Co-Current Scrubber

PAGE:

GENERAL DETAILS

SECTION A :GENERAL DESIGN DETAILS, SAFETY FACTOR AND ALLOWABLE LOADS

1

GENERAL DETAILS
a
b
c
d
e

project
Title of the work
File name for further reference
Name of the client
Name of manufacturer

=
=
=
=
=

DNL
Dmax ML Storage tank 3
MECHANICAL DESIGN
DNL
M/S BHAVI PLAST PVT LTD

GEOMETRICAL DETAILS

a
b
c
d
e

Shell Volume Desired

L/D Ratio
Diameter
Total Height of the CYL. Shell (FRP)
Tank Shell FRP Wt.

f
g
h
i

Cover Height or Length

Cover Volume
FRP Weight
Total FRP Weight

V
L/Di
Di
Hs
Hwt

=
=
=
=
=

>
>

33.2
1.23
3250
4000

33.2
1.23
3250.0
4000.0

Top/Left
629.76623 mm
0 m3
1166.4045 Kg
Kg

=
=
=
=

Bottom/Left
0.0

M^3
Ratio
mm
mm
kg

mm
m3
Kg
Kg

STORED LIQUID
a

Assumptions Regarding Stirring

Density of the liquid

Design Fluid height (from base line)

= Not Stirred
r

F-Ht
d

Fluid Weight

Total Process Wt.

= 1073
1.073

Kg/m
g/cm3

4000

mm max

= 4000

mm max

L/B Covr
Consider? > no
'Weight > 0
=
35610

Shell
yes
35610.1
Kg

R/T Covr
no
0.0

Total
35610.1

PRESSURE/VACUUM
a

Fluid/Gas in equilibrium with stored Liquid

Pressure over and above fluid head

Pi

= 150.00
= 0.0014715

mm W.C
N/mm2

Vacuum

Pv

= 150.00
= 0.0014715

mm W.C
N/mm2

CYCLIC LOAD: number of Cycles

Ns

= 3650

Nos/10 years

TEMPERATURE
Ot
Dt

= 70
= 80

Deg Cel
Deg Cel

a
b

Operating Temp
Design Temperature

4/18/2013 10:02 AM

= Dnax ML

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Co-Current Scrubber

c
7

HDT of resin used

HDT

WHETHER IN-DOOR OR OUT-DOOR

PAGE:

GENERAL DETAILS

100

Deg Cel

= Outdoor

Wind Pressure***

Pw

200.00
= 0.001962

Kg/m^2
N/mm2

Seismic Coefficient***

Ef

= 0.08

No Unit

*** Numerical value to be verified by approver

MATERIALS OF CONSTRUCTION
a

Resin
Heat Distortion Temperature

= Isophthalic Resin
HDT = 100
Degree Cel.
e-r
= 2
%
Furane? = N

CSM
WRM
= 0.45
0.61
= 33
45
Strain at break
= 2

b
c

Glass Density
Fibre Content

Other Parameters

UV protective top coat

= [YES]
= Resin Rich Coat with UV

thermoplastic lining

= YES
= 58.04

10

Thermosetting lining

= NO

resin density
1.10

SM
0.04
Kg/m^2
10
%
Coefficient of thermal exp
0
0.0000046 / C

3
155
0

mm of
Kg Approx

glass density
2.54
g/cc

GL-PP

mats of CSM/RESIN

FABRICATION
a

Method of manufacturing

Construction

Post Curing

= NO

Post Curing Temperature

= -

11

= Hand Lay-Up
TOP = CSM
SHELL = CSM/WRM
BOTTOM = CSM

DESIGN PROPERTIES

Degree Cel.

