Plot Reference:13) Pl+Pb+Q+F < Sa (EXP,Outside) Case 4
Header away from Junction
Pl+Pb+Q+F Sa Primary+Secondary+Peak (Outer) Load Case 46 568,400 Stress Concentration Factor = 1.000psi psi Strain Concentration Factor = 1.000Cycles Allowed for this Stress = 1000000.00% "B31" Fatigue Stress Allowable = 50000.0Markl Fatigue Stress Allowable = 245000.0WRC 474 Mean Cycles to Failure = 525177519939WRC 474 99% Probability Cycles = 122005826012WRC 474 95% Probability Cycles = 169392146502BS5500 Allowed Cycles(Curve F) =*************Membrane-to-Bending Ratio = 7.765Bending-to-PL+PB+Q Ratio = 0.114Plot Reference:13) Pl+Pb+Q+F < Sa (EXP,Outside) Case 4
Table of Contents
Stress Intensification Factors
Branch/Nozzle Sif Summary
Peak Primary SecondaryAxial : 63.401 35.895 93.927Inplane : 18.143 19.158 26.878Outplane: 86.509 26.240 128.162Torsion : 14.919 21.770 22.102Pressure: 0.931 1.125 1.379
The above stress intensification factors are to be usedin a beam-type analysis of the piping system. Inplane,Outplane and Torsional sif's should be used with thematching branch pipe whose diameter and thickness is givenbelow. The axial sif should be used to intensify theaxial stress in the branch pipe calculated by F/A. The
151/226
pressure sif should be used to intensify the nominalpressure stress in the PARENT or HEADER, calculatedfrom PD/2T.
Pipe OD : 16.000 in.Pipe Thk: 0.999 in.Z approx: 176.638 cu.in.Z exact : 166.339 cu.in.
B31.3Peak Stress Sif .... 0.000 Axial93.672 Inplane122.231 Outplane1.000 TorsionalB31.1Peak Stress Sif .... 0.000 Axial122.231 Inplane122.231 Outplane122.231 TorsionalWRC 330Peak Stress Sif .... 0.000 Axial100.454 Inplane119.358 Outplane102.311 Torsional
Table of Contents
Allowable Loads
SECONDARY Maximum Conservative RealisticLoad Type (Range): Individual Simultaneous SimultaneousOccuring Occuring OccuringAxial Force (lb. ) 30088. 10028. 15041.Inplane Moment (in. lb.) 371319. 87504. 185624.Outplane Moment (in. lb.) 77873. 18351. 38929.Torsional Moment (in. lb.) 451554. 150489. 225734.Pressure (psi ) 617.08 0.15 0.15
PRIMARY Maximum Conservative RealisticLoad Type: Individual Simultaneous SimultaneousOccuring Occuring OccuringAxial Force (lb. ) 39367. 13117. 19676.Inplane Moment (in. lb.) 260468. 61372. 130190.Outplane Moment (in. lb.) 190175. 44809. 95055.Torsional Moment (in. lb.) 229223. 76382. 114572.Pressure (psi ) 378.15 0.15 0.15
NOTES:
1) Maximum Individual Occuring Loads are the maximumallowed values of the respective loads if all otherload components are zero, i.e. the listed axial forcemay be applied if the inplane, outplane and torsionalmoments, and the pressure are zero.
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2) The Conservative Allowable Simultaneous loads arethe maximum loads that can be applied simultaneously.A conservative stress combination equation is usedthat typically produces stresses within 50-70% of theallowable stress.
3) The Realistic Allowable Simultaneous loads are themaximum loads that can be applied simultaneously. Amore realistic stress combination equation is usedbased on experience at Paulin Research. Stresses aretypically produced within 80-105% of the allowable.
4) Secondary allowable loads are limits for expansionand operating piping loads.
5) Primary allowable loads are limits for weight,primary and sustained type piping loads.
Table of Contents
Flexibilities
The following stiffnesses should be used in a piping,"beam-type" analysis of the intersection. The stiff-nesses should be inserted at the surface of thebranch/header or nozzle/vessel junction. The generalcharacteristics used for the branch pipe should be:
Outside Diameter = 16.000 in.Wall Thickness = 0.999 in.
Axial Translational Stiffness = 5782656. lb./in.Inplane Rotational Stiffness = 4622923. in.lb./degOutplane Rotational Stiffness = 997225. in.lb./degTorsional Rotational Stiffness = 57612744. in.lb./deg
Table of Contents
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Finite Element Model
Finite Element Model• 1) Pl < 1.5(k)Smh (SUS Membrane) Case 2• 2) Qb < 3(Smh) (SUS Bending) Case 2• 3) Pl+Pb+Q < 3(Smavg) (OPE Inside) Case 3• 4) Pl+Pb+Q < 3(Smavg) (OPE Outside) Case 3• 10) Pl+Pb+Q < 3(Smavg) (EXP Inside) Case 4• 11) Pl+Pb+Q < 3(Smavg) (EXP Outside) Case 4• 12) Pl+Pb+Q+F < Sa (EXP Inside) Case 4• 13) Pl+Pb+Q+F < Sa (EXP Outside) Case 4• 5) Pl+Pb+Q+F < Sa (SIF Outside) Case 5• 6) Pl+Pb+Q+F < Sa (SIF Outside) Case 6• 7) Pl+Pb+Q+F < Sa (SIF Outside) Case 7• 8) Pl+Pb+Q+F < Sa (SIF Outside) Case 8• 9) Pl+Pb+Q+F < Sa (SIF Outside) Case 9•
Tabular Results
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TS Outlet (N2)
ASME Section VIII Division 1, 2007 Edition
tw(lower) = 0.1875 inLeg41 = 0.125 in
Note: round inside edges per UG-76(c)
Located on: Front ChannelLiquid static head included: 0.5785 psiNozzle material specification: SA-455 <= 3/8 (II-D p. 22, ln. 14)Nozzle longitudinal joint efficiency: 1Flange description: 8 inch Class 150 WN A105Bolt Material: SA-193 B7 Bolt <= 2 1/2 (II-D p. 348, ln. 33)Flange rated MDMT: -55°F(UCS-66(b)(1)(b))Liquid static head on flange: 0.7258 psiASME B16.5 flange rating MAWP: 195.65 psi @ 414.5°FASME B16.5 flange rating MAP: 285 psi @ 70°FASME B16.5 flange hydro test: 450 psi @ 70°FNozzle orientation: 180°Local vessel minimum thickness: 0.1875 inNozzle center line offset to datum line: 91.8642 inEnd of nozzle to shell center: 14.8125 inNozzle inside diameter, new: 8.071 inNozzle nominal wall thickness: 0.277 inNozzle corrosion allowance: 0.0625 inProjection available outside vessel, Lpr: 4.88 inProjection available outside vessel to flange face, Lf: 6 in
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Reinforcement Calculations for Internal Pressure
Available reinforcement per UG-37 governs the MAWP of this nozzle.
UG-37 Area Calculation Summary (in2)For P = 161.32 psi @ 414.5 °F
The opening is adequately reinforced
UG-45 NozzleWall
ThicknessSummary (in)The nozzle passes
UG-45
Arequired
Aavailable A1 A2 A3 A5
Awelds treq tmin
0.5772 0.5775 0.4473 0.1146 -- -- 0.0156 0.1329 0.277
Weld Failure Path Analysis Summary
The nozzle is exempt from weld strengthcalculations per UW-15(b)(1)
UW-16 Weld Sizing Summary
Weld description Required weldthroat size (in)
Actual weldthroat size (in) Status
Nozzle to shell fillet (Leg41) 0.0875 0.0875 weld size is adequate
Calculations for internal pressure 161.32 psi @ 414.5 °F
Nozzle impact test exemption temperature from Fig UCS-66 Curve A = 18 °FFig UCS-66.1 MDMT reduction = 45.6 °F, (coincident ratio = 0.56336).
Nozzle UCS-66 governing thk: 0.1875 inNozzle rated MDMT: -27.6 °F
Limits of reinforcement per UG-40
Parallel to the vessel wall: d = 8.196 inNormal to the vessel wall outside: 2.5*(t - C) = 0.3125 in
Nozzle required thickness per UG-27(c)(1)
trn = P*Rn/(Sn*E - 0.6*P)= 161.3249*4.098/(21,300*1 - 0.6*161.3249)= 0.0312 in
Required thickness tr from UG-37(a)
tr = P*R/(S*E - 0.6*P)= 161.3249*8.6875/(20,000*1 - 0.6*161.3249)= 0.0704 in
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Area required per UG-37(c)
Allowable stresses: Sn = 21,300, Sv = 20,000 psi
fr1 = lesser of 1 or Sn/Sv = 1fr2 = lesser of 1 or Sn/Sv = 1
A = d*tr*F + 2*tn*tr*F*(1 - fr1)= 8.196*0.0704*1 + 2*0.2145*0.0704*1*(1 - 1)= 0.5772 in2
Area available from FIG. UG-37.1
A1 = larger of the following= 0.4473 in2
= d*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1)= 8.196*(1*0.125 - 1*0.0704) - 2*0.2145*(1*0.125 - 1*0.0704)*(1 - 1)= 0.4473 in2
= 2*(t + tn)*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1)= 2*(0.125 + 0.2145)*(1*0.125 - 1*0.0704) - 2*0.2145*(1*0.125 - 1*0.0704)*(1 - 1)= 0.0371 in2
A2 = smaller of the following= 0.1146 in2
= 5*(tn - trn)*fr2*t= 5*(0.2145 - 0.0312)*1*0.125= 0.1146 in2
= 5*(tn - trn)*fr2*tn= 5*(0.2145 - 0.0312)*1*0.2145= 0.1966 in2
A41 = Leg2*fr2= 0.1252*1= 0.0156 in2
Area = A1 + A2 + A41
= 0.4473 + 0.1146 + 0.0156= 0.5775 in2
As Area >= A the reinforcement is adequate.
UW-16(c) Weld Check
Fillet weld: tmin = lesser of 0.75 or tn or t = 0.125 intc(min) = lesser of 0.25 or 0.7*tmin = 0.0875 intc(actual) = 0.7*Leg = 0.7*0.125 = 0.0875 in
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The fillet weld size is satisfactory.
Weld strength calculations are not required for this detail which conforms to Fig. UW-16.1, sketch (c-e).
UG-45 Nozzle Neck Thickness Check
Wall thickness per UG-45(a): tr1 = 0.0937 in (E =1)Wall thickness per UG-45(b)(1): tr2 = 0.1329 inWall thickness per UG-16(b): tr3 = 0.125 inStandard wall pipe per UG-45(b)(4): tr4 = 0.3443 inThe greater of tr2 or tr3: tr5 = 0.1329 inThe lesser of tr4 or tr5: tr6 = 0.1329 in
Required per UG-45 is the larger of tr1 or tr6 = 0.1329 in
Available nozzle wall thickness new, tn = 0.277 in
The nozzle neck thickness is adequate.
% Extreme fiber elongation - UCS-79(d)
= (50*t / Rf)*(1 - Rf / Ro)= (50*0.277 / 4.174)*(1 - 4.174 / ∞)= 3.3182%
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The extreme fiber elongation does not exceed 5%.
Reinforcement Calculations for MAP
Available reinforcement per UG-37 governs the MAP of this nozzle.
