White Liquor Oxidizer Design Calculation

Doc.
No 0001/CAL-1
DESIGN CALCULATION Sheet .No 1 of 33
Rev. 01
EQUIPMENT : White Liquor Oxidizer Date 02-03-16
CUSTOMER: ANDRITZ TECHNOLOGY
COVER SHEET
EQUIPMENT NAME : WHITE LIQUOR OXIDIZER
QUANTITY : ONE
CLIENT : ANDRITZ TECHNOLOGY
ENGINEERING & SUPPLY : MABEL ENGINEERS PRIVATE LIMITED

PLOT NO: 66-69,
EPIP SIPCOT INDUSTRIAL COMPLEX,
GUMMIDIPOONDI
TAMILNADU - 601 201.
INDIA
DESIGN CONSTRUCTION CODE : ASME BOILER & PRESSURE VESSEL CODE

SECTION VIII -DIV 1, 2013 EDITION
CODE STAMPING : ASME STAMP WITH “U” DESIGNATOR
MANUFACTURER'S NAME : MABEL ENGINEERS PRIVATE LIMITED

PLOT NO: 66-69,
EPIP SIPCOT INDUSTRIAL COMPLEX,
GUMMIDIPOONDI
TAMILNADU - 601 201.
INDIA
PREPARED CHECKED APPROVED

Doc.No 0001/CAL-1
DESIGN CALCULATION
Sheet No 2 of 33
EQUIPMENT : White Liquor Oxidizer Rev. 01
CUSTOMER: ANDRITZ TECHNOLOGY Date 3/2/2016
Content
S.No. DESCRIPTION Sheet No.

1 Cover Sheet 1 of 33
2 Content 2 of 33
3 Design Validity of Drawings & Calculation 3 of 33
4 Applicable Codes and Standards 4 of 33
5 Conversion factor 5 of 33
6 Design Data 6 of 33
7 Applicable Loading 7 of 33
8 Maximum Allowable working pressure 8 of 33
9 Static Head & Nozzle static Head 09-10 of 33
10 Corrosion allowance / Drain opening 11 of 33
11 Allowable stress of material 12 of 33
12 Minimum required thickness of cylindrical shell 13 of 33
13 Minimum required thickness of 2:1 Ellipsoidal head 14 of 33
14 Minimum required thickness of Of nozzles 15 - 16 of 33
15 Inspection opening and reinforcement requirement 17 of 33
16 Reinforcement Calculation 18 of 33
17 Weld Size & Strength calculation 19 of 33
18 Shell to head Transition requirement 20 of 33
19 Hydrostatic test pressure requirement 21 of 33
20 Flange Rating check 22 of 33
21 Non standard Flange calculation 23-25 of 33
22 Minimum design metal temprature & Impact test requirement 26 of 33
23 Radiogrphy Requirement 27 of 33
24 Post weld heat treatment & Post forming Heat treatment 28 of 33
25 Seismic load 29 of 33
26 Wind Load 30 of 33
27 Skirt support design 31 of 33
28 Skirt Base plate & Anchor Bolt design 32 of 33
29 Design of Lifting Lug 33 of 33

Doc.No 0001/CAL-1
DESIGN CALCULATION
Sheet No 3 of 33
Design Validity of Drawings & Calculation
Design calculation/ Revision Design

Ref. Drawing/ Approve
Sl.No Revision carried Validity Reviewd By
Revision carried out 0 1 2 3 4 5 d By
out checked
MEPL-010-01-GA-01 x YES RS AI
Sheet 0
MEPL-010-01-P-01 x YES RS AI
Sheet 01
Sheet No. 1 of 33 Sheet 01A
1
to 33 of 33 Rev.0
Sheet 04
Sheet 05
Sheet 06
MEPL-010-01-GA-01 x YES RS AI
Sheet 0
Sheet 01
Sheet No. 1 of 33 Sheet 01A
2
to 33 of 33 Rev.1
Sheet 04
Sheet 05
Sheet 06

Doc.No 0001/CAL-1
DESIGN CALCULATION
Sheet No 4 of 33
Applicable Codes and Standards
I CODES & STANDARDS AVAILABILITY
1 ASME SEC. VIII DIV.1 ED.2013 YES
2 ASME SEC. II PART-A ED.2013 YES
3 ASME SEC. II PART-D ED. 2013 YES
4 Pipe Flanges and Flanged Fittings ASME B16.5 – 2009 YES
Welded and Seamless Wrought Steel Pipe

5 ASME B36.10M 2010 Edition
YES
Factory Made Wrought Buttwelding Fittings

6 ASME B16.9 2012 Edition
YES
Factory Made Wrought Buttwelding Fittings

7 ASME B16.11 2011 Edition
YES

Doc.No 0001/CAL-1
DESIGN CALCULATION
Sheet No 5 of 33
Conversion factor
Sl.No CUSTOMARY UNIT SI UNIT
1 1 Inch 25.4mm (2.54 cm)
2 1 ft 0.3048 Meters/304.8 mm
3 1 pound (lbm) 0.4535924 Kg
4 1 pound (lbf) 4.448222 N
5 2.2046 (lb) 1 Kg
14.2233 PSI ie 14.2233 lb/in²

6 ie ((2.54)²/0.4535924) 1 Kg/Cm²g
7 1 PSI 0.006894757 Mpa
8 1 PSI 6.894757 Kpa
9 1 PSI 0.06894757 Bar
10 in-lb 112.98484 N-mm
11 ˚F 5/9˚C (For Temp. Diifrence only)
12 ((˚Cx9/5)+32)˚F ˚C (Not For Temp. Diifrence)
13 ˚F ((˚F-32)5/9)˚C

Doc.No 0001/CAL-1
DESIGN CALCULATION
Sheet No 6 of 33
Design Data
Design Contruction Code : ASME SECTION VIII -DIV 1 ,ED.2013
Design Pressure (Internal) : 10 bar 1 Mpa
Design Pressure (External) : 1 bar 0.1 Mpa
Operating Pressure : 6.7 bar 0.67 Mpa
MAWP (Internal) : 10 bar 1 Mpa
MAWP (External) : 1 bar 0.1 Mpa
Design Temperature : 200 °C
Operating Temperature : 133 °C
MDMT : 20 °C
Hydro static Test Pressure : 14 bar 1.4 Mpa
Hydro static Test Temperature : Not more than 48 °C
Joint Efficiency : 1 for Dish / 0.85 for Shell
Radiography : Refer Page No: 26
Post Weld Heat Treatment : Refer Page No: 27
Corrosion Allowance : NIL
Vessel Size : ID – 1900 mm
: Length – 5100 mm TL to TL
Medium : WHITE LIQUOR + OXYGEN
Inspection By : AUTHORIZED INSPECTOR
Volume : 17 m³
NB registration : Not Required
ASME certification with U designator : Required
Impact Test Exemption : Refer Page No: 25
Specific Gravity of fluid : 1.2
Empty Weight : 8753 Kgs
Hydro test weight : 25753 Kgs
Wind load : IS 875-1983-Part-III
Seismic load : IS 1893 - Part-I (2002)
Insulation : By Other

DESIGN CALCULATION Doc No. 0001/CAL-1
Sheet No 7 of 33
Applicable Loading
UG-22
Sl. No. description Applicability
Clause
a) Design pressure
1 1. Internal Design pressure Applicable
2. External Design pressure Applicable
2 b) Weight of vessel & Normal Content Applicable
3 c) Superimposed static reaction from weight of attached equipment Not applicable
d) Attachment of
4 1. Internals Not applicable
2. Vessel Support Applicable
5 e) Cyclic / Dynamic reaction due to pressure or Thermal variation Not applicable
Wind Load Applicable
6 f) Snow Not applicable
Seismic Load Applicable
7 g) Impact reactions such as those due to fluid shock Not applicable
8 h) Temperature gradient and differential thermal expansion Not applicable
9 i) Abnormal pressures such as those caused by deflagration Not applicable
10 j) Test pressure and coincedent static head acting during the Test Applicable

Doc.No 0001/CAL-1
DESIGN CALCULATION
Sheet No 8 of 33
Maximum Allowable Working pressure
As per paragraph 3.2 of Appendix-3, Design Pressure may be used in all cases in
which calculations are not made to determine the value of the Maximum Allowable
Working Pressure (MAWP).
MAWP = Design Pressure = 10 Bar(g)

