v 2154 101 a 214 c_mechanical calculation (v 410)
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7/16/2019 V 2154 101 a 214 C_Mechanical Calculation (v 410)
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Project: NOEV LUBE OIL BLENDING PLANT
Job No.: AL-2499
Document No.: V-2154-101-A-214
Reference Drawing: V-2154-101-A-201_Rev.D & V-2154-101-A-205_Rev.A
Vessel Name: Blending Vessel
Vessel Tag No.: V410
C 5/20/2013
B 5/3/2013
A 4/9/2013
Rev Date
L.N.B
MECHANICAL CALCULATION SHEET
Description Prepared Approval
Issue for review / approval
Issue for review / approval
Issue for review / approval L.D.T
L.D.T
L.D.T
L.A.V
L.A.V
L.A.V
Checked
L.N.B
L.N.B
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. No.: C
INDEX Page
1. Design Data 2
2. Shell Thickness Calculation 2
3. Bottom Head Thickness Calculation 3
4. Top Head Thickness Calculation 4
5. Auxiliary Stiffener Calculation 5
6. Main Stiffener Calculation 6
7. Coil Half-Pipe Calculation 7
8. Weight Calculation Sheet 89. Lug Support 9
10. Nozzle Calculation 12
11. Welding 18
12. Wind Load Analysis 21
13. Seismic Analysis 22
14. Support Analysis for Wind/Seismic 24
15. Stresses in Shell by Wind/Seismic 26
16. Lifting Lug Calculation 27
17. Vibration Calculation 31
18. Baffle Plate Thickness Calculation Sheet 43
19. Conclusion 45
MECHANICAL CALCULATION SHEET
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
1. Design Data
Design Code : None
Service: Blending Vessel
Design pressure
Max. Internal pressure - (Full 3.79 meters of Water) P = 0.372 barg = 0.0372 MPa G
External pressure 0.0 barg = 0.0 MPa GWorking pressure 0.0 barg = 0.0 MPa G
Design temperature 180 degrees C
Working temperature 60 ~ 80 degrees C
Corrosion allowance 0.0 mm
Vessel inside diameter 2400 mm (O/D = 2416 mm)
Vessel length (Flat Head to T.L) 2800 mm
Material S : Maximum allowable stress value
Shell SA-240 TP304 / 304L 112 MPa
Flat Top Head SA-240 TP304 / 304L 112 MPa
Bottom Cone Head SA-240 TP304 / 304L 112 MPa
Nozzle Neck SA-312 TP304 / 304L 112 MPa
Support SA-240 TP304 / 304L 112 MPa
Nozzle Flange: ASME B16.5 Standard
SCH THK.
N1 A/B 150 80S 5.54
N2 150 80S 5.08
N3 150 80S 5.54
N4 150 - 10
N5 150 40S 6.02
N6 150 40S 6.02
N7 A/B/C 150 80S 4.55
N8 A/B/C 150 80S 4.55
N9 150 40S 5.49
N10 150 40S 6.02
2. Shell Thickness Calculation (Refer to ASME Section VIII, Division 1, UG-27)
2.1 Minimum required thickness of shell exclusive corrosion allowance (t):
Circumferential Stress (Longitudinal Joints)
0.0372 x 1200.0
112.0 x 0.85 - 0.6 x 0.0372
where:
P : internal design pressure = 0.0372 MPa < = 36.652 MPa
R : Inside radius of the shell = 1200.0 mm
S : Maximum allowable stress value = 112.0 MPa
E : Joint efficiency = 0.85
Longitudinal Stress (Circumferential Joints)
0.0372 x 1200.0
2.0 x 112.0 x 0.85 + 0.4 x 0.0372
where:
E : Joint efficiency = 0.85
Degree of Radiographic Examination: 10%
2.2 Minimum Thickness of Pressure retaining Components (UG-16 (b)) = 2.5 mm
2.3 Minimum required thickness of shell included corrosion allowance
tr = 0.47 + 0.0 = 0.47 mm
DN 100 (4") SO RF 114.3 102.26
DN 25 (1") SO RF 33.4
DN 100 (4") SO RF 114.3 102.26
DN 100 (4") SO RF 114.3 102.26
DN 25 (1") SO RF 33.4 24.3
77.9288.9SO RFDN 80 (3")
24.3
Nozzle Size Flange Type ClassNozzle Neck Nozzle outside
diameter, mm
Nozzle inside
diameter, mm
DN 50 (2") SO RF 60.3 49.22
DN 40 (1-1/2") SO RF 48.3 38.14
DN 50 (2") SO RF 60.3 49.22
DN 250 (10") SO RF 273.1 253.1
=
= 0.23
95.2
=
=44.6
mm
mm
0.47
=44.6
190.4
=
0.385SE
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
2.4 Choose Nominal thickness of shell, ts = 8.0 mm
3. Bottom Head Thickness Calculation (Refer to ASME Section VIII, Division 1, UG-32)
Type of head: Toriconical Head (with Knuckle)
3.1 Conical Section
3.1.1 Minimum required thickness of Conical Section exclusive corrosion allowance (t):
0.0372 x 2400.0
where:
P : internal design pressure = 0.0372 MPa < = 36.65 MPa
D : Inside diameter of the head skirt = 2400.0 mm
S : Maximum allowable stress value = 112.0 MPa
E : Joint efficiency = 0.85
α : one-half of the included angle of = 60 degrees
the cone at the centerline of head
3.1.2 Minimum required thickness of Head included corrosion allowance
= 0.94 + 0.0 = 0.94 mm
3.1.3 Minimum required thickness of Head, tb = Min. 8.0 mm
3.2 Knuckle Section
r : inside knuckle radius = 250 mm
Di : inside cone diameter at point of tangency = = 2150.0
to knuckle
3.2.1 Minimum required thickness of Knuckle Section exclusive corrosion allowance (t):
where:
3.2.2 Minimum required thickness of Knuckle included corrosion allowance
= 0.62 + 0.0 = 0.62 mm
3.2.3 Minimum required thickness of Knuckle, tK = Min. 8.0 mm
3.3 Stress Relief (Refer to UCS-79)
Type of head: Toriconical Head (Double Curvature)
=> Percent extreme fiber elongation is not exceeded by 5% so that a stress relief is not required
where:
t : Nominal Straight Flange thickness t = 8.0 mm
Rf : Final centerline radius (mean knuckle radius) Rf = 250.0 mm
Ro : Original centerline radius (Crown radius) Ro = 2150.0 mm
4. Top Head Thickness Calculation (Refer to Roark's Formulas for Stress and Strain)
0.94 mm2 x cos(60) x (112 x 0.85 - 0.6 x 0.0372) 95.2
mm2 x 112 x 0.85 - 0.2 x 0.0372 190.4
: Crown radius = 2150 mm
=0.0372 x 2150 x 1.48
=118.6
0.385SE
= 0.6227
: Factor =
= =89.2
1.48
= 2.12 %
=
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev.
Type of head: Flat Head
Assume square plate (axb) 500x500 mm with all edges simply supported
and uniform loads over entire plate.
Top Head Self-Weight = 293.402 kg
F = m x g = 2878.28 N
Area (A) = πD2
/4 = 4.58 m2
P1 = F/A = 0.628 kPa
Structural Weight = 150 kg (Including weight of nozzles, manhole on Top Head - 150 kg)
F = m x g = 1471.5 N
Area (A) = πD2/4 = 4.58 m
2
P2 = F/A = 0.321 kPa
Concentrated Load = 200 kg (Assumed)
F = m x g = 1962 N
Area (A) = πD2/4 = 4.58 m
2
P3 = F/A = 0.428 kPa
Total Dead Load (P) = P1+P2+P3 = 1.38 kPa
Total Live Load (L) = 1.0 kPa (As per API 650 11th Ed. Errata, Oct. 2011, Clause 5.2.1)
Total Uniform Load (q) = P + L = 2.38 kPa
Edges of Plate (a x b) = 500 x 500 mm
a/b = 1
β = 0.2874
α = 0.0444
Elastic Modulus (E) = 183600000 kPa (Interpolate from API 650 11th Ed. Errata, October 2011, Appendix S)
Allowable Stress ([ϭ]) = 112000 kPa (Refer to ASME Section II, Part D, Table 1A)
Required Plate thickness (Refer to Roark's Formulas, Table 11.4, Case 1a)
Choose thickness of Top Head Plate = 8 mm
Max. Deflection (Refer to Roark's Formulas, Table 11.4, Case 1a)
Max. Stress in plate
5. Auxiliary Stiffener Calculation
Length of stiffener L = 500 mm
Width of Plate that using stiffener Wp = 500 mm (Assumed)
Uniform load wa = q x Wp = 1.188 kN/m
= mm1.23
0.07 mm
= 2668 kPa = 112000
= (ACCEPTED)<
kPa (ACCEPTED)
t/2 = 4 mm
< [ϭ]
=
=
=
L
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
Select stiffener properties as below
Area moment of inertia (As per Roark's Formulas, Table A.1, Case 4: Tee section):
Effective area = 1.1 x (D x t)0.5 = 19 x t (Base on ASME Section VIII, Division 1, Appendix 1-8)
where:
t : The thickness of Top Head = 8 mm
b : Effective area (about 19 x t) = 152 mm
tw : The thickness of Stiffener = 8 mm
d : Stiffener height = 50 mm
= 1616 mm2
Elastic modulus (E) = kPa
Plastic section modulus (Zx)
Max. deflection at the center of stiffener (Refer to Roark's Formulas, Table 8.1, Case 2e )
-5 x 1.188 x 7804
Unity Check (UC) ratio calculation
M : Maximum bending moment caused by uniform load wa = 0.037 KN.m
S : Bending Stress caused by M = 2697.2026 KPa
UC ratio : = 0.024 < 1
=> (ACCEPTED)
6. Main Stiffener Calculation
Length of stiffener L = 2400 mm
Width of Plate that using stiffener Wp = 340 mm (Assumed)
mm=
183600000
384 x 183600 x 342951= -0.015
I = = 342951 mm4
= 11.178 mm
= 13769 mm3
M =
8
S =
=
5 0
L
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev.
Uniform load wa = q x Wp = 0.808 kN/m
Agitator Concentrated load W = 310 kg = 3.041 kN
Select stiffener properties as below
b3 : Effective area (about 19 x d3) = 152 mm
d3 : The thickness of Top Head = 8 mm
d2 : Web height = 150 mmb2 : Web thickness = 8 mm
b1 : Bottom flange length = 70 mm
d1 : Bottom flange thickness = 8 mm
PART Area (a) y a x y h h2
bd3/12
mm mm mm mm mm mm
1 560 4 2240 96.41 9295.7 2986.6667
2 1200 83 99600 17.41 303.25 2250000
3 1216 162 196992 -61.59 3792.84 6485.3333TOTAL 2976 298832 2259472
Therefore,
Distance from bottom to Neutral axis
C = 298832 / 2976 = 100.414 mm
Area moment of inertia
I = 10181553.978 + 2259472 = 12441026 mm
Section Modulus
Z = I /C = 123897.35 mm3
Max. deflection at the center of stiffener (Refer to Roark's Formulas, Table 8.1,Case 1e & Case 2e )
-3.0411 x 24003
x 24004
Unity Check (UC) ratio calculation
M : Maximum bending moment caused by uniform load W = 2.406 KN.m
S : Bending Stress caused by M = 19423.324 KPa
UC ratio : = 0.173 < 1
=> (ACCEPTED)
7. Coil Half-Pipe Calculation (Refer to ASME Section VIII, Division 1, Nonmandatory Appendix EE)
7.1 Because of the same thickness of shell and cone head, the half-pipe calculation shall be considered for shell only.
ts : Thickness of the shell = 8.0 mm = 1/3 in
R : Inside shell radius = 1200 mm
D = 2R : Inside shell diameter = 2400 mm = 94.5 in
Half-pipe jacket is DN80 (3")
S : Allowable tensile stress of shell = 112.0 MPa
S1 : Allowable tensile stress of coil half-pipe = 112.0 MPa
P : Internal Pressure in vessel = 0.0372 MPa (Positive pressure inside the shell)
P1 : Design Pressure in coil = 0.98 MPa (Positive pressure inside the half-pipe)
From Fig. EE-2, with D = 94.5 in. and t = 1/3 in., so K = 70
=48 x183600 x 12441026
mm4
a x h2
4612091.063
363895.9764
5205566.94
= -0.536-5 x 0.808
mm
10181553.978
+384 x 183600 x 12441026
M =
4+
8
S =
=
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499
Actual longitudinal tensile pressure in shell
S' = PR/2ts = 2.79 MPa
Permissible coil pressure - Maximum allowable external pressure applied to the shell
P' = F / K = (1.5S - S') / K = 2.36 MPa > P1 = 0.98 MPa
=> PASS
The thickness of shell is satisfactory for pressure inside Half-pipe
Choose Half-pipe DN80 (3"), SCH. 40
Half-pipe thickness included 12.5% undertolerance
t = 0.875 x 5.49 = 4.8 mm
Inside half-pipe radius
r = 88.9/2 - 4.8 = 39.65 mm
The required half-pipe thickness
=> PASS
The minimum fillet weld size
= 1.414 x 0.411 = 0.581 mm
Choose Fillet weld size = 6 mm
7.2 Hydrotest Pressure for Coil Half-pipe (Refer to ASME Section VIII, Division 1, UG-99 (b))
Design Temperature = 180 degrees CTest Temperature = A.T.M
Internal Design Pressure P = 0.980 MPa G
Max. Allowable Stress at Design Temperature Sd = 112 MPa
Max. Allowable Stress at Test Temperature St = 115 MPa
Hydrotest Pressure Ph = 1.3 x P x (St/Sd)
Ph = 1.3 x 0.98 (115/112) = 1.31 MPa G
8. Weight Calculation Sheet
No.