UG-37 Area Calculation Summary (in2)For P = 248.71 psi @ 70 °F
The opening is adequately reinforced
UG-45 NozzleWall
ThicknessSummary (in)The nozzle passes
UG-45
Arequired
Aavailable A1 A2 A3 A5
Awelds treq tmin
0.8722 0.8722 0.6412 0.2154 -- -- 0.0156 0.1081 0.277
Weld Failure Path Analysis Summary
The nozzle is exempt from weld strengthcalculations per UW-15(b)(1)
UW-16 Weld Sizing Summary
Weld description Required weldthroat size (in)
Actual weldthroat size (in) Status
Nozzle to shell fillet (Leg41) 0.1312 0.0875 weld size is NOT adequate
Calculations for internal pressure 248.71 psi @ 70 °F
Limits of reinforcement per UG-40
Parallel to the vessel wall: d = 8.071 inNormal to the vessel wall outside: 2.5*(t - C) = 0.4688 in
Nozzle required thickness per UG-27(c)(1)
trn = P*Rn/(Sn*E - 0.6*P)= 248.705*4.0355/(21,400*1 - 0.6*248.705)= 0.0472 in
Required thickness tr from UG-37(a)
tr = P*R/(S*E - 0.6*P)= 248.705*8.625/(20,000*1 - 0.6*248.705)= 0.1081 in
Area required per UG-37(c)
Allowable stresses: Sn = 21,400, Sv = 20,000 psi
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fr1 = lesser of 1 or Sn/Sv = 1fr2 = lesser of 1 or Sn/Sv = 1
A = d*tr*F + 2*tn*tr*F*(1 - fr1)= 8.071*0.1081*1 + 2*0.277*0.1081*1*(1 - 1)= 0.8722 in2
Area available from FIG. UG-37.1
A1 = larger of the following= 0.6412 in2
= d*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1)= 8.071*(1*0.1875 - 1*0.1081) - 2*0.277*(1*0.1875 - 1*0.1081)*(1 - 1)= 0.6412 in2
= 2*(t + tn)*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1)= 2*(0.1875 + 0.277)*(1*0.1875 - 1*0.1081) - 2*0.277*(1*0.1875 - 1*0.1081)*(1 - 1)= 0.0738 in2
A2 = smaller of the following= 0.2154 in2
= 5*(tn - trn)*fr2*t= 5*(0.277 - 0.0472)*1*0.1875= 0.2154 in2
= 5*(tn - trn)*fr2*tn= 5*(0.277 - 0.0472)*1*0.277= 0.3183 in2
A41 = Leg2*fr2= 0.1252*1= 0.0156 in2
Area = A1 + A2 + A41
= 0.6412 + 0.2154 + 0.0156= 0.8722 in2
As Area >= A the reinforcement is adequate.
UW-16(c) Weld Check
Fillet weld: tmin = lesser of 0.75 or tn or t = 0.1875 intc(min) = lesser of 0.25 or 0.7*tmin = 0.1312 intc(actual) = 0.7*Leg = 0.7*0.125 = 0.0875 in
** The fillet weld size IS NOT satisfactory. **UG-45 Nozzle Neck Thickness Check
Wall thickness per UG-45(a): tr1 = 0.0472 in (E =1)Wall thickness per UG-45(b)(1): tr2 = 0.1081 in
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Wall thickness per UG-16(b): tr3 = 0.0625 inStandard wall pipe per UG-45(b)(4): tr4 = 0.2818 inThe greater of tr2 or tr3: tr5 = 0.1081 inThe lesser of tr4 or tr5: tr6 = 0.1081 in
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Required per UG-45 is the larger of tr1 or tr6 = 0.1081 in
Available nozzle wall thickness new, tn = 0.277 in
The nozzle neck thickness is adequate.
Reinforcement Calculations for External Pressure
UG-37 Area Calculation Summary (in2)For Pe = 29.83 psi @ 414.5 °F
The opening is adequately reinforced
UG-45Nozzle WallThicknessSummary
(in)The nozzle
passes UG-45
Arequired
Aavailable A1 A2 A3 A5
Awelds treq tmin
0.3842 0.3842 0.2561 0.1125 -- -- 0.0156 0.125 0.277
Weld Failure Path Analysis Summary
Weld strength calculations are not required forexternal pressure
UW-16 Weld Sizing Summary
Weld description Required weldthroat size (in)
Actual weldthroat size (in) Status
Nozzle to shell fillet (Leg41) 0.0875 0.0875 weld size is adequate
Calculations for external pressure 29.83 psi @ 414.5 °F
Limits of reinforcement per UG-40
Parallel to the vessel wall: d = 8.196 inNormal to the vessel wall outside: 2.5*(t - C) = 0.3125 in
Nozzle required thickness per UG-28 trn = 0.0345 in
From UG-37(d)(1) required thickness tr = 0.0938 in
Area required per UG-37(d)(1)
Allowable stresses: Sn = 21,300, Sv = 20,000 psi
fr1 = lesser of 1 or Sn/Sv = 1fr2 = lesser of 1 or Sn/Sv = 1
A = 0.5*(d*tr*F + 2*tn*tr*F*(1 - fr1))
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= 0.5*(8.196*0.0938*1 + 2*0.2145*0.0938*1*(1 - 1))= 0.3842 in2
Area available from FIG. UG-37.1
A1 = larger of the following= 0.2561 in2
= d*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1)= 8.196*(1*0.125 - 1*0.0938) - 2*0.2145*(1*0.125 - 1*0.0938)*(1 - 1)= 0.2561 in2
= 2*(t + tn)*(E1*t - F*tr) - 2*tn*(E1*t - F*tr)*(1 - fr1)= 2*(0.125 + 0.2145)*(1*0.125 - 1*0.0938) - 2*0.2145*(1*0.125 - 1*0.0938)*(1 - 1)= 0.0212 in2
A2 = smaller of the following= 0.1125 in2
= 5*(tn - trn)*fr2*t= 5*(0.2145 - 0.0345)*1*0.125= 0.1125 in2
= 5*(tn - trn)*fr2*tn= 5*(0.2145 - 0.0345)*1*0.2145= 0.1931 in2
A41 = Leg2*fr2= 0.1252*1= 0.0156 in2
Area = A1 + A2 + A41
= 0.2561 + 0.1125 + 0.0156= 0.3842 in2
As Area >= A the reinforcement is adequate.
UW-16(c) Weld Check
Fillet weld: tmin = lesser of 0.75 or tn or t = 0.125 intc(min) = lesser of 0.25 or 0.7*tmin = 0.0875 intc(actual) = 0.7*Leg = 0.7*0.125 = 0.0875 in
The fillet weld size is satisfactory.
Weld strength calculations are not required for this detail which conforms to Fig. UW-16.1, sketch (c-e).
UG-45 Nozzle Neck Thickness Check
Wall thickness per UG-45(a): tr1 = 0.097 inWall thickness per UG-45(b)(2): tr2 = 0.0755 inWall thickness per UG-16(b): tr3 = 0.125 in
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Standard wall pipe per UG-45(b)(4): tr4 = 0.3443 inThe greater of tr2 or tr3: tr5 = 0.125 inThe lesser of tr4 or tr5: tr6 = 0.125 in
Required per UG-45 is the larger of tr1 or tr6 = 0.125 in
Available nozzle wall thickness new, tn = 0.277 in
The nozzle neck thickness is adequate.
External Pressure, (Corroded & at 414.50°F) UG-28(c)
L/Do = 7.1273/8.6250 = 0.8264Do/t = 8.6250/0.034461 = 250.2845
From table G: A = 0.000408From table CS-2: B = 5598.6196 psi
Pa = 4*B/(3*(Do/t))= 4*5598.6196/(3*(8.6250/0.034461))= 29.8254 psi
Design thickness for external pressure Pa = 29.8254 psi
= t + Corrosion = 0.034461 + 0.0625 = 0.0970"
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Tabular Results
Results were generated with the finite element program FE/Pipe®. Stress results are post-processed inaccordance with the rules specified in ASME Section III and ASME Section VIII, Division 2.
Analysis Time Stamp: Thu Nov 25 14:30:21 2010.
Model Notes• Load Case Report• Solution Data• ASME Code Stress Output Plots• ASME Overstressed Areas• Highest Primary Stress Ratios• Highest Secondary Stress Ratios• Highest Fatigue Stress Ratios• Stress Intensification Factors• Allowable Loads• Flexibilities• Graphical Results•
Model Notes
Input Echo:
Model Type : Cylindrical Shell
Parent Outside Diameter : 17.625 in.Thickness : 0.125 in.Fillet Along Shell : 0.125 in.
Parent Properties:Cold Allowable : 20000.0 psiHot Allowable : 20000.0 psiMaterial ID #2 : Low Alloy SteelUltimate Tensile (Amb) : 70000.0 psiYield Strength (Amb) : 38000.0 psiYield Strength (Hot) : 32300.0 psiElastic Modulus (Amb) : 29400000.0 psiPoissons Ratio : 0.300Weight Density : 0.283 lb./cu.in.(NOT USED)
Nozzle Outside Diameter : 8.625 in.Thickness : 0.214 in.Length : 6.062 in.Nozzle Weld Length : 0.125 in.Nozzle Tilt Angle : 0.000 deg.Distance from Top : 11.625 in.Distance from Bottom : 11.625 in.
Nozzle Properties
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Cold Allowable : 21400.0 psiHot Allowable : 21300.0 psiMaterial ID #2 : Low Alloy SteelUltimate Tensile (Amb) : 75000.0 psiYield Strength (Amb) : 38000.0 psiYield Strength (Hot) : 32300.0 psiElastic Modulus (Amb) : 29200000.0 psiPoissons Ratio : 0.300Weight Density : 0.283 lb./cu.in. (NOT USED)
Design Operating Cycles : 0.Ambient Temperature (Deg.) : 70.00Nozzle Pressure : 0.6 psiVessel Pressure : 0.6 psi
No external forces or bending moments were included in this analysis.
Both ends of the model are "fixed," except that one endis free axially so that longitudinal pressure stressesmay be developed in the geometry.
Stresses are NOT averaged.
Unstructured Mesh Generation used for this model.
Vessel Centerline Vector : 0.000 0.000 1.000Nozzle Orientation Vector : 0.000 -1.000 0.000
Table of Contents
Load Case Report
Inner and outer element temperatures are the samethroughout the model. No thermal ratchetingcalculations will be performed.
THE 9 LOAD CASES ANALYZED ARE:
1 Weight ONLY
Weight ONLY case run to get the stress rangebetween the installed and the operating states.It is assumed that the weight only case accuratelyrepresents the installed stress state.
/-------- Loads in Case 1Forces due to Weight
2 Sustained
Sustained case run to satisfy Pl Qb, the bending stress due to primary loads mustbe less than 3Smh as per Note 3 of Fig. NB-3222-1,and Table 4-120.1
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/-------- Loads in Case 2Forces due to WeightPressure Case 1
3 Operating
Operating case run to compute the extreme operatingstress state to be used in the shakedown and peakstress calculations.
/-------- Loads in Case 3Pressure Case 1Force Case (Operating)
4 Expansion (Fatigue Calc Performed)
Expansion case run to get the RANGE of stressesas described in NB-3222.2, or Note 1 of 4-130.1.The allowable is 3Smavg.
/-------- Combinations in Expansion Case 4Plus Stress Results from CASE 3Minus Stress Results from CASE 1
5 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 5Force Case (Axial)
6 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 6Force Case (Inplane)
7 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 7Force Case (Outplane)
8 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 8Force Case (Torsion)
9 Program Generated -- Force Only
Case run to compute sif's and flexibilities.
/-------- Loads in Case 9
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Pressure Case 1
Table of Contents
Solution Data
Maximum Solution Row Size = 708Number of Nodes = 1215Number of Elements = 388Number of Solution Cases = 8
Largest On-Diagonal Stiffness = 296151034771.Smallest On-Diagonal Stiffness = 2.
Largest Off-Diagonal Stiffness = 133911826400.Smallest Off-Diagonal Stiffness = 1.
Summation of Loads per Case
Case # FX FY FZ
1 0. -54. 0.2 0. -52. 137.3 0. -52. 137.4 0. -125324. 0.5 0. 0. 0.6 0. 0. 0.7 0. 0. 0.8 0. 2. 137.
Equation Coefficient (Stiffness) Distribution)
OnDiagonal Number of AveragePercentile Coefficients Stiffness
90-to-100% 24 294248147250.70-to-90% 0 0.50-to-70% 12 149628597740.30-to-50% 172 113004092414.10-to-30% 152 72134257559.1-to-10% 148 6028634056..1-to- 1% 186 1185434547..01-to-.1% 918 74504631..001-to-.01% 2663 14583238..0001-TO-.001% 3015 633054.
OFF Diagonal Number of AveragePercentile Coefficients Stiffness
90-to-100% 48 132839369693.70-to-90% 0 0.50-to-70% 0 0.
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30-to-50% 192 50154167788.10-to-30% 1464 22256099087.1-to-10% 5696 4020734916..1-to- 1% 6324 614066247..01-to-.1% 6300 44266165..001-to-.01% 25469 3801545..0001-TO-.001% 282835 147879.
