TORISPHERICAL ENDS ACC.

AD2000-B3
NAME Outside Diameter of Cylinder or Ends inside Diameter of Openings Knuckle Radius= Cylindrical Part Required Wall Thickness Mill Under tolerance Corrosion Allowance Da Di r h s C1 C2 HEAD 609.6 573.6 60.96 109.77 18 0.8 1.5 145 ### 511.8 100 1.5 mm mm mm mm mm mm mm N/mm N/mm -% --

Design Strength Value at design temperature K Modulus of Elasticity at Design Temperature E Design Factor Joint Efficiency Factor of Safety Material Used Product Form Limits of Application Ratio Se-c1-c2/DA or Da/Di V S

P265GH (DIN EN10028-2) / SA 516 Gr. 70 PLATE within 0.003

Smallest Wall Thickness B1 Chap. 6.1/6.2, B0 Chap. 10

Req. min wall Thickness Req. nominal Thickness Smin Serf=Smin+C1+C2 ### ### mm mm B1 eq.2

AD 2000-B3 RESULT
Pressure Temperature Stress Value Safety Factor Modulus of Elasticity Req. Wall Thickness Sphere Req. Wall Thickness Knuckle Design Coefficient Req. Cylindrical Part Reinforcing length of shell Max opening without reinforcement P T S Sreq SA Sreq K K B dA bar C -mm mm -mm mm

DESIGN TESTING ANNOTATION 31 66.8 380 145 1.5 2.4 2.65 370.6 7.18 0 30 255 1.050 210000 2.38 2.65 -7.18 0 B1 eq.3 B3 eq.15 B3 sect. 2.2 B9 eq.3

K N/mm

E N/mm 188200

246.47 B3 sect. 8.1.3

Hreq mm

CYLINDRICAL SHELL ACC. To AD 2000-B1

NAME Outside Diameter Inside Diameter design pressure required wall thickness actual wall thickness tolerance on wall thickness corrosion allowance factor of safety Da Di P s Se C1 C2 S CYLINDRICAL SHELL 609.6 573.6 31 11.93 18 0.8 1.5 145 1.5 100 mm mm barg mm mm mm mm N/mm -%

design strength value at design temperature K factor to make use of the maximum design v stress in the welding seam Material Product Form Limits of Application Diameter Ratio Da>200 mm Da/Di<1.2

P265GH (EN10028-2) / SA 516 Gr. 70 PLATE within 609.6 1.063 mm --

Smallest Wall Thickness B1 Chap. 6.1/6.2, B0 Chap. 10 Req. wall Thickness Req. nominal Thickness Smin Serf=Smin+C1+C2 ### ### mm mm B1 eq.2

The calculation of openings according to AD2000-B9 is only necessary if diameter of openings exceeds di> 212mm AD 2000-B1 RESULT Pressure Temperature Stress Value Safety Factor Reinforcing length of shell MAX nozzle opening w/o reinf. MAX nozzle opening w/o reinf. MAX opening in longit. Direction P T K S B dA dA d1 bar C N/mm -mm mm -mm

DESIGN TESTING ANNOTATION 31 66.8 380 145 1.5 37.83 168.3 -609.6 609.6 30 255 1.050 37.83 168.3 limited B9 eq.3 W1 (Table 2)

OPENING ACC. To AD 2000-B9

NAME Insertion Height Circumf. Angle Offset Nozzle Type Outside Diameter of cylinder Inside Radius of Sphere Outside Diameter of Opening Inside Diameter of Opening Design Pressure Actual Wall thickness of vessel component Actual Wall Thickness of Tube Da R da di P Se Ss NO2,NO3,NO4 Design 200 180 0.00 Set-On 609.6 286.8 168.3 139.9 31.0 18.0 11.93 14.2 ---37.83 0.8 1.5 145 1.5 331.7 St 35.8l / A106B PIPE 255 1.05 66.8 Testing mm mm mm mm mm mm mm bar mm mm mm Sch 120 mm mm mm mm mm mm N/mm -mm

