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Example Shell Analysis

PVElite Licensee: ICAS Local White Lock

FileName : VESEXMPL -------------------------------------- Page 2

Shell Analysis : EX1CHCYL Item: 1 2:38p Dec 16,2002

Input Echo, Component 1, Description: EX1CHCYL

Design Internal Pressure P 200.00 psig

Temperature for Internal Pressure 150.00 F

Design External Pressure PEXT 15.00 psig

Temperature for External Pressure 150.00 F

External Pressure Chart Name CS-2

Include Hydrostatic Head Components NO

Material Specification (Normalized) SA-516 70

Material UNS Number K02700

Allowable Stress At Temperature S 20000.00 psi

Allowable Stress At Ambient SA 20000.00 psi

Curve Name for Chart UCS 66 D

Joint efficiency for Shell Joint E 0.85

Maximum Thickness before Full Radiography 1.2500 in.

Design Length of Section L 20.0000 in.

Length of Cylinder for Volume Calcs. CYLLEN 20.0000 in.

Inside Diameter of Cylindrical Shell D 46.0000 in.

Minimum Thickness of Pipe or Plate T 0.5000 in.

Corrosion Allowance CA 0.1250 in.

Skip UG-16(b) Min. thickness calculation NO

Type of Element: Cylindrical Shell

INTERNAL PRESSURE RESULTS, SHELL NUMBER 1, Desc.: EX1CHCYL

ASME Code, Section VIII, Division 1, Ed-2001, A-02

Thickness Due to Internal Pressure (TR):

= (P*(D/2+CA))/(S*E-0.6*P) per UG-27 (c)(1)

= (200.00*(46.0000/2+0.1250))/(20000.00*0.85-0.6*200.00)

= 0.2740 in.

Max. All. Working Pressure at Given Thickness (MAWP):

= (S*E*(T-CA))/((D/2+CA)+0.6*(T-CA)) per UG-27 (c)(1)

= (20000.00*0.85*(0.3750))/((46.0000/2+0.1250)+0.6*0.3750)

= 273.02 psig

Maximum Allowable Pressure, New and Cold (MAPNC):

= (SA*E*T)/(D/2+0.6*T) per UG-27 (c)(1)

= (20000.00*0.85*0.5000)/(46.0000/2+0.6*0.5000)

= 364.81 psig

Actual stress at given pressure and thickness (Sact):

= (P*((D/2+CA)+0.6*(T-CA)))/(E*(T-CA))

= (200.00*((46.0000/2+0.1250)+0.6*(0.3750)))/(0.85*(0.3750))

= 14650.98 psi

SUMMARY OF INTERNAL PRESSURE RESULTS:

Required Thickness plus Corrosion Allowance, Trca 0.3990 in.

Actual Thickness as Given in Input 0.5000 in.

Maximum Allowable Working Pressure MAWP 273.019 psig

Design Pressure as Given in Input P 200.000 psig

HYDROSTATIC TEST PRESSURES ( Measured at High Point ):

Hydrotest per UG-99(b); 1.3 * MAWP * Sa/S 354.93 psig

Hydrotest per UG-99(c); 1.3 * MAPN 474.25 psig

Pneumatic per UG-100 ; 1.1 * MAWP * Sa/S 300.32 psig

Percent Elongation per UCS-79 ( 50t/Rf * (1-Rf/Ro) ) 1.075 %

Min. Metal Temp. w/o impact per Fig. UCS-66 -55 F

Min. Metal Temp. w/o impact per UG-20(f) -20 F

WEIGHT and VOLUME RESULTS, ORIGINAL THICKNESS:

Volume of Shell Component VOLMET 1460.8 in.**3

Weight of Shell Component WMET 413.4 lb.

Inside Volume of Component VOLID 33238.1 in.**3

Weight of Water in Component WWAT 1200.3 lb.

WEIGHT AND VOLUME RESULTS, CORRODED THICKNESS:

Volume of Shell Component, Corroded VOLMETCA 1098.6 in.**3

Weight of Shell Component, Corroded WMETCA 310.9 lb.

Inside Volume of Component, Corroded VOLIDCA 33600.3 in.**3

Weight of Water in Component, Corroded WWATCA 1213.3 lb.

EXTERNAL PRESSURE RESULTS, SHELL NUMBER 1, Desc.: EX1CHCYL

ASME Code, Section VIII, Division 1, Ed-2001, A-02

External Pressure Chart CS-2 at 300.00 F

Elastic Modulus for Material 29000000.00 psi

Results for Max. Allowable External Pressure (Emawp):

TCA OD SLEN D/T L/D Factor A B

0.3750 47.0000 20.00 125.33 0.4255 0.0024044 15619.96

EMAWP=(4*B)/(3*(D/T))=(4*15619.9551)/(3*125.3333)=166.1697 psig

Results for Reqd Thickness for Ext. Pressure (Tca):

TCA OD SLEN D/T L/D Factor A B

0.1059 47.0000 20.00 443.64 0.4255 0.0003442 4991.14

EMAWP=(4*B)/(3*(D/T))=(4*4991.1372)/(3*443.6432)=15.0005 psig

Results for Maximum Length Between Stiffeners (Slen):

TCA OD SLEN D/T L/D Factor A B

0.3750 47.0000 449.66 125.33 9.5672 0.0000972 1410.12

EMAWP=(4*B)/(3*(D/T))=(4*1410.1167)/(3*125.3333)=15.0012 psig

SUMMARY of EXTERNAL PRESSURE RESULTS:

Allowable Pressure at Corroded thickness 166.17 psig

Required Pressure as entered by User 15.00 psig

Required Thickness including Corrosion all. 0.2309 in.

Actual Thickness as entered by User 0.5000 in.

Maximum Length for Thickness and Pressure 449.658 in.

Actual Length as entered by User 20.00 in.

PVElite by ICAS Engineering Software

Example Shell Analysis

PVElite Licensee: ICAS Local White Lock

FileName : VESEXMPL -------------------------------------- Page 5

Shell Analysis : EX1CHCYL Item: 2 2:38p Dec 16,2002

Input Echo, Component 2, Description: EX1CHCYL

Design Internal Pressure P 275.00 psig

Temperature for Internal Pressure 150.00 F

Design External Pressure PEXT 15.00 psig

Temperature for External Pressure 150.00 F

External Pressure Chart Name CS-2

Include Hydrostatic Head Components NO

Material Specification (Normalized) SA-516 70

Material UNS Number K02700

Allowable Stress At Temperature S 20000.00 psi

Allowable Stress At Ambient SA 20000.00 psi

Curve Name for Chart UCS 66 D

Joint efficiency for Shell Joint E 0.85

Maximum Thickness before Full Radiography 1.2500 in.

Design Length of Section L 218.2500 in.

Length of Cylinder for Volume Calcs. CYLLEN 218.2500 in.

Inside Diameter of Cylindrical Shell D 46.0000 in.

Minimum Thickness of Pipe or Plate T 0.6250 in.

Corrosion Allowance CA 0.1250 in.

Skip UG-16(b) Min. thickness calculation NO

Type of Element: Cylindrical Shell

INTERNAL PRESSURE RESULTS, SHELL NUMBER 2, Desc.: EX1CHCYL

ASME Code, Section VIII, Division 1, Ed-2001, A-02

Thickness Due to Internal Pressure (TR):

= (P*(D/2+CA))/(S*E-0.6*P) per UG-27 (c)(1)

= (275.00*(46.0000/2+0.1250))/(20000.00*0.85-0.6*275.00)

= 0.3777 in.

Max. All. Working Pressure at Given Thickness (MAWP):

= (S*E*(T-CA))/((D/2+CA)+0.6*(T-CA)) per UG-27 (c)(1)

= (20000.00*0.85*(0.5000))/((46.0000/2+0.1250)+0.6*0.5000)

= 362.86 psig

Maximum Allowable Pressure, New and Cold (MAPNC):

= (SA*E*T)/(D/2+0.6*T) per UG-27 (c)(1)

= (20000.00*0.85*0.6250)/(46.0000/2+0.6*0.6250)

= 454.55 psig

Actual stress at given pressure and thickness (Sact):

= (P*((D/2+CA)+0.6*(T-CA)))/(E*(T-CA))

= (275.00*((46.0000/2+0.1250)+0.6*(0.5000)))/(0.85*(0.5000))

= 15157.35 psi

SUMMARY OF INTERNAL PRESSURE RESULTS:

Required Thickness plus Corrosion Allowance, Trca 0.5027 in.

Actual Thickness as Given in Input 0.6250 in.

Maximum Allowable Working Pressure MAWP 362.860 psig

Design Pressure as Given in Input P 275.000 psig

HYDROSTATIC TEST PRESSURES ( Measured at High Point ):

Hydrotest per UG-99(b); 1.3 * MAWP * Sa/S 471.72 psig

Hydrotest per UG-99(c); 1.3 * MAPN 590.91 psig

Pneumatic per UG-100 ; 1.1 * MAWP * Sa/S 399.15 psig

Percent Elongation per UCS-79 ( 50t/Rf * (1-Rf/Ro) ) 1.340 %

Min. Metal Temp. w/o impact per Fig. UCS-66 -48 F

Min. Metal Temp. at Req'd thk. (per UCS 66.1) -55 F

Min. Metal Temp. w/o impact per UG-20(f) -20 F

WEIGHT and VOLUME RESULTS, ORIGINAL THICKNESS:

Volume of Shell Component VOLMET 19980.4 in.**3

Weight of Shell Component WMET 5654.4 lb.

Inside Volume of Component VOLID 362710.2 in.**3

Weight of Water in Component WWAT 13097.9 lb.

WEIGHT AND VOLUME RESULTS, CORRODED THICKNESS:

Volume of Shell Component, Corroded VOLMETCA 16027.2 in.**3

Weight of Shell Component, Corroded WMETCA 4535.7 lb.

Inside Volume of Component, Corroded VOLIDCA 366663.4 in.**3

Weight of Water in Component, Corroded WWATCA 13240.6 lb.

EXTERNAL PRESSURE RESULTS, SHELL NUMBER 2, Desc.: EX1CHCYL

ASME Code, Section VIII, Division 1, Ed-2001, A-02

External Pressure Chart CS-2 at 300.00 F

Elastic Modulus for Material 29000000.00 psi

Results for Max. Allowable External Pressure (Emawp):

TCA OD SLEN D/T L/D Factor A B

0.5000 47.2500 218.25 94.50 4.6190 0.0003095 4487.30

EMAWP=(4*B)/(3*(D/T))=(4*4487.3042)/(3*94.5000)=63.3129 psig

Results for Reqd Thickness for Ext. Pressure (Tca):

TCA OD SLEN D/T L/D Factor A B

0.2814 47.2500 218.25 167.94 4.6190 0.0001303 1889.40

EMAWP=(4*B)/(3*(D/T))=(4*1889.3954)/(3*167.9354)=15.0010 psig

Results for Maximum Length Calculation: No Conversion

TCA OD SLEN D/T L/D Factor A B

0.5000 47.2500 0.28E+13 94.50 .5834E+11 0.0001232 1786.06

EMAWP=(4*B)/(3*(D/T))=(4*1786.0642)/(3*94.5000)=25.2002 psig

SUMMARY of EXTERNAL PRESSURE RESULTS:

Allowable Pressure at Corroded thickness 63.31 psig

Required Pressure as entered by User 15.00 psig

Required Thickness including Corrosion all. 0.4064 in.

Actual Thickness as entered by User 0.6250 in.

Maximum Length for Thickness and Pressure 0.2757E+13 in.