Table of Contents
ASME Code Stress Output Plots
1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
2) Qb < 3(Smh) (SUS,Bending) Case 2
3) Pl+Pb+Q < 3(Smavg) (OPE,Inside) Case 3
4) Pl+Pb+Q < 3(Smavg) (OPE,Outside) Case 3
5) Pl+Pb+Q+F < Sa (SIF,Outside) Case 5
6) Pl+Pb+Q+F < Sa (SIF,Outside) Case 6
7) Pl+Pb+Q+F < Sa (SIF,Outside) Case 7
8) Pl+Pb+Q+F < Sa (SIF,Outside) Case 8
9) Pl+Pb+Q+F < Sa (SIF,Outside) Case 9
10) Pl+Pb+Q < 3(Smavg) (EXP,Inside) Case 4
11) Pl+Pb+Q < 3(Smavg) (EXP,Outside) Case 4
12) Pl+Pb+Q+F < Sa (EXP,Inside) Case 4
13) Pl+Pb+Q+F < Sa (EXP,Outside) Case 4
Table of Contents
ASME Overstressed Areas
*** NO OVERSTRESSED NODES IN THIS MODEL ***
Table of Contents
Highest Primary Stress Ratios
Header Next to Nozzle Weld
Pl 1.5(k)Smh Primary Membrane Load Case 2
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103 30,000 Plot Reference:psi psi 1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
0%
Branch Next to Header Weld
Pl 1.5(k)Smh Primary Membrane Load Case 286 31,950 Plot Reference:psi psi 1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
0%
Branch Transition
Pl 1.5(k)Smh Primary Membrane Load Case 225 31,950 Plot Reference:psi psi 1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
0%
Header away from Junction
Pl 1.5(k)Smh Primary Membrane Load Case 293 30,000 Plot Reference:psi psi 1) Pl < 1.5(k)Smh (SUS,Membrane) Case 2
0%
Table of Contents
Highest Secondary Stress Ratios
Header Next to Nozzle Weld
Pl+Pb+Q 3(Smavg) Primary+Secondary (Outer) Load Case 3135 60,000 Plot Reference:psi psi 4) Pl+Pb+Q < 3(Smavg) (OPE,Outside) Case 3
0%
Branch Next to Header Weld
Pl+Pb+Q 3(Smavg) Primary+Secondary (Inner) Load Case 390 64,050 Plot Reference:psi psi 3) Pl+Pb+Q < 3(Smavg) (OPE,Inside) Case 3
0%
Branch Transition
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Pl+Pb+Q 3(Smavg) Primary+Secondary (Outer) Load Case 435 64,050 Plot Reference:psi psi 11) Pl+Pb+Q < 3(Smavg) (EXP,Outside) Case 4
0%
Header away from Junction
Pl+Pb+Q 3(Smavg) Primary+Secondary (Outer) Load Case 3112 60,000 Plot Reference:psi psi 4) Pl+Pb+Q < 3(Smavg) (OPE,Outside) Case 3
0%
Table of Contents
Highest Fatigue Stress Ratios
Header Next to Nozzle Weld
Pl+Pb+Q+F Sa Primary+Secondary+Peak (Outer) Load Case 472 568,400 Stress Concentration Factor = 1.350psi psi Strain Concentration Factor = 1.000Cycles Allowed for this Stress = 1000000.00% "B31" Fatigue Stress Allowable = 50000.0Markl Fatigue Stress Allowable = 245000.0WRC 474 Mean Cycles to Failure = 643321676431WRC 474 99% Probability Cycles = 149452320931WRC 474 95% Probability Cycles = 207498678108BS5500 Allowed Cycles(Curve F) = 562908506986Membrane-to-Bending Ratio = 1.475Bending-to-PL+PB+Q Ratio = 0.404Plot Reference:13) Pl+Pb+Q+F < Sa (EXP,Outside) Case 4
Branch Next to Header Weld
Pl+Pb+Q+F Sa Primary+Secondary+Peak (Inner) Load Case 450 564,533 Stress Concentration Factor = 1.350psi psi Strain Concentration Factor = 1.000Cycles Allowed for this Stress = 1000000.00% "B31" Fatigue Stress Allowable = 53375.0Markl Fatigue Stress Allowable = 245000.0WRC 474 Mean Cycles to Failure = 125324822052WRC 474 99% Probability Cycles = 291146479697WRC 474 95% Probability Cycles = 404226006056BS5500 Allowed Cycles(Curve F) = 347097910875Membrane-to-Bending Ratio = 8.475Bending-to-PL+PB+Q Ratio = 0.106Plot Reference:12) Pl+Pb+Q+F < Sa (EXP,Inside) Case 4
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Branch Transition
Pl+Pb+Q+F Sa Primary+Secondary+Peak (Outer) Load Case 423 564,533 Stress Concentration Factor = 1.350psi psi Strain Concentration Factor = 1.000Cycles Allowed for this Stress = 1000000.00% "B31" Fatigue Stress Allowable = 53375.0Markl Fatigue Stress Allowable = 245000.0WRC 474 Mean Cycles to Failure = 144103830034WRC 474 99% Probability Cycles = 334772635172WRC 474 95% Probability Cycles = 464796294053BS5500 Allowed Cycles(Curve F) =1556488726366Membrane-to-Bending Ratio = 0.757Bending-to-PL+PB+Q Ratio = 0.569Plot Reference:13) Pl+Pb+Q+F < Sa (EXP,Outside) Case 4
Header away from Junction
Pl+Pb+Q+F Sa Primary+Secondary+Peak (Outer) Load Case 445 568,400 Stress Concentration Factor = 1.000psi psi Strain Concentration Factor = 1.000Cycles Allowed for this Stress = 1000000.00% "B31" Fatigue Stress Allowable = 50000.0Markl Fatigue Stress Allowable = 245000.0WRC 474 Mean Cycles to Failure = 107512107892WRC 474 99% Probability Cycles = 249765140889WRC 474 95% Probability Cycles = 346772408893BS5500 Allowed Cycles(Curve F) = 134516131590Membrane-to-Bending Ratio = 2.484Bending-to-PL+PB+Q Ratio = 0.287Plot Reference:13) Pl+Pb+Q+F < Sa (EXP,Outside) Case 4
Table of Contents
Stress Intensification Factors
Branch/Nozzle Sif Summary
Peak Primary SecondaryAxial : 27.038 9.026 40.057Inplane : 8.121 6.505 12.031Outplane: 33.302 7.533 49.336Torsion : 3.394 4.193 5.028Pressure: 1.756 2.072 2.602
The above stress intensification factors are to be usedin a beam-type analysis of the piping system. Inplane,Outplane and Torsional sif's should be used with thematching branch pipe whose diameter and thickness is givenbelow. The axial sif should be used to intensify theaxial stress in the branch pipe calculated by F/A. The
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pressure sif should be used to intensify the nominalpressure stress in the PARENT or HEADER, calculatedfrom PD/2T.
Pipe OD : 8.625 in.Pipe Thk: 0.214 in.Z approx: 11.917 cu.in.Z exact : 11.628 cu.in.
B31.3Peak Stress Sif .... 0.000 Axial20.103 Inplane26.232 Outplane1.000 TorsionalB31.1Peak Stress Sif .... 0.000 Axial29.555 Inplane29.555 Outplane29.555 TorsionalWRC 330Peak Stress Sif .... 0.000 Axial17.999 Inplane19.950 Outplane9.588 Torsional
Table of Contents
Allowable Loads
SECONDARY Maximum Conservative RealisticLoad Type (Range): Individual Simultaneous SimultaneousOccuring Occuring OccuringAxial Force (lb. ) 8489. 2825. 4237.Inplane Moment (in. lb.) 57989. 13644. 28943.Outplane Moment (in. lb.) 14141. 3327. 7058.Torsional Moment (in. lb.) 138764. 46179. 69268.Pressure (psi ) 327.06 0.58 0.58
PRIMARY Maximum Conservative RealisticLoad Type: Individual Simultaneous SimultaneousOccuring Occuring OccuringAxial Force (lb. ) 18837. 6263. 9394.Inplane Moment (in. lb.) 53624. 12604. 26737.Outplane Moment (in. lb.) 46311. 10888. 23096.Torsional Moment (in. lb.) 83195. 27653. 41480.Pressure (psi ) 205.34 0.58 0.58
NOTES:
1) Maximum Individual Occuring Loads are the maximumallowed values of the respective loads if all otherload components are zero, i.e. the listed axial forcemay be applied if the inplane, outplane and torsionalmoments, and the pressure are zero.
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2) The Conservative Allowable Simultaneous loads arethe maximum loads that can be applied simultaneously.A conservative stress combination equation is usedthat typically produces stresses within 50-70% of theallowable stress.
3) The Realistic Allowable Simultaneous loads are themaximum loads that can be applied simultaneously. Amore realistic stress combination equation is usedbased on experience at Paulin Research. Stresses aretypically produced within 80-105% of the allowable.
4) Secondary allowable loads are limits for expansionand operating piping loads.
5) Primary allowable loads are limits for weight,primary and sustained type piping loads.
Table of Contents
Flexibilities
The following stiffnesses should be used in a piping,"beam-type" analysis of the intersection. The stiff-nesses should be inserted at the surface of thebranch/header or nozzle/vessel junction. The generalcharacteristics used for the branch pipe should be:
Outside Diameter = 8.625 in.Wall Thickness = 0.214 in.
Axial Translational Stiffness = 519157. lb./in.Inplane Rotational Stiffness = 235239. in.lb./degOutplane Rotational Stiffness = 44442. in.lb./degTorsional Rotational Stiffness = 5304302. in.lb./deg
Table of Contents
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Finite Element Model
Finite Element Model• 1) Pl < 1.5(k)Smh (SUS Membrane) Case 2• 2) Qb < 3(Smh) (SUS Bending) Case 2• 3) Pl+Pb+Q < 3(Smavg) (OPE Inside) Case 3• 4) Pl+Pb+Q < 3(Smavg) (OPE Outside) Case 3• 10) Pl+Pb+Q < 3(Smavg) (EXP Inside) Case 4• 11) Pl+Pb+Q < 3(Smavg) (EXP Outside) Case 4• 12) Pl+Pb+Q+F < Sa (EXP Inside) Case 4• 13) Pl+Pb+Q+F < Sa (EXP Outside) Case 4• 5) Pl+Pb+Q+F < Sa (SIF Outside) Case 5• 6) Pl+Pb+Q+F < Sa (SIF Outside) Case 6• 7) Pl+Pb+Q+F < Sa (SIF Outside) Case 7• 8) Pl+Pb+Q+F < Sa (SIF Outside) Case 8• 9) Pl+Pb+Q+F < Sa (SIF Outside) Case 9•
Tabular Results
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Tube Side Flange (front)
ASME VIII-1, 2007 Edition, Appendix 2 Flange Calculations
Flange is attached to: Front Channel (Right)Flange type: Weld neck integralFlange material specification: SA-516 70 (II-D p. 18, ln. 22)
Bolt material specification: SA-193 B7 Bolt <= 2 1/2 (II-D p. 348,ln. 33)
Internal design pressure, P: 0 psi @ 414.5 °FLiquid static head acting on flange: 0.5739 psiRequired flange thickness: tr= 1.7279 inMaximum allowable working pressure,MAWP: 265.6 psi @ 414.5 °F
Maximum allowable pressure, MAP: 285.33 psi @ 70 °FExternal design pressure, Pe 13.18 psi @ 414.5 °FMaximum allowable external pressure,MAEP: 989.51 psi @ 414.5 °F
Corrosion allowance: Bore = 0 in Flange = 0 inBolt corrosion (root), Cbolt: 0 inDesign MDMT: -20 °F No impact test performedRated MDMT: -26.9 °F Flange material is not normalized
Material is not produced to fine grainpracticePWHT is not performed
Estimated weight: New = 50.7 lb corroded = 50.7 lb
Flange dimensions, new
flange OD A = 20.5 inbolt circle C = 19.25 ingasket OD = 18.125 ingasket ID = 17.25 inflange ID B = 17.25 inthickness t = 1.75 inbolting = 24- 0.625 in diahub thickness g1 = 0.1875 inhub thickness g0 = 0.125 inhub length h = 1.25 inlength e = 3 ingasket factor m = 3seating stress y = 5,000.00 psi
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Note: this flange is calculated as an integral type.