CSM

WRM

Units

Ultimate Tensile unit strength

(p 10, BS4994-87)

200.00

250.00

N/mm per Kg/m2 glass mat

Ultimate Tensile Strength

S = U/Tg

89.29

166.67

N/mm2

4/18/2013 10:02 AM

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Co-Current Scrubber

PAGE:

GENERAL DETAILS

Unit Modulus
(p 10, BS4994-87)

14000.00

16000.00

N/mm per Kg/m2 glass mat

Unit modulus of 1 mat

X1

6300.00

9760.00

N/mm per Kg/m2 glass mat

Modulus of Elasticity
E=X/Tg

6250.00

10666.67

N/mm for (1 mat as specified at 9b)

Fiber content {wt %}

(ref p 20, Figure 5 BS4994-87)

Fc

33.00

45.00

Resin to glass ratio

2.03

1.22

No Unit

Layer Thickness Constant

TG

2.24

1.50

mm per Kg/m2 glass mat

Inter Laminar Lap Shear Strength

Tou

7.00

6.00

N/mm

In Plane Poisson's Ratio

IPPR

0.30

0.30

Single mat thickness

T-1

1.01

0.92

12

mm (for 1 mat as specified at 9b)

CALCULATION OF SAFETY FACTOR

a

13

Factor for Method of Manufacturing

K1

= Hand Lay-Up
= 1.50

K2

= yes
= N/A
= 1.20

HDT
DT
K3

= 100
= 80
= 1.10

K4

= 3650
= 1.27

K5

= not post cured

= [Degree Cel.]
= 1.50

Factor for Strength Loss

Strength Loss

Factor for Design Temperature

[1.25-.0125(HDT-20-Dt)]

Factor For Cyclic Loading

Number Of Cycles in life time
[1.1+.9(log N-3)/3]
Factor for Curing Temperature
Post Curing
Post Cure TEMPERATURE

Over all Safety Factor

K-cal

Degree Cel.
Degree Cel.

= 11.3157

11.32

CALCULATIONS FOR ALLOWABLE DESIGN LOADS

a

LOAD LIMITED UNIT LOAD

[=U/K]

b DESIGN STRAIN
b1 Max allowable resin-strain
[min of 0.1*e-r and 0.2]
b2 Resin strain limited unit load
b3 Allowable reinforcement strain
[(Ul/X)*100]
b4 Design Strain (reinforcement limited)
[minimum of e-l's of csm and wrm]

4/18/2013 10:02 AM

Ul

CSM
= 17.67

e-res

= 0.200

Urs
e-rein

= 28.00
= 0.126
0.000
e-d,rein =

WRM
22.09

N/mm per Kg/m2 Reinforcement

%
32.00
0.138

N/mm per Kg/m2 Reinforcement

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Co-Current Scrubber

b5 Over all design strain

[min of all strains]

e-d

= 0.126

c STRAIN LIMITED LOADS

c1 CSM-Strain limited unit load
[=X*e-d/100]

Us

= 17.67

d DESIGN UNIT LOADS

d1 Design Unit Load
[Minimum among Ul and Us]

Ud

Allowed Unit load per current mat

4/18/2013 10:02 AM

PAGE:

GENERAL DETAILS

Ud-1

17.67

= 7.954

20.20

N/mm per Kg/m2 Reinforcement

20.20

N/mm per Kg/m2 Reinforcement

12.322

N/mm (for mats specified at 9b)

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SECTION B: TORISPHERICAL TOP

1

DATA
a Shape of top end
b Radius of Dishing
c

= 3250

mm No Error Message

= 325.0
=

mm No Error Message

d Diameter

Di

= 3250

mm

e Height

Ht

= 629.8

mm

Ad

= 6.4

m^2

Vd

= 3.41

m^3

Area of the dish (APPROX)

DESIGN FOR INTERNAL PRESSURES

a ht/Di

= 0.1938

b t/Di

= 0.0049

= 0.1000

ri/Di

Assumed Thk =

d Shape Factor
(Ref table 11, BS4994, 1997)