Actual Length as entered by User 218.25 in.

PVElite by ICAS Engineering Software

al - Example Shell Analysis

PVElite Licensee: ICAS Local White Lock

FileName : VESEXMPL -------------------------------------- Page 8

Shell Analysis : EX1CVCYL Item: 3 2:38p Dec 16,2002

Input Echo, Component 3, Description: EX1CVCYL

Design Internal Pressure P 275.00 psig

Temperature for Internal Pressure 150.00 F

Design External Pressure PEXT 15.00 psig

Temperature for External Pressure 150.00 F

External Pressure Chart Name CS-2

Include Hydrostatic Head Components NO

Material Specification (Normalized) SA-516 70

Material UNS Number K02700

Allowable Stress At Temperature S 20000.00 psi

Allowable Stress At Ambient SA 20000.00 psi

Curve Name for Chart UCS 66 D

Joint efficiency for Shell Joint E 0.85

Maximum Thickness before Full Radiography 1.2500 in.

Design Length of Section L 20.0000 in.

Length of Cylinder for Volume Calcs. CYLLEN 20.0000 in.

Inside Diameter of Cylindrical Shell D 50.0000 in.

Minimum Thickness of Pipe or Plate T 0.6250 in.

Corrosion Allowance CA 0.1250 in.

Skip UG-16(b) Min. thickness calculation NO

Type of Element: Cylindrical Shell

INTERNAL PRESSURE RESULTS, SHELL NUMBER 3, Desc.: EX1CVCYL

ASME Code, Section VIII, Division 1, Ed-2001, A-02

Thickness Due to Internal Pressure (TR):

= (P*(D/2+CA))/(S*E-0.6*P) per UG-27 (c)(1)

= (275.00*(50.0000/2+0.1250))/(20000.00*0.85-0.6*275.00)

= 0.4104 in.

Max. All. Working Pressure at Given Thickness (MAWP):

= (S*E*(T-CA))/((D/2+CA)+0.6*(T-CA)) per UG-27 (c)(1)

= (20000.00*0.85*(0.5000))/((50.0000/2+0.1250)+0.6*0.5000)

= 334.32 psig

Maximum Allowable Pressure, New and Cold (MAPNC):

= (SA*E*T)/(D/2+0.6*T) per UG-27 (c)(1)

= (20000.00*0.85*0.6250)/(50.0000/2+0.6*0.6250)

= 418.72 psig

Actual stress at given pressure and thickness (Sact):

= (P*((D/2+CA)+0.6*(T-CA)))/(E*(T-CA))

= (275.00*((50.0000/2+0.1250)+0.6*(0.5000)))/(0.85*(0.5000))

= 16451.47 psi

SUMMARY OF INTERNAL PRESSURE RESULTS:

Required Thickness plus Corrosion Allowance, Trca 0.5354 in.

Actual Thickness as Given in Input 0.6250 in.

Maximum Allowable Working Pressure MAWP 334.317 psig

Design Pressure as Given in Input P 275.000 psig

HYDROSTATIC TEST PRESSURES ( Measured at High Point ):

Hydrotest per UG-99(b); 1.3 * MAWP * Sa/S 434.61 psig

Hydrotest per UG-99(c); 1.3 * MAPN 544.33 psig

Pneumatic per UG-100 ; 1.1 * MAWP * Sa/S 367.75 psig

Percent Elongation per UCS-79 ( 50t/Rf * (1-Rf/Ro) ) 1.235 %

Min. Metal Temp. w/o impact per Fig. UCS-66 -48 F

Min. Metal Temp. at Req'd thk. (per UCS 66.1) -55 F

Min. Metal Temp. w/o impact per UG-20(f) -20 F

WEIGHT and VOLUME RESULTS, ORIGINAL THICKNESS:

Volume of Shell Component VOLMET 1988.0 in.**3

Weight of Shell Component WMET 562.6 lb.

Inside Volume of Component VOLID 39269.9 in.**3

Weight of Water in Component WWAT 1418.1 lb.

WEIGHT AND VOLUME RESULTS, CORRODED THICKNESS:

Volume of Shell Component, Corroded VOLMETCA 1594.4 in.**3

Weight of Shell Component, Corroded WMETCA 451.2 lb.

Inside Volume of Component, Corroded VOLIDCA 39663.6 in.**3

Weight of Water in Component, Corroded WWATCA 1432.3 lb.

EXTERNAL PRESSURE RESULTS, SHELL NUMBER 3, Desc.: EX1CVCYL

ASME Code, Section VIII, Division 1, Ed-2001, A-02

External Pressure Chart CS-2 at 300.00 F

Elastic Modulus for Material 29000000.00 psi

Results for Max. Allowable External Pressure (Emawp):

TCA OD SLEN D/T L/D Factor A B

0.5000 51.2500 20.00 102.50 0.3902 0.0036227 16683.28

EMAWP=(4*B)/(3*(D/T))=(4*16683.2773)/(3*102.5000)=217.0182 psig

Results for Reqd Thickness for Ext. Pressure (Tca):

TCA OD SLEN D/T L/D Factor A B

0.1114 51.2500 20.00 459.96 0.3902 0.0003569 5174.80

EMAWP=(4*B)/(3*(D/T))=(4*5174.8022)/(3*459.9623)=15.0007 psig

Results for Maximum Length Calculation: No Conversion

TCA OD SLEN D/T L/D Factor A B

0.5000 51.2500 0.10E+09 102.50 .2019E+07 0.0001047 1518.14

EMAWP=(4*B)/(3*(D/T))=(4*1518.1440)/(3*102.5000)=19.7482 psig

SUMMARY of EXTERNAL PRESSURE RESULTS:

Allowable Pressure at Corroded thickness 217.02 psig

Required Pressure as entered by User 15.00 psig

Required Thickness including Corrosion all. 0.2364 in.

Actual Thickness as entered by User 0.6250 in.

Maximum Length for Thickness and Pressure 0.1035E+09 in.

Actual Length as entered by User 20.00 in.

PVElite by ICAS Engineering Software

Example Shell Analysis

PVElite Licensee: ICAS Local White Lock

FileName : VESEXMPL -------------------------------------- Page 11

Shell Analysis : EX1CVCHEA Item: 4 2:38p Dec 16,2002

Input Echo, Component 4, Description: EX1CVCHEA

Design Internal Pressure P 275.00 psig

Temperature for Internal Pressure 150.00 F

Design External Pressure PEXT 15.00 psig

Temperature for External Pressure 150.00 F

External Pressure Chart Name CS-2

Include Hydrostatic Head Components NO

Material Specification (Normalized) SA-516 70

Material UNS Number K02700

Allowable Stress At Temperature S 20000.00 psi

Allowable Stress At Ambient SA 20000.00 psi

Curve Name for Chart UCS 66 D

Joint efficiency for Head Joint E 0.85

Maximum Thickness before Full Radiography 1.2500 in.

Inside Diameter of Elliptical Head D 50.0000 in.

Minimum Thickness of Pipe or Plate T 0.6900 in.

Corrosion Allowance CA 0.1250 in.

Aspect Ratio AR 2.0000

Length of Straight Flange STRTFLG 0.0000 in.

Skip UG-16(b) Min. thickness calculation NO

Type of Element: Elliptical Head

INTERNAL PRESSURE RESULTS, SHELL NUMBER 4, Desc.: EX1CVCHEA

ASME Code, Section VIII, Division 1, Ed-2001, A-02

Thickness Due to Internal Pressure (TR):

= (P*(D+2*CA)*K)/(2*S*E-0.2*P) Appendix 1-4(c)

= (275.00*(50.0000+2*0.1250)*1.00)/(2*20000.00*0.85-0.2*275.00)

= 0.4071 in.

Max. All. Working Pressure at Given Thickness (MAWP):

= (2*S*E*(T-CA))/(K*(D+2*CA)+0.2*(T-CA)) per Appendix 1-4 (c)

= (2*20000.00*0.85*(0.5650))/(1.00*(50.0000+2*0.1250)+0.2*(0.5650))

= 381.43 psig

Maximum Allowable Pressure, New and Cold (MAPNC):

= (2*SA*E*T)/(K*D+0.2*T) per Appendix 1-4 (c)

= (2*20000.00*0.85*0.6900)/(1.00*50.0000+0.2*0.6900)

= 467.91 psig

Actual stress at given pressure and thickness (Sact):

= (P*(K*(D+2*CA)+0.2*(T-CA)))/(2*E*(T-CA))

= (275.00*(1.00*(50.0000+2*0.1250)+0.2*(0.5650)))/(2*0.85*(0.5650))

= 14419.39 psi

SUMMARY OF INTERNAL PRESSURE RESULTS:

Required Thickness plus Corrosion Allowance, Trca 0.5321 in.

Actual Thickness as Given in Input 0.6900 in.

Maximum Allowable Working Pressure MAWP 381.431 psig

Design Pressure as Given in Input P 275.000 psig

HYDROSTATIC TEST PRESSURES ( Measured at High Point ):

Hydrotest per UG-99(b); 1.3 * MAWP * Sa/S 495.86 psig

Hydrotest per UG-99(c); 1.3 * MAPN 608.28 psig

Pneumatic per UG-100 ; 1.1 * MAWP * Sa/S 419.57 psig

Percent Elongation per UCS-79 ( 75t/Rf * (1-Rf/Ro) ) 6.005 %

Min. Metal Temp. w/o impact per Fig. UCS-66 -45 F

Min. Metal Temp. at Req'd thk. (per UCS 66.1) -55 F

Min. Metal Temp. w/o impact per UG-20(f) -20 F

WEIGHT and VOLUME RESULTS, ORIGINAL THICKNESS:

Volume of Shell Component VOLMET 2121.9 in.**3

Weight of Shell Component WMET 600.5 lb.

Inside Volume of Component VOLID 16362.5 in.**3

Weight of Water in Component WWAT 590.9 lb.

Inside Vol. of 0.00 in. Straight VOLSCA 0.0 in.**3

Total Volume for Head + Straight VOLTOT 16362.5 in.**3

WEIGHT AND VOLUME RESULTS, CORRODED THICKNESS:

Volume of Shell Component, Corroded VOLMETCA 1737.5 in.**3

Weight of Shell Component, Corroded WMETCA 491.7 lb.

Inside Volume of Component, Corroded VOLIDCA 16609.1 in.**3

Weight of Water in Component, Corroded WWATCA 599.8 lb.

Inside Vol. of 0.00 in. Straight, Corr. VOLSCA 0.0 in.**3

Total Volume for Head + Straight Corroded VOLTCA 16609.1 in.**3

EXTERNAL PRESSURE RESULTS, SHELL NUMBER 4, Desc.: EX1CVCHEA

ASME Code, Section VIII, Division 1, Ed-2001, A-02

External Pressure Chart CS-2 at 300.00 F

Elastic Modulus for Material 29000000.00 psi

Results for Max. Allowable External Pressure (Emawp):

TCA OD D/T Factor A B

0.5650 51.3800 90.94 0.0015273 14105.11

EMAWP=B/(K0*(D/T))=14105.1133/(0.9000*90.9381)=172.3409 psig

Results for Reqd Thickness for Ext. Pressure (Tca):

TCA OD D/T Factor A B

0.1330 51.3800 386.22 0.0003596 5214.29

EMAWP=B/(K0*(D/T))=5214.2935/(0.9000*386.2247)=15.0007 psig

SUMMARY of EXTERNAL PRESSURE RESULTS:

Allowable Pressure at Corroded thickness 172.34 psig

Required Pressure as entered by User 15.00 psig

Required Thickness including Corrosion all. 0.2580 in.