Determination of Flange MDMT
UCS-66(b)(1)(b) has been applied.Flange impact test exemption temperature from Fig UCS-66 Curve B = -20 °FFig UCS-66.1 MDMT reduction = 6.9 °F, (coincident ratio = 0.9308646)UCS-66 governing thickness = 0.125 inBolts rated MDMT per Fig UCS-66 note (e) = -55 °F
The rated flange MDMT is -26.9 °F
Flange calculations for Internal Pressure + Weight Only
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Gasket details from facing sketch 1(a) or (b), Column II
Gasket width N = 0.4375 in
b0 = N/2 = 0.2188 in
Effective gasket seating width, b = b0 = 0.2188 in
G = (OD of contact face + gasket ID) / 2 = 17.6875 in
hG = (C - G)/2 = (19.25 - 17.6875)/2 = 0.7813 in
hD = R + g1/2 = 0.8125 + 0.1875/2 = 0.9063 in
hT = (R + g1 + hG)/2 = (0.8125 + 0.1875 + 0.7813)/2 = 0.8906 in
Hp = 2*P*(b*3.14*G*m + br*rl*m')= 2*0.5739*(0.2188*3.14*17.6875*3 + 0.3188*23.25*3)= 67.35 lbf
H = 0.785*G2*P= 0.785*17.68752*0.5739= 140.94 lbf
HD = 0.785*B2*P= 0.785*17.252*0.5739= 134.06 lbf
HT = H - HD= 140.94 - 134.06= 6.89 lbf
Wm1 = H + Hp= 140.94 + 67.35= 208.29 lbf
Per VIII-1, Appendix 2-5(a)(2): Wm1 from the mating flange governs so Wm1 = 19,501.65 lbf
Wm2 = 3.14*b*G*y + br*rl*Y'= 3.14*0.2188*17.6875*5,000 + 0.3188*23.25*5,000= 97,800.2 lbf
The pass partition gasket load has been included in the calculation of Wm1 and Wm2 per TEMA RGP-RCB-11.7.
Required bolt area, Am = greater of Am1, Am2 = 3.912008 in2
Am1 = Wm1/Sb = 19,501.65/25,000 = 0.7801 in2
Am2 = Wm2/Sa = 97,800.2/25,000 = 3.912 in2
Total area for 24- 0.625 in dia bolts, corroded, Ab = 4.848 in2
W = (Am + Ab)*Sa/2= (3.912 + 4.848)*25,000/2= 109,500.1 lbf
MD = HD*hD = 134.06*0.9063 = 121.5 lb-in
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MT = HT*hT = 6.89*0.8906 = 6.1 lb-in
HG = Wm1 - H = 19,501.65 - 140.94 = 19,360.71 lbf
MG = HG*hG = 19,360.71*0.7813 = 15,125.6 lb-in
Mo = MD + MT + MG = 121.5 + 6.1 + 15,125.6 = 15,253.2 lb-in
Mg = W*hG = 109,500.1*0.7813 = 85,547 lb-in
The bolts are adequately spaced so the TEMA RCB-11.23 load concentration factor does not apply.
Hub and Flange Factors
h0 = (B*g0)1/2 = (17.25*0.125)1/2 = 1.4684 in
From FIG. 2-7.1, where K = A/B = 20.5/17.25 = 1.1884
T = 1.8436 Z = 5.8507 Y = 11.3396 U =12.4611
h/h0 = 0.8513 g1/g0 = 1.5
F = 0.8078 V = 0.2647 e = F/h0 = 0.5501
d = (U/V)*h0*g02= (12.46108/0.2647)*1.4684*0.1252
= 1.0802 in3
Stresses at operating conditions - VIII-1, Appendix 2-7
f = 1
L = (t*e + 1)/T + t3/d= (1.75*0.5501 + 1)/1.843613 + 1.753/1.0802= 6.026093
SH = f*Mo/(L*g12*B)
= 1*15,253.2/(6.026093*0.18752*17.25)= 4,174 psi
SR = (1.33*t*e + 1)*Mo/(L*t2*B)= (1.33*1.75*0.5501 + 1)*15,253.2/(6.026093*1.752*17.25)= 109 psi
ST = Y*Mo/(t2*B) - Z*SR= 11.3396*15,253.2/(1.752*17.25) - 5.8507*109= 2,635 psi
Allowable stress Sfo = 20,000 psiAllowable stress Sno = 20,000 psi
ST does not exceed SfoSH does not exceed Min[ 1.5*Sfo, 2.5*Sno ] = 30,000 psiSR does not exceed Sfo0.5(SH + SR) = 2,142 psi does not exceed Sfo0.5(SH + ST) = 3,404 psi does not exceed Sfo
Stresses at gasket seating - VIII-1, Appendix 2-7
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SH = f*Mg/(L*g12*B)
= 1*85,547/(6.026093*0.18752*17.25)= 23,409 psi
SR = (1.33*t*e + 1)*Mg/(L*t2*B)= (1.33*1.75*0.5501 + 1)*85,547/(6.026093*1.752*17.25)= 613 psi
ST = Y*Mg/(t2*B) - Z*SR= 11.3396*85,547/(1.752*17.25) - 5.8507*613= 14,777 psi
Allowable stress Sfa = 20,000 psiAllowable stress Sna = 20,000 psi
ST does not exceed SfaSH does not exceed Min[ 1.5*Sfa, 2.5*Sna ] = 30,000 psiSR does not exceed Sfa0.5(SH + SR) = 12,011 psi does not exceed Sfa0.5(SH + ST) = 19,093 psi does not exceed Sfa
Flange rigidity per VIII-1, Appendix 2-14
J = 52.14*V*Mo/(L*E*g02*KI*h0)
= 52.14*0.2647*85,547/(6.0261*29,400,000*0.1252*0.3*1.4684)= 0.9681055
The flange rigidity index J does not exceed 1; satisfactory.
Flange calculations for External Pressure + Weight Only per VIII-1, Appendix 2-11
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Gasket details from facing sketch 1(a) or (b), Column II
Gasket width N = 0.4375 in
b0 = N/2 = 0.2188 in
Effective gasket seating width, b = b0 = 0.2188 in
G = (OD of contact face + gasket ID) / 2 = 17.6875 in
hG = (C - G)/2 = (19.25 - 17.6875)/2 = 0.7813 in
hD = R + g1/2 = 0.8125 + 0.1875/2 = 0.9063 in
hT = (R + g1 + hG)/2 = (0.8125 + 0.1875 + 0.7813)/2 = 0.8906 in
Hp = 2*P*(b*3.14*G*m + br*rl*m')= 2*13.1759*(0.2188*3.14*17.6875*3 + 0.3188*23.25*3)= 1,546.33 lbf
H = 0.785*G2*P= 0.785*17.68752*13.1759= 3,235.81 lbf
HD = 0.785*B2*P= 0.785*17.252*13.1759= 3,077.71 lbf
HT = H - HD= 3,235.81 - 3,077.71= 158.1 lbf
Wm1 = H + Hp= 3,235.81 + 1,546.33= 4,782.14 lbf
Wm2 = 3.14*b*G*y + br*rl*Y'= 3.14*0.2188*17.6875*5,000 + 0.3188*23.25*5,000= 97,800.2 lbf
The pass partition gasket load has been included in the calculation of Wm1 and Wm2 per TEMA RGP-RCB-11.7.
Required bolt area, Am = greater of Am1, Am2 = 3.912008 in2
Am1 = 0.785*G2*(Pm - Pr)/Sb = 0/25,000 = 0 in2
Am2 = Wm2/Sa = 97,800.2/25,000 = 3.912 in2
Total area for 24- 0.625 in dia bolts, corroded, Ab = 4.848 in2
W = (Am2 + Ab)*Sa/2= (3.912 + 4.848)*25,000/2= 109,500.1 lbf
Mo = HD*(hD - hG) + HT*(hT - hG)= 3,077.71*(0.9063 - 0.7813) + 158.1*(0.8906 - 0.7813)= 402 lb-in
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Mg = W*hG = 109,500.1*0.7813 = 85,547 lb-in
The bolts are adequately spaced so the TEMA RCB-11.23 load concentration factor does not apply.
Hub and Flange Factors
h0 = (B*g0)1/2 = (17.25*0.125)1/2 = 1.4684 in
From FIG. 2-7.1, where K = A/B = 20.5/17.25 = 1.1884
T = 1.8436 Z = 5.8507 Y = 11.3396 U =12.4611
h/h0 = 0.8513 g1/g0 = 1.5
F = 0.8078 V = 0.2647 e = F/h0 = 0.5501
d = (U/V)*h0*g02= (12.46108/0.2647)*1.4684*0.1252
= 1.0802 in3
Stresses at operating conditions - VIII-1, Appendix 2-7
f = 1
L = (t*e + 1)/T + t3/d= (1.75*0.5501 + 1)/1.843613 + 1.753/1.0802= 6.026093
SH = f*Mo/(L*g12*B)
= 1*402/(6.026093*0.18752*17.25)= 110 psi
SR = (1.33*t*e + 1)*Mo/(L*t2*B)= (1.33*1.75*0.5501 + 1)*402/(6.026093*1.752*17.25)= 3 psi
ST = Y*Mo/(t2*B) - Z*SR= 11.3396*402/(1.752*17.25) - 5.8507*3= 69 psi
Allowable stress Sfo = 20,000 psiAllowable stress Sno = 20,000 psi
ST does not exceed SfoSH does not exceed Min[ 1.5*Sfo, 2.5*Sno ] = 30,000 psiSR does not exceed Sfo0.5(SH + SR) = 56 psi does not exceed Sfo0.5(SH + ST) = 90 psi does not exceed Sfo
Stresses at gasket seating - VIII-1, Appendix 2-7
SH = f*Mg/(L*g12*B)
= 1*85,547/(6.026093*0.18752*17.25)= 23,409 psi
SR = (1.33*t*e + 1)*Mg/(L*t2*B)= (1.33*1.75*0.5501 + 1)*85,547/(6.026093*1.752*17.25)= 613 psi
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ST = Y*Mg/(t2*B) - Z*SR= 11.3396*85,547/(1.752*17.25) - 5.8507*613= 14,777 psi
Allowable stress Sfa = 20,000 psiAllowable stress Sna = 20,000 psi
ST does not exceed SfaSH does not exceed Min[ 1.5*Sfa, 2.5*Sna ] = 30,000 psiSR does not exceed Sfa0.5(SH + SR) = 12,011 psi does not exceed Sfa0.5(SH + ST) = 19,093 psi does not exceed Sfa
Flange rigidity per VIII-1, Appendix 2-14
J = 52.14*V*Mo/(L*E*g02*KI*h0)
= 52.14*0.2647*85,547/(6.0261*29,400,000*0.1252*0.3*1.4684)= 0.9681055
The flange rigidity index J does not exceed 1; satisfactory.