Thickness
(mm) Q'ty
Unit Weight
(kg)
Total Weight
(kg)
1 Shell 8 1 1341.7 1341.68
2 Bottom Cone 8 1 418.64 418.64
3 Roof 8 1 330.97 330.97
4 Stiffenner T-150x8+70x8 - 4 33.37 133.48
5 Stiffenner PL.50x8 - 2 19.47 38.94
6 Top Angle Bar L-70x70x8 - 1 68.01 68.01
7 Half Pipe Coil - 160.3 5.76 923.33
8 Support Lug - Reinforcement PL. 8 4 18.20 72.79
9 Support Lug - Base Plate 25 4 30.31 121.26
10 Support Lug - Compress Plate 18 4 13.33 53.32
11 Support Lug - Gusset Plate 1 16 8 3.03 24.26
12 Support Lug - Gusset Plate 2 16 8 13.07 104.55
13 Lifting Lug 25 2 6.33 12.66
14 Nozzle N1A - Neck - 0.15 7.63 1.14 2" SCH 80S
15 Nozzle N1A - Flange - 1 2.30 2.30 2" 150#
16 Nozzle N1B - Neck - 0.15 7.63 1.14 2" SCH 80S
17 Nozzle N1B - Flange - 1 2.30 2.30 2" 150#
18 Nozzle N2 - Neck - 0.172 5.51 0.95 1-1/2" SCH 80S
19 Nozzle N2 - Flange - 1 1.40 1.40 1-1/2" 150#
20 Nozzle N3 - Neck - 0.15 7.63 1.14 2" SCH 80S
21 Nozzle N3 - Flange - 1 2.30 2.30 2" 150#
22 Nozzle N4 - Neck - 0.2 61.52 12.30 10" SCH 40S
Description
0.411 mm
Unit
Ea
Ea
=
Remark
m
m
m
m
m
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
Ea
m
Ea
Ea
Ea
Ea
Ea
= 2 ×
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499
23 Nozzle N4 - Flange - 1 19.50 19.50 10" 150#
24 Nozzle N4 - Reinforcement 8 1 21.24 21.24
25 Nozzle N4 - Gusset 16 4 2.68 10.72
26 Nozzle N5 - Neck - 0.15 16.40 2.46 4" SCH 40S
27 Nozzle N5 - Flange - 1 5.90 5.90 4" 150#
28 Nozzle N6 - Neck - 0.15 16.40 2.46 4" SCH 40S
29 Nozzle N6 - Flange - 1 5.90 5.90 4" 150#30 Nozzle N7A - Neck - 0.19 3.29 0.63 1" SCH 80S
31 Nozzle N7A - Flange - 1 0.90 0.90 1" 150#
32 Nozzle N7B - Neck - 0.18 3.29 0.59 1" SCH 80S
33 Nozzle N7B - Flange - 1 0.90 0.90 1" 150#
34 Nozzle N7C - Neck - 0.3 3.29 0.99 1" SCH 80S
35 Nozzle N7C - Flange - 1 0.90 0.90 1" 150#
36 Nozzle N8A - Neck - 0.3 3.29 0.99 1" SCH 80S
37 Nozzle N8A - Flange - 1 0.90 0.90 1" 150#
38 Nozzle N8B - Neck - 0.3 3.29 0.99 1" SCH 80S
39 Nozzle N8B - Flange - 1 0.90 0.90 1" 150#
40 Nozzle N8C - Neck - 0.172 3.29 0.57 1" SCH 80S
41 Nozzle N8C - Flange - 1 0.90 0.90 1" 150#
42 Nozzle N9 - Neck - 0.15 11.52 1.73 3" SCH 40S
43 Nozzle N9 - Flange - 1 3.70 3.70 3" 150#
44 Nozzle N10 - Neck - 0.15 16.40 2.46 4" SCH 40S
45 Nozzle N10 - Flange - 1 5.90 5.90 4" 150#
46 Nozzle N10 - Spray Nozzle - 1 13.08 13.08
47 MANWAY M1 - Reinforcement 8 1 40.44 40.44
48 MANWAY M1 - Shell 8 1 32.00 32.00
49 MANWAY M1 - Cap 8 1 32.81 32.81
50 Baffle 6 4 15.98 63.94
51 Angle Bar (Baffle Support) L-50x50x6 - 12 1.06 12.67
52 Insulation - 1 900.00 900.00Empty Weight 4856
Weight of Liquid at Operating Level 10083.0
Weight of Full Water 14345.0
Total Weight of Liquid at Operating Level 14939
Total Weight of Full Water 19201
9. Lug Support (Refer to Pressure Vessel Handbook 10th Edition - By Eugene F. Megyesy)
9.1 Wear plate (Refer to Pressure Vessel Handbook 10th Edition - By Eugene F. Megyesy)
BCD : Bolt Circle Diameter 3060 mm
OD : Vessel Outside Diameter 2416 mm
W : Weight of Vessel (Full of Water) = 19511 kg (Total Weight + Agitator weight)
n : Number of lugs = 4
Q = W/n : Load on one lug = 4877.7 kg
R : Radius of shell = 1208 mm
H : Lever arm of load = 322 mm
2A : 1st Dimension of wear plate = 582 mm (Minimum, Including Top Angle Bar Width)*
2B : 2nd Dimension of wear plate = 550 mm (Minimum)
t : Wall thickness of shell = 8.0 mm
tw : Wear plate thickness (approximate shell thickness) = 8.0 mm
P : Internal Pressure at Wear plate location = 0.00 MPa
* Top angle bar connected with wear plate by full welding therefore using this angle bar as a part of wear plate.
Shell material : SA-240 TP304 / 304L
Allowable stress value : 112 0 MPa
Ea
Ea
Ea
m
Ea
Ea
Ea
Ea
m
m
m
m
m
m
m
m
m
Ea
Ea
Pipe & Flange 2",
B. Flange 4", Bolt/Nut
Ea
Ea
Ea
Ea
Ea
Ea
Ea
set
Ea
Ea
Ea
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. No
Joint Efficiency : 0.85
Shape factors C :
1208 275
8.0 291
C1 = 1C2 = 1
C3 = 1
C4 = 1
The factors K
K1 = 3.3
K2 = 0.01
K3 = 6
K4 = 0.0075
Longitudinal Stress :
= 73.87 MPa
Stress due to internal pressure:
PR
2t
The sum of tensional stresses:
73.87 + 0.00 = 73.87 MPa
It does not exceed the stress value of the girth seam:
112.0 x 0.85 = 95.2 MPa (ACCEPTED)
Circumferential Stress:
= 71.44 MPa
Stress due to internal pressure:
PR
t
The sum of tensional stresses:
71.44 + 0.00 = 71.44 MPa
It does not exceed the stress value of shell material multiplied by 1.5 :
112.0 x 1.50 = 168 MPa (ACCEPTED)
Choose wear plate = 582x550x8 mm
B/A
=
= =0 x 1208
2 x 8
0 x 1208
0.00 MPa
= 0.00 MPa8
= = 151 = 0.945
=
R/t ; =
0.24 =
=291
1208
275
291
= ±
+ 6
+
2 1.17+ /×
= ±
+ 6
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
9.2 Gussets (Refer to Pressure Vessel Design Manual 3rd Ed. 2004 - Dennis R. Moss, Procedure 3-13)
Q : Vertical load per lug = 4877.7 kg = 47851 N
n : Number of gussets per lug = 2 (Double Gusset)
b = 372 mm
h = 346.5 mm
tg : Gusset thickness = 16 mm
θ = 57 degrees
Fy : Minimum Yield Strength of gusset material = 170 MPa
Fa : Allowable axial Stress = 68 MPa (0.4 Fy)
Fb : Allowable bending Stress = 102 MPa (0.6 Fy)
Qa = Q.sinθ : Axial load on gusset = 40131 N
Qb = Q.cosθ : Bending load on gusset = 26061 N
A = tg.C : Cross-sectional area of assumed column = 2495.9 mm2
Axial stress
=> PASS
Bending Stress
=> PASS
Choose dimensions of Double Gusset as shown above
9.3 Base Plate for Double Gusset (Refer to Pressure Vessel Design Manual 3rd Ed. 2004 - Dennis R. Moss, Procedure 3-13)
l : Base plate width = 410 mm
a : Bearing width = 100 mm (Client to confirm)
l1 = 340 mm
φ : Bolt hole diameter = 38 mm
mm
: Section modulus
Nmm
64890 mm3
413.15 mm
=
: Bending moment =
=
=
5E+06
Mpa= 82.966 MPa < Fb = 102
8.039 MPa < Fa = 68
= 155.99
MPa
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
9.3.1 Bending (Assume to be between simply supported with two equal spans)
9.3.2 Bearing
9.3.3 Thickness required base plate
where Mb is bending moment
Choose the actual thickness base plate tb = 25 mm
9.4 Compression Plate for Double Gusset (Refer to Pressure Vessel Design Manual 3rd Ed. 2004 - Dennis R. Moss, Procedure 3-13)
e = 322 (Refer to figure of 8.2 Gussets)
Ev : Modulus of elasticity of vessel = 183600 MPa
Es : Modulus of elasticity of compression plate = 183600 MPa
t : Shell Vessel thickness = 8.0 mm
R : Inside Radius of vessel = 1200.0 mm
tc : Assumed Compression Plate thickness = 18.0 mm
y : Compression Plate width = 220.0 mm
x : Distance between loads = 340.0 mm
Fy : Minimum Yield Strength of gusset material = 170 MPa
Fb : Allowable bending Stress = 102 MPa (0.6 Fy)
Concentrated load on Double Gusset
Foundation modulus
Moment of inertial of Compression plate
Section modulus of Compression plate
Damping factor
Internal bending moment in Compression plate
2E+07 mm4
= 145200 mm3
= 0.0005
1.1671 Nmm2
= 13492 Nmm
= 20.78 mm
= 1.02 N/mm3
= 2E+06 Nmm
= (Uniform load on base plate)
= 1E+07 Nmm
=
= 22234 N (Assumed)
Bending
(w.l = Q) =
8=
8
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
Bending stress
=> PASS
Choose Compression Plate thickness, tc = 18.0 mm
10. Nozzle calculation
10.1 Shell Nozzle N2 DN40 (1-1/2") (Refer to ASME Section VIII, Division 1, UG-45)
Minimum Nozzle neck thickness
where:
S : Maximum allowable stress value, S = 112.0 MPa
E : Joint efficiency E = 1.00
Nozzle inside radius Rn = 19.1 mm
tn (min) : minimum required thickness of Nozzle
10.1.1. ta : minimum neck thickness required for internal and external pressure using UG-27 and UG-28
(plus corrosion allowance), as applicable. The effects of external forces and moments from supplemental
loads (see UG-22) shall be considered. Shear stresses caused by UG-22 loadings shall not exceed 70%
of the allowable tensile stress for the nozzle material.
0.0372 x 19.1 0.71
112.0 x 1.00 - 0.6 x 0.0372 112.0
ta = 0.01 + 0.0 = 0.01 mm
10.1.2. = min ( 3.22 , 2.5 ) = 2.5 mm
where:
tb1 : for vessels under internal pressure, the thickness (plus corrosion allowance) required for pressure
(assuming E = 1.0) for the shell or head at the location where the nozzle neck or other connection
attaches to the vessel but in no case less than the minimum thickness specified for the material in UG-16(b).
tb1 = 2.5 mm
tb2 : for vessels under external pressure
tb2 = 0.0 mm
Max (tb1, tb2) = Max ( 2.5 , 0.0 ) = 2.5 mm
tb3 : the thickness given in Table UG-45 plus the thickness added for corrosion allowance.
(for standard wall pipe)
tb3 = 3.22 + 0.0 = 3.22 mm
=> = max ( 0.01 , 2.50 ) = 2.50 mm
10.1.3. Choose Nozzle actual thickness = 5.08 mm (SCH 80S)
10.1.4. Nozzle actual thickness is compared with the minimum thickness provided which for pipe
material would include a 12.5% undertolerance
= 0.875 x 5.08 = 4.45 > tn (min) = 2.50 mm
Result: the actual thickness provided meets the rules of UG-45 <PASS>
10.2 Flat Top Head Nozzle N1A/B, N3 DN50 (2") (Refer to API 650 11th Edition, Appendix S)
10.2.1 Minimum Nozzle Neck thickness
Base on table S.3.3.1
== = 0.01
102 MPa= 94.689 MPa < Fb =
mm
bant t t ,max(min)
bant t t ,max(min)
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Minimum thickness of Nozzle Neck = 5.54 mm (SCH 80S)
Corrosion Allowance (C.A) = 0.00 mm
Minimum thickness of Nozzle Neck including C.A = 5.54 mm
10.2.2 Choose Nozzle actual thickness = 5.54 mm (SCH 80S)
10.3 Flat Top Head Nozzle N9 DN80 (3") (Refer to API 650 11th Edition, Appendix S)
10.3.1 Minimum Nozzle Neck thickness
Base on table S.3.3.1
Minimum thickness of Nozzle Neck = 5.49 mm (SCH 40S)
Corrosion Allowance (C.A) = 0.00 mm
Minimum thickness of Nozzle Neck including C.A = 5.49 mm
10.3.2 Choose Nozzle actual thickness = 5.49 mm (SCH 40S)
10.4 Flat Top Head Nozzle N6, N10 DN100 (4") (Refer to API 650 11th Edition, Appendix S)
10.4.1 Minimum Nozzle Neck thickness
Base on table S.3.3.1
Minimum thickness of Nozzle Neck = 6.02 mm (SCH 40S)
Corrosion Allowance (C.A) = 0.00 mm
Minimum thickness of Nozzle Neck including C.A = 6.02 mm
10.4.2 Choose Nozzle actual thickness = 6.02 mm (SCH 40S)
10.5 Flat Top Head Nozzle N4 DN250 (10") (Refer to API 650 11th Edition, Appendix S)
10.5.1 Minimum Nozzle Neck thickness
Base on table S.3.3.1
Minimum thickness of Nozzle Neck = 6 mm
Corrosion Allowance (C.A) = 0.00 mm
Minimum thickness of Nozzle Neck including C.A = 6.00 mm
10.5.2 Choose Nozzle actual thickness = 10 mm
10.6. Cone Bottom Head Nozzle N5 DN100 (4") (Refer to ASME Section VIII, Division 1 & API 650 11th Edition, Appendix S)
10.6.1 Minimum Nozzle neck thickness (Refer to ASME Section VIII, Division 1)
where:
S : Maximum allowable stress value, S = 112 MPa
E : Joint efficiency E = 1.00
Nozzle inside radius Rn = 51.13 mm
bant t t ,max(min)
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
tn (min) : minimum required thickness of Nozzle
10.6.1.1 ta : minimum neck thickness required for internal and external pressure using UG-27 and UG-28
(plus corrosion allowance), as applicable. The effects of external forces and moments from supplemental
loads (see UG-22) shall be considered. Shear stresses caused by UG-22 loadings shall not exceed 70%
of the allowable tensile stress for the nozzle material.
0.0372 x 51.1 1.901
112.0 x 1.00 - 0.6 x 0.0372 112.0
ta = 0.02 + 0.0 = 0.02 mm
10.6.1.2 = min ( 5.27 , 2.5 ) = 2.50 mm
where:
tb1 : for vessels under internal pressure, the thickness (plus corrosion allowance) required for pressure
(assuming E = 1.0) for the shell or head at the location where the nozzle neck or other connection
attaches to the vessel but in no case less than the minimum thickness specified for the material in UG-16(b).
tb1 = 2.50 mm
tb2 : for vessels under external pressure
tb2 = 0.00 mm
Max (tb1, tb2) = Max ( 2.50 , 0.00 ) = 2.5 mm
tb3 : the thickness given in Table UG-45 plus the thickness added for corrosion allowance.