Actual Thickness as entered by User 0.6900 in.

PVElite by ICAS Engineering Software

Example Shell Analysis

PVElite Licensee: ICAS Local White Lock

FileName : VESEXMPL -------------------------------------- Page 14

Shell Analysis : EX1HEEXT Item: 5 2:38p Dec 16,2002

Input Echo, Component 5, Description: EX1HEEXT

Design Internal Pressure P 275.00 psig

Temperature for Internal Pressure 300.00 F

Design External Pressure PEXT 15.00 psig

Temperature for External Pressure 150.00 F

External Pressure Chart Name CS-2

Include Hydrostatic Head Components NO

Material Specification (Normalized) SA-516 70

Material UNS Number K02700

Allowable Stress At Temperature S 20000.00 psi

Allowable Stress At Ambient SA 20000.00 psi

Curve Name for Chart UCS 66 D

Joint efficiency for Head Joint E 0.85

Maximum Thickness before Full Radiography 1.2500 in.

Inside Diameter of Elliptical Head D 50.0000 in.

Minimum Thickness of Pipe or Plate T 0.6900 in.

Corrosion Allowance CA 0.1250 in.

Aspect Ratio AR 2.0000

Length of Straight Flange STRTFLG 0.0000 in.

Skip UG-16(b) Min. thickness calculation NO

Type of Element: Elliptical Head

INTERNAL PRESSURE RESULTS, SHELL NUMBER 5, Desc.: EX1HEEXT

ASME Code, Section VIII, Division 1, Ed-2001, A-02

Thickness Due to Internal Pressure (TR):

= (P*(D+2*CA)*K)/(2*S*E-0.2*P) Appendix 1-4(c)

= (275.00*(50.0000+2*0.1250)*1.00)/(2*20000.00*0.85-0.2*275.00)

= 0.4071 in.

Max. All. Working Pressure at Given Thickness (MAWP):

= (2*S*E*(T-CA))/(K*(D+2*CA)+0.2*(T-CA)) per Appendix 1-4 (c)

= (2*20000.00*0.85*(0.5650))/(1.00*(50.0000+2*0.1250)+0.2*(0.5650))

= 381.43 psig

Maximum Allowable Pressure, New and Cold (MAPNC):

= (2*SA*E*T)/(K*D+0.2*T) per Appendix 1-4 (c)

= (2*20000.00*0.85*0.6900)/(1.00*50.0000+0.2*0.6900)

= 467.91 psig

Actual stress at given pressure and thickness (Sact):

= (P*(K*(D+2*CA)+0.2*(T-CA)))/(2*E*(T-CA))

= (275.00*(1.00*(50.0000+2*0.1250)+0.2*(0.5650)))/(2*0.85*(0.5650))

= 14419.39 psi

SUMMARY OF INTERNAL PRESSURE RESULTS:

Required Thickness plus Corrosion Allowance, Trca 0.5321 in.

Actual Thickness as Given in Input 0.6900 in.

Maximum Allowable Working Pressure MAWP 381.431 psig

Design Pressure as Given in Input P 275.000 psig

HYDROSTATIC TEST PRESSURES ( Measured at High Point ):

Hydrotest per UG-99(b); 1.3 * MAWP * Sa/S 495.86 psig

Hydrotest per UG-99(c); 1.3 * MAPN 608.28 psig

Pneumatic per UG-100 ; 1.1 * MAWP * Sa/S 419.57 psig

Percent Elongation per UCS-79 ( 75t/Rf * (1-Rf/Ro) ) 6.005 %

Min. Metal Temp. w/o impact per Fig. UCS-66 -45 F

Min. Metal Temp. at Req'd thk. (per UCS 66.1) -55 F

Min. Metal Temp. w/o impact per UG-20(f) -20 F

WEIGHT and VOLUME RESULTS, ORIGINAL THICKNESS:

Volume of Shell Component VOLMET 2121.9 in.**3

Weight of Shell Component WMET 600.5 lb.

Inside Volume of Component VOLID 16362.5 in.**3

Weight of Water in Component WWAT 590.9 lb.

Inside Vol. of 0.00 in. Straight VOLSCA 0.0 in.**3

Total Volume for Head + Straight VOLTOT 16362.5 in.**3

WEIGHT AND VOLUME RESULTS, CORRODED THICKNESS:

Volume of Shell Component, Corroded VOLMETCA 1737.5 in.**3

Weight of Shell Component, Corroded WMETCA 491.7 lb.

Inside Volume of Component, Corroded VOLIDCA 16609.1 in.**3

Weight of Water in Component, Corroded WWATCA 599.8 lb.

Inside Vol. of 0.00 in. Straight, Corr. VOLSCA 0.0 in.**3

Total Volume for Head + Straight Corroded VOLTCA 16609.1 in.**3

EXTERNAL PRESSURE RESULTS, SHELL NUMBER 5, Desc.: EX1HEEXT

ASME Code, Section VIII, Division 1, Ed-2001, A-02

External Pressure Chart CS-2 at 300.00 F

Elastic Modulus for Material 29000000.00 psi

Results for Max. Allowable External Pressure (Emawp):

TCA OD D/T Factor A B

0.5650 51.3800 90.94 0.0015273 14105.11

EMAWP=B/(K0*(D/T))=14105.1133/(0.9000*90.9381)=172.3409 psig

Results for Reqd Thickness for Ext. Pressure (Tca):

TCA OD D/T Factor A B

0.1330 51.3800 386.22 0.0003596 5214.29

EMAWP=B/(K0*(D/T))=5214.2935/(0.9000*386.2247)=15.0007 psig

SUMMARY of EXTERNAL PRESSURE RESULTS:

Allowable Pressure at Corroded thickness 172.34 psig

Required Pressure as entered by User 15.00 psig

Required Thickness including Corrosion all. 0.2580 in.

Actual Thickness as entered by User 0.6900 in.

PVElite by ICAS Engineering Software

Example Shell Analysis

PVElite Licensee: ICAS Local White Lock

FileName : VESEXMPL -------------------------------------- Page 17

Nozzle Analysis : EX1NOZAB Item: 1 2:38p Dec 16,2002

Input Echo, Nozzle Item 1, Description: EX1NOZAB

Design Internal Pressure ( Case 1 ) P 200.00 psig

Temperature for Internal Pressure TEMP 150.00 F

Include Hydrostatic Head Components NO

Shell Material (Not Normalized or NA) SA-516 70

Material UNS Number K02700

Shell Allowable Stress at Temperature S 20000.00 psi

Shell Allowable Stress At Ambient SA 20000.00 psi

Inside Diameter of Cylindrical Shell D 46.0000 in.

Actual Thickness of Shell or Head T 0.5000 in.

Corrosion Allowance for Shell or Head CAS 0.1250 in.

Is this Nozzle a Radial Nozzle YES

Is this Nozzle a Lateral Nozzle (Y-angle) NO

The Attached Flange is Class CL 150 Grade GR 1.1

Nozzle Material (Not Normalized or NA) SA-106 B

Material UNS Number K03006

Nozzle Allowable Stress at Temperature SN 17100.00 psi

Nozzle Allowable Stress At Ambient SNA 17100.00 psi

Diameter Basis for Nozzle BASISN ID

Inside Diameter of Nozzle DIA 11.7500 in.

Nozzle Size and Thickness Basis DBN Actual

Actual Thickness of Nozzle THK 0.5000 in.

Corrosion Allowance for Nozzle CAN 0.1250 in.

Joint Efficiency of Shell Seam at Nozzle ES 1.00

Joint Efficiency of Nozzle Neck EN 1.00

Insert or Abutting Nozzle Type NTYP Abutting

Outward Projection of Nozzle HO 10.0000 in.

Weld leg size between Nozzle and Pad/Shell WO 0.5000 in.

Groove weld depth between Nozzle and Vessel WGNV 0.5000 in.

Pad Material (Not Normalized or NA) SA-516 70

Pad Allowable Stress at Temperature SN 20000.00 psi

Pad Allowable Stress At Ambient SNA 20000.00 psi

Diameter of Pad along vessel surface DP 15.7500 in.

Thickness of Pad TP 0.5000 in.

Weld leg size between Pad and Shell WP 0.5000 in.

Groove weld depth between Pad and Nozzle WGPN 0.5000 in.

Is this is Manway/Access/Inspection Opening No

Skip Iterative Failure Thickness Calculations No

NOZZLE CALCULATION, NOZZLE NUMBER 1, Description: EX1NOZAB

ASME Code, Section VIII, Div. 1, Ed-2001, A-02, UG-37 to UG-45

Actual Nozzle Inside Diameter Used in Calculation 11.750 in.

Actual Nozzle Thickness Used in Calculation 0.500 in.

Internal Pressure Results for SHELL/HEAD :

Required thickness per UG-37(a) of Cylindrical Shell, Tr CASE 1

Thickness Due to Internal Pressure (TR):

= (P*(D/2+CA))/(S*E-0.6*P) per UG-27 (c)(1)

= (200.00*(46.0000/2+0.1250))/(20000.00*1.00-0.6*200.00)

= 0.2326 in.

Internal Pressure Results for NOZZLE :

Required thickness per UG-37(a) of Nozzle Wall, Tr CASE 1

Thickness Due to Internal Pressure (TR):

= (P*(D/2+CA))/(S*E-0.6*P) per UG-27 (c)(1)

= (200.00*(11.7500/2+0.1250))/(17100.00*1.00-0.6*200.00)

= 0.0707 in.

UG-40, Thickness and Diameter Limit Results : CASE 1

Effective material diameter limit, DL 24.0000 in.

Effective material thickness limit, no pad TLNP 0.9375 in.

Effective material thickness limit, pad side TLWP 0.9375 in.

RESULTS of NOZZLE REINFORCEMENT AREA CALCULATIONS:

AREA AVAILABLE, A1 to A5 Design External Mapnc

Area Required AR 2.792 NA NA sq.in.

Area in Shell A1 1.708 NA NA sq.in.

Area in Nozzle Wall A2 0.488 NA NA sq.in.

Area in Inward Nozzle A3 0.000 NA NA sq.in.

Area in Welds A4 0.460 NA NA sq.in.

Area in Pad A5 1.500 NA NA sq.in.

TOTAL AREA AVAILABLE ATOT 4.157 NA NA sq.in.

Pressure Case 1 Governs the Analysis

Nozzle Tangent Angle Used in Area Calculations 90.00 Degs.

The area available without a pad is Insufficient.

The area available with the given pad is Sufficient.

SELECTION OF POSSIBLE REINFORCING PADS: Diameter Thickness

Based on given Pad Thickness: 13.1250 0.5000 in.

Based on given Pad Diameter: 15.7500 0.0625 in.

Based on Shell or Nozzle Thickness: 13.1250 0.5000 in.

Reinforcement Area Required for Nozzle:

AR = (DLR*TR+2*THK*TR*(1-FFR1)) UG-37(c) or UG-39

AR = (12.0000*0.2326+2*(0.5000-0.1250)*0.2326*(1.0-1.00))

AR = 2.792 sq.in.

Areas per UG-37.1 but with DL = Diameter Limit, DLR = Corroded ID:

Area Available in Shell (A1):

A1 = (DL-DLR)*(ES*(T-CAS)-TR)-2*(THK-CAN)*(ES*(T-CAS)-TR)*(1-FFR1)

A1 = (24.000-12.000)*(1.00*(0.5000-0.125)-0.233)-2*(0.500-0.125)

*(1.00*(0.5000-0.1250)-0.2326)*(1.0-1.00)

A1 = 1.708 sq.in.

