Sheet1, Page 1 of 39

File : 357927304.xls
Job No. : 1314

FURNACE FABRICA (INDIA) LTD.

Navi Mumbai 400 705

Clients : M/s.ONGC Through M/s. NICCO Corporation Ltd.

Consultants : M/s. Engineers India Limited.
Inspection By : NICCO / EIL
P. O. No. : LOI No. : PUR/RKD/C168/RGC/19 Dt. 25-11-1998
Project : ONGC Gas Lifting Facilities, Pakhajan, Gujarat
Plant : Gas Lifting Facilities
Equipment : 10 E 101 : Regeneration Gas CoolerDrawing No.: 01-1314-001

INDEX
Serial Nos. Descriptions Sheet Nos. Page Nos.
1 Cover Sheet / Index 1 1
2 Design Data 2 2
3 Calculation for Hydro Test Pressure 2 2
4 Shell Design 2 2
5 Channel Shell Design 2 2
6 Minimum Nozzle Wall Thickness 3 3
7 Baffle / Support Plate Thickness 3 3
8 Tie Rods 3 3
9 Pass Partition Plate Thickness 3 3
10 Tubes Under Internal/External Pressure 3 3
11 Calculations For Channel Flange - Shell Side 4 4
12 Calculations For Channel Flange - Cover side 5 5
13 Channel Cover Flange 6 5 to 7
14 Fixed Tube Sheets 7 8 to11
15 TEMA Expansion Bellow Calculations 8 12 & 13
16 Nozzle Reinforcement For N-1 & N-2 9 14 & 15
17 Nozzle Reinforcement For N-3 & N-4 10

Designed By : A.R Approved By : S. S. Rao

Date : 06/14/2017
 Sheet2, Page 2
Equipment No.: File: 357927304.xls
Clients: Consultants: Dwg.:01-1314-001
E - 1108
DESIGN DATA
DESIGN CODE : ASME SEC.VIII Div.1, 1998 / TEMA
TEMA TYPE-BES,TEMA CLASS-R
DESIGN DATA Shell Side Tube Side Units
Design Pressure 10 45 Kg/Cm^2g
Working Pressure 8 41 Kg/Cm^2g
Hydrotest Pressure 13.0 58.5 Kg/Cm^2g
Design Temperature 160 120 C
Working Temp.: In/out 140 /100 60/99 C
Mean Wall Metal Temp. 120 79.5 C
Joint Efficiency 0.85 0.85 Factor
Radiography Spot Full -
Corrosion Allowance (C) 3 0 mm
P.W.H.T. Nil Nil - 55C
Insulation Nil Nil
Wind Pressure 32C
Seismic Factor
No. of Passes 1 1 160C
Pressure Drop Allowed 0.5 0.5 Kg/Cm^2
Fluid Circulated Cooling water Shift Gas
CALCULATIONS FOR HYDRO TEST PRESSURE 144C
Shell Side Test Pressure is Governed by Expansion Bellow:
M.A.S. for Shell at Ambient = 1406.1731 Kg/Cm^2 0.0
M.A.S. for Shell at Design Temp = 1406.1731 Kg/Cm^2
Stress Ratio = (1406.1 /1406.1) = 1.0000 Assumed = 1.00
\ Hydro Test Pressure = 1.3 x 6 x Stress Ratio = Ph = 13.00 Kg/Cm^2g

Tube Side Test Pressure is Governed by Channel:

M.A.S.for Channel at Ambient = 1406.1731
M.A.S.for Channel at Desn Temperature = 1174.1545
Stress Ratio = 1 Assumed = 1.000
\ Hydro Test Pressure = 1.3 x desin presure x Stress Ratio = Ph = 58.500 Kg/Cm^2g

SHELL DESIGN:
Shell Out Side Diameter 591 + 2 x 10 = Do 607 mm
Material of Construction SA 516 Gr 70
Max.Allowable Stress at Design Temperature (Higher Stress Value) S 1406.1731 Kg/Cm^2
Max.Allowable Stress at Ambient Sa 1406.1731 Kg/Cm^2
Yield Stress at Ambient Ys 2671.7289 Kg/Cm^2
Shell Side Effective Design Pressure P 10 Kg/Cm^2g
Joint Efficiency E 1
Shell Thickness Required = t = P.Ro / (S.E+0.4P) + C = 5.1522 mm
Minimum Thickness Required as per TEMA : R-3.13 = 3/16" = 4.7625 mm
For Hydrotest Condition-Shell Thickness Reqd. = Ph.Ro/(0.9Ys.E+0.4Pts)+C = 4.6373 mm
Thickness Provided (With Plus Tolerance on Thickness) = 8.0 mm
CHANNEL SHELL DESIGN:
Shell Out Side Diameter Do 615 mm
Material of Construction - SA 516 Gr 70
Max.Allowable Stress at Design Temperature S 1406.1731 Kg/Cm^2 4769
Max.Allowable Stress at Ambient Sa 1406.1731 Kg/Cm^2 19.48
Yield Stress at Ambient Ys 2671.7289 Kg/Cm^2 175.7
Shell Side Effective Design Pressure P 45 Kg/Cm^2g 17.800
Joint Efficiency E 0.85 13.931
Shell Thickness Required = t = P.Ro / (S.E+0.4P) + C = 11.405 mm

Date : 06/14/2017
 Sheet2, Page 3
Equipment No.: File: 357927304.xls
Clients: Consultants: Dwg.:01-1314-001
Minimum Thickness Required as per TEMA : R-3.13 = 3/8" = 9.525 mm
For Hydrotest Condition-Shell Thickness Reqd. = Ptt.Ro/(0.9Ys.E+0.4Ptt)+C = 8.702 mm
Thickness Provided = 12 mm

Date : 06/14/2017
 Sheet2, Page 4
Equipment No.: File: 357927304.xls
Clients: Consultants: Dwg.:01-1314-001
Temp F

YIELD UTS 100 200 300 400 500 600 650 700
SA 240 TP 304 High 30000 75000 20000 16700 15000 13800 12900 12300 12000 11700

SA 213/312TP304 High 30000 75000 20000 16700 15000 13800 12900 12300 12000 11700

SA 182 F 304 > 5" High 30000 70000 20000 18900 17700 17100 16900 16600 16200 15800

SA 516 Gr.70 38000 70000 20000 20000 20000 20000 20000 19400 18800 18100
SA 106 Gr B 17100 17100 17100 17100 17100 17100 17100 15600

Temp F 554 320 500 600 650 Amb/D

131 F SHELL High 12576 13980 12900 12300 12000 S.R.= 1.5903
LOW 0 0 0 0
89.6 F Tube Sheet Low 0 0 0 0 0 S.R.= ###
149 100 200
320 F Tubes High 18383 20000 16700 S.R.= 1.088
149 F Channel 15000
291.2 300 400
291.2 F Mean Metal - Shell High 15106 15000 13800
291.2 300 400
306.5deg C LOW 0 0 0
172.5
342.5 LINEAR INTERPOLATION

x y
2 5
5 9

Value at 55

Result 75.667

194

110.848
190

Date : 06/14/2017
 Sheet3, Page 5
Equipment No.: 10 E 101- Regeneration Gas Cooler File : 357927304.xls
Clients: Inspection - Dwg.: 01-1314-001
CALCULATIONS FOR MINIMUM NOZZLE NECK THICKNESS :
LOCATIONS > NOZZLES ON SHELL SIDE NOZZLES ON TUBE S
NOZZLE MARKS > N-1 N-2 N3 N4 N5 N6
Nozzle Sizes N.B. 80 80 50 40 100 50
Nozzle Pipe O/Dia. mm 88.9 88.9 60.3 48.3 114.3 60.3
Corrosion Allowance mm 1.5 1.5 1.5 1.5 0 0
Design Pressure Kg/Cm^2g 6 6 6 6 31 31
Material of Construction for Shell <--------- SA 106 Gr B --------------> <------- SA 312 Tp.304-----
Max. Allowable Stress for Shell Kg/Cm^2 1202.3 1202.3 1202.3 1202.3 1406.2 1406.2
Material of Construction for Neck <--------- SA 106 Gr B --------------> <------- SA 312 Tp.304-----
Max. Allowable Stress for Neck Kg/Cm^2 1202.3 1202.3 1202.3 1202.3 1406.2 1406.2
Shell O/Dia. mm 607 607 607 607 615 615
Reqd. Shell Thick. with E = 1 + C mm 3.012 3.012 3.012 3.012 6.720 6.720
Neck Thick.with Intl.Pressure + C mm 1.721 1.721 1.721 1.721 1.249 0.659
Min.Thickness as per UG-16 mm 1.588 1.588 1.588 1.588 1.588 1.588
Min.Thickness as per UG-45 mm
(Std. Wall Pipe Thickness + C) mm 6.304 6.304 6.400 5.963 5.338 4.900
Minimum Thickness Required mm 3.012 3.012 3.012 3.012 6.720 6.720
Thickness Provided : Sch 40 40 80 80 40S 80S
Nom.Thick. mm 5.49 5.49 5.6 5.1 6.1 5.6
Min. Thick. mm 4.804 4.804 4.900 4.463 5.338 4.900
a) BAFFLE / SUPPORT PLATE THICKNESS (Ref. Table R-4.41) : MATERIAL : SA 51
Max. Unsupported Length of the Tubes 400 15.74803
Required Baffle / Support Plate Thickness 3/16" 4.7625
Baffle Plate Thickness Provided 5
b) TIE-RODS (Ref. Table R-4.71): MATERIAL : IS 2
TIE-RODS REQUIRED = 4 Nos. x 3/8" Dia.
TIE-RODS PROVIDED = 4 Nos.x M10 Tie-Rods
c) TUBES : (Material : SA 179) Internal External
Under Intl. Pressure, Thickness Required = t E=1 Design Pressure : 6.00 36.00
t = P.Ro / (S.E + 0.4 P) = 0.04058 mm Tube O/Dia. = 19.05 \ Ro = 9.525
Tube thickness Provided = 2.03 mm Max. Allowable Stress = S= 1406.1
Under External Pressure : As per UG-28(c)(2): For External Pressure Design:
Tube length = 5600 L / Do = 293.96, Do/t = 11.54 Stress at Design Temperature = Ys = 20700
From Fig. G, A = 0.0095, Fig. HA-4, B = 13500 PSI 2B = 27000
Pa1=[2.167/(Do/t)-0.0833]xB = 1410.5 PSI M.A.S.at Tube side design metal Temp.= 18300
99.1705 Kg/Cm^2 S = Smaller of 0.9 YS & 2 x 20000 = 18300
Pa2 = (2S / (Do/t)).(1-t / Do) = 203.675 Kg/Cm^2 1286.648
Both of above External Allowable Pressures are Greater than Tube External Design Pressure
\ Tube Thickness Provided is Adequate.

