GP-QM-7.

3-2 R1
GP-839
GRAND PRIX DESIGN CALCULATION
SHT. 1 OF 12

Client : M/s. Bharat Pumps & Compressors Ltd.

Project : MSQU / IOCL

P.O. No. : 461-16430421-1533 Dtd. 14.02.2005

Item : Discharge Volume Bottles - D2A( 6510418/D )

Drg. No. : 2-GP839-1324

Inspection : BPCL/ EIL

G.P. Job No. : GP-839

1 Revised as per clients comment. 1.04.04 A.S.

0 Issued for Approval 02.03.05 N.J.
Rev. No. Description Date Prepared By Checked By Approved By
DATE Doc. No. Rev.
GRAND PRIX FARIDABAD
 GP-QM-7.3-2 R1
GRAND PRIX FARIDABAD
02.03.05 GP839-DC-01 1
GP-839
GRAND PRIX DESIGN CALCULATION
SHT. 2 OF 12

DESIGN DATA

Design Code : ASME SEC VIII, DIV. 1 - 2004

Design Pressure : 56.2 Kg/Cm2g

Design Temp. : 204 o

C

Flange Rating. : 600 #

Radiography : 100 %

Joint Efficiency : 1.0

Corrosion Allowance : 3.2 mm

Vessel OD, D : 450.0 mm

Vessel Outer Radius, R : 225.0 mm

Name of Part Material of Construction Stress Value at Design Temp.

Shell : SA 516 Gr. 60 1202.47 Kg/Cm2

Dish End : SA 516 Gr. 60 1202.47 Kg/Cm2

Nozzle : SA 106 Gr. B 1202.47 Kg/Cm2

 GP-QM-7.3-2 R1

DATE Doc. No. Rev.

GRAND PRIX FARIDABAD
02.03.05 GP839-DC-01 1
GP-839
GRAND PRIX DESIGN CALCULATION
SHT. 3 OF 12

DESIGN SUMMARY

Actual
Calculated Minimum
S. No. Description Size Thickness
Thickness
Provided

1 Shell OD 450 x 14 Thk. 13.52 mm 14.0 mm

2 Dish End OD 450x13.3 Thk(min). 13.29 mm 16.0 mm(nom)

3 S3 6" NB x Sch. 80 7.06 mm 10.972 mm

4 S1,S2 4"NB x Sch. 120 5.82 mm 11.12 mm

5 S4,S5,S8,S9 1½"NB x Sch. XX 4.31 mm 10.16 mm

 GP-QM-7.3-2 R1

DATE Doc. No. Rev.

GRAND PRIX FARIDABAD
02.03.05 GP839-DC-01 1
GP-839
GRAND PRIX DESIGN CALCULATION
SHT. 4 OF 12

Shell Thickness :-

t = P.R
(SE + 0.4P)

= 10.32 mm

= 10.32 + 3.2 Adding 3.2 mm Corrosion Allownace

= 13.52

Used Plate 14 mm Thick

Dish End Tickness :-

Type of D/End, Semi-Elliptical , 2 : 1 K =1.0

t = P.D.K
2SE + 2P(K - 0.1)

= 10.09 mm

= 10.09 + 3.2 Adding 3.2 mm Corrosion Allownace

= 13.29 mm

Used Plate 16 mm Thick

 GP-QM-7.3-2 R1

DATE Doc. No. Rev.