Area Available in Nozzle Wall, no Pad:

A2NP = ( 2 * MIN(TLNP,HO) ) * ( THK - CAN - TRN ) * FFR2

A2NP = ( 2 * 0.9375 ) * ( 0.5000 - 0.1250 - 0.0707 ) * 0.86 )

A2NP = 0.488 sq.in.

Area Available in Nozzle Wall, with Pad:

A2WP = (2*MIN(TLWP,HO))*(THK-CAN-TRN)*FFR2

A2WP = ( 2 * 0.9375 ) * ( 0.5000 - 0.1250 - 0.0707 ) * 0.86 )

A2WP = 0.488 sq.in.

Area Available in Welds, no Pad:

A4NP = Wo^2*FFR2 + ( Wi-Can/0.707 )^2*FFR2

A4NP = 0.5000^2 * 0.8550 + ( 0.0000 )^2 * 0.8550

A4NP = 0.214 sq.in.

Area Available in Welds, with Pad:

A4wp = (Wo^2 - Ar Lost)*FFR3 + ((Wi-Can/0.707)^2 - Ar Lost)*FFR2 + Wp^2*FFR4

A4wp = ( 0.2461 ) * 0.86 + ( 0.0000 ) * 0.86 + 0.2500 * 1.00

A4WP = 0.460 sq.in.

Area Available in Pad:

A5 = (MIN(DP,DL)-(DIA+2*THK))*(Min(TP,TLWP,TE))*FFR4

A5 = ( 15.7500 - 12.7500 ) * 0.5000 * 1.00

A5 = 1.500 sq.in.

UG-45 Minimum Nozzle Neck Thickness Requirement:

= Max(Min(Max(Max(UG45B1,UG16B),Max(UG45B2,UG16B)),UG45B4),UG45A)

= Max(Min(Max(Max( 0.3576, 0.1875),Max( 0.1250, 0.1875)), 0.4531), 0.1957)

= 0.3576 < Minimum Nozzle Thickness 0.5000 in. OK

M.A.W.P. RESULTS FOR THIS NOZZLE GEOMETRY

Approximate M.A.W.P. for given geometry AMAP 247.914 psig

Pressure Rating for B16.5 Flange at 100.00 F is 285.0 psig

Pressure Rating for B16.5 Flange at 150.00 F is 272.5 psig

Weight of Nozzle, with Flange and Pad, Uncorroded 121.81 lb.

Weight of Nozzle, with Flange and Pad, Corroded 108.54 lb.

MINIMUM DESIGN METAL TEMPERATURE RESULTS: Nozzle Shell Pad

Minimum Temp. w/o impact per Fig. UCS-66 -6 -6 -6 F

Minimum Temp. at operating stress -146 -44 -44 F

Minimum Temp. w/o impact per UG-20(f) -20 -20 -20 F

Nozzle MDMT Thickness Calc. per UCS-66 1(b), MIN(tn,t,te)

Min. Metal Temp. w/o impact per Fig. UCS-66 -6 F

Min. Metal Temp. at Req'd thk. (per UCS 66.1) -146 F

Min. Metal Temp. w/o impact per UG-20(f) -20 F

WELD SIZE CALCULATIONS, NOZZLE NUMBER 1, Desc.: EX1NOZAB

Intermediate Calcs. for nozzle/shell welds Tmin 0.3750 in.

Intermediate Calcs. for pad/shell welds TminPad 0.3750 in.

Results Per UW-16.1, Required Thickness Actual Thickness

Nozzle Weld 0.2500 = Min per Code 0.3535 = 0.7 * WO , in.

Pad Weld 0.1875 = 0.5*TminPad 0.3535 = 0.7 * WP , in.

WELD STRENGTH AND WELD LOADS PER UG-41.1, SKETCH (a) OR (b)

W = (AR-A1)*S

W = ( 2.7918 - 1.7082 ) * 20000

W = 21670. lb.

W1 = (A2+A5+A4-(WII-CAN/.707)^2*FFR2)*S

W1 = ( 0.4879 + 1.5000 + 0.4604 - 0.0313 * 0.86 ) * 20000

W1 = 48431. lb.

STRENGTH OF CONNECTION ELEMENTS FOR FAILURE PATH ANALYSIS

SHEAR, OUTWARD NOZZLE WELD:

SONW = (PI/2)*DLO*WO*0.49*SNW

SONW = ( 3.1416 / 2.0 ) * 12.7500 * 0.5000 * 0.49 * 17100

SONW = 83906. lb.

SHEAR, PAD ELEMENT WELD:

SPEW = (PI/2)*DP*WP*0.49*SEW

SPEW = ( 3.1416 / 2.0 ) * 15.7500 * 0.5000 * 0.49 * 20000

SPEW = 121226. lb.

TENSION, PAD GROOVE WELD:

TPGW = (PI/2.0)*DLO*WGPN*0.74*SEG

TPGW = ( 3.1416 / 2.0 ) * 12.7500 * 0.5000 * 0.74 * 17100

TPGW = 126715. lb.

SHEAR, NOZZLE GROOVE WELD:

SNGW = (PI/2)*(DLR+WGNVA)*(WGNVA-CAN)*0.60*SNG

SNGW = ( 3.14/2)*( 12.000+ 0.500)*( 0.500- 0.1250)*0.6* 17100

SNGW = 75545. lb.

STRENGTH OF FAILURE PATHS:

PATH11 = ( SPEW + SNGW ) = ( 121226 + 75545 ) = 196771 lb.

SUMMARY OF FAILURE PATH CALCULATIONS:

Path 1-1 = 196771 lb., must exceed W = 21670 lb. or W1 = 48431 lb.

Iterative Results per Pressure, Area and UG-45:

( Assuming same Corr. All. for Shell and Nozzle)

Maximum (failure) Corrosion Allowance: 0.2107 in.

Minimum (failure) Nozzle Thickness: 0.2893 in.

Minimum (failure) Shell Thickness: 0.2893 in.

PVElite by ICAS Engineering Software

Example Shell Analysis

PVElite Licensee: ICAS Local White Lock

FileName : VESEXMPL -------------------------------------- Page 22

Nozzle Analysis : EX1NOZAC Item: 2 2:38p Dec 16,2002

Input Echo, Nozzle Item 2, Description: EX1NOZAC

Design Internal Pressure ( Case 1 ) P 275.00 psig

Temperature for Internal Pressure TEMP 150.00 F

Include Hydrostatic Head Components NO

Shell Material (Not Normalized or NA) SA-516 70

Material UNS Number K02700

Shell Allowable Stress at Temperature S 20000.00 psi

Shell Allowable Stress At Ambient SA 20000.00 psi

Inside Diameter of Cylindrical Shell D 46.0000 in.

Actual Thickness of Shell or Head T 0.6250 in.

Corrosion Allowance for Shell or Head CAS 0.1250 in.

Is this Nozzle a Radial Nozzle YES

Is this Nozzle a Lateral Nozzle (Y-angle) NO

The Attached Flange is Class CL 300 Grade GR 1.1

Nozzle Material (Not Normalized or NA) SA-106 B

Material UNS Number K03006

Nozzle Allowable Stress at Temperature SN 17100.00 psi

Nozzle Allowable Stress At Ambient SNA 17100.00 psi

Diameter Basis for Nozzle BASISN ID

Nominal Diameter of Nozzle DIA 10.0000 in.

Nozzle Size and Thickness Basis DBN Nominal

Nominal Thickness of Nozzle THKNOM SCH 80

Corrosion Allowance for Nozzle CAN 0.1250 in.

Joint Efficiency of Shell Seam at Nozzle ES 1.00

Joint Efficiency of Nozzle Neck EN 1.00

Insert or Abutting Nozzle Type NTYP Abutting

Outward Projection of Nozzle HO 10.0000 in.

Weld leg size between Nozzle and Pad/Shell WO 0.5000 in.

Groove weld depth between Nozzle and Vessel WGNV 0.5930 in.

Pad Material (Not Normalized or NA) SA-516 70

Pad Allowable Stress at Temperature SN 20000.00 psi

Pad Allowable Stress At Ambient SNA 20000.00 psi

Diameter of Pad along vessel surface DP 14.6250 in.

Thickness of Pad TP 0.6250 in.

Weld leg size between Pad and Shell WP 0.5000 in.

Groove weld depth between Pad and Nozzle WGPN 0.5000 in.

Is this is Manway/Access/Inspection Opening No

Skip Iterative Failure Thickness Calculations No

NOZZLE CALCULATION, NOZZLE NUMBER 2, Description: EX1NOZAC

ASME Code, Section VIII, Div. 1, Ed-2001, A-02, UG-37 to UG-45

Actual Nozzle Inside Diameter Used in Calculation 9.564 in.

Actual Nozzle Thickness Used in Calculation 0.593 in.

Internal Pressure Results for SHELL/HEAD :

Required thickness per UG-37(a) of Cylindrical Shell, Tr CASE 1

Thickness Due to Internal Pressure (TR):

= (P*(D/2+CA))/(S*E-0.6*P) per UG-27 (c)(1)

= (275.00*(46.0000/2+0.1250))/(20000.00*1.00-0.6*275.00)

= 0.3206 in.

Internal Pressure Results for NOZZLE :

Required thickness per UG-37(a) of Nozzle Wall, Tr CASE 1

Thickness Due to Internal Pressure (TR):

= (P*(D/2+CA))/(S*E-0.6*P) per UG-27 (c)(1)

= (275.00*(9.5640/2+0.1250))/(17100.00*1.00-0.6*275.00)

= 0.0797 in.

UG-40, Thickness and Diameter Limit Results : CASE 1

Effective material diameter limit, DL 19.6280 in.

Effective material thickness limit, no pad TLNP 1.1700 in.

Effective material thickness limit, pad side TLWP 1.2500 in.

RESULTS of NOZZLE REINFORCEMENT AREA CALCULATIONS:

AREA AVAILABLE, A1 to A5 Design External Mapnc

Area Required AR 3.147 NA NA sq.in.

Area in Shell A1 1.760 NA NA sq.in.

Area in Nozzle Wall A2 0.830 NA NA sq.in.

Area in Inward Nozzle A3 0.000 NA NA sq.in.

Area in Welds A4 0.464 NA NA sq.in.

Area in Pad A5 2.422 NA NA sq.in.

TOTAL AREA AVAILABLE ATOT 5.476 NA NA sq.in.

Pressure Case 1 Governs the Analysis

Nozzle Tangent Angle Used in Area Calculations 90.00 Degs.

The area available without a pad is Insufficient.

The area available with the given pad is Sufficient.

SELECTION OF POSSIBLE REINFORCING PADS: Diameter Thickness

Based on given Pad Thickness: 11.0000 0.6250 in.

Based on given Pad Diameter: 14.6250 0.0625 in.

Based on Shell or Nozzle Thickness: 11.0000 0.6250 in.

Reinforcement Area Required for Nozzle:

AR = (DLR*TR+2*THK*TR*(1-FFR1)) UG-37(c) or UG-39

AR = (9.8140*0.3206+2*(0.5930-0.1250)*0.3206*(1.0-1.00))

AR = 3.147 sq.in.