(for standard wall pipe)
tb3 = 5.27 + 0.0 = 5.27 mm
=> = max ( 0.02 , 2.5 ) = 2.50 mm
10.6.2. Minimum Nozzle neck thickness (Refer to API 650 11th Edition, Appendix S)
Base on table S.3.3.1
Minimum thickness of Nozzle Neck = 6.02 mm (SCH 40S)
Corrosion Allowance (C.A) = 0.00 mm
Minimum thickness of Nozzle Neck including C.A = 6.02 mm
10.6.3. Choose Nozzle actual thickness = 6.02 mm (SCH 40S)
10.7 Coil Half-pipe Steam Nozzle N7A/B/C & N8A/B/C DN25 (1") (Refer to ASME Section VIII, Division 1)
Minimum Nozzle neck thickness
where:
S : Maximum allowable stress value, S = 112 MPa
E : Joint efficiency E = 1.00
Nozzle inside radius Rn = 12.15 mm
tn (min) : minimum required thickness of Nozzle
10.7.1 ta : minimum neck thickness required for internal and external pressure using UG-27 and UG-28
(plus corrosion allowance), as applicable. The effects of external forces and moments from supplemental
loads (see UG-22) shall be considered. Shear stresses caused by UG-22 loadings shall not exceed 70%
of the allowable tensile stress for the nozzle material.
0.980 x 12.15 11.907
112.0 x 1.00 - 0.6 x 0.980 111.4
ta = 0.11 + 0.0 = 0.11 mm
= = = 0.11 mm
mm= = = 0.02
bant t t ,max(min)
bant t t ,max(min)
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
10.7.2 = min ( 2.96 , 5.49 ) = 2.96 mm
where:
tb1 : for vessels under internal pressure, the thickness (plus corrosion allowance) required for pressure
(assuming E = 1.0) for the shell or head at the location where the nozzle neck or other connection
attaches to the vessel but in no case less than the minimum thickness specified for the material in UG-16(b).
tb1 = 5.49 mm
tb2 : for vessels under external pressure
tb2 = 0.00 mm
Max (tb1, tb2) = Max ( 5.49 , 0.00 ) = 5.49 mm
tb3 : the thickness given in Table UG-45 plus the thickness added for corrosion allowance.
(for standard wall pipe)
tb3 = 2.96 + 0.0 = 2.96 mm
=> = max ( 0.11 , 2.96 ) = 2.96 mm
10.7.3 Choose Nozzle actual thickness = 4.55 mm (SCH 80S)
10.7.4 Nozzle actual thickness is compared with the minimum thickness provided which for pipe
material would include a 12.5% undertolerance
= 0.875 x 4.55 = 3.98 > tn (min) = 2.96 mm
Result: The actual thickness provided meets the rules of UG-45 <PASS>
10.8 Spray Nozzle N10 (Refer to ASME Section VIII, Division 1, UG-45)
10.8.1 Outlet Connection DN50 (2")
Minimum Nozzle neck thickness
where:
P : Design Pressure P = 0.98 MPa G (As per Specification)
S : Maximum allowable stress value, S = 112 MPa
E : Joint efficiency E = 1.00
Nozzle inside radius Rn = 24.6 mm
tn (min) : minimum required thickness of Nozzle
10.8.1.1. ta : minimum neck thickness required for internal and external pressure using UG-27 and UG-28
(plus corrosion allowance), as applicable. The effects of external forces and moments from supplemental
loads (see UG-22) shall be considered. Shear stresses caused by UG-22 loadings shall not exceed 70%
of the allowable tensile stress for the nozzle material.
0.98 x 24.6 24.12
112.0 x 1.00 - 0.6 x 0.98 111.4
ta = 0.22 + 0.0 = 0.22 mm
10.8.1.2. = min ( 3.42 , 24.0 ) = 3.4 mm
where:
tb1 : for vessels under internal pressure, the thickness (plus corrosion allowance) required for pressure
(assuming E = 1.0) for the shell or head at the location where the nozzle neck or other connection
attaches to the vessel but in no case less than the minimum thickness specified for the material in UG-16(b).
tb1 = 24.0 mm (Thickness of 4" Blind Flange RF 150#)
tb2 : for vessels under external pressure
tb2 = 0.0 mm
= = = 0.22 mm
ban t t t ,max(min)
bant t t ,max(min)
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
Max (tb1, tb2) = Max ( 24.0 , 0.0 ) = 24.0 mm
tb3 : the thickness given in Table UG-45 plus the thickness added for corrosion allowance.
(for standard wall pipe)
tb3 = 3.42 + 0.0 = 3.42 mm
=> = max ( 0.22 , 3.42 ) = 3.42 mm
10.8.1.3. Choose Nozzle actual thickness = 5.54 mm (SCH 80S)
10.8.1.4. Nozzle actual thickness is compared with the minimum thickness provided which for pipe
material would include a 12.5% undertolerance
= 0.875 x 5.54 = 4.85 > tn (min) = 3.42 mm
Result: the actual thickness provided meets the rules of UG-45 <PASS>
10.8.2 Inlet Connection DN20 (3/4")
Minimum Nozzle neck thickness
where:
P : Design Pressure P = 0.98 MPa G (As per Specification)
S : Maximum allowable stress value, S = 112 MPa
E : Joint efficiency E = 1.00
Nozzle inside radius Rn = 9.4 mm
tn (min) : minimum required thickness of Nozzle
10.8.2.1. ta : minimum neck thickness required for internal and external pressure using UG-27 and UG-28
(plus corrosion allowance), as applicable. The effects of external forces and moments from supplemental
loads (see UG-22) shall be considered. Shear stresses caused by UG-22 loadings shall not exceed 70%
of the allowable tensile stress for the nozzle material.
0.98 x 9.4 9.25
112.0 x 1.00 - 0.6 x 0.98 111.4
ta = 0.08 + 0.0 = 0.08 mm
10.8.2.2. = min ( 2.51 , 24.0 ) = 2.5 mm
where:
tb1 : for vessels under internal pressure, the thickness (plus corrosion allowance) required for pressure
(assuming E = 1.0) for the shell or head at the location where the nozzle neck or other connection
attaches to the vessel but in no case less than the minimum thickness specified for the material in UG-16(b).
tb1 = 24.0 mm (Thickness of 4" Blind Flange RF 150#)
tb2 : for vessels under external pressure
tb2 = 0.0 mm
Max (tb1, tb2) = Max ( 24.0 , 0.0 ) = 24.0 mm
tb3 : the thickness given in Table UG-45 plus the thickness added for corrosion allowance.
(for standard wall pipe)
tb3 = 2.51 + 0.0 = 2.51 mm
=> = max ( 0.08 , 2.51 ) = 2.51 mm
10.8.2.3. Choose Nozzle actual thickness = 3.91 mm (SCH 80S)
10.8.2.4. Nozzle actual thickness is compared with the minimum thickness provided which for pipe
material would include a 12.5% undertolerance
= 0.875 x 3.91 = 3.42 > tn (min) = 2.51 mm
= = = 0.08 mm
ban t t t ,max(min)
bant t t ,max(min)
ban t t t ,max(min)
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev.
Result: the actual thickness provided meets the rules of UG-45 <PASS>
11. Welding
11.1 Shell Nozzle N2 DN40 (1-1/2") - (Refer to ASME Section VIII, Division 1, UW-16)
11.1.1 Size of weld / Shell thickness
tn (actual) = 5.08 mm
Fillet Leg Length = 6.00 mm
=> tc (actual) = 4.20 mm
t = 8.00 mm
11.1.2 Check for full penetration groove weld and fillet cover weld shown in Fig above
tc (min) = Min ( 6 , 0.7 tmin )
where:
tmin = the smaller of 19 mm or the thickness of the thinner of the parts joined by a fillet, single-bevel, or single-J weld
tmin = Min ( 19.0 , 5.08 , 8.00 ) = 5.08 mm
0.7tmin = 0.7 x 5.08 = 3.56 mm
=> tc (min) = Min ( 6 , 0.7 tmin ) = Min ( 6.00 , 3.56 ) = 3.56 < tc (actual) = 4.2 mm
=> PASS
11.2 Flat Top Head Nozzle N1A/B, N3 DN50 (2") - (Refer to API 650 11th Edition, Clause 5.9)
As per Fig. 5-19 - Flanged Roof Nozzles
where :
DP : Diameter of Hole in Roof Plate (Table 5-14)
DP = 65 mm
11.3 Flat Top Head Nozzle N9 DN80 (3") - (Refer to API 650 11th Edition, Clause 5.9)
As per Fig. 5-19 - Flanged Roof Nozzles
where :
DP : Diameter of Hole in Roof Plate (Table 5-14)
DP = 92 mm
Refer to Table 5-14: Reinforcing plates are not required on nozzle DN 80
11.4 Flat Top Head Nozzle N6, N10 DN100 (4") - (Refer to API 650 11th Edition, Clause 5.9)
As per Fig. 5-19 - Flanged Roof Nozzles
where :
DP : Diameter of Hole in Roof Plate (Table 5-14)
DP = 120 mm
Refer to Table 5-14: Reinforcing plates are not required on nozzle DN 100
11.5 Flat Top Head Nozzle N4 DN250 (10") - (Refer to API 650 11th Edition, Clause 5.9)
As per Fig. 5-19 - Flanged Roof Nozzles
& Table 5-14
where :
DP : Diameter of Hole in Reinforcing Plate
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev
DP = 280 mm
DR : Minimum Outside Diameter of Reinforcing Plate
DR = 550 mm
11.6 Cone Bottom Head Nozzle N5 DN100 (4")
11.6.1 Size of weld, Nozzle thickness & Shell thickness
tn = 6.02 mm (Nozzle thickness)
Fillet Leg Length = 7.00 mm
tc (actual) = 4.90 mm (Refer to fabrication detail drawing)
t = 8.00 mm (Min. Bottom Head thickness after forming)
11.6.2 Check for full penetration groove weld and fillet cover weld shown in Fig above
tc (min) = Min ( 6 , 0.7 tmin )
where:
tmin = the smaller of 19 mm or the thickness of the thinner of the parts joined by a fillet, single-bevel, or single-J weld
tmin = Min ( 19.0 , 6.02 ) = 6.02 mm
0.7tmin = 0.7 x 6.02 = 4.21 mm
=> tc (min) = Min ( 6 , 0.7 tmin ) = Min ( 6.00 , 4.21 ) = 4.21 < tc (actual) = 4.90 mm
=> PASS
11.6.3 Reinforcement Calculation (Refer to ASME Section VIII, Division 1, UG-37)
A : Area of Reinforcement required
A = dtr F + 2tn tr F (1-f r1) = 95.872 mm2
A1 : area in excess thickness in the vessel wall available for reinforcement
(includes consideration of nozzle area through shell if Sn /Sv<1.0)
A1 = larger of below value = 722 mm2
d(E1t - Ftr ) - 2tn(E1t - Ftr )(1 - f r1) = 722.21 mm2
2(t + tn)(E1t - Ftr ) - 2tn(E1t - Ftr )(1 - f r1) = 198.03 mm2
A2 : area in excess thickness in the nozzle wall available for reinforcement (see Fig. UG-37.1)
A2 = smaller of below value = 105.95 mm2
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Re
5(tn - tr n) f r2t = 140.8 mm2
5(tn - tr n) f r2tn = 105.95 mm2
A3 : area available for reinforcement when the nozzle extends inside the vessel wall
A3 = min (5t ti f r2, 5ti ti f r2, 2h ti f r2) = 0 mm2
A41 : cross-sectional area available in outward weld
A41 = (leg)2f r2 = 49.00 mm
2
A42 : cross-sectional area available in inward weld = 0 mm2
where:
leg : Fillet weld size = 7.00 mm
d : finished diameter of circular opening or finished dimension = 102.26 mm
h : distance nozzle projects = 0 mm
t : specified vessel wall thickness = 8.0 mm
tn : nozzle wall thickness = 6.02 mmtr : required thickness of a seamless shell = 0.94 mm
tr n : required thickness of a seamless Nozzle wall = 2.50 mm
ti : nominal thickness of internal projection of nozzle wall = 0 mm
Sn : allowable stress in nozzle = 112 MPa
Sv : allowable stress in vessel = 112 MPa
F : correction factor = 1
E1 = 1
f r1 = 1
f r2 = Sn /Sv = 1
A1 + A2 + A3 + A41 + A42 = 877 mm2 > A = 95.872 mm
2
RESULT : Reforcement for Nozzle N5 is not needed
11.7 Coil Half-pipe Steam Nozzle N7A/B/C & N8A/B/C DN25 (1")
11.7.1 Size of weld, Nozzle thickness & Shell thickness
tn = 4.55 mm (Nozzle thickness)
Fillet Leg Length = 6.00 mm
tc (actual) = 4.20 mm (Refer to fabrication detail drawing)
t = 5.49 mm (Coil Half-pipe thickness)
11.7.2 Check for full penetration groove weld and fillet cover weld shown in Fig above
tc (min) = Min ( 6 , 0.7 tmin )
where:
tmin = the smaller of 19 mm or the thickness of the thinner of the parts joined by a fillet, single-bevel, or single-J weld
tmin = Min ( 19.0 , 4.55 ) = 4.55 mm
0.7tmin = 0.7 x 4.55 = 3.19 mm
=> tc (min) = Min ( 6 , 0.7 tmin ) = Min ( 6.00 , 3.19 ) = 3.19 < tc (actual) = 4.20 mm
=> PASS
11.8 Cone Bottom Head Welded Joint
Weld type : Butt weld, Full Penetration
Critical weld length K = 8.0 mm (Assumed equal to the thickness of shell)
Inside Diameter of Tank D = 2400 mm
Area of weld Aw = 60319 mm2 Aw = πDK
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev.
Allowable Stress of Shell material = 112.0 MPa
Applied by force Total Weight Load (TWL)
Weight Load of Water inside the tank Ww = 140724 N (Estimate)
Weight Load of Cone Bottom Head Wb = 4106.9 N (Estimate)
TWL = 144831 N TWL = Ww + Wb
Tensile Stress on Welded Joint
Tensile = 2.40 MPa Tensile = TWL / Aw
Allowable = 112.0 MPa
Safety Factor = 46.6 => PASS
12. Wind Load Analysis (Refer to Pressure Vessel Design Manual 3rd Ed. 2004 - Dennis R. Moss, Procedure 3-1)
12.1 Design Specification
Vessel Support Type Support Lug
N : Number of Support Lugs = 4
Wo : Operating Weight of Vessel = 14939 kg = 146551 N
h : Overall Height of Vessel = 3798 mm = 12.461 ft.
