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PV Elite and CodeCalc Verification and Quality Assurance Manual
Version 2014 (16.0)
November 2013
DICAS-PE-200110E
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2 PV Elite and CodeCalc Verification and Quality Assurance Manual
Copyright
Copyright 1993-2013 Intergraph CAS, Inc. All Rights Reserved. Intergraph is part of Hexagon.
Including software, file formats, and audiovisual displays; may be used pursuant to applicable software license agreement; contains confidential and proprietary information of Intergraph and/or third parties which is protected by copyright law, trade secret law, and international treaty, and may not be provided or otherwise made available without proper authorization from Intergraph Corporation.
Contains RealDWG by Autodesk, Inc. Copyright 1998-2013 Autodesk, Inc. All rights reserved.
U.S. Government Restricted Rights Legend
Use, duplication, or disclosure by the government is subject to restrictions as set forth below. For civilian agencies: This was developed at private expense and is "restricted computer software" submitted with restricted rights in accordance with subparagraphs (a) through (d) of the Commercial Computer Software - Restricted Rights clause at 52.227-19 of the Federal Acquisition Regulations ("FAR") and its successors, and is unpublished and all rights are reserved under the copyright laws of the United States. For units of the Department of Defense ("DoD"): This is "commercial computer software" as defined at DFARS 252.227-7014 and the rights of the Government are as specified at DFARS 227.7202-3.
Unpublished - rights reserved under the copyright laws of the United States.
Intergraph Corporation 300 Intergraph Way Huntsville, AL 35813
Documentation
Documentation shall mean, whether in electronic or printed form, User's Guides, Installation Guides, Reference Guides, Administrator's Guides, Customization Guides, Programmer's Guides, Configuration Guides and Help Guides delivered with a particular software product.
Other Documentation
Other Documentation shall mean, whether in electronic or printed form and delivered with software or on eCustomer, SharePoint, or box.net, any documentation related to work processes, workflows, and best practices that is provided by Intergraph as guidance for using a software product.
Terms of Use
a. Use of a software product and Documentation is subject to the End User License Agreement ("EULA") delivered with the software product unless the Licensee has a valid signed license for this software product with Intergraph Corporation. If the Licensee has a valid signed license for this software product with Intergraph Corporation, the valid signed license shall take precedence and govern the use of this software product and Documentation. Subject to the terms contained within the applicable license agreement, Intergraph Corporation gives Licensee permission to print a reasonable number of copies of the Documentation as defined in the applicable license agreement and delivered with the software product for Licensee's internal, non-commercial use. The Documentation may not be printed for resale or redistribution.
b. For use of Documentation or Other Documentation where end user does not receive a EULA or does not have a valid license agreement with Intergraph, Intergraph grants the Licensee a non-exclusive license to use the Documentation or Other Documentation for Licensees internal non-commercial use. Intergraph Corporation gives Licensee permission to print a reasonable number of copies of Other Documentation for Licensees internal, non-commercial. The Other Documentation may not be printed for resale or redistribution. This license contained in this subsection b) may be terminated at any time and for any reason by Intergraph Corporation by giving written notice to Licensee.
Disclaimer of Warranties
Except for any express warranties as may be stated in the EULA or separate license or separate terms and conditions, Intergraph Corporation disclaims any and all express or implied warranties including, but not limited to the implied warranties of merchantability and fitness for a particular purpose and nothing stated in, or implied by, this document or its contents shall be considered or deemed a modification or amendment of such disclaimer. Intergraph believes the information in this publication is accurate as of its publication date.
The information and the software discussed in this document are subject to change without notice and are subject to applicable technical product descriptions. Intergraph Corporation is not responsible for any error that may appear in this document.
The software, Documentation and Other Documentation discussed in this document are furnished under a license and may be used or copied only in accordance with the terms of this license. THE USER OF THE SOFTWARE IS EXPECTED TO MAKE THE FINAL EVALUATION AS TO THE USEFULNESS OF THE SOFTWARE IN HIS OWN ENVIRONMENT.
Intergraph is not responsible for the accuracy of delivered data including, but not limited to, catalog, reference and symbol data. Users should verify for themselves that the data is accurate and suitable for their project work.
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PV Elite and CodeCalc Verification and Quality Assurance Manual 3
Limitation of Damages
IN NO EVENT WILL INTERGRAPH CORPORATION BE LIABLE FOR ANY DIRECT, INDIRECT, CONSEQUENTIAL INCIDENTAL, SPECIAL, OR PUNITIVE DAMAGES, INCLUDING BUT NOT LIMITED TO, LOSS OF USE OR PRODUCTION, LOSS OF REVENUE OR PROFIT, LOSS OF DATA, OR CLAIMS OF THIRD PARTIES, EVEN IF INTERGRAPH CORPORATION HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES.
UNDER NO CIRCUMSTANCES SHALL INTERGRAPH CORPORATIONS LIABILITY EXCEED THE AMOUNT THAT INTERGRAPH CORPORATION HAS BEEN PAID BY LICENSEE UNDER THIS AGREEMENT AT THE TIME THE CLAIM IS MADE. EXCEPT WHERE PROHIBITED BY APPLICABLE LAW, NO CLAIM, REGARDLESS OF FORM, ARISING OUT OF OR IN CONNECTION WITH THE SUBJECT MATTER OF THIS DOCUMENT MAY BE BROUGHT BY LICENSEE MORE THAN TWO (2) YEARS AFTER THE EVENT GIVING RISE TO THE CAUSE OF ACTION HAS OCCURRED.
IF UNDER THE LAW RULED APPLICABLE ANY PART OF THIS SECTION IS INVALID, THEN INTERGRAPH LIMITS ITS LIABILITY TO THE MAXIMUM EXTENT ALLOWED BY SAID LAW.
Export Controls
Intergraph Corporations software products and any third-party Software Products obtained from Intergraph Corporation, its subsidiaries, or distributors (including any Documentation, Other Documentation or technical data related to these products) are subject to the export control laws and regulations of the United States. Diversion contrary to U.S. law is prohibited. These Software Products, and the direct product thereof, must not be exported or re-exported, directly or indirectly (including via remote access) under the following circumstances:
a. To Cuba, Iran, North Korea, Sudan, or Syria, or any national of these countries.
b. To any person or entity listed on any U.S. government denial list, including but not limited to, the U.S. Department of Commerce Denied Persons, Entities, and Unverified Lists, http://www,bis.doc.gov/complianceandenforcement/liststocheck.htm, the U.S. Department of Treasury Specially Designated Nationals List, www.treas.gov/offices/enforcement/ofac/http://www.pmddtc.state.gov/compliance/debar.html, and the U.S. Department of State Debarred List.
c. To any entity when Licensee knows, or has reason to know, the end use of the Software Product is related to the design, development, production, or use of missiles, chemical, biological, or nuclear weapons, or other un-safeguarded or sensitive nuclear uses.
d. To any entity when Licensee knows, or has reason to know, that an illegal reshipment will take place.
Any questions regarding export or re-export of these Software Products should be addressed to Intergraph Corporations Export Compliance Department, Huntsville, Alabama 35894, USA.
Trademarks
Intergraph, the Intergraph logo, Intergraph Smart, PDS, SmartPlant, SmartMarine, FrameWorks, I-Sketch, IntelliShip, ISOGEN, SmartSketch, SPOOLGEN, SupportManager, and SupportModeler are trademarks or registered trademarks of Intergraph Corporation or its subsidiaries in the United States and other countries. Microsoft and Windows are registered trademarks of Microsoft Corporation. MicroStation is a registered trademark of Bentley Systems, Inc. Other brands and product names are trademarks of their respective owners.