Required wall thickness of Vessel Component SA

Load Bearing Length of Nozzle on the external ls side Load Bearing Length of Nozzle on the internal side l's actual wall thickness of reinforcing pad width of reinforcing pad tolerance on wall thickness Corrosion Allowance Safety Factor Measured Distance between two Nozzles Material Product Form h b C1 C2 S L

Design Strength Value at Design Temperature K

Smallest Wall Thickness Using B9 eq. 2

Derived value for the required wall thickness at the edge of the opening: Req. nominal Wall Thickness SA-C1-C2 9.63 mm Maximum possible value to be chosen for load bearing length of nozzle: ls = (di + Ss -C1-C2) * (Sa-C1-C2) substitute: ls = 42.5 mm and l's < ls/2 ls 1 = 42.5 Maximum possible value to be chosen for width: b = (Di + SA -C1-C2) * (Ss -C1 C2) b substitute Eq. 6

= =

74.90 mm 74.90 mm

Eq. 3

Derived values according to the above calculated ones for length: Ap = 47929 A 0 = b * (Se C1 C2) = 1175.93 A 1 = (ls1 + Se -C1 C2 + l's1) * (Ss1 -C1 -C2) = 692.58 A 3 = B1 * h1 = 0.00 Substituted into equation 2: p/10*Ap (K/S -P/20) A 0+ (K/S -P/20) A 1 + (K/S -P/20) A 3 ### + 65875.9 + 0 Reserve
operating Test

= 148579 <= = 177726 OK = 19.62

### <= ### OK 34.29

An adverse effect of openings can be ignored, if the measured distance between the nozzles is >

149.80

B9 eq 8

The maximum permissible design pressure in pmax = 39 bar

Maximum permissible design pressure is limited by the flange,which is 23.8 bar

OPENING ACC. To AD 2000-B9

NAME Insertion Height Circumf. Angle Offset Nozzle Type Outside Diameter of cylinder Inside Radius of Sphere Outside Diameter of Opening Inside Diameter of Opening Design Pressure Actual Wall thickness of vessel component Actual Wall Thickness of Tube Da R da di P Se Ss NO5 Design 300 315 0.00 Set-On 609.6 286.8 48.3 41.1 31.0 18.0 11.93 3.6 ---74.9 0.8 1.5 145 1.5 0 St 35.8l / A106B PIPE 255 1.05 66.8 Testing mm mm mm mm mm mm mm bar mm mm mm mm mm mm mm mm mm N/mm -mm Sch STD.

Required wall thickness of Vessel Component SA

Load Bearing Length of Nozzle on the external ls side Load Bearing Length of Nozzle on the internal side l's actual wall thickness of reinforcing pad width of reinforcing pad tolerance on wall thickness Corrosion Allowance Safety Factor Measured Distance between two Nozzles Material Product Form h b C1 C2 S L

Design Strength Value at Design Temperature K

Smallest Wall Thickness Using B9 eq. 2

Derived value for the required wall thickness at the edge of the opening: Req. nominal Wall Thickness SA-C1-C2 9.63 mm Maximum possible value to be chosen for load bearing length of nozzle: ls = (di + Ss -C1-C2) * (Ss-C1-C2) substitute: ls = 7.42 mm and l's < ls/2 ls 1 = 7.42 Maximum possible value to be chosen for width: b = (Di + SA -C1-C2) * (SA -C1 C2) b substitute Eq. 6

= =

74.90 mm 74.90 mm

Eq. 3

Derived values according to the above calculated ones for length: Ap = 27900 A 0 = b * (Se C1 C2) = 1176 A 1 = (ls1 + Se -C1 C2 + l's1) * (Ss1 -C1 -C2) = 30.06 = 0.00 A 3 = B1 * h1 Substituted into equation 2: operating p/10*Ap = 86491 <= (K/S -P/20) A 0+ (K/S -P/20) A 1 + (K/S -P/20) A 3 = 114709 ### + 2858.83 + 0 OK Reserve = 32.63