Areas per UG-37.1 but with DL = Diameter Limit, DLR = Corroded ID:

Area Available in Shell (A1):

A1 = (DL-DLR)*(ES*(T-CAS)-TR)-2*(THK-CAN)*(ES*(T-CAS)-TR)*(1-FFR1)

A1 = (19.628-9.814)*(1.00*(0.6250-0.125)-0.321)-2*(0.593-0.125)

*(1.00*(0.6250-0.1250)-0.3206)*(1.0-1.00)

A1 = 1.760 sq.in.

Area Available in Nozzle Wall, no Pad:

A2NP = ( 2 * MIN(TLNP,HO) ) * ( THK - CAN - TRN ) * FFR2

A2NP = ( 2 * 1.1700 ) * ( 0.5930 - 0.1250 - 0.0797 ) * 0.86 )

A2NP = 0.777 sq.in.

Area Available in Nozzle Wall, with Pad:

A2WP = (2*MIN(TLWP,HO))*(THK-CAN-TRN)*FFR2

A2WP = ( 2 * 1.2500 ) * ( 0.5930 - 0.1250 - 0.0797 ) * 0.86 )

A2WP = 0.830 sq.in.

Area Available in Welds, no Pad:

A4NP = Wo^2*FFR2 + ( Wi-Can/0.707 )^2*FFR2

A4NP = 0.5000^2 * 0.8550 + ( 0.0000 )^2 * 0.8550

A4NP = 0.214 sq.in.

Area Available in Welds, with Pad:

A4wp = Wo^2*FFR3 + (Wi-Can/0.707)^2*FFR2 + Wp^2*FFR4

A4wp = ( 0.5000 )^2 * 0.86 + ( 0.0000 )^2 * 0.86 + 0.5000^2 * 1.00

A4WP = 0.464 sq.in.

Area Available in Pad:

A5 = (MIN(DP,DL)-(DIA+2*THK))*(Min(TP,TLWP,TE))*FFR4

A5 = ( 14.6250 - 10.7500 ) * 0.6250 * 1.00

A5 = 2.422 sq.in.

UG-45 Minimum Nozzle Neck Thickness Requirement:

= Max(Min(Max(Max(UG45B1,UG16B),Max(UG45B2,UG16B)),UG45B4),UG45A)

= Max(Min(Max(Max( 0.4456, 0.1875),Max( 0.1250, 0.1875)), 0.4444), 0.2047)

= 0.4444 < Minimum Nozzle Thickness 0.5189 in. OK

M.A.W.P. RESULTS FOR THIS NOZZLE GEOMETRY

Approximate M.A.W.P. for given geometry AMAP 374.121 psig

Pressure Rating for B16.5 Flange at 100.00 F is 740.0 psig

Pressure Rating for B16.5 Flange at 150.00 F is 707.5 psig

Weight of Nozzle, with Flange and Pad, Uncorroded 150.03 lb.

Weight of Nozzle, with Flange and Pad, Corroded 139.44 lb.

MINIMUM DESIGN METAL TEMPERATURE RESULTS: Nozzle Shell Pad

Minimum Temp. w/o impact per Fig. UCS-66 3 6 6 F

Minimum Temp. at operating stress -137 -30 -30 F

Minimum Temp. w/o impact per UG-20(f) -20 -20 -20 F

Nozzle MDMT Thickness Calc. per UCS-66 1(b), MIN(tn,t,te)

Min. Metal Temp. w/o impact per Fig. UCS-66 3 F

Min. Metal Temp. at Req'd thk. (per UCS 66.1) -137 F

Min. Metal Temp. w/o impact per UG-20(f) -20 F

WELD SIZE CALCULATIONS, NOZZLE NUMBER 2, Desc.: EX1NOZAC

Intermediate Calcs. for nozzle/shell welds Tmin 0.4680 in.

Intermediate Calcs. for pad/shell welds TminPad 0.5000 in.

Results Per UW-16.1, Required Thickness Actual Thickness

Nozzle Weld 0.2500 = Min per Code 0.3535 = 0.7 * WO , in.

Pad Weld 0.2500 = 0.5*TminPad 0.3535 = 0.7 * WP , in.

WELD STRENGTH AND WELD LOADS PER UG-41.1, SKETCH (a) OR (b)

W = (AR-A1)*S

W = ( 3.1465 - 1.7605 ) * 20000

W = 27720. lb.

W1 = (A2+A5+A4-(WII-CAN/.707)^2*FFR2)*S

W1 = ( 0.8300 + 2.4219 + 0.4638 - 0.0313 * 0.86 ) * 20000

W1 = 73779. lb.

STRENGTH OF CONNECTION ELEMENTS FOR FAILURE PATH ANALYSIS

SHEAR, OUTWARD NOZZLE WELD:

SONW = (PI/2)*DLO*WO*0.49*SNW

SONW = ( 3.1416 / 2.0 ) * 10.7500 * 0.5000 * 0.49 * 17100

SONW = 70744. lb.

SHEAR, PAD ELEMENT WELD:

SPEW = (PI/2)*DP*WP*0.49*SEW

SPEW = ( 3.1416 / 2.0 ) * 14.6250 * 0.5000 * 0.49 * 20000

SPEW = 112567. lb.

TENSION, PAD GROOVE WELD:

TPGW = (PI/2.0)*DLO*WGPN*0.74*SEG

TPGW = ( 3.1416 / 2.0 ) * 10.7500 * 0.5000 * 0.74 * 17100

TPGW = 106838. lb.

SHEAR, NOZZLE GROOVE WELD:

SNGW = (PI/2)*(DLR+WGNVA)*(WGNVA-CAN)*0.60*SNG

SNGW = ( 3.14/2)*( 9.814+ 0.593)*( 0.593- 0.1250)*0.6* 17100

SNGW = 78494. lb.

STRENGTH OF FAILURE PATHS:

PATH11 = ( SPEW + SNGW ) = ( 112567 + 78494 ) = 191061 lb.

SUMMARY OF FAILURE PATH CALCULATIONS:

Path 1-1 = 191061 lb., must exceed W = 27720 lb. or W1 = 73778 lb.

Iterative Results per Pressure, Area and UG-45:

( Assuming same Corr. All. for Shell and Nozzle)

Maximum (failure) Corrosion Allowance: 0.1990 in.

Minimum (failure) Nozzle Thickness: 0.3940 in.

Minimum (failure) Shell Thickness: 0.4260 in.

PVElite by ICAS Engineering Software

Example Shell Analysis

PVElite Licensee: ICAS Local White Lock

FileName : VESEXMPL -------------------------------------- Page 32

Flohead Analysis : FLOATING HEAD Item: 1 2:38p Dec 16,2002

Input Echo, Floating Head Item 1, Description: FLOATING HEAD

Floating Head Type Appendix 1-6 type (d)

Tube Side ( Internal ) Design Pressure PTS 215.00 psig

Shell Side ( External ) Design Pressure PSS 275.00 psig

Design Temperature for Spherical Head TEMP 300.00 F

Head Material SA-516 70

Head Material UNS Number K02700

Head Allowable Stress at Temperature SOH 20000.00 psi

Head Allowable Stress at Ambient SAH 20000.00 psi

Crown Radius for Spherical Head CR 45.0000 in.

Head Thickness TH 1.1250 in.

Tube Side ( Internal ) Corrosion Allowance CATS 0.1250 in.

Shell Side ( External ) Corrosion Allowance CASS 0.1250 in.

Flange Material SA-105

Flange Material UNS Number K03504

Flange Allowable Stress at Temperature SOC 20000.00 psi

Flange Allowable Stress at Ambient SAC 20000.00 psi

Flange Outside Diameter FOD 49.3750 in.

Flange Inside Diameter FID 45.1250 in.

Flange Thickness TC 7.7500 in.

Bolt Material SA-193 B7

Bolt Material UNS Number G41400

Bolt Allowable Stress At Temperature SBO 23000.00 psi

Bolt Allowable Stress At Ambient SBA 23000.00 psi

Diameter of Bolt Circle DB 46.7500 in.

Nominal Bolt Diameter DBOLT 0.7500 in.

Type of Threads TEMA Thread Series

Number of Bolts 52

Full Face Gasket ( Yes or No ) No

Flange Face Outside Diameter FOD 45.6880 in.

Flange Face Inside Diameter FID 45.1250 in.

Gasket Outside Diameter GOD 45.7500 in.

Gasket Inside Diameter GID 45.1250 in.

Gasket Factor, m, M 5.5000

Gasket Design Seating Stress Y 18000.00 psi

Flange Facing Sketch 5, Code Sketch 2

Column for Gasket Seating 2, Code Column II

Gasket Thickness 0.1250 in.

Flange Face Nubbin Width 0.1250 in.

Distance from Head Centerline to Flange Centroid 1.5000 in.

The Flange is not Slotted.

Backing Ring Material Specification SA-105

Backing Ring Material UNS Number K03504

Backing Ring Allowable Stress, Temperature SOTS 20000.00 psi

Backing Ring Allowable Stress, Ambient SATS 20000.00 psi

Backing Ring Inside Diameter DR 45.6875 in.

Backing Ring Thickness TR 4.2500 in.

Number of Splits in Backing Ring NSPLIT 1

INTERNAL PRESSURE RESULTS FOR SPHERICAL HEADS

ASME Code, Section VIII, Div. 1, Ed-2001, A-02 Appendix 1-6

Thickness Due to Internal Pressure:

t = 5PL / 6S per Appendix 1-6

t = ( 5 * 215.00 * 45.1250 ) / ( 6 * 20000 )

t = 0.4042 in.

Maximum Allowable Working Pressure at Given Thickness:

Pa = 6S(T-Cass-Cats) / 5L per Appendix 1-6

Pa = ( 6 * 20000 * 0.8750 ) / ( 5 * 45.1250 )

Pa = 465.37 psig

Maximum Allowable Working Pressure, New and Cold:

Pnc = 6ST / 5L per Appendix 1-6

Pnc = ( 6 * 20000 * 1.1250 ) / ( 5 * 45.0000 )

Pnc = 600.00 psig

Actual stress at given pressure and thickness:

Sact = 5PL / 6(T-Cass-Cats) per Appendix 1-6

Sact = ( 5 * 215.00 * 45.1250 ) / ( 6 * 0.8750 )

Sact = 9240. psi

EXTERNAL PRESSURE RESULTS, SPHERICAL HEAD

ASME Code, Section VIII, Division 1, Ed-2001, A-02

External Pressure Chart CS-2 at 300.00 F

Elastic Modulus for Material 29000000.00 psi

Results for Maximum Allowable External Pressure:

TCA OD D/T Factor A B

0.8750 46.0000 105.14 0.0023777 15586.98

EMAWP = B/( (0D/T)/ 2 ) = 15586.9805 /( 105.1429/2.0) = 296.4915

Results for Reqd Thickness for Ext. Pressure (Tca):

TCA OD D/T Factor A B

0.8217 92.0000 111.97 0.0022328 15397.09

EMAWP=B/((D/T)/2)=15397.0898/(111.9651/2)=275.0337 psig

INTERMEDIATE CALCULATIONS FOR FLANGED PORTION:

ASME Code, Section VIII, Div. 1, Ed-2001, A-02 App. 2 Gasket Contact Width, N = (GOD-GID) / 2 0.312 in.

Basic Gasket Width, B0 = (GNBWTH+3*N) / 8.0 0.133 in.

Effective Gasket Width, BE = B0 0.133 in.

Gasket Reaction Diameter, G = (GOD+GID) / 2.0 45.407 in.

Bolting Information for TEMA Thread Series :

Total Area of Bolts 15.704 sq.in.

Minimum radial distance between hub and bolts 1.125 in.

Minimum radial distance between bolts and edge 0.813 in.

Minimum circumferential spacing between bolts 1.750 in.

