Pressure Vessel Design (Shell, Head & Nozzle) - by Abdel Halim Galala

DESIGN CALCULATIONS OF PRESSURE VESSEL Page : 5 of 126
According to ASME Code, Section VIII, Division 1, Edition 2001, Addenda 2002 Sheet : 1 of 1
Designed by : Eng. Abdel Halim Galala, Design General Manager (assist.) Rev. : 1
Project : Design & Procurement of ASME Pressure Vessel Date : 18.2.2004

Job Name : Demineralization Plant Job No. : 7434-33
Serial No. : 7434-33-U-2006 Dwg. No. : 7434-33-3A, Rev. 1 Client : APRC
Vessel : Deputanizer Reflux Receiver Drum Item No. : 1-D-5 Capacity : 10.152 M3 Type : Horizontal
D. Contents. Description Page

A. Title. Page : 1 of 126
B. Copyright. Page : 3 of 126
C. Revision Description. Page : 4 of 126
D. Contents. Page : 5 of 126
E. Applicable Loading Considered in Design. Page : 6 of 126
F. Impact Test Requirements. Page : 7 of 126
G. Standarad ASME B16.5 Flange Rating Class. Page : 7 of 126
H. Cylindrical Shell Thickness. Page : 8 of 126
I. Check of Cylindrical Shell Thickness for External Pressure, FV. Page : 12 of 126
J. Ellipsoidal Head Thickness Under Internal Pressure. Page : 13 of 126
K. Maximum Working Pressure, MWP (New/cold & Operating/corroded). Page : 14 of 126
L. Check of Ellipsoidal Head Thickness for External Pressure (Convex Side), FV. Page : 15 of 126
M. Nozzle Neck thicknesses & Nozzle Openings Compensation : Thk., MM

M1 N11 1-1/2" 300# WNRF Sch. XXS 10.16 Page : 16 of 126
M2 N8 24" 300# WNRF Sch. 30 14.27 Page : 21 of 126
M3 Leg 20" Sch. 30 12.7 Page : 26 of 126
Integral Type Flange (Blind) N1 8" 300# Thickness Calculation Page : 36 of 126
M9 N3,N4&N7 2" 300# WNRF Sch. XXS 10.16 Page : 65 of 126
M10 N6&N17 1-1/2" 300# WNRF Sch. XXS 9.09 Page : 70 of 126
M11 N16 1" 300# WNRF Sch. XXS 10.16 Page : 75 of 126
M12 N5A,N5B&N12 1-1/2" 300# WNRF Sch. XXS 10.16 Page : 79 of 126
M13 N10A& N10B 1/2" 300# WNRF Sch. XXS 7.47 Page : 85 of 126
N. Design of Saddle Supports. Page : 90 of 126

O. Lowest MDMT Without Impact Test. Page : 97 of 126
P. Radiography. Page : 110 of 126
Q. Hydrostatic Test Pressure. Page : 110 of 126
R. Post Weld Heat Treatment (PWHT). Page : 110 of 126
S. Vessel Weight Calculation. Page : 111 of 126
T. Sresses in Vessel on Two Saddle Supports. Page : 114 of 126
U. Check of the Anchor Bolts Due to Seismic and Wind Loading. Page : 122 of 126
V. Lifting Lugs Thickness Calculations. Page : 123 of 126
W. Mesh Pad (Demister) Calculations. Page : 125 of 126
X. References. Page : 126 of 126
Designed by : Eng. Abdel Halim Galala, Design General Manager (assist.) Page : 2 of 126

E. Applicable Loading Considered in Design. [UG-22 & UG-98]
I. By considering UG-22 :
1. The loadings to be considered in design of vessel shall include the following :
a. Internal design pressure (see item II below).
b. Weight of the vessel and contents under test conditions.
c. Attachment of vessel supports such as lifting lugs and saddles.
2. No expected effect for superimposed static reactions such as piping.
There is no attached equipment such as motors, machinery, other vessels,
lining and insulation.
3. The effect of the following loadings is considered negligible and/or not applicable :
a. Cyclic and dynamic reactions due to pressure for thermal variations.
b. Wind, snow, and seismic reactions.
c. Impact reactions due to fluid chock.
d. Temperature gradients and differential thermal expansion.
II. By considering UG-21 & UG-98 :

The max. allowable working pressure for a vessel part is the max.internal
pressure at the highest point of vessel.
Since the vessel is intended to be erected horizontaly, the static head
equals almost the ID and the hight of leg :
Max. Operating Pressure 227.3 PSIG 16 Kg/cm2G

Internal design pressure, P (MAWP) (at highest point of vessel) 257 PSIG 18 Kg/cm2G
External design pressure, Pex 0 PSIG 0 Kg/cm2G
Vessel ID 61.2598 INCH 1556 MM

Max. leg height = 12 + 12 + 503 + 2 + 165 27.3228 INCH 694 MM
Max. height of drain N4 = 12 + 12 + 502 + 2 + 165 + 200 35.1969 INCH 894 MM
Water sp. gr. 1