D : Outside Vessel Diameter = 2416 mm
De : Vessel Effective Diameter from Table 3-4 = 1.4D = 3382.4 mm
Le : Vessel Effective Length = 3798 mm
l : Distance to the center of the projected area = 1349 mm
B : Bolt Circle Diameter = 3060 mm
Structure Category = IV
Exposure Category = BCf : Force Coefficient (shape factor) = 0.8 (for cylindrical Vessel)
G : Gust effect factor = 0.8
KZ : Velocity pressure exposure coefficient from Table 3-3a
= 0.57
KZT : Topographic factor = 1
V : Basic Wind Speed = 39 m/sec = 87.24 mph
I : Importance factor = 1.15
Ct : Period Coefficient (0.02 - 0.035) = 0.035 (Assume Max. Value)
12.2 Design Calculation
h/D ratio
h/D = = 1.57 < 4
Approximate fundamental period
T = = 0.232 sec < 1 sec
=> The Vessel is considered rigid
3798 / 2416
Ct x h3/4
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
Projected area of vessel
Af = Le x De = 3798 x 3382.4 = 1.285E+07 mm2 = 12.85 m
2
Velocity pressure at height z above the ground
qz = = 12.772439 psf = 611.54 N/m2
Design Wind force (Shear force)
= 5027.9145 N
Moment at the base plate
M = F x l = 6782656.7 Nmm
Max. Vertical force per lug
Q = (Wo/N) + (Fl/B) = 38854.259 N
13. Seismic Analysis (Refer to Pressure Vessel Design Manual 3rd Ed. 2004 - Dennis R. Moss, Procedure 3-8)
Neutral Axis Calculation
A = 220.0 mm
B = 364.0 mm
C = 100 mm
D = 25 mm
H = 225 mm
Distance from base to neutral axis
= 78.4 mm
where:
S1 = B x D = 9100 mm2
S2 = B x C = 36400 mm2
S3 = (A+B) x H / 2 = 65700 mm2
13.1 Design Specification
Wo : Operating Weight of Vessel = 14939 kg = 146551 N
=
12
+12
+(2+ )3( + )
+ +
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev.
L : Level Arm to Neutral axis = 1349 mm
B : Bolt Circle Diameter = 3060 mm
a : Force arm of Vertical Load = 322 mm
b ~ Y : Force arm of Horizontal Load = 78.4 mm
Ch : Horizontal seismic factor = 0.1291 (Assumed)
Cv : Vertical seismic factor = 0.1291 (Assumed)
N : Number of lugs = 4
13.2 Design Calculation
Horizontal force
Fh = Ch x Wo = = 18919.7 N
Horizontal shear per lug
Vertical force
Fv = (1 + Cv)Wo = = 165470.53 N
Vertical shear per lug
Max. Vertical load Q per lug
Max. moment M per lug
M = ML3 = = 16376900 Nmm
14. Support Analysis for Wind/Seismic (Refer to Pressure Vessel Design Handbook 2nd Ed. 1986 - Henry H. Bednar, Chapter 5)
Maximum Vertical force per lug in Wind Case
Fw = = 38854.259 N
Maximum Moment per lug in Wind Case
Mw = = 6782656.7 Nmm
Maximum Vertical force per lug in Seismic Case
Fs = = 49708.381 N
Maximum Moment per lug in Seismic Case
Ms = = 16376900 Nmm
Maximum Vertical force per lug in Support Lug Analysis
F = = 49708.381 N
Maximum Moment per lug in Support Lug Analysis
M = = 16376900 Nmm
0.1291 x 146551
=18919.71068
= 4729.93 N4
(1 + 0.1291) x 146551
=165470.53
= 41367.63 N4
Q = Q3 = 41367.63 +18919.7 x 1349
= 49708.381 N3060
49708.381 x 322 + 4729.93 x 78.4
Q
M
Q3
ML3
Max(Fw , Fs)
Max(Mw , Ms)
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
w : = 100 mm (Client to confirm)
c : Compression Plate width = 220.0 mm
a : Base plate width = 410 mm
ta : Actual Compression Plate thickness = 18.0 mm
tb : Actual Base plate thickness = 25 mm
tg : Actual Gusset thickness = 16 mm
α : = 57 degrees
[σ] : Allowable stress of support material = 112 MPa
d : Level arm of load F = 322 mm
Sb : Allowable stress in bending for top bar material = 102 MPa (0.6 Fy)
Sa : Allowable stress in compression
h = 346.5 mm
b = 372 mm
14.1 Base plate
Bearing Pressure
q = F/(w x a) = = 1.2124 MPa
Maximum stress in base plate (Refer to Roark's Formulas, Table 11.4, Case 2a)
=> PASS
where
β : Factor from (a/w) = 0.7935
14.2 Compression Plate (Top bar Plate)
The top bar can be assumed to be a simple supported beam with uniformly distributed load.
The minimum compression plate thickness tmin is then given by
=> PASS
14.3 Gusset Plate
Allowable Compressive Stress
where
= 413.2 mm
r : Least radius of gyration of Gusset = 0.289 x tg = 4.624 mm
Maximum compressive stress
49708.381 / (100 x 410)
= 15.39 MPa < [σ] = 112 MPa
= 2.9 mm < ta = 18.0 mm
= psi12469 = 85.977 MPa
=
=0.75 ×
ℎ
= 18000
1 +
18000
= ℎ/sin ()
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
=> PASS
where
= 29635 N
= 114.1 mm
= 312.0 mm
14.4 Size of the lug-to-shell weld
Shear
= 32.9 N/mm
where
Lw = 2 x h + 2 x a = 1513.0 mm
Bending
= 87.9 N/mm
where
Zw = a x h + h2/3 = 182086 mm2
Combined
= 93.8 N/mm
Minimum size of the weld leg
= 2.5 mm
where
f w : Allowable unit force for weld = 0.55 x [σ] x 0.6 = 36.96 MPa
14.5 Anchor Bolts (Refer to Pressure Vessel Design Handbook 2nd Ed. 1986 - Henry H. Bednar, Chapter 5, Size of Anchor Bolts)
By inspection,
=> No Uplift exists and the minimum bolt size is about 3/4 to 1 in.
where:
Mb : Overturning moment at base ~ Maximum moment M = 16376900 Nmm
Db : Bolt Diameter Circle = 3060 mm
W : Operating Weight of Vessel = 14939 kg
N : Number of Support Legs = 4
Choose Anchor Bolt Diameter M36 is satisfactory in this case.
15. Stresses in Shell by Wind/Seismic
(Refer to Pressure Vessel Design Handbook, Chapter 7-Local Stresses in Shell Due to Loads on Attachments)
: Half-length of the loaded square area = 188.45755 mm
β = c/r : Attachment parameter = 0.16
ϒ =r/t : Shell parameter = 150.5
r : Mean Shell Radius = 1204.0 mm
t : Shell thickness = 8.0 mm
Maximum bending stress
85.98 MPa
= -31286
= 19.0 MPa < Sa =
0<
=
+6
= /(2sin ())
= −
2sin ()
= ()
= /
= /
= +
= /
= (ℎ)//2
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev.
where
CLt : Bending Stress factor = 0.125
ML = Fd = 16006099 Nmm
Internal pressure Stress
σt = pr/t = 5.60 MPa
where
p : Internal pressure = 0.0372 MPa
Combined Stress
σ=σb + σt = 171 MPa < 2 x [σ] = 224 MPa
=> PASS
16. Lifting Lug Calculation
Equipment weight We = 4856 kg
Lifting Lug material SA-240 TP304 / 304L
16.1 Check for β = 90 degrees
Angle β = 90.0 degree
Refer to GA Drawing for detail Lifting Lug form
Considered a load factor of 2.0 applied to the structure gravity loads
Design Load P = 2x9.81xWe = 95273.18 N
Force
Fz = 0.5 P = 47637 N
Fx = Fz / tg β = 0 N
Max tensile force in Wire Rope
Ps = Fz / sin β = 47637 N
Lifting lug configuration
where :
SWL = Safe working load
Rh = Hole radiusr = Cheek plate radius
R = Main plate radius
Tp = Main plate thickness
t = Cheek plate thickness
T = Total plate thickness
h = Base width
b = Distance from edge of taper to center of hole
c = Distance from base of plate to center of hole
a = Taper angle
D = Shackle pin diameter
Fy = Yield Strength of lifting lug material
The dimension T should equal 60 - 85% of shackle jaw width.
The pin hole diameter should be 3 mm greater than the selected shackle pin size
Cheek plate radius is approximately r = R - 1.5t
The main plate radius is approximately R = 3 R h
The cheek plate thickness (t) should be less than or equal to the plate thickness (Tp).
Choose Shackle
= 165.9 MPa
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
Shackle load Ps = 47637 N = 4.856 tonne
Choose Shackle with SWL = 8.5 tonne
As per Table shown above :
Shackle jaw width W = 43 mm
Shackle pin size D = 29 mm
Choose Lug Configuration
Rh = 16 mm
r = 42 mm
R = 50 mm
Tp = 25 mm
t = 6 mm
T = 37 mm
h = 174 mm
b = 210 mm
c = 122 mm
a = 71 degrees
D = 29 mm
Fy = 170 MPa
Stress in Lifting Lug
Bearing Stress
Bearing = 44.40 MPa Bearing = Ps/(T x D)
Allowable = 153 MPa Allowable = 0.9 x Fy
Safety Factor = 3.45 => PASS
Shear Stress
Shear = 20.50 MPa Shear = Ps/(4(r-Rh)*t+2(R-Rh)*Tp)
Allowable = 68 MPa Allowable = 0.4 x Fy
Safety Factor = 3.32 => PASS
Tensile Stress
From Section D3.2 of AISC, the distance used in calculations, across the hole, is the minimum of 4 times the plate
thickness at the pinhole or 0.8 times the hole diameter.
Effective width = 25.6 mm
Plate thickness = 37 mm
Tensile = 50.29 MPa Tensile = Ps/(Effective width*plate thickness)
Allowable = 76.5 MPa Allowable = 0.45 Fy (AISC Section D3.2)
Safety Factor = 1.52 => PASS
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev
Bending Stress
Section modulus Z = 126150 mm3 Z = h
2x Tp / 6
Area of lug base A = 4350 mm2 A = h x Tp
Bending = 46.07 MPa Bending = (Fz*c / Z) + (Fx / A)
Allowable = 102 MPa Allowable = 0.6 Fy
Safety Factor = 2.21 => PASS
Stress in Weld Joint
Weld type : T-Butt weld, Full Penetration
Critial weld length K = 25 mm (Assumed equal to the thickness of lug)
Section modulus of weld Zw = 252300 mm Zw = h2
x K / 3
Area of weld Aw = 8700 mm Aw = 2 x K x h
Applied by force Fz
Bending S1 = 23.0 MPa Bending S1 = Fz*c/Zw
Shear S2 = 5.5 MPa Shear S2 = Fz/Aw
Combined = 23.68 MPa Combined = (S12
+ S22)0.5
Allowable = 102 MPa Allowable = 0.6 Fy
Safety Factor = 4.31 => PASS
Applied by force Fx
Tensile S3 = 0.00 MPa Tensile S3 = Fx/Aw
Allowable = 102 MPa Allowable = 0.6 Fy
=> PASS
16.2 Check for β = 85 degrees (Considering Tolerance 5 degrees)
Angle β = 85.0 degree
Refer to GA Drawing for detail Lifting Lug form
Considered a load factor of 2.0 applied to the structure gravity loads
Design Load P = 2x9.81xWe = 95273.18 N
Force
Fz = 0.5 P = 47637 N
Fx = Fz / tg β = 4168 N
Max tensile force in Wire Rope
Ps = Fz / sin β = 47819 N
Stress in Lifting Lug
Bearing Stress
Bearing = 44.57 MPa Bearing = Ps/(T x D)
Allowable = 153 MPa Allowable = 0.9 x Fy
Safety Factor = 3.43 => PASS
Shear Stress
Shear = 20.58 MPa Shear = Ps/(4(r-Rh)*t+2(R-Rh)*Tp)
Allowable = 68 MPa Allowable = 0.4 x Fy
Safety Factor = 3.30 => PASS
Tensile Stress
From Section D3.2 of AISC, the distance used in calculations, across the hole, is the minimum of 4 times the platethickness at the pinhole or 0.8 times the hole diameter.
Effective width = 25.6 mm
Plate thickness = 37 mm
Tensile = 50.48 MPa Tensile = Ps/(Effective width*plate thickness)
Allowable = 76.5 MPa Allowable = 0.45 Fy (AISC Section D3.2)
Safety Factor = 1.52 => PASS
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev
Bending Stress
Section modulus Z = 126150 mm3 Z = h
2x Tp / 6
Area of lug base A = 4350 mm2 A = h x Tp
Bending = 47.03 MPa Bending = (Fz*c / Z) + (Fx / A)
Allowable = 102 MPa Allowable = 0.6 Fy
Safety Factor = 2.17 => PASS
Stress in Weld Joint
Weld type : T-Butt weld, Full Penetration
Critial weld length K = 25 mm (Assumed equal to the thickness of lug)
Section modulus of weld Zw = 252300 mm Zw = h2
x K / 3
Area of weld Aw = 8700 mm Aw = 2 x K x h
Applied by force Fz
Bending S1 = 23.0 MPa Bending S1 = Fz*c/Zw
Shear S2 = 5.5 MPa Shear S2 = Fz/Aw
Combined = 23.68 MPa Combined = (S1
2
+ S2
2
)
0.5
Allowable = 102 MPa Allowable = 0.6 Fy
Safety Factor = 4.31 => PASS
Applied by force Fx
Tensile S3 = 0.48 MPa Tensile S3 = Fx/Aw
Allowable = 102 MPa Allowable = 0.6 Fy
Safety Factor = 212.93 => PASS
Choose Lug Configuration as shown above is satisfactory
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
19. Conclusion
Shell thickness:
Thickness required: 2.50 mmThickness actual: 8.0 mm
Bottom Head thickness:
Min. Thickness required: 8.00 mm
Top Head thickness:
Thickness actual: 8.00 mm
Auxiliary Stiffener size: 50 x 8 mm
Main Stiffener size: T-150x8 + 70x8 mm (Refer to GA Drawing for more details)
Nozzle thickness:
Shell Nozzle N2 DN40 (1-1/2")
Thickness required: 2.50 mm
Thickness actual: 5.08 mm (SCH 80S)
Flat Top Head Nozzle N1A/B, N3 DN50 (2")
Thickness required: 5.54 mm
Thickness actual: 5.54 mm (SCH 80S)
Flat Top Head Nozzle N9 DN80 (3")
Thickness required: 5.49 mm
Thickness actual: 5.49 mm (SCH 40S)
Flat Top Head Nozzle N6, N10 DN100 (4")
Thickness required: 6.02 mm
Thickness actual: 6.02 mm (SCH 40S)
Flat Top Head Nozzle N4 DN250 (10")
Thickness required: 6.00 mm
Thickness actual: 10.00 mm
Cone Bottom Head Nozzle N5 DN100 (4")
Thickness required: 6.02 mm
Thickness actual: 6.02 mm (SCH 40S)
Coil Half-pipe Steam Nozzle N7A/B/C & N8A/B/C DN25 (1")
Thickness required: 2.96 mm
Thickness actual: 4.55 mm (SCH 80S)
Spray Nozzle N10
Outlet Connection DN50 (2")
Thickness required: 3.42 mm
Thickness actual: 5.54 mm (SCH 80S)
Inlet Connection DN20 (3/4")
Thickness required: 2.51 mm
Thickness actual: 3.91 mm (SCH 80S)
Baffle thickness:
Thickness required: 0.94 mm
Thickness actual: 6.00 mm
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
1. Design Data
Design Code : None
Service: Blending Vessel
Design pressure
Max. Internal pressure - (Full 3.79 meters of Water) P = 0.372 barg = 0.0372 MPa G
External pressure 0.0 barg = 0.0 MPa GWorking pressure 0.0 barg = 0.0 MPa G
Design temperature 180 degrees C
Working temperature 60 ~ 80 degrees C
Corrosion allowance 0.0 mm
Vessel inside diameter 2400 mm (O/D = 2416 mm)
Vessel length (Flat Head to T.L) 2800 mm
Material S : Maximum allowable stress value
Shell SA-240 TP304 / 304L 112 MPa
Flat Top Head SA-240 TP304 / 304L 112 MPa
Bottom Cone Head SA-240 TP304 / 304L 112 MPa
Nozzle Neck SA-312 TP304 / 304L 112 MPa
Support SA-240 TP304 / 304L 112 MPa
Nozzle Flange: ASME B16.5 Standard
SCH THK.