= 1 Mpa

Doc.No 0001/CAL-1
DESIGN CALCULATION
Sheet No 9 of 33
STATIC HEAD
CALCULATION OF PRESSURE DUE TO STATIC HEAD (UG-21)
consider that the vessel with full of operating fluid to calculate the static head. (specific gravity
provided by client is 1.2 is higher than water)
Specific Gravity of Fluid = 1.2

Density of Process Liquid g = 1200 kg/m3
1. Static Liquid Head Dish End
Maximum liquid level H = 525+5000+525 = 6050 mm = 6.050 m

Additional pressure due to static head, ps = H x g = 6.050 x 1200
= 7260 kg/m2
= 72.60 kpa
= 0.72 Barg (0.072 Mpa)
Design Pressure Taken as = MAWP + Static Head

= 10 + 0.72
= 10.72 Barg (1.072 Mpa)
2. Static Liquid Head Shell
Maximum liquid level H = 525+5000 = 5525 mm = 5.525 m

Additional pressure due to static head, ps = H x g = 5.525 x 1200
= 6630 kg/m2
= 66.30 kpa
= 0.66 Barg (0.066 Mpa)
Design Pressure Taken as = MAWP + Static Head

= 10 + 0.66
= 10.66 Barg (1.066 Mpa)
PREPARED CHECKED APPROVED BY

Doc.No 0001/CAL-1
DESIGN CALCULATION
Sheet No 10 of 33
STATIC HEAD NOZZLES
Static Head for the Nozzles

MAWP = 1 Mpa
Nozzle
Max Liquid Density of Static Head
Nozzle Design
Sl.No Nozzle Mark Level (H) Liquid (g) (ps)
Location Pressure
(m) Kg/m3 (Mpa)
(Mpa)
Top of
1 N1 Head 1200 0 1
Vessel
2 N2 Shell 2.84 1200 0.03 1.03
3 N3 Head 6.05 1200 0.073 1.073
4 N4 & N5 Shell 4.90 1200 0.059 1.059
5 N6.1,6.2,7.1,7.2 Shell 4.92 1200 0.059 1.059
6 N12,N13 Shell 5.31 1200 0.064 1.064
7 N14 Head 0.06 1200 0.001 1.001
8 N16 Shell 2.61 1200 0.031 1.031
N17,N18,N19,N20,
9 Shell 6.65 1200 0.0798 1.0798
N21,N22,N23,N24
10 N27 Head 5.82 1200 0.0698 1.0698
11 BOOT SHELL Head 6.05 1200 0.0726 1.0726

Doc.No 0001/CAL-1
DESIGN CALCULATION
Sheet No 11 of 33
CORROSION ALLOWANCE & DRAIN OPENING UG-25
DRAIN OPENING REQUIREMENTS AS PER UG-25 (f)
Specified Corrosion Allowance = 0 mm (Hence it’s a stainless steel and

Recommended by the user)
Provided corrosion allowance = 0 mm
A NPS 3 (N3) Drain pipe connection is provided at the bottom of the vessel

Doc.No 0001/CAL-1
DESIGN CALCULATION
Sheet No 12 of 33
Allowable stress of material
Allowable stress (UG 23) As per ASME SEC II Part D Edition 2013
Allowable Allowable
yield strength at Page
stress ('S') at stress ('S') at Stress
Hydro test No./ line
Hydro test Design Ratio
temperature no
temperature temperature P.No./
Sl. Material of
Gr. Notes No.
No. Construction
Minimum S Hydro test No.
Temp. Temp.
Temp. yield Stress Stress / S TABLE-
(o
( o C) strength in (MPa) (MPa) Temp.
1A
C) ( oC )
(Mpa) Design Temp.
01 SA 240 S32304 48 400 48 172 200 150 1.15 10H/1 138/141 G19
02 SA 312 TP.304L 48 170 48 105.0 200 81.2 1.29 8/1 90/5 G21,T5
03 SA 240 Gr.304L 48 170 48 115 200 110 1.05 8/1 88/42 G5,G21,T5
04 SA 182 F.304L 48 170 48 115 200 110 1.05 8/1 86/38 G5,G21,T4
05 SA 193 Gr.B8 48 205 48 130 200 95.7 1.36 362/20 TABLE-3 G5,G6,T10
Notes:
1) Precautionary notes G5,G6,G19,G21,T4,T5,T10 are not applicable
2) * - Usage of all the above materials are permitted for SEC VIII DIV. I as per SEC II part D (Metric)
Lowest Vessel Stress Ratio = 1.05

Doc.No 0001/CAL-1
DESIGN CALCULATION
Sheet No 13 of 33
Minimum required Thickness of cylindrical shell
Design pressure (P) : 1.066 Mpa Design Temperature : 200 °C

Shell Material : SA 240 S32304 Joint Efficiency (E) : 85 %
Corrosion Allowance(CA) : 0 mm Max. allowable Stress (S) : 150 Mpa
Ext.corrosionAllowance (Ext. CA): 0.00 mm Shell Length(TL-TL) : 5100 mm
Inside Diameter(ID) : 1900 mm Thin out : 0.00 mm
Inside Diameter (Corroded)(Di) : 1900 mm Nominal Shell Thickness Selected: 10 mm
Radius(corroded)(Ri): 950 mm 950.00 mm
Outside diameter(Do): 1920 mm
External Pressure Data
Design Pressure (Pa) : 0.10133 Mpa(g) Nominal L/Do : 0.65
Design Temperature : 200 °C Nominal Do/t : 192.00
Nominal tn : 10.00 mm Factor A(ASME SEC II Part D fig G) : 0.0004
t( t n- CA - Ext. CA - Thin Out) : 10.00 mm Factor B( from CS-2 chart): 50.50 Mpa
Shell support length( L ): 1250.00 mm
Design Thickness Calculations
Longitudinal Stress Calculations per Paragraph UG-27(c)(2)

(i)t< Ri/2 Ri/2 = 475.00mm
(ii)P<1.25SE 1.25SE = 159.38 bar
P Ri 1.066 x950
t= + CA + Ext.CA +thn out = '=+0+0+0 = 4.40 mm
2SE + 0.4P (2X150X0.85)+(0.4X1.066)
Circumferential Stress Calculations per Paragraph UG-27(c)(1)

(i)t< Ri/2 Ri/2 = 475.00mm
(ii)P<0.385SE 0.385SE = 57.75 bar

P Ri 1.066 x950
t= + CA + Ext. CA+thn out = '+0+0+0 = 7.30 mm
SE - 0.6P (150 X0.85)-(0.6X1.066)
Maximum External Pressure Calculation per Paragraph UG-28

Pa(max) = 4B 4 X50.50
= = 0.35 Mpa
3 ( Do / t ) 3 X 192
3.5 Bar
Result
Nominal Shell Thickness Selected = = 10.00 mm

Required Thk of the Shell (incl.of all allowances) = = 7.30 mm
Minimum Required Thk of the Shell (incl.of all allowances) = 1.5 mm (As per UG-16(b))
For external pressure, Pa(max) > Design pressure, Pa
Here Provided Thickness > Required Thickness HENCE SATISFACTORY
Note:
1) Provided shell thickness = 10 mm

Doc.No 0001/CAL-1
DESIGN CALCULATION Sheet No 14 of 33
Minimum required thickness of 2:1 Ellipsoidal head
Design pressure (P) : 1.072 Mpa Design Temperature : 200 °C

Head Material : SA 240 S32304 Joint Efficiency (E): 100 %
Corrosion Allowance (CA): 0.00 mm Max allowable stress (S) : 150 Mpa
External Corrosion Allowance(Ext.CA) : 0.00 mm Thin Out : 2 mm
Inside Diameter (ID) : 1900 mm
Inside Diameter (Corroded)(D) : 1900 mm
Outside Diameter (D0) : 1920 mm
Ext. Nominal tn : 12.00 mm Head depth(ho): = 475 mm
External Pressure Data
Design Pressure (Pa) : 0.10 bar(a)
Ext. Nominal tn : 10.00 mm
t( tn - CA - Ext. CA - Thin Out) : 4.57 mm
Factor A(ASME Sec II Part D fig G) : 0.0007
Factor B (from HA-6 Chart): 70.50 MPa
Design Thickness Calculations for Internal Pressure as Per UG -32 (d)
ts= Minimum specified Thickness after forming = 10mm.
L= Inside crown radius = 1692 mm.