Tube Side Flange (front) - Flange hub
ASME Section VIII Division 1, 2007 Edition
Component: Flange hubMaterial specification: SA-516 70 (II-D p. 18, ln. 22)Material is impact test exempt per UG-20(f)UCS-66 governing thickness = 0.125 in
Internal design pressure: P = 0 psi @ 414.5°FExternal design pressure: Pe = 13.1759 psi @ 414.5°F
Static liquid head:
Not Considered
Corrosion allowance: Inner C = 0.0000" Outer C = 0.0000"
Design MDMT = -20.00°F No impact test performedRated MDMT = -20.00°F Material is not normalized
Material is not produced to Fine Grain PracticePWHT is not performed
Radiography: Longitudinal joint - Seamless No RTLeft circumferential joint - Full UW-11(a) Type 1Right circumferential joint - N/A
Estimated weight: New = 2.3963 lb corr = 2.3963 lbCapacity: New = 1.2646 gal corr = 1.2646 galID = 17.2500"Length Lc = 1.2500"t = 0.1250"
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Design thickness, (at 414.50°F) UG-27(c)(1)
t = P*R/(S*E - 0.60*P) + Corrosion= 0.57*8.6250/(20000*1.00 - 0.60*0.57) + 0.0000= 0.0003"
Maximum allowable working pressure, (at 414.50°F) UG-27(c)(1)
P = S*E*t/(R + 0.60*t) - Ps= 20000*1.00*0.1250 / (8.6250 + 0.60*0.1250) - 0.5739= 286.7824 psi
Maximum allowable pressure, (at 70.00°F) UG-27(c)(1)
P = S*E*t/(R + 0.60*t)= 20000*1.00*0.1250 / (8.6250 + 0.60*0.1250)= 287.3563 psi
External Pressure, (Corroded & at 414.50°F) UG-28(c)
L/Do = 29.7083/17.5000 = 1.6976Do/t = 17.5000/0.067955 = 257.5244
From table G: A = 0.000186From table CS-2: B = 2544.8130 psi
Pa = 4*B/(3*(Do/t))= 4*2544.8130/(3*(17.5000/0.067955))= 13.1758 psi
Design thickness for external pressure Pa = 13.1758 psi
= t + Corrosion = 0.067955 + 0.0000 = 0.0680"
Maximum Allowable External Pressure, (Corroded & at 414.50°F) UG-28(c)
L/Do = 29.7083/17.5000 = 1.6976Do/t = 17.5000/0.1250 = 140.0000
From table G: A = 0.000467From table CS-2: B = 6426.6948 psi
Pa = 4*B/(3*(Do/t))= 4*6426.6948/(3*(17.5000/0.1250))= 61.2066 psi
% Extreme fiber elongation - UCS-79(d)
= (50 * t / Rf) * (1 - Rf / Ro)= (50 * 0.1250 / 8.6875) * (1 - 8.6875 / ∞)= 0.7194 %
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Allowable Compressive Stress, Hot and Corroded- ScHC, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (8.7500 / 0.1250)= 0.001786
B = 12529.6797 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScHC = 12529.6797 psi
Allowable Compressive Stress, Hot and New- ScHN
ScHN = ScHC
= 12529.6797 psi
Allowable Compressive Stress, Cold and New- ScCN, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (8.7500 / 0.1250)= 0.001786
B = 14521.1133 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScCN = 14521.1133 psi
Allowable Compressive Stress, Cold and Corroded- ScCC
ScCC = ScCN
= 14521.1133 psi
Allowable Compressive Stress, Vacuum and Corroded- ScVC, (table CS-2)A = 0.125 / (Ro / t)
= 0.125 / (8.7500 / 0.1250)= 0.001786
B = 12529.6797 psi
S = 20000.0000 / 1.0000= 20000.0000 psi
ScVC = 12529.6797 psi
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Saddle
Saddle material: A36Saddle construction is: Web at edge of ribSaddle allowable stress: Ss = 24,000 psiSaddle yield stress: Sy = 36,000 psiSaddle distance to datum: 6.7646 inTangent to tangent length: L = 107.4892inSaddle separation: Ls = 34.5778 inVessel radius: R = 13.5292 inTangent distance left: Al = 64.1469 inTangent distance right: Ar = 8.7646 inTubesheet distance left: Atsl = 35.389 inSaddle height: Hs = 25.5292 inSaddle contact angle: θ = 120 °Wear plate thickness: tp = 0.25 inWear plate width: Wp = 5 inWear plate contact angle: θw = 132 °Web plate thickness: ts = 0.25 inBase plate length: E = 27 inBase plate width: F = 4 inBase plate thickness: tb = 0.375 inNumber of stiffener ribs: n = 2Largest stiffener rib spacing: di = 25.75 inStiffener rib thickness: tw = 0.25 inSaddle width: B = 3 inAnchor bolt size & type: 1 inch series 8 threadedAnchor bolt material: SA-193 B8Anchor bolt allowable shear: 18,800 psiAnchor bolt corrosion allowance: 0 inAnchor bolts per saddle: 4Base coefficient of friction: µ = 0.45
Weight on left saddle: operating corr =3,362 lb, test new =3,828 lbWeight on right saddle: operating corr =-473 lb, test new =-557 lbWeight of saddle pair =108 lb
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Notes:(1) Saddle calculations are based on the method presented in "Stresses in Large Cylindrical Pressure Vessels onTwo Saddle Supports" by L.P. Zick.(2) If CL of tubesheet is located within a distance of Ro/2 to CL of saddle, the shell is assumed stiffened as iftubesheet is a bulk head.
Load Vesselcondition
Bending + pressurebetween saddles
(psi)
Bending + pressure atthe saddle
(psi)
S1(+)
allow(+)
S1(-)
allow(-)
S2(+)
allow(+)
S2(-)
allow(-)
Weight Operating 5,944 20,000 -219 8,298 20,697 20,000 14,533 8,298
Weight Test 3,846 34,200 -130 8,323 12,241 34,200 8,266 8,323
Load Vesselcondition
Tangentialshear (psi)
Circumferentialstress (psi)
Stressover
saddle(psi)
Splitting(psi)
S3 allow S4(horns)
S4(Wearplate)
allow(+/-) S5 allow S6 allow
Weight Operating 2,326 16,000 -4,642 -59,320 30,000 2,366 16,750 288 16,000
Weight Test 1,335 27,360 -21,007 NA 34,200 2,062 32,400 328 32,400
Load Case 1: Weight ,Operating
Longitudinal stress between saddles (Weight ,Operating, right saddle loading and geometry govern)
S1 = +- 3*K1*Q*(L/12) / (π*R2*t)= 3*0.6175*-473*(107.4892/12) / (π*13.49792*0.0625)= -219 psi
Sp = P*R/(2*t)= 57.21*13.4667/(2*0.0625)= 6,164 psi
Maximum tensile stress S1t = S1 + Sp = 5,944 psiMaximum compressive stress (shut down) S1c = S1 = -219 psi
Tensile stress is acceptable (<=1*S*E = 20,000 psi)Compressive stress is acceptable (<=1*Sc = 8,298 psi)
Longitudinal stress at the left saddle (Weight ,Operating)
Le = 2*(Left head depth)/3 + L + 2*(Right head depth)/3= 2*4.4375/3 + 107.4892 + 2*6.8271/3= 114.999 in
w = Wt/Le = 2,889/114.999 = 25.12 lb/in
Bending moment at the left saddle:
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Mq = w*(2*H*Al/3 + Al2/2 - (R2 - H2)/4)
= 25.12*(2*4.4375*64.1469/3 + 64.14692/2 - (13.52922 - 4.43752)/4)= 55,427.7 lb-in
S2 = +- Mq*K1'/ (π*R2*t)= 55,427.7*9.3799/ (π*13.49792*0.0625)= 14,533 psi
Sp = P*R/(2*t)= 57.21*13.4667/(2*0.0625)= 6,164 psi
Maximum tensile stress S2t = S2 + Sp = 20,697 psiMaximum compressive stress (shut down) S2c = S2 = 14,533 psi
** WARNING Tensile stress at the saddle is excessive (> 20,000 psi)**
** WARNING Compressive stress at the saddle is excessive (> 8,298 #)**
Tangential shear stress in the shell (left saddle, Weight ,Operating)
Qshear = Q - w*(a + 2*H/3)= 3,362 - 25.12*(64.1469 + 2*4.4375/3)= 1,676.18 lbf
S3 = K2.2*Qshear/(R*t)= 1.1707*1,676.18/(13.4979*0.0625)= 2,326 psi
Tangential shear stress is acceptable (<= 0.8*S = 16,000 psi)
Circumferential stress at the left saddle horns (Weight ,Operating)
S4 = -Q/(4*(t+tp)*(b+1.56*Sqr(Ro*t))) - 12*K3*Q*R/(L*(t2+tp2))= -3,362/(4*(0.0625+0.25)*(3+1.56*Sqr(13.5292*0.0625))) - 12*0.0529*3,362*13.4979/(107.4892*(0.06252+0.252))= -4,642 psi
Circumferential stress at saddle horns is acceptable (<=1.5*Sa = 30,000 psi)
Circumferential stress at the left saddle wear plate horns (Weight ,Operating)
S4 = -Q/(4*t*(b+1.56*Sqr(Ro*t))) - 12*K3*Q*R/(L*t2)= -3,362/(4*0.0625*(3+1.56*Sqr(13.5292*0.0625))) - 12*0.0434*3,362*13.4979/(107.4892*0.06252)= -59,320 psi
** WARNING Circumferential stress at the wear plate horns is excessive (> 30,000 psi)**
Ring compression in shell over left saddle (Weight ,Operating)
S5 = K5*Q/((t + tp)*(ts + 1.56*Sqr(Ro*tc)))= 0.7603*3,362/((0.0625 + 0.25)*(0.25 + 1.56*Sqr(13.5292*0.3125)))= 2,366 psi
Ring compression in shell is acceptable (<= 0.5*Sy = 16,750 psi)
202/226
Saddle splitting load (left, Weight ,Operating)
Area resisting splitting force = Web area + wear plate area
Ae = Heff*ts + tp*Wp= 4.5097*0.25 + 0.25*5= 2.3774 in2
S6 = K8*Q / Ae= 0.2035*3,362 / 2.3774= 288 psi
Stress in saddle is acceptable (<= (2/3)*Ss = 16,000 psi)
Load Case 2: Weight ,Test
Longitudinal stress between saddles (Weight ,Test, right saddle loading and geometry govern)
S1 = +- 3*K1*Q*(L/12) / (π*R2*t)= 3*0.6175*-557*(107.4892/12) / (π*13.46672*0.125)= -130 psi
Sp = P*R/(2*t)= 74.15*13.4042/(2*0.125)= 3,976 psi
Maximum tensile stress S1t = S1 + Sp = 3,846 psiMaximum compressive stress (shut down) S1c = S1 = -130 psi
Tensile stress is acceptable (<= 0.9*Sy = 34,200 psi)Compressive stress is acceptable (<=1*Sc = 8,323 psi)
Longitudinal stress at the left saddle (Weight ,Test)
Le = 2*(Left head depth)/3 + L + 2*(Right head depth)/3= 2*4.4375/3 + 107.4892 + 2*6.8271/3= 114.999 in
w = Wt/Le = 3,271/114.999 = 28.44 lb/in
Bending moment at the left saddle:
Mq = w*(2*H*Al/3 + Al2/2 - (R2 - H2)/4)
= 28.44*(2*4.4375*64.1469/3 + 64.14692/2 - (13.52922 - 4.43752)/4)= 62,756.7 lb-in
S2 = +- Mq*K1'/ (π*R2*t)= 62,756.7*9.3799/ (π*13.46672*0.125)= 8,266 psi
Sp = P*R/(2*t)= 74.15*13.4042/(2*0.125)= 3,976 psi
Maximum tensile stress S2t = S2 + Sp = 12,241 psiMaximum compressive stress (shut down) S2c = S2 = 8,266 psi
203/226
Tensile stress is acceptable (<= 0.9*Sy = 34,200 psi)Compressive stress is acceptable (<=1*Sc = 8,323 psi)
Tangential shear stress in the shell (left saddle, Weight ,Test)
Qshear = Q - w*(a + 2*H/3)= 3,828 - 28.44*(64.1469 + 2*4.4375/3)= 1,919.28 lbf
S3 = K2.2*Qshear/(R*t)= 1.1707*1,919.28/(13.4667*0.125)= 1,335 psi
Tangential shear stress is acceptable (<= 0.8*(0.9*Sy) = 27,360 psi)
Circumferential stress at the left saddle horns (Weight ,Test)
S4 = -Q/(4*t*(b+1.56*Sqr(Ro*t))) - 12*K3*Q*R/(L*t2)= -3,828/(4*0.125*(3+1.56*Sqr(13.5292*0.125))) - 12*0.0529*3,828*13.4667/(107.4892*0.1252)= -21,007 psi
Circumferential stress at saddle horns is acceptable (<= 0.9*Sy = 34,200 psi)The wear plate was not considered in the calculation of S4 because the wear plate width is not at least {B +1.56*(Rotc)0.5} =5.0287 in
Ring compression in shell over left saddle (Weight ,Test)
S5 = K5*Q/((t + tp)*(ts + 1.56*Sqr(Ro*tc)))= 0.7603*3,828/((0.125 + 0.25)*(0.25 + 1.56*Sqr(13.5292*0.375)))= 2,062 psi
Ring compression in shell is acceptable (<= 0.9*Sy = 32,400 psi)
Saddle splitting load (left, Weight ,Test)
Area resisting splitting force = Web area + wear plate area
Ae = Heff*ts + tp*Wp= 4.5097*0.25 + 0.25*5= 2.3774 in2
S6 = K8*Q / Ae= 0.2035*3,828 / 2.3774= 328 psi
Stress in saddle is acceptable (<= 0.9*Sy = 32,400 psi)
Shear stress in anchor bolting, one end slotted
Maximum seismic or wind base shear = 0 lbf
Thermal expansion base shear = W*µ = 3,416 * 0.45= 1,537.2 lbf
Corroded root area for a 1 inch series 8 threaded bolt = 0.551 in2 ( 4 per saddle )
Bolt shear stress = 1,537.2/(0.551*4) = 697 psi
204/226
Anchor bolt stress is acceptable (<= 18,800 psi)
Web plate buckling check (Escoe pg 251)
Allowable compressive stress Sc is the lesser of 24,000 or 3,162 psi: (3,162)
Sc = Ki*π2*E/(12*(1 - 0.32)*(di/tw)2)= 1.28*π2*29E+06/(12*(1 - 0.32)*(25.75/0.25)2)= 3,162 psi
Allowable compressive load on the saddle
be = di*ts/(di*ts + 2*tw*(b - 1))= 25.75*0.25/(25.75*0.25 + 2*0.25*(3 - 1))= 0.8655
Fb = n*(As + 2*be*tw)*Sc= 2*(0.6875 + 2*0.8655*0.25)*3,162= 7,085.4 lbf
Saddle loading of 3,882 lbf is <= Fb; satisfactory.