Actual circumferential spacing between bolts 2.823 in.

Maximum circumferential spacing between bolts 9.250 in.

Basic Flange and Bolt loads:

Hydrostatic End Load due to Pressure H 348148.4 lb.

Contact Load on Gasket Surfaces HP 44806.2 lb.

Hydrostatic End Load at Flange ID HD 347665.5 lb.

Pressure Force on Flange Face HT 482.9 lb.

Radial Component of Head Membrane Force HH 609473.4 lb.

Operating Bolt Load: WM1 392954.6 lb.

Gasket Seating Bolt Load WM2 341019.6 lb.

Required Bolt Area AM 17.085 sq.in.

Flange Design Bolt Load (Seating) W 377073.3 lb.

Gasket Seating Force (Operating) HG 44806.2 lb.

Distance to Gasket Load Reaction DHG 0.6717 in.

Distance to Face Pressure Reaction DHT 0.6796 in.

Distance to End Pressure Reaction DHD 0.6875 in.

SUMMARY OF MOMENTS FOR INTERNAL PRESSURE:

LOADING Force Distance Bolt Corr Moment

End Pressure, Md 347666. 0.6875 1.0000 19918. ft.lb.

Face Pressure, Mt 483. 0.6796 1.0000 27. ft.lb.

Gasket Load, Mg 44806. 0.6717 1.0000 2508. ft.lb.

Floating Hd. Load, Mh 609473. 1.5000 1.0000 -76184. ft.lb.

Gasket Seating, Ma 377073. 0.6717 1.0000 21108. ft.lb.

TOTAL MOMENT FOR OPERATION ( Internal Pressure ) 53730. ft.lb.

TOTAL MOMENT FOR GASKET SEATING ( Int. Pressure ) 21108. ft.lb.

Basic Flange and Bolt loads:

Hydrostatic End Load due to Pressure H 445306.1 lb.

Contact Load on Gasket Surfaces HP 57310.2 lb.

Hydrostatic End Load at Flange ID HD 444688.5 lb.

Pressure Force on Flange Face HT 617.7 lb.

Radial Component of Head Membrane Force HH 779559.0 lb.

Operating Bolt Load: WM1 392954.6 lb.

Gasket Seating Bolt Load WM2 341019.6 lb.

Required Bolt Area AM 17.085 sq.in.

Flange Design Bolt Load (Seating) W 377073.3 lb.

Gasket Seating Force (Operating) HG 445306.1 lb.

Distance to Gasket Load Reaction DHG 0.6717 in.

Distance to Face Pressure Reaction DHT 0.6796 in.

Distance to End Pressure Reaction DHD 0.6875 in.

SUMMARY OF MOMENTS FOR EXTERNAL PRESSURE:

LOADING Force Distance Bolt Corr Moment

End Pressure, Md 444688. 0.0158 1.0000 584. ft.lb.

Face Pressure, Mt 618. 0.0079 1.0000 0. ft.lb.

Floating Hd. Load, Mh 779559. 1.5000 1.0000 -97445. ft.lb.

Gasket Seating, Ma 377073. 0.6717 1.0000 21108. ft.lb.

TOTAL MOMENT FOR OPERATION ( External Pressure ) 96861. ft.lb.

TOTAL MOMENT FOR GASKET SEATING ( Ext. Pressure ) 21108. ft.lb.

Required thickness for Main Flange, internal operating conditions:

T = F + SQRT( F * F + J ) per 1-6(g)

T = 1.268 + SQRT( 1.268 * 1.268 + 17.904 )

T = 5.6858 in.

Required thickness for Main Flange, internal bolt-up conditions:

T = F + SQRT( F * F + J ) per 1-6(g)

T = 0.000 + SQRT( 0.000 * 0.000 + 7.034 )

T = 2.6521 in.

Required thickness for Main Flange, external operating conditions:

T = F + SQRT( F * F + J ) per 1-6(g)

T = 1.622 + SQRT( 1.622 * 1.622 + 32.276 )

T = 7.5308 in.

Required thickness for Main Flange, external bolt-up conditions:

T = F + SQRT( F * F + J ) per 1-6(g)

T = 0.000 + SQRT( 0.000 * 0.000 + 7.034 )

T = 2.6521 in.

Required thickness for Backing Ring, internal operating conditions:

T = SQRT( M Y / S B ) Per App 2-7(b)(9)

T = SQRT( 417514.3 * 24.888 / ( 20000.0 * 45.688 ) )

T = 3.3722 in.

Required thickness for Backing Ring, internal bolt-up conditions:

T = SQRT( M Y / S B ) Per App 2-7(b)(9)

T = SQRT( 400640.4 * 24.888 / ( 20000.0 * 45.688 ) )

T = 3.3034 in.

SUMMARY OF REQUIRED THICKNESSES: Head Flange Backing Ring

Tubeside (Internal) Pressure 0.4042 5.6858 3.3722 in.

Shellside (External) Pressure 0.8217 7.5308 in.

Tubeside Gasket Seating Load 2.6521 3.3034 in.

Shellside Gasket Seating Load 2.6521 in.

Maximum + Corrosion Allowance 1.0717 7.7808 3.3722 in.

Actual Thickness as Given 1.1250 7.7500 4.2500 in.

WEIGHT OF HEAD AND FLANGE:

Weight of Spherical Head, Uncorroded WHD 544.9 lb.

Weight of Spherical Head, Corroded WHDCA 428.9 lb.

Weight of Flange Ring, Uncorroded WFL 691.8 lb.

Weight of Flange Ring, Corroded WFLCA 610.4 lb.

Weight of Backing Ring, Uncorroded WBR 331.1 lb.

Weight of Backing Ring, Corroded WBRCA 286.2 lb. PVElite by ICAS Engineering Software

al - Example Shell Analysis

PVElite Licensee: ICAS Local White Lock

FileName : VESEXMPL -------------------------------------- Page 37

Flange Analysis : EX1CHLF1 Item: 1 2:38p Dec 16,2002

Input Echo, Flange Item 1, Description: EX1CHLF1

Description of Flange Geometry (Type) Integral Weld Neck

Description of Flange Analysis Partial, Thickness

Design Pressure P 200.00 psig

Design Temperature 150.00 F

Corrosion Allowance FCOR 0.0000 in.

Flange Inside Diameter B 46.2500 in.

Flange Outside Diameter A 51.2500 in.

Thickness of Hub at Small End G0 0.3750 in.

Thickness of Hub at Large End G1 0.5625 in.

Length of Hub HL 1.5000 in.

Perform thickness calcs. based on rigidity No

Flange Material (Not Normalized) SA-105

Flange Material UNS Number K03504

Flange Allowable Stress At Temperature SFO 20000.00 psi

Flange Allowable Stress At Ambient SFA 20000.00 psi

Bolt Material SA-193 B7

Bolt Material UNS Number G41400

Bolt Allowable Stress At Temperature SBO 25000.00 psi

Bolt Allowable Stress At Ambient SBA 25000.00 psi

Diameter of Bolt Circle C 49.6250 in.

Nominal Bolt Diameter DB 0.7500 in.

Type of Threads TEMA Thread Series

Number of Bolts 92

Flange Face Outside Diameter FOD 48.0000 in.

Flange Face Inside Diameter FID 46.2500 in.

Flange Facing Sketch 5, Code Sketch 2

Gasket Outside Diameter GOD 47.7500 in.

Gasket Inside Diameter GID 46.7500 in.

Gasket Factor, m, M 3.7600

Gasket Design Seating Stress Y 7600.00 psi

Column for Gasket Seating 2, Code Column II

Gasket Thickness 0.1250 in.

Flange Face Nubbin Width 0.1250 in.

FLANGE ANALYSIS, FLANGE NUMBER 1, Description: EX1CHLF1

ASME Code, Section VIII, Division 1, App. 2, Ed-2001, A-02

Corroded Flange ID, BCOR = B+2.0*FCOR 46.250 in.

Corroded Large Hub, G1COR = G1-FCOR 0.562 in.

Corroded Small Hub, G0COR = G0-FCOR 0.375 in.

Code R Dimension, R = (C-B)/2.0 - G1 1.125 in.

Gasket Contact Width, N = (GOD-GID) / 2 0.500 in.

Basic Gasket Width, B0 = (GNBWTH+3*N) / 8.0 0.203 in.

Effective Gasket Width, BE = B0 0.203 in.

Gasket Reaction Diameter, G = (GOD+GID) / 2.0 47.250 in.

Basic Flange and Bolt loads:

Hydrostatic End Load due to Pressure:

H = 0.785 * G * G * PEQ

H = 0.7854 * 47.2500 * 47.2500 * 200.0000

H = 350690. lb.

Contact Load on Gasket Surfaces:

HP = 2 * BE * PI * G * M * P

HP = 2 * 0.2031 * 3.1416 * 47.2500 * 3.7600 * 200.00

HP = 45348. lb.

Hydrostatic End Load at Flange ID:

HD = 0.785 * Bcor * Bcor * P

HD = 0.785 * 46.2500 * 46.2500 * 200.0000

HD = 336003. lb.

Pressure Force on Flange Face:

HT = H - HD

HT = 350690 - 336003

HT = 14687. lb.

Operating Bolt Load:

WM1 = H + HP + HPP

WM1 = ( 350690 + 45348 + 0 )

WM1 = 396039. lb.

Gasket Seating Bolt Load:

WM2 = Y * BE * PI * G + Ypart * BEpart * GLPG + HPGY

WM2 = 7600.00*0.2031*3.141*47.250+7600.00*0.0000*0.00

WM2 = 229155. lb.

Required Bolt Area:

AM = Maximum of WM1/SBO, WM2/SBA

AM = Maximum of 396038 / 25000 , 229154 / 25000

AM = 15.8415 sq.in.

Bolting Information for TEMA Thread Series:

Total Area of Bolts, AB 27.784 sq.in.

Minimum radial distance between hub and bolts 1.125 in.

Minimum radial distance between bolts and edge 0.813 in.

Minimum circumferential spacing between bolts 1.750 in.

Actual circumferential spacing between bolts 1.694 in.

Maximum circumferential spacing between bolts 5.667 in.

Min. Gasket Contact Width (Brownell Young):

Nmin = AB * SBA/(Y * PI * (GOD+GID) )

= 27.784 * 25000.00/( 7600.00 * 3.14 * ( 47.75 + 46.75) )

Nmin = 0.308 in.

Flange Design Bolt Load, Gasket Seating:

W = SBA * ( AM + AB ) / 2.0

W = 25000.00 * ( 15.8415 + 27.7840 ) / 2.0

W = 545319.31 lb.

Gasket Seating Force:

HG = WM1 - H

HG = 396038 - 350690

HG = 45348.50 lb.

MOMENT ARM CALCULATIONS:

Distance to Hub Large End:

R = (C - BCOR) / 2 - G1COR

R = ( 49.625 - 46.250) / 2 - 0.562

R = 1.1250 in.

Distance to Gasket Load Reaction:

DHG = (C - G ) / 2.0

DHG = ( 49.6250 - 47.2500 ) / 2.0

DHG = 1.1875 in.

Distance to Face Pressure Reaction:

DHT = ( R + G1COR + DHG ) / 2.0

DHT = ( 1.1250 + 0.5625 + 1.1875 ) / 2.0

DHT = 1.4375 in.

Distance to End Pressure Reaction:

DHD = R + ( G1COR / 2.0 )

DHD = 1.1250 + ( 0.5625 / 2.0 )

DHD = 1.4062 in.