ts/L = 10/1692 = 0.005mm > 0.002 , Hence the Following formula can be used for min. required thickness,
PD 1.072 X 1900
t= + CA + Ext.CA + Thin Out = '=+0+0+0 = 6.57 mm
2 S E - 0.2 P (2X150X1)-(0.2 X1.072)
Maximum External Pressure Calculation per UG-33
RO= K0 *DO Ko= 0.9 (from Table UG -33.1) Do/2ho= 2
=0.9 x 1920= 1728 A= 0.125 =0.0007
Ro/t
B 70.50
Pa(max) = = = 0.407 Mpa
Ro/t 172.8
= 4.07 Bar
Result
Nominal Head Thickness Selected = 12.00 mm

Required Thk of the Head (incl. of all allowance) = 6.57 mm
Minimum Required Thk of the Shell (incl.of all allowances) =1.5 mm (As per UG-16(b))
Note:
1) Pressure acting on concave side of Dished head.
2) Provided Head thickness = 12 mm, Minimum thickness after forming = 10 mm

Doc.No 0001/CAL-1
DESIGN CALCULATION Sheet No. 15 of 33
Minimum required Thickness of nozzles As per UG-45
Nozzle Identification N2 N6.1,6.2,7.1,7.2 N4,5 N12,13 N16 N17 to N24
Nozzle is attached to ST-Shell ST-Shell ST-Shell ST-Shell ST-Shell ST-Shell
Nozzle Material Specification SA 312 Gr.304L SA 240 Gr.304L SA 240 S32304 SA 312 Gr.304L SA 312 Gr.304L SA 182 Gr.304L
Negative Tolerance (As per UG – 16(d)) % 12.50 12.50 12.50 12.50 12.50 12.50
O.D of the nozzle (D) mm 88.9 356.0 609.6 48.3 26.67 210.0
Std. thk of the nozzle mm 5.49 10.00 10.00 3.68 2.87 59.50
Provided thk of the nozzle mm 5.49 10.00 10.00 3.68 2.87 59.50
Nozzle Design Pressure (P) MPa 1.030 1.059 1.059 1.064 1.031 1.0798
Nozzle Design Temperature o
C 200 200 200 200 200 200
Inside radius of the nozzle (R) mm 38.96 168.00 294.80 20.47 10.47 45.50
Max allowable stress value of the nozzle (S) MPa 81.2 110 150 81.2 81.2 110
Joint Efficiency (E) 1.00 1.00 1.00 1.00 1.00 1.00
ta = PRo/(SE+0.4P) as per App. 1-1 (ta) ( ta) mm 0.50 1.63 2.09 0.27 0.13 0.45
Corrosion Allowance of the nozzle (C.A) mm 0.00 0.00 0.00 0.00 0.00 0.00
Required thk of the Nozzle (trn + C.A) as per UG-45(a) (a) mm 0.50 1.63 2.09 0.27 0.13 0.45
Inside radius of the Shell mm 950 950 950 950 950 950
Max allowable stress value of the shell MPa 150 150 150 150 150 150
Required thk of the shell for internal pressure (Assuming E=1) + C.A as per UG-27 (b) mm 6.59 6.70 6.70 6.70 6.50 6.70
Min thk of the shell for internal pressure (1.5 mm+C.A) as per UG-16(b) (c) mm 1.50 1.50 1.50 1.50 2.50 1.50
Greater of (b) or (c) as per UG-45 (t b1) (d) mm 6.59 6.70 6.70 6.70 6.50 6.70
Min. noz. wall thk of Std. Wall pipe less 12.5% + C.A as per UG-45 (tb 3) (g) mm 4.80 8.75 8.75 3.22 2.51 52.06
Required thk of nozzle neck (Greater of (a) or (g)) as per tUG-45 mm 4.80 8.75 8.75 3.22 2.51 52.06
Min. provided thickness less 12.5% (Tolerance as per ASME B36.10M) mm 4.80 8.75 8.75 3.22 2.51 52.06
Thk provided as per UG-45 is OK OK OK OK OK OK
Provided Nozzle schedule SCH40 10 THK 10 THK SCH40 SCH40 Forged

Doc.No 0001/CAL-1
STRESS CALCULATION
Sheet No. 16 of 33
NOZZLE NECK THICKNESS AS PER UG-45
Nozzle Identification N1 N3 N14 N27 BOOT SHELL
Nozzle is attached to ST- Head ST-Head ST-Head ST-Head ST-Head

Nozzle Material Specification SA 312 Gr.304L SA 312 Gr.304L SA 312 Gr.304L SA 312 Gr.304L SA 240 S32304
Negative Tolerance % 12.50 12.50 12.50 12.50 12.50
O.D of the nozzle (D) mm 323.8 88.9 114.3 21.3 833.0
Std. thk of the nozzle mm 9.52 5.49 6.02 2.77 10.00
Provided thk of the nozzle mm 9.52 5.49 6.02 2.77 10.00
Nozzle Design Pressure (P) Mpa 1.00 1.073 1.00 1.070 1.073
Nozzle Design Temperature o
C 200 200 200 200 200
Inside radius of the nozzle (R) mm 152.38 38.96 51.13 7.88 406.50
Max allowable stress value of the nozzle (S) Mpa 81.2 81.2 81.2 81.2 150.0
Joint Efficiency (E) 1.00 1.00 1.00 1.00 1.00
trn = PRo/(SE+0.4P) as per App. 1-1 ( trn) mm 1.89 0.52 0.63 0.105 2.92
Corrosion Allowance of the nozzle (C.A) mm 0.00 0.00 0.00 0.00 0.00
Required thk of the Nozzle (trn + C.A) as per UG-45(a) (a) mm 1.89 0.52 0.63 0.105 2.92
Inside radius of the Shell/head mm 950 406.5 950 950 950
Max allowable stress value of the shell/Head Mpa 150 150 150 150 150
Req. thk of the Head for internal pressure (Assuming E=1) + C.A as per UG-37 a 3 (b) mm 5.70 2.90 5.70 6.70 6.70
Min thk of the shell for internal pressure (1.5mm+C.A) as per UG-16(b) (c) mm 1.50 1.50 1.50 1.50 1.50
Greater of (b) or (c) as per UG-45(t b1) (d) mm 5.70 2.90 5.70 6.70 6.70
Min. noz. wall thk of Std. Wall pipe less 12.5% + C.A as per UG-45(tb 3) (g) mm 8.33 4.80 5.27 2.42 8.75
Required thk of nozzle neck (Greater of (a) or (g)) as per UG-45 mm 8.33 4.80 5.27 2.42 8.75
Min. provided thickness less 12.5% (Tolerance as per ASME B36.10M) mm 8.33 4.80 5.27 2.42 8.75
Thk provided as per UG-45 is OK OK OK OK OK
Provided Nozzle schedule SCH40S SCH40S SCH40S SCH40S Rolled Plate

Doc.No 0001/CAL-1
DESIGN CALCULATION
Sheet No 17 of 33
Inspection opening & reinforcement requirement
REINFORCEMENT CHECK REQUIREMENT AS PER UG-36 – C 3(a)

Welded connections with a finished openings more than 89mm in vessel shell or heads over a
required minimum thickness 10mm or less
Thickness required for shell (including allowance) = 7.30 < 8

Thickness required for Dish (including allowance) = 6.57 < 10
Hence reinforcement check required for finished hole diameter more than 89mm.
Nominal CA (mm) Finished Opening Diameter Reinforcement

Nozzle OD (mm)
thk (mm) (mm) Requirement
N1 323.9 9.52 0.00 304.86 REQUIRED

N6.1,N6.2,N7.1
355.6 10 0.00 335.6 REQUIRED
,N7.2
N2 & N3, N17
88.9 5.49 0.00 77.92 NOT REQUIRED
TO N24
N4 & N5 609.6 10 0.00 589.6 REQUIRED
N14 114.3 6.02 0.00 102.26 REQUIRED
N12,N13 48.3 3.68 0.00 40.94 NOT REQUIRED