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4 PV Elite and CodeCalc Verification and Quality Assurance Manual
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PV Elite and CodeCalc Verification and Quality Assurance Manual 5
Contents Introduction .................................................................................................................................................. 7
Intergraph CAS Quality Assurance ........................................................................................................... 9
Software Purpose.................................................................................................................................... 9 Intellectual Property Statement ............................................................................................................... 9 Management/Organization .................................................................................................................... 10 PV Elite Development ........................................................................................................................... 10 User Documentation ............................................................................................................................. 10 Product Support .................................................................................................................................... 11 Software Issue Tracking/Resolution ..................................................................................................... 11
Software Verification ................................................................................................................................. 13
Test Control ........................................................................................................................................... 13 Beta Tests ............................................................................................................................................. 14 Additional Manual Checks for Staff and Beta Users ............................................................................. 15 PV Elite Test Jobs ................................................................................................................................. 19 Corrective Action Standard ................................................................................................................... 20 Post-Development Procedures ............................................................................................................. 20 Distribution Control ............................................................................................................................... 21 Pre-Shipping Procedures ...................................................................................................................... 21 CodeCalc QA Checks ........................................................................................................................... 23
Introduction ..................................................................................................................................... 23 Shell and Head Checks .................................................................................................................. 24 Nozzle Checks ................................................................................................................................ 26 Flange Checks ................................................................................................................................ 28 Cone Checks .................................................................................................................................. 31 Floating Heads Checks .................................................................................................................. 32 Horizontal Vessel Checks .............................................................................................................. 34 Leg and Lug .................................................................................................................................... 34 ASME Tubesheets Checks ............................................................................................................ 36 TEMA Tubesheets Checks ............................................................................................................. 37 WRC 107 Checks ........................................................................................................................... 38 Pipe and Pad Checks ..................................................................................................................... 39 Base Ring Checks .......................................................................................................................... 39 Half-Pipe Check .............................................................................................................................. 40 Large Opening Checks ................................................................................................................... 41 Rectangular Vessel Checks ........................................................................................................... 42
PV Elite Sample Benchmark Problem Sets .......................................................................................... 45 Problem 1 - Natural Frequency Calculation ................................................................................... 45 Problem 2 - Example of Stiffening Ring Calculation ...................................................................... 49 Problem 3 - Nozzle Reinforcement, Weld Strength, Weld Size ..................................................... 52 Problem 4 - Vessel under Internal and External Pressure on Legs ............................................... 65 Problem 5 - Vertical Vessel with Wind and Seismic Loads ............................................................ 74 Problem 6 - Comparison against CAESAR II ................................................................................. 83 Problem 7 - ASME Section VIII Division 2 Sample Comparisons .................................................. 86 Problem 8 - EN-13445 Nozzle Reinforcement ............................................................................... 93
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Contents
6 PV Elite and CodeCalc Verification and Quality Assurance Manual
Index ......................................................................................................................................................... 101
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PV Elite and CodeCalc Verification and Quality Assurance Manual 7
S E C T I O N 1
The PV Elite/CodeCalc
Verification and Quality Assurance Manual provides a standard set of
PV Elite/CodeCalc jobs that are used in verifying both the operation of the software and the accuracy of the result for each release of the PV Elite/CodeCalc package. The examples presented in this manual are a representative cross-section of the jobs run by Intergraph CAS. The jobs selected for this manual compare the PV Elite/CodeCalc output with results published in industry journals and with results from other software products. The PV Elite/CodeCalc output is (also) verified with hand and/or MathCad calculations.
The component-analysis part of PV Elite, when sold separately, is called CodeCalc. CodeCalc-specific results can be found in the Software Verification section of this manual. In all other sections, the software is referred to simply as PV Elite.
This manual consists of two major sections: Intergraph CAS Quality Assurance and Software Verification.
Intergraph CAS Quality Assurance describes the quality assurance procedures employed by Intergraph CAS to ensure that PV Elite is producing correct results.
Software Verification explains a series of benchmark jobs that you can use to confirm software accuracy. These jobs compare PV Elite output to published results, to output from similar software, or to hand calculations. For each job in this section, a brief description of the job and any special considerations are discussed. Following the discussion is a graphical representation of the system with selected result comparisons. Because of the volume of output, important results like required thickness, maximum allowable working pressure (MAWP), and stress are listed in tables. Users interested in the entire output can re-analyze the jobs as necessary.
The PV Elite development team is constantly testing and adding new test jobs to the QA benchmark problem set. Currently, there are more than 250 test jobs run which test thousands of different calculations. It is impractical to include all of these tests in this manual. As new Quality Assurance procedures are published, they will be incorporated into the QA methods employed by Intergraph CAS. Users with questions, comments, or suggestions are encouraged to contact Intergraph CAS to discuss future revisions to this document. User requests for new features are always welcome. By working with the user, the PV Elite development staff will continue to develop a product that best meets the demands of pressure-vessel design and analysis users.
Introduction
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PV Elite and CodeCalc Verification and Quality Assurance Manual 9
S E C T I O N 2
Software quality assurance is generally a speculative pursuit because, no matter how much testing is performed, the next test may reveal an error in the software. The goal of any quality assurance standard is to perform enough testing to achieve such a level of confidence in the software that errors are rare and unlikely. With this objective in mind, several organizations have published guidelines for use in software quality assurance.
In This Section Software Purpose .......................................................................... 9 Intellectual Property Statement...................................................... 9 Management/Organization ............................................................ 10 PV Elite Development .................................................................... 10 User Documentation ...................................................................... 10 Product Support ............................................................................. 11 Software Issue Tracking/Resolution .............................................. 11
Software Purpose PV Elite is a package of nineteen applications that work together to design and analyze pressure vessels and heat exchangers. The purpose of the software is to provide the mechanical engineer with easy-to-use, technically sound, well-documented calculations that will expedite and simplify vessel-design and re-rating tasks. The software also provides recent, industry-accepted analyses of the designs.
Calculations in PV Elite are based on the latest editions of national codes such as the ASME Boiler and Pressure Vessel Code, or other relevant industry standards that are not covered directly by ASME VIII-1, VIII-2 or other codes.
Intellectual Property Statement This manual and its contents should be considered proprietary. This material should not be copied or distributed to other parties without the expressed written consent of Intergraph CAS.
Intergraph CAS Quality Assurance
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10 PV Elite and CodeCalc Verification and Quality Assurance Manual
Management/Organization At Intergraph CAS, the Chief Architect, Software Engineering Manager, and Product Manager oversee the development and testing of the software product. Software development team members include: engineers, software developers, and a technical writer. All members of the development team support customers and test the software prior to each release. Specialized technical support representatives work closely with the development team. In addition, an on-staff, certified Nuclear Quality Assurance (NQA) lead auditor oversees the quality assurance program followed by the team.
PV Elite Development Intergraph CAS is wholly responsible for all software made available to the public that bears the Intergraph label on the distribution media.
Changes to PV Elite are made by or with the consent of the Product Manager. Additional members of the software team include engineers, who interact at the same level and communicate directly with the product manager. Therefore, all software issues can be brought to the attention of Product Manager quickly and easily.
Software engineers each bring a different kind of expertise to the team and write routines for specialized functions in the software. For example, the source code to perform structural steel checks may be written by an engineer at Intergraph CAS whose educational background permits him to do this efficiently.
All members of the development staff provide customer support for PV Elite, directly or indirectly. One member of the team is tasked with quality assurance procedures for each release.
User Documentation The PV Elite user has online access to documentation spanning all facets of the software, including all of the ancillary processors and interfaces. The standard PV Elite documentation set consists of the following documents:
PV Elite User's Guide
CodeCalc User's Guide
Quick Start Guide
All of these documents can be accessed online, from the Help tab in PV Elite. The PV Elite documentation accompanies each new version of the program and is supplied in both PDF and CHM (online help) formats.
Contact information for Intergraph CAS is included in these documents, as well as displayed in the help system, and in a variety of other locations in the software. We encourage users experiencing problems or confusion with the software to reference the documentation first, and then contact us for further resolution and suggestions.
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PV Elite and CodeCalc Verification and Quality Assurance Manual 11
Product Support Intergraph CAS welcomes input/suggestions from our users. Users having problems with our software may freely contact Intergraph CAS through our eCustomer support system, which is found on our company website.
Our Technical Support staff may ask users with a numerical/computational issue in PV Elite to submit the job to Intergraph CAS. This allows our support staff to identify the problem and locate the cause, and then contact the user for resolution.
Software Issue Tracking/Resolution PV Elite supports standard practices for tracking released software issues, including:
Incorporating user feedback directly back into the development process.
Notifying users regarding hot fix or service pack updates issued throughout development
Following software release criteria based on issue review and prioritization.
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Intergraph CAS Quality Assurance
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PV Elite and CodeCalc Verification and Quality Assurance Manual 13
S E C T I O N 3
This section describes the test methods through which PV Elite software team performs Quality Assurance testing on PV Elite. In addition, the section describes test methods that you can implement to validate your PV Elite program data against industry-standard benchmarks.
In This Section Test Control ................................................................................... 13 Beta Tests ...................................................................................... 14 Additional Manual Checks for Staff and Beta Users ..................... 15 PV Elite Test Jobs ......................................................................... 19 Corrective Action Standard ............................................................ 20 Post-Development Procedures ...................................................... 20 Distribution Control ........................................................................ 21 Pre-Shipping Procedures ............................................................... 21 CodeCalc QA Checks .................................................................... 23 PV Elite Sample Benchmark Problem Sets ................................... 45
Test Control Currently in the United States there is no organization that formally establishes the credibility of pressure-vessel analysis software. Therefore, software suppliers take on this responsibility.
Generally, there are two ways to establish that any software product is performing correctly:
Comparing product results to hand calculations.
Comparing results to previously verified results from an external source.
If these methods compare favorably to software-generated results, then the software is assumed to be performing as expected. If the results do not compare favorably, the PV Elite development team identifies the differences and corrects the problem.
Testing Process
Before a new version of PV Elite is released, the development personnel perform alpha-level testing. This involves checking the Fortran/C++ or assembler code and running of basic test problems designed to test the functionality of the feature addition, error and abort conditions, and so forth. Next, the development staff generates a series of alpha jobs that:
Test new features against existing software.
Run tests against industry standard programs, such as Compress and BJAC teams.