Fluid sp. gr.at 15 oC 0.5
Max. hydrostatic head at internal bottom of vessel 2.21023 PSIG 0.1556 Kg/cm2G
Max. hydrostatic head at bottom of leg 3.19602 PSIG 0.225 Kg/cm2G
Max. hydrostatic head at drain N4 3.48011 PSIG 0.245 Kg/cm2G
2
Max. pressure for calculation at internal bottom of vessel 257.892 PSIG 18.1556 Kg/cm G
2
Max. pressure for calculation at bottom of leg 258.878 PSIG 18.225 Kg/cm G
2
Max. pressure for calculation at outlet drain N4 259.162 PSIG 18.245 Kg/cm G

F. Impact Test Requirements. [UG-22 & UG-98]

Impact test is not mandatory for the following pressure vessels materials :
I. Pressure Parts.
a. Main Vessel Components : P-No. Group No. Curve
a. Shell : ASME SA516 Grade 70 1 2 D
b Heads : ASME SA516 Grade 70 1 2 D
c. Flanges : ASME SA 105 1 2 B
d. Nozzle Necks : ASME SA 106 Grade B 1 1 B
e. Fittings, Tees : ASME SA 234 Grade WPB 1 1 B
b. Stud Bolts & Nuts :

f. Stud Boltshell ASME SA 193 Grade B7 UNS No. G41400 [Size < 2-1/2"]
g. Nuts ASME SA 194 Grade 2H
II. Non-Pressure Parts.

a. Saddle plate : ASME SA516 Grade 70 1 2 D
b. Lifting lugs & Pads : ASME SA516 Grade 70 1 2 D
Thickness of vessel components :

- Shell & Heads ASME SA516 Grade 70 0.9 INCH 22 MM
- Max. Nozzle Necks Thk. ASME SA 106 Grade B 0.56181 INCH 14.27 MM
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Where the MDMT is 10 F -12 C
in accordance with UG-20(f), UCS-66 and FIG. UCS-66, no impact test is required.
Please refer pages from Page : 97 of 126
Impct Test is not required as per Code,

but is required as a client request.
G. Standard ASME Flange Rating Class.

1. Standard ASME B16.5 welded neck flanges shall be used.
2. For standard flange, Carbon Steel material in accordance
with ASME SA105, P-No. 1, Group No. 2, and for MAWP 255.682 PSIG 18 Kg/CM2G
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and Design temp. 149 F 65 C
The rating of flanges shall be 150# class, which satisfys the requirements of
Table 2 of ASME B16.5-1996.
3. As a client request, the rating shall be 300#

H. Cylindrical Shell Thickness Under Internal Pressure [UG-27(c)]
Shell material, Killed Carbon Steel, ASME SA516 Grade 70

Normalized & Notch Toughness Tested
Shell material Specifications [Table 1A, Suppart 1, ASME Sec. II, Part D]
P-No. 1
Group No. 2
External Pressure Chart No. CS-2
Vessel Inside Diameter, D 61.2598 INCH 1556 MM

Shell Inside Diameter, D 61.2598 INCH 1556 MM
Shell Inside Radius, Ri 30.6299 INCH 778 MM
Shell length from Tangent-to-Tangent (T/T), L 189.764 INCH 4820 MM
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Max. Design Temperature 149 F 65 C
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Min. Design Metal Temperature, MDMT 10 F -12 C
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Max. Operating Temperature 122 F 50 C
Max. Operating Pressure 227.273 PSIG 16 Kg/CM2G

Max. Internal Design Pressure, P (MAWP) 255.682 PSIG 18 Kg/CM2G
External Design Pressure (Full Vacuum) Not Applicable 0 PSIG 0 Kg/CM2G
Shell Inside Diameter, D 61.26 INCH 1556 MM

Shell Inside Radius, R 30.63 INCH 778 MM
Static Head = Vessel Diameter 1.556 M
Static Head Pressure (water head x sp. gr. 1.0) 2.216 PSIG 0.156 Kg/CM2G
Internal Design Pressure at bottom of vessel, 257.898 PSIG 18.156 Kg/CM2G
Max. Allowable Stress @ Design Temp.(65 oC), S 20000 PSIG 1408 Kg/CM2G
Max. Allowable Stress @ Test Temp.(40 oC), St 20000 PSIG 1408 Kg/CM2G
[Table 1A, SubPart 1, ASME Sec. II, Part D]
Hydrostatic Test Pressure, Ph = 1.3 x MAWP x (St/S) [UG-99(b)] 332.386 PSIG 23.4 Kg/CM2G
Hydrostatic Test Pressure, Ph = 1.5 x MAWP x (St/S) [Client request] 383.523 PSIG 27 Kg/CM2G
Corrosion Allowance, C [UG-25] 0.236 INCH 6 MM

Joint Efficiency, E [TABLE UW-12] 0.85
[Spot Radiography], [Table UCS-57] 15%

H. Cylinderical Shell Thickness Under Internal Pressure (cont.) [UG-27(c)]
Value of 0.385 SE [UG-27(c)(1)] 6545 PSIG 460.768 Kg/CM2G

Since P does not exceed 0.385 SE, Use Thin Wall Equation:
[1] Min. Wall Thickness for Longitudinal Joints,
t1 = PR / (SE - 0.6P) [UG-27(c)(1)] 0.469 INCH 11.913 MM
Value of 1.25 SE [UG-27(c)(1)] 21250 PSIG 1496 Kg/CM2G