Date: 06/14/2017
 Sheet3, Page 6
Equipment No.: 10 E 101- Regeneration Gas Cooler File : 357927304.xls
Clients: Inspection - Dwg.: 01-1314-001

ES ON TUBE SIDES
N7
40
48.3
0
31
312 Tp.304------>
1406.2
312 Tp.304------>
1406.2
615
6.720
0.528
1.588

4.463
6.720
80S
5.1
4.463
SA 516 Gr. 70
mm/inch
inch/mm
mm
IS 2062 Gr.A

Kg/Cm^2.g
mm
Kg/Cm^2.g

PSI
PSI
PSI
PSI
Kg/Cm^2.g

Date: 06/14/2017
 Equipments : SHELL SIDE CHANNEL FLANGE DESIGN Sheet4, Page 7
File: 357927304.xls
Clients : FEDO - VVF Inspection - Dwg.: 01-1314-001

CHANNEL FLANGE ON SHELL SIDE

P = Design Pressure 45 Kg/Cm2g bo = N/2 = 6.5 mm

Pe = External Design Pressure 0 Kg/Cm2g b = 2.52(bo) or bo (If N < 12.7) = 6.5 mm
Pt = Hydrotest Pressure 58.5 Kg/Cm2g bp = Np/2 = 3 mm
Design Temperature 120 oC G = Go - 2 b = 612.000 mm
Go = Gasket - Out Side Dia. 625 mm Nmin= Ab.Sa/(2p.y.Gm) = 3.252 mm
N = Gasket - Contact Width 13 mm H = p G^2.P/400 = 132374.8 Kgs.
Np = Partition Gasket- Effective Width 6 mm Hp = m.P(p .b.G+bp.L)/50 = 38529.7 Kgs.
L = Partition Gasket- Total Length=L 591 mm Wm1= H + Hp = 170904.5 Kgs.
m = Gasket Factor 3 Factor Wm2= p .b.G.y+L.bp.y = 100332.2 Kgs.
y = Gasket Design Seating Stress 7.031 Kg/mm^2 Ab = Nob.Cab = 4676.1 mm^2
Ca = Corrosion Allowance 0 mm Am1 = Wm1/Sb = 9090.7 mm^2
A = Flange OD 838 mm Am2 = Wm2/Sa = 5336.8 mm^2
B = Flange ID 591 mm Am = >of Am1&Am2 = 9090.7 mm^2
C = Flange P.C.D. 680 mm Wb = Ab.Sa = 87911.0 Kgs.
dB = Bolt Dia. 34.9 mm Mating Flange Bolt Load : Operating = Kgs.
Nob = No. of Bolts 24 Nos. Gasket Seating = Kgs.
Cab = C.S.A. of Bolts 194.838 mm^2 go = Hub Thickness at Small End = 12.00 mm
Sa = M.A.S.:Bolts at Ambient 18.8 Kg/mm^2 g1 = Hub Thickness at Large End = 20.00 mm
Sb = M.A.S.:Bolts at Design Temp. 18.8 Kg/mm^2 h = Hub Height = 22.00 mm
Sfa = M.A.S.:Flange at Ambient 14.062 Kg/mm^2 ho = (B.go) = 84.21 mm
Sfo = M.A.S.:Flange at Design Temp. 14.062 Kg/mm^2 g1/go 1.667 h/ho = 0.261 K=A/B= 1.418 Ratios
Gm = Mean Dia. of Gasket = Go-N 612.00 mm F = 0.882 V = 0.359 f= 1.577 Factor
MOMENT CALCULATIONS: LOAD UNITS T = 1.746 U= 6.293 Factor
OPERATING LOADS UNDER INTL. PRESSURE Y = 5.727 Z= 2.979 Factor
Hd = p.B^2.P/400 123446.1 Kgs. e=F/ho 0.010 d = (U/V)ho.go^2= 212425 Factor
Hg = Wm1 - H 38529.7 Kgs. From Table TEMA D-5 & RCB-11.2
Ht = H - Hd 8928.7 Kgs. Particulars Actual Min.Reqd. mm
OPERATING MOMENT UNDER INTL. PRESSURE Bolt Spacings = B = 88.758 44.450 mm
MD = Hd.hD 4258890.283 Kg-mm Bmax = Max. Allowed = 189.800 mm
MG = Hg.hG 1310009 Kg-mm Radial Distance = Rh = 24.500 28.575 mm
MT = Ht.hT 350451 Kg-mm Edge Distance = E = 79.000 20.638 mm
Mo = Total Moment(Op) = MD+MG+MT 5919350 Kg-mm Flange Material SA 105
OPERATING LOADS UNDER EXTL. PRESSURE Bolting Material SA 193 Gr. B7
He = p.G^2.Pe / 400 0.0 Kgs. Gasket Material: SWAG-SS 304
HDe= p.B^2.Pe / 400 0.0 Kgs. Lever Arm For Calculation of Bolting Moments:
HTe= He - HDe 0.0 Kgs. hD = R+g1/2 = 34.50 hG= (C-G)/2= 34.00 mm
OPERATING MOMENT UNDER EXTL. PRESSURE hT=(R+g1+hG)/2 39.25 mm
Me = HDe(hD-hG)+HTe(hT-hG) 0.0 Kg-mm Ma=>of Mo/Me 5919350 = Kg-mm
GASKET SEATING CONDITION:- Correction Factor to be Applied to Moment = Cf = 1.00
Hg = W (Full Bolt Load) = Ab.Sa 87911.0 Kgs. [If B > Bmax, Cf = (B/Bmax) Otherwise Cf =1]
hG = (C - G)/2 34.00 mm Mos= Hg.hG 2988976 Kg-mm
Corrected Moments (Moments x Correction Factor): t = Flange Thk.= 70.00 b=(4t.e/3)+1= 1.9770 Factor
Ma = 5919350 Kg-mm Mos = 2988975.6995 Kg-mm a = t.e + 1 = 75.0000 d = t^3/d = 1.6147 Factor
STRESS CALCULATIONS: l= d + g = 44.5597 g= a/T= 42.9450 Factor
Operating Condition Actual Allowable Stresses A = 838
Sh = f.Mo / (l.B.g1^2) 0.886 21.093 Kg/Cm^2 C = 680
Sr = b.Mo / (l.B.t^2) 0.091 14.062 Kg/Cm^2 Go = 625
St = Mo.Y / (B.t^2)-Z.Sr 11.436 14.062 Kg/Cm^2 N = 13
Sm1= (Sh + Sr) / 2 0.488 14.062 Kg/Cm^2
Sm2= (Sh + St) / 2 6.161 14.062 Kg/Cm^2
Gasket Seating Conditions Actual Allowable Stresses t = 70 g1
Sh = f.Mos / (l.B.g1^2) 0.303 21.093 Kg/Cm^2 20.0 B = 591
Sr = b.Mos / (l.B.t^2) 0.046 14.062 Kg/Cm^2
St = Mos.Y / (B.t^2)-Z.Sr 5.774 14.062 Kg/Cm^2
Sm1= (Sh + Sr) / 2 0.174 14.062 Kg/Cm^2 h = 22.00
Sm2= (Sh + St) / 2 3.039 14.062 Kg/Cm^2 24 Nos. Bolts Equally Spaced go = 12.0
CHANNEL FLANGE ON SHELL SIDE
Equipments : SHELL SIDE CHANNEL FLANGE DESIGN Sheet4, Page 8
File: 357927304.xls
Clients : FEDO - VVF Inspection - Dwg.: 01-1314-001
 Equipments : SHELL SIDE CHANNEL FLANGE DESIGN Sheet4, Page 9
File: 357927304.xls
Clients : FEDO - VVF Inspection - Dwg.: 01-1314-001

p= 3.14159265 A=A/B= 1.4179357

SHAPE CONSTANT C= 680
A=g1/go 0.67 ok
C 0.20343979 ok
C1 0.38888889 ok
C2 0.15277778 ok
C3 0.00661376 ok
C4 14.7847376 ok
C5 -22.742338 ok
C6 4.92604127 ok
C7= 121.951331 ok
C8= 15.6488297 ok
C9= 13.681903 ok
C10= -18.069188 ok
C11= 6.61718808 ok
C12= 3.85342514
C13= 1.1092196
C14= -1.377729
C15= 0.6055098
C16= 87.4536353 ok
C17= 37.9897501 ok
C18= -58.447566 ok
C19= 12.6504376 ok
C20= 0.07523317 ok
C21= -0.0875759 ok
C22= 0.04392497 ok
C23= -0.0828734 ok
C24= 0.09842926 ok
C25= -0.042957 ok
C26= -0.474891 ok
C27= -56.372176 ok
C28= -18.697425 ok
C29= -0.2255215 ok
C30= -0.1070981 ok
C31= 5.0686316 ok
C32= 1.85483834 ok
C33= -3.6497139 ok
C34= -86.032883 ok
C35= 6.25962569 ok
C36= 2.62850194 ok
C37= -3.4715458 ok
E1= -2.5080083 ok
E2= -0.042313 ok
E3= 0.02972356 ok
E4= 3.18336299 ok
E5= -1.5463306 ok
E6= -10.481796 ok
FOR INTEGRAL TYPE
F= 0.88157048 0.52247837 22.7567558 -0.88157
V= 0.35925947 -10.481796
f= 1.57710116 min=1
T= 1.74641831
Z= 2.97913662
Y= 5.72675696
U= 6.29312553
Equipments : SHELL SIDE CHANNEL FLANGE DESIGN Sheet4, Page 10
File: 357927304.xls
Clients : FEDO - VVF Inspection - Dwg.: 01-1314-001
Equipment No.: DESIGN OF CHANNEL FLANGE ON COVER SIDE Sheet5, Page No. 11
File : 357927304.xls
Clients: Inspection - Dwg.: 01-1314-001
CHANNEL FLANGE ON COVER SIDE
P = Design Pressure 15 Kg/Cm2g bo = N/2 = 10 mm
Pe = External Design Pressure 0 Kg/Cm2g b = 2.52(bo) or bo (If N < 12.7) = 8.0 mm
Pt = Hydrotest Pressure 27 Kg/Cm2g bp = Np/2 = 3 mm
Design Temperature 65 oC G = Go - 2 b = 432.062 mm
Go = Gasket - Out Side Dia. 448 mm Nmin= Ab.Sa/(2p.y.Gm) = 18.113 mm
N = Gasket - Contact Width 20 mm H = p G^2.P/400 = 21992.4 Kgs.
Np = Partition Gasket- Effective Width 6 mm Hp = m.P(p .b.G+bp.L)/50 = 7930.0 Kgs.
L = Partition Gasket- Total Length=L 800 mm Wm1= H + Hp = 29922.5 Kgs.
m = Gasket Factor 2 Factor Wm2= p .b.G.y+L.bp.y = 14868.0 Kgs.
y = Gasket Design Seating Stress 1.12494 Kg/mm^2 Ab = Nob.Cab = 3117.4 mm^2
Ca = Corrosion Allowance 0 mm Am1 = Wm1/Sb = 1702.4 mm^2
A = Flange OD 524 mm Am2 = Wm2/Sa = 845.9 mm^2
B = Flange ID 393 mm Am = >of Am1&Am2 = 1702.4 mm^2
C = Flange P.C.D. 482 mm Wb = Ab.Sa = 54795.3 Kgs.
dB = Bolt Dia. 19.05 mm Mating Flange Bolt Load : Operating = Kgs.
Nob = No. of Bolts 16 Nos. Gasket Seating = Kgs.
Cab = C.S.A. of Bolts 194.838 mm^2 go = Hub Thickness at Small End 7.00 mm
Sa = M.A.S.:Bolts at Ambient 17.5772 Kg/mm^2 g1 = Hub Thickness at Large End 15.00 mm
Sb = M.A.S.:Bolts at Design Temp. 17.5772 Kg/mm^2 h = Hub Height = 32.00 mm
Sfa = M.A.S.:Flange at Ambient 12.304 Kg/mm^2 ho = (B.go) = 52.45 mm
Sfo = M.A.S.:Flange at Design Temp. 12.304 Kg/mm^2 g1/go= 2.143 h/ho = 0.610 K=A/B= 1.333 Ratios
Gm = Mean Dia. of Gasket = Go-N 428.00 mm F = 0.797 V = 0.186 f= 1.040 Factor
MOMENT CALCULATIONS: LOAD UNITS T = 1.783 U= 7.586 Factor
OPERATING LOADS UNDER INTL. PRESSURE Y = 6.903 Z= 3.571 Factor
Hd = p.B^2.P/400 18195.6 Kgs. e=F/ho 0.015 d =(U/V)ho.go^2= 104882 Factor
Hg = Wm1 - H 7930.0 Kgs. From Table TEMA D-5 & RCB-11.2
Ht = H - Hd 3796.9 Kgs. Particulars Actual Min.Reqd. mm
OPERATING MOMENT UNDER INTL. PRESSURE Bolt Spacings = B = 94.034 44.450 mm
MD = Hd.hD 673237 Kg-mm Bmax = Max. Allowed = 98.100 mm
MG = Hg.hG 198005 Kg-mm Radial Distance = Rh = 29.500 28.575 mm
MT = Ht.hT 131882 Kg-mm Edge Distance = E = 21.000 20.638 mm
Mo = Total Moment(Op)=MD+MG+MT 1003123 Kg-mm Flange Material SA 105
OPERATING LOADS UNDER EXTL. PRESSURE Bolting Material SA 193 Gr. B7
He = p.G^2.Pe / 400 0.0 Kgs. Gasket Material: 3 mm Thick CAF
HDe= p.B^2.Pe / 400 0.0 Kgs. Lever Arm For Calculation of Bolting Moments:
HTe= He - HDe 0.0 Kgs. hD = R+g1/2 = 37.00 hG= (C-G)/2= 24.97 mm
OPERATING MOMENT UNDER EXTL. PRESSURE hT=(R+g1+hG)/2 34.73 mm
Me = HDe(hD-hG)+HTe(hT-hG) 0.0 Kg-mm Ma= >of Mo/Me 1003123 = Kg-mm
GASKET SEATING CONDITION:- Correction Factor to be Applied to Moment = Cf = 1.00
Hg = W (Full Bolt Load) = Ab.Sa 54795.3 Kgs. [If B > Bmax, Cf = (B/Bmax) Otherwise Cf =1]
hG = (C - G)/2 24.97 mm Mos= Hg.hG 1368180 Kg-mm
Corrected Moments (Moments x Correction Factor): t = Flange Thk.= 25.00 b=(4t.e/3)+1= 1.5066 Factor
Ma = 1003123 Kg-mm Mos = 1368180 Kg-mm a = t.e + 1 = 1.3800 d = t^3/d = 0.1490 Factor
STRESS CALCULATIONS: l= d + g = 0.9229 g = a / T = 0.7739 Factor
Operating Condition Actual Allowable Stresses A = 524
Sh = f.Mo / (l.B.g1^2) 12.778 18.456 Kg/Cm^2 C = 482
Sr = b.Mo / (l.B.t^2) 6.667 12.304 Kg/Cm^2 Go = 448
St = Mo.Y / (B.t^2)-Z.Sr 4.381 12.304 Kg/Cm^2 N = 20
Sm1= (Sh + Sr) / 2 9.723 12.304 Kg/Cm^2
Sm2= (Sh + St) / 2 8.580 12.304 Kg/Cm^2
Gasket Seating Conditions Actual Allowable Stresses t = 25 g1
Sh = f.Mos / (l.B.g1^2) 9.978 18.456 Kg/Cm^2 15.0 B = 393
Sr = b.Mos / (l.B.t^2) 9.093 12.304 Kg/Cm^2
St = Mos.Y / (B.t^2)-Z.Sr 5.976 12.304 Kg/Cm^2 h = 32.00
Sm1= (Sh + Sr) / 2 9.536 12.304 Kg/Cm^2 go = 7.0