Suggest to customers that they independently compare the results of PV Elite against their own in-house program or spreadsheets.
Test new features against hand calculations.
Test new features against published literature, such as the ASME VIII-1, PTB-3, and other codes.
Software Verification
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Test the interaction between new features and features already existing in the software.
Once these selected alpha jobs are run and verified to the satisfaction of the lead developer, beta series testing begins.
The new job results are compared to the previously verified results. Program errors that have been identified are remedied and/or justified.
To summarize, at Intergraph CAS, we believe that thoroughly checking software results by hand and comparing these results to those of other software and to benchmarks assures a quality product. This method has worked very well in the past and we will check new versions using this same methodology.
Beta Tests Often before releasing the PV Elite software, we distribute the alpha-tested software to users to perform beta testing. At the end of the test period, we ask that beta users send evaluations to us, so that we can process the information, resolve any issues found, and archive feedback.
The following are the beta test files for the CodeCalc module available from within PV Elite. Intergraph CAS ships some of these files with the PV Elite software.
Beta Test Files
Checks.cci Shell.cci
Extra_qa.cci Texample.cci
Fexample.cci Texample2.cci
Fexample2.cci Vesexmpl.cci
Lg_nozzl.cci WRC107.cci
Lg_nozzl.cci Rctexmpl.cci
Mm_wrc.cci Appy.cci
ASME_Tubesheet.cci
The following section discusses manual checks that users can perform additional verification of the software.
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PV Elite and CodeCalc Verification and Quality Assurance Manual 15
Additional Manual Checks for Staff and Beta Users The tables below display a list of items that should be verified for each release of PV Elite. Different individuals should check each item multiple times.
Installation Checklist
Items to Check Initials Initials Comments
A. Program Installation
B. File Extraction
C. File CRC Check
Database Access Checklist
Items to Check Initials Initials Comments
A. Structural Steel - AISC89.BIN
B. ASME Materials *
1. Check some material properties (selected randomly) with ASME Code
2. Check yield stress vs. temperature table.
* Specify different material ID in the input, and check the allowable stresses, density, TEMA number, and external pressure chart.
Units Checklist
Items to Check Initials Initials Comments
A. Creation of input files
B. Verify change of units
Check each input field of the following modules to verify that the help facilities function properly.
Help Checklist
Items to Check Initials Initials Comments
A. Check Modules
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Items to Check Initials Initials Comments
1. Shells and Heads
2. Nozzles
3. Flange
4. Conical Sections
5. Floating head
6. Horizontal Vessels
7. ASME Tubesheets
8. Tubesheets
9. WRC107/FEA
10. Leg and Lug
11. Pipe and Pad
12. Base Rings
13. Thin Bellows Exp. Joints
14. Thick Joints
15. Half-Pipe
16. Large Openings
17. Rectangular Vessels
18. WRC 297/Annex G
19. Appendix Y
B. Check HELP Index.
C. Search on a topic.
D. Print a HELP topic.
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New Input Generation/General Operation Checklist
Items to Check Initials Initials Comments
A. Check each module with a random example.
1. Shells and Heads
2. Nozzles
3. Flange
4. Conical Sections
5. Floating head
6. Horizontal Vessel
7. ASME Tubesheets
8. TEMA Tubesheets
9. WRC 107
10. Leg and Lug
11. Pipe and Pad
12. Base Rings
13. Thin Joints
14. Thick Joints
15. Half Pipes
16. Large Openings
17. Rectangular Vessels
18. WRC 297
19. Appendix Y
B. Graphics
1. Onscreen
2. Printed
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Items to Check Initials Initials Comments
C. Window operation
1. Merge operation
2. Insert/Delete an item
3. Add an item
4. Browse items
Output Review Checklist
Items to Check Initials Initials Comments
A. Review output data in
1. Terminal
2. Printer
3. Disk file
B. Output Processor
1. Results on screen
2. Print the selected chapters
Operating Environments Checklist
Items to Check Initials Initials Comments
A. Dealer Version
B. Windows
C. Network
1. PV Elite and data on network
2. PV Elite on network, data local
3. PV Elite local, data on network
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PV Elite and CodeCalc Verification and Quality Assurance Manual 19
Vessel Code Checklist
Items to Check Initials Initials Comments
ASME Section VIII, Div. 1
ASME Section VIII, Div. 2
PD-5500
EN - 13445
Miscellaneous Checklist
Items to Check Initials Initials Comments
A. ESL/SPLM (a)
B. Mouse Operations
C. Material Database Editor
1. Editing materials
2. Adding materials
(a) Insures program does not run without the ESL.
PV Elite Test Jobs The PV Elite QA benchmark problem set consists of over 250 different analysis jobs. Each of these jobs is run prior to release time and compared with the results from previous versions. A wide variety of jobs are checked, which includes tests of all wind and seismic codes, checks of baserings, weights, stresses, liquid pressures, MAWP, weights, volumes, required thickness and many others. By analyzing these jobs, the quality of the software is kept very high and consistent. Again, these are just a few sample problems run every time we test the software. Many of the jobs contained in this manual are listed in the table below.
Quality Assurance Test Form
Job Name Perform Analysis Analysis Date
104EX4
11436
ANDY1
APP1_7
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Job Name Perform Analysis Analysis Date
APP1_7_2
APP1_7_3
APPLCHK
AS_450V2
BEDN237
+200 more jobs
Corrective Action Standard PV Elite users have many channels through which they can reach the Intergraph CAS development staff. The main way to contact us is through the eCustomer system. When a problem or error is detected, the development staff reviews the problem and takes corrective action. When a user problem is verified to be a defect, a TR (trouble report) is filled out using internal Intergraph software. After the TR is completed, the problem is fixed, and the user is notified by email through the eCustomer system. Updated PV Elite files are made available in a product Hot Fix or Service Pack, which can be downloaded from the eCustomer website. In many cases, software issues have workarounds. The Intergraph CAS technical support staff notifies users of workarounds whenever possible.
Post-Development Procedures After a new version of the software has been developed, Intergraph CAS uses the following quality assurance procedures to ensure that the new CDs are correct in content, contain the proper ESL protection schemes, and can be reproduced properly.
1. Scan the development machine for virus infection before producing any distribution set. Use the latest version of Trend Micro Office Scan virus-scanning software.
2. Assemble in a "clean" directory all of the files that comprise the installation set. This includes .EXE files, database files, and example files.
3. Run the CRCCHK program to build the CRC verification file.
4. Generate an installation program using Install Shield. Once the DVD is made, test it according to the Distribution Control procedures outlined below.
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Distribution Control To control the distribution and integrity of the program DVDs before sending them out for mass production, Intergraph CAS adheres to the following procedures:
1. After the quality assurance procedures have been completed, use the lead developer's computer to make a production copy of PV Elite.
2. Modify the installation program to load any new executables that may be released with the new version.
3. Load PV Elite onto at least one PC in the production department to check the installation program and DVD integrity.
4. Use Office Scan virus-scanning software to scan each original, all disk drives, and memory for known viruses.
5. Using the appropriate ESL, install and test the masters on another computer. All EXE files accessing the ESL must be tested.
6. Install the masters on a production computer for further use. ESL-specific files should be copied into the appropriate subdirectories for organizational purposes.
7. Send the masters to the DVD duplicator.
8. Install the software from the DVD onto each of the PCs in the engineering and development groups at Intergraph CAS.
9. Load the required set of PV Elite executables onto at least one computer in the production department.
10. Using the DVD and installation checklists, perform periodic testing of the software as necessary.
The following section provides the tasks that must be performed by the development and production personnel to verify the quality of disk sets before shipment.
Pre-Shipping Procedures The following procedures help to ensure that the disk sets shipped by Intergraph CAS contain the correct product, are not infected with a virus, and are void of imperfections.
1. When DVDs are received from the duplicator, install and test a random selection from the batch. These final tests will ensure that the DVDs were correctly assembled by the duplicator, that they are not flawed, and that the ESL interaction routines are in order.
The tests are software-specific and are detailed elsewhere in this manual. None of these tests should use the environment support available from the programs. Run the tests from the installation directory. Ensure that the installation directory is empty before beginning this procedure.
2. Archive a set of DVDs from the first duplication for future use and referral.
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PV Elite and CodeCalc Verification and Quality Assurance Manual 23
S E C T I O N 4
CodeCalc QA Checks
In This Section Introduction .................................................................................... 23 Shell and Head Checks ................................................................. 24 Nozzle Checks ............................................................................... 26 Flange Checks ............................................................................... 28 Cone Checks ................................................................................. 31 Floating Heads Checks .................................................................. 32 Horizontal Vessel Checks .............................................................. 34 Leg and Lug ................................................................................... 34 ASME Tubesheets Checks ............................................................ 36 TEMA Tubesheets Checks ............................................................ 37 WRC 107 Checks .......................................................................... 38 Pipe and Pad Checks .................................................................... 39 Base Ring Checks ......................................................................... 39 Half-Pipe Check ............................................................................. 40 Large Opening Checks .................................................................. 41 Rectangular Vessel Checks ........................................................... 42
Introduction
This section provides the results of QA tests for CodeCalc, which is also the component-analysis part of PV Elite. For simplicity, this part of PV Elite will be referred to as CodeCalc in this chapter. The following CodeCalc modules have been subjected to Intergraph CAS quality assurance procedures.