Since P does not exceed 1.25 SE, Use Thin Wall Equation:
[2] Min. Wall Thickness for Circumferential Joints,
t2 = PR / (2SE + 0.4P) [UG-27(c)(2)] 0.232 INCH 5.893 MM
The min. wall thickness shall be the greater of t1 or t2 0.469 INCH 11.913 MM
By Adding Corrosion Allowance to Wall Tickness, t 0.705 INCH 17.907 MM
Use Thickness of Construction, t (Adopted thickness) 0.866 INCH 22 MM
Corroded Thickness = Adopted thk. - Corrosion allowance 0.63 INCH 16 MM
In case of using shell fab. from pipe '20" Pipe nominal thickness, t (Sch.40) 0.472440945 INCH 12 MM
20" Pipe nominal thickness under tolerance tn = t - 0.125 t 0.472440945 INCH 12 MM
20" Pipe Corroded Thickness = tn - Corrosion allow ance 0.236440945 INCH 6 MM
Using 20" pipe sch. 40 is OK
By using APPENDIX 1-1 (In terms of the Outside Diameter) :
tm = P Ro / (SE + 0.4 P) 0.458 INCH 11.633 MM
Thickness adjusted for w all thickness tolerance :
t = tm / (100%-12.5%) 0.523 INCH 13.284 MM
By Adding Corrosion Allow ance to Wall Tickness, t 0.759 INCH 19.284 MM
Using 20" pipe w ith commercial w all thickness, sch. 40 is OK
Ladders and Platforms N.A.

Vessel saddle supports Yes Page : 90 of 126
Hot/cold Insulation N.A.
Post Weld Heat Treatment, PWHT Not required per Code
Page : 110 of 126
Impact Test Per Code Page : 7 of 126
Note. Impact test is required as a client request.

H. Check of Shell Thickness Under Internal Pressure

[ For horizontal pressure vessels, with supplemental loading ] (vessel weight & hydrostatic liquid content)
[APPENDIX L-2.2.2]
Vessel OD 61.2598 INCH 1600 MM
Vessel Wall Thickness in the Corroded Condition, t 0.63 INCH 16 MM
Vessel I.D. in the Corroded Condition, 2R = OD - 2 t 59.9998 INCH 1568 MM
Shell length from Tangent-to-Tangent (T/T), L 189.764 INCH 4820 MM
Shell Length from W.L.- to - W.L, L' 186.614 INCH 4740 MM
Joint Efficiency (Longitudinal Seams), E 0.85
Joint Efficiency (Circumferential Seams), E 0.85
Weight of Vessel, W 16377.3 lb 7428 Kg
Weight of Contents, Wc 22383.2 lb 10152 Kg
Total Weight of Vessel and Contents, Wt 38760.5 lb 17580 Kg
Assume a Total no. of Saddles 2
Reaction at each Saddle, Q 19380.3 lb 8790 Kg
Head (Cap) Depth - to - T.L, [Table 8, ASME B16.9-1993] 15.315 INCH 389 MM
Saddle - to - T.L., A 22.047 INCH 560 MM
Material to Chart for Compressive Stress,
[ FIG.CS-2 CHART, SUBPART 3 , ASME SEC.II , PART D ]
Shell, Ro 31.4961 INCH 800 MM
N.B. See vessel drawing layout, Page : 91 of 126
* Here three cases must be investigated:

Case 1. Circumferential Stress due to Internal Pressure,
t = PR / ( SE-0.6 P) [UG-27C(1)] 0.465 INCH 11.811 MM
Case 2. Longitudinal Tensile Strength due to Bending
( at the midpoint between the saddles) must be
added to the longitudinal Stress due to Internal
Pressure.
[ APPENDIX L-2.2.2]
t 0.238 INCH 6.045 MM
N.B. Circumferential joint at center of vessel is the point of max. positive moment.
Max. negative moment is at supports but there is no joint there.Other circumferential joint
must be investigated using moment at the joint in calculating the compined stresses.

H. Check of Shell Thickness Under Internal Pressure (cont.)

[ For horizontal pressure vessels, with supplemental loading ] (vessel weight & hydrostatic liquid content)
[APPENDIX L-2.2.2]
Case 3 . Longitudinal Compressive Stress due to Bending.

First determine the max. allowable compressive stress :
Factor A = 0.125 / (Ro / t ) [UG-23(b)] 0.00344
Therefore, B [SUBPART 3 OF ASME SEC.II, PART D, FIG.CS-2] 16000 PSIG 1126.4 Kg/CM2G
NOTES:
1. No need to calculate the value of B by equation B = AE / 2 ,
since the value of A falls under the applicable Material/Temp. line.
[ Suppart 3 of ASME Sec.II, Part D, Fig. CS-2]
2. The general equatioin for thickness is the same as for

longitudinal tensile stress except the pressure portion drops
out since the most severe condition occurs when there is no
pressure in the vessel .
3. The joint efficiency for butt-welded joints shall be taken as

unity when investigating longitudinal compression. [UG-23(b)]
[ APPENDIX L-2.2.2]
Thickness , t 0.00902 INCH 0.229 MM


I. Check of Shell Thickness for External Pressure (Full Vacuum)
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Design Temperature 149 F 65 C
For external pressure on cylinder, use UG-28 and Subpart 3.
Determine the effective length of shell without stiffening rings, L
Shell length from Tangent-to-Tangent (T/T), L1 189.764 INCH 4820 MM