N1 A/B 150 80S 5.54
N2 150 80S 5.08
N3 150 80S 5.54
N4 150 - 10
N5 150 40S 6.02
N6 150 40S 6.02
N7 A/B/C 150 80S 4.55
N8 A/B/C 150 80S 4.55
N9 150 40S 5.49
N10 150 40S 6.02
2. Shell Thickness Calculation (Refer to ASME Section VIII, Division 1, UG-27)
2.1 Minimum required thickness of shell exclusive corrosion allowance (t):
Circumferential Stress (Longitudinal Joints)
0.0372 x 1200.0
112.0 x 0.85 - 0.6 x 0.0372
where:
P : internal design pressure = 0.0372 MPa < = 36.652 MPa
R : Inside radius of the shell = 1200.0 mm
S : Maximum allowable stress value = 112.0 MPa
E : Joint efficiency = 0.85
Longitudinal Stress (Circumferential Joints)
0.0372 x 1200.0
2.0 x 112.0 x 0.85 + 0.4 x 0.0372
where:
E : Joint efficiency = 0.85
Degree of Radiographic Examination: 10%
2.2 Minimum Thickness of Pressure retaining Components (UG-16 (b)) = 2.5 mm
2.3 Minimum required thickness of shell included corrosion allowance
tr = 0.47 + 0.0 = 0.47 mm
Nozzle Size Flange Type ClassNozzle Neck Nozzle outside
diameter, mm
DN 50 (2") SO RF 60.3 49.22
DN 250 (10") SO RF 273.1 253.1
Nozzle inside
diameter, mm
DN 50 (2") SO RF 60.3 49.22
DN 40 (1-1/2") SO RF 48.3 38.14
DN 25 (1") SO RF 33.4 24.3
DN 25 (1") SO RF 33.4 24.3
DN 100 (4") SO RF 114.3 102.26
DN 100 (4") SO RF 114.3 102.26
mm95.2
DN 80 (3") SO RF 88.9 77.92
DN 100 (4") SO RF 114.3 102.26
0.385SE
= =44.6
= 0.23
= =44.6
= 0.47
mm190.4
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
2.4 Choose Nominal thickness of shell, ts = 8.0 mm
3. Bottom Head Thickness Calculation (Refer to ASME Section VIII, Division 1, UG-32)
Type of head: Toriconical Head (with Knuckle)
3.1 Conical Section
3.1.1 Minimum required thickness of Conical Section exclusive corrosion allowance (t):
0.0372 x 2400.0
where:
P : internal design pressure = 0.0372 MPa < = 36.65 MPa
D : Inside diameter of the head skirt = 2400.0 mm
S : Maximum allowable stress value = 112.0 MPa
E : Joint efficiency = 0.85
α : one-half of the included angle of = 60 degrees
the cone at the centerline of head
3.1.2 Minimum required thickness of Head included corrosion allowance
= 0.94 + 0.0 = 0.94 mm
3.1.3 Minimum required thickness of Head, tb = Min. 8.0 mm
3.2 Knuckle Section
r : inside knuckle radius = 250 mm
Di : inside cone diameter at point of tangency = = 2150.0
to knuckle
3.2.1 Minimum required thickness of Knuckle Section exclusive corrosion allowance (t):
where:
3.2.2 Minimum required thickness of Knuckle included corrosion allowance
= 0.62 + 0.0 = 0.62 mm
3.2.3 Minimum required thickness of Knuckle, tK = Min. 8.0 mm
3.3 Stress Relief (Refer to UCS-79)
Type of head: Toriconical Head (Double Curvature)
=> Percent extreme fiber elongation is not exceeded by 5% so that a stress relief is not required
where:
t : Nominal Straight Flange thickness t = 8.0 mm
Rf : Final centerline radius (mean knuckle radius) Rf = 250.0 mm
Ro : Original centerline radius (Crown radius) Ro = 2150.0 mm
4. Top Head Thickness Calculation (Refer to Roark's Formulas for Stress and Strain)
0.385SE
=0.0372 x 2150 x 1.48
=118.6
=
= =89.2
= 0.94 mm2 x cos(60) x (112 x 0.85 - 0.6 x 0.0372) 95.2
1.48
= 2.12 %
0.6227 mm2 x 112 x 0.85 - 0.2 x 0.0372 190.4
: Crown radius = 2150 mm
: Factor =
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev.
Type of head: Flat Head
Assume square plate (axb) 500x500 mm with all edges simply supported
and uniform loads over entire plate.
Top Head Self-Weight = 293.402 kg
F = m x g = 2878.28 N
Area (A) = πD2
/4 = 4.58 m2
P1 = F/A = 0.628 kPa
Structural Weight = 150 kg (Including weight of nozzles, manhole on Top Head - 150 kg)
F = m x g = 1471.5 N
Area (A) = πD2/4 = 4.58 m
2
P2 = F/A = 0.321 kPa
Concentrated Load = 200 kg (Assumed)
F = m x g = 1962 N
Area (A) = πD2/4 = 4.58 m
2
P3 = F/A = 0.428 kPa
Total Dead Load (P) = P1+P2+P3 = 1.38 kPa
Total Live Load (L) = 1.0 kPa (As per API 650 11th Ed. Errata, Oct. 2011, Clause 5.2.1)
Total Uniform Load (q) = P + L = 2.38 kPa
Edges of Plate (a x b) = 500 x 500 mm
a/b = 1
β = 0.2874
α = 0.0444
Elastic Modulus (E) = 183600000 kPa (Interpolate from API 650 11th Ed. Errata, October 2011, Appendix S)
Allowable Stress ([ϭ]) = 112000 kPa (Refer to ASME Section II, Part D, Table 1A)
Required Plate thickness (Refer to Roark's Formulas, Table 11.4, Case 1a)
Choose thickness of Top Head Plate = 8 mm
Max. Deflection (Refer to Roark's Formulas, Table 11.4, Case 1a)
Max. Stress in plate
5. Auxiliary Stiffener Calculation
Length of stiffener L = 500 mm
Width of Plate that using stiffener Wp = 500 mm (Assumed)
Uniform load wa = q x Wp = 1.188 kN/m
= 1.23 mm
= 0.07 mm <
kPa (ACCEPTED)
t/2 = 4 mm (ACCEPTED)
= 2668 kPa < [ϭ] = 112000
=
=
=
L
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
Select stiffener properties as below
Area moment of inertia (As per Roark's Formulas, Table A.1, Case 4: Tee section):
Effective area = 1.1 x (D x t)0.5 = 19 x t (Base on ASME Section VIII, Division 1, Appendix 1-8)
where:
t : The thickness of Top Head = 8 mm
b : Effective area (about 19 x t) = 152 mm
tw : The thickness of Stiffener = 8 mm
d : Stiffener height = 50 mm
= 1616 mm2
Elastic modulus (E) = kPa
Plastic section modulus (Zx)
Max. deflection at the center of stiffener (Refer to Roark's Formulas, Table 8.1, Case 2e )
-5 x 1.188 x 7804
Unity Check (UC) ratio calculation
M : Maximum bending moment caused by uniform load wa = 0.037 KN.m
S : Bending Stress caused by M = 2697.2026 KPa
UC ratio : = 0.024 < 1
=> (ACCEPTED)
6. Main Stiffener Calculation
Length of stiffener L = 2400 mm
Width of Plate that using stiffener Wp = 340 mm (Assumed)
I = = 342951 mm4
= 11.178 mm
183600000
= 13769 mm3
= = -0.015 mm384 x 183600 x 342951
M =
8
S =
=
5 0
L
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev.
Uniform load wa = q x Wp = 0.808 kN/m
Agitator Concentrated load W = 310 kg = 3.041 kN
Select stiffener properties as below
b3 : Effective area (about 19 x d3) = 152 mm
d3 : The thickness of Top Head = 8 mm
d2 : Web height = 150 mmb2 : Web thickness = 8 mm
b1 : Bottom flange length = 70 mm
d1 : Bottom flange thickness = 8 mm
PART Area (a) y a x y h h2
bd3/12
mm mm mm mm mm mm
1 560 4 2240 96.41 9295.7 2986.6667
2 1200 83 99600 17.41 303.25 2250000
3 1216 162 196992 -61.59 3792.84 6485.3333
TOTAL 2976 298832 2259472
Therefore,
Distance from bottom to Neutral axis
C = 298832 / 2976 = 100.414 mm
Area moment of inertia
I = 10181553.978 + 2259472 = 12441026 mm
Section Modulus
Z = I /C = 123897.35 mm3
Max. deflection at the center of stiffener (Refer to Roark's Formulas, Table 8.1,Case 1e & Case 2e )
-3.0411 x 24003
x 24004
Unity Check (UC) ratio calculation
M : Maximum bending moment caused by uniform load W = 2.406 KN.m
S : Bending Stress caused by M = 19423.324 KPa
UC ratio : = 0.173 < 1
=> (ACCEPTED)
7. Coil Half-Pipe Calculation (Refer to ASME Section VIII, Division 1, Nonmandatory Appendix EE)
7.1 Because of the same thickness of shell and cone head, the half-pipe calculation shall be considered for shell only.
ts : Thickness of the shell = 8.0 mm = 1/3 in
R : Inside shell radius = 1200 mm
D = 2R : Inside shell diameter = 2400 mm = 94.5 in
Half-pipe jacket is DN80 (3")
S : Allowable tensile stress of shell = 112.0 MPa
S1 : Allowable tensile stress of coil half-pipe = 112.0 MPa
P : Internal Pressure in vessel = 0.0372 MPa (Positive pressure inside the shell)
P1 : Design Pressure in coil = 0.98 MPa (Positive pressure inside the half-pipe)
From Fig. EE-2, with D = 94.5 in. and t = 1/3 in., so K = 70
= +-5 x 0.808
a x h2
= -0.536 mm48 x183600 x 12441026 384 x 183600 x 12441026
mm4
5205566.94
363895.9764
4612091.063
10181553.978
M =
4+
8
S =
=
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499
Actual longitudinal tensile pressure in shell
S' = PR/2ts = 2.79 MPa
Permissible coil pressure - Maximum allowable external pressure applied to the shell
P' = F / K = (1.5S - S') / K = 2.36 MPa > P1 = 0.98 MPa
=> PASS
The thickness of shell is satisfactory for pressure inside Half-pipe
Choose Half-pipe DN80 (3"), SCH. 40
Half-pipe thickness included 12.5% undertolerance
t = 0.875 x 5.49 = 4.8 mm
Inside half-pipe radius
r = 88.9/2 - 4.8 = 39.65 mm
The required half-pipe thickness
=> PASS
The minimum fillet weld size
= 1.414 x 0.411 = 0.581 mm
Choose Fillet weld size = 6 mm
7.2 Hydrotest Pressure for Coil Half-pipe (Refer to ASME Section VIII, Division 1, UG-99 (b))
Design Temperature = 180 degrees CTest Temperature = A.T.M
Internal Design Pressure P = 0.980 MPa G
Max. Allowable Stress at Design Temperature Sd = 112 MPa
Max. Allowable Stress at Test Temperature St = 115 MPa
Hydrotest Pressure Ph = 1.3 x P x (St/Sd)
Ph = 1.3 x 0.98 (115/112) = 1.31 MPa G
8. Weight Calculation Sheet
No.