Shell/Head
Nozzle
Flange
Cone
Floating Head
Horizontal Vessel
Leg and Lug
ASME Tubesheets
TEMA Tubesheets
WRC 107/537
Pipe and Pad
Base Ring
Thin Joint
Thick Joint
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Half-Pipe
Large Opening
Rectangular Vessel
Shell and Head Checks
As a part of its quality assurance procedures, Intergraph CAS completed the following shell and head checks on CodeCalc:
ASME Appendix 1-4, 2 (CodeCalc job: Checks.cc2/ASME VIII-1 2011a, APP 1, 1-4, 2) - Ellipsoidal head under internal pressure.
Parameters CodeCalc ASME
MAWP (psi) 338.87 339
ASME Appendix 1-4, D (CodeCalc job: Checks.cc2/ASME VIII-1 2011a, APP 1, 1-4, D) -Torispherical head under internal pressure
Parameters CodeCalc ASME
Req. thickness (in.) 0.4488 0.45
ASME Appendix 1-4, D2 (CodeCalc job: Checks.cc2/ASME VIII-1 2011a, APP 1, 1-4, D2) -Torispherical head under internal pressure
Parameters CodeCalc ASME
MAWP (psi) 167.16 167
ASME Appendix L-6.1 (CodeCalc job: Checks.cc2/ASME VIII-1 2011a, APP L, L-6.1) - Ellipsoidal head under external pressure
Parameters CodeCalc ASME
A 0.0004623 0.000462
B 5662.91* 5100
EMAWP (psi) 20.9427* 18.9
ASME Appendix L-6.2 (CodeCalc job: Checks.cc2/ASME VIII-1 2011a, APP L, L-6.2) -Torispherical head under external pressure
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Parameters CodeCalc ASME
A 0.0004157 0.00042
B 5092.85* 4700
EMAWP (psi) 16.9385* 15.6
ASME Appendix L-6.3 (CodeCalc job: Checks.cc2/APP L, L-6.3) -Hemispherical head under external pressure
Parameters CodeCalc ASME
A 0.0004623 0.00046
B 5662.91* 5200
EMAWP (psi) 20.9427* 19.23
ASME Appendix L-6.4 (CodeCalc job: Checks.cc2/APP L, L-6.4) - Conical head under external pressure
Parameters CodeCalc ASME
Design Len. 102.30 102.30
A 0.0005912 0.0006
B 7004.29 6900
EMAWP (psi) 38.1777 37.5
ASME Appendix L-9.2.1 (CodeCalc job: Checks.cc2/APP L, L-9.1, 2) - Minimum design metal temperature (MDMT) of a cylinder
Parameters CodeCalc ASME
Unadjusted MDMT (F) 31 31
Adjusted MDMT (F) 12 12
ASME Appendix. L-5 (CodeCalc job: Checks.cc2/APP L, L-5): Selection of a circumferential stiffening ring for a cylinder under external pressure. A bar type 2 in. x 3.75 in. stiffening ring selected.
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Parameters CodeCalc ASME
Moment of Inertia (in. 4) 16.541 16.57
Required Moment of Inertia (in.
4)
16.1933 16.25
Weld load 643.78 644
Weld Allowable load 1828.75 1830
Minimum Weld Thickness 0.25 0.25
* As of this printing the ASME Appendix L6.1, 6.2, 6.3 appear to be in error in determining the B value from the External Pressure chart CS-2 for SA-285C, with E = 24.5 x 106 psi. When points lie in the linear portion of the chart CS-2 (as in cases 4, 5, 60, CodeCalc uses the formula B = A*E/2.
Nozzle Checks
Nozzle checks involve the area of reinforcement and failure path calculations. Intergraph CAS performed the following nozzle checks using CodeCalc:
ASME Appendix L-7.3b (CodeCalc Job: Checks.cc2/APP L, L-7.3B): Insert-type Nozzle lying on a longitudinal weld of a cylindrical shell. A 19-in. Diameter and 0.5-in. thick reinforcement pad is selected.
Parameters CodeCalc ASME
Req. Thk. Shell (in.) 0.5300 0.530
Req. Thk. Noz (in.) 0.0893 0.0893
Reinforcement Area Req. (in.2) 6.228 6.23
Total Area available (in.2) 6.267 6.27
Total weld load, W (lb) 72539.17 72600
Weld load for path 1-1, W1-1 (lb) 71556.86 71600
Weld load for path 2-2, W2-2 (lb) 34856.25 34900
Weld load for path 3-3, W3-3 (lb) 82280.86 82300
Strength of failure path 1-1 (lb) 203289 203000
Strength of failure path 2-2 (lb) 229116 229000
Strength of failure path 3-3 (lb) 250441 250000
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ASME Appendix L-7.4 (CodeCalc Job Checks.cc2/APP L, L-7.4): Abutting-type Nozzle on a cylindrical shell. A 26-in. Diameter and 2.75-in. (average value) thick reinforcement pad is selected.
Parameters CodeCalc ASME
Req. Thk. Shell (in.) 1.8593 1.83
Req. Thk. Noz (in.) 0.3542 0.292
Reinforcement Area Req. (in.2) 29.554 29.6
Total Area available (in.2) 33.647 33.7
Total weld load, W (lb) 317668.22 318000
Weld load for path 1-1, W1-1 (lb) 364331.03 364000
Strength of failure path 1-1 (lb) 319507 318000
ASME Appendix L-7.6 (CodeCalc Job Checks.cc2/APP L, L-7.6): Insert-type Nozzle without pad on a 2:1 ellipsoidal head.
Parameters CodeCalc ASME
Req. Thk. Head (in.) 0.0912 0.091
Req. Thk. Noz (in.) 0.0512 0.051
Reinforcement Area Req. (in.2) 0.755 0.754
Total Area available (in.2) 1.146 1.15
Total weld load, W (lb) 302.43* 250
Weld load for path 1-1, W1-1 (lb) 2992.86 2990
Weld load for path 2-2, W2-2 (lb) 7691.86 7690
Strength of failure path 1-1 (lb) 47542 47500
Strength of failure path 2-2 (lb) 39831 39800
*The differences in dimensions, of the order of 1E-3, are magnified after being multiplied by the allowable stress.
ASME Appendix L-7.7 (CodeCalc Job Checks.cc2/APP L, L-7.71): Abutting-type Hillside Nozzle on a cylindrical shell.
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Parameters CodeCalc ASME
Req. Thk. Shell (in.) 1.1364 1.14
Req. Thk. Noz (in.) 0.1389 0.139
Area Req. in circumferential dir. (in.
2)
3.720 3.68
Area available in circumferential dir. (in.
2)
7.486 7.16
Area Req. in longitudinal dir. (in.
2)
4.545 4.56
Area available in longitudinal dir. (in.
2)
2.607 2.59
The area available in the longitudinal direction is insufficient. The new area values after increasing the nozzle thickness from 0.5 in. to 0.875 in.
Parameters CodeCalc ASME
Area Req. in longitudinal dir. in.2) 4.545 4.56
Area available in longitudinal dir. (in.
2)
5.198 5.18
Minimum Weld throat. (in.2) 0.25 0.25
Actual Weld throat. (in.2) 0.3535 0.35
Flange Checks
Intergraph CAS completed the following flange checks on CodeCalc:
Taylor Forge, Bulletin 502 (CodeCalc Job: Checks.cc2/TAYLOR FORGE)- Integral weld neck flange.
Parameters CodeCalc Taylor Forge
Gasket Reaction Diameter, G (in.) 33.888 33.88
Operating
Bolt Load WM1 (lb) 432484.688 432484
Gasket Seating Force, HG (lb) 71713.25 71713
End Pressure, MD (in. lb) 623292 623292
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Parameters CodeCalc Taylor Forge
Face Pressure, MT (in. lb) 79248 79242
Gasket Load, MG (in. lb) 111600 111599
Total Moment, Mo (in. lb) 814128 814133
Longitudinal Hub Stress (psi) 22865.0 22865
Radial Flange Stress (psi) 10981.8 10982
Tangential Stress Flange (psi) 6799.5 6800
Seating
Bolt Load, WM2 (lb) 120608.648 120609
Flange Design Bolt Load, W (lb) 464192.38 464192
Total Moment, MG (in. lb) * 722364 722371
Longitudinal Hub Stress (psi) 20287.8 20288
Radial Flange Stress (psi) 9744.0 9744
Tangential Stress Flange (psi) 6033.1 6033
*Total Moment is MG in the Taylor Forge bulletin 502 and MA in CodeCalc output.