N16 26.7 2.87 0.00 20.96 NOT REQUIRED
BOOT SHELL 833 10 0.00 813 REQUIRED
UG-36 (b) 1 - Large opening:
For vessels exceeds 1500 mm inside diameter,
1/3 Vessel Diameter but not to exceed 1000mm.
(1/3)*1900 = 634 mm but not more than 1000 mm. Maximum diameter of opening
in vessel = 833 mm
Hence there is no large openings in the vessel.
Notes:
1)As per UG-46, manhole is used for inspection & cleaning purpose.
2) For Nozzle N2 & N3 RF element is provided as per client requirement

eventhough its not required as per UG-36 c 3 (a)
Doc.No 0001/CAL-1
DESIGN CALCULATION
Sheet No 18 of 33
REINFORCEMENT REQUIREMENT FOR OPENINGS IN SHELLS AND FORMED HEADS AS PER UG-37
N6.1,N6.2,
Nozzle Identification N1 N7.1,N7.2 N4&N5 N14 BOOT SHELL
Nozzle is attached to ST-HEAD ST-SHELL ST-SHELL ST-HEAD ST-HEAD
Shell or head Material Specification S32304 S32304 S32304 S32304 S32304
Nozzle Material Specification SA 312 TP 304L SA 240 F 304L S32304 SA 312 TP 304L S32304
Max. All. stress value of the Shell/Head ( Sv ) Mpa 150 150 150 150 150
Max. All. stress value of the Nozzle ( Sn ) Mpa 81.2 81.2 150.0 81.2 150
Negative Tolerance for the Shell/Head % 0 0 0 0 0
Negative Tolerance for the Nozzle % 12.50 0.00 0.00 12.50 0.00
Corrosion Allowance for the Shell/Head mm 0 0 0 0 0
Corrosion Allowance for the Nozzle mm 0.0 0.0 0.0 0.0 0.0
Thinning Allowance for the Shell/Head mm 0 2 2 0 2
Thinning Allowance for the Nozzle mm 0 0 0 0 0
Reqd. thk of seamless shell/head (excl. all allowances) ( tr ) mm 5.70 6.70 6.70 5.70 6.70
Reqd. thk of Noz. wall (excl. all allowances) ( trn ) mm 8.33 1.63 2.0897 0.63 2.92
Provided thickness of the Shell/head (excl. all allowances) (t) mm 10.0 10.00 10.00 10.00 10.00
Provided. thickness of Nozzle. wall (excl.all allowances) ( tn ) mm 9.52 10.0000 10.000 6.02 10.0000
Nominal thickness of nozzle wall at internal projection. ( ti ) 0.000 0.0000 0.000 0.0000 0.0000
O.D of the nozzle mm 323.80 356.00 609.60 114.30 833.00
Finished dia. of circular opening (d) mm 304.7600 336.00 589.6000 102.26 813.0000
E1=1,when opening is in solid plate ( E1 ) 1 1 1 1 1
Correction factor (Given F=1) (F) 1 1 1 1 1
Sn/Sv for nozzle inserted thru the vessel ( fr1 ) 0.54 0.5413 1.0000 0.5413 1.0000
Sn/Sv ( fr2 ) 0.54 0.5413 1.0000 0.5413 1.0000
SP/SV ( fr4 ) 1.0000 1.0000 1.0000 1.0000 1.0000
h1 = Nozzle proj. inside the vessel (h1) mm 0.0 0.0 0 0 0
Distance Nozzle projects beyond inner surface = h = min
(h1,2.5t,2.5ti) (h) mm 0.0000 0.0000 0.0000 0.0000 0.0000
Area Required (A) mm2 1786.9102 2312.6613 3950.3200 614.3594 5447.1000

OD of RF element ( DP ) mm 473.0000 556.0000 910.0000 214.0000 1083.0000
Max. All. stress value of the RF PAD ( SP ) Mpa 150.0000 150.0000 150.0000 150.0000 150.0000
THICKNESS RF PAD ( Te ) mm 10.0000 10.0000 10.0000 10.0000 10.0000
Area available in shell/head ( A1 ) mm2 1272.9160 1078.5280 1945.6800 415.9719 2682.9000
Area available in nozzle proj. outward ( A2 ) mm2 30.6633 226.6335 395.5151 87.7465 354.0365
Area available in inward nozzle ( A3 ) mm2 0.0000 0.0 0.0000 0.0000 0.0000
A41(leg) A41(leg) mm 9 9 9 7 9
A41 = Outward nozzle weld = (leg)2 X fr2 ( A41 ) mm2 43.8480 43.8480 81.0000 26.5253 81.0000
A43(leg) A43(leg) mm 0.00 0.00 0.00 0.00 0.00
A43 = Inward nozzle weld = (leg) 2 X fr2 ( A43 ) mm2 0.0 0.0 0.00 0.0 0.0
Area available without RF element mm2 1347.43 1349.01 2422.20 530.24 3117.94
Reinforcement Pad requirement YES YES YES YES YES
A42(leg) A42(leg) mm 8.0 8.0 8.0 8.0 8.0
Outer element weld ( A42 ) mm2 64.0 64.0 64.0 64.0 64.0
A5 = Area available in RF element A5 mm2 1492.0 2000.0 3004.0 997.0 2500.0
Area available with RF element mm2 2903.4273 3413.0095 5490.1951 1591.2437 5681.9365
cm² 29.0343 34.1301 54.9020 15.9124 56.8194
Opening is adequately Reinforced ? YES YES YES YES YES

Doc.No 0001/CAL-1
DESIGN CALCULATION
Sheet No 19 of 33
Weld size & Strength Calculation
Minimum Requirements for Attachment Welds As per UW-16
Thk tmin = t leg req

tc = t leg req t leg req t leg req
Nozzle (1/2xte/0.7 Applicable
Nozzle Nozzle Min (19 min(6, tmin (tcx1.414) provided provided
thk tc 07) Sketch from
Mark No. OD mm, 0.7t ) Nozzle to (Nozzle (Shell to
(tn) Vessel Pad Shell to UW 16.1
tn,ts) min
Pad to Pad) Pad OD)
(ts) (te) Pad OD
mm mm mm mm mm mm mm mm mm mm mm mm Sketch No
N1 323.9 9.52 10 10 9.52 6.66 9.52 6.00 8.48 9.00 7.07 8.00 UW 16.1 d
N6.1,N6.
2,N7.1,N 355.6 10 10 10 10.00 7.00 10.00 6.00 8.48 9.00 7.07 8.00 UW 16.1 d
7.2
N2 & N3 88.9 5.49 10 10 5.49 3.84 5.49 3.84 5.43 6.00 7.07 8.00 UW 16.1 d
N4 & N5 609.6 10 10 10 10.00 7.00 10.00 6.00 8.48 9.00 7.07 8.00 UW 16.1 d
N14 114.3 6.02 10 10 6.02 4.21 6.02 4.21 5.96 7.00 7.07 8.00 UW 16.1 d
N12,N13 48.3 3.68 10 - 3.68 2.58 - - 3.64 5.00 - - UW 16.1 c
N16 26.7 2.87 10 - 2.87 2.01 - - 2.84 4.00 - - UW 16.1 c
N27 21.3 2.77 10 - 2.77 1.94 - - 2.74 4.00 - - UW 16.1 c
N17 TO
210 59 10 - 10.00 7.00 10.00 6.00 8.48 9.00 - - UW 16.1 c
N24
BOOT 833 10 10 10 10.00 7.00 10.00 6.00 8.48 9.00 7.07 8.00 UW 16.1 d

DESIGN CALCULATION Doc.No 0001/CAL-1
EQUIPMENT : White Liquor Oxidizer Sheet No 20 of 33
CUSTOMER: ANDRITZ TECHNOLOGY Rev. 01

Date
Shell to Head transition Requirement UW9 , UW13 3/2/2016
Shell Thickness = 10 mm
Max. Head thickness = 12 mm
Diffrence in Thickness y = 12 - 10
= 2 mm
a> 1/4 of the Thinner section 10x1/4 = 2.5 mm
b> 3 mm
Diffrence y ie 2 mm is smaller than smaller of (a) and (b) ie 2.5 mm
hence a tapered transition not required
How ever 1:3 Taper transition provided as per good engineering Practice


Date
Hydro Static Test Pressure requirement 3/2/2016
MAWP = 10 Barg (1 Mpa) (Refer Page No.8)

Lowest Stress Ratio = 1.05 (Refer Page No.11)
Minimum Hydrostatic Test pressure As per UG-99 (b)

= 1.3 x MAWP x Lowest Stress Ratio
= 1.3 x 1 x 1.05
= 1.365 Mpa
= 13.65 Barg
Provided Hydrostatic test pressure = 14 Barg
Stress During Hydro test (Shell)

Ss = PR + 0.6 t
Et
1.066 x 950 + 0.6 x 10
=
0.85 x 10
= 119.84 Mpa
90% of Yield Strength = 0.9 x 119.84
Not Mandatory = 107.85 Mpa (Adequate)
Stress During Hydro test (Head)

Sh = PD + 0.2 t
2Et
1.072 x 1900 + 0.2 x 10
=
2 x 1 x 10
= 101.94 Mpa
90% of Yield Strength = 0.9 x 101.94
Not Mandatory = 91.746 Mpa (Adequate)

Doc.No 0001/CAL-1
DESIGN CALCULATION
Sheet No 22 of 33
Flange rating Check
Table 2.1.1 of ASME B 16.5 -2009
Allowable
Design Design
Class Working
Sl.no Nozzle No Material spec. Pressure Temp. Remarks
# Pressure
(Mpa) (°C)
(Mpa)
1 - SA 182 Gr.304L 300 1.0 200 2.920 SAFE
Conditions:
Design pressure <Allowable working pressure
Hence provided 300 # class flanges are satisfied.