Test

### <= ### OK 48.9

An adverse effect of openings can be ignored, if the measured distance between the nozzles is >

149.80

B9 eq 8

The maximum permissible design pressure in pmax = 43 bar

Maximum permissible design pressure is limited by the flange,which is 23.8 bar

SYNGAS HEADER
FLANGE SUMMARY: MARK N01 N02 N03 N04 N05 DN 600 150 150 150 60 PN 40 63 63 63 100 GRADE/ MAT'L NUMBER C22.8/1.046 C22.8/1.046 C22.8/1.046 C22.8/1.046 C22.8/1.046 MATERIAL USED A105 A105 A105 A105 A105 MAX MATERIAL PRESSURE @ ATTACHEMENT GROUP 400C 3E0 23.8 Attachment 1 3E0 3E0 3E0 3E0 37.5 37.5 37.5 59.5 Attachment 2 Attachment 2 Attachment 2 Attachment 3

AS per AD2000 B8 this N01 is acceptable see Attachment 4.

INTEGRAL TYPE FLANGE under Internal Pressure and Additional Forces acc to AD 2000-B7: 2000-10 B8: 2000-10 DINV 2505: 1986-01
input data Type Declaration flange type : 1- welding neck flange (inside gasket) bolt type : 2- neckeddown bolts, S=1.5 / S'=1.1 / phi=1.0 (AD-B7) calculation of bolting torque = 1- yes Design Data design pressure p = 31 test pressure = 66.8 p' design temperature T = 380 code no. of external loads: 1- without external loads Geometry Data, Flange outside diameter flange da = 890 outside diameter hub dr = 610 bolt circle diameter dt = 795 outer dia of tapered neck at trans to flange d3 = 666 flange thickness hF = 70 total length of flange ha = 128 bolt hole diameter dL = 48 number of bolts or bolt holes n = 20 act wall thickness of hub respectively tube s1 = 18 manufacturing tolerance of hub respect. Tube c1 = 7 DIN EN corrosion allowance of hub respect. Tube c2 = 1.5 Material Data, Flange material : 100 C 22.8 (1.0460) DIN 17243 AD-W12/W13 strength value, design K = 110 yield strength Rp 0.2 (380 C , 75 mm) safety factor, design S = 1.5 strength value, test/bolting-up K = 240 yield strength Rp 0.2 (20 C , 75 mm) safety factor, test/bolting up S = 1.05 modulus of elasticity, design (380 C ) E = 185600 modulus of elasticity, bolting-up (20 C ) E = 212000 Gasket Data gasket type: 26- free enter, soft gasket calculation without reduction of setting load = 0 no retighten the bolts after setting of gasket = 0 no mean gasket diameter dD = 652 gasket characteristic for service conditions kl = 30.8 gasket characteristic for service conditions kl = 30.8 gasket characteristic for service conditions k0*KD = 1210 Bolt Data material : 297 21 CrMoV 5 7 (1.7709) DIN EN 10269 : 1999 08 AD W7 : 2002 07 strength value, design K = 420 yield strength Rp 0.2 (380 C , 45 mm) strength value, test/bolting-up K' = 550 yield strength Rp 0.2 (20 C , 45 mm) shaft diameter of screw ds = 35.5 effective diameter thread d2 = 42.08

bar bar C

mm mm mm mm mm mm mm Stck mm 10029A mm

N/mm

N/mm

N/mm N/mm

mm mm mm N/mm

N/mm N/mm mm mm

continuation Bolt Data outer diameter of bearing surface (bolting) thread angle, bolts thread pitch, bolts min coefficient of friction, thread min coefficient of friction, bearing surface max coefficient of friction, thread max coefficient of friction, bearing surface results summary of results flange act. Stresses and reserve section A-A section B-B section C-C act. Flange deflection bolts req shaft diameter