Thickness
(mm) Q'ty
Unit Weight
(kg)
Total Weight
(kg)
1 Shell 8 1 1341.7 1341.68
2 Bottom Cone 8 1 418.64 418.64
3 Roof 8 1 330.97 330.97
4 Stiffenner T-150x8+70x8 - 4 33.37 133.48
5 Stiffenner PL.50x8 - 2 19.47 38.94
6 Top Angle Bar L-70x70x8 - 1 68.01 68.01
7 Half Pipe Coil - 106.3 5.76 612.29
8 Support Lug - Reinforcement PL. 8 4 18.20 72.79
9 Support Lug - Base Plate 25 4 30.31 121.26
10 Support Lug - Compress Plate 18 4 13.33 53.32
11 Support Lug - Gusset Plate 1 16 8 3.03 24.26
12 Support Lug - Gusset Plate 2 16 8 13.07 104.55
13 Lifting Lug 25 2 6.33 12.66
14 Nozzle N1A - Neck - 0.15 7.63 1.14 2" SCH 80S
15 Nozzle N1A - Flange - 1 2.30 2.30 2" 150#
16 Nozzle N1B - Neck - 0.15 7.63 1.14 2" SCH 80S
17 Nozzle N1B - Flange - 1 2.30 2.30 2" 150#
18 Nozzle N2 - Neck - 0.172 5.51 0.95 1-1/2" SCH 80S
19 Nozzle N2 - Flange - 1 1.40 1.40 1-1/2" 150#
20 Nozzle N3 - Neck - 0.15 7.63 1.14 2" SCH 80S
21 Nozzle N3 - Flange - 1 2.30 2.30 2" 150#
22 Nozzle N4 - Neck - 0.2 61.52 12.30 10" SCH 40S
= 0.411 mm
Remark
Ea
Ea
Ea
Ea
Ea
Description Unit
Ea
Ea
m
Ea
m
Ea
Ea
m
Ea
Ea
Ea
Ea
m
Ea
m
Ea
m
= 2 ×
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499
23 Nozzle N4 - Flange - 1 19.50 19.50 10" 150#
24 Nozzle N4 - Reinforcement 8 1 21.24 21.24
25 Nozzle N4 - Gusset 16 4 2.68 10.72
26 Nozzle N5 - Neck - 0.15 16.40 2.46 4" SCH 40S
27 Nozzle N5 - Flange - 1 5.90 5.90 4" 150#
28 Nozzle N6 - Neck - 0.15 16.40 2.46 4" SCH 40S
29 Nozzle N6 - Flange - 1 5.90 5.90 4" 150#30 Nozzle N7A - Neck - 0.19 3.29 0.63 1" SCH 80S
31 Nozzle N7A - Flange - 1 0.90 0.90 1" 150#
32 Nozzle N7B - Neck - 0.18 3.29 0.59 1" SCH 80S
33 Nozzle N7B - Flange - 1 0.90 0.90 1" 150#
34 Nozzle N7C - Neck - 0.3 3.29 0.99 1" SCH 80S
35 Nozzle N7C - Flange - 1 0.90 0.90 1" 150#
36 Nozzle N8A - Neck - 0.3 3.29 0.99 1" SCH 80S
37 Nozzle N8A - Flange - 1 0.90 0.90 1" 150#
38 Nozzle N8B - Neck - 0.3 3.29 0.99 1" SCH 80S
39 Nozzle N8B - Flange - 1 0.90 0.90 1" 150#
40 Nozzle N8C - Neck - 0.172 3.29 0.57 1" SCH 80S
41 Nozzle N8C - Flange - 1 0.90 0.90 1" 150#
42 Nozzle N9 - Neck - 0.15 11.52 1.73 3" SCH 40S
43 Nozzle N9 - Flange - 1 3.70 3.70 3" 150#
44 Nozzle N10 - Neck - 0.15 16.40 2.46 4" SCH 40S
45 Nozzle N10 - Flange - 1 5.90 5.90 4" 150#
46 Nozzle N10 - Spray Nozzle - 1 13.08 13.08
47 MANWAY M1 - Reinforcement 8 1 40.44 40.44
48 MANWAY M1 - Shell 8 1 32.00 32.00
49 MANWAY M1 - Cap 8 1 32.81 32.81
50 Baffle 6 4 15.98 63.94
51 Angle Bar (Baffle Support) L-50x50x8 - 12 1.41 16.90
52 Insulation - 1 900.00 900.00
Empty Weight 4549.1
Weight of Liquid at Operating Level 10083.0
Weight of Full Water 14345.0
Total Weight of Liquid at Operating Level 14632.1
Total Weight of Full Water 18894.1
9. Lug Support (Refer to Pressure Vessel Handbook 10th Edition - By Eugene F. Megyesy)
9.1 Wear plate (Refer to Pressure Vessel Handbook 10th Edition - By Eugene F. Megyesy)
BCD : Bolt Circle Diameter 3060 mm
OD : Vessel Outside Diameter 2416 mm
W : Weight of Vessel (Full of Water) = 19204 kg (Total Weight + Agitator weight)
n : Number of lugs = 4
Q = W/n : Load on one lug = 4801 kgR : Radius of shell = 1208 mm
H : Lever arm of load = 322 mm
2A : 1st Dimension of wear plate = 512 mm (Minimum)
2B : 2nd Dimension of wear plate = 550 mm (Minimum)
t : Wall thickness of shell = 8.0 mm
tw : Wear plate thickness (approximate shell thickness) = 8.0 mm
P : Internal Pressure at Wear plate location = 0.00 MPa
Shell material : SA-240 TP304 / 304L
Allowable stress value : 112.0 MPa
Joint Efficiency : 0.85
Ea
Ea
m
Ea
m
Ea
Ea
Pipe & Flange 2",
B. Flange 4", Bolt/Nut
m
Ea
m
Ea
m
Ea
m
Ea
m
Ea
m
Ea
Ea
Ea
Ea
Ea
Ea
set
m
Ea
m
Ea
Ea
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. No
Shape factors C :
1208 275
8.0 256
C1 = 1
C2 = 1
C3 = 1C4 = 1
The factors K
K1 = 3.8
K2 = 0.012
K3 = 7
K4 = 0.0075
Longitudinal Stress :
= 92.94 MPa
Stress due to internal pressure:
PR
2t
The sum of tensional stresses:
92.94 + 0.00 = 92.94 MPa
It does not exceed the stress value of the girth seam:
112.0 x 0.85 = 95.2 MPa (ACCEPTED)
Circumferential Stress:
= 82.57 MPa
Stress due to internal pressure:
PR
t
The sum of tensional stresses:
82.57 + 0.00 = 82.57 MPa
It does not exceed the stress value of shell material multiplied by 1.5 :
112.0 x 1.50 = 168 MPa (ACCEPTED)
Choose wear plate = 512x550x8 mm
9.2 Gussets (Refer to Pressure Vessel Design Manual 3rd Ed. 2004 - Dennis R. Moss, Procedure 3-13)
= = 1.0742
= 0.22
R/t = = 151 ; B/A
=0 x 1208
= 0.00 MPa8
=0 x 1208
= 0.00 MPa2 x 8
=
=256
1208
275
256
= ±
+ 6
+
2 1.17+ /×
= ±
+ 6
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
Q : Vertical load per lug = 4801 kg = 47098 N
n : Number of gussets per lug = 2 (Double Gusset)
b = 372 mm
h = 346.5 mm
tg : Gusset thickness = 16 mm
θ = 57 degrees
Fy : Minimum Yield Strength of gusset material = 170 MPa
Fa : Allowable axial Stress = 68 MPa (0.4 Fy)
Fb : Allowable bending Stress = 102 MPa (0.6 Fy)
Qa = Q.sinθ : Axial load on gusset = 39500 N
Qb = Q.cosθ : Bending load on gusset = 25651 N
A = tg.C : Cross-sectional area of assumed column = 2495.9 mm2
Axial stress
=> PASS
Bending Stress
=> PASS
Choose dimensions of Double Gusset as shown above
9.3 Base Plate for Double Gusset (Refer to Pressure Vessel Design Manual 3rd Ed. 2004 - Dennis R. Moss, Procedure 3-13)
l : Base plate width = 410 mm
a : Bearing width = 100 mm (Client to confirm)
l1 = 340 mm
φ : Bolt hole diameter = 38 mm
= 413.15 mm
: Bending moment = 5E+06 Nmm
= 155.99 mm
: Section modulus = 64890 mm3
68 MPa
= 81.661 MPa < Fb = 102 Mpa
= 7.913 MPa < Fa =
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
9.3.1 Bending (Assume to be between simply supported with two equal spans)
9.3.2 Bearing
9.3.3 Thickness required base plate
where Mb is bending moment
Choose the actual thickness base plate tb = 25 mm
9.4 Compression Plate for Double Gusset (Refer to Pressure Vessel Design Manual 3rd Ed. 2004 - Dennis R. Moss, Procedure 3-13)
e = 322 (Refer to figure of 8.2 Gussets)
Ev : Modulus of elasticity of vessel = 183600 MPa
Es : Modulus of elasticity of compression plate = 183600 MPa
t : Shell Vessel thickness = 8.0 mm
R : Inside Radius of vessel = 1200.0 mm
tc : Assumed Compression Plate thickness = 18.0 mm
y : Compression Plate width = 220.0 mm
x : Distance between loads = 340.0 mm
Fy : Minimum Yield Strength of gusset material = 170 MPa
Fb : Allowable bending Stress = 102 MPa (0.6 Fy)
Concentrated load on Double Gusset
Foundation modulus
Moment of inertial of Compression plate
Section modulus of Compression plate
Damping factor
Internal bending moment in Compression plate
Bending stress
=> PASS
Bending
= 2E+06 Nmm (w.l = Q)
= 1.1487 Nmm2 (Uniform load on base plate)
= 21884 N (Assumed)
= 1.02 N/mm3
= 13279 Nmm
= 20.62 mm
= 0.0005
= 1E+07 Nmm
= 2E+07 mm4
= 145200 mm3
102 MPa= 93.2 MPa < Fb =
=
8=
8
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
Choose Compression Plate thickness, tc = 18.0 mm
10. Nozzle calculation
10.1 Shell Nozzle N2 DN40 (1-1/2") (Refer to ASME Section VIII, Division 1, UG-45)
Minimum Nozzle neck thickness
where:
S : Maximum allowable stress value, S = 112.0 MPa
E : Joint efficiency E = 1.00
Nozzle inside radius Rn = 19.1 mm
tn (min) : minimum required thickness of Nozzle
10.1.1. ta : minimum neck thickness required for internal and external pressure using UG-27 and UG-28
(plus corrosion allowance), as applicable. The effects of external forces and moments from supplemental
loads (see UG-22) shall be considered. Shear stresses caused by UG-22 loadings shall not exceed 70%
of the allowable tensile stress for the nozzle material.
0.0372 x 19.1 0.71
112.0 x 1.00 - 0.6 x 0.0372 112.0
ta = 0.01 + 0.0 = 0.01 mm
10.1.2. = min ( 3.22 , 2.5 ) = 2.5 mm
where:
tb1 : for vessels under internal pressure, the thickness (plus corrosion allowance) required for pressure
(assuming E = 1.0) for the shell or head at the location where the nozzle neck or other connection
attaches to the vessel but in no case less than the minimum thickness specified for the material in UG-16(b).
tb1 = 2.5 mm
tb2 : for vessels under external pressure
tb2 = 0.0 mm
Max (tb1, tb2) = Max ( 2.5 , 0.0 ) = 2.5 mm
tb3 : the thickness given in Table UG-45 plus the thickness added for corrosion allowance.
(for standard wall pipe)
tb3 = 3.22 + 0.0 = 3.22 mm
=> = max ( 0.01 , 2.50 ) = 2.50 mm
10.1.3. Choose Nozzle actual thickness = 5.08 mm (SCH 80S)
10.1.4. Nozzle actual thickness is compared with the minimum thickness provided which for pipe
material would include a 12.5% undertolerance
= 0.875 x 5.08 = 4.45 > tn (min) = 2.50 mm
Result: the actual thickness provided meets the rules of UG-45 <PASS>
10.2 Flat Top Head Nozzle N1A/B, N3 DN50 (2") (Refer to API 650 11th Edition, Appendix S)
10.2.1 Minimum Nozzle Neck thickness
Base on table S.3.3.1
= = = 0.01 mm
bant t t ,max(min)
bant t t ,max(min)
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
Minimum thickness of Nozzle Neck = 5.54 mm (SCH 80S)
Corrosion Allowance (C.A) = 0.00 mm
Minimum thickness of Nozzle Neck including C.A = 5.54 mm
10.2.2 Choose Nozzle actual thickness = 5.54 mm (SCH 80S)
10.3 Flat Top Head Nozzle N9 DN80 (3") (Refer to API 650 11th Edition, Appendix S)
10.3.1 Minimum Nozzle Neck thickness
Base on table S.3.3.1
Minimum thickness of Nozzle Neck = 5.49 mm (SCH 40S)
Corrosion Allowance (C.A) = 0.00 mm
Minimum thickness of Nozzle Neck including C.A = 5.49 mm
10.3.2 Choose Nozzle actual thickness = 5.49 mm (SCH 40S)
10.4 Flat Top Head Nozzle N6, N10 DN100 (4") (Refer to API 650 11th Edition, Appendix S)
10.4.1 Minimum Nozzle Neck thickness
Base on table S.3.3.1
Minimum thickness of Nozzle Neck = 6.02 mm (SCH 40S)
Corrosion Allowance (C.A) = 0.00 mm
Minimum thickness of Nozzle Neck including C.A = 6.02 mm
10.4.2 Choose Nozzle actual thickness = 6.02 mm (SCH 40S)
10.5 Flat Top Head Nozzle N4 DN250 (10") (Refer to API 650 11th Edition, Appendix S)
10.5.1 Minimum Nozzle Neck thickness
Base on table S.3.3.1
Minimum thickness of Nozzle Neck = 6 mm
Corrosion Allowance (C.A) = 0.00 mm
Minimum thickness of Nozzle Neck including C.A = 6.00 mm
10.5.2 Choose Nozzle actual thickness = 10 mm
10.6. Cone Bottom Head Nozzle N5 DN100 (4") (Refer to ASME Section VIII, Division 1 & API 650 11th Edition, Appendix S)
10.6.1 Minimum Nozzle neck thickness (Refer to ASME Section VIII, Division 1)
where:
S : Maximum allowable stress value, S = 112 MPa
E : Joint efficiency E = 1.00
Nozzle inside radius Rn = 51.13 mm
tn (min) : minimum required thickness of Nozzle
10.6.1.1 ta : minimum neck thickness required for internal and external pressure using UG-27 and UG-28
(plus corrosion allowance), as applicable. The effects of external forces and moments from supplemental
loads (see UG-22) shall be considered. Shear stresses caused by UG-22 loadings shall not exceed 70%
bant t t ,max(min)
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
of the allowable tensile stress for the nozzle material.
0.0372 x 51.1 1.901
112.0 x 1.00 - 0.6 x 0.0372 112.0
ta = 0.02 + 0.0 = 0.02 mm
10.6.1.2 = min ( 5.27 , 2.5 ) = 2.50 mm
where:
tb1 : for vessels under internal pressure, the thickness (plus corrosion allowance) required for pressure
(assuming E = 1.0) for the shell or head at the location where the nozzle neck or other connection
attaches to the vessel but in no case less than the minimum thickness specified for the material in UG-16(b).
tb1 = 2.50 mm
tb2 : for vessels under external pressure
tb2 = 0.00 mm
Max (tb1, tb2) = Max ( 2.50 , 0.00 ) = 2.5 mm
tb3 : the thickness given in Table UG-45 plus the thickness added for corrosion allowance.
(for standard wall pipe)
tb3 = 5.27 + 0.0 = 5.27 mm
=> = max ( 0.02 , 2.5 ) = 2.50 mm
10.6.2. Minimum Nozzle neck thickness (Refer to API 650 11th Edition, Appendix S)
Base on table S.3.3.1
Minimum thickness of Nozzle Neck = 6.02 mm (SCH 40S)
Corrosion Allowance (C.A) = 0.00 mm
Minimum thickness of Nozzle Neck including C.A = 6.02 mm
10.6.3. Choose Nozzle actual thickness = 6.02 mm (SCH 40S)
10.7 Coil Half-pipe Steam Nozzle N7A/B/C & N8A/B/C DN25 (1") (Refer to ASME Section VIII, Division 1)
Minimum Nozzle neck thickness
where:
S : Maximum allowable stress value, S = 112 MPa
E : Joint efficiency E = 1.00
Nozzle inside radius Rn = 12.15 mm
tn (min) : minimum required thickness of Nozzle
10.7.1 ta : minimum neck thickness required for internal and external pressure using UG-27 and UG-28
(plus corrosion allowance), as applicable. The effects of external forces and moments from supplemental
loads (see UG-22) shall be considered. Shear stresses caused by UG-22 loadings shall not exceed 70%
of the allowable tensile stress for the nozzle material.