GRAND PRIX FARIDABAD
02.03.05 GP839-DC-01 1
GP-839
GRAND PRIX DESIGN CALCULATION
SHT. 5 OF 12

Nozzle Thickness :- (6"NB Size)

Do = 168.27 mm
t = P.Ro Ro = 84.135 mm
(SE + 0.4P) E= 1.0

= 3.86 mm

= 3.86 + 3.2 Adding 3.2 mm Corrosion Allownace

= 7.06 mm

Used 6" NB x Sch. 80 Pipe (10.972 mm)

Nozzle Thickness :- (4" NB Size)

Do = 114.3 mm
t = P.Ro Ro = 57.15 mm
(SE + 0.4P) E= 1.0

= 2.62 mm

= 2.62 + 3.2 Adding 3.2 mm Corrosion Allownace

= 5.82 mm

Used 4" NB x Sch. 120 Pipe (11.12 mm)

Nozzle Thickness :- (1½" NB Size)

Do = 48.26 mm
t = P.Ro Ro = 24.13 mm
(SE + 0.4P) E= 1.0

= 1.11 mm

= 1.11 + 3.2 Adding 3.2 mm Corrosion Allownace

 GP-QM-7.3-2 R1

= 4.31 mm

Used 1½" NB x Sch. XX Pipe (10.16 mm)

DATE Doc. No. Rev.

GRAND PRIX FARIDABAD
02.03.05 GP839-DC-01 1
GP-839
GRAND PRIX DESIGN CALCULATION
SHT. 6 OF 12

Table 1

Nozzle Size (NB) Shell/ D.End Std. Wall Cal. Nozzle Smaller of T1 & T2 Greater of T3 Provided
Thk.+C.A. (T1) Thk. Less Thk.+C.A. (T4) & T4 / 0.875 Thk. /
12.5% + (T3) for (Pipes) Sch.
C.A. (T2)

10.972
S3 150 13.29 9.42 7.06 9.42 10.77
Sch. 80

S1 100 13.52 8.46 5.82 8.46 9.67 11.12

Sch. 120

S2 100 13.29 8.46 5.82 8.46 9.67 11.12

Sch. 120
S4,S5,S 10.16
8, S9 40 13.52 6.42 4.31 6.42 7.34
Sch. XX
 GP-QM-7.3-2 R1

DATE Doc. No. Rev.

GRAND PRIX FARIDABAD
02.03.05 GP839-DC-01 1
GP-839
GRAND PRIX DESIGN CALCULATION
SHT. 7 OF 12

Nozzle Reinforcement
1.0 Nozzle No.
2.0 Size (NB) 150 100
3.0 tr = Required Shell Thk. 10.09 10.09
4.0 t = Provied Shell Thk. - C.A. 10.8 10.8
5.0 tm= Required Nozzle Thk. 3.86 2.62
6.0 tn = Provied Nozzle Thk. - C.A. 7.772 7.92
7.0 d = Inside Dia of Nozzle + C.A. 149.52 95.24
8.0 Sn = Allowable Stress in Nozzle (Kg/Cm 2) 1202.47 1202.47
9.0 Sv = Allowable Stress in Vessel (Kg/Cm 2) 1202.47 1202.47
10.0 Sp = Allowable Stress in RF. Pad (Kg/Cm 2) 1202.47 1202.47
11.0 fr1 = Sn/Sv (1.0 Max.) 1.0 1.0
12.0 fr2 = Sn/Sv (1.0 Max.) 1.0 1.0
13.0 fr3 , fr4= Sp/Sv (1.0 Max.) 1.0 1.0
14.0 F = Correction Factor 1.0 1.0
15.0 te = Thickness of RF. Pad 14.0 14.0
Dr = Dia. of RF. Pad (Available) 299.04 190.48
16.0
Dp = Dia. of RF. Pad (Provided) 250.0 200.0
17.0 Area Required, A = dtrF+2tntrF(1-fr1) 1508.86 961.10
18.0 Value , E1 1.0 1.0
Area Available in Shell, A 1 = Larger of
d(E1t-Ftr)-2tn(E1t-Ftr)(1-fr1) OR
19.0 2(t+t )(E t-Ft )-2t (E t-Ft )(1-f ) 105.95 67.49
n 1 r n 1 r r1

Area Available in Nozzle, A2 = Smaller of

20.0 152.02 209.88
5(tn-tm)t.fr2 OR 5(tn-tm)tn.fr2

21.0 Welding Area, A41 = (LEG)2.fr2 100.0 100.0

22.0 Area in RF. Pad, A5 = (Dp-d-2tn)te.fr3 1189.104 1244.88
 GP-QM-7.3-2 R1
23.0 Welding Area, A42 = (LEG)2.fr4 100.0 100.0
24.0 Total Area Available = A1+A2+A41+A5+A42 1647.08 1722.25

Remarks :- 1. Reinforcement Provided is OK

2. No Reinforcement Required.

DATE Doc. No. Rev.

