DESIGN CALCULATIONS OF PRESSURE VESSEL Page : 31 of 126

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

M4. Nozzle Mark : N1 8"NPS, Sch. 80, 300# WNRF (Located at Shell)
No. of nozzles, n 1

Nozzle Neck Thickness Calculation [UG-45, UG-27 & APPENDIX 1-1]

Nozzle Size, NPS 8 INCH 200 DN
Nozzle Material ASME SA 106 Grade B

Design Pressure, P 257.898 PSIG 18.156 Kg/CM2G

o o
Design Temperature 149 F 65 C
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 4.3125 INCH 109.5375 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) 0.06465 INCH 1.642111 MM

[APPENDIX 1.1]
By adding Corrosion Allowance, t [UG-25] 0.30087 INCH 7.642111 MM

By adding Pipe Tolerance 12.5% to the Thickness of Nozzle, t 0.33848 INCH 8.597375 MM

Use Nozzle 8" NPS with Selected Neck Sch. 80, 0.5 INCH 12.7 MM
with Thickness 0.5" ( 12.7 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% 0.4375 INCH 11.1125 MM
Nozzle wall thickness less tolerance 12.5% - Corrosion allowance 0.20128 INCH 5.1125 MM
MWP, New & cold (9.271 MM) P = Snt E t /(Ron - 0.4 t) [App. 1.1] 1808.16 PSIG 127.2943 Kg/CM2G
MWP, Operating & corroded (4.289 MM) P = Sn E t /(Ron - 0.4 t) 813.301 PSIG 57.25639 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
DESIGN CALCULATIONS OF PRESSURE VESSEL Page : 32 of 126
According to ASME Code, Section VIII, Division 1, Edition 2001, Addenda 2002 Sheet : 2 of 5
Designed by : Eng. Abdel Halim Galala, Design General Manager (assist.) Date : 18.2.2004

Project : Design & Procurement of ASME Pressure Vessel Client : APRC

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

M4. Nozzle Mark : N1 8" 300# WNRF (located at shell) (cont.)

Nozzle Opening Calculation With Reinforcing [UG-27(c) & APPENDIX 1-1]
Nozzle Pipe Size, NPS 8 INCH 200 DN
Nozzle Pipe Sch. 80
Design Pressure, P 257.898 PSIG 18.15602 Kg/CM2G
o o
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 less 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 0.5 INCH 12.7 MM

Nozzle Wall Thickness less Pipe Tolerance 12.5% 0.4375 INCH 11.1125 MM
Nozzle Corrosion Allowance, Can 0.23622 INCH 6 MM
Nozzle Wall Thick. less Corr. Allowance & 12.5% , tn 0.20128 INCH 5.1125 MM
Nozzle Wall Thick.of Internal Projection (less Corr. Allowance & 12.5%), ti 0.20128 INCH 5.1125 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 8.625 INCH 219.075 MM

Nozzle Inside Diameter, ID 7.625 INCH 193.675 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 0.5032 INCH 12.78125 MM
Nozzle ID Without Corrosion Allowance & 12.5% , d = OD - 2*tn 8.22244 INCH 208.85 MM
Finished Radius of Circular Opening, Rn 4.11122 INCH 104.425 MM
 DESIGN CALCULATIONS OF PRESSURE VESSEL Page : 33 of 126
According to ASME Code, Section VIII, Division 1, Edition 2001, Addenda 2002 Sheet : 3 of 5
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

M4. Nozzle Mark : N1 8" 300# WNRF (located at shell) (cont.)

Nozzle Opening Calculation With Reinforcing (cont.) [UG-27(c) & APPENDIX 1-1]

* Outside Diameter of Reinforced Pad [UG-40(b)&FIG.UG-37.1]

Dp1 = 2 d 16.4449 INCH 417.7 MM
Dp2 = 2 (Rn + nozzle wall thk. , tn + vessel wall thk. , t ) 9.88484 INCH 251.075 MM
OD of Reinf. Pad, Dp = the greater of Dp1 or Dp2 16.4449 INCH 417.7 MM

Calculating Size 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) 0.5 INCH 12.7 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 41 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 t min. 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
Leg 42 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) 0.06257 INCH 1.589294 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
DESIGN CALCULATIONS OF PRESSURE VESSEL Page : 34 of 126
According to ASME Code, Section VIII, Division 1, Edition 2001, Addenda 2002 Sheet : 4 of 5
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

M4. Nozzle Mark : N1 8" 300# WNRF (located at shell) (cont.)

Min. Nozzle Neck Wall Thickness Check Per UG-45

A. Wall Thickness per UG-45(a) : trna = trn + Can 0.29879 INCH 7.589294 MM

B. Wall Thickness per UG-45(b) : trnb = Min. (trnb1, trnb2, trnb3, trnb4) 0.32997 INCH 8.38125 MM
Wall Thickness per UG-45(b)(1), trnb1 = Min. (trnb11, trnb12) 0.32997 INCH 8.38125 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 0.32997 INCH 8.38125 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) 0.32997 INCH 8.38125 MM
Wall Thickness per UG-45(b)(4), trnb4
= Min. thickness of std. wall pipe (1-0.125)+ Can 0.51797 INCH 13.15645 MM
(Under tolerance12.5% in accordance with ASME B36.10M)
Nominal thickness of std. pipe wall thickness, NPS 8", Sch. Std. 0.322 INCH 8.1788 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 0.32997 INCH 8.38125 MM

The min. nozzle wall thk. = Max. thk. determined by UG-45(a), or by UG-45(b) 0.32997 INCH 8.38125 MM
The nominal nozzle pipe wall thk. 0.5 INCH 12.7 MM
The min. nozzle thk. provided = t (1-0.125) 0.4375 INCH 11.1125 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).
DESIGN CALCULATIONS OF PRESSURE VESSEL Page : 35 of 126
According to ASME Code, Section VIII, Division 1, Edition 2001, Addenda 2002 Sheet : 5 of 5
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

M4. Nozzle Mark : N1 8" 300# WNRF (located at shell) (cont.)

Nozzle Opening Calculation With Reinforcing (cont.) [UG-27]

Area of Reinforcement (with reinforcing Element) :

Required Area, A = d tr F + 2 tn tr F(1-fr1) 3.91314 INCH2 2524.602 MM2

Area Available in Shell, A1:

A11 = d (E1 t - F tr) - 2tn (E1 t - F tr)(1-fr1) 1.28475 INCH2 828.8676 MM2
A12 = 2 (t + tn)(E1 t - F tr) - 2tn (E1 t - F tr)(1-f r1) 0.25242 INCH2 162.8512 MM2
A1 = The Greater of A11 or A12 1.28475 INCH2 828.8676 MM2

Area Available in Nozzle Projecting Outward, A2 :

A21 = 5 (tn - trn) fr2 t 0.37353 INCH2 240.9873 MM2
A22 = 2 (tn - trn)(2.5tn+te) fr2 0.3248 INCH2 209.546 MM2
A2 = The Lesser of A21 or A22 0.3248 INCH2 209.546 MM2

Area Available in Inward Nozzle, A3 : (Not applicable)

A31 = 5 t ti fr2 0.54203 INCH2 349.695 MM2
A32 = 5 ti ti fr2 0.17319 INCH2 111.7385 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 fr3 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 6.77313 INCH2 4369.75 MM2

Total Area Available, AT :

AT = A1 + A2 + A41 + A42 + A43 + A5 8.90116 INCH2 5742.674 MM2

AT is greater than A, therefore opening is adequately reinforced.

NOTE. No need for Strength Path Calculations.