NON STANDARD FLANGE Date 3/2/2016
Sr No Description Notation Unit
Loads
1 Internal Pressure P Mpa 1.0
General
2 Flange Class NON STD
3 Neck Outside Dia. 356
4 Neck plate Thickness 10
Material Properties
5 Flange Allow. at Amb. Temp Sfs Mpa 115
6 Flange Allow. at Design Temp Sfd Mpa 110
7 Bolt Allow. at Amb. Temp Sa Mpa 130
8 Bolt Allow. at Design Temp Sb Mpa 95.7
9 Gasket Factor m 2
10 Gasket Factor y Mpa 11.03
Dimension
11 Flange OD A mm 520
12 Flange ID B mm 336
13 Bolt Circle Diameter C mm 470
14 Hub Thickness at Small end g0 mm 10
15 Hub Thk at back of flange g1 mm 24
16 Hub Length h mm 14
17 Flange Thickness t mm 40
18 Nom Thk of Neck Plate tn mm 10
19 Nominal Bolt Diameter a mm 24.0
20 Number of Bolts n Nos. 16
21 Area of Bolt at Thread cm2 50.04
22 Gasket OD mm 442
23 Gasket ID mm 359

Calculations
24 Width of Gasket N mm 41.50
25 Basic gasket seating width b0 mm 20.750
26 Effective Gasket width b mm 11.4
27 Location of Gasket Load G mm 419.22
28 Axial Force on Flange F kgf 540.00
29 Bending Moment on Flange M kg-m 400.00
30 Axial Force Equivalent pressure (4F/(pi*G*G) Mpa 0.03912
31 Bending Moment Equivalent pressure (16M/(pi*G*G*G) Mpa 0.276
32 Final Equivalent design Pressure Peq Mpa 1.316
33 Total Pressure P Mpa 1.0
34 Hydrostatic End Load due to pressure H kgf 18150.64
35 Contact Load on Gasket surface Hp kgf 5999.36
36 Operating bolt load Wm1 kgf 24150.0
37 Gasket seating Bolt Load Wm2 kgf 16543.2
38 Area of Bolt for Operating Am1 cm2 25.2
39 Area of Bolt for Seating Am2 cm2 12.7
40 Required Bolt Area Am cm2 25.2
41 Bolt Stress % in Operating 31.52%
42 Bolt Stress % in Seating 0.0122%
43 Is Bolt area Adequate YES
44 Flange Design Bolt Load Oper W1 kgf 24150.0
45 Flange Design Bolt Load Seat W2 kgf 48928.8
46 Radial Distance ((C-B)/2)-g1 R mm 43
47 Moment Arm (Dist. To end pressure reaction) hd mm 55
48 Moment Arm (Dist. to Face pressure Reacion) ht mm 46.19
49 Moment Arm (Dist. to Gasket load Reacion) hg mm 25.39
50 Hydrostatic End Load at flange ID Hd kgf 8866.8
51 Pressure Force on Flange Face Ht kgf 9283.8
52 Gasket Load for Operating condition HG kgf 5999.4
53 Circumferential bolt facing Bs mm 91.7
54 Bolt Spacing factor Bsc 1.0
55 Moment (End Pressure) Md kg-m 487.68
56 Moment (Face Pressure) Mt kg-m 428.86
57 Moment (Gasket Load) Mg kg-m 152.31
58 Total Momet for Gasket operating Mop kg-m 1068.84
59 Total Momet for Gasket seating Mos kg-m 1242.2
Calculate Stresses
60 Effective hub length ho mm 57.97
61 Hub rato h/ho 0.242
62 Thickness ratio g1/g0 2.4
63 Flange factor for Intergral Flange
64 Factor (Fig 2-7.2) F 0.880
65 Factor (Fig 2-7.3) V 0.309
66 Factor (Fig 2-7.6) f 3.455
67 Factor (Fig 2-7.1) K 1.548
68 Factor (Fig 2-7.1) T 1.69
69 Factor (Fig 2-7.1) U 5.077
70 Factor (Fig 2-7.1) Y 4.62
71 Factor (Fig 2-7.1) Z 2.434
72 Factor (U/V)*h0*g0² d mm3 95240
73 Factor (F/ho) e mm 0.0152
74 Factor (t*e + 1)/T + t3/d L 0.6805
75 Operating Longitudinal Hub Stress SHo Mpa 117.49
76 Operating Radial Flange Stress SRo Mpa 22.18
77 Operating Tangential Flange Stress STo Mpa 37.87
78 Seating Longitudinal Hub Stress SHa Mpa 136.55
79 Seating Radial Flange Stress SRa Mpa 25.78
80 Seating Tangential Flange Stress STa Mpa 44.01
81 Average flange stress operating SAo Mpa 77.68
82 Average flange stress Seating SAa Mpa 90.28
83 Bolt stress operating BSo Mpa 48.26
84 Bolt stress Seating BSa Mpa 33.06
85 Flange Rigitity Based on Required Thickness
86 Flange rigitity Index, seating(rotation check) Js (<=1) 0.44
87 Flange rigitity Index, Operating(rotation check) J (<=1) 0.40
88 Flange Rigitity Based on Given Thickness
91 (1.5 x Sfd) / SHo 1.404
92 Sfd / SRo 4.959
93 Sfd / STa 2.905
94 Sfd / ((SHo + SRa) / 2) 1.575
95 Sfd / ((SHo + STa) / 2) 1.416
96 (1.5 x Sfs) / SHa 1.263
97 Sfs / SRa 4.461
98 Sfs / STa 2.613
99 Sfs / ((SHa + SRa) / 2) 1.417
100 Sfs / ((SHa + STa) / 2) 1.274
101 If above (Sr.No 91 to 100) 10 values are > 1.0, All Pass PASS
Sr No Description Notation Unit
Loads
1 Internal Pressure P Bar 10
General
2 Flange Class NON STD
3 Neck Outside Dia. 356
4 Neck plate Thickness 10
Material Properties
5 Flange Allow. at Amb. Temp Sfs Bar 1150
6 Flange Allow. at Design Temp Sfd Bar 1100
7 Bolt Allow. at Amb. Temp Sa Bar 1300
8 Bolt Allow. at Design Temp Sb Bar 957
9 Gasket Factor m 2
10 Gasket Factor y Bar 110.3
Dimension
11 Flange OD A mm 520
12 Flange ID B mm 336
13 Bolt Circle Diameter C mm 470
14 Hub Thickness at Small end g0 mm 10
15 Hub Thk at back of flange g1 mm 24
16 Hub Length h mm 14
17 Flange Thickness t mm 40
18 Nom Thk of Neck Plate tn mm 10
19 Nominal Bolt Diameter a mm 24.0
20 Number of Bolts n Nos. 16
21 Area of Bolt at Thread cm2 50.04
22 Gasket OD mm 442
23 Gasket ID mm 359