Date : 06/14/2017
Equipment No.: DESIGN OF CHANNEL FLANGE ON COVER SIDE Sheet5, Page No. 12
File : 357927304.xls
Clients: Inspection - Dwg.: 01-1314-001
Sm2= (Sh + St) / 2 7.977 12.304 Kg/Cm^2 16 Nos. Bolts Equally Spaced
CHANNEL FLANGE ON COVER SIDE

Date : 06/14/2017
Equipment No.: DESIGN OF CHANNEL FLANGE ON COVER SIDE Sheet5, Page No. 13
File : 357927304.xls
Clients: Inspection - Dwg.: 01-1314-001

p= 3.14159265 A=A/B= 1.33333333

SHAPE CONSTANT C= 482
A=g1/go 1.14285714 ok
C 6.05203404 ok
C1 0.42857143 ok
C2 0.17687075 ok
C3 0.00793651 ok
C4 0.7756835 ok
C5 -1.6090618 ok
C6 0.17742191 ok
C7= 7.50498877 ok
C8= 1.03608497 ok
C9= 0.92946444 ok
C10= -1.4067175 ok
C11= 0.39761075 ok
C12= 0.2498509
C13= 0.08313665
C14= -0.1133426
C15= 0.04150068
C16= 0.33818683 ok
C17= 1.77027367 ok
C18= -3.7060468 ok
C19= 0.39346046 ok
C20= 0.10280836 ok
C21= -0.1256604 ok
C22= 0.05263233 ok
C23= -0.1498147 ok
C24= 0.18517202 ok
C25= -0.0646529 ok
C26= -1.1090735 ok
C27= -4.0474956 ok
C28= -0.8605381 ok
C29= -1.2300441 ok
C30= -1.3642094 ok
C31= 4.12930964 ok
C32= 1.03676245 ok
C33= -1.9526503 ok
C34= -7.6073314 ok
C35= 5.05582372 ok
C36= 2.22762067 ok
C37= -2.8043205 ok
E1= -0.8659378 ok
E2= -0.0442403 ok
E3= 0.03274915 ok
E4= 1.49896024 ok
E5= -0.6147662 ok
E6= -1.5814689 ok
FOR INTEGRAL TYPE
F= 0.797164 1.22021028 1.62584184 -0.797164
V= 0.18588534 -1.5814689
f= 1.03955631 min=1
T= 1.78309712
Z= 3.57142857
Y= 6.90314838
U= 7.5858606

Date : 06/14/2017
Equipment No.: DESIGN OF CHANNEL FLANGE ON COVER SIDE Sheet5, Page No. 14
File : 357927304.xls
Clients: Inspection - Dwg.: 01-1314-001

Date : 06/14/2017
Equipment No. : Sheet6, Page No. 15
File : 357927304.xls
Inspection -
Clients: Dwg.: 01-1314-001

P Design Pressure 45 Kg/Cm2g GASKET FACTORS

Design Temperature 120 oC bo N/2 = 10
Go Gasket - Out Side Dia. 448 mm b 2.52(bo),N/2 If N<12.7 = 7.969
N Gasket - Contact Width 20 mm bp Np/2 = 3
Np Gasket Partitn.Strip Effective Width 6 Factor G Go - 2 b = 432.062

L Gasket Partition Strip-Total Length 800 Kg/mm^2 H p G^2.P/400 = 65977.34

m Gasket Factor 2 Factor Hp m.P(p .b.G+bp.L)/50 = 23790.14

y Gasket Design Seating Stress 1.12494 Kg/mm^2 Wm1 H + Hp = 89767.48
Ca Corrosion Allowance 0 mm Wm2 p .b.G.y+L.bp.y = 14868.03
A Flange OD 410 mm Ab Nob.Cab = 3117.41
B Flange ID 304 mm Am1 Wm1/Sb = 5107.05
C Flange P.C.D. 375 mm Am2 Wm2/Sa = 845.87
dB Bolt Dia. 19.05 mm Am > of Am1&Am2 = 5107.05
Nob No. of Bolts 16 Nos. Wb Design Bolt Load = Ab.Sa
Cab C.S.A. of Bolts 194.838 mm^2 = Full Bolt Load = 54795.28
E Young's Modulus for Flange Material 20217.3 Kg/mm^2 Bolt Spacing-Minimum Reqd. = 44.45
Sa M.A.S.:Bolts at Ambient 17.5772 Kg/mm^2 Actual Available = 94.03
Sb M.A.S.:Bolts at Design Temp. 17.5772 Kg/mm^2 Maximum Allowed = 98.10

Sfa M.A.S.:Flange at Ambient 12.304 Kg/mm^2 Flange Material : SA 516 Gr.70

Sfo M.A.S.:Flange at Design Temp. 12.304 Kg/mm^2 Bolting Material : SA 193 Gr.B7 Cl.2

T Actual Thickness of Cover Flange 25 mm Gasket Material : 3 mm Thick CAF

THICKNESS CALCULATIONS: [UG-34 fig(j),Equation UG-34 (2)] Ca = Depth of Partition Groove = 5

Operating Condition: in mm d=G = 432.062

t = d[C.P/(100 S.E)+1.9 Wm1.hG/(S.E.d^3)]^0.5 + Ca = 43.5937 C = from Fig.UG-34(j) = 0.3

P = Design Pressure = 45
Gasket Seating Condition: S = Sfo(For Operating & Sfa(For Seating)

t = d. [1.9 W.hG/(S.E.d^3)]^0.5 + Ca = #VALUE! E = Joint Efficiency = 1

Wm1 = Operatg.Load = 89767.48

For TEMA Covers : Deflection = Y & (E = 20217.25 & T = 42-5 = 37) W = (Full Bolt Load-NA) = 54795.28

Y = (G/ET^3)x(0.000435P.G^3+0.5Sb.Ab.hG) = 2.130 hG = (PCD - G)/2 = -28.531

Max. Deflection Permitted (For Dia.< 24") 0.03" = 0.762 & 0.125% Nom.Dia.For Dia > 24" = N.A.

Date: 06/14/2017
Equipment No. : Sheet6, Page No. 16
File : 357927304.xls
Inspection -
Clients: Dwg.: 01-1314-001

Date: 06/14/2017
 Equipment No. : Sheet6, Page No. 17
File : 357927304.xls
Inspection -
Clients: Dwg.: 01-1314-001

mm
mm
mm
mm

Kgs.

Kgs.
Kgs.
Kgs.
mm^2
mm^2
mm^2
mm^2
Kgs.
Kgs.
mm
mm
mm

A 193 Gr.B7 Cl.2

3 mm Thick CAF

mm

mm

Factor
Kg/Cm^2

a(For Seating)