Primary bending + axial stress in the saddle due to end loads (assumes one saddle slotted)σb = V * (Hs - xo)* y / I + Q / A= 0 * (25.5292 - 11.1885)* 2.125 / 2.42 + 3,362 / 7.2333= 465 psi
The primary bending + axial stress in the saddle <= 24,000 psi; satisfactory.
Secondary bending + axial stress in the saddle due to end loads (includes thermal expansion, assumes onesaddle slotted)σb = V * (Hs - xo)* y / I + Q / A= 1,537.2 * (25.5292 - 11.1885)* 2.125 / 2.42 + 3,362 / 7.2333= 19,817 psi
The secondary bending + axial stress in the saddle < 2*Sy= 72,000 psi; satisfactory.
Saddle base plate thickness check (Roark sixth edition, Table 26, case 7a)
where a = 25.75, b = 3.75 in
tb = (β1*q*b2/(1.5*Sa))0.5
= (3*36*3.752/(1.5*24,000))0.5
= 0.2052 in
The base plate thickness of 0.375 in is adequate.
Foundation bearing check
Sf = Qmax / (F*E)= 3,882 / (4*27)= 36 psi
Concrete bearing stress < 1,658 psi ; satisfactory.
205/226
Data Inputs Summary
General Options
Identifier Kettle reboiler
Codes ASME VIII-1,2007 Edition TEMA Eighth Edition (1999)
Description U-tube Class C Kettle, transition front end only SIZE 17-72.0008 TYPE BKU
Shell material: SA-516 70 Perform ASME tube design check
Tube supports\baffle plates are not present
Tube Options
Tube material: SA-179 Smls tube Tube length from outer tubesheet face to bend: L t= 72.0008in
Tube dimensions, new, in do= 1 tt= 0.091 Inner corrosion: 0 Outer corrosion: 0
Tube to tubesheet joint option Tube to tubesheet joint calculations have not been performed
Channel and Shell Options
Shell dimensionsnew, in
Material:SA-516 70 Di= 26.8083 ts= 0.125 Inner corrosion: 0.0625 Outer corrosion: 0 MDMT:
-20 °F
Front channeldimensions, new, in
Type: bonnet Ellipsoidal head Inner corrosion: 0.0625 Outer corrosion: 0 MDMT: -20 °F
Cylinder SA-516 70 Di= 17.25 tc= 0.1875 L= 23.25
Closure SA-516 70 Di= 17.25 tmin= 0.125 LSF= 2
Tubesheet Options
Tube Layout Shear doesnot govern Tube count: 116 Tube pitch: 1.25 in Pattern: 30° (triangular)
Tubesheet dimensions,in
(front and rear)
Material:SA-516 70 T = 1.0158 OD = 17.625
Shell sidecorrosion =
0.0625
Tube sidecorrosion =
0.0625MDMT = -20 °F
Tubesheetpass groove
depth =0.1875
Impact test isnot
performed
Notnormalized
Not produced fine grainpractice PWHT not performed Gasketed shell
sideGasketed tube
side
206/226
Design Conditions Summary
Design Conditions
Description Design Condition 1 Tube side hydrotest Shell sidehydrotest
Tube Side
Pressure (psi) -13.18 37.24 0
Design temperature (°F) 414.5 70 70
Et (psi) 28,219,040 29,400,000 29,400,000
St (psi) 13,400 23,400 23,400
Shell Side
Pressure (psi) 60.3 0 73.98
Design temperature (°F) 307.57 70 70
Es (psi) 28,270,240 29,400,000 29,400,000
Ss (psi) 20,000 34,200 34,200
TubesheetDesign temperature (°F) 414.5 70 70
E (psi) 28,214,560 29,400,000 29,400,000
S (psi) 20,000 34,200 34,200
207/226
Liquid Level bounded by Rear Channel Head
Location from Center Line 19.5292"
Operating Liquid Specific Gravity 0.9145Test liquid specific gravity 1.0000
208/226
Liquid Level bounded by Tubesheet
Location from Center Line 14.7500"
Operating Liquid Specific Gravity 0.6802Test liquid specific gravity 1.0000
209/226
Materials and Gaskets Summary
Materials And Gaskets
Part Quantity Size Material Gasket
Front ellipsoidal head 1 17.25 ID x 0.125 in min thk SA-516 70 -
Front channel cylinder 1 17.25 ID x 0.1875 thkx 23.25 in SA-516 70 -
Tube Side Flange (front) 1 20.50 OD x 1.75 in thk SA-516 7018.13 OD x 17.25
ID inFront tubesheet 1 17.63 OD x 1.0158 in thk SA-516 70
Shell Side Flange (front) 1 20.50 OD x 1.75 in thk SA-516 70 18.13 OD x 17.25ID in
Front Tubesheet flange bolts 24 0.625 in dia. stud x 6.88 in long SA-193 B7 -
Tubes 58 1.00 OD x 0.091 wall in SA-179 Smls tube -
Shell cylinder 1 26.81 ID x 0.125 in thkx 48.11 in SA-516 70 -
Rear ellipsoidal head 1 26.81 ID x 0.125 in min thk SA-516 70 -
Front pass partition - 0.375 in thk SA-516 70 -
210/226
Nozzle Materials And Gaskets
Part Quantity Size Material Gasket
TS Inlet (N1) 1 16 in 150# WN A105-
1 13.88 ID x 1.062 in wall SA-455 <= 3/8
Bolts for TS Inlet (N1) 16 1 in dia. bolt x 4.5 in long SA-193 B7
TS Outlet (N2) 1 8 in 150# WN A105-
1 8.07 ID x 0.277 in wall SA-455 <= 3/8
Bolts for TS Outlet (N2) 8 0.75 in dia. bolt x 3.5 in long SA-193 B7
SS Outlet (N3) 1 8 in 150# WN A105-
1 8.00 ID x 0.312 in wall SA-455 <= 3/8
Bolts for SS Outlet (N3) 8 0.75 in dia. bolt x 3.5 in long SA-193 B7
SS Inlet (N4) 1 4 in 150# WN A105-
1 4.00 ID x 0.25 in wall SA-455 <= 3/8
Bolts for SS Inlet (N4) 8 0.625 in dia. bolt x 3 in long SA-193 B7
SS Outlet 2 (N5) 1 8 in 150# WN A105-
1 7.63 ID x 0.5 in wall SA-455 ( 3/8 < t <= 0.58)
Bolts for SS Outlet 2 (N5) 8 0.75 in dia. bolt x 3.5 in long SA-193 B7
211/226
TEMA RCB-9.132 Pass Partition Plate Calculations
Minimum Front Pass Partition Plate Thickness
Front tube side pressure drop: q = 0.2976 psiFront pass plate material: SA-516 70 (II-D p. 18, ln. 22)Front pass plate allowable stress: S = 20,000 psiFront pass plate dimension: a = 17.1875inFront pass plate dimension: b = 29.8125inFront pass plate thickness, new: T = 0.375 inFront pass plate corrosion allowance: C = 0.125 inFront pass plate fillet weld leg size, new 0.25 in
From TABLE RCB-9.131
t = 0.375
From TABLE RCB-9.132, three sides fixed, a/b = 0.5765, B = 0.1092
t = b*(q*B/(1.5*S))1/2 + C= 29.8125*(0.2976*0.1092/(1.5*20,000.00))1/2 + 0.125= 0.156 in
The pass partition plate thickness of 0.375 in is adequate.
Pass partition minimum weld size = 0.75*t + C/0.7= 0.2018 in
The pass partition fillet weld size of 0.25 in is adequate.