Taylor Forge, Bulletin 502 (CodeCalc Job: Checks.cc2/ FULL FACE SLIP)- Loose, Slip on Flange with a full face gasket.
Parameters CodeCalc Taylor Forge
Dist. to Gasket Load Reaction hg, (in.) 1.328 1.325
Gasket Reaction Diameter, G (in.) 26.844 26.85
Full Face ID Pressure Load, HGY (lb) 48614.715 48555
Operating
Bolt Load, WM1 (lb) 96302.469 96286
Gasket Seating Force, HG (lb) 68003.63 67994
End Pressure, MD (in. lb) 93300 93305
Face Pressure, MT (in. lb) 17364 17390
Total Moment, MO (in. lb) 110676 110695
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Parameters CodeCalc Taylor Forge
Longitudinal Hub Stress (psi) 1951.8 1995
Radial Flange Stress (psi) 5141.6 5236
Tangential Flange Stress (psi) 13470.3 13176
Bolt Circle Stress (psi) 2585.7 2679
Seating
Bolt Load, WM2 (lb) 71806.469 23196
Flange Design Bolt Load, W (lb) 110451.23 110460
Reverse Moment MG (in. lb) * 29160 29101
*Reverse Moment is MG in Taylor Forge bulletin 502 and MR in CodeCalc output. See "Notes" below.
a. The value of hg, in the Taylor Forge Bulletin is off by 0.0029, using
With C = 29.5 in. and B =24 in. this comes out to be 1.3279 and not 1.325. This error is magnified resulting in error in the calculations of G, WM1, W, H
G, MT, MO, MG, and HGY.
b. The value of WM2 computed in the Taylor Forge Bulletin is incorrect,
Where b = 1.375, y = 200
Gives WM2 = 71806.5
An example taken from Process Equipment Design by Brownell and Young. (P-243) (CodeCalc Job: Checks.cc2/BROWNELL&YOUNG)- Loose-ring type flange.
*Total Flange Moment is MA in Brownell & Young and RMA in CodeCalc output.
Parameters
CodeCalc
Brownell & Young
Gasket Reaction Diameter, G (in.) 33.250 33.25
Operating
Bolt Load, WM1 (lb) 151790.469 152100
Gasket Seating Force, HG (lb) 21544.45 21600
End Pressure, MD (in. lb) 198132 226000
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Parameters
CodeCalc
Brownell & Young
Face Pressure, MT (in. lb) 20220 25200
Gasket Load, MG (in. lb) 13464 18900
Total Moment, MO (in. lb) 231816 270100
Seating
Bolt Load, WM2 (lb) 96623.617 93600
Flange Design Bolt Load, W (lb) 172855.25 160500
Total Moment MG (in. lb) * 1806036 140500
Cone Checks
Cone checks involve area-of-reinforcement and moment-of-inertia requirements. Intergraph CAS performed the following cone checks using CodeCalc:
ASME Appendix L-2.3 (CodeCalc Job: Checks.cc2/ASME VIII-1 2011a, APP L, L-2.3): - A cone-to-cylinder transition under internal pressure.
Parameters CodeCalc ASME
Large end
Line Force, QL (lb) 2749.608 2750
Reinforcement Area Req., Arl (in.2) 12.8802 4.54
Total Area available , Ael(in.2) 0.3490 0.500
Small end
Line Force, QA (lb) 1312.383 1312.5
Reinforcement Area Req., Ars (in.2) 2.2146 2.22
Total Area available, Aes (in.2) 0.7799 0.78
ASME Appendix L-3.3 (CodeCalc File: Checks.cc2/APP L, L-3.3): - A cone-to-cylinder transition under external pressure.
Parameters CodeCalc ASME
Large end
Line Force, QL (lb) 9.6960 2781
Reinforcement Area Req., Arl (in.2) 12.6509 12.7
Total Area available, Ael (in.2) 23.5682 28.9
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Small end
Line Force, QS (lb) 697.3355 696.9
Reinforcement Area Req., Ars (in.2) 0.7046 0.71
Area available in Shell, Aes ( in.2)* 2.5022 2.05*
Area available in Pad (in.2) 2.6250 2.63
Total Area available, Aes (in.2) 5.8318 4.68
The small end available area from the shell does not match as a result of different values of tr, the minimum required thickness of cone at small end. CodeCalc calculates this value iteratively so that the cone can withstand the design pressure.
With, E = 25.125 * 106 psi, A = 4.453 * 10-6, B = 5595.042, D/T = 149.191
CodeCalc computes a tr of 0.392 in., resulting in a MAWP of
which matches the design pressure of 50 psi. The ASME example uses a tr = 0.55 in., which seems incorrect.
Floating Heads Checks
Intergraph CAS completed the following floating heads checks on CodeCalc:
Tested against Exxons in-house design program PEAs- A Type D floating head under both external and internal pressure. (CodeCalc job: Extra_Qa.cc2/TYPE D)
Tubeside Internal Pressure Results:
Parameters CodeCalc PEAs
Operating
Head Req. Thickness (in.) 0.3601 0.360
Flange Req. Thickness (in.) 3.2956 3.296
Operating Bolt Load, WM1 (lb) 302398.0 302398
Gasket Seating Force, HG (lb) 44348.5 44348.4
Flo. Head Moment, Mh (in. lb) -136812 -136739.5
Total Moment, Internal, MO (in. lb) 127584 127660.90
Seating Flange Req. Thickness, Internal Bolt-Up (in.)
3.4527 3.453
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Parameters CodeCalc PEAs
Flange Design Bolt Load, W (lb) 335559.0 335559.0
Total Moment, Internal MG (in. lb) * 235939.9 235939.92
Shellside External Pressure Results:
Parameters CodeCalc PEAs
Operating
Head Req. Thickness (in.) 0.6158 0.609
Flange Req. Thickness (in.) 4.0155 4.015
Operating Bolt Load, WM1 (lb) 302398.0 302398
Gasket Seating Force, HG (lb) 430082.6 430082.59
Flo. Head Moment, Mh (in. lb) -228012 -227899.17
Total Moment, MO (in. lb) 141715.56 141604.46
Seating
Flange Req. Thickness (in.) 3.4527 3.453
Flange Design Bolt Load, W (lb) 335559.0 335559.0
Total Moment MG (in. lb) ** 235939.94 235939.92
The results below are for Soehrens Calculations for Stresses in Spherical Heads and Flanges. The following table displays the Nomenclature and Equation Numbers per ASME Paper 57-A-247.
Parameters
CodeCalc Tubeside Int.
Parameter
CodeCalc Shellside Ext.
PEA Shellside Ext.
Ttl Stress at Head OD, psi Eqn. 30
6611.2 6611.218 21175.1 21175.1
Ttl Stress at Head ID, psi Eqn. 31
1202.5 1202.488 -33058.6 -33058.6
Ttl Flange Stress, Upper psi Eqn. 35
746.6 746.647 5081.8 5081.8
Ttl Flange Stress, Lower psi Eqn. 36
-7432.6 -7432.58 -3803.6 -3803.6
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Horizontal Vessel Checks
Intergraph CAS completed the following horizontal vessel checks on CodeCalc:
ASME APP L, L-2.2 (CodeCalc job Checks.cc2/ASME PG 530): Insert-type Nozzle lying on a longitudinal weld of a cylindrical shell. A 19-in. diameter and 0.5-in. thick reinforcement pad selected.
Parameters CodeCalc ASME
Factor K.2 * 0.7906 0.7904
Total weight of the vessel, full (lb) 345837.91 350000
Longitudinal Compressive Shell allowable (psi)
9440.10 9446
The factor k.2 is an important factor used by CodeCalc to compute the stresses using Zick analysis. ASME has used a different method to find the required thickness. Moreover, ASME does not compute shear stresses at the saddles in this example.
Leg and Lug
Intergraph CAS completed the following leg and lug checks on CodeCalc:
Design of legs for a vertical vessel under internal pressure and wind loading, verified by hand calculations (CodeCalc job: ExtraQa.cc2/Hand Check Legs). Angle legs attached in the diagonal orientation (both legs attached to the vessel).
Wind velocity is 100 miles/hr.
Importance factor = 1
Force coefficient = 1
Exposure category = C
Parameters CodeCalc Hand Check
Wind Pressure (psf) 28.038 28.88
Total Wind Force (lb) 1345.848 1376.7
Shear at Top of Leg (lb) 530.53 542.02
Total Overturning Moment at Top of Legs (ft-lb)
3364.6 3441.85
Axial Compression on Leg
Furthest from Neutral Axis (psi)
910.71 915.76
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Unity Check on the Legs:
Parameters CodeCalc Hand Check
Actual Allowable Actual Allowable
Weak Axis Bending Stress (psi) 16384.77 24227.28 16723.5 24227
Strong Axis Bending Stress (psi)
11613.22 24227.28 11869 24227
Axial Compressive Stress (psi) 910.71 16053.99 915.7 16068
Unity Check Ratio 1.212 1.237
Design of a support lug for a vertical vessel. Taken from the Pressure Vessel Design Handbook by Bednar, 2nd edition (page 154) example 5.1 (CodeCalc job: Lugs.cc2/BEDNAR EX. 5.1).