Factor

Kgs

Kgs

mm

mm

Date: 06/14/2017
Equipment No.: TUBESHEET DESIGN Sheet7, Page No. 18
File : 357927304.xls
Clients: Inspection - Dwg.:01-1314-001
DESIGN DATA: Symbols Corroded UNITS
Shell Side Design Pressure Ps 36 Kg/Cm^2g
Tube Side Design Pressure Pt 6 Kg/Cm^2g
Design Temperature: Shell Side 131 55 F/C
Design Temperature: Tube Side 320.0 160 F/C
Shell Mean Metal Wall Temperature 342.5 172.5 F/C
Tube Sheet Mean Metal Wall Temperature 342.5 172.5 F/C
Tube Mean Metal Wall Temperature 225.5 107.5 F/C
Shell Mean Metal Wall Temperature (-) 70 Ts 272.5 F
Tube Mean Metal Wall Temperature (-) 70 Tt 155.5 F
Thermal Expansion Coefficient : Shell / F as 9.0808E-06 Unit Lg./F
Thermal Expansion Coefficient : Channel / F at 8.8136E-06 Unit Lg./F
For Flanged Joint From Flange Design G 438.0000 mm
Modulus of Elasticity: Shell Material Es 1883393 Kg/Cm^2
Modulus of Elasticity: Tube Material Et 1929762 Kg/Cm^2
Modulus of Elasticity: T/Sheet Matl. E 1883393 Kg/Cm^2
Yield Strength: Tube at Design Temperature Sy 1623.3565 Kg/Cm^2
Max.Allow.Stress: Shell at Design Temp. (Lower Stress Value) Ss 1406.1731 Kg/Cm^2
Max.Allow.Stress: Tube at Design Temp. (Lower Stress Value) St 970.2594 Kg/Cm^2
Max.Allow.Stress: T/Sheet at Ambient (Lower Stress Value) Sa 1406.1731 Kg/Cm^2
Max.Allow.Stress: T/Sheet at Mean Metal Wall Temp. (Lower Stress Value) S 1328.8336 Kg/Cm^2
Corrosion Allowance: Shell Side Cas 1.5 mm
Tube Side Cat 0 mm
T/Sheet-Shell Side Tcs 0 mm
T/Sheet-Tube Side Tct 0 mm
Expansion Joint Cae 0 mm
Depth of Pass Partition Groove Dpg 5 mm
Spring Rate of Expansion Joint Sj 2538.5035 Kg/mm
Shell Out Side Dia. Do 399 mm
Tube Out Side Dia. do 25.4 mm
No. of Tubes N 88 Quantity
Pitch Type : D / Sq. = Dler Tube Pitch p 32 mm
Flange Moment: Operating M1 5919350 Kg-mm
Flange Moment: Bolting M2 2988975.7 Kg-mm
MATERIAL OF CONSTRUCTIONS : DIMENSIONS As New Corroded Units
Shell SA 240 Gr. 304L Thickness of Shell ts 6 6 mm
Channel SA 240 Gr. 304L Thickness of Tubes tt 1.65 1.65 mm
Tubes SA 213 TP 316L Tube Sheet Thk.+ Groove TA 45 45 mm
Tube Sheets SA 240 Gr. 304L Tube Sheet Thk. - Groove Ta 40 40 mm
Expansion Joint SA 240 Gr. 304L For Shell Side = Shell Inside Dia. G 387 390 mm
I/Dia. of Expansion Joint Dj 555.5 558.5 mm
Spring Rate of The Expansion Jt. Sj 2538.50 2538.50 Kg/mm
Effective Length of Tubes L 4904 4904 mm
Equivalent Bolting Pressure: (RCB-7.162)
PBt PBt = 620M1 / (F^2 . G^3) 63.31883 61.86883 Kg/Cm^2
PBs PBs = 620M2 / (F^2 . G^3) 31.97284 31.24066 Kg/Cm^2
J1 Sj.L/[Sj.L+p(Do-ts).ts.Es/100)] 0.0819173 0.0819173
J2 [(Do-ts).ts.Es / (1000 L)] 905.596 905.596 Kg/mm
J For Shell With Expansion Joint Where Sj < J2 0 0 Factor
J For Shell Without Expansion Joint 1 1 Factor
J Applicable 0.08191726 0.0819173 Factor
ts/G Shell Wall Thickness / Shell Inside Dia. Ratio 0.0155 0.0154 Ratio
F = From TEMA Fig. RCB-7.132 1 1 Factor
K = Es.ts.(Do-ts) / {(Et.tt.N.(do-tt)} 0.667346 0.667346 Factor

Date: 06/14/2017
Equipment No.: TUBESHEET DESIGN Sheet7, Page No. 19
File : 357927304.xls
Clients: Inspection - Dwg.:01-1314-001

Equivalent Differential Expansion Pressure: (RCB-7-161) As New Corroded Units

Fq1 = 0.25+(F-0.6)[(300tsEs/(KLE).(G/T)^3)]^0.25 2.13969 2.15067 Factor
Fq2 = Minimum Value 1.0000 1.0000 Factor
Fq = Applicable = Larger Value of Fq1 & Fq2 2.1397 2.1507 Factor
DL= L.(as.Ts-at.Tt) 5.4140 5.4140 mm
Pd = 4J.Es.ts(DL/L)/[(Do-3ts).(1+J.K.Fq)] 9.6057 9.6005 Kg/Cm^2
fs = 1 - N.(do / G)^2 0.6209 0.6267 Factor
ft = 1-N [(do - 2tt) / G]^2 0.7130 0.7174 Factor
P's = [Ps/(1+J.K.Fq)]*[0.4J(1.5+K(1.5+fs))-{((1-J)/2).((Dj/G)^2-1}] -12.6093 -12.4564 Kg/Cm^2
RCB-7.162 PBt = 620M1 / (F^2 . G^3) 63.3188 61.8688 Kg/Cm^2
PBs = 620M2 / (F^2 . G^3) 31.9728 31.2407 Kg/Cm^2
Effective Design Pressure:
Shell Side: 1 P= (P's-Pd)/2 -11.1075 -11.0285 Kg/Cm^2
(RCB-7.163) 2 P= P's -12.6093 -12.4564 Kg/Cm^2
3 P= PBs 31.9728 31.2407 Kg/Cm^2
4 P= 0.5(P's-Pd-PBs) -27.0939 -26.6488 Kg/Cm^2
5 P= 0.5(PBs+Pd) 20.7893 20.4206 Kg/Cm^2
6 P= P's-PBs -44.5821 -43.6971 Kg/Cm^2
Greatest Absolute Value of The Above 44.5821 43.6971 Kg/Cm^2
Tube Side: P't = Pt[(1+0.4J.K.(1.5 + ft)) / (1+J.K.Fq)] 5.6316 5.6291 Kg/Cm^2
(RCB-7.164) 1 P = (P't+PBt+Pd)/2 39.2781 38.5492 Kg/Cm^2
2 P = (P't+PBt) 68.95 67.50 Kg/Cm^2
3 P = 0.5(P't+PBt+Pd-P's) 45.5827 44.7774 Kg/Cm^2
4 P = P't+PBt-P's 81.5597 79.9543 Kg/Cm^2
Tube Side Effective Design Pressure= Greatest Absolute Value of above = 81.5597 79.9543 Kg/Cm^2
Calculations For Tube Sheet Thickness:
C = Perimeter of the Tube Lay Out 1633 1633 mm
At = Total Area Enclosed By Perimeter C 209442 209442 mm^2
Shear Formula: (RCB-7.133) P= 81.5597 79.9543 Kg/Cm^2
DL = 4A / C = 513.0239 513.0239 mm
Effective Tube Sheet Thickness = T = 0.31 DL.P / {S.(1-do/p)} = 47.3272 46.3956 mm
Tube Sheet Thickness For Bending: (RCB-7.132)
m = 1-[0.907*(do/p)^2] = 0.42855 0.42855 Factor
For Shell Side = Shell I./Dia. 387 390 mm
T = (F.G/3).(P/(mS))^0.5 With Shell Side Effective Pressure = 36.0937 36.3735 mm
With Tube Side Effective Pressure = 48.8190 48.7109 mm
Tube Sheet Thickness Required (Including Partition Groove) = 53.8190 53.7109 mm
Tube Sheet Thickness Provided = 45.0000 76.2407 mm
Thickness of Tube Sheet Flanged Extension: (Ref. Cl. RCB-7.1341)
A = Out Side Dia. of The Tube Sheet 524 524 mm
r= A/G 1.3540 1.3436 Factor
M = The Larger of M1 & M2 2988975.7 2988975.7 Kg-mm
Tr = Minimum Thickness of Tube Sheet Extended Portion
= 0.98[(100M(r^2-1+3.71r^2. Ln(r))/(S(A-G)(1+1.86r^2)))^0.5] 32.1717 32.0884 mm
Thickness Provided 34.0 34.0 mm
Shell Longitudinal Stress : (RCB-7.22) P1= Pt - P't = 0.37 0.37 Kg/Cm^2
As New Corroded
P*s Cs P*s Cs P*s.Cs P*s.Cs
P*s = P1 = 0.37 0.5 0.37 0.5 0.1842 0.1854 Kg/Cm^2
or P*s = P's = ### 1 ### 1 -12.6093 -12.4564 Kg/Cm^2
or P*s = (-) Pd = 9.61 0.5 9.60 0.5 4.8028 4.8003 Kg/Cm^2
or P*s = P1 + P's = ### 1 ### 1 -12.2409 -12.0855 Kg/Cm^2
or P*s = P1 - Pd = -9.24 1 -9.23 1 -9.2373 -9.2296 Kg/Cm^2
or P*s = P's - Pd = -22.215 1 -22.06 1 -22.2150 -22.0569 Kg/Cm^2
or P*s = P1+P's-Pd = -21.847 1 -21.69 1 -21.8466 -21.6861 Kg/Cm^2
Greatest of Possitive Value of P*s.Cs = 4.8028 4.8003 Kg/Cm^2
Greatest of Negative Value of P*s.Cs = -22.2150 -22.0569 Kg/Cm^2
Effective Longitudinal Shell Tensile Stress = Ss = (P*s.Cs).(Do-ts) / 4ts = 78.6466 78.6044 Kg/Cm^2
Maximum Allowable Tensile Stress for Shell 'Ss' = 1406.17 1406.17 Kg/Cm^2

Date: 06/14/2017
Equipment No.: TUBESHEET DESIGN Sheet7, Page No. 20
File : 357927304.xls
Clients: Inspection - Dwg.:01-1314-001

As New Corroded Units

Effective Longitudl.Shell Compressive Stress = Ss = (P*s.Cs).(Do-ts) / 4ts = -363.7702 -361.1824 Kg/Cm^2
A = 0.125 x ts / Do = 0.0019 0.0019 Factor
Max.Allow.Shell Comp.Stress From Sec.II Part- D Fig.HA-3 For SS 304L, B= 5250 5250 PSI
= 369.12 369.12 Kg/Cm^2
Tube Longitudinal Stress : (RCB-7.23) P2 = P't - (ft.Pt / Fq) = 3.6322 3.6276 Kg/Cm^2
P3 = P's - (fs.Ps / Fq) = -23.0562 -22.9473 Kg/Cm^2
As New Corroded
P*t Ct P*t Ct P*t.Ct P*t.Ct
P*t = P2 3.6322 0.5 3.6276 0.5 1.8161 1.8138 Kg/Cm^2
or P*t = (-) P3 23.0562 0.5 22.9473 0.5 11.5281 11.4736 Kg/Cm^2
or P*t = Pd 9.6057 0.5 9.6005 0.5 4.8028 4.8003 Kg/Cm^2
or P*t = P2 - P3 26.6884 0.5 26.5749 0.5 13.3442 13.2874 Kg/Cm^2
or P*t = P2 + Pd 13.2379 0.5 13.2282 0.5 6.6189 6.6141 Kg/Cm^2
or P*t = (-) P3+Pd 32.6619 0.5 32.5478 0.5 16.3309 16.2739 Kg/Cm^2
or P*t = P2-P3+Pd 36.2941 0.5 36.1754 0.5 18.1470 18.0877 Kg/Cm^2
Greatest of Possitive Value of P*t.Ct = 18.1470 18.0877 Kg/Cm^2
Greatest of Negative Value of P*t.Ct = 0.0 0.0 Kg/Cm^2
Effective Longl.Tube Tensile Stress = St = (P*t.Ct).Fq.G^2/(4N.tt(do-tt)) = 421.589 428.939 Kg/Cm^2
Maximum Allowable Tensile Stress for Tube 'St' = 970.259 970.259 Kg/Cm^2
Effective Longitudl.Tube Comp.Stress = St = (P*t.Ct).Fq.G^2/(4N.tt(do-tt)) = 0.0 0.0 Kg/Cm^2
Max. Un-Supported Tube Span Between Tube Sheet & Baffle K = 0.8 L = 452 452 mm
Max. Un-Supported Tube Span Between Baffles K= 1 L= 400 400 mm
Greatest of (L x K) = Kl = 400 400 mm
r = Radius of Gyration of Tube = 0.25[do^2+(d-2tt)^2]^0.5 = 3.13 , Kl/r = 127.796 127.796 Factor
Cc = [2 p^2.Et / Sy] = 153.18 > than Kl/r Fs1 = 3.25 - 0.5 Fq = 2.1802 2.1747 Factor
Fs = Not Less Than 1.25 & Not More Than 2.0 \ Fs(Applicable) = 2 2 Factor
When Cc<= Kl/r Then Sc = [p^2.Et / (Fs.(Kl/r)^2)] NOT APPLICABLE = 583.0973 583.0973 Kg/Cm^2
When Cc > Kl/r Then Sc = (Sy/Fs).[1-(Kl/r)/(2Cc)] = 473.0990 473.0990 Kg/Cm^2
Tube to Tube Sheet Joint Load: Pt* = P2 = 3.6322 3.6276 Kg/Cm^2
Joint Type: Expanded in 2 Grooves or Pt* = (-) P3 = 23.0562 22.9473 Kg/Cm^2
fe = 1 or Pt* = P2 - P3 = 26.6884 26.5749 Kg/Cm^2
fr = 0.7 (No Test) Pt* (Applicable) = 26.6884 26.5749 Kg/Cm^2
fy = 1 Load on Joint = Wj = p.Fq.Pt*.G^2 / 400N = 763.31 775.86 Kgs.
Max. Allow. Tube to Tube Sheet Jt. Load (As per ASME Sec.VIII Div.1 Appendix-A Clause-A2) :
At = p[do^2 - (do -2tt^2)] / 400 = = 1.23111 1.23111 Cm^2
Max. Allowable Tube to Tube Sheet Joint Load = Lmax = At.St.fe.fy.fr = 836.148 836.148 Kgs.