SUMMARY OF MOMENTS FOR INTERNAL PRESSURE:

LOADING Force Distance Bolt Corr Moment

End Pressure, MD 336003. 1.4062 1.0000 39375. ft.lb.

Face Pressure, MT 14687. 1.4375 1.0000 1759. ft.lb.

Gasket Load, MG 45348. 1.1875 1.0000 4488. ft.lb.

Gasket Seating, MA 545319. 1.1875 1.0000 53964. ft.lb.

TOTAL MOMENT FOR OPERATION, RMO 45622. ft.lb.

TOTAL MOMENT FOR GASKET SEATING, RMA 53964. ft.lb.

Effective Hub Length, H0 = SQRT(BCOR*G0COR) 4.165 in.

Hub Ratio, HRAT = HL / H0 0.360

Thickness Ratio, GRAT = (G1COR/G0COR) 1.500

Flange Factors for Integral Flange:

Factor F per 2-7.2 0.870

Factor V per 2-7.3 0.349

Factor f per 2-7.6 1.000

Factors from Figure 2-7.1 K = 1.108

T = 1.874 U = 20.753

Y = 18.885 Z = 9.776

d = 34.776 in.^3 e = 0.209 in.^-1

Stress Factors ALPHA = 1.618

BETA = 1.824 GAMMA = 0.863

DELTA = 0.745 LAMBDA = 1.608 Longitudinal Hub Stress, Operating:

SHO = ( f * RMO / BCOR ) / ( Rlambda * G1COR^2 )

SHO = ( 1.0000 * 547468 / 46.2500 ) / ( 1.6078 * 0.5625^2 )

SHO = 23268. psi

Longitudinal Hub Stress, Seating:

SHA = ( f * RMA / BCOR ) / ( Rlambda * G1COR^2 )

SHA = ( 1.0000 * 647566 / 46.2500 ) / ( 1.6078 * 0.5625^2 )

SHA = 27523. psi

Radial Flange Stress, Operating:

SRO = ( BETA * RMO / BCOR ) / ( Rlambda * TH^2 )

SRO = ( 1.8239 * 547468 / 46.2500 ) / ( 1.6078 * 2.9585^2 )

SRO = 1534. psi

Radial Flange Stress, Seating:

SRA = ( BETA*RMA/BCOR ) / ( Rlambda*TH^2 )

SRA = ( 1.8239 * 647566/ 46.2500 ) / ( 1.6078 * 2.9585^2 )

SRA = 1815. psi

Tangential Flange Stress, Operating:

STO = ( Y*RMO / (TH*TH*BCOR) ) - Z*SRO

STO = ( 18.8853 * 547468 / ( 2.9585^2 * 46.2500) ) - 9.7756 * 1534

STO = 10543. psi

Tangential Flange Stress, Seating:

STA = ( Y*RMA / (TH^2*BCOR) ) - Z*SRA

STA = ( 18.8853 * 647566 / ( 2.9585^2 * 46.2500) ) - 9.7756 * 1814

STA = 12471. psi

Average Flange Stress, Operating:

SAO = ( SHO + MAX( SRO, STO ) ) / 2

SAO = ( 23268 + MAX( 1534, 10543 ))/ 2

SAO = 16906. psi

Average Flange Stress, Seating:

SAA = ( SHA + MAX( SRA, STA ) ) / 2

SAA = ( 27522 + MAX( 1814, 12471 ))/ 2

SAA = 19997. psi

Bolt Stress, Operating:

BSO = ( WM1 / AB )

BSO = ( 396038 / 27.7840 )

BSO = 14254. psi

Bolt Stress, Seating:

BSA = ( WM2 / AB )

BSA = ( 229154 / 27.7840 )

BSA = 8248. psi

Stress Computation Results: OPERATING GASKET SEATING

Actual Allowed Actual Allowed

Longitudinal Hub 23268. 30000. 27523. 30000. psi

Radial Flange 1534. 20000. 1815. 20000. psi

Tangential Flange 10543. 20000. 12471. 20000. psi

Maximum Average 16906. 20000. 19997. 20000. psi

Bolting 14254. 25000. 8248. 25000. psi

Minimum Required Flange Thickness + CA 2.958 in.

Estimated M.A.W.P. ( Operating ) 236.6 psig

Estimated M.A.W.P. ( Gasket Seating ) 200.1 psig

Estimated Finished Weight of Flange 349.8 lb.

Estimated Unfinished Weight of Forging 483.1 lb.

APP. S Flange Rigidity Index for Seating Case 1.431

APP. S Flange Rigidity Index for Operating Case 1.228

Minimum Design Metal Temperature Results:

Min. Metal Temp. w/o impact per Fig. UCS-66 15 F

Min. Metal Temp. at Req'd thk. (per UCS 66.1) 15 F

Min. Metal Temp. w/o impact per UG-20(f) -20 F PVElite by ICAS Engineering Software

Example Shell Analysis

PVElite Licensee: ICAS Local White Lock

FileName : VESEXMPL -------------------------------------- Page 42

Flange Analysis : EX1CHLF2 Item: 2 2:38p Dec 16,2002

Input Echo, Flange Item 2, Description: EX1CHLF2

Description of Flange Geometry (Type) Integral Weld Neck

Description of Flange Analysis Partial, Thickness

Design Pressure P 200.00 psig

Design Temperature 150.00 F

Corrosion Allowance FCOR 0.0000 in.

Flange Inside Diameter B 46.2500 in.

Flange Outside Diameter A 51.2500 in.

Thickness of Hub at Small End G0 0.3750 in.

Thickness of Hub at Large End G1 0.5625 in.

Length of Hub HL 1.5000 in.

Perform thickness calcs. based on rigidity No

Flange Material (Not Normalized) SA-105

Flange Material UNS Number K03504

Flange Allowable Stress At Temperature SFO 20000.00 psi

Flange Allowable Stress At Ambient SFA 20000.00 psi

Bolt Material SA-193 B7

Bolt Material UNS Number G41400

Bolt Allowable Stress At Temperature SBO 25000.00 psi

Bolt Allowable Stress At Ambient SBA 25000.00 psi

Diameter of Bolt Circle C 49.6250 in.

Nominal Bolt Diameter DB 0.7500 in.

Type of Threads TEMA Thread Series

Number of Bolts 92

Flange Face Outside Diameter FOD 48.0000 in.

Flange Face Inside Diameter FID 46.2500 in.

Flange Facing Sketch 5, Code Sketch 2

Gasket Outside Diameter GOD 47.7500 in.

Gasket Inside Diameter GID 46.7500 in.

Gasket Factor, m, M 3.7600

Gasket Design Seating Stress Y 7600.00 psi

Column for Gasket Seating 2, Code Column II

Gasket Thickness 0.1250 in.

Flange Face Nubbin Width 0.1250 in.

Mating Flange Operating Bolt Load 563270.00 lb.

Mating Flange Seating Bolt Load 233280.00 lb.

Mating Flange Design Bolt Load 583369.00 lb.

FLANGE ANALYSIS, FLANGE NUMBER 2, Description: EX1CHLF2

ASME Code, Section VIII, Division 1, App. 2, Ed-2001, A-02

Corroded Flange ID, BCOR = B+2.0*FCOR 46.250 in.

Corroded Large Hub, G1COR = G1-FCOR 0.562 in.

Corroded Small Hub, G0COR = G0-FCOR 0.375 in.

Code R Dimension, R = (C-B)/2.0 - G1 1.125 in.

Gasket Contact Width, N = (GOD-GID) / 2 0.500 in.

Basic Gasket Width, B0 = (GNBWTH+3*N) / 8.0 0.203 in.

Effective Gasket Width, BE = B0 0.203 in.

Gasket Reaction Diameter, G = (GOD+GID) / 2.0 47.250 in.

Basic Flange and Bolt loads:

Hydrostatic End Load due to Pressure:

H = 0.785 * G * G * PEQ

H = 0.7854 * 47.2500 * 47.2500 * 200.0000

H = 350690. lb.

Contact Load on Gasket Surfaces:

HP = 2 * BE * PI * G * M * P

HP = 2 * 0.2031 * 3.1416 * 47.2500 * 3.7600 * 200.00

HP = 45348. lb.

Hydrostatic End Load at Flange ID:

HD = 0.785 * Bcor * Bcor * P

HD = 0.785 * 46.2500 * 46.2500 * 200.0000

HD = 336003. lb.

Pressure Force on Flange Face:

HT = H - HD

HT = 350690 - 336003

HT = 14687. lb.

Operating Bolt Load:

WM1 = H + HP + HPP

WM1 = ( 350690 + 45348 + 0 )

WM1 = 396039. lb.

WM1 = 563270. lb., Mating Flange Load Governs

Gasket Seating Bolt Load:

WM2 = Y * BE * PI * G + Ypart * BEpart * GLPG + HPGY

WM2 = 7600.00*0.2031*3.141*47.250+7600.00*0.0000*0.00

WM2 = 229155. lb.

WM2 = 233280. lb., Mating Flange Load Governs

Required Bolt Area:

AM = Maximum of WM1/SBO, WM2/SBA

AM = Maximum of 563270 / 25000 , 233280 / 25000

AM = 22.5308 sq.in.

Bolting Information for TEMA Thread Series:

Total Area of Bolts, AB 27.784 sq.in.

Minimum radial distance between hub and bolts 1.125 in.

Minimum radial distance between bolts and edge 0.813 in.

Minimum circumferential spacing between bolts 1.750 in.

Actual circumferential spacing between bolts 1.694 in.

Maximum circumferential spacing between bolts 6.149 in.

Min. Gasket Contact Width (Brownell Young):

Nmin = AB * SBA/(Y * PI * (GOD+GID) )

= 27.784 * 25000.00/( 7600.00 * 3.14 * ( 47.75 + 46.75) )

Nmin = 0.308 in.

Flange Design Bolt Load, Gasket Seating:

W = SBA * ( AM + AB ) / 2.0

W = 25000.00 * ( 22.5308 + 27.7840 ) / 2.0

W = 628935.00 lb.

Gasket Seating Force:

HG = WM1 - H

HG = 563270 - 350690

HG = 212579.91 lb.

MOMENT ARM CALCULATIONS:

Distance to Hub Large End:

R = (C - BCOR) / 2 - G1COR

R = ( 49.625 - 46.250) / 2 - 0.562

R = 1.1250 in.

Distance to Gasket Load Reaction:

DHG = (C - G ) / 2.0

DHG = ( 49.6250 - 47.2500 ) / 2.0

DHG = 1.1875 in.

Distance to Face Pressure Reaction:

DHT = ( R + G1COR + DHG ) / 2.0

DHT = ( 1.1250 + 0.5625 + 1.1875 ) / 2.0

DHT = 1.4375 in.

Distance to End Pressure Reaction:

DHD = R + ( G1COR / 2.0 )

DHD = 1.1250 + ( 0.5625 / 2.0 )

DHD = 1.4062 in.

SUMMARY OF MOMENTS FOR INTERNAL PRESSURE:

LOADING Force Distance Bolt Corr Moment

End Pressure, MD 336003. 1.4062 1.0000 39375. ft.lb.

Face Pressure, MT 14687. 1.4375 1.0000 1759. ft.lb.

Gasket Load, MG 212580. 1.1875 1.0000 21037. ft.lb.

Gasket Seating, MA 628935. 1.1875 1.0000 62238. ft.lb.

TOTAL MOMENT FOR OPERATION, RMO 62171. ft.lb.

TOTAL MOMENT FOR GASKET SEATING, RMA 62238. ft.lb.