Internal Height of Elliptical Head 2:1, h = ID/4 15.315 INCH 389 MM
Head Wall Thickness, th 0.7874 INCH 20 MM
Internal Height of Ellipsoidal Head 2:1, ho = h + th 16.1024 INCH 409 MM
Effective shell length without stiffening, L = L1 + 2/3 ho 200.499 INCH 5092.667 MM
Assume t for internal pressure (at corroded condition) 0.62992 INCH 16 MM

Do = ID + 2 t 62.7559 INCH 1594 MM
L / Do 3.1949
Do / t 99.625 > 10
Since Do/t > 10, use UG-28(c)(1)

a. Enter Fig. G with L / Do and read across to sloping line of Do/t
Read factor A 0.00038
b. Enter Fig. CS-2 with A (to find factor B), which falls under the curve. 5500 PSI 387.2 Kg/CM2G
Follow step (6) of UG-28(c)(1), and calculate the value of max. allowable
external working pressure, PA = 4B / 3 (Do / t) 73.6094 PSI 5.1821 Kg/CM2G
Change t untill PA > 15 PSI (full vacuum) 15 PSI 1.056 Kg/CM2G
OK
E = Modulus of elasticity at design temp. 2.9E+07 PSI 2024352 Kg/CM2G
at amp. temp. 2.9E+07 PSI 2055680 Kg/CM2G
Notes.
1. For value of A falling to the left of the material-temp. line, the value
of Pa can be calculated as follows : Pa = 2 A E / 3 (Do /t)
2. For L/Do > 50, use L/Do = 50

For L/Do < 0.05, use L/Do = 0.05
3. For Do/t > 10, use UG-28(c)(1)

For Do/t < 10, use UG-28(c)(2)

J. Ellipsoidal Head Thickness Under Internal Pressure [UG-32(f)]
Head material, Carbon Steel ASME SA516 Grade 70

Head type [Seamless] Ellipsoidal 2:1
Head material Specifications [Table 1A, Suppart 1, ASME Sec. II, Part D]
P-No. 1
Group No. 2
External Pressure Chart No. CS-2
Head ID 61.2598 INCH 1556 MM

Head OD [ASME B16.5-1996] 62.9921 INCH 1600 MM
Head Outside Radius 31.4961 INCH 800 MM
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Min. Design Metal Temperature, MDMT 10 F -12 C
Max. Allowable Working Pressure, MAWP 257.898 PSIG 18.156 Kg/CM2G
Operating Pressure 227.273 PSIG 16 Kg/CM2G
Internal Design Pressure, P 257.898 PSIG 18.156 Kg/CM2G
Head Skirt Inside Diameter, D 61.26 INCH 1556 MM
Head Inside Radius, L ( ri ) 30.63 INCH 778 MM
Max. Allowable Stress @ Design Temp.(60 oC), S 20000 PSIG 1408 Kg/CM2G
Max. Allowable Stress @ Test Temp.(40 oC), St 20000 PSIG 1408 Kg/CM2G
[TABLE 1A , SUBPART 1 , ASME SEC. II , PART D]
Hydrostatic Test Pressure, Ph = 1.3*MAWP(St/S) [UG-99(b)] 335.27 PSIG 23.603 Kg/CM2G
Corrosion Allowance, C [UG-25] 0.23622 INCH 6 MM

Joint Efficiency, E (Seamless & Full Radiography) [TABLE UW-12] 0.85
Outside Diameter of Head, Do 62.9921 INCH 1600 MM

Outside Radius of Head, Ro 31.4961 INCH 800 MM
Value of 0.665 SE 11305 PSIG 795.872 KG/CM2G

Since the value of 0.66SE > P, Use Thin Wall Equation for
Calculating the Min. required Thickness of Head, t:
t1 = PD / (2SE-0.2P) [UG-32(d)] (1) 0.46538 INCH 11.82059 MM
Compare to Thickness of Seamless Spherical Shell :
Ps = 0.665 SE 11305 PSIG 795.872 KG/CM2G
Since P < Ps, Calculate Thickness for thin Wall Spherical Shell:
t2 = PRo/(2SE+0.8P) [APPENDIX 1-1] (2) 0.23746 INCH 6.031587 MM
For thin Wall ellipsoidal 2:1 head :
t = PD/(2SE-0.2P) [UG-32(d)] 0.46538 INCH 11.82059 MM

J. Ellipsoidal Head Thickness Under Internal Pressure (cont.) [UG-32(f)]
Head Thickness due to Internal Pressure, t = MAX ( t1 , t2) 0.46538 INCH 11.82059 MM
By adding Corrosion Allowance to Wall Thickness, 0.7016 INCH 17.82059 MM
Use Thickness of Construction, t (Adopted thickness) 0.787 INCH 20 MM
[ t Represents the Min. Thickness after Forming ]
Corroded Thickness = Adopted thk. - Corrosion allowance 0.55118 INCH 14 MM
In case of using '20" Cap nominal thickness, t (Sch. 40) 0.787401575 INCH 20 MM
20" Cap nominal thickness under tolerance tn = t - 0.125 t 0.787401575 INCH 20 MM
20" Cap Corroded Thickness = tn - Corrosion allow ance 0.551181102 INCH 14 MM
Using 20" Cap sch. 80 is OK
Required Head Thickness :