Parameters CodeCalc BEDNAR
Force on One Lug, F (lb) 41,000.64 41,000
Bending Stress in the Base Plate (psi)
13,814.78 18,700
Gusset Plate Allowable
Compressive Stress, SgaB (psi)
9,785.29 9,885
The bending stress in the base plate s which, is Spl2 in the CodeCalc printouts is calculated as,
This expression is for stress on a rectangular plate under uniform pressure p, with three edges fixed and one edge free. (Formulas for Stress and Strain, Roark and Young, 5th edition page 396.)
With,
Where,
a = 15 in.,
b = 12 in.,
t = 1.125 in.
The factor is taken from a table in Roark and Young for a known of a/b, which in this case is
1.25. The correct value of after interpolating is 0.524, which gives a value of 13580.22 psi.
While Bednar took the next higher value of as 0.72, this results in a different value of .
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This example is for the design of a support lug with Full Ring-Girder type reinforcement ring. Taken from the Pressure Vessel Design Handbook by Bednar, 2
nd edition (page 158) example
5.2 (CodeCalc job: Lugs.cc2/BEDNAR EX. 5.2).
Parameters CodeCalc Bednar
Force on one lug (compression side), Flug (lb.)
5000.00 5000
Force acting in the plane of ring, P (lb.)
2500.00 2500
Ring load pt
Bending moment, M1 (lb-in) 29841.55 29900
Tangential thrust, T1 (lb.) 0.00 0.0
Ring mid pt
Bending moment, M2 (lb-in) 42583.66 17062.5
Tangential thrust, T2 (lb.) 1250.00 1250
ASME Tubesheets Checks
These examples follow the 1997 edition of the ASME code.
ASME Part UHX - 20.1.1 (c) (CodeCalc job: ASME_Tubesheet.cc2/UHX-20.1.1): U-tube type heat exchanger with integral tubesheet construction.
Parameters CodeCalc ASME
Eff. Tube hole dia., d*(in.) 0.7500 0.75
Eff. Tube pitch, p*(in.) 1.1508 1.15
Axial Shell bending Stress, s,b (psi) -17575.04 -17600
ASME Part UHX - 20.2.1 (c) (CodeCalc job: ASME_Tubesheet.cc2/UHX-20.2.1) A fixed tubesheet with tubesheet extended as flange and gasketed channel side. This is compared with ASME UHX 20.2.1, step 10 case 7.
Parameters CodeCalc ASME
Shell Membrane Stress due to Joint Interaction, sm (psi)
-99.1947 -96.1
Shell Bending Stress due to Joint Interaction, s, b (psi)
-61109 -61100
Shell Stress Summation, s (psi) 61217.12 61200
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Parameters CodeCalc ASME
s, Allow 61500.00 61500
Bending stress (Pres. Only) (psi)
Effective pres. Pe (Temp. only) (psi)
Bending stress (Temp. only) (psi)
TEMA Tubesheets Checks
A fixed tubesheet with the tubesheet extended has a flange and a gasketed channel side. This is compared with B-JAC
TM teams, a heat exchanger design package. (CodeCalc job:
Checks.cc2/COMPARISON).
Parameters CodeCalc B-JACTM
Eff. Shell side design Pres., bend., PSU (psi)
5.664 5.8
Eff. Tube side design Pres., bend., PTU (psi)
55.069 55.1
Req. Thk. Shellside, Trs (in.) 0.8304 0.8205
Req. Thk. Tubeside. Trc (in.) 2.5893 2.524
Equiv. Differential Exp. Pres., PD (psi) -0.488 0.0*
Shell longitudinal stress (Tensile), STSMAX (psi)
44 0.0*
Shell longitudinal stress (Comp.), STSMIN (psi)
278 296
Tube longitudinal stress (Tensile), STTMAX (psi)
12556.94 12772
Tube longitudinal Stress (Comp.), STTMIN (psi)
117.77 0*
Tube to Tubesheet load, WJ (lb) 1355.03 1378
This difference in the value of Pd and stresses is due to different interpretation of factor J,
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TEMA suggests that if, (a)
Then, J can be assumed equal to 0, this is used by BJAC. According to some experts J should be taken 0 if,
and (b)
CodeCalc uses this interpretation. Consequently, there are differences in the Pd, the Shell longitudinal tensile stress, and the Tube longitudinal compressive stress values obtained from both the programs.
WRC 107 Checks
This example is a comparison with another computer program, called CompressTM
. This example compares a round solid attachment on a cylindrical shell. (CodeCalc job: Extra_qa.cc2/COMPAR. TO COMP).
Using WRC 107 March 1979 Version
Parameters CodeCalc CompressTM
Beta 0.230 0.23
Total circumferential stress @ Au (psi)
-34281 -30118
Total Longitudinal stress @ Bl (psi) 30083 32407
Total shear stress @ Cu (psi) -92 -92
Stress Intensity, @ Al (psi) 30283 32574
Stress Intensity, @ Bu (psi) 47999 45950
Stress Intensity, @ Cl (psi) 41165 43630
Stress Intensity, @ Du (psi) 58573 51845
Stress Intensity, @ Dl (psi) 40655 43100
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Pipe and Pad Checks
A B31.3 intersection area of reinforcement and MAWP calculations tested with MathCad calculations. (CodeCalc Job: Extra_Qa.cc2 /Hand_Calcs).
Parameters CodeCalc PEAs
Req. thk. of header (in.) 0.450 0.449
Req. thk. of branch (in.) 0.194 0.194
Req. reinforcement area (in.2) 3.4855 3.485
Available reinforcement area (in.2) 3.6052 3.604
MAWP of Header (psi) 694.18 694.13
MAWP of Branch (psi) 1385.28 1385.19
Est. MAWP of Assembly (psi) 609.60 609.55
Base Ring Checks
This example is benchmarked with hand calculations. A base ring with a continuous top ring. (CodeCalc job: Checks.cc2/PVHB EXAMPLE).
The following illustrates the comparison of results for a simplified analysis for base ring thickness from Jawad and Farr.
Parameters CodeCalc Hand Calcs
Load per bolt, (lb) 43527.7344 43528
Req. Area/Bolt, (in.2) 1.7411 1.741
Bolt stress, approx. analysis (psi) 18925.10 16413
Concrete stress, operating condition (psi)
813.64 875.31
Basering Thk., simplified (in.) 1.8677 1.937
More accurate analysis using neutral axis shift calculations for base ring thickness, from Singh and Soler.
Parameters CodeCalc Hand Calcs
Bolt stress (psi) 14244.13 12549
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Parameters CodeCalc Hand Calcs
Concrete stress (psi) 493.33 478.84
Basering Thk. (in.) 1.4573 1.432
Continuous Top Ring Calculations:
Parameters CodeCalc Hand Calcs
Req. Thk. as fixed beam (in.) 1.7850 1.916
Req. Thk. per Moss (in.) 1.3669 1.467
Gusset Thickness:
Parameters CodeCalc Hand Calcs
Req. Thk. in tension (in.) 0.3286 0.378
Req. Thk. in compression (in.) 0.672 0.672
Skirt Thickness at Operating Condition:
Parameters CodeCalc Hand Calcs
Req. Thk. in tension (in.) 0.3286 0.398
Req. Thk. in compression (in.) 0.2835 0.287
Half-Pipe Check
ASME Appendix EE-3 (CodeCalc Job: Checks.cc2/ ASME EXAMPLE): A cylindrical shell with a half-pipe.
Parameters CodeCalc ASME
Min. req. thk. of shell, Int. press. (in.) 0.2392 0.24
Max. permissible pressure, P
(Pprime) (psig) 385.3763 366
Longitudinal tensile stress in shell, S
(Sprime) (psi) 6080.0000 6080
Req. half-pipe thk., T (in.) 0.0502 0.050
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Parameters CodeCalc ASME
Min. fillet weld size, Fillet (in.) 0.1180 0.12
Large Opening Checks
Shell with a large nozzle (CodeCalc Job: Checks.cc2/SENIOR GB TEST): Tested against hand calculations performed by a client.
Parameters CodeCalc Hand Calcs.
Longitudinal hub stress, SH* (psi) 19520 19494
Radial flange stress, SR* (psi) 1036 1032
Tangential flange stress, ST* (psi) 10945 10960
Stresses at the head-shell junction,
Parameters CodeCalc Hand Calcs.
Longitudinal hub stress, Shs (psi) 13314.04 13161
Radial stress, Srs (psi) 603.63 610
Tangential stress, Sts (psi) 5578.62 5564
Stresses at the opening head junction,
Parameters CodeCalc Hand Calcs.
Longitudinal hub stress, Sho (psi) 16997.471 16960
Radial stress, Sro (psi) 902.257 898
Tangential stress, Sto (psi) 9750.84 9759
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Rectangular Vessel Checks
ASME APP. 13, 13-17(b) (CodeCalc job: Rctexmpl.cc2/EXAMPLE A2): A rectangular vessel with two long sides having different thickness (sketch A2), designed for internal pressure.