Calculations
24 Width of Gasket N mm 41.50
25 Basic gasket seating width b0 mm 20.750
26 Effective Gasket width b mm 11.4
27 Location of Gasket Load G mm 419.22
28 Axial Force on Flange F kgf 540.00
29 Bending Moment on Flange M kg-m 400.00
30 Axial Force Equivalent pressure (4F/(pi*G*G) Bar 0.391
31 Bending Moment Equivalent pressure (16M/(pi*G*G*G) Bar 2.765
32 Final Equivalent design Pressure Peq Bar 13.156
33 Total Pressure P Bar 10.0
34 Hydrostatic End Load due to pressure H kgf 18150.64
35 Contact Load on Gasket surface Hp kgf 5999.36
36 Operating bolt load Wm1 kgf 24150.0
37 Gasket seating Bolt Load Wm2 kgf 16543.2
38 Area of Bolt for Operating Am1 cm2 25.2
39 Area of Bolt for Seating Am2 cm2 12.7
40 Required Bolt Area Am cm2 25.2
41 Bolt Stress % in Operating 3.15%
42 Bolt Stress % in Seating 0.0012%
43 Is Bolt area Adequate YES
44 Flange Design Bolt Load Oper W1 kgf 24150.0
45 Flange Design Bolt Load Seat W2 kgf 48928.8
46 Radial Distance ((C-B)/2)-g1 R mm 43
47 Moment Arm (Dist. To end pressure reaction) hd mm 55
48 Moment Arm (Dist. to Face pressure Reacion) ht mm 46.19
49 Moment Arm (Dist. to Gasket load Reacion) hg mm 25.39
50 Hydrostatic End Load at flange ID Hd kgf 8866.8
51 Pressure Force on Flange Face Ht kgf 9283.8
52 Gasket Load for Operating condition HG kgf 5999.4
53 Circumferential bolt facing Bs mm 91.7
54 Bolt Spacing factor Bsc 1.0
55 Moment (End Pressure) Md kg-m 487.68
56 Moment (Face Pressure) Mt kg-m 428.86
57 Moment (Gasket Load) Mg kg-m 152.31
58 Total Momet for Gasket operating Mop kg-m 1068.84
59 Total Momet for Gasket seating Mos kg-m 1242.2
Calculate Stresses
60 Effective hub length ho mm 57.97
61 Hub rato h/ho 0.242
62 Thickness ratio g1/g0 2.4
63 Flange factor for Intergral Flange
64 Factor (Fig 2-7.2) F 0.88
65 Factor (Fig 2-7.3) V 0.309
66 Factor (Fig 2-7.6) f 3.455
67 Factor (Fig 2-7.1) K 1.548
68 Factor (Fig 2-7.1) T 1.6
69 Factor (Fig 2-7.1) U 5.077
70 Factor (Fig 2-7.1) Y 4.6
71 Factor (Fig 2-7.1) Z 2.434
72 Factor (U/V)*h0*g0² d mm3 95240
73 Factor (F/ho) e mm 0.0152
74 Factor (t*e + 1)/T + t3/d L 0.7074
75 Operating Longitudinal Hub Stress SHo bar 1174.94
76 Operating Radial Flange Stress SRo bar 221.83
77 Operating Tangential Flange Stress STo bar 374.72
78 Seating Longitudinal Hub Stress SHa bar 1365.51
79 Seating Radial Flange Stress SRa bar 257.81
80 Seating Tangential Flange Stress STa bar 435.49
81 Average flange stress operating SAo bar 774.83
82 Average flange stress Seating SAa bar 900.50
83 Bolt stress operating BSo bar 482.61
84 Bolt stress Seating BSa bar 330.60
85 Flange Rigitity Based on Required Thickness
88 Flange Rigitity Based on Given Thickness
91 (1.5 x Sfd) / SHo 1.404
92 Sfd / SRo 4.959
93 Sfd / STa 2.936
94 Sfd / ((SHo + SRa) / 2) 1.575
95 Sfd / ((SHo + STa) / 2) 1.420
96 (1.5 x Sfs) / SHa 1.263
97 Sfs / SRa 4.461
98 Sfs / STa 2.641
99 Sfs / ((SHa + SRa) / 2) 1.417
100 Sfs / ((SHa + STa) / 2) 1.277
101 If above (Sr.No 91 to 100) 10 values are > 1.0, All Pass PASS
Doc.No 0001/CAL-1
DESIGN CALCULATION
Sheet No 26 of 33
Minimum Design Metal Temperature & Impact Test Requirement as per UHA-51 (d) 1
Nozzle
Nozzle Size
Component Thk. Material MDMT o
C
(DN)
(SCH)
SHELL 10 mm S32304 -29.00
DISHED HEAD 12 mm S32304 Refer Note.2
MANHOLE+BLRF+DAVIT(N4&N5) 600 10 mm SA 240 TP 304L -196.00
AGITATOR(N1) 300 40 SA 312 TP 304L -196.00
LIQUOR IN & OUT(N2&N3) 80 40 SA 312 TP 304L -196.00
HEAT EXCHANGER (N6.1,N6.2N7.1,N7.2) 350 10 mm SA 240 TP 304L -196.00
O2 IN (N12&N13) 40 40 SA 312 TP 304L -196.00
VENT OUT (N14) 100 40 SA 312 TP 304L -196.00
SAMPLING (N16) 20 40 SA 312 TP 304L -196.00
LEVEL,TEMP.,PRESS MEASURING (N17

80 80 SA 312 TP 304L -196.00
TO N24)
SE MOE OPENING 1520 10 mm SA 312 TP 304L -196.00
Design MDMT: 20 oC
The required design MDMT of 20 °C has been met or exceeded.
Note:
1. As per UHA 51(d)(1),No impact testing is required for the following flanges when used at minimum
design metal temperatures no colder than -29 °C :
2. IMPACT TEST REQUIRED AT 20°C FOR AUSTENITIC FERRITIC DUPLEX STAINLESS STEELS
WITH THE THICKNESS ABOVE 10MM
Conclusion : As per code , Impact test required for (Refer Note.2)

Doc.No 0001/CAL-1
DESIGN CALCULATION
Sheet No 27 of 33
Radiography requirement
SL.NO. PARTICULARS REQUIREMENT
A FULL RADIOGRAPHY AS PER UW 11 (a)
1 All butt welds in the shell and heads of vessel used to contain lethal substances. NO
All butt welds in the shell and heads of vessel in which the nominal thickness [see (g)
below] at the welded joint exceeds 11⁄2 in. (38 mm), or exceeds the lesser thicknesses
2 prescribed in UCS-57, UNF-57, UHA-33, UCL-35, or UCL-36 for the materials covered NO
therein, or as otherwise prescribed in UHT-57, ULW-51, ULW-52(d), ULW-54, or ULT-
57;
3 All butt welds in the shell and heads of unfired steam boilers having a design pressure
a) Exceeding 50 Psi (350 Kpa) (see UW - 2 (c ) ) NO

b)Not exceeding 50 psi(350KPa)(see UW - 2 (c ) ) but with nominal thickness at the
NO
welded joint exceeding the thickness specified in (2) above;
All butt welds in nozzles,communicating chambers, etc.. with the nominal thickness at
the welded joint that exceed the thickness in (2) above or attached to the shell or
heads of vessels under (1),(2),or(3) above that are required to be fully
4 NO
Radiographed;however except as required by UHT-57(a), Catgories B and C butt
welds in nozzles and communicating chambers that neither exceed NPS 10 (DN250)
nor 1 1/8" (29mm) in wall thickness do not require any radiographic examination
All category A & D butt welds in the shell and heads of vessels where the design of the
5 YES
joint or part is based on joint efficiency permitted by UW -12 (a) in which case.
Category A & B welds connecting the vessel sections or heads shall be type No. 1 or 2
a) YES
Table UW - 12.
Category B or C butt welds which intersect the category A butt welds in shell or heads
b) of vessels or connect seamless shell or heads shall as a minimum meet the NO
requirements for spot radiography as accordance with UW-52.
B SPOT RADIOGRAPHY REQUIREMENT UW -11 (b)
Except as required in (a) (5) (b) above butt welded joints made in accordance with
Type No.(1) or (2) of Table UW 12 which are not required to be fully Radiography by NO
(a) above may be examined by spot Radiography.
CONCLUSION :-
1. All Butt joint in the Dish End and connected to the Shell shall be 100% radio graphed. Other Butt joint in the shell shall
be 10% radiographed. Name plate marking shall be RT 4

Doc.No 0001/CAL-1
DESIGN CALCULATION
Sheet No 28 of 33
Post Weld Heat Treatment as per UHA-32
POST WELD HEAT TREATMENT REQUIRED UNDER THE FOLLOWING CONDITIONS
As per Table UHA-32 for Materials P.NO. 10H

NOTE: For the austenitic-ferritic wrought or cast duplex stainless steels
postweld heat treatment is neither required nor prohibited
REQUIREMENTS FOR POST FABRICATION HEAT TREATMENT DUE TO STRAINING