Head tr = PD / (2SE - 0.2 P) 0.46538 INCH 11.82059 MM
K. Maximum Working Pressure, MWP (New & Operating)
a. For Shell :
MWP, New & cold (20 MM) P = SE t /(R + 0.6 t) [UG-27(c)(1)] 472.622 PSIG 33.273 Kg/CM2G
MWP, Operating & corroded (14 MM) P = SE t /(R + 0.6 t) 345.395 PSIG 24.316 Kg/CM2G
b. For Head :
MWP, New & cold (20 MM) P = 2SE t /(D + 0.2 t) [UG-32(d)(1)] 435.675 PSIG 30.67149 Kg/CM2G
MWP, Operating & corroded (14 MM), P = 2SE t /(D + 0.2 t) 305.362 PSIG
[ 21.49751 Kg/CM2G

L. Check of Ellipsoidal Head Thickness for External Pressure (Convex Side), (Full Vacuum)
[UG-33(d)]
Assumed corroded thickness of head, t 0.55118 INCH 14 MM
Outside diameter of the head skirt, Do 62.3622 INCH 1584 MM
The equivalent outside spherical, Ro = Ko Do [UG-33(b)] 54.342 INCH 1380.288 MM
Outside height of the ellipsoidal head (measured from head-bend line), ho 16.1024 INCH 409 MM
Ratio of the major to the minor axis of ellipsoidal head, Do/2ho 1.93643
Factor depending on the ellipsoidal head proportions Do/2ho, Ko 0.87139

(use interpolation) [See Table UG-33.1]
The required thickness of an ellipsoidal head having pressure on the

convex side, either seamless or of built-up construction with butt joints,
shall not be less than that determined by the following procedure :
Step 1. Assume a value for t and calculate the value of factor A

using the following formula : A = 0.125 / (Ro / t) 0.00127
Step 2. Using the value of A calculate in Step 1, follow the same

procedure as that given for spherical shells in UG-28(d),
Step 2 through 6 :
a. Enter Fig. CS-2 with A (to find factor B), which is under the curve, B 9500 PSI 668.8 Kg/CM2G
Follow step (4) of UG-28(d), and calculate the value of max. allowable
2
external working pressure, PA = B / (Ro / t) 96.3567 PSI 6.783514 Kg/CM G
Change t untill PA > 15 PSI (full vacuum) 0 PSI 0 Kg/CM2G
Notes. OK
1. For value of A falling to the left of the material-temp. line, the value
of Pa can be calculated in accordance with Step 5 of UG-28(d), as
follows : Pa = 0.0625 E / (Ro /t)2
E = Modulus of elasticity at design temp. 2.6E+07 PSI

According to ASME Code, Section VIII, Division 1, Edition 2001, Addenda 2002 Shee t : 1 of 5

M2. Nozzle Mark : N8 24" NPS, Sch. 30, 300# WNRF (Manhole Located at Shell with Reinforcement)
No. of nozzles, n 1
Nozzle Neck Thickness Calculation [UG-27(c) & Appendix 1-1]
Nozzle Size, NPS 24 INCH 600 DN

Nozzle Material ASME SA 106 Grade B
Design Pressure, P 257.898 PSIG 18.156 Kg/CM2G

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For nominated Design Pressure & Temperature, Flange Rating 300#
[ANSI/ASME B16.5-1996]
Max. Allowable Stress of Nozzle Material @ Design Temp.(75 oC), Sn 17100 PSIG 1203.84 Kg/CM2G
Max. Allowable Stress of Nozzle Materiall @ Test Temp.(40 oC), Snt 17100 PSIG 1203.84 Kg/CM2G
[Table 1A, SubPart 1, ASME Sec. II, Part D]
Outside Radius of Nozzle, Ron 12 INCH 304.8 MM

Joint Efficiency of Nozzle, En (Seamless Pipe) 1
Nozzle Corrosion Allowance, Can 0.23622 INCH 6 MM
Nozzle Thickness Calculation :
Longitudinal Stress, t = PRon /(Sn*En + 0.4 P) 0.1799 INCH 4.569353 MM

[APPENDIX 1.1]
By adding Corrosion Allowance, t [UG-25] 0.41612 INCH 10.56935 MM
By adding Pipe Tolerance 12.5% to the Thickness of Nozzle, t 0.46813 INCH 11.89052 MM
Use Nozzle 24" NPS with Selected Neck Sch. 30, 0.562 INCH 14.2748 MM
with Thickness 0.562" (14.27 MM). [Table 2 of ANSI B 36.10M-1985-(R-1994)]
Nozzle Neck Maximum Working Pressure, MWP (New & Operating)

Nozzle wall thickness less tolerance 12.5% 0.49175 INCH 12.49045 MM
Nozzle wall thickness less tolerance 12.5% - Corrosion allowance 0.25553 INCH 6.49045 MM
MWP, New & cold (14.275 MM) P = Snt E t /(Ron - 0.4 t) [App. 1.1] 712.422 PSIG 50.15448 Kg/CM2G
MWP, Operating & corroded (9.49 MM) P = Sn E t /(Ron - 0.4 t) 367.258 PSIG 25.85495 Kg/CM2G
Nozzle Flange Maximum Working Pressure, MWP (New & Operating)