Ks

= 2.95

e Internal Pressure

Pi

= 0.001472

N/mm^2

Pi-std

= 1300
= 0.012753

Kg/m^2
N/mm^2

Standard Design Load

(Load of person working etc)

g Self Weight

SW-d

= 9.00

Kg / squire meter

h Pressure due to self weight

P-sw

= 0.000088

N/mm^2

Internal Vacuum

Pv

= 0.001472

N/mm^2

Design Pressure
(max of Pi, Pi-std)+Psw

Pi-d

= 0.012841

N/mm^2

Unit Load due to pressure

[0.5*Pi*Di*Ks]

Qcp

= 61.56

N/mm

Unit Load due to Vaccum

[0.66*Pv*Di*Ks]
Note: Refer equation (44), BS 4994-87

Qcc

= 9.31

N/mm

Qd

= 61.56

N/mm

n Number of mats
(Qd / U1-csm please also see GENERAL DETAILS 13e)

= 7.73968
16

N/mm

o Current Thickness
p t/Di

= 16.13
= 0.00496246

mm

q Final no. of mats

r mass for above no of mat

= 16
= 7.2

kg

Weight of TP lining if any

= 17.35

Kg

Weight of Chemical Res CSM

Resin for Chemical Res CSM

= 0.000
= 0.000

Kg
Kg

Weight of mechanical CSM

Resin for mechanical CSM

= 46.3
= 93.9

Kg
Kg

Surface Mat (SM)

Resin for SM and Gelcot

= 0.3
= 0.5

kg
Kg

m Design unit Load Q

(MAX of Qcp and Qcc)

Ri

Knuckle Radius
ri
Enter different value and select from blue cell above

g Volume of dished portion

= Torispherical

WEIGHT CALCULATIONS

16.00

C: CYLINDRICAL SHELL
Chemical Resistant

CSM-WRM balance

CSM - WRM=

1
SM
Above Supp

SHELL

2
a
b
c
d

Number of segments
Segments starts (from base-line)
Support Centre Line (from base-line)
Segment Length

Ns-A
from
To
Sl-A

2. 2 Segment, to (mm from base line)

2. 5 Stiffner Gap in the segment (mm)

2. 6 Max Fluid Head at lawest point. (mm)

2 7 Fluid weight tensile load on shell

NS-B=
from=
To=
Sl-B=

2. SEGMENT DETAILS
2. 1 Segment, from (mm from base line)

2. 4 Length from support to free end

Below Supp

1
4000
2800
1200

=
=
=
=

SHELL DESIGN

2. 3 Segment length (mm)

1
SM

Hs
Hs-W
L

Hs-f
Fw-ten

= 4000.0
to
= 2800.0

2800.0
to
0.0

= 1200.0

2800.0

1200.0

2800.0

= 1200.0

2800.0

= 1200

4000

= 0

40036

3. DESIGN FOR CIRCUMFERENCIAL UNIT LOAD

3. 1 Unit load d.t. fluid pressure (N/mm)
[sp gravity*height*dia*9.81/2000000]

Qcf

= 20.53

68.42

3. 2 Unit load d. t. internal pressure,

[Qcp=Pi*Di/2]

Qcp

= 14.00

14.00

3. 3 Max Circumferential Unit Load

[Qcm = Qcf+Qcp]

Qcm

= 34.52

68.42

Qcv

= 2.39

2.39

Q-fi

= 34.52

68.42

3. 4 Circumferencial Unit Load

due to vaccum,
[Qcv=Pv*Di/2]
3. 5 Design Circumfer. Unit load
[MAXIMUM of Qcv or Qcm]
[Eq 7 of BS 4994-87]
3. 6 Mat requirement for this (Nos)

CSM
= 3
WRM = 1
CSMroundup 5
WRM
3
4. DESIGN OF SHELL OF AXIAL LOAD, 14.3, BS 4994-87

4.