As per UHA-44, the cold formed areas of pressure-retaining components manufactured of
austenitic alloys shall be solution annealed by heating at the temperatures given in Table UHA-44
Plate Thickness (t nom) 10 mm

Head thickness (t nom) 12 mm
Final Mean Radius (Rf) 955 mm
Original Mean Radius equal to infinity (Ro) ∞
1 % Extreme Fibre Elongation (Head)

75 x t nom 1-Rf
= x
Rf Ro
= 2.57%
2 % Fibre Elongation (Shell)

50 x t nom 1-Rf
= x
Rf Ro
= 0.52%
CONCLUSION :- PW
Extreme Fibre Elongation is Not exceeded. And Austenitic feritic steel
as mentioned in UHA 44 Table do not required PFHT

DESIGN OF SKIRT Seismic Load Date 2.3.2016
DESIGN OF SKIRT AS PER IS:875 (Part 3) : 1987 & IS:1893 (Part 1) : 2002
Self weight of the vessel with skirt and puff insulation = 8.75 T = 85.87 KN
Self weight of the content = 17.00 T = 166.77 KN
Total Weignt (W) = 25.75 T = 252.64 KN
Seismic intensity = severe for Seismic Zone III (considering Location – Bhadrachalam, Telangana )
OD of the vessel = 1.920 m
ID of the vessel = 1.900 m
Height of centre of gravity from base (C.G of the vessel) = 4.305 m
Radius of Gyration (re) = (1/4) x sqrt (Do 2 + Di2) '= (1/4)*SQRT(1.922 + 1.92) = 0.675 m
Height of the structure above the base (h') = 8.600 m
Slenderness ratio (k) = h'/re K= 8.6/0.675 = 12.74
Coefficient CT corres to k from the Table-6 (clauses 5.3.2 and 5.3.4) = 26.24
Coefficient Cv corres to k from the Table-6 (clauses 5.3.2 and 5.3.4) = 1.14
Total weight of the vessel (Wt) = 252.64 KN
Modulus of Elasticity of the Material (Es) = 200000000 KN/m2
Area of cross-section at the base of the structural shell (A) = 2 x pi x r x t '=0.06 m^2
A = 2*3.14*1.910 *.01
Acceleration due to gravity (g) = 9.81 m/s2
Period of Free vibration (T) = CT x sqrt ( (Wt*h')/(Es*A*g)) = 0.125 seconds
T = 26.24 * sqrt ((313.92*8.6) / (2E8*0.06*9.81))
Zone Factor (Z) (from Table-2 pg.no.16) = 0.16
Importance Factor (I) (from Table-6 pg.no.18) = 1.50
Response Reduction Factor ( R ) (from Table-7 pg.no.23 & I/R is not greater than 1) = 1.50
I/R Ratio = 1.5/1.5 = 1.00
Average response acceleration coefficient (Sa/g) for T value = 1+15T = 1+15*0.125 = 2.88
Design Horizontal seismic coefficient (Ah)= ah = (Z/2) x (I/R) x (Sa/g) = 0.230
'=(0.16/2)*(1)*2.88
The Design shear force (V) at the Base = Cv ah Wt '= 1.14*0.230*313.92 = 66.24 KN
The Design Bending Moment at the Base (M) = ah Wt h '= 0.230*313.92*4.75 = 250.15 KN-m
Shear @ base due to seismic = 66.24 KN
Moment @ base due to seismic = 250.15 KN-m
From the above 2 cases the seismic Force governs,
Hence Moment @ Base = 250.15 KN-m

DESIGN OF SKIRT Wind Load Date 2.3.2016
DESIGN OF SKIRT AS PER IS:875 (Part 3) : 1987 & IS:1893 (Part 1) : 2002
Self weight of the vessel with skirt and puff insulation = 8.75 T = 85.87 KN
Self weight of the content = 17.00 T = 166.77 KN
Total Weignt (W) = 25.75 T = 252.64 KN
Design wind speed (VZ) as per IS:875 (part 3) - 1987 clause 5.3 (considering Location - Bhadrachalam, Telangana) :
Basic wind speed as per Fig 1 (Vb) = 54 m/s
Probability Factor (Risk coefficient) as per Table 5.3.1 (k1) = 1.07
Terrain, height and structure size factor as per table 5.3.2 (k2)(Category 3,class A) = 0.91
Topology Factor as per table 5.3.3 (k3) = 1.00
Design wind speed at any Height (VZ) = Vb x k1 x k2 x k3 =54 * 1.07 * 0.91 * 1 = 52.58 m/s
Design wind Pressure at Height z (Pz) = 0.6 Vz 2 '= 0.6 * 52.58 = 1.66 KN/m2
Shape Factor ( = 0.80 clause 6.2.2.8) = 0.80
Outer Dia of the Vessel ( Do ) = 1920.00 mm
Height of the Vessel ( H ) = 8600.00 mm
Projected Area = Do x H = 16.51 m2
Wind Force = Shape Factor x Projected Area x Wind Pressure = 21.91 KN
= 0.8*16.51*1.66
Centre of gravity of the projected area from the Base (h) = 4.04 m
Moment at the Base (MT) = 88.41 KN-m
Shear @ base due to wind = 21.91 KN
Moment @ base due to wind = 88.41 KN-m

DESIGN OF SKIRT Date 3/2/2016
DESIGN OF SKIRT
Outside dia of the skirt (D) = 1920.00 mm = 75.59 in

Efficiency of skirt to head Joint = 0.70
(E=0.7 for butt weld , E=0.45 for lap weld)
Moment at the skirt to head joint (MT) = 250 KN-m = 184500 ft-lb
Outside radius of the skirt ( R ) = 960.00 mm = 37.80 in
Stress value of the head or skirt material whichever is smaller (S) = 21750 psi
Wt of the tower above the skirt to the head joint in operating condn.(W) = 32000 kg = 70548 lb
Required thk of the skirt for seismic force (t) = (12*MT) / (R^2*Pi*S*E)
t = (12*252952)/(37.80 ^2*3.14*20000*0.60) = 0.03 in
Reqd thk of skirt for wt. above the skirt-head joint (t) = (W) / (D*3.14*S*E)
t = (70548)/(75.59*3.14*21750*0.70) = 0.02 in
Total thk required for the skirt considering the seismic force & self wt. (t) = 0.05 in = 1.32 mm
Here we are selecting the skirt thk = 10 mm > 1.62 mm

Hence satisfactory.

DESIGN OF SKIRT Date 2.3.2016
DESIGN OF ANCHOR BOLT WHEN THE VESSEL IS FULL& SEISMIC SHEAR
Assume no of bolts used (N) = 16 nos

The value of seismic shear at base ( Fs) = 66.24 KN
seismic shear for one bolt ,fs = Fs/N '= (82.3X1000)/16 = 4140.09 N
shear stress value of bolt (Zs) = 80.00 N/mm2
factor,k = 1.25
Required area for one bolt,a = (fs/(Zs*k)
A = (5144.36/(80.00*1.25) = 41.40 mm2
Dia of one bolt,d = sqrt(a*4/pi())
d= sqrt ( 51.44*4/3.14) = 3.63 mm
Provide M24 bolts in 16 numbers
DESIGN OF BASE PLATE WHEN THE VESSEL IS FULL & SEISMIC SHEAR
Weight of the vessel with skirt = 8.75 T = 85.87 KN

Content weight = 17.00 T = 166.77 KN
Total weight (self) ws = 25.75 T = 252.64 KN
Lining weight (puf insuln)wl = 0.00 T = 0.00 KN
Seismic load wseismic = 66.24 KN
Permissible bearing stress on the foundations (zc) = 5000.00 KN/m2
Let the width of the base plate ( b ) = 225 mm
Critical section of the base plate ( l ) = 100 mm
Permissible bending stress on the slab bases (zbs) = 185.00 N/mm2
Diameter of the skirtdc = 1.950 m
The maximum compressive force per unit circumferential

length of the
plateFc=((ws+wl)/(pi*dc))+((4*wseismic)/(pi(dc^2)))
= ((252.64+0.00)/(3.14*1.950))+((4*66.24)/3.14(1.950^2))) =63.45 kn/M2
The width of the base plate ,m =Fc / zc = (63.45/5000)*1000 =12.69 mm
Provide width of the base plate,b = 225 mm
Compressive stress on the base plate,Qs = (Fc*1000)/(1000*b)
Qs = (63.45*1000)/(1000*225) = 0.28 N/mm2
Compressive force per mm width of the base plate( fc) = 0.28 N/mm
Bending moment of base plate due to fc,Mc = fc*l^2/2
Mc = 0.28*1002/2 = 1400.00 N-mm
Thickness of base plate,t =sqrt(6*Mc/Zbs) + c.a
t= sqrt(6*1400/185)+0 = 6.73 mm
Provided 36 mm thickness base plate
Hence Satisfactory.