daS p G_min A_min G_max A_max

= = = = = = =

70 60 4.5 0.15 0.15 0.15 0.15

mm mm mm mm mm mm

bolting-up N/mm N/mm N/mm ds mm 70 227% 78 193% 38 500% 0.163 61 68 25

design 21% 8% 190% 0.161 338% 131 146 54

testing 75% 56% 320% 0.303 264%

FSO max 398 444 217 0.920 35.50

15.57 420% ###

18.61

geometry data calc. Wall thickness of hub respectively tube with manufacturing tolerance corosion allowance moment arms - of hub load - of ring area load - of gasket load - of bolt load (for section C-C) reduced bolt hole diameter mean gasket diameter bolt pitch / dL gasket data medium characteristic k1 characteristic kO*KD loads hub load int. press bending area load gasket load design setting load red. Setting load min req bolt load flange (DIN 2505) bending moments section A-A , B-B section C-C section modulus section A-A section B-B section C-C bolt-up (0) gases/vap. mm N/mm N FI.. FF.. FD.. FDV' FDV FS.. Nmm 136912288 123508288 mm^3 1956849 1752052 3240396
--

s1 c1 c2 aR aF aD a1 dL' dD

= = = = = = = = = =

15.90 0.60 1.50 100.45 89.95 71.50 64.50 24.00 652.00 2.60

mm mm mm mm mm mm mm mm mm mm

1210.00 ---2478466 1914857 1914857

design (B) gases/vap. 30.8 -813969 221047 234688 --1269704

testing (P) liquids 30.8 -1753972 476320 505715 --2736007

118426504 81895872 1949169 1744718 3240396

255190032 176472416 1949358 1744898 3240396

bolt-up (0) act stresses section A-A section B-B section C-C design stress eff. Stress reserve section A-A section B-B section C-C act flange deflection bolts req shaft diameter auxiliary factor design allowance N/mm 69.97 78.14 38.12 228.57 227 193 500 0.1627 15.57 1.18 0.00 420

design (B) 60.76 67.88 25.27 73.33 21 8 190 0.1607 16.97 1.38 0.00 338 pmax pTmax = =

testing (P) 130.91 146.25 54.46 228.57 75 56 320 0.3032 18.61 1.18 0.00 264 33.47 bar 103.78 bar

N/mm % % % ds Z c5 mm mm

max allow operating pressure max allow test pressure remarks ATTENTION! Check gasket with regard to allowable load FSO <= V * FDV fulfilled? min bolt load for bolting up condition (FSO) was calculated with an allowance of 20% to minimum bolt load of design condition (FSB) (see DIN 2505 chapt 4.5). results (bolting up) basic bolt load acc. to stress value of 100% of strength value of bolts (testing/ bolting up) actual actual actual actual stress stress stress flange section A-A section B-B section C-C deflection

FSO max

### N

= = = =

397.8 N/mm 444.3 N/mm 216.7 N/mm 0.925

remarks ATTENTION! Check gasket with regard to allowable load FSO max <= V * FDV fulfilled? bolting torques acc. to VDI Richtlinie 2230 req bolting torque (with max) with FVM = FSOmaxT = 2736007 N / 20 bolts

M A min

= = = =

1205 Nm 136800 N 2468 Nm 280048 N

max bolting torque (bolting up / with min) M A max with FVM = FSOmaxT = 5600966 N / 20 bolts FSOmaxT = cause of usage factor of flange reduced force FSOmax. MA phi rho' rA = = = = FVM * ( d2/2 * tan ( phi + rho' ) + A * rA ) Arctan ( P / ( d2 * ) ) Arctan ( G / cos ( / 2 ) ) ( dL + daS ) / 4

the seating stress of gasket was not checked with M A max!