0.980 x 12.15 11.907
112.0 x 1.00 - 0.6 x 0.980 111.4
ta = 0.11 + 0.0 = 0.11 mm
10.7.2 = min ( 2.96 , 5.49 ) = 2.96 mm
where:
= = = 0.02 mm
= = = 0.11 mm
bant t t ,max(min)
bant t t ,max(min)
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
tb1 : for vessels under internal pressure, the thickness (plus corrosion allowance) required for pressure
(assuming E = 1.0) for the shell or head at the location where the nozzle neck or other connection
attaches to the vessel but in no case less than the minimum thickness specified for the material in UG-16(b).
tb1 = 5.49 mm
tb2 : for vessels under external pressure
tb2 = 0.00 mm
Max (tb1, tb2) = Max ( 5.49 , 0.00 ) = 5.49 mm
tb3 : the thickness given in Table UG-45 plus the thickness added for corrosion allowance.
(for standard wall pipe)
tb3 = 2.96 + 0.0 = 2.96 mm
=> = max ( 0.11 , 2.96 ) = 2.96 mm
10.7.3 Choose Nozzle actual thickness = 4.55 mm (SCH 80S)
10.7.4 Nozzle actual thickness is compared with the minimum thickness provided which for pipe
material would include a 12.5% undertolerance= 0.875 x 4.55 = 3.98 > tn (min) = 2.96 mm
Result: The actual thickness provided meets the rules of UG-45 <PASS>
10.8 Spray Nozzle N10 (Refer to ASME Section VIII, Division 1, UG-45)
10.8.1 Outlet Connection DN50 (2")
Minimum Nozzle neck thickness
where:
P : Design Pressure P = 0.98 MPa G (As per Specification)
S : Maximum allowable stress value, S = 112 MPa
E : Joint efficiency E = 1.00
Nozzle inside radius Rn = 24.6 mm
tn (min) : minimum required thickness of Nozzle
10.8.1.1. ta : minimum neck thickness required for internal and external pressure using UG-27 and UG-28
(plus corrosion allowance), as applicable. The effects of external forces and moments from supplemental
loads (see UG-22) shall be considered. Shear stresses caused by UG-22 loadings shall not exceed 70%
of the allowable tensile stress for the nozzle material.
0.98 x 24.6 24.12
112.0 x 1.00 - 0.6 x 0.98 111.4
ta = 0.22 + 0.0 = 0.22 mm
10.8.1.2. = min ( 3.42 , 24.0 ) = 3.4 mm
where:
tb1 : for vessels under internal pressure, the thickness (plus corrosion allowance) required for pressure
(assuming E = 1.0) for the shell or head at the location where the nozzle neck or other connection
attaches to the vessel but in no case less than the minimum thickness specified for the material in UG-16(b).
tb1 = 24.0 mm (Thickness of 4" Blind Flange RF 150#)
tb2 : for vessels under external pressure
tb2 = 0.0 mm
Max (tb1, tb2) = Max ( 24.0 , 0.0 ) = 24.0 mm
tb3 : the thickness given in Table UG-45 plus the thickness added for corrosion allowance.
(for standard wall pipe)
tb3 = 3.42 + 0.0 = 3.42 mm
0.22 mm= = =
bant t t ,max(min)
bant t t ,max(min)
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. No
=> = max ( 0.22 , 3.42 ) = 3.42 mm
10.8.1.3. Choose Nozzle actual thickness = 5.54 mm (SCH 80S)
10.8.1.4. Nozzle actual thickness is compared with the minimum thickness provided which for pipe
material would include a 12.5% undertolerance
= 0.875 x 5.54 = 4.85 > tn (min) = 3.42 mm
Result: the actual thickness provided meets the rules of UG-45 <PASS>
10.8.2 Inlet Connection DN20 (3/4")
Minimum Nozzle neck thickness
where:
P : Design Pressure P = 0.98 MPa G (As per Specification)
S : Maximum allowable stress value, S = 112 MPa
E : Joint efficiency E = 1.00
Nozzle inside radius Rn = 9.4 mm
tn (min) : minimum required thickness of Nozzle
10.8.2.1. ta : minimum neck thickness required for internal and external pressure using UG-27 and UG-28
(plus corrosion allowance), as applicable. The effects of external forces and moments from supplemental
loads (see UG-22) shall be considered. Shear stresses caused by UG-22 loadings shall not exceed 70%
of the allowable tensile stress for the nozzle material.
0.98 x 9.4 9.25
112.0 x 1.00 - 0.6 x 0.98 111.4
ta = 0.08 + 0.0 = 0.08 mm
10.8.2.2. = min ( 2.51 , 24.0 ) = 2.5 mm
where:
tb1 : for vessels under internal pressure, the thickness (plus corrosion allowance) required for pressure
(assuming E = 1.0) for the shell or head at the location where the nozzle neck or other connection
attaches to the vessel but in no case less than the minimum thickness specified for the material in UG-16(b).
tb1 = 24.0 mm (Thickness of 4" Blind Flange RF 150#)
tb2 : for vessels under external pressure
tb2 = 0.0 mm
Max (tb1, tb2) = Max ( 24.0 , 0.0 ) = 24.0 mm
tb3 : the thickness given in Table UG-45 plus the thickness added for corrosion allowance.
(for standard wall pipe)
tb3 = 2.51 + 0.0 = 2.51 mm
=> = max ( 0.08 , 2.51 ) = 2.51 mm
10.8.2.3. Choose Nozzle actual thickness = 3.91 mm (SCH 80S)
10.8.2.4. Nozzle actual thickness is compared with the minimum thickness provided which for pipe
material would include a 12.5% undertolerance
= 0.875 x 3.91 = 3.42 > tn (min) = 2.51 mm
Result: the actual thickness provided meets the rules of UG-45 <PASS>
11. Welding
11.1 Shell Nozzle N2 DN40 (1-1/2") - (Refer to ASME Section VIII, Division 1, UW-16)
= = = 0.08 mm
bant t t ,max(min)
bant t t ,max(min)
bant t t ,max(min)
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev.
11.1.1 Size of weld / Shell thickness
tn (actual) = 5.08 mm
Fillet Leg Length = 6.00 mm
=> tc (actual) = 4.20 mm
t = 8.00 mm
11.1.2 Check for full penetration groove weld and fillet cover weld shown in Fig above
tc (min) = Min ( 6 , 0.7 tmin )
where:
tmin = the smaller of 19 mm or the thickness of the thinner of the parts joined by a fillet, single-bevel, or single-J weld
tmin = Min ( 19.0 , 5.08 , 8.00 ) = 5.08 mm
0.7tmin = 0.7 x 5.08 = 3.56 mm
=> tc (min) = Min ( 6 , 0.7 tmin ) = Min ( 6.00 , 3.56 ) = 3.56 < tc (actual) = 4.2 mm
=> PASS
11.2Flat Top Head Nozzle N1A/B, N3 DN50 (2") - (Refer to API 650 11th Edition, Clause 5.9)
As per Fig. 5-19 - Flanged Roof Nozzles
where :
DP : Diameter of Hole in Roof Plate (Table 5-14)
DP = 65 mm
11.3 Flat Top Head Nozzle N9 DN80 (3") - (Refer to API 650 11th Edition, Clause 5.9)
As per Fig. 5-19 - Flanged Roof Nozzles
where :
DP : Diameter of Hole in Roof Plate (Table 5-14)
DP = 92 mm
Refer to Table 5-14: Reinforcing plates are not required on nozzle DN 80
11.4 Flat Top Head Nozzle N6, N10 DN100 (4") - (Refer to API 650 11th Edition, Clause 5.9)
As per Fig. 5-19 - Flanged Roof Nozzles
where :DP : Diameter of Hole in Roof Plate (Table 5-14)
DP = 120 mm
Refer to Table 5-14: Reinforcing plates are not required on nozzle DN 100
11.5 Flat Top Head Nozzle N4 DN250 (10") - (Refer to API 650 11th Edition, Clause 5.9)
As per Fig. 5-19 - Flanged Roof Nozzles
& Table 5-14
where :
DP : Diameter of Hole in Reinforcing Plate
DP = 280 mm
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev
DR : Minimum Outside Diameter of Reinforcing Plate
DR = 550 mm
11.6 Cone Bottom Head Nozzle N5 DN100 (4")
11.6.1 Size of weld, Nozzle thickness & Shell thickness
tn = 6.02 mm (Nozzle thickness)
Fillet Leg Length = 7.00 mm
tc (actual) = 4.90 mm (Refer to fabrication detail drawing)
t = 8.00 mm (Min. Bottom Head thickness after forming)
11.6.2 Check for full penetration groove weld and fillet cover weld shown in Fig above
tc (min) = Min ( 6 , 0.7 tmin )
where:
tmin = the smaller of 19 mm or the thickness of the thinner of the parts joined by a fillet, single-bevel, or single-J weld
tmin = Min ( 19.0 , 6.02 ) = 6.02 mm
0.7tmin = 0.7 x 6.02 = 4.21 mm
=> tc (min) = Min ( 6 , 0.7 tmin ) = Min ( 6.00 , 4.21 ) = 4.21 < tc (actual) = 4.90 mm
=> PASS
11.6.3 Reinforcement Calculation (Refer to ASME Section VIII, Division 1, UG-37)
A : Area of Reinforcement required
A = dtr F + 2tn tr F (1-f r1) = 95.872 mm2
A1 : area in excess thickness in the vessel wall available for reinforcement
(includes consideration of nozzle area through shell if Sn /Sv<1.0)
A1 = larger of below value = 722 mm2
d(E1t - Ftr ) - 2tn(E1t - Ftr )(1 - f r1) = 722.21 mm2
2(t + tn)(E1t - Ftr ) - 2tn(E1t - Ftr )(1 - f r1) = 198.03 mm2
A2 : area in excess thickness in the nozzle wall available for reinforcement (see Fig. UG-37.1)
A2 = smaller of below value = 105.95 mm2
5(tn - tr n) f r2t = 140.8 mm2
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Re
5(tn - tr n) f r2tn = 105.95 mm2
A3 : area available for reinforcement when the nozzle extends inside the vessel wall
A3 = min (5t ti f r2, 5ti ti f r2, 2h ti f r2) = 0 mm2
A41 : cross-sectional area available in outward weld
A41 = (leg)2f r2 = 49.00 mm
2
A42 : cross-sectional area available in inward weld = 0 mm2
where:
leg : Fillet weld size = 7.00 mm
d : finished diameter of circular opening or finished dimension = 102.26 mm
h : distance nozzle projects = 0 mm
t : specified vessel wall thickness = 8.0 mm
tn : nozzle wall thickness = 6.02 mm
tr : required thickness of a seamless shell = 0.94 mmtr n : required thickness of a seamless Nozzle wall = 2.50 mm
ti : nominal thickness of internal projection of nozzle wall = 0 mm
Sn : allowable stress in nozzle = 112 MPa
Sv : allowable stress in vessel = 112 MPa
F : correction factor = 1
E1 = 1
f r1 = 1
f r2 = Sn /Sv = 1
A1 + A2 + A3 + A41 + A42 = 877 mm2 > A = 95.872 mm
2
RESULT : Reforcement for Nozzle N5 is not needed
11.7 Coil Half-pipe Steam Nozzle N7A/B/C & N8A/B/C DN25 (1")
11.7.1 Size of weld, Nozzle thickness & Shell thickness
tn = 4.55 mm (Nozzle thickness)
Fillet Leg Length = 6.00 mm
tc (actual) = 4.20 mm (Refer to fabrication detail drawing)
t = 5.49 mm (Coil Half-pipe thickness)
11.7.2 Check for full penetration groove weld and fillet cover weld shown in Fig above
tc (min) = Min ( 6 , 0.7 tmin )
where:
tmin = the smaller of 19 mm or the thickness of the thinner of the parts joined by a fillet, single-bevel, or single-J weld
tmin = Min ( 19.0 , 4.55 ) = 4.55 mm
0.7tmin = 0.7 x 4.55 = 3.19 mm
=> tc (min) = Min ( 6 , 0.7 tmin ) = Min ( 6.00 , 3.19 ) = 3.19 < tc (actual) = 4.20 mm
=> PASS
11.8 Cone Bottom Head Welded Joint
Weld type : Butt weld, Full Penetration
Critical weld length K = 8.0 mm (Assumed equal to the thickness of shell)
Inside Diameter of Tank D = 2400 mm
Area of weld Aw = 60319 mm2 Aw = πDK
Allowable Stress of Shell material = 112.0 MPa
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev.
Applied by force Total Weight Load (TWL)
Weight Load of Water inside the tank Ww = 140724 N (Estimate)
Weight Load of Cone Bottom Head Wb = 4106.9 N (Estimate)
TWL = 144831 N TWL = Ww + Wb
Tensile Stress on Welded Joint
Tensile = 2.40 MPa Tensile = TWL / Aw
Allowable = 112.0 MPa
Safety Factor = 46.6 => PASS
12. Wind Load Analysis (Refer to Pressure Vessel Design Manual 3rd Ed. 2004 - Dennis R. Moss, Procedure 3-1)
12.1 Design Specification
Vessel Support Type Support Lug
N : Number of Support Lugs = 4
Wo : Operating Weight of Vessel = 14632 kg = 143541 N
h : Overall Height of Vessel = 3798 mm = 12.461 ft.