MWP, New & cold, 300# @ 100 oF [ASME B.165, Table 2] 740 PSIG 52.096 Kg/CM2G
MWP, Operating & corroded, 300# @ 149 oF [ANSI B16.5, Table 2] 708.15 PSIG 49.85376 Kg/CM2G
Designed by : Eng. Abdel Halim Galala, Design General Manager (assist.) Date : 18.2.2004
Project : Design & Procurement of ASME Pressure Vessel Client : APRC

M2. Nozzle Mark : N8 24" Sch. 30, 300# WNRF Manhole (cont.)
Nozzle Opening Calculation With Reinforcing [UG-27(c) & Appendix 1-1]
Nozzle Pipe Size, NPS 24 INCH 600 DN

Nozzle Pipe Sch. 30
Design Pressure, P 257.898 PSIG 18.15602 Kg/CM2G
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Design Temparture 149 F 65 C
Shell Material ASME SA516 Grade 70

Nozzle Material ASME SA 106 Grade B
Reinforcing Pad Material ASME SA516 Grade 70
Allowable Stress of Shell Material, Sv 20000 PSIG 1408 Kg/CM2G
Allowable Stress of Nozzle Material, Sn 17100 PSIG 1203.84 Kg/CM2G
Allowable Stress of Pad Material, Sp 20000 PSIG 1408 Kg/CM2G
Shell Thickness 0.86614 INCH 22 MM

Shell Corrosion Allowance, Cas 0.23622 INCH 6 MM
Shell Thickness l ess Pipe Tolerance 12.5% (12.5% NA) 0.86614 INCH 22 MM
Shell Thickness less Corrosion Allowance & 12.5%, t (12.5% NA) 0.62992 INCH 16 MM
Nozzle Wall Nominal Thickness 0.562 INCH 14.2748 MM

Nozzle Wall Thickness less Pipe Tolerance 12.5% 0.49175 INCH 12.49045 MM
Nozzle Corrosion Allowance, Can 0.23622 INCH 6 MM
Nozzle Wall Thick. less Corr. Allowance & 12.5% , tn 0.25553 INCH 6.49045 MM
Nozzle Wall Thick.of Internal Projection (less Corr. Allowance & 12.5%), ti 0.25553 INCH 6.49045 MM
Reinforced Pad Thickness, te 0.86614 INCH 22 MM
Joint Efficiency of Shell, E 1
Joint Efficiency of Nozzle, En 1
Correction Factor, F [UG-37(a)] 1
E1 [Nozzle in solid plate] 1
Shell Outside Diameter, OD 62.9921 INCH 1600 MM
Shell Inside Diameter in Corroded Condition, 2R = OD - 2 t 61.7323 INCH 1568 MM
Shell Inside Radius in Corroded Condition, R 30.8661 INCH 784 MM
Nozzle Outside Diameter, OD 24 INCH 609.6 MM

Nozzle Inside Diameter, ID 22.876 INCH 581.0504 MM
Nozzle Projection beyond Inner Vessel Wall, h = min. (h1,h2) 0 INCH 0 MM
h1 = 2.5 t 1.5748 INCH 40 MM
h2 = 2.5 ti 0.63882 INCH 16.22613 MM
Nozzle ID Without Corrosion Allowance & 12.5% , d = OD - 2*tn 23.4889 INCH 596.6191 MM
Finished Radius of Circular Opening, Rn 11.7445 INCH 298.3096 MM

Nozzle Opening Calculation With Reinforcing (cont.)
[UG-27(c) & APPENDIX 1-1]
* Outside Diameter of Reinforced Pad (if used) [UG-40(b)&FIG.UG-37.1]
Dp1 = 2 d 46.9779 INCH 1193.238 MM
Dp2 = 2 (Rn + nozzle wall thk. , tn + vessel wall thk. , t ) 25.2598 INCH 641.6 MM
OD of Reinf. Pad, Dp = the greater of Dp1 or Dp2 46.9779 INCH 1193.238 MM
Calculating Siz of Fillet Welds : [UW-16(c)(2)&FIG.UW-16.1]

* For Outward Nozzle Weld [UW-16(c)(2)&FIG.UW-16.1SKETCH (c)]
Calculation of tmin. :
tmin.1 = 0.75 inch 0.75 INCH 19.05 MM
tmin.2 (nozzle wall nominal thickness) 0.562 INCH 14.2748 MM
tmin.3 (shell wall thickness) 0.47244 INCH 12 MM
tmin. = lesser of tmin.1, tmin. & tmin.3 0.47244 INCH 12 MM
Calculation of tc : tc1 = 0.25 inch 0.25 INCH 6.35 MM
tc2 = 0.7 t min. 0.33071 INCH 8.4 MM
tc = lesser of tc1 & tc2 0.25 INCH 6.35 MM
By Considering Equal Legs Fillet Welds :
Leg of Outward Nozzle Weld = SQRT2 * tc 0.35355 INCH 8.980256 MM
Use Leg with Dimension E in Dwg. No. 7434-33-3A 0.35433 INCH 9 MM
* For Outer Reinforcing Pad Weld [FIG.UW-16 SKETCH (c)]