Date: 06/14/2017
Equipment No.: TUBESHEET DESIGN Sheet7, Page No. 21
File : 357927304.xls
Clients: Inspection - Dwg.:01-1314-001
p = 3.141592654
MODULUS OF ELASTICITY
342.5 300 400
SA240Gr.304 26.7875 27 26.5 1883393
225.5 200 300
SA240316L 27.447 27.6 27 1929762 SA 240 TP 304 High
342.5 300 400
C.S.: C < 0.3% 28.045 28.3 27.7 1971806
C.S.: C > 0.3% 27.845 28.1 27.5 1957744 SA 213/312TP304 High
342.5 300 400
SHELL-304L 9.08075 9 9.19 SA 182 F 304 > 5" High
342.5 300 400
SHELL: C.S. 6.92E-06 6.87E-06 6.98E-06 SA 516 Gr.70
SA 106 Gr B

100 200 300

TUBE-SS316L 8.54 8.76 8.97
225.5 200 300
### 8.81355 8.76 8.97
Kg/Cm2.g q
149 100 200
23089 25000 21100
16700 16700
1174.155
F 608 600 650
LSV: SS304L 721.9292695 10300 10100
F 342.5 300 400
LSV: SS304L 867.0814877 12800 11700
149 100 200
LSV-SS316L 1084.581312 16700 14100

F 608 600 650

HSV: SS304L 980.9463545 14000 13700
F 342.5 300 400
HSV: SS304L 1057.793714 15300 14700
320 100 200
HSV: SS304L 1091.47156 16700 14300

0.25+(F-0.6)[(300tsEs/(KLE).(G/T)^3)]^0.25= 2.139692

Date: 06/14/2017
Equipment No.: TUBESHEET DESIGN Sheet7, Page No. 22
File : 357927304.xls
Clients: Inspection - Dwg.:01-1314-001

[(300tsEs/(KLE).(G/T)^3)]^0.25 = 4.72423
300tsEs/(KLE) = 0.550011
(G/T)^3 = 905.6344

NEW CORRODED
ts/G= <=0.02 >= 0.05 0.02< & >0.05
F= 1 0.8 ts/G = 0.000000 0
F1 = 1.133333 1.133333
F(Aplicab) 1 1

0.125

Date: 06/14/2017
Equipment No.: TUBESHEET DESIGN Sheet7, Page No. 23
File : 357927304.xls
Clients: Inspection - Dwg.:01-1314-001

-5173.903031
A = 0.125 x ts / Do
ts = .16*Do 65.76
608

608

Date: 06/14/2017
Equipment No.: TUBESHEET DESIGN Sheet7, Page No. 24
File : 357927304.xls
Clients: Inspection - Dwg.:01-1314-001

Temp F
YIELD UTS 100 200 300 400 500 600 650 700
30000 75000 20000 16700 15000 13800 12900 12300 12000 11700

30000 75000 20000 16700 15000 13800 12900 12300 12000 11700

30000 70000 20000 18900 17700 17100 16900 16600 16200 15800

38000 70000 20000 20000 20000 20000 20000 19400 18800 18100
17100 17100 17100 17100 17100 17100 17100 15600