212/226
Tubes
ASME Section VIII Division 1, 2007 Edition
Component: TubesMaterial specification: SA-179 Smls tube (II-D p. 6, ln. 11)Material is impact test exempt per UCS-66(d) (NPS 4 or smaller pipe)
Internal design pressure: P = 0 psi @ 414.5°FExternal design pressure: Pe = 73.48 psi @ 414.5°F
Static liquid head:
Ps =0.5650 psi (SG=0.6802, Hs=23.0125" Operating head)Pse =0.9174 psi (SG=0.9145, Hs=27.7916" Vacuum head)Pth =0.8307 psi (SG=1.0000, Hs=23.0125", Horizontal test head)
Corrosion allowance: Inner C = 0.0000" Outer C = 0.0000"
Design MDMT = -20.00°F No impact test performedRated MDMT = -155.00°F Material is not normalized
Material is not produced to Fine Grain PracticePWHT is not performed
Estimated weight: New = 6.8436 lb corr = 6.8436 lbCapacity: New = 0.2117 gal corr = 0.2117 galOD = 1.0000"Length Lc = 72.0008"t = 0.0910"
Design thickness, (at 414.50°F) Appendix 1-1
t = P*Ro/(S*E + 0.40*P) + Corrosion= 0.56*0.5000/(13400*1.00 + 0.40*0.56) + 0.0000= 0.0001"
Maximum allowable working pressure, (at 414.50°F) Appendix 1-1
P = S*E*t/(Ro - 0.40*t) - Ps= 13400*1.00*0.0796 / (0.5000 - 0.40*0.0796) - 0.5650= 2278.5703 psi
Maximum allowable pressure, (at 70.00°F) Appendix 1-1
P = S*E*t/(Ro - 0.40*t)= 13400*1.00*0.0796 / (0.5000 - 0.40*0.0796)= 2279.1355 psi
External Pressure, (Corroded & at 414.50°F) UG-28(c)
L/Do = 72.0008/1.0000 = 50.0000Do/t = 1.0000/0.015055 = 66.4232
From table G: A = 0.000263From table CS-1: B = 3706.3921 psi
Pa = 4*B/(3*(Do/t))
213/226
= 4*3706.3921/(3*(1.0000/0.015055))= 74.3996 psi
Design thickness for external pressure Pa = 74.3996 psi
= t + Corrosion = 0.015055 + 0.0000 = 0.0151"
Maximum Allowable External Pressure, (Corroded & at 414.50°F) UG-28(c)
L/Do = 72.0008/1.0000 = 50.0000Do/t = 1.0000/0.0796 = 12.5588
From table G: A = 0.007927
From table CS-1: B = 12430.4736psi
Pa = 4*B/(3*(Do/t)) - Pse
= 4*12430.4736/(3*(1.0000/0.0796)) -0.9174
= 1318.7872 psi
214/226
Tubesheet -- ASME
ASME Section VIII, Division 1, 2007 Edition
TubesheetType of heat exchanger: U-Tube
Type of construction: Fig. UHX-12.1 Configuration d:tubesheet gasketed with shell and channel
Simply supported: NoTubesheet material specification: SA-516 70 (II-D p. 18, ln. 22)Tube layout: TriangularTubesheet outer diameter, A: 17.625 inTubesheet thickness, h: 1.0158 in (tdesign = 1.0125 in)Number of tubes, Nt: 116Tube pitch, p: 1.25 inRadius to outer tube center, ro: 7.7625 inTotal area of untubed lanes, AL: 0 in2
Pass partition groove depth, hg: 0.1875 inCorrosion allowance shell side , cs: 0.0625 inCorrosion allowance tube side , ct: 0.0625 inTubesheet poisson's ratio, ν: 0.31Gasket groove depth shell side: 0.1875 inGasket groove depth tube side: 0.1875 in
Port cylinderPort cylinder material specification: SA-516 70 (II-D p. 18, ln. 22)Port cylinder inner diameter, Ds: 17.25 inPort cylinder thickness, ts: 0.125 inPort cylinder inner corrosion allowance: 0.0625 inPort cylinder outer corrosion allowance: 0 inPort cylinder poisson's ratio, νs: 0.31
ChannelChannel material specification: SA-516 70 (II-D p. 18, ln. 22)Channel inner diameter, Dc: 17.25 inChannel thickness, tc: 0.1875 inChannel inner corrosion allowance: 0.0625 inChannel outer corrosion allowance: 0 inChannel poisson's ratio, νc: 0.31
TubesTube material specification: SA-179 Smls tube (II-D p. 6, ln. 11)Tube outer diameter, dt: 1 inTube nominal thickness, tt: 0.091 inTube inner corrosion allowance: 0 inTube outer corrosion allowance: 0 inTube expansion depth ratio, ρ: 0.85Tube poisson's ratio, νt: 0.31
FlangeBolt circle diameter, C: 19.25 inShell side gasket load reaction diameter, Gs: 17.6875 inChannel side gasket load reaction diameter,Gc:
17.6875 in
Tube SupportsTube supports present: No
215/226
Summary Tables
Tubesheet DesignThickness Summary
Condition tdesign(in)
Design Condition 1 1.0124588
Tube side hydrotest 0.6183662
Shell side hydrotest 0.7967882
Bolt Load Summary
Condition Load CaseShell design bolt load
Ws(lbf)
Channel designbolt load
Wc(lbf)
Design Condition 1 All load cases 109,500.1 109,500.1
Tube side hydrotest Load case 1 109,500.1 109,500.1
Shell side hydrotest Load case 2 109,500.1 109,500.1
Pressures and Temperatures
Condition
Shell side designpressure
Ps(psi)
Tube side designpressure
Pt(psi)
Tubesheet designtemp
T(°F)
Shell designtemp
Ts(°F)
Channel designtemp
Tc(°F)
Tube designtemp
Tt(°F)
Design Condition 1 60.3 -13.18 414.5 307.57 414.5 414.5
Tube sidehydrotest 0 37.24 70 70 70 70
Shell sidehydrotest 73.98 0 70 70 70 70
Material Properties
Condition Component MaterialModulus ofElasticity
(psi)
AllowableStress(psi)
YieldStress(psi)
Design Condition 1
Port cylinder SA-516 70 Es = 28,269,720 Ss = 20,000 Sy,s =33,500
Channel SA-516 70 Ec =27,813,000 Sc =20,000 Sy,c =32,300
Tubesheet SA-516 70 E =27,813,000 S =20,000 S =32,300
Tubes SA-179 Smls tube Et =27,813,000 St =13,400 Sy,t =22,100
Tube side hydrotest
Port cylinder SA-516 70 Es = 29.4E+06 Ss = 34,200 Sy,s =38,000
Channel SA-516 70 Ec =29.4E+06 Sc =34,200 Sy,c =38,000
Tubesheet SA-516 70 E =29.4E+06 S =34,200 S =38,000
Tubes SA-179 Smls tube Et =29.4E+06 St =23,400 Sy,t =26,000
Shell side hydrotest
Port cylinder SA-516 70 Es = 29.4E+06 Ss = 34,200 Sy,s =38,000
Channel SA-516 70 Ec =29.4E+06 Sc =34,200 Sy,c =38,000
Tubesheet SA-516 70 E =29.4E+06 S =34,200 S =38,000
Tubes SA-179 Smls tube Et =29.4E+06 St =23,400 Sy,t =26,000
Calculations for Design Condition 1 Condition
216/226
UHX-12.5.1 Step 1
Do = 2*ro + dt
µ = (p - dt) / p
d* = MAX{[dt - 2*tt*(Et / E)*(St / S)*ρ], [dt - 2*tt]}
p* = p /(1 - 4*MIN(AL, 4*Do*p) /(π*Do2))0.5
µ* = (p* - d*)/p*
hg' = MAX[(hg - ct), 0]
Condition Design Condition 1
New or corroded Do = 2*7.7625 + 1 = 16.525
New or corroded µ = (1.25 - 1) /1.25 = 0.2
Newd* = MAX{[1 - 2*0.091*(27,813,000 / 27,813,000)*(13,400 / 20,000)*0.85],
[1 - 2*0.091]} = 0.896349
Corrodedd* = MAX{[1 - 2*0.091*(27,813,000 / 27,813,000)*(13,400 / 20,000)*0.8991],
[1 - 2*0.091]} = 0.8903604
New or corroded p* = 1.25 /(1 - 4*MIN(0, 4*16.525*1.25) /(π*16.5252))0.5 = 1.25
New µ* = (1.25 - 0.896349)/1.25 = 0.282921
Corroded µ* = (1.25 - 0.8903604)/1.25 = 0.287712
hg' = 0.125
UHX-12.5.2 Step 2
ρs = Gs / Do
ρc = Gc / Do
MTS = Do2 / 16 *[(ρs -1)*(ρs
2 + 1)*Ps - (ρc - 1)*(ρc2 + 1)*Pt]
Condition Design Condition 1
New orcorroded
All loadcases ρs = 17.6875 / 16.525 = 1.0703
New orcorroded
All loadcases ρc = 17.6875 / 16.525 = 1.0703
New orcorroded
Load case 1MTS = 16.5252 / 16 *[(1.0703481 -1)*(1.07034812 + 1)*0 - (1.0703481 -
1)*(1.07034812 + 1)*-13.18] = 33.94
Load case 2MTS = 16.5252 / 16 *[(1.0703481 -1)*(1.07034812 + 1)*60.3 - (1.0703481 -
1)*(1.07034812 + 1)*0] = 155.35
Load case 3MTS = 16.5252 / 16 *[(1.0703481 -1)*(1.07034812 + 1)*60.3 - (1.0703481 -
1)*(1.07034812 + 1)*-13.18] = 189.3
217/226
UHX-12.5.3 Step 3
E* / E = α0 + α1*µ* + α2*µ*2 + α3*µ*3 + α4*µ*4
ν* = β0 + β1*µ* + β2*µ*2 + β3*µ*3 + β4*µ*4
Condition Design Condition 1
New h/p = 1.0158/1.25 = 0.8127
Corroded h/p = 0.8908/1.25 = 0.7127
New - from Fig. UHX-11.3(a) E*/E = 0.3011
Corroded - from Fig. UHX-11.3(a) E*/E = 0.3112
New E* = 0.3010515*27,813,000 = 8,373,146
Corroded E* = 0.3111648*27,813,000 = 8,654,426
New - from Fig. UHX-11.3(b) ν* = 0.3035
Corroded - from Fig. UHX-11.3(b) ν* = 0.2877
UHX-12.5.5 Step 5
K = A / Do
F = ((1 - ν*) / E*)*(E*ln(K))
Condition Design Condition 1
New or corroded All load cases K = 17.625 / 16.525 = 1.0666
New All load cases F = ((1 - 0.3034659) / 8,373,146)*(27,813,000*ln(1.0666)) = 0.1491
Corroded All load cases F = ((1 - 0.2876637) / 8,654,426)*(27,813,000*ln(1.0666)) = 0.1475
UHX-12.5.6 Step 6
M* = MTS + Wmax*(Gc - Gs) / (2*π*Do)
Condition Design Condition 1
New or corroded
Load case 1 M* = 33.94 + 109,500.1*(17.6875 - 17.6875) / (2*π*16.525) = 33.94
Load case 2 M* = 155.35 + 109,500.1*(17.6875 - 17.6875) / (2*π*16.525) = 155.35
Load case 3 M* = 189.3 + 109,500.1*(17.6875 - 17.6875) / (2*π*16.525) = 189.3
UHX-12.5.7 Step 7
Mp = (M* - (Do2 / 32)*F*(Ps - Pt)) / (1 + F)
Mo = Mp + (Do2 / 64)*(3 + ν*)*(Ps - Pt)
M = Max[Abs(Mp),Abs(Mo)]
218/226
Condition Design Condition 1
New
Load case 1 Mp = (33.94 - (16.5252 / 32)*0.1491*(0 - -13.1759)) / (1 + 0.1491) = 14.95
Load case 2 Mp = (155.35 - (16.5252 / 32)*0.1491*(60.3041 - 0)) / (1 + 0.1491) = 68.42
Load case 3 Mp = (189.3 - (16.5252 / 32)*0.1491*(60.3041 - -13.1759)) / (1 + 0.1491) = 83.37
Corroded
Load case 1 Mp = (33.94 - (16.5252 / 32)*0.1475*(0 - -13.1759)) / (1 + 0.1475) = 15.12
Load case 2 Mp = (155.35 - (16.5252 / 32)*0.1475*(60.3041 - 0)) / (1 + 0.1475) = 69.22
Load case 3 Mp = (189.3 - (16.5252 / 32)*0.1475*(60.3041 - -13.1759)) / (1 + 0.1475) = 84.34
New
Load case 1 Mo = 14.9495 + (16.5252 / 64)*(3 + 0.3034659)*(0 - -13.1759) = 200.67
Load case 2 Mo = 68.4215 + (16.5252 / 64)*(3 + 0.3034659)*(60.3041 - 0) = 918.42
Load case 3 Mo = 83.3709 + (16.5252 / 64)*(3 + 0.3034659)*(60.3041 - -13.1759) = 1,119.09
Corroded
Load case 1 Mo = 15.1241 + (16.5252 / 64)*(3 + 0.2876637)*(0 - -13.1759) = 199.95
Load case 2 Mo = 69.2208 + (16.5252 / 64)*(3 + 0.2876637)*(60.3041 - 0) = 915.16
Load case 3 Mo = 84.3449 + (16.5252 / 64)*(3 + 0.2876637)*(60.3041 - -13.1759) = 1,115.11
New
Load case 1 M = Max[Abs(14.9495),Abs(200.67)] = 200.67
Load case 2 M = Max[Abs(68.4215),Abs(918.42)] = 918.42
Load case 3 M = Max[Abs(83.3709),Abs(1,119.09)] = 1,119.09
Corroded
Load case 1 M = Max[Abs(15.1241),Abs(199.95)] = 199.95
Load case 2 M = Max[Abs(69.2208),Abs(915.16)] = 915.16
Load case 3 M = Max[Abs(84.3449),Abs(1,115.11)] = 1,115.11
UHX-12.5.8 Step 8
σ = 6*M / (µ**(h - hg')2)
Condition Design Condition 1 Stress(psi)
Allowable2*S(psi)
Over-stressed?
New
Load case 1 σ = 6*200.667 / (0.2829208*(1.0158 - 0.1875)2) = 6,202 40,000 No
Load case 2 σ = 6*918.4225 / (0.2829208*(1.0158 - 0.1875)2) = 28,387 40,000 No
Load case 3 σ = 6*1,119.0896 / (0.2829208*(1.0158 - 0.1875)2) = 34,589 40,000 No
Corroded
Load case 1 σ = 6*199.9533 / (0.2877117*(0.8908 - 0.125)2) = 7,110 40,000 No
Load case 2 σ = 6*915.1559 / (0.2877117*(0.8908 - 0.125)2) = 32,540 40,000 No
Load case 3 σ = 6*1,115.1093 / (0.2877117*(0.8908 - 0.125)2) = 39,650 40,000 No
UHX-12.5.9 Step 9
219/226
τ = (1 / (4*µ))*(Do / h)*ABS(Ps - Pt)
Condition Design Condition 1
Tubesheet Shear Stress Stress(psi)
Allowable(psi)
Over-stressed?