Design Of Lifting Lug Date 2.3.2016
As per “The Pressure Vessel Handbook by Dennis R. Moss”
Material Specification of Lifting Lug : SA-240 304L

Maximum erection Weight of Vessel (W) : 8753 kg
Dynamic load factor (f) :2
No. of Lifting Lugs (n) :3
Ultimate Tensile Strength of Lug Material (Ts) : 485 Mpa
Yield Strength of Lug Material (Ys) : 170 Mpa
Allowable Shear Stress for Lug Material (Ss)
= 0.45 * Ys : = 0.45*170 = 76.5 Mpa
Allowable Shear Stress for the Weld as per
UW-15(c) of ASME Section VIII Div. 1(Sw) = 0.49 * TS
: = 0.49*485 = 237.65 Mpa
Load at Lug (F) = (W * f * 9.81) / n : = (8753*2*9.81)/3 = 57244.62 N
Diameter of hole in lug (d) : 40 mm
Edge radius of lug from center of hole (Er) : 50 mm
Thickness of Lifting Lug (t) : 25 mm
Width of lug at base (wl) : 170 mm
Shear Area at Lifting Lug Hole (As) = (Er - (d / 2)) * t : = (50-(40/2))*25 = 750 mm2
Allowable Shear load lug material (Fs) = As * Ss : = 750*76.5 = 57375 N
Since F < Fs, Lug cross section is adequate
Total length of lug weld (Lw) = 2 * wl + 2 * t : = 2*170+2*25 = 390 mm
Minimum Lug weld fillet size (Leg) : 10 mm
Lug weld fillet throat length (Wth) = 0.7 * Leg : = 0.7*10 = 7 mm
Total Lug weld shear Area (Wsa) = Wth * Lw : = 7*390 = 2730 mm2
Allowable shear load for the weld ( Fsw) = Wsa * Sw : = 2730*237.65 = 648784.5 N
Since F < Fsw, Lug attachment fillet size is adequate
Actual Capacity of each Lug = Min (Fs, Fsw) : 57375 N = ~5848 kg

PREPARED PREPARED APPROVED
Doc.No 0001/CAL-1
DESIGN CALCULATION Sheet No 15
DISHED HEAD THICKNESS CALCULATION
Design pressure (P) : 10.00 bar(g) Design Temperature : 200 °C

Head Material : SA 240 S32304 Joint Efficiency (E): 100 %
Corrosion Allowance (CA): 0.00 mm Max allowable stress (S) : 1500 bar
External Corrosion Allowance(Ext.CA) : 0.00 mm Thin Out : 2 mm
Inside Diameter (ID) : 1900 mm
Inside Diameter (Corroded)(D) : 1900 mm
Outside Diameter (D0) : 1924 mm
Ext. Nominal tn : 12.00 mm Head depth(ho): = 475 mm
External Pressure Data(for full vacuum condition)
Design Pressure (Pa) : 1.01325 bar(a)
Ext. Nominal tn : 10.00 mm
t( tn - CA - Ext. CA - Thin Out) : 6.34 mm
Factor A(ASME Sec II Part D fig G) : 0.0005
Factor B (from HA-6 Chart): 455.00 bar(g)
Design Thickness Calculations for Internal Pressure as Per UG -32 (d)
ts= Minimum specified Thickness after forming = 10mm.
L= Inside crown radius = 1742 mm.

ts/L = 8/1742 = 0.004mm > 0.002 , Hence the Following formula can be used for min. required thickness,
PD 10 X 1900
t= + CA + Ext.CA + Thin Out = '=+0+0+0 = 8.34 mm
2 S E - 0.2 P (2X1500X1)-(0.2 X10)
Maximum External Pressure Calculation per UG-33
RO= K0 *DO Ko= 0.9 (from Table UG -33.1) Do/2ho= 2
=0.9 x 920= 1732 A= 0.125 =0.0005
Ro/t
B 455.00
Pa(max) = = = 1.67 bar
Ro/t 273.22825
Result
Nominal Head Thickness Selected = 12.00 mm

Required Thk of the Head (incl. of all allowance) = 8.34 mm
Minimum Required Thk of the Shell (incl.of all allowances) =5.50 mm (As per UG-16(b))
Note:
1) Pressure acting on concave side of Dished head.
2) Provided Head thickness = 12 mm, Minimum thickness after forming = 10 mm

White Liquor Oxidizer Design Calculation

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EQUIPMENT NAME : WHITE LIQUOR OXIDIZER

CLIENT : ANDRITZ TECHNOLOGY

ENGINEERING & SUPPLY : MABEL ENGINEERS PRIVATE LIMITED

DESIGN CONSTRUCTION CODE : ASME BOILER & PRESSURE VESSEL CODE

CODE STAMPING : ASME STAMP WITH “U” DESIGNATOR

MANUFACTURER'S NAME : MABEL ENGINEERS PRIVATE LIMITED

PREPARED CHECKED APPROVED

S.No. DESCRIPTION Sheet No.

3 Design Validity of Drawings & Calculation 3 of 33

4 Applicable Codes and Standards 4 of 33

8 Maximum Allowable working pressure 8 of 33

9 Static Head & Nozzle static Head 09-10 of 33

10 Corrosion allowance / Drain opening 11 of 33

11 Allowable stress of material 12 of 33

12 Minimum required thickness of cylindrical shell 13 of 33

13 Minimum required thickness of 2:1 Ellipsoidal head 14 of 33

14 Minimum required thickness of Of nozzles 15 - 16 of 33

15 Inspection opening and reinforcement requirement 17 of 33

17 Weld Size & Strength calculation 19 of 33

18 Shell to head Transition requirement 20 of 33

19 Hydrostatic test pressure requirement 21 of 33

20 Flange Rating check 22 of 33

21 Non standard Flange calculation 23-25 of 33

22 Minimum design metal temprature & Impact test requirement 26 of 33

24 Post weld heat treatment & Post forming Heat treatment 28 of 33

27 Skirt support design 31 of 33

28 Skirt Base plate & Anchor Bolt design 32 of 33

29 Design of Lifting Lug 33 of 33

PREPARED CHECKED APPROVED

Design calculation/ Revision Design

PREPARED CHECKED APPROVED

I CODES & STANDARDS AVAILABILITY

1 ASME SEC. VIII DIV.1 ED.2013 YES

2 ASME SEC. II PART-A ED.2013 YES

3 ASME SEC. II PART-D ED. 2013 YES

4 Pipe Flanges and Flanged Fittings ASME B16.5 – 2009 YES

Welded and Seamless Wrought Steel Pipe

Factory Made Wrought Buttwelding Fittings

Factory Made Wrought Buttwelding Fittings

PREPARED CHECKED APPROVED

Sl.No CUSTOMARY UNIT SI UNIT

1 1 Inch 25.4mm (2.54 cm)

3 1 pound (lbm) 0.4535924 Kg

4 1 pound (lbf) 4.448222 N

14.2233 PSI ie 14.2233 lb/in²

7 1 PSI 0.006894757 Mpa

8 1 PSI 6.894757 Kpa

9 1 PSI 0.06894757 Bar

10 in-lb 112.98484 N-mm

11 ˚F 5/9˚C (For Temp. Diifrence only)

12 ((˚Cx9/5)+32)˚F ˚C (Not For Temp. Diifrence)

PREPARED CHECKED APPROVED

Design Contruction Code : ASME SECTION VIII -DIV 1 ,ED.2013

Design Pressure (Internal) : 10 bar 1 Mpa

Design Pressure (External) : 1 bar 0.1 Mpa

Operating Pressure : 6.7 bar 0.67 Mpa

MAWP (Internal) : 10 bar 1 Mpa

MAWP (External) : 1 bar 0.1 Mpa

Design Temperature : 200 °C

Operating Temperature : 133 °C

Hydro static Test Pressure : 14 bar 1.4 Mpa

Hydro static Test Temperature : Not more than 48 °C