Date: 06/14/2017
Equipment : EXPANSION BELLOW DESIGN Sheet8, Page No. 25
File : 357927304.xls
Clients : Insnpection : Dwg.:01-1314-001
EFFECTIVE GEOMETRY CONSTANTS (Ref.-RCB-8.22):- As New Corroded p =
All dimensions in inches unless stated. Corrosn. Allow. = 0 0
Thickness of the Shell ts = 0.3150 0.3150
Thickness of the Expansion Bellow Outer Shell to = 0.3150 0.3150
Thickness of the Bellow tE = 0.2756 0.2756
Shell Inside Dia. G= 15.8661 15.8661
Outside Dia. of the Bellow OD = 22.5000 22.5000
Expansion Bellow: Outer End Knuckle Radius rb = 0.984252 0.984252
Expansion Bellow: Inner End Knuckle Radius ra = 0.984252 0.984252
Expansion Bellow: Outer End Straight Face fb = 0.984252 0.984252
Expansion Bellow: Inner End Straight Face fa = 0.984252 0.984252
Expansion Bellow has Knuckle Radius at Inner/Outer Junctions \ ta = tb = tE = 0.2756 0.2756
a = 0.5(G+ta) a= 8.0709 8.0709
b = 0.5(OD-tb)-0.25(4-p).(ra+rb) b= 10.6898 10.6898
la = fa+0.25p.ra+tE/2 la = 1.8951 1.8951
lb = fb+0.25p.rb+tE/2 lb = 1.8951 1.8951
lo = Half of the Cylindrical Length of Outer Cylinder lo = 1.9685 1.9685
li = Half of the Cylindrical Length of Inner Cylinder li = 0.9843 0.9843
As New Corroded
ya = la + li = 2.87933 ya(max) = 2 (a.ta) = 2.9828 2.9828 ya = 2.8793 2.8793
yb1= lb + lo = 3.86358 yb(max) = 2 (b.tb) = 3.4328 3.4328 yb = 3.4328 3.4328
ELEMENT FLEXIBILITY FACTORS: (RCB-8.3)
ba = 1.285/(ata) per/inch ba = 0.8616 0.8616
bb = 1.285/(btb) per/inch bb = 0.7487 0.7487
Es = Modulus of elasticity: Inner Cylinder @342.5 F PSI Es = 26787500 26787500
Eo = Modulus of elasticity: Outer Cylinder @342.5 F PSI Eo = 26787500 26787500
EE = Modulus of elasticity: Flexible Element @ 342.5 F PSI EE = 26787500 26787500
Ea = EE PSI Ea = 26787500 26787500
Eb = EE PSI Eb = 26787500 26787500
Da = 0.0916 Ea.ta^3 Lb-inch Da = 51359.5 51359.5
Db = 0.0916 Eb.tb^3 Lb-inch Db = 51359.5 51359.5
DE = 0.0916 EE.tE^3 Lb-inch DE = 51359.5 51359.5
At the Inside Junction At the Outside Junction
Factors As New Corroded As New Corroded
W = Inner Cyl.= 2ba.ya & Outer Cyl.= 2bb.yb W (Radians) = 4.962 4.962 5.140 5.140
j1 = Sin(W/2).Sinh(W/2) j1 = 3.641629 3.6416287 3.513422 3.513422
j2 = Cos(W/2).Cosh(W/2) j2 = -4.751152 -4.751152 -5.526628 -5.526628
z = j1^2 + j2^2 z = 35.834909 35.834909 42.887756 42.887756
ko = Sinh(W)+Sin(W) ko = 70.446985 70.446985 84.444996 84.444996
k1 = [Cosh(W)+Cos(W)] / ko k1 = 1.017358 1.017358 1.015756 1.015756
k2 = [Sinh(W)-Sin(W)] / ko k2 = 1.027512 1.027512 1.021552 1.021552
k3 = [Cosh(W)-Cos(W)] / ko k3 = 1.010353 1.010353 1.005934 1.005934
Cylinder to Cylinder Flexibility Factors: (RCB-8.31)
Cylinder to Cylinder Flexibility Factors are given by ea & eb ea ea eb eb
If there is no Outer Cylinder,eb =1 Else e = ea = eb = 2.718^C8 = 0.98317 0.98317 1 1
At the Inside Junction At the Outside Junction
C1 = la / (a.ta) lb / (b.tb) C1min=0.4 1.27068 1.27068 1.10411 1.104106
C2 = ts / ta to / tb 1.1429 1.1429 1.1429 1.1429
C3 = Ea / Es Eb / Eo C3 = 1 1 1 1
When C2 < 1: C2 < 1 =
C4 = (-0.364661+0.338172/C2 - 0.0366351/C2^2) C4 =
C5 = (-1.06871+1.01164/C2 - 0.122627/C2^2) C5 =
C6 = 0.0696709 + 1.76415C2 - 5.46103C2^3 C6 =
C7 = (-0.142734 + 0.918656C2 - 2.00749C2^3) C7 =
Element Geometry Factors: (RCB-8.4) At the Inside Junction At the Outside Junction
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At the Inside Junction At the Outside Junction As New Corroded As New Corroded
When C2 => 1: C2 >or=1 1 1 1 1
C4 = (3.3731-1.707962C2+0.226216C2^2)/1000 C4 = 0.001717 0.001717 0.001717 0.001717
C5 = (-0.403287+ 0.320037C2 - 0.0307508C2^2) C5 = -0.077695 -0.077695 -0.077695 -0.077695
C6 = (-0.684978+ 0.582549C2 - 0.0547812C2^2) C6 = -0.090759 -0.090759 -0.090759 -0.090759
C7 = (-0.201334+ 0.168201C2 - 0.0157280C2^2) C7 = -0.029647 -0.029647 -0.029647 -0.029647
C8 = [(C5/C1^2-C6/C1^3+C7/C1^4-C4)/(C3^0.2)] C8 = -0.016972 -0.016972 -0.017970 -0.017970
When C2 & C3 are both = 1, e = ea = eb =1 Applicable,e = 0.98317 0.98317 1 1
y1 = ea/(Da.ba).[k3-k2^2/2k1] y2 = eb/(Db.bb).[k3-k2^2/2k1] 1.092E-05 1.092E-05 1.28E-05 1.28E-05
c = a^2/(b^2-a^2) factor c= 1.3257909 1.3257909 1.3257909 1.3257909
d= b/a factor d= 1.3244874 1.3244874 1.324487 1.324487
X1 = (-) a.c(0.769+1.428d^2) / DE per Lb. X1 = -0.000682 -0.000682 -0.000682 -0.000682
X2 = 2.2a.c.d^2 / DE per Lb. X2 = 0.0008041 0.0008041 0.0008041 0.0008041
X3 = (-)a^2[1.538+ln(d){2+c(2+3.71d^2)}] / (4DE) X3 = -0.001671 -0.001671 -0.001671 -0.001671
X4 = (-)2.2b.c/DE per Lb. X4 = -0.000607 -0.000607 -0.000607 -0.000607
X5 = b.c(0.769d^2+1.428)/DE per Lb. X5 = 0.0007663 0.0007663 0.0007663 0.0007663
X6 = (-)a.b(1.538+5.714c.ln(d))/(4DE) per Lb. X6 = -0.001540 -0.001540 -0.001540 -0.001540
X = (X1-y1).(X5+y2)-X2.X4 per Lb. X= -5.183E-08 -5.183E-08 -5.183E-08 -5.183E-08
X7 = (X2.X6-X3.X5-X3Y2) / X Factor X7 = ### ### -1.2283731 -1.2283731
X8 = (X3.X4-X1.X6+X6.y1) / X Factor X8 = 1.0194233 1.0194233 1.0194233 1.0194233
q1 = 0.385a^2+1.429c.b^2.ln(d) mm^2 q1 = 85.918424 85.918424 85.918424 85.918424
q2 = (-) [0.385+1.429c.ln(d)].b^2 mm^2 q2 = ### ### -104.83428 -104.83428
q3 = 0.25a.b^2.{1.269/(c.d^2)+3.714c(ln(d))^2} q3 = 215.46302 215.46302 215.46302 215.46302
g= a/b Factor g= 0.7550091 0.7550091 0.7550091 0.7550091
g*= {g^4/(1-g^2)}.ln(g) Factor g* = ### ### -0.2123856 -0.2123856
m1= 0.51-0.635.g^2 + g* Factor m1 = ### ### -0.0643602 -0.0643602
m2= 0.635(1 - g^2) + g* Factor m2 = 0.0606398 0.0606398 0.0606398 0.0606398
m3= 2.357 g^2 + 3.714 g* Factor m3 = 0.5547811 0.5547811 0.5547811 0.5547811
No.of Flexible Elements = 6 6 6 6
SjE(Total) = 2p.a.DE / (X7.q1+ X8.q2 + q3) Lbs./in 853189.3 853189.3 853189.3 853189.3
SjE= SjE(Total) / (No.of Flexible Elements x 56.016555) Kg/mm 2538.5 2538.5 2538.5 2538.5
Ps = 142.230 Pt = 640.035 Pd = 136.622 PSI
Ps'= -179.342 Pt' = 80.098 P1=Pt-Pt'= 559.937 PSI
Ps*= P1+ P's - Pd = -315.96 Shellside Pressure Only Differential Expansion Only Shellside Pr.+Diff.Expansion
As New Corroded As New Corroded As New Corroded
P*s= Shell Press.in Consideration (PSI) -179.342 -179.342 -136.62 -136.62 -315.96354 -315.96354
Fax= 0.5a.Ps* lb/in -723.7215 -723.7215 -551.33 -551.33 -1275.0497 -1275.0497
Ps= Shell side Pressure (PSI) 142.23 142.23 0.00 0.00 142.23 142.23
Moment at the Junction: (Ref. Clause RCB-8.71)
qa= Ps.b^3[-2gm2-m3/g-0.5g^3-2g^3 ln(g)] / (8DE) -0.33814 -0.33814 0.00 0.00 -0.338136 -0.338136
qb= Ps.b^3/(8DE)x[-2m2-m3+0.5 -g^2] = -0.315487 -0.315487 0.00 0.00 -0.315487 -0.315487
Za= (Ps.a^2-0.3a.Fax) / (Ea.ta) 0.001492 0.001492 0.000181 0.000181 0.001673 0.001673
Zb= [Ps.b^2-0.3{a.Fax+0.5Ps(b^2-a^2)}]/(Eb.tb) 0.002297 0.002297 0.000181 0.000181 0.002478 0.002478
Ma= [(x5+y2)(-qa-Fax.x3-ba.Za)+{x2(Fax.x6+qb-(bb.k2.Zb)/k1)}] / X
Mb= [(y1-x1){qb+Fax.x6-(bb.k2.Zb)/k1}+x4(Fax.x3+qa+ba.Za)] / X
As per above formulas Ma = 746.7280 746.7280 681.7001 681.7001 1428.4281 1428.4281
Mb = -441.4746 -441.4746 -558.3834 -558.3834 -999.85804 -999.85804
Ps = Shell Press.in Consideration (PSI) 142.23 142.23 0 0 142.23 142.23
Annular Plate Element: Meridional Bending Stresses: (Ref. Cl.RCB-8.72)
A1= (-)c.Ma+c.d^2.Mb+0.65a.c.Fax.ln(g)-Ps(0.325m2.b^2+0.4125a^2)
A2= b^2(c.Ma-c.Mb-0.65a.c.Fax.ln(g)+0.0875m3.Ps.b^2)
\ A1 = -4744.21 -4744.21 -1124.86 -1124.86 -5869.06 -5869.06
A2 = 108522.84 108522.84 64731.59 64731.59 173254.43 173254.43
A3 = 0.206Ps = 29.2994 29.2994 0.0000 0.0000 29.2994 29.29938
A4 = 0.65a(Fax-0.5a.Ps) = -6807.72 -6807.72 -2892.30 -2892.30 -9700.02 -9700.020
Shellside Pressure Only Differential Expansion Only Shellside Pr.+Diff.Expansion
When Ps is not 0 As New Corroded As New Corroded As New Corroded
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r = ((-A4(A4^2+16A3.A2)^0.5)/(4A3))^0.5 11.925559 11.925559 0 0 13.99079 13.99079
or a 8.07087 8.07087 8.07087 8.07087 8.07087 8.07087
or b 10.68976 10.68976 10.68976 10.68976 10.68976 10.68976
Annular Pl. Meridional Bending Stress (PSI):
r = r for Sh.Pr.,a for Diff.Expn,b for Sh.Pr.+Diff.Expn 11.92556 11.92556 8.07087 8.07087 10.68976 10.68976
Annular Plate Element Stresses Smbp Smbp Smbd Smbd Sn Sn
Sb@a = 6{A1+A2/r^2+A3.r^2+A4.ln(r/b)} / tE^2 58734.8 58734.8 53853.8 53853.8 112588.6 112588.6
S= 13980 PSI Allowed = 3S 41940.0 41940.0 Fatigue Fatigue Fatigue Fatigue
Sb@b = 6{A1+A2/r^2+A3.r^2+A4.ln(r/b)} / tE^2 -35268.5 -35268.5 -44111.8 -44111.8 -79380.3 -79380.3
Allowed = 3S 41940.0 41940.0 Fatigue Fatigue Fatigue Fatigue
Sb@r = 6{A1+A2/r^2+A3.r^2+A4.ln(r/b)} / tE^2 -44157.3 -44157.3 53853.8 53853.8 -146877.3 -146877.3
Allowed = 1.5S 20970.0 20970.0 Fatigue Fatigue Fatigue Fatigue
Sn for Cycle Life = Sn 112588.6 112588.6
CYLINDRICAL ELEMENT STRESSES (Ref. Clause RCB-8.73) :
For the Inner Cylindrical Element: Shell Side Pressure Only Differential Expansion Only Shellside Pr.only + Diff.Expn
As New Corroded As New Corroded As New Corroded
x = ya \ ya-x = 0.00 0.00 0.00 0.00 0.00 0.00
li = 1.0 1.0 1.0 1.0 1.0 1.0
t= ts for (ya-x)< li, ta for (ya-x)>li \ t =0.3149606 0.3149606 0.3149606 0.3149606 0.3149606 0.3149606
= <of ta or ts for (ya-x) = li N.A. N.A. N.A. N.A. N.A. N.A.
E= Ea 26787500 26787500 26787500 26787500 26787500 26787500
M= Ma 746.73 746.73 681.70 681.70 1,428.43 1,428.43
e= ea 0.9832 0.9832 0.9832 0.9832 0.9832 0.9832
D= Da 51,359 51,359 51,359.5 51,359.5 51,359 51,359
b= ba 0.86 0.86 0.86 0.86 0.86 0.86
y= ya 2.879329 2.879329 2.879329 2.879329 2.879329 2.879329
x= ya (Inner Shell), yb (Outer Cylinder) 2.879329 2.879329 2.879329 2.879329 2.879329 2.879329
= la 1.895077 1.895077 1.895077 1.895077 1.895077 1.895077
r= a for inner cylinder 8.070866 8.070866 8.070866 8.070866 8.070866 8.070866
f2= Fax for inner cylinder (723.722) (723.722) (551.328) (551.328) (1,275.05) (1,275.05)
d= (r/Et).[Ps.r-0.3F2] 0.0013058 0.0013058 0.0001582 0.0001582 0.0014640 0.0014640
j1= 3.641629 3.641629 3.641629 3.641629 3.641629 3.641629
j2= -4.751152 -4.751152 -4.751152 -4.751152 -4.751152 -4.751152
z = -3547.819 74972.5935 -0.0015 35.83491 35.83491 35.83491 35.83491 35.83491 35.834909
B1= (1/z).{j2.M / (2b^2.e.D)-j1.d} -0.001453 -0.001453 ### ### -0.0026749 -0.0026749
B2= (1/z).{-j1.M / (2b^2.e.D)-j2.d} -0.000839 -0.000839 ### ### -0.0017421 -0.0017421
For the Inner Cylinder @ X = ya
u1= b(y-x) 0.0 0.0 0.0 0.0 0.0 0.0
u2= B1Sin(u1)Sinh(u1)+B2Cos(u1)Cosh(u1) -0.000839 -0.000839 ### ### -0.0017421 -0.0017421
Sm@ya = E(d+u2)/r PSI 1,549.2 1,549.2 (2,472.1) (2,472.1) (922.9) (922.9)
For the Inner Cylinder @ X = La
u1= b(y-x) 0.8480417 0.8480417 0.8480417 0.8480417 0.8480417 0.8480417
u2= B1Sin(u1)Sinh(u1)+B2Cos(u1)Cosh(u1) -0.001806 -0.001806 ### ### -0.0035047 -0.0035047
Sm@la = E(d+u2)/r PSI (1,659.9) (1,659.9) (5,113.3) (5,113.3) (6,773.2) (6,773.2)
Allowed = 13,980.0 13,980.0 Fatigue Fatigue Fatigue Fatigue
For the Outer Cylindrical Element:
F2= Fax.(a/b)+[(b^2-a^2)/2b].Ps ### ### (416.258) (416.258) (635.8166) (635.8166)
r= b 10.68976 10.68976 10.68976 10.68976 10.68976 10.68976
E = Eb 26787500 26787500 26787500 26787500 26787500 26787500
y = yb 3.432781 3.432781 3.432781 3.432781 3.432781 3.432781
= Lb 1.895077 1.895077 1.895077 1.895077 1.895077 1.895077
Lo= 1.968500 1.968500 1.968500 1.968500 1.968500 1.968500
e = eb 1.0 1.0 1.0 1.0 1.0 1.0
D = Db 51,359 51,359 51,359.5 51,359.5 51,359 51,359
b = bb 0.74866 0.74866 0.74866 0.74866 0.74866 0.74866
z= 42.88776 42.88776 42.88776 42.88776 42.88776 42.88776
M = Mb ### ### ### ### -999.85804 -999.85804
For the Outer Cylindrical Element: Shell Side Pressure Only Differential Expansion Only Shellside Pr.only+Diff.Expn
As New Corroded As New Corroded As New Corroded
For Outer Cylinder @x = yb \ yb-x = 0.0 0.0 0.0 0.0 0.0 0.0
Equipment : EXPANSION BELLOW DESIGN Sheet8, Page No. 28
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Clients : Insnpection : Dwg.:01-1314-001
lo = 1.9685 1.9685 1.9685 1.9685 1.9685 1.9685
For Outer Cylinder @x = Lb \ yb-x = 1.5377 1.5377 1.5377 1.5377 1.5377 1.5377
t = tb for (yb-x)>lo,to for (yb-x)<lo \ t = 0.3150 0.3150 0.3150 0.3150 0.3150 0.3150
= <of tb or to for (yb-x) = lo N.A. N.A. N.A. N.A. N.A. N.A.
B1= {j2.M/(2b^2.e.D)-j1.d} / z 0.000823 0.000823 0.001237 0.001237 0.002060 0.002060
B2= {-j1.M/(2b^2.e.D)-j2.d} / z 0.000887 0.000887 0.000815 0.000815 0.001702 0.001702
d = (r / Et).(Ps.r - 0.3F2) 0.002010 0.002010 0.000158 0.000158 0.002168 0.002168
For Outer Cylinder @x=yb u1 = b(y-x) 0.0 0.0 0.0 0.0 0.0 0.0
u2= B1Sin(u1)Sinh(u1)+B2Cos(u1)Cosh(u1) 0.000887 0.000887 0.000815 0.000815 0.001702 0.001702
Sm @ yb = E(d+u2) / r PSI 7,259.6 7,259.6 2,438.62,438.6 9,698.1 9,698.1
For Outer Cylinder @x=Lb u1 = b(y-x) 1.151224 1.151224 1.151224 1.151224 1.151224 1.151224
u2= B1Sin(u1)Sinh(u1)+B2Cos(u1)Cosh(u1) 0.001699 0.001699 0.002185 0.002185 0.003883 0.003883
Sm @ lb = E(d+u2) / r PSI 9,293.0 9,293.0 5,870.85,870.8 15,163.8 15,163.8
S= 13980.0 Allowable Stress = S 13,980.0 13,980.0 Fatigue Fatigue Fatigue Fatigue
CYCLE LIFE CALCULATION (Ref. RCB-8.74) :
Sm= Max. Cylinder Stress: M = Ma 746.7280 746.7280 681.7001 681.7001 1428.4281 1428.4281
M = Mb -441.4746 -441.4746 -558.3834 -558.3834 -999.8580 -999.8580
a for inner cylinder t = ta 0.314961 0.314961 0.314961 0.314961 0.314961 0.314961
b for outer cylinder t = tb 0.275591 0.275591 0.275591 0.275591 0.275591 0.275591
F2a = (723.72) (723.72) (551.33) (551.33) (1,275.05) (1,275.05)
F2b = (219.56) (219.56) (416.26) (416.26) (635.82) (635.82)
Sna= Scl@a = [(6Ma / t^2)+(F2 / t)] 47,462.7 47,462.7 42,982.2 42,982.2 90,445.0 90,445.0
Allowed = Fatigue Fatigue Fatigue Fatigue Fatigue Fatigue
Snb= Scl@b = [(6Mb / t^2)+(F2 / t)] 35672.8 35672.8 45622.3 45622.3 81295.1 81295.1
Allowed = Fatigue Fatigue Fatigue Fatigue Fatigue Fatigue
Summary of Stresses
Circl.Membrane Stress due to Intl. Press. Scmp Scmp Scmd Scmd Scmpd Scmpd
RCB-8.73: Inner Cylindrical Element @ya 1,549.2 1,549.2 (2,472.1) (2,472.1) (922.9) (922.9)
Inner Cylindrical Element @La (1,659.9) (1,659.9) (5,113.3) (5,113.3) (6,773.2) (6,773.2)
Outer Cylindrical Element @yb 7,259.6 7,259.6 2,438.6 2,438.6 9,698.1 9,698.1
Outer Cylindrical Element @Lb 9,293.0 9,293.0 5,870.8 5,870.8 15,163.8 15,163.8
Maximum of the above Values = 7,259.6 7,259.6 5,870.8 5,870.8 15,163.8 15,163.8
Max. Allowable Stress = S = 13,980.0 13,980.0 Fatigue Fatigue Fatigue Fatigue
Meridional Bending Stress due to Intl.Press. Smbp Smbp Smbd Smbd Sn Sn
RCB-8.72: Annular Plate Element Sb@a = 58734.8 58734.8 53853.8 53853.8 112588.6 112588.6
Annular Plate Element Sb@b = -35268.5 -35268.5 -44111.8 -44111.8 -79380.3 -79380.3
Max Allowable Stress = 3S = 41940.0 41940.0 Fatigue Fatigue Fatigue Fatigue
Annular Plate Element Sb@r = -44157.3 -44157.3 53853.8 53853.8 -146877.3 -146877.3
Max Allowable Stress = 1.5S = 20970.0 20970.0 Fatigue Fatigue Fatigue Fatigue
RCB-8.74 Max Stress for Cyclic Life = Scl@a 47462.7 47462.7 42982.2 42982.2 90445.0 90445.0
Scl@b 35672.8 35672.8 45622.3 45622.3 81295.1 81295.1
Max Allowable Stress = Fatigue Fatigue Fatigue Fatigue Fatigue Fatigue
Material of Construction for Expansion Bellow SA 240 Gr. 304L
Modulus of Elasticity for the Expansion Bellow Eb = 26787500 26787500
Max. Value of Sn From Above Table Sn = 112588.6 112588.6
FOR BELLOW FABRICATED OUT OF SA 240 Gr.304L : AS NEW CORRODED
Kg= 1 Flanged Expansion Bellow [{ln(28300000Sn/Eb)-14.12}^2 / 1.023] = 5.78915 5.78915