1 Weight Transmitted from.....

Top Cover or Bottom Cover (Kg)

W1

= 158

5
3
6
4

1
2800
0
2800

Total weight transmtd from top/bot

Self Weight (kg)
Weight of fluid supported in shell
Weight of fluid supported at bottom con
Total wt transmitted on the segment

Wts
Wsw

= 158
= 81
Not Applic.

0
261
40036

Wtb

= 239

40297

Wt

= 239
= 2344

40297
395315

= 0.23

38.74

Qcv

= 2.39

2.39

pi

= 0.001

0.001

Qcp

= 0.802

0.802

Fw

= 6.38

6.38

4. 8 Horiz Earth Quake Load per Unit Ht

Fe
Ef*density*3.142*Di Squire*9.81/(4,000,000)
[weight per unit ht * Ef]

= 0.65

0.65

4. 9 Design horizontal load

max (Fw,Fe)

= 6.38

6.38

= 4591080

24995880

4. 2 Weight that transilate to axial load(Kg)

Total (N)

4. 3 Axial Compres./Tensile unit load

due to Weight,
Qc-wt
[Wt/(3.145*Di)]
[This is a part of RHS of eq 9, BS 4994-87]
4. 4 Axial Compressive unit
load due to vaccum (N/mm)
[Pv*Di/4]
4. 5 Total effective pressure
contributing to axial stress

4. 6 Axial tensile unit load

due to pressure
[pi Di / 4]
[This is first part of eq 9, BS 4994-87]
4. 7 Wind horizontal load per unit height
[Pw*Di]

4. 10 Design Bending Moment due to

horizontal load
Fh*height^2/2

Fh

Mhd

4. 10 Axial unit tension/compression

QM
= 0.55
load due to wind pressure
and earth quake pressure (N/mm)
4 * Mhd / (3.142*Di squire)
[This is middle part of RHS of eq 9, BS 4994-87 ]
QXt
QXc

= 1.126
= 3.17

3.01

42.554
5.41

4. 11 Max Axial Unit Load (N/mm)

Qx
= 37.70
110.97
MAX(Qcp+QM+/-Qc.wt (tension) and Qcv+QM+/-Qc.wt (compression))
Mat requirement

4. 12 Mat Requirement

CSM
WRM

= 3
= 1

7
5

CSMroundup= 2
WRM = 0

3
1

CSM
WRM

= 5
= 3

7
5

4. 13 Thickness

CSM
WRM
TOTAL

= 4.68
= 2.75
= 7.43

6.64
4.66
11.29

5. DESIGN FOR COMPRESSIVE LOAD (14.3.3, BS 4994-87)

4. 15 OD of the shell
Pl refer final laminate properties below
5. 1 Assumed mat for compressive load
[this should be less than finalised
number of mats]
4. 14 Unit modulus of laminate X-lam

OD

= 3264.9

3272.6

CSM
WRM

5.00
3.00

CSM
WRM
TOTAL

= 31500
= 29280
= 60780

44659
49667
94326

7.09
5.09

5. 1 Total compressive load on shell

Qcv+QM+Qc.wt for above support
Qcv+QM for below support

Qp

= 3.17

5.41

5. 2 Thickness to limit permissible

compressive load (mm)
Qp = (0.6 tc*X lam)/F Do

tc

= 1.14

1.25

5. 3 Mats requirement to meet this

thickness
[ F Do Qc / (0.6 t Xlam) ]

CSM
WRM

= 3
= 1

3
1

Final mat Requirement

CSM
WRM

= 5
= 3
7.43
60780.00

7
5
11.29
94326.25

Thickness
Xlam

6. DESIGN FOR EXTERNAL PRESSURE (14.4, BS 4994-87)

6. 1 Total effective External pressure

= 0.003434

0.003434

6. 2 Effective length of the shell

[see Fig 8, BS 4994-87]