New
Load case 1 τ = (1 / (4*0.2))*(16.525 / 1.0158)*ABS(0 - -13.18) = 268 16,000 No
Load case 2 τ = (1 / (4*0.2))*(16.525 / 1.0158)*ABS(60.3 - 0) = 1,226 16,000 No
Load case 3 τ = (1 / (4*0.2))*(16.525 / 1.0158)*ABS(60.3 - -13.18) = 1,494 16,000 No
Corroded
Load case 1 τ = (1 / (4*0.2))*(16.525 / 0.8908)*ABS(0 - -13.18) = 306 16,000 No
Load case 2 τ = (1 / (4*0.2))*(16.525 / 0.8908)*ABS(60.3 - 0) = 1,398 16,000 No
Load case 3 τ = (1 / (4*0.2))*(16.525 / 0.8908)*ABS(60.3 - -13.18) = 1,704 16,000 No
Calculations for Tube side hydrotest Condition
UHX-12.5.1 Step 1
Do = 2*ro + dt
µ = (p - dt) / p
d* = MAX{[dt - 2*tt*(Et / E)*(St / S)*ρ], [dt - 2*tt]}
p* = p /(1 - 4*MIN(AL, 4*Do*p) /(π*Do2))0.5
µ* = (p* - d*)/p*
hg' = MAX[(hg - ct), 0]
Condition Tube side hydrotest
New Do = 2*7.7625 + 1 = 16.525
New µ = (1.25 - 1) /1.25 = 0.2
Newd* = MAX{[1 - 2*0.091*(29.4E+06 / 29.4E+06)*(23,400 / 45,600)*0.85],
[1 - 2*0.091]} = 0.9206125
New p* = 1.25 /(1 - 4*MIN(0, 4*16.525*1.25) /(π*16.5252))0.5 = 1.25
New µ* = (1.25 - 0.9206125)/1.25 = 0.26351
hg' = 0.1875
UHX-12.5.2 Step 2
ρs = Gs / Do
ρc = Gc / Do
MTS = Do2 / 16 *[(ρs -1)*(ρs
2 + 1)*Ps - (ρc - 1)*(ρc2 + 1)*Pt]
Condition Tube side hydrotest
New ρs = 17.6875 / 16.525 = 1.0703
220/226
All loadcases
New All loadcases ρc = 17.6875 / 16.525 = 1.0703
New Load case 1MTS = 16.5252 / 16 *[(1.0703481 -1)*(1.07034812 + 1)*0 - (1.0703481 - 1)*(1.07034812 +
1)*37.24] = -95.93
UHX-12.5.3 Step 3
E* / E = α0 + α1*µ* + α2*µ*2 + α3*µ*3 + α4*µ*4
ν* = β0 + β1*µ* + β2*µ*2 + β3*µ*3 + β4*µ*4
Condition Tube side hydrotest
New h/p = 1.0158/1.25 = 0.8127
New - from Fig. UHX-11.3(a) E*/E = 0.2747
New E* = 0.2747335*29.4E+06 = 8,077,166
New - from Fig. UHX-11.3(b) ν* = 0.3165
UHX-12.5.5 Step 5
K = A / Do
F = ((1 - ν*) / E*)*(E*ln(K))
Condition Tube side hydrotest
New All load cases K = 17.625 / 16.525 = 1.0666
New All load cases F = ((1 - 0.3165134) / 8,077,166)*(29.4E+06*ln(1.0666)) = 0.1603
UHX-12.5.6 Step 6
M* = MTS + Wmax*(Gc - Gs) / (2*π*Do)
Condition Tube side hydrotest
New Load case 1 M* = -95.93 + 109,500.1*(17.6875 - 17.6875) / (2*π*16.525) = -95.93
UHX-12.5.7 Step 7
Mp = (M* - (Do2 / 32)*F*(Ps - Pt)) / (1 + F)
Mo = Mp + (Do2 / 64)*(3 + ν*)*(Ps - Pt)
M = Max[Abs(Mp),Abs(Mo)]
Condition Tube side hydrotest
New Load case 1 Mp = (-95.93 - (16.5252 / 32)*0.1603*(0 - 37.2375)) / (1 + 0.1603) = -38.77
221/226
New Load case 1 Mo = -38.7678 + (16.5252 / 64)*(3 + 0.3165134)*(0 - 37.2375) = -565.71
New Load case 1 M = Max[Abs(-38.7678),Abs(-565.71)] = 565.71
UHX-12.5.8 Step 8
σ = 6*M / (µ**(h - hg')2)
Condition Tube side hydrotest Stress(psi)
Allowable(psi)
Over-stressed?
New Load case 1 σ = 6*565.7131 / (0.26351*(1.0158 - 0.1875)2) = 18,773 68,400 No
UHX-12.5.9 Step 9
Condition Tube side hydrotest
Tubesheet Shear Stress Stress(psi)
Allowable(psi)
Over-stressed?
New Load case 1 τ = (1 / (4*0.2))*(16.525 / 1.0158)*ABS(0 - 37.24) = 757 27,360 No
Calculations for Shell side hydrotest Condition
UHX-12.5.1 Step 1
Do = 2*ro + dt
µ = (p - dt) / p
d* = MAX{[dt - 2*tt*(Et / E)*(St / S)*ρ], [dt - 2*tt]}
p* = p /(1 - 4*MIN(AL, 4*Do*p) /(π*Do2))0.5
µ* = (p* - d*)/p*
hg' = MAX[(hg - ct), 0]
Condition Shell side hydrotest
New Do = 2*7.7625 + 1 = 16.525
New µ = (1.25 - 1) /1.25 = 0.2
Newd* = MAX{[1 - 2*0.091*(29.4E+06 / 29.4E+06)*(23,400 / 45,600)*0.85],
[1 - 2*0.091]} = 0.9206125
New p* = 1.25 /(1 - 4*MIN(0, 4*16.525*1.25) /(π*16.5252))0.5 = 1.25
New µ* = (1.25 - 0.9206125)/1.25 = 0.26351
hg' = 0.1875
UHX-12.5.2 Step 2
ρs = Gs / Do
222/226
ρc = Gc / Do
MTS = Do2 / 16 *[(ρs -1)*(ρs
2 + 1)*Ps - (ρc - 1)*(ρc2 + 1)*Pt]
Condition Shell side hydrotest
New All loadcases ρs = 17.6875 / 16.525 = 1.0703
New All loadcases ρc = 17.6875 / 16.525 = 1.0703
New Load case 2MTS = 16.5252 / 16 *[(1.0703481 -1)*(1.07034812 + 1)*73.98 - (1.0703481 -
1)*(1.07034812 + 1)*0] = 190.57
UHX-12.5.3 Step 3
E* / E = α0 + α1*µ* + α2*µ*2 + α3*µ*3 + α4*µ*4
ν* = β0 + β1*µ* + β2*µ*2 + β3*µ*3 + β4*µ*4
Condition Shell side hydrotest
New h/p = 1.0158/1.25 = 0.8127
New - from Fig. UHX-11.3(a) E*/E = 0.2747
New E* = 0.2747335*29.4E+06 = 8,077,166
New - from Fig. UHX-11.3(b) ν* = 0.3165
UHX-12.5.5 Step 5
K = A / Do
F = ((1 - ν*) / E*)*(E*ln(K))
Condition Shell side hydrotest
New All load cases K = 17.625 / 16.525 = 1.0666
New All load cases F = ((1 - 0.3165134) / 8,077,166)*(29.4E+06*ln(1.0666)) = 0.1603
UHX-12.5.6 Step 6
M* = MTS + Wmax*(Gc - Gs) / (2*π*Do)
Condition Shell side hydrotest
New Load case 2 M* = 190.57 + 109,500.1*(17.6875 - 17.6875) / (2*π*16.525) = 190.57
UHX-12.5.7 Step 7
Mp = (M* - (Do2 / 32)*F*(Ps - Pt)) / (1 + F)
Mo = Mp + (Do2 / 64)*(3 + ν*)*(Ps - Pt)
223/226
M = Max[Abs(Mp),Abs(Mo)]
Condition Shell side hydrotest
New Load case 2 Mp = (190.57 - (16.5252 / 32)*0.1603*(73.976 - 0)) / (1 + 0.1603) = 77.02
New Load case 2 Mo = 77.0161 + (16.5252 / 64)*(3 + 0.3165134)*(73.976 - 0) = 1,123.84
New Load case 2 M = Max[Abs(77.0161),Abs(1,123.84)] = 1,123.84
UHX-12.5.8 Step 8
σ = 6*M / (µ**(h - hg')2)
Condition Shell side hydrotest Stress(psi)
Allowable(psi)
Over-stressed?
New Load case 2 σ = 6*1,123.8444 / (0.26351*(1.0158 - 0.1875)2) = 37,295 68,400 No
UHX-12.5.9 Step 9
Condition Shell side hydrotest
Tubesheet Shear Stress Stress(psi)
Allowable(psi)
Over-stressed?
New Load case 2 τ = (1 / (4*0.2))*(16.525 / 1.0158)*ABS(73.98 - 0) = 1,504 27,360 No
224/226
Tubesheet -- TEMA
TEMA RCB-7.13 Required Effective Tubesheet Thickness, in
Actual Tubesheet Thickness Used, TNominal = 1.0158 in
TMin effective for bending/shear, corr
= TNominal - Larger (Tube Side Pass Groove Depth, Tube Side Corrosion) - ShellSide Corrosion
= 1.0158 - Larger(0.1875, 0.0625) - 0.0625 = 0.7658 in
TMin effective for bending/shear, new
= TNominal - Larger (Tube Side Pass Groove Depth, Tube Side Corrosion) - ShellSide Corrosion
= 1.0158 - Larger(0.1875, 0) - 0 = 0.8283 in
Equations used
RCB-7.132(bending)
η = 1 - 0.907/(Pitch/Tube OD)2 = 1 - 0.907/(1.25/1)2
= 0.4195
F = 1.25
Tbending = (F*G/3)*(P/(η*S))1/2
RCB-7.133(shear)
DL = 4*A/C
Tshear = 0.31*DL*(P/S)/(1 - do/Pitch)
Shear does not control if (P/S) < 1.6*(1 - do/Pitch)2
Design Condition 1 Corroded
Shell Side
Tbending =(1.25*17.6875/3)*(73.48/(0.4195*20,000.00))1/2 =0.6897
Shear does not control as (73.48/20,000.00) <1.6*(1 - 1/1.25)2
Tube Side
Tbending =(1.25*17.6875/3)*(13.1759/(0.4195*20,000.00)) 1/2 =0.2921
Shear does not control as (-13.1759/20,000.00) <1.6*(1 - 1/1.25)2
Tube side hydrotest New Tube Side
Tbending =(1.25*17.6875/3)*(37.23753/(0.4195*34,200.00)) 1/2
= 0.3755
Shear does not control as (37.23753/34,200.00) <1.6*(1 - 1/1.25)2
Shell side hydrotest New Shell Side
Tbending =(1.25*17.6875/3)*(73.976/(0.4195*34,200.00)) 1/2 =0.5292
Shear does not control as (73.976/34,200.00) <1.6*(1 - 1/1.25)2
225/226
Tubesheet Maximum Pressure Report
ASME Tubesheet Maximum Pressure Ratings
Description Design Condition 1 Tube side hydrotest Shell side hydrotest
Tube Side Pressure (psi) -13.51 135.67 0
Design temperature (°F) 414.5 70 70
Shell Side Pressure (psi) 60.62 0 135.67
Design temperature (°F) 307.57 70 70
Tubesheet Design temperature (°F) 414.5 70 70
TEMA Tubesheet Maximum Pressure Ratings
Description Design Condition 1 Tube side hydrotest Shell side hydrotest
Tube Side Pressure (psi) 0 181.24 0
Design temperature (°F) 414.5 70 70
Shell Side Pressure (psi) 90.6 0 181.24
Design temperature (°F) 307.57 70 70
Tubesheet Design temperature (°F) 414.5 70 70
226/226