No.of Designed Cycle= 47.11 Exp[{ln(28300000Sn/Eb)-14.12}^2/1.023] = 15393 15393

> 100 \ O.K.
Equipment : EXPANSION BELLOW DESIGN Sheet8, Page No. 29
File : 357927304.xls
Clients : Insnpection : Dwg.:01-1314-001
3.14159265 MODULUS OF ELASTICITY OF MATERIALS IN PSI
MATERIAL SPECIFICATION Values Given x 10^6 PSI for Mean Metal Temperature in F
Group Matl Details -325 -200 -100 70 200 300 400 500 600 700 800 900
C.S, with C <= 0.30% 31.4 30.8 30.2 29.5 28.8 28.3 27.7 27.3 26.7 25.5 24.2 22.4
C.S, with C > 0.30% 31.2 30.6 30.0 29.3 28.6 28.1 27.5 27.1 26.5 25.3 24.0 22.3
Group-A C-1/2Mo,Mn-1/4Mo 31.1
Mo Steel Mn-1/2Mo,Mn-V
571.5 Group-B Ni Steel 29.6
Group-C Cr-1/2Mo Steel 31.6
Group-D 2 1/4-3Cr-1Mo Steel 32.6
Group-E 5-9Cr-1/2Mo-Si/Ti Steel 32.9
Group-F Chromium Steel:12-17Cr 31.2
Group-G ALL SS GRADES 30.3 29.7 29.1 28.3 27.6 27.0 26.5 25.8 25.3 24.8 24.1 23.5
-325 -200 -100 70 200 300 400 500 600 700 800 900
554.0 500 600
369.5 E= 25.8 25.3
25.530215
289.976

abcdefghijklmnopqrstuvwxyz
\abcdefghjlmpqs@DSw
Kg/Cm2.g qq^

26787498.6

1.14285714 1.14286
-0.0968092 -0.09681
-0.2774 -0.27741
-6.0659 -6.06590
-2.0894 -2.08944
Equipment : EXPANSION BELLOW DESIGN Sheet8, Page No. 30
File : 357927304.xls
Clients : Insnpection : Dwg.:01-1314-001

1.06595855

1.733493
1.32448736
 Sheet9

OPTIMUM VESSEL SIZE

Design Pressure P= 10 Kg/cm^2

Corrosion Allowance C= 3 Kg/cm^2
Allowable Stress S= 1230.14 Kg/cm^2
Joint Efficiency E= 1
Volume of the Vessel V= 100 m^3 3531.467 ft^3
Find the Value of 'F'
F = P/CSE 0.00271
Refer Chart on Pressure Vessel Hand Book(Page.241)

D= 11 ft 3.3528 m

Length of Vessel = 4V/pD^2 11.32648 m

Page 31
 Sheet10

Wind,Seismic Calculation

Fabricated Weight of the Vessel 30000 Kgs

Operating Weight of the Vessel 55000 Kgs
Hydrotest Weight of the Vessel 73200 Kgs
Basic Wind Speed 200 Km/Hr 55.5556 m/sec
K1 = 1.08 Factor
K2 = 1.09 Factor
K3 = 1 Factor
Vz = 55.55x1.08x1.09x1 65.3935 m/sec
Pz = 0.6 Vz^2/9.81 261.548 Kg/m
Say = 262 Kg/m
D= Diameter of Vessel 3 m
H= Height of Vessel 10.725 m
H1= Height Above Bottom T/L 7.425 m
Sf = Shape Factor 0.8
Fw = Wind Force on the Vessel = Pz.H.D.Sf 6743.88 Kgs
Mw = Wind Moment at Base = 0.5.Fw.H 36164 Kg-m
Fw1= Wind Force above Bottom T/L = Pz.H.D.Sf 4668.84 Kgs
Mw1= Wind Moment at Base = 0.5.Fw.H 17333 Kg-m

Seismic Zone = IV
ao = Seismic Coefficient 0.05 Factor
B = Soil Factor 1
I = Importance Factor 2
ah = ao.B.I 0.1
Assume C.G at center of Shell from Base 6 m
Seismic Force (Erected) 3000 Kgs
Seismic Moment (Erected) 18000 Kg-m
Seismic Force (Operating) 5500 Kgs
Seismic Force (Erected) 33000 Kg-m
STRESS IN THE SKIRT AT BASE
Erected Operat. Test Units
W = Weight 30000 55000 73200 Kgs
M = > of Wind or Seismic Moment 36165 36165 12055 Kg-m
D = Mean Dia.of the Skirt 296.8 296.8 296.8 cm
t = Thickness of the Skirt 1.2 1.2 1.2 cm
Tensile Stress = (400.M/p.D^2.t)-(W/p.D.t) 16.74835 -5.594829 -50.901 Kg/cm
Compr. Stress = (400.M/p.D^2.t)+(W/p.D.t) 70.37198 92.71517 79.9409 Kg/cm
Max. Tensile Stress in Skirt = 16.75 Kg/cm^2
Max.Compressive Stress in Skirt = 92.715 Kg/cm^2

Design Calculation Of skirt Support

W = Total Weight at the Base Level 30000 Kgs
M = Greater of Mw & Me 36165 Kg-m
Ds1= Skirt O.D at the Base Level 2980 mm
Ds2= Skirt O.D at the Comp.Plate Level 2980 mm
Ts = Provided Skirt Thickness 12 mm
Fa = Allowable Stress for Skirt Material 16.38 Kg/mm