Effective Hub Length, H0 = SQRT(BCOR*G0COR) 4.165 in.

Hub Ratio, HRAT = HL / H0 0.360

Thickness Ratio, GRAT = (G1COR/G0COR) 1.500

Flange Factors for Integral Flange:

Factor F per 2-7.2 0.870

Factor V per 2-7.3 0.349

Factor f per 2-7.6 1.000

Factors from Figure 2-7.1 K = 1.108

T = 1.874 U = 20.753

Y = 18.885 Z = 9.776

d = 34.776 in.^3 e = 0.209 in.^-1

Stress Factors ALPHA = 1.689

BETA = 1.919 GAMMA = 0.901

DELTA = 1.034 LAMBDA = 1.935

Longitudinal Hub Stress, Operating:

SHO = ( f * RMO / BCOR ) / ( Rlambda * G1COR^2 )

SHO = ( 1.0000 * 746055 / 46.2500 ) / ( 1.9352 * 0.5625^2 )

SHO = 26344. psi

Longitudinal Hub Stress, Seating:

SHA = ( f * RMA / BCOR ) / ( Rlambda * G1COR^2 )

SHA = ( 1.0000 * 746860 / 46.2500 ) / ( 1.9352 * 0.5625^2 )

SHA = 26373. psi

Radial Flange Stress, Operating:

SRO = ( BETA * RMO / BCOR ) / ( Rlambda * TH^2 )

SRO = ( 1.9191 * 746055 / 46.2500 ) / ( 1.9352 * 3.3005^2 )

SRO = 1468. psi

Radial Flange Stress, Seating:

SRA = ( BETA*RMA/BCOR ) / ( Rlambda*TH^2 )

SRA = ( 1.9191 * 746860/ 46.2500 ) / ( 1.9352 * 3.3005^2 )

SRA = 1470. psi

Tangential Flange Stress, Operating:

STO = ( Y*RMO / (TH*TH*BCOR) ) - Z*SRO

STO = ( 18.8853 * 746055 / ( 3.3005^2 * 46.2500) ) - 9.7756 * 1468

STO = 13610. psi

Tangential Flange Stress, Seating:

STA = ( Y*RMA / (TH^2*BCOR) ) - Z*SRA

STA = ( 18.8853 * 746860 / ( 3.3005^2 * 46.2500) ) - 9.7756 * 1470

STA = 13624. psi

Average Flange Stress, Operating:

SAO = ( SHO + MAX( SRO, STO ) ) / 2

SAO = ( 26344 + MAX( 1468, 13609 ))/ 2

SAO = 19977. psi

Average Flange Stress, Seating:

SAA = ( SHA + MAX( SRA, STA ) ) / 2

SAA = ( 26372 + MAX( 1470, 13624 ))/ 2

SAA = 19999. psi

Bolt Stress, Operating:

BSO = ( WM1 / AB )

BSO = ( 563270 / 27.7840 )

BSO = 20273. psi

Bolt Stress, Seating:

BSA = ( WM2 / AB )

BSA = ( 233280 / 27.7840 )

BSA = 8396. psi

Stress Computation Results: OPERATING GASKET SEATING

Actual Allowed Actual Allowed

Longitudinal Hub 26344. 30000. 26373. 30000. psi

Radial Flange 1468. 20000. 1470. 20000. psi

Tangential Flange 13610. 20000. 13624. 20000. psi

Maximum Average 19977. 20000. 19999. 20000. psi

Bolting 20273. 25000. 8396. 25000. psi

Minimum Required Flange Thickness + CA 3.301 in.

MAWP Cannot be calculated due to Entered Mating Flange Loads.

Estimated Finished Weight of Flange 386.8 lb.

Estimated Unfinished Weight of Forging 520.2 lb.

APP. S Flange Rigidity Index for Seating Case 1.371

APP. S Flange Rigidity Index for Operating Case 1.390

Minimum Design Metal Temperature Results:

Min. Metal Temp. w/o impact per Fig. UCS-66 21 F

Min. Metal Temp. at Req'd thk. (per UCS 66.1) 21 F

Min. Metal Temp. w/o impact per UG-20(f) -20 F

PVElite by ICAS Engineering Software

al - Example Shell Analysis

PVElite Licensee:

FileName : VESEXMPL -------------------------------------- Page 66

Vessel Results Summary Item: 1 2:38p Dec 16,2002

Summary for shell/head, Div 1:

MAPNC MAWP Tr-int Tr-ext EMAWP

Description psig psig in. in. psig

--------------------------------------------------------------------

EX1CHCYL 364.807 273.019 0.399 0.231 166.170

EX1CHCYL 454.545 362.860 0.503 0.406 63.313

EX1CVCYL 418.719 334.317 0.535 0.236 217.018

EX1CVCHEA 467.909 381.431 0.532 0.258 172.341

EX1HEEXT 467.909 381.431 0.532 0.258 172.341

--------------------------------------------------------------------

Minimum MAWP 364.807 273.019 63.313

Note: Reqd. thk. reported above includes Corrosion Allowance.

The Total Shell/Head weight is ( New and Cold ) 7831.5 lb.

The Total Shell/Head weight is ( Corroded ) 6281.2 lb.

The Total Shell/Head volume is ( New and Cold ) 467943.1 in.**3

The Total Shell/Head volume is ( Corroded ) 473145.6 in.**3

Summary for Nozzles :

MAWP FLG MAWP EXT P UG-45 WLD PATH

Description psig psig CHECK CHECK CHECK

----------------------------------------------------------------------------

EX1NOZAB 247.914 272.500 -- OK OK 90°

EX1NOZAC 374.121 707.500 -- OK OK 90°

EX1NOZAD 383.184 707.500 -- OK OK 90°

----------------------------------------------------------------------------

Minimum MAWP 247.914 272.500

ASME Floating Head Results Summary for : FLOATING HEAD

Required Thicknesses: Head Flange Backing Ring

Tubeside (Internal) Pressure 0.4042 5.6858 3.3722 in.

Shellside (External) Pressure 0.8217 7.5308 0.0000 in.

Tubeside Gasket Seating Load 2.6521 3.3034 in.

Shellside Gasket Seating Load 2.6521 0.0000 in.

Maximum + Corrosion Allowance 1.0717 7.7808 3.6222 in.

Actual Thickness as Given 1.1250 7.7500 4.2500 in.

MAWP Results for Spherical Head :

MAWP New and Cold ( Internal Pressure ) 600.000 psig

MAWP Corroded ( Internal Pressure ) 465.374 psig

External MAWP for Spherical Head 296.491 psig

Note: MAWP calculations are not performed for the Flange/Backing Ring !

Flange Results Summary for : EX1CHLF1

Flange Type: Integral Weld Neck Analyze Option: Partial, Thk

Design Pressure Peq: 200.00 psig

Flange Diameters id: 46.250 od: 51.250 in.

Gasket Diameters id: 46.750 od: 47.750 in.

Gasket Factors m: 3.760 y: 7600.000 psi

Flange has 92 Bolts 0.750 in. at BCD 49.625 in.

Min. Required Flange Thickness per ASME + CA 2.958 in.

Operating Seating

MAWP 236.604 200.084

Rigidity Index 1.228 1.431

Note: The Flange passed, for the Internal Pressure.

Flange MDMT -20.00 F

The finished weight of the flange 349.775 lb.

The unfinished weight of the flange 483.103 lb.

Flange Results Summary for : EX1CHLF2

Flange Type: Integral Weld Neck Analyze Option: Partial, Thk

Design Pressure Peq: 200.00 psig

Flange Diameters id: 46.250 od: 51.250 in.

Gasket Diameters id: 46.750 od: 47.750 in.

Gasket Factors m: 3.760 y: 7600.000 psi

Flange has 92 Bolts 0.750 in. at BCD 49.625 in.

Min. Required Flange Thickness per ASME + CA 3.301 in.

Operating Seating

Rigidity Index 1.390 1.371

Flange MDMT -20.00 F

The finished weight of the flange 386.837 lb.

The unfinished weight of the flange 520.165 lb.

Flange Results Summary for : EX1SHFLF1

Flange Type: Integral Weld Neck Analyze Option: Partial, Thk

Design Pressure Peq: 200.00 psig

Flange Diameters id: 46.250 od: 51.250 in.

Gasket Diameters id: 46.750 od: 47.750 in.

Gasket Factors m: 3.760 y: 7600.000 psi

Flange has 92 Bolts 0.750 in. at BCD 49.625 in.

Min. Required Flange Thickness per ASME + CA 3.300 in.

Operating Seating

Rigidity Index 1.390 1.371

Flange MDMT -20.00 F

The finished weight of the flange 386.817 lb.

The unfinished weight of the flange 520.145 lb.

Flange Results Summary for : EX1SHFLF2

Flange Type: Integral Weld Neck Analyze Option: Partial, Thk

Design Pressure Peq: 275.00 psig

Flange Diameters id: 46.250 od: 55.500 in.

Gasket Diameters id: 51.625 od: 52.625 in.

Gasket Factors m: 3.760 y: 7600.000 psi

Flange has 92 Bolts 0.750 in. at BCD 53.875 in.

Min. Required Flange Thickness per ASME + CA 4.502 in.

Operating Seating

MAWP 275.013 1264.783

Rigidity Index 1.068 0.320

Note: The Flange passed, for the Internal Pressure.

Flange MDMT 36.89 F

The finished weight of the flange 980.931 lb.

The unfinished weight of the flange 1255.653 lb.

Flange Results Summary for : EX1CVFL2

Flange Type: Integral Weld Neck Analyze Option: Partial, Thk

Design Pressure Peq: 275.00 psig

Flange Diameters id: 50.250 od: 55.500 in.

Gasket Diameters id: 51.625 od: 52.625 in.

Gasket Factors m: 3.760 y: 7600.000 psi

Flange has 92 Bolts 0.750 in. at BCD 53.875 in.

Min. Required Flange Thickness per ASME + CA 3.206 in.

Operating Seating

MAWP 275.033 587.714

Rigidity Index 1.331 0.845

Note: The Flange passed, for the Internal Pressure.

Flange MDMT -20.00 F

The finished weight of the flange 435.848 lb.

The unfinished weight of the flange 580.672 lb.

Flange Results Summary for : EX1CHCV

Flange Type: TEMA Channel Cover Analyze Option: Partial, Thk

Design Pressure Peq: 200.00 psig

Flange Diameters id: 0.000 od: 51.250 in.

Gasket Diameters id: 47.375 od: 48.375 in.

Gasket Factors m: 3.760 y: 7600.000 psi

Flange has 92 Bolts 0.750 in. at BCD 49.625 in.

Min. Required Flange Thickness per ASME + CA 4.118 in.

Min. Required Flange Thickness per TEMA + CA 2.753 in.

TEMA Cover Deflection Actual: 0.0300 in. Allowed: 0.0300 in.

Warning: TEMA Actual Deflection > Allowed Deflection !

Operating Seating

MAWP 199.999 1279.802

Warning: The Flange Failed, for Internal Pressure !

Flange MDMT -55.00 F

The finished weight of the flange 2403.840 lb.

The unfinished weight of the flange 2403.840 lb.

Least MAWP and Overall Weight Results :

The Least MAWP (N C) for EX1CHCYL was 364.81 psig .

The Least MAWP (Cor) for EX1CHLF2 was 0.00 psig .

The total sum of the Weights ( N C ) was 13595.08 lb. .

The total sum of the Weights ( Cor ) was 11225.28 lb. .

PVElite by ICAS Engineering Software