Parameters CodeCalc ASME
Membrane
Short side plate, (psi) 1242.00 1242
Long side plate, t2 (psi) 488.39 488
Long side plate, t22 (psi) 100.81 101
Bending
Short side plate, @ Q (psi) 2560.62 2571
Short side plate, @ Q1 (psi) 15775.12 15778
Long side plate, @ M (psi) 3679.71 3683
Long side plate, @ Q (psi) 250.06 250
Long side plate, @ M1 (psi) 9556.91 9572
Long side plate, @ Q1 (psi) 6162.16 6153
ASME APP. 13, 13-17(c) (CodeCalc job Rctexmpl.cc2/EXAMPLE A3): A rectangular vessel with uniform wall thickness and corners bend to a radius (sketch A3) designed for internal pressure.
Parameters* CodeCalc ASME
Membrane
Short side plate, @ C (psi) 450.00 450
Long side plate, @ A (psi) 300.00 300
Corner section, (psi) 485.41 485
Bending
Moment at mid pt of long side, Ma (in.-lb)
-2812.6814 -2820
Short side plate, Inner @ C (psi) 10123.91 10084
Short side plate, Outer @ C (psi) -10123.91 -10084
Short side plate, Inner @ D (psi) 5623.91 -5583*
Short side plate, Outer @ D (psi) -5623.91 5583*
Long side plate, Inner @ A (psi) -16876.09 -16927
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Parameters* CodeCalc ASME
Long side plate, Outer @ A (psi) 16876.09 16927
Long side plate, Inner @ B (psi) 1123.91 1080
Long side plate, Outer @ B (psi) -1123.91 -1080
Corner section, Inner (psi) 12248.52 12209
Corner section, Outer (psi) -12248.52 -12209
As of this printing, ASME is in error about the stress state at point D. The stress at the point D on the short side is as per ASME Section VIII Div. 1 Appendix 13-7 Equation 29.
With,
MA = -2812.68 in-lb
P = 15 psi
I1 = 0.0833 in4
L1 = 10 in.
L2 = 20 in.
R = 10 in.
For the inner side,
c=ci=0.5
Which gives, (Sb)Di = 5623.91 psi,
while ASME has a stress value of -5583 psi.
ASME Appendix 13, 13-17(g) (CodeCalc job: Extra_QA.cc2/ASME EXAMPLE 13): A vessel of obround cross section, with an I-section reinforcement member welded on, Sketch B2.
Taking the pressure P = 29.9 psi. to get the ASME stress values.
Parameters CodeCalc ASME
Combined MOI, I11 (in.4) 6.8592 6.859
Membrane
Short side plate, @ C (psi) 978.19 978.32
Long side plate, @ A (psi) 489.09 489.16
Bending
Short side plate, Outer @ C (psi) -15647.72 -15641.75
Long side plate, Outer @ A (psi) 16935.70 16928.78
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Parameters CodeCalc ASME
Total
Short side plate, Outer @ C (psi) -14669.54 -14662.96
Long side plate, Outer @ A (psi) 17424.79 17417.946
ASME Appendix 13, 13-17(i) (CodeCalc job: Rctexmpl.cc2/EXAMPLE C1): A vessel of circular cross section, with a single diametral staying plate, Sketch C1.
These stresses are maximum stresses occurring at the shell-plate junction.
Parameters CodeCalc ASME
Membrane
Shell section (psi) 800.00 800
Diametral plate (psi) 2.10 2.1
Bending
Shell section, Inner (psi) 8884.12 8856
Diametral plate, Inner (psi) 25140.69 25020
Total
Shell section, Inner (psi) 9684.12 9656
Diametral plate, Inner (psi) 25142.79 25022
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PV Elite and CodeCalc Verification and Quality Assurance Manual 45
S E C T I O N 5
PV Elite Sample Benchmark Problem Sets
In This Section Problem 1 - Natural Frequency Calculation ................................... 45 Problem 2 - Example of Stiffening Ring Calculation ...................... 49 Problem 3 - Nozzle Reinforcement, Weld Strength, Weld Size .... 52 Problem 4 - Vessel under Internal and External Pressure on Legs ....................................................................................................... 64 Problem 5 - Vertical Vessel with Wind and Seismic Loads ........... 74 Problem 6 - Comparison against CAESAR II ................................ 83 Problem 7 - ASME Section VIII Division 2 Sample Comparisons . 86 Problem 8 - EN-13445 Nozzle Reinforcement .............................. 93
Problem 1 - Natural Frequency Calculation
The purpose of this problem is to ensure that PV Elite is computing the fundamental frequency of a vertical tower correctly. This problem is a comparison against the sample presented in Henry Bednars Pressure Vessel Design Handbook, 2nd Edition (Page 126). The result for this problem should be approximately 1.15 sec/cycle or 0.9 hertz.
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PV Elite Vessel Analysis Program: Input Data
Natural Frequency Comparison to Bednar p126
Design Internal Pressure (for Hydrotest) 100.00 psig
Design Internal Temperature 200 F
Type of Hydrotest UG99-b
Hydrotest Position Vertical
Projection of Nozzle from Vessel Top 0.0000 in.
Projection of Nozzle from Vessel Bottom 0.0000 in.
Minimum Design Metal Temperature - 1994 F
Type of Construction Welded
Special Service None
Degree of Radiography RT 1
Miscellaneous Weight Percent 0.0
Use Higher Longitudinal Stresses (Flag) Y
Select t for Internal Pressure (Flag) N
Select t for External Pressure (Flag) N
Select t for Axial Stress (Flag) N
Select Location for Stiff. Rings (Flag) N
Consider Vortex Shedding
Perform a Corroded Hydrotest
Is this a Heat Exchanger N
User Defined Hydro. Press (Used if > 0) 0.0000 psig
User defined MAWP 0.0000 psig
Load Case 1 NP+EW+WI+BW
Load Case 2 NP+EW+EQ+BS
Load Case 3 NP+OW+WI+BW
Load Case 4 NP+OW+EQ+BS
Load Case 5 NP+HW+HI
Load Case 6 NP+HW+HE
Load Case 7 IP+OW+WI+BW
Load Case 8 IP+OW+EQ+BS
Load Case 9 EP+OW+WI+BW
Load Case 10 EP+OW+EQ+BS
Load Case 11 HP+HW+HI
Load Case 12 HP+HW+HE
Wind Design Code ASCE-7 93
Basic Wind Speed [V] 0.0000 mile/hr
Surface Roughness Category C: Open Terrain
Importance Factor 1.0
Base Elevation 0.0000 ft.
Percent Wind for Hydrotest 0.0
Using User defined Wind Press. Vs. Elev. N
Damping Factor (Beta) for Wind (Ope) 0.0000
Damping Factor (Beta) for Wind (Empty) 0.0000
Damping Factor (Beta) for Wind (Filled) 0.0000
Seismic Design Code ASCE-7 88
Seismic Zone 0.0000
Importance Factor 1.0000
Soil Type S1
Horizontal Force Factor 2.0000
Percent Seismic for Hydrotest 0.0000
Design Nozzle for M.A.W.P. + Static Head Y
Consider MAP New and Cold in Noz. Design
Consider External Loads for Nozzle Des. N
Use ASME VIII-1 Appendix 1-9 N
Material Database Year 1997
Configuration Directives:
Do not use Nozzle MDMT Interpretation VIII-1 01-37 No
Use Table G instead of exact equation for "A" No
Shell Head Joints are Tapered No
Compute "K" in corroded condition No
Use Code Case 2286 No
Use the MAWP to compute the MDMT No
Using Metric Material Databases, ASME II D No
Complete Listing of Vessel Elements and Details:
Element From Node 10
Element To Node 20
Element Type Skirt Sup.
Description
Distance "FROM" to "TO" 10.000 ft.
Skirt Inside Diameter 60.000 in.
Diameter of Skirt at Base 60.000 in.
Skirt Thickness 0.5000 in.
Internal Corrosion Allowance 0.0000 in.
Design Temperature Internal Pressure 100 F
Design Temperature External Pressure 100 F
Effective Diameter Multiplier 1.2
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Material Name SA516-70
Allowable Stress, Ambient 17500. psi
Allowable Stress, Operating 17500. psi
Allowable Stress, Hydrotest 26250. psi
Material Density 0.0010000 lb./cu.in.
P Number Thickness 1.25 in.
Yield Stress, Operating 38000. psi
UCS-66 Chart Curve Designation B
External Pressure Chart Name CS-2
UNS Number K02700
Product Form Plate
Efficiency, Longitudinal Seam 1.0
Efficiency, Head-to-Skirt or Circ. Seam 1.0
Element From Node 10
Detail Type Weight
Detail ID F
Dist. from "FROM" Node / Offset dist 5.0000 ft.
Miscellaneous Weight 10000. lb.
Offset from Element Centerline 0.0000in.