= 1200

2800

t-lam

= 7.43

11.29

6. 4 X-lam based on final laminate

= 60780

94326

6. 5 OD of shell

= 3264.9

3272.6

= 0.368

0.856

= 12.946

12.991

= 8186

8354

= 4

= 7.43

10.35

6. 3 Thickness of shell

6. 6 Shape Factor
[L/ Do]
b Factor 1.35(Elam/Fp)^.17
6. 7 E-lam = X-lam/t-lam
6. 8 FACTOR [Refer eq 14 and 15 of
of BS 4994- 87]
6. 9 Minimum Shell Thk to avoid
buckling
[Refer eq 15 and 16 of BS 4994- 87]

tm

6. 10 Mat requirement to meet this

6. 11 Design Mats Quantity

CSM
WRM

= 5
= 3

7
5

CSMroundup= 4
WRM = 2

4
2

7
5

CSM

WRM
Thickness

= 3
= 8.17

11.29

Chemical Resistant Layer

Thickness
Thickness of TP lining

= 0
= 0.00
3.00

0.00
3.00

Total Thk

= 11.2

14.3

6. 12 W-lam (Kg/m^2)
[Number Of Mat*Type Of Mat*W-FI]
Mechanical Layers

CSM FRP = 90.17

WRM FRP = 56.39
TOTAL = 146.55

276.18
196.91
473.10

Chemical Layers
Gel coat/Surface mat (Internal)
Surface mat / Resin Coat (External)

= 50.09
= 1.00
= 1.00

50.09
2.32
2.32

Total Wlam

= 198.64

527.83

= 0.68

8.10

6. 14 Weight of Segment (Kg)

= 11.3

153.8

6 16 Total FRP weight of Shell

= 726.5

6. 13 Area of the segment (m^2)

A-s

SECTION B: TORISPHERICAL TOP

1

DATA
a Shape of top end
b Radius of Dishing
c

Knuckle Radius
ri
Enter different value and select from blue cell above

mm No Error Message

= 325.000
=

mm No Error Message

Di

= 3250.000

mm

e Height

Ht

= 629.766

mm

Ad

= 6.427

m^2

Vd

= 3.412

m^3

Area of the dish (APPROX)

DESIGN FOR INTERNAL PRESSURES

a ht/Di

= 0.194

b t/Di

= 0.0098

ri/Di

Assumed Thk =

= 0.100

d Shape Factor
(Ref table 11, BS4994, 1997)

Ks

= 2.910

e Internal Pressure

Pi

= 0.049

N/mm^2

Pi-std

= 150.000
= 0.002

Kg/m^2
N/mm^2

g Self Weight

SW-d

= 9.000

Kg / squire meter

h Pressure due to self weight

P-sw

= 0.000088

N/mm^2

Standard Design Load

(Load of person working etc)

Internal Vacuum

Pv

= 0.00147

N/mm^2

Design Pressure
(max of Pi, Pi-std)+Psw

Pi-d

= 0.049

N/mm^2

Unit Load due to pressure

[0.5*Pi*Di*Ks]

Qcp

= 230.866

N/mm

Unit Load due to Vaccum

[0.66*Pv*Di*Ks]
Note: Refer equation (44), BS 4994-87

Qcc

= 9.185

N/mm

Qd

= 230.866

N/mm

m Design unit Load Q

(MAX of Qcp and Qcc)

= 3250.000

d Diameter

g Volume of dished portion

= Torispherical
Ri

n Number of mats
(Qd / U1-csm please also see GENERAL DETAILS 13e)

= 29.027
30.000

o Current Thickness
p t/Di

= 30.240
= 0.0093

q Final no. of mats

r mass for above no of mat

= 30.000
= 13.500

mm

kg

WEIGHT CALCULATIONS
Weight of TP lining if any

= 17.931

Kg

Weight of Chemical Res CSM

Resin for Chemical Res CSM

= 0.000
= 0.000

Kg
Kg

Weight of mechanical CSM

Resin for mechanical CSM

= 86.761
= 176.125

Kg
Kg

Surface Mat (SM)

Resin for SM and Gelcot

= 0.257
= 0.522

kg
Kg

32.00