GRAND PRIX FARIDABAD
02.03.05 GP839-DC-01 1
GP-839
GRAND PRIX DESIGN CALCULATION
SHT. 8 OF 12

Nozzle Reinforcement
1.0 Nozzle No.
2.0 Size (NB) 100
3.0 tr = Required Shell Thk. 10.32
4.0 t = Provied Shell Thk. - C.A. 10.8
5.0 tm= Required Nozzle Thk. 2.62
6.0 tn = Provied Nozzle Thk. - C.A. 7.92
7.0 d = Inside Dia of Nozzle + C.A. 95.24
8.0 Sn = Allowable Stress in Nozzle (Kg/Cm 2) 1202.47
9.0 Sv = Allowable Stress in Vessel (Kg/Cm 2) 1202.47
10.0 Sp = Allowable Stress in RF. Pad (Kg/Cm 2) 1202.47
11.0 fr1 = Sn/Sv (1.0 Max.) 1.0
12.0 fr2 = Sn/Sv (1.0 Max.) 1.0
13.0 fr3 , fr4= Sp/Sv (1.0 Max.) 1.0
14.0 F = Correction Factor 1.0
15.0 te = Thickness of RF. Pad 10.8
Dr = Dia. of RF. Pad (Available) 190.48
16.0
Dp = Dia. of RF. Pad (Provided) 200.0
17.0 Area Required, A = dtrF+2tntrF(1-fr1) 983.15
18.0 Value , E1 1.0
Area Available in Shell, A 1 = Larger of
d(E1t-Ftr)-2tn(E1t-Ftr)(1-fr1) OR
19.0 2(t+tn)(E1t-Ftr)-2tn(E1t-Ftr)(1-fr1) 45.44

Area Available in Nozzle, A2 = Smaller of

20.0 198
5(tn-tm)t.fr2 OR 5(tn-tm)tn.fr2

21.0 Welding Area, A41 = (LEG)2.fr2 100.0

 GP-QM-7.3-2 R1
22.0 Area in RF. Pad, A5 = (Dp-d-2tn)te.fr3 960.336
23.0 Welding Area, A42 = (LEG)2.fr4 100.0
24.0 Total Area Available = A1+A2+A41+A5+A42 1403.78

Remarks :- 1. Reinforcement Provided is OK

2. No Reinforcement Required.

DATE Doc. No. Rev.

GRAND PRIX FARIDABAD
02.03.05 GP839-DC-01 1
GP-839
GRAND PRIX DESIGN CALCULATION
SHT. 9 OF 12

Calculation for Nozzle Loads

( Code used : BSI-PD 5500 :2000)

(a) Calculation for Nozzles S1 & S2 ( 4" NB ) :-

Inside Diametre of Shell , D i = 422.4 mm

Nozzle Flange bolt ( PCD ) , d o = 200.15 mm

Corrosion Allowance , CA = 3.2 mm

Shell Thickness, ts = 14.0 mm

Reinforcing Pad Thickness, tp = 14.0 mm

Nozzle Thickness , tn = 11.12 mm

Shell, Calculation Thickness, tcs = 28 mm

=
AllowableStress of Shell Material,Sa = 12.0247 Kg/mm2

AllowableStress of Pad Material ,S p = 12.0247 Kg/mm2

Constant ,S = 1
 GP-QM-7.3-2 R1

Polynomial Coeffecients ,a0 to a4 (As per Table 1)

Calculation Factors , C2 to C4 (As per PD 5500)

C2 = 2.90760147956962

C3 = 5.33964267969865

C4 = 13.81

DATE Doc. No. Rev.