--------------------------------------------------------
Element From Node 20
Element To Node 40
Element Type Cylinder
Description
Distance "FROM" to "TO" 20.000 ft.
Inside Diameter 60.000 in.
Element Thickness 0.5000 in.
Internal Corrosion Allowance 0.0000 in.
Nominal Thickness 0.0000 in.
External Corrosion Allowance 0.0000 in.
Design Internal Pressure 10.000 psig
Design Temperature Internal Pressure 100 F
Design External Pressure 10.000 psig
Design Temperature External Pressure 100 F
Effective Diameter Multiplier 1.2
Material Name SA-516 70
Efficiency, Longitudinal Seam 1.0
Efficiency, Circumferential Seam 1.0
Element From Node 20
Detail Type Weight
Detail ID E
Dist. from "FROM" Node/Offset dist 10.000 ft.
Miscellaneous Weight 15000. lb.
Offset from Element Centerline 0.0000 in.
--------------------------------------------------------
Element From Node 40
Element To Node 50
Element Type Cylinder
Description
Distance "FROM" to "TO" 19.000 ft.
Inside Diameter 60.000 in.
Element Thickness 0.5000 in.
Internal Corrosion Allowance 0.0000 in.
Nominal Thickness 0.0000 in.
External Corrosion Allowance 0.0000 in.
Design Internal Pressure 10.000 psig
Design Temperature Internal Pressure 100 F
Design External Pressure 10.000 psig
Design Temperature External Pressure 100 F
Effective Diameter Multiplier 1.2
Material Name SA-516 70
Efficiency, Longitudinal Seam 1.0
Efficiency, Circumferential Seam 1.0
Element From Node 50
Detail Type Weight
Detail ID C
Dist. from "FROM" Node / Offset dist 9.5000 ft.
Miscellaneous Weight 10000. lb.
Offset from Element Centerline 0.0000 in.
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Element From Node 60
Element To Node 80
Element Type Cylinder
Description
Distance "FROM" to "TO" 16.000 ft.
Inside Diameter 96.000 in.
Element Thickness 0.7500 in.
Internal Corrosion Allowance 0.0000 in.
Nominal Thickness 0.0000 in.
External Corrosion Allowance 0.0000 in.
Design Internal Pressure 10.000 psig
Design Temperature Internal Pressure 100 F
Design External Pressure 10.000 psig
Design Temperature External Pressure 100 F
Effective Diameter Multiplier 1.2
Material Name SA-516 70
Efficiency, Longitudinal Seam 1.0
Efficiency, Circumferential Seam 1.0
Element From Node 60
Detail Type Weight
Detail ID B
Dist. from "FROM" Node / Offset dist 8.0000 ft.
Miscellaneous Weight 20000. lb.
Offset from Element Centerline 0.0000 in.
--------------------------------------------------------
Element From Node 60
Element To Node 80
Element Type Cylinder
Description
Distance "FROM" to "TO" 16.000 ft.
Inside Diameter 96.000 in.
Element Thickness 0.7500 in.
Internal Corrosion Allowance 0.0000 in.
Nominal Thickness 0.0000 in.
External Corrosion Allowance 0.0000 in.
Design Internal Pressure 10.000 psig
Design Temperature Internal Pressure 100 F
Design External Pressure 10.000 psig
Design Temperature External Pressure 100 F
Effective Diameter Multiplier 1.2
Material Name SA-516 70
Efficiency, Longitudinal Seam 1.0
Efficiency, Circumferential Seam 1.0
Element From Node 60
Detail Type Weight
Detail ID B
Dist. from "FROM" Node / Offset dist 8.0000 ft.
Miscellaneous Weight 20000. lb.
Offset from Element Centerline 0.0000 in.
--------------------------------------------------------
Element From Node 80
Element To Node 90
Element Type Cylinder
Description
Distance "FROM" to "TO" 16.000 ft.
Inside Diameter 96.000 in.
Element Thickness 0.7500 in.
Internal Corrosion Allowance 0.0000 in.
Nominal Thickness 0.0000 in.
External Corrosion Allowance 0.0000 in.
Design Internal Pressure 10.000 psig
Design Temperature Internal Pressure 100 F
Design External Pressure 10.000 psig
Design Temperature External Pressure 100 F
Effective Diameter Multiplier 1.2
Material Name SA-516 70
Efficiency, Longitudinal Seam 1.0
Efficiency,. Circumferential Seam 1.0
Element From Node 80
Detail Type Weight
Detail ID A
Dist. from "FROM" Node / Offset dist 8.0000 ft.
Miscellaneous Weight 20000. lb.
Offset from Element Centerline 0.0000 in.
PV Elite is a trademark of Intergraph CADWorx & Analysis Solutions, Inc. 2014
Natural Frequency for the Operating Case (No Liquid), Freese Method
Natural Frequency Calculation
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| | Element | Centroid | Elem. End | Elem. Ang. | Element
From| To | Total Wgt. | Deflection | Deflection | Rotation | Empty Wgt.
| | lbm | in. | in. | | lbm
-------------------------------------------------------------------------
10 | 20 | 10011.4 | 0.077412 | 0.30044 | 0.0048560 | 10011.4
20 | 40 | 15022.8 | 1.13129 | 2.39547 | 0.012092 | 15022.8
40 | 50 | 10021.7 | 3.91854 | 5.68701 | 0.016406 | 10021.7
50 | 60 | 10021.7 | 7.63959 | 9.72088 | 0.018672 | 10021.7
60 | 80 | 20043.8 | 11.5172 | 13.3188 | 0.018782 | 20043.8
80 | 90 | 20043.8 | 15.1227 | 16.9273 | 0.018798 | 20043.8
The Natural Frequency for the Vessel (Empty.) is 0.90323 Hz.
Natural Frequency for the Operating Case, Freese Method
Natural Frequency Calculation
| | Element | Centroid | Elem. End | Elem. Ang. | Element
From| To | Total Wgt. | Deflection | Deflection | Rotation | Emtpy Wgt.
| | lbm | in. | in. | | lbm
10 | 20 | 10011.4 | 0.077412 | 0.30044 | 0.0048560 | 10011.4
20 | 40 | 15022.8 | 1.13129 | 2.39547 | 0.012092 | 15022.8
40 | 50 | 10021.7 | 3.91854 | 5.68701 | 0.016406 | 10021.7
50 | 60 | 10021.7 | 7.63959 | 9.72088 | 0.018672 | 10021.7
60 | 80 | 20043.8 | 11.5172 | 13.3188 | 0.018782 | 20043.8
80 | 90 | 20043.8 | 15.1227 | 16.9273 | 0.018798 | 20043.8
The Natural Frequency for the Vessel (Ope...) is 0.90323 Hz.
Natural Frequency for the Filled Case, Freese Method
The Natural Frequency for the Vessel (Filled) is 0.48376 Hz.
PV Elite is a trademark of Intergraph CADWorx & Analysis Solutions, Inc. 2014.
Problem 2 - Example of Stiffening Ring Calculation
This sample problem was taken from the ASME Section VIII Division 1 pressure vessel code page 531-532 A-98 addenda. This stiffening ring is a channel welded to the outside of a 169-inch OD vessel. The test here is to compute the required moment of inertia of the ring. The ASME code calculated value for Is (the required moment of inertia) 15.61 in
4. PV Elite obtains
an almost identical result of 16.2 in4. The difference is due to the fact that PV Elite computes the
strain factor A to more significant figures than the code example.
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PV Elite Vessel Analysis Program: Input Data
Design Internal Pressure (for Hydrotest) 0.0000 psig
Design Internal Temperature 0 F
Type of Hydrotest Not Specified
Hydrotest Position Horizontal
Projection of Nozzle from Vessel Top 0.0000 in.
Projection of Nozzle from Vessel Bottom 0.0000 in.
Minimum Design Metal Temperature -20 F
Type of Construction Welded
Special Service None
Degree of Radiography RT 1
Miscellaneous Weight Percent 0.0
Use Higher Longitudinal Stresses (Flag) Y
Select t for Internal Pressure (Flag) N
Select t for External Pressure (Flag) N
Select t for Axial Stress (Flag) N
Select Location for Stiff. Rings (Flag) N
Consider Vortex Shedding Y
Perform a Corroded Hydrotest N
Is this a Heat Exchanger N
User Defined Hydro. Press. (Used if > 0) 0.0000 psig
User Defined MAWP 0.0000 psig
User Defined MAPnc 0.0000 psig
Load Case 1 NP+EW+WI+FW+BW
Load Case 2 NP+EW+EE+FS+BS
Load Case 3 NP+OW+WI+FW+BW
Load Case 4 NP+OW+EQ+FS+BS
Load Case 5 NP+HW+HI
Load Case 6 NP+HW+HE
Load Case 7 IP+OW+WI+FW+BW
Load Case 8 IP+OW+EQ+FS+BS
Load Case 9 EP+OW+WI+FW+BW
Load Case 10 EP+OW+EQ+FS+BS
Load Case 11
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