D : Outside Vessel Diameter = 2416 mm
De : Vessel Effective Diameter from Table 3-4 = 1.4D = 3382.4 mm
Le : Vessel Effective Length = 3798 mm
l : Distance to the center of the projected area = 1349 mm
B : Bolt Circle Diameter = 3060 mm
Structure Category = IV
Exposure Category = B
Cf : Force Coefficient (shape factor) = 0.8 (for cylindrical Vessel)G : Gust effect factor = 0.8
KZ : Velocity pressure exposure coefficient from Table 3-3a
= 0.57
KZT : Topographic factor = 1
V : Basic Wind Speed = 39 m/sec = 87.24 mph
I : Importance factor = 1.15
Ct : Period Coefficient (0.02 - 0.035) = 0.035 (Assume Max. Value)
12.2 Design Calculation
h/D ratio
h/D = = 1.57 < 4
Approximate fundamental period
T = = 0.232 sec < 1 sec
=> The Vessel is considered rigid
Projected area of vessel
3798 / 2416
Ct x h3/4
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
Af = Le x De = 3798 x 3382.4 = 1.285E+07 mm2 = 12.85 m
2
Velocity pressure at height z above the ground
qz = = 12.772439 psf = 611.54 N/m2
Design Wind force (Shear force)
= 5027.9145 N
Moment at the base plate
M = F x l = 6782656.7 Nmm
Max. Vertical force per lug
Q = (Wo/N) + (Fl/B) = 38101.793 N
13. Seismic Analysis (Refer to Pressure Vessel Design Manual 3rd Ed. 2004 - Dennis R. Moss, Procedure 3-8)
Neutral Axis Calculation
A = 220.0 mm
B = 364.0 mm
C = 100 mm
D = 25 mm
H = 225 mm
Distance from base to neutral axis
= 78.4 mm
where:
S1 = B x D = 9100 mm2
S2 = B x C = 36400 mm2
S3 = (A+B) x H / 2 = 65700 mm2
13.1 Design Specification
Wo : Operating Weight of Vessel = 14632 kg = 143541 N
L : Level Arm to Neutral axis = 1349 mm
=
12
+12
+(2+ )3( + )
+ +
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev.
B : Bolt Circle Diameter = 3060 mm
a : Force arm of Vertical Load = 322 mm
b ~ Y : Force arm of Horizontal Load = 78.4 mm
Ch : Horizontal seismic factor = 0.1291 (Assumed)
Cv : Vertical seismic factor = 0.1291 (Assumed)
N : Number of lugs = 4
13.2 Design Calculation
Horizontal force
Fh = Ch x Wo = = 18531.1 N
Horizontal shear per lug
Vertical force
Fv = (1 + Cv)Wo = = 162072.09 N
Vertical shear per lug
Max. Vertical load Q per lug
Max. moment M per lug
M = ML3 = = 16040551 Nmm
14. Support Analysis for Wind/Seismic (Refer to Pressure Vessel Design Handbook 2nd Ed. 1986 - Henry H. Bednar, Chapter 5)
Maximum Vertical force per lug in Wind Case
Fw = = 38101.793 N
Maximum Moment per lug in Wind Case
Mw = = 6782656.7 Nmm
Maximum Vertical force per lug in Seismic Case
Fs = = 48687.468 N
Maximum Moment per lug in Seismic Case
Ms = = 16040551 Nmm
Maximum Vertical force per lug in Support Lug Analysis
F = = 48687.468 N
Maximum Moment per lug in Support Lug Analysis
M = = 16040551 Nmm
0.1291 x 143541
=18531.13711
= 4632.78 N4
(1 + 0.1291) x 143541
=162072.09
= 40518.02 N4
N3060
48687.468
48687.468 x 322 + 4632.78 x 78.4
Q
M
Q3
Q = Q3 = 40518.02 +18531.1 x 1349
=
ML3
Max(Fw , Fs)
Max(Mw , Ms)
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
w : = 100 mm (Client to confirm)
c : Compression Plate width = 220.0 mm
a : Base plate width = 410 mm
ta : Actual Compression Plate thickness = 18.0 mm
tb : Actual Base plate thickness = 25 mm
tg : Actual Gusset thickness = 16 mm
α : = 57 degrees
[σ] : Allowable stress of support material = 112 MPa
d : Level arm of load F = 322 mm
Sb : Allowable stress in bending for top bar material = 102 MPa (0.6 Fy)
Sa : Allowable stress in compression
h = 346.5 mm
b = 372 mm
14.1 Base plate
Bearing Pressure
q = F/(w x a) = = 1.1875 MPa
Maximum stress in base plate (Refer to Roark's Formulas, Table 11.4, Case 2a)
=> PASS
where
β : Factor from (a/w) = 0.7935
14.2 Compression Plate (Top bar Plate)
The top bar can be assumed to be a simple supported beam with uniformly distributed load.
The minimum compression plate thickness tmin is then given by
=> PASS
14.3 Gusset Plate
Allowable Compressive Stress
where
= 413.2 mm
r : Least radius of gyration of Gusset = 0.289 x tg = 4.624 mm
Maximum compressive stress
MPa < [σ] = 112 MPa
48687.468 / (100 x 410)
= 15.08
18.0 mm
= 12469 psi = 85.977 MPa
= 2.8 mm < ta =
=
=0.75×
ℎ
=18000
1 +
18000
= ℎ/sin ()
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
=> PASS
where
= 29027 N
= 114.1 mm
= 312.0 mm
14.4 Size of the lug-to-shell weld
Shear
= 32.2 N/mm
where
Lw = 2 x h + 2 x a = 1513.0 mm
Bending
= 86.1 N/mm
where
Zw = a x h + h2/3 = 182086 mm2
Combined
= 91.9 N/mm
Minimum size of the weld leg
= 2.5 mm
where
f w : Allowable unit force for weld = 0.55 x [σ] x 0.6 = 36.96 MPa
14.5 Anchor Bolts (Refer to Pressure Vessel Design Handbook 2nd Ed. 1986 - Henry H. Bednar, Chapter 5, Size of Anchor Bolts)
By inspection,
=> No Uplift exists and the minimum bolt size is about 3/4 to 1 in.
where:
Mb : Overturning moment at base ~ Maximum moment M = 16040551 Nmm
Db : Bolt Diameter Circle = 3060 mm
W : Operating Weight of Vessel = 14632 kg
N : Number of Support Legs = 4
Choose Anchor Bolt Diameter M36 is satisfactory in this case.
15. Stresses in Shell by Wind/Seismic
(Refer to Pressure Vessel Design Handbook, Chapter 7-Local Stresses in Shell Due to Loads on Attachments)
: Half-length of the loaded square area = 188.45755 mm
β = c/r : Attachment parameter = 0.16
ϒ =r/t : Shell parameter = 150.5
r : Mean Shell Radius = 1204.0 mm
t : Shell thickness = 8.0 mm
Maximum bending stress
85.98 MPa
= -30643 < 0
= 18.6 MPa < Sa = =
+6
= /(2sin ())
= −
2 sin ()
= ()
= /
= /
= +
= /
= (ℎ)//2
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev.
where
CLt : Bending Stress factor = 0.125
ML = Fd = 15677365 Nmm
Internal pressure Stress
σt = pr/t = 5.60 MPa
where
p : Internal pressure = 0.0372 MPa
Combined Stress
σ=σb + σt = 168 MPa < 2 x [σ] = 224 MPa
=> PASS
16. Lifting Lug Calculation
Equipment weight We = 4549 kg
Lifting Lug material SA-240 TP304 / 304L
16.1 Check for β = 90 degrees
Angle β = 90.0 degree
Refer to GA Drawing for detail Lifting Lug form
Considered a load factor of 2.0 applied to the structure gravity loads
Design Load P = 2x9.81xWe = 89253.45 N
Force
Fz = 0.5 P = 44627 N
Fx = Fz / tg β = 0 N
Max tensile force in Wire Rope
Ps = Fz / sin β = 44627 N
Lifting lug configuration
where :
SWL = Safe working load
Rh = Hole radius
r = Cheek plate radiusR = Main plate radius
Tp = Main plate thickness
t = Cheek plate thickness
T = Total plate thickness
h = Base width
b = Distance from edge of taper to center of hole
c = Distance from base of plate to center of hole
a = Taper angle
D = Shackle pin diameter
Fy = Yield Strength of lifting lug material
The dimension T should equal 60 - 85% of shackle jaw width.
The pin hole diameter should be 3 mm greater than the selected shackle pin size
Cheek plate radius is approximately r = R - 1.5t
The main plate radius is approximately R = 3 R h
The cheek plate thickness (t) should be less than or equal to the plate thickness (Tp).
Choose Shackle
Shackle load Ps = 44627 N = 4.549 tonne
= 162.5 MPa
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
Choose Shackle with SWL = 8.5 tonne
As per Table shown above :
Shackle jaw width W = 43 mm
Shackle pin size D = 29 mm
Choose Lug Configuration
Rh = 16 mm
r = 42 mm
R = 50 mm
Tp = 25 mm
t = 6 mm
T = 37 mm
h = 174 mm
b = 210 mm
c = 122 mm
a = 71 degrees
D = 29 mm
Fy = 170 MPa
Stress in Lifting Lug
Bearing StressBearing = 41.59 MPa Bearing = Ps/(T x D)
Allowable = 153 MPa Allowable = 0.9 x Fy
Safety Factor = 3.68 => PASS
Shear Stress
Shear = 19.20 MPa Shear = Ps/(4(r-Rh)*t+2(R-Rh)*Tp)
Allowable = 68 MPa Allowable = 0.4 x Fy
Safety Factor = 3.54 => PASS
Tensile Stress
From Section D3.2 of AISC, the distance used in calculations, across the hole, is the minimum of 4 times the plate
thickness at the pinhole or 0.8 times the hole diameter.
Effective width = 25.6 mm
Plate thickness = 37 mm
Tensile = 47.11 MPa Tensile = Ps/(Effective width*plate thickness)
Allowable = 76.5 MPa Allowable = 0.45 Fy (AISC Section D3.2)
Safety Factor = 1.62 => PASS
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev
Bending Stress
Section modulus Z = 126150 mm3 Z = h x Tp / 6
Area of lug base A = 4350 mm2 A = h x Tp
Bending = 43.16 MPa Bending = (Fz*c / Z) + (Fx / A)
Allowable = 102 MPa Allowable = 0.6 Fy
Safety Factor = 2.36 => PASS
Stress in Weld Joint
Weld type : T-Butt weld, Full Penetration
Critial weld length K = 25 mm (Assumed equal to the thickness of lug)
Section modulus of weld Zw = 252300 mm Zw = h x K / 3
Area of weld Aw = 8700 mm Aw = 2 x K x h
Applied by force Fz
Bending S1 = 21.6 MPa Bending S1 = Fz*c/Zw
Shear S2 = 5.1 MPa Shear S2 = Fz/Aw
Combined = 22.18 MPa Combined =(S
1+ S
2)
.
Allowable = 102 MPa Allowable = 0.6 Fy
Safety Factor = 4.60 => PASS
Applied by force Fx
Tensile S3 = 0.00 MPa Tensile S3 = Fx/Aw
Allowable = 102 MPa Allowable = 0.6 Fy
=> PASS
16.2 Check for β = 85 degrees (Considering Tolerance 5 degrees)
Angle β = 85.0 degree
Refer to GA Drawing for detail Lifting Lug form
Considered a load factor of 2.0 applied to the structure gravity loads
Design Load P = 2x9.81xWe = 89253.45 N
Force
Fz = 0.5 P = 44627 N
Fx = Fz / tg β = 3904 N
Max tensile force in Wire Rope
Ps = Fz / sin β = 44797 N
Stress in Lifting Lug
Bearing Stress
Bearing = 41.75 MPa Bearing = Ps/(T x D)
Allowable = 153 MPa Allowable = 0.9 x Fy
Safety Factor = 3.66 => PASS
Shear Stress
Shear = 19.28 MPa Shear = Ps/(4(r-Rh)*t+2(R-Rh)*Tp)
Allowable = 68 MPa Allowable = 0.4 x Fy
Safety Factor = 3.53 => PASS
Tensile Stress
From Section D3.2 of AISC, the distance used in calculations, across the hole, is the minimum of 4 times the plate
thickness at the pinhole or 0.8 times the hole diameter.Effective width = 25.6 mm
Plate thickness = 37 mm
Tensile = 47.29 MPa Tensile = Ps/(Effective width*plate thickness)
Allowable = 76.5 MPa Allowable = 0.45 Fy (AISC Section D3.2)
Safety Factor = 1.62 => PASS
Bending Stress
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev
Section modulus Z = 126150 mm3 Z = h x Tp / 6
Area of lug base A = 4350 mm2 A = h x Tp
Bending = 44.06 MPa Bending = (Fz*c / Z) + (Fx / A)
Allowable = 102 MPa Allowable = 0.6 Fy
Safety Factor = 2.32 => PASS
Stress in Weld Joint
Weld type : T-Butt weld, Full Penetration
Critial weld length K = 25 mm (Assumed equal to the thickness of lug)
Section modulus of weld Zw = 252300 mm Zw = h x K / 3
Area of weld Aw = 8700 mm Aw = 2 x K x h
Applied by force Fz
Bending S1 = 21.6 MPa Bending S1 = Fz*c/Zw
Shear S2 = 5.1 MPa Shear S2 = Fz/Aw
Combined = 22.18 MPa Combined = (S12
+ S22)0.5
Allowable = 102 MPa Allowable = 0.6 FySafety Factor = 4.60 => PASS
Applied by force Fx
Tensile S3 = 0.45 MPa Tensile S3 = Fx/Aw
Allowable = 102 MPa Allowable = 0.6 Fy
Safety Factor = 227.29 => PASS
Choose Lug Configuration as shown above is satisfactory
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Project: NOEV LUBE OIL BLENDING PLANT Job No.: AL-2499 Rev. N
19. Conclusion
Shell thickness:
Thickness required: 2.50 mm
Thickness actual: 8.0 mm
Bottom Head thickness:
Min. Thickness required: 8.00 mm
Top Head thickness:
Thickness actual: 8.00 mm
Auxiliary Stiffener size: 50 x 8 mm
Main Stiffener size: T-150x8 + 70x8 mm (Refer to GA Drawing for more details)
Nozzle thickness:
Shell Nozzle N2 DN40 (1-1/2")
Thickness required: 2.50 mm
Thickness actual: 5.08 mm (SCH 80S)
Flat Top Head Nozzle N1A/B, N3 DN50 (2")
Thickness required: 5.54 mm
Thickness actual: 5.54 mm (SCH 80S)
Flat Top Head Nozzle N9 DN80 (3")
Thickness required: 5.49 mm
Thickness actual: 5.49 mm (SCH 40S)
Flat Top Head Nozzle N6, N10 DN100 (4")Thickness required: 6.02 mm
Thickness actual: 6.02 mm (SCH 40S)
Flat Top Head Nozzle N4 DN250 (10")
Thickness required: 6.00 mm
Thickness actual: 10.00 mm
Cone Bottom Head Nozzle N5 DN100 (4")
Thickness required: 6.02 mm
Thickness actual: 6.02 mm (SCH 40S)
Coil Half-pipe Steam Nozzle N7A/B/C & N8A/B/C DN25 (1")
Thickness required: 2.96 mm
Thickness actual: 4.55 mm (SCH 80S)
Spray Nozzle N10
Outlet Connection DN50 (2")
Thickness required: 3.42 mm
Thickness actual: 5.54 mm (SCH 80S)
Inlet Connection DN20 (3/4")
Thickness required: 2.51 mm
Thickness actual: 3.91 mm (SCH 80S)