Page 32
 Sheet10

M = Poisson ratio 0.3 Factor

C= Bolt Circle Dia 3110 mm
N= No.of Anchor Bolts 4 Nos
Db = Dia of Anchor Bolts 36 mm
Ab = Root Area of Bolt 865 mm
Sb = Allowable Bolt Stress 10 Kg/mm
. Bearing Stress in Concrete 0.4 Kg/mm
Do = Base Ring OD 3200 mm
Di = Base Ring ID 2880 mm
Tb= Thickness of Base Ring 35 mm
Fr = Allowable Stress For Base Ring 16.38 Kg/mm
Wc= Type of Compression Plate 1
Dc = Outside Diameter of Compression Plate 3200 mm
Tc = Thickness of Comp.Plate 25 mm
Fp= Allow.Stress For Comp.Plate 16.38 Kg/mm
h= Height of Gusset Plate 200 mm
Tg = Thickness of Gusset Plate 12 mm
b= Gusset Spacing 100 mm
e= Rad.of Action of Concentrated Load of Nut 40 mm
Skirt,Base Ring ,Compression Ring & Gusset Mat. SA 516 Gr.70
L1 = Dis.Between O.D of Base Ring & Skirt O.D (Do-Ds1)/2 110 mm
L2 = Dis.Between I.D of Base Ring & Skirt I.D ( Ds1-(2*Ts)-Di)/2 38 mm
a= Dis.Between O.D of Skirt & P.C.D at Comp.Ring Level (C-Ds2)/2 65 mm
L3 = Dis.Between O.D of Comp.Ring & O.D of Skirt (Dc-Ds2)/2 110 mm
Ft = Tensile Force /mm on BCD = Ft = 4000.M/p.C^2 -W/p.C 1.690263 Kg/m
Fc = Comp Force /mm on BCD = Ft = 4000.M/p.C^2+W/p.C 7.83129 Kg/m
Ar = Required Bolt Area = Ft.C.p/Sb.N 412.8617 mm
As = Stress Induced in Bolt = Ft.C.p/Ab.N 4.772968 Kg/mm
fc = Actual Compressive Stress in Concrete Fc/(Do-Di)/2 0.004949 Kg/mm
Bs = Bolt Spacing Bs = (p.C)/N 2442.588 mm
BASE RING
L1/Bs 0.0450342
FROM TABLE-Mx= 308.04 Kg-mm My = 290.354 Kg-mm
Maximum of Mx & My = M(max) = 308.04 Kg-mm
Required Thickness of Base Plate - Greater of 1,2,& 3
Tb = (6.Mmax/Fr)^ 0.5 10.62239 mm
Tb = ((3.Ab.As.b)/(4.L1.Fr))^0.5 13.1093 mm
Tb = L2.(3.fc/Fr)^0.5 1.144016 mm
Required Thickness of Base Plate = Tb = 13.1093 mm
Compression Ring
L3/b= 1.1
Factor t1 = 0.4575 Factor t2 = 0.125
Total Bolt Load = P =Ab.As = 4128.617 Kg
Mx = P/4.p((1+m).Ln (2.l.Sin(p.a/l)/p.e)+1)-(1-m-t2)P/4.p 361.159 Kg-mm
My = P/4.p((1+m).Ln (2.l.Sin(p.a/l)/p.e)+1)-(1-m-t2)P/4.p 399.7631 Kg-mm
Maximum of Mx & My = M(max) = 399.7631 Kg-mm
Thickness of Compression Plate = Tc =(6*Mmax/Fp)^0.5 mm
Skirt Shell Thickness
R = Mean radius of Skirt at Comp.Ring Level = (Ds2-Ts)/2 1484 mm

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Wc = 1221.94 mm
Ts = Req.Thickness of Skirt shell = 1.76.(P.a/2.Wc.h.Fa)^2/3xR(1/3) 2.086989 mm
Gusset Plate
Compression Stress in Gusset = P/(Lower of L1 & L3).Tg 3.12774 Kg/mm
Allowable Compr.Stress = (18000/(1+(h^2/(1500.Tg^2))/1422.3 10.67813 Kg/mm

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1.737931

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WIND LOAD CALCULATIONS

Pw = Wind Pressure 150 Kg/m^2
Sf = Shape Factor 0.7 Factor
Do = Sphere O.D 8.756 m
Ins = Insulation Thk 0.05 m
Asp = Proj.Sphere Area = p.((Do+2Ins)/2)^2 61.59779 m^2
Ww = Wind Load = Wp.Asp.Sf/1000 6.467767 Tons
Awl = Assumed Wind Load (For Calculation) 10 Tons
H = Sphere Ht.From Base 8.008 m
N = No.of Column Supports 8 Nos
C = Column P.C.D. 8.6 m
Mw = Wind Moment = Awl.H 80.08 Ton-Mtr.
Wwu = Wind Load/Column = 4.Mw/(N.C) 4.655814 Tons
SEISMIC FORCES BY RESPONSE SPECTRUM METHOD
I = Importance factor for Operating 2
I = Importance factor for Erection / Test 1
a= 0.04
Fo = 0.2
Sag = 0.28
B= Soil Factor 1.2
Operting Erection Testing
ah = Seismic Factor = B.I.Fo.Sag 0.1344 0.0672 0.0672
W= Weight of the Equipment 258.86 50 397.175
Feh = Horz.Seis.Force =Feh = ah.W 34.790784 3.36 26.69016
Me = Seismic Moment = Feh.H 278.6046 26.90688 213.7348
Weu = Load/Column = 4.Me/(N.C) 16.197942 1.5643535 12.42644
SUMMARY
Total Mom. Total Load Load/Col
in Ton - M in Tons in Tons
Weight of Sphere in Tons 50 6.25
Weight of Sphere + Full of Service Fluid 258.8603 32.3575
Weight of Sphere + Full of Water in Tons 397.1747 49.6468
Wind Moment in Ton -M 80.08
Load/Column Due to Wind in Tons 4.66
Seismic Moment : Full of Ser.Fluid Ton-m 278.6
Seismic Load/Column(Ser. Fluid) in Tons 16.2
Seismic Moment(When Empty) in Ton-m 26.91
Seismic Load/Column (When Empty) Tons 1.56

COLUMN DESIGN
Dc = Diameter of the Column 457 mm
Do = Diameter of the Sphere 8756 mm
C= P.C.D.of Column 8600 cm
Dcs = Dist.-Col.inward Edge/Vert.CL.=(C-Dc)/2 4071.5 mm
Rpo = Column Pad Plate Outer Radius = 0.5Do+Tp 4390 mm
Cos(b) = Dcs/Rpo 0.9274487 Ratio
b = Horz.Cl & Column Inward Edge at Column Pad 21.959 Deg.
Cos(b1) = 0.5C/Rpo 0.9794989 Ratio
b1 = Horz.Cl & Column Centre at Pad 11.622 Deg.

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D= Column Outer Dia. 45.7 mm

d= Column Outer Dia. 43.7 mm
K= Radius of Gyration =(D^2+d^2)^0.5/4 15.807791 mm
As = Column Cross Sectional Area 140.4474 cm^2
N= No.of Columns 8 Nos
H= Ht.from Sph.Cl.to Base in cm 800.8 cm
L= Effective Column Length = H-Rpo.Sin(b1) 712.4 cm
SR = Slenderness Ratio = L/K 45.066386 cm
Allowable Compressive Stress (IS : 800) 1329.82

Ic = Moment of inertia of Column =(D^4-d^4).p / 64 35091.324 cm^4

N= No.of Column Supports 8 Nos
R= Pitch Circle Radius of the Column 430 cm
Rc = Outer Radius of the Column =D/2 22.85 cm
Iyy = Mom.of inert.of System =N.Ic+0.5N.As.R^2 104155628 cm^4
Y= Cl./Extreme Fibre Dist.in cm =R+Rc 452.85 cm
Do = Outer Dia of Sphere 875.6 cm
e= Eccentricity =0.5(Y-Rpo) 6.925 cm
a= Factor 6.667E-05 Factor
Fds = Direct Stress Factor 1 Factor
Fsb = Bending Stress Buckling Factor = a.SR^2 0.1353986 Factor
Fsl = Bending Stress Eccentric Loading Factor =
Fsl = e.Rc.(1+ Fsb)/K^2 0.718972 Factor
Fc = Total of Above Factors = 1+Fsl+Fsb 1.8543706 Factor

Stress in Column Under Various Operating Erection Testing

Loading Conditions(in Kg/Cm^2) Condition Condition Condition
Wind Moment in Kg-cm = Mw 8008000 8008000 2669333
Wind Stress in Kg/cm^2= fw = Mw.Y/Iyy 34.817349 34.817349 11.60578
Seismic Moment in Kg-cm = Me 27860492 2690688 N.A
Seismic Stress in Kg/cm^2= fw = Me.Y/Iyy 121.13243 11.698629 N.A
ECCENTRIC LOADING:
Weight of the Equipment (in Kgs) = W 258860 50000 397175
Load per Column (in Kgs) =P =W/N 32357.5 6250 49646.88
Comb.Stress due to Ecc.Loading =f=(P.Fc/As) 427.22612 82.52069 655.5031
SUMMARY OF STRESSESS Operating Condition Erection Condition Test Condition
Direct Stress = fd = P.Fds/As 230.3887434 44.500646 353.4909
Bending Stress
Column Buckling = fb=P.Fsb/As 31.194315 6.025326 47.86217
Due to Ecc.Loading =P=P.Fsl/As 165.64306 31.99472 254.15
Bending Stress(Seismic) =fe 121.148 34.822 11.607
Total Direct/Bending Stresses 230.3887434 317.98537 44.500646 72.84204 353.4909 313.6192

WIND BRACINGS (SWAY-RODS) DESIGN

Ww = Total Force due to Wind 10000 Kgs
Weo = Total Force due to Seismic - Operating 34791 Kgs
Wee = Total Force due to Seismic - Erection 3360 Kgs
A= Angle Between two Columns = 360/Noc 45 Deg.

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C1 = Distance Between Columns = C.Sin(A/2) 3291.1 mm

q = Inv Tan(Lsr/C1) 62.448 Deg.

Tension in Sway Rod = 2 x Horizontal Force/[N.Cos(q)]

Tensile Force in S-Rod Due To

fw = Wind = 2 x Awl/(N.Cos(q)) 5405 Kg/m^2
Seismic Operating = 2 x Weo/(N.Cos(q)) 18803 Kgs
Seismic Erecting = 2 x Wee/(N.Cos(q)) 1816 Kgs
Applicable Force in Kgs = Str =>of above 18803 Kg/m^2
Sway-Rod Diameter 42 mm
Pitch of Threads 0.4 cm
Sra = Cross Sectional area of S-Rod 11.5 cm^2
Stress in S-Rod = Str/Sra 1635.0435 Kg/m^2
Allowable Stress in S-Rod = 0.8*Ys 1920 Kg/m^2

BASE PLATE DESIGN

Ap = Base Plate Area = (Bpl/10)^2 4900 cm^2
Zc = Section Modulus of Column 1535.725 cm^3
Ab = Root Area of Anchor Bolt (M36x3P) 8.65 cm^2
COMPRESSIVE STRESS IN CONCRETE
Operating Erection Test
Condition Condition Condition
fd = Direct Stress 230.419 44.506 353.536 Kg/cm^2
Wd = Total Load 32358 6250 49647 Kg/cm^2
Sd = Direct Comp. Stress 6.604 1.276 10.132 Kg/cm^2
fb = Bending Stress in Column 318.006 72.835 313.65 Kg/cm^2
M= fb.Zc 488370 111855 481680 kg-cm
Sb = Compressive Bending Stress = M/Zb 8.543 1.957 8.426 Kg/cm^2
W= Total Stress in Concrete = Sd+Sb 15.147 3.233 18.558 Kg/cm^2
Max.Allowable Stress in Concrete Bs 66.5
SHEAR FORK/LUG(DOUBLE SHEAR)
Tpl = Total Lug Plate Thickness 3 cm for lug on Fork
Total Lug Plate Thickness = 2 x 1.6 3.2 cm for lug on Column
R1 = Lug Plate Beyond Hole=6-(0.5*3.1) 4.45 cm
Sl1 = Stress in Lug = Str/(2.R1.Tpl) 704.23221 Kg/cm^2
Sl2 = Stress in Lug = Str/(2.R1.Tpl) 660.2177 Kg/cm^2
Swa = Allow.Weld Stress = 0.8*Swa 1152 Kg/cm^2
FOR LUG ON FORK
Lw = Total Weld Leng. Available=2x3+4x3 18 cm
Reqd.throat of Weld = Str/(Lwx1152) 0.9067805 cm
TURN BUCKLE
Used 3"NB Sch-80 SA106 Gr.B Pipe With 90 Dia.Nuts Welded at the Ends
Cross Sec.Area of the of 3"NB Sch-80 Pipe

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