tmin.1 = 0.75 inch 0.75 INCH 19.05 MM
tmin.2 ( te = thk. of reinforcing element) 0.86614 INCH 22 MM
tmin.3 ( shell wall thickness) 0.86614 INCH 22 MM
tmin. = lesser of tmin.1, tmin. 2 & tmin.3 0.75 INCH 19.05 MM
1/2 tmin. 0.375 INCH 9.525 MM
By Considering Equal Legs Fillet Welds :
Leg of Outer Pad Weld = SQRT(2)*(tmin./2) 0.53033 INCH 13.5 MM
Use Leg with Dimension D in Dwg. No. 7434-33-3A 0.55118 INCH 14 MM
* Wall Thickness Required : [UG-27(c)(1)]

Shell tr = PR / (SE - 0.6 P) 0.47256 INCH 12.0029 MM
Nozzle trn = PRn /(SnEn - 0.6 P) 0.17874 INCH 4.540115 MM
* Strength Reduction Factors : Sp / Sv 1

fr1 = Sn / Sv 0.855
fr2 = Sn / Sv 0.855
fr3 = lesser of Sn/Sv or Sp/Sv 0.855
fr4 = Sp / Sv 1

Min. Nozzle Neck Wall Thickness Check Per UG-45
A. Wall Thickness per UG-45(a) : trna = trn + Can 0.41497 INCH 10.54012 MM
B*. Wall Thickness per UG-45(b) : trnb = Min. (trnb1, trnb2, trnb3, trnb4) 0.29872 INCH 7.5875 MM
Wall Thickness per UG-45(b)(1), trnb1 = Min. (trnb11, trnb12) 0.29872 INCH 7.5875 MM
trnb11 = tr + Cas (tr for shell or head at E=1) 0.70878 INCH 18.0029 MM
trnb12 = Min Wall Thickness per UG-16(b), see below 0.29872 INCH 7.5875 MM
Wall Thickness per UG-45(b)(2), trnb2 (apply to external pressure only), NA INCH #VALUE! MM
Wall Thickness per UG-45(b)(3), trnb3 (apply to internal & external pressure)
= Max. (trnb1, trnb2) 0.29872 INCH 7.5875 MM
Wall Thickness per UG-45(b)(4), trnb4
= Min. thickness of std. wall pipe (1-0.125)+ Can 0.56435 INCH 14.33438 MM
(Under tolerance12.5% in accordance with ASME B36.10M)
Nominal thickness of std. pipe wall thickness, NPS 24", Sch. Std. 0.375 INCH 9.525 MM
Wall Thickness per UG-16(b), trnb12

I - Min. Wall Thickness 1/16" + Cas 0.29872 INCH 7.5875 MM
II - Min. Wall Thickness of Unfired Steam Boilers = 1/4" + Cas 0.48622 INCH 12.35 MM
III - Min. Wall Thickness of Shell/Head in Compressed Air
Service, Steam Service, and Water Service = 3/32" + Cas 0.32997 INCH 8.38125 MM
Selected Vessel Service in our case is : Case III (compressed air)
So, the Min. Wall Thickness per UG-16(b), trnb12 0.29872 INCH 7.5875 MM
The min. nozzle wall thk. = Max. thk. determined by UG-45(a), or by UG-45(b) 0.41497 INCH 10.54012 MM
The nominal nozzle pipe wall thk. 0.562 INCH 14.2748 MM
The min. nozzle thk. provided = t (1-0.125) 0.49175 INCH 12.49045 MM
So, the thickness provided meets the rules of UG-45. OK
Since there is no superimposed loads, the vessel doesn't require

a calculationon shear stresses caused by UG-22(c).
* Since the opening is access/inspection, UG-45(b) is not applicable [UG-45(b)[


Nozzle Opening Calculation With Reinforcing (cont.) [UG-27]
Area of Reinforcement (witht Reinforcing element) :

Required Area, A = d tr F + 2 tn tr F(1-fr1) 11.1348 INCH2 7183.753 MM2
Area Available in Shell, A1:

2 2
A11 = d (E1 t - F tr) - 2tn (E1 t - F tr)(1-fr1) 3.6847 INCH 2377.221 MM
A12 = 2 (t + tn)(E1 t - F tr) - 2tn (E1 t - F tr)(1-f r1) 0.26702 INCH2 172.2696 MM2
A1 = The Greater of A11 or A12 3.6847 INCH2 2377.221 MM2
Area Available in Nozzle Projecting Outward, A2 :

A21 = 5 (tn - trn) fr2 t 0.20677 INCH2 133.4029 MM2
A22 = 2 (tn - trn)(2.5tn+te) fr2 0.19761 INCH2 127.4869 MM2
A2 = The Lesser of A21 or A22 0.19761 INCH2 127.4869 MM2
Area Available in Inward Nozzle, A3 : (Not applicable)

A31 = 5 t ti fr2 0.68812 INCH2 443.9468 MM2
A32 = 5 ti ti fr2 0.27914 INCH2 180.0884 MM2
A33 = 2 h ti fr2 0 INCH2 0 MM2
A3 = The Greater of A31, A32 or A33 0 INCH2 0 MM2
Area Available in Outward Nozzle Weld, A41:

A41 = (LEG)2 fr2 0.10735 INCH2 69.255 MM2
Area Available in Outer Reinforcing Pad Weld, A42:

A42 = (LEG)2 fr4 0.3038 INCH2 196 MM2
Area Available in Inward Nozzle Weld, A43 :

A43 = (LEG)2 fr2 0.10735 INCH2 69.255 MM2
Area Available in Reinforcing Pad, A5 :

A5 = (Dp - d - 2tn) te fr4 19.9021 INCH2 12840.04 MM2
Total Area Available, AT :

AT = A1 + A2 + A41 + A42 + A43 + A5 24.3029 INCH2 15679.26 MM2
AT is greater than A, therefore opening is adequately reinforced.
NOTE. No need for Strength Path Calculations.

Pressure Vessel Design (Shell, Head & Nozzle) - by Abdel Halim Galala

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Pressure Vessel Design (Shell, Head & Nozzle) - by Abdel Halim Galala

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DESIGN CALCULATIONS OF PRESSURE VESSEL Page : 5 of 126

Project : Design & Procurement of ASME Pressure Vessel Date : 18.2.2004

D. Contents. Description Page

M. Nozzle Neck thicknesses & Nozzle Openings Compensation : Thk., MM

N. Design of Saddle Supports. Page : 90 of 126

Project : Design & Procurement of ASME Pressure Vessel Date : 18.2.2004

E. Applicable Loading Considered in Design. [UG-22 & UG-98]

II. By considering UG-21 & UG-98 :

Max. Operating Pressure 227.3 PSIG 16 Kg/cm2G

Vessel ID 61.2598 INCH 1556 MM

Water sp. gr. 1

Project : Design & Procurement of ASME Pressure Vessel Date : 18.2.2004

F. Impact Test Requirements. [UG-22 & UG-98]

b. Stud Bolts & Nuts :

II. Non-Pressure Parts.

Thickness of vessel components :

Impct Test is not required as per Code,

G. Standard ASME Flange Rating Class.

Project : Design & Procurement of ASME Pressure Vessel Date : 18.2.2004

H. Cylindrical Shell Thickness Under Internal Pressure [UG-27(c)]

Shell material, Killed Carbon Steel, ASME SA516 Grade 70

Vessel Inside Diameter, D 61.2598 INCH 1556 MM

Max. Operating Pressure 227.273 PSIG 16 Kg/CM2G

Shell Inside Diameter, D 61.26 INCH 1556 MM

Corrosion Allowance, C [UG-25] 0.236 INCH 6 MM

Project : Design & Procurement of ASME Pressure Vessel Date : 18.2.2004

H. Cylinderical Shell Thickness Under Internal Pressure (cont.) [UG-27(c)]

Value of 0.385 SE [UG-27(c)(1)] 6545 PSIG 460.768 Kg/CM2G

Value of 1.25 SE [UG-27(c)(1)] 21250 PSIG 1496 Kg/CM2G

20" Pipe nominal thickness under tolerance tn = t - 0.125 t 0.472440945 INCH 12 MM

20" Pipe Corroded Thickness = tn - Corrosion allow ance 0.236440945 INCH 6 MM

Using 20" pipe sch. 40 is OK

By using APPENDIX 1-1 (In terms of the Outside Diameter) :

tm = P Ro / (SE + 0.4 P) 0.458 INCH 11.633 MM

Thickness adjusted for w all thickness tolerance :

t = tm / (100%-12.5%) 0.523 INCH 13.284 MM

By Adding Corrosion Allow ance to Wall Tickness, t 0.759 INCH 19.284 MM

Using 20" pipe w ith commercial w all thickness, sch. 40 is OK

Ladders and Platforms N.A.

Project : Design & Procurement of ASME Pressure Vessel Date : 18.2.2004

H. Check of Shell Thickness Under Internal Pressure

* Here three cases must be investigated:

t 0.238 INCH 6.045 MM

Project : Design & Procurement of ASME Pressure Vessel Date : 18.2.2004

H. Check of Shell Thickness Under Internal Pressure (cont.)

Case 3 . Longitudinal Compressive Stress due to Bending.

2. The general equatioin for thickness is the same as for

3. The joint efficiency for butt-welded joints shall be taken as

Thickness , t 0.00902 INCH 0.229 MM

Project : Design & Procurement of ASME Pressure Vessel Date : 18.2.2004

I. Check of Shell Thickness for External Pressure (Full Vacuum)

Shell length from Tangent-to-Tangent (T/T), L1 189.764 INCH 4820 MM

Assume t for internal pressure (at corroded condition) 0.62992 INCH 16 MM

Since Do/t > 10, use UG-28(c)(1)

2. For L/Do > 50, use L/Do = 50

3. For Do/t > 10, use UG-28(c)(1)

Project : Design & Procurement of ASME Pressure Vessel Date : 18.2.2004

J. Ellipsoidal Head Thickness Under Internal Pressure [UG-32(f)]

Head material, Carbon Steel ASME SA516 Grade 70

Head ID 61.2598 INCH 1556 MM

Corrosion Allowance, C [UG-25] 0.23622 INCH 6 MM

Outside Diameter of Head, Do 62.9921 INCH 1600 MM