GRAND PRIX FARIDABAD
02.03.05 GP839-DC-01 1
GP-839
GRAND PRIX DESIGN CALCULATION
SHT. 10 OF 12

Shell effective mean Diametre, D e = 453.6 mm

Nozzle Mean Diametre, d m = 192.23 mm

Geometric Parametre for shells λ C = 2.41226571099003

Maximum allowable Axial Force

on the Nozzle ,FX Max = 27411.0198409225 Kg
268902.10463945 N

Maximum allowable Circumferential

Forceon the Nozzle ,FY Max = 50338.7594431687 Kg
493823.230137485 N

Maximum allowable Longitudinal Force

on the Nozzle ,FZ Max = 130167.342017879 Kg
1276941.62519539 N

Maximum allowable Axial Moment

on the Nozzle ,M X Max = 1317318.79151505 Kg-mm
12922.8973447627 Nm
Maximum Allowable Circumferential
moment on the Nozzle , MY Max = 2419180.1013198 Kg-mm
23732.1567939472 Nm

Maximum Allowable Longitudinal

 GP-QM-7.3-2 R1
moment on the Nozzle , MZ Max = 6255582.12269522 Kg-mm
61367.2606236401 Nm

TABLE 1 Coefficients to define factore C2 , C3 or C4

Factor a0 a1 a2 a3 a4
C2 0.60072181 0.95196257 0.00520 -0.0014064 0
C3 4.526315 0.064021889 0.15888 -0.0214193 0.00104
C4 with
tp / ts ≤ 0.2 4.8844124 -0.07138921 0.79991 -0.0241557 0
C4 with
tp / ts ≥ 0.5 6.3178075 -3.6618209 4.51454 -0.8309484 0.0507

DATE Doc. No. Rev.

GRAND PRIX FARIDABAD
02.03.05 GP839-DC-01 1
GP-839
GRAND PRIX DESIGN CALCULATION
SHT. 11 OF 12

CALCULATED FX FY FZ MX MY MZ
MAX ALLOWABLE
268902.1 493823.2 1276941.6 12922.90 23732.157 61367.26
LOAD N / Nm

ALLOWABLE
2700.00 3350.00 3350.00 1250.00 850.00 850.00
LOAD N / Nm

The forces and Moments are on the safer Side.

 GP-QM-7.3-2 R1

DATE Doc. No. Rev.

GRAND PRIX FARIDABAD
02.03.05 GP839-DC-01 1
GP-839
GRAND PRIX DESIGN CALCULATION
SHT. 12 OF 12
Calculation for Saddle Support.
( Code used : BS- PD 5500 )

Allowable Stress of Saddle Mat. = 9.80 Kg/mm2

Design Stress of the web section = 6.533 Kg/mm2

( Considered 2/3rd of the allowable stress )

Outer Dia of Vessel , D = 450 mm

Outer radius of Vessel , R = 225 mm

Test Weight of the Vessel , W = 640.00 Kg.

The load on one Saddle , Q = 640.00 Kg.

Numerical Constant , k9 = 0.204 ( From Table 1)

Web Plate Thickness , T = 10.00 mm

Horizontal Force F = 130.56 Kg.

 GP-QM-7.3-2 R1

VALUE OF CONSTANT K9 (As per PD 5500:2000 Annex. G)

CONTACT ANGLE 120 130 140 150 160 170 180
K9 0.204 0.222 0.241 0.259 0.279 0.298 0.318

R/3 = 75 mm.

To Resist this Force The effective area of Web Plate = 750 mm2

Stress due to Horizontal Force, F = 0.17408 kg/mm2

Since the allowable Stress is 6.533 Kg/mm 2 , The Selected size is satisfactory

DATE Doc. No. Rev.

GRAND PRIX FARIDABAD
02.03.05 GP839-DC-01 1
Approved By