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ENGINEERING SOFTWARE

Pressure Vessel
Design and AnalVsis

Seminar Notes

Revised 6/2001

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 Table of Contents

Table ofContents

Chapter 1: II/trodl/ctioll to the Semil/a/' & the Sofhl'are

Purpose of the Seminar 1
Structure of the Seminar 1
Seminar Da)' I /
Semillar Da)' 2 2
Seminar Da)' 3 2
Overall Notes 2
About the Software 2
CodeCalc: The PVElite Component Anal)'sis Pmgram 2
Features 2
SUlJlmalY ojApplications 3

Chapter 2: Ol'erl'iew ofthe ASME Code

History of the Code 1
Organization of the Code 2
Scope and Limitations of the Code 3
Allowable Tensile Stress per the Code 4
Internal pressure 011 shells and heads 5
C)'lindCl's 5
Spheres, Elliptical Heads, Torispherieal Heads 7
Important Terms for analyzing cylinders and heads 8
Geometry for Pressure Vessel Heads 8
Elliptical Heads 8
Hemispherical Heads 9
Geometry for Pressure Vessel Heads 10
Torispherical Heads /0

Press lire Vessel Design am/ Af1al)'sis

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Chapter 3: Usil/g the Program-The 1I1ail/ Mel/II
File Menu 1
New 2
Open 2
Save 2
Save As 3
Prillt 3
Prilll Prel';ew 3
Prilll Setup J
Exit 3
Previous FOlll' Files 3
Edit Menu 4
Title Page 4
Project Data 4
Insert New Item 4
Delete Current Item 4
Se/ecl All 4
Dese/ecl All 4
Analyze Menu 5
Browse 5
Analyze Selected Items 5
Analyze Current Componenl 5
SlImmll1Y 5
Choose Analysis Type 5
Output Menu 6
Tools Menu 7
Configuratioll Options 7
Comput3tion Control Tab 7
Miscellaneous Options 9
Set Unit 9
Make UI/il File 10
Calculator I J
Edit/Add Materials Dialog JJ
Diagnostics Menu 13
CRC Check /3
Build Version Check J3
DLL Versio/1 Check 13

ii Pressure Vessel Design find Analysis

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 View Menu 14
ESL Menu 15
Phone Updmc J5
GClIemle Fax Codes J5
ReceiJ'c lind Enler Fax Codes /5
View ESL In/ormation J 5
Help Menu 16
Camel/IS J6
Tip of Ihe Da)' 16
Illfo 16

Chapter 4: Example Problem l-A Simple Dl'lIm

Problem 1
Specifications
Brittle Fracture - Minimum Design Metal Temperature 10
External Pressure on shells aud heads 21
Stiffening 27
What do )'011 need to kllow 10 analyze cylinders alld heads for external
pressure? 28
External Pressure OUU1 28
Diameter 28
Actual (or assumed) Thickness 29
Design Length for the Vessel or Vessel Segment 29
Width and Thickness of Reinforcing Rings 29
Nozzle Reinforcement and Failure Path Calculations 36
Hillside and Off-Angle Nozzle Angles 45
What do you need 10 know /0 pelform nozzle reinforcement calClllatiolls? 50
Required Thickness of Head or Shell and N07..z1e 50
Geometry ofNol.7.le and Shell 50
Diameter Limit, Thickness Limit 51
Is the Nozzle ill a Seam? 51
Details of Nozzle Welds 51
Largc Nozzle Considerations 51
Mallway or Access Opening 51

Press"re Vessel Design and Analysis iii

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Chapter 5: Cones and Conical Sections
Guidelines for Cones I
Typical Geometry for a Simple Cone 2
What do yOll need (0 know to perform cone calculations? 5
Dimensions of/he COile am/the Cylinders at Either End 5
Dimensions o/Trallsifioll Klluckles ar
allY exist) 5
HalfApex Angle of fhe COliC 5
Axial Forces 011 'he COile 5
Width alld 11/ickncss o.rCone Reinforcement 5

Chapter 6: Welt/ed Flat Heads

Guidelines for Welded Flal Heads 1
Whal do you need to know to analyze welded nat heads? 4
Af/achme,,' Dctails 4
Required lIlId AClllal Thickness o/Ihe Shelf 4
Large ami Small Dimensions for the Head 4

Chapter 7: Half-Pipe Jackets

Guidelines for Half-Pipe Jackets
Flange Design and Analysis 7
Gaskets 7
Gasket Materials and Gasket Factors 8
Other Gasket Types 12
Facing Sketches 12
Flange Types 13
Flange Behavior 16
Flange Stresses 20
Stress Analysis 20
Blind Flanges and Channel Covers 38
Large Central Openings 46

Chapter 8: Floating Heads ami Spherically Dished Covers

Types of Spherically Dished Covers 1
Description 1
Exmnple 2

iv Pressure Vessel Design find Analysis

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Chapter 9: Heat Exchallger Tubesheets
TEMA Tubesheets 1
ASME Tubesheets 17

Chapter 10: Expallsioll Joillts

Flanged and Flued Expansion loints 1
Prc~surc Vessel Design and Analysis Seminar Component Design Problem 5
Metal Bellows Expansion Joints 16
Pressure Vessel Design and Analysis Seminar Cornponcllt Design Problem 19

Chapter 11: Stresses

Stresses in Shells due to Loads on Attachments
Discussion of Results 3
WRC 107 Stress Calculations 3
Why are the Stresses al Edge of the Pad the Same as at the Edge of the NOlzle? 3
What arc the Allowable Stresses? 4
IYRe/O? Stress SUlIlmatiollS 5
ASME Section VIII Division2-Elaslic Analysis a/Nozzle 6
Stresses in Horizontal Pressure Vessels 20

Chapter 12: Tall Vertical Towers

Allowable Stresses on Tall Towers 1
Analyzing Tall Vertical Process Towers 2
Design Procedure 3
Wind Load Computations 3
Wind Pressl/re Complllation 4
Earthquake Load Computation 5
Skirt and BaseRing Design 11
Basering Thickness Calculations 11
Thickness of Basering llnder Tension 14
Thickness of Top Ring under Tension 14
Basering Design Selections 15
Calculation of Required Area for Each Bolt 15
Selection of tile Bolt Size 15

PreSSl/re Vessel Design and Analysis v

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 Selection of Preliminary l3asering Gcometly 15
Analysis of Preliminary Uasering Geometry 15
Sclection of Final Bascring Gcomctry 15
Analysis of Uasering Thickncsses 16
Skirt 11lickness Calculations /6
13asic Skirt Thickness 16
Stress in Ski'1 due to Gussets or Top Ring 16

Chapter 13: Vessel Legs, Support Lugs, and Lifting Lugs

Vessel Legs I
Support Lugs 3
Lining Lugs 4

Bibliogmphy

vi Pressure Vessel Design alltl Analysis

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Pressure Vessel Design and Analysis - Seminar Notes

Chapter 1: Introduction to the

Seminar & the Software

PURPOSE OF THE SEMINAR

Weleome to COADE's Pressure Vessel Design and Analysis Seminar. The purpose of this
course is to help you become comfortable with the guidelines for designing and analyzing
pressure vessels, and to make you more effective at your job by introducing you to com-
puterized design tools for pressure vessels-the CodeCale program and the PVElile pro-
gram.
The intent of this course is IlQ1 to have you memorize the exael rules of the ASME Code
for pressure vessel design. Instead, we want you to become morc familiar with the ASME
Code, be able to find what you need to know in it. "'nd above all be able to spot unrealistic
results or questionable designs, whether gcncrated by you, by a computer. or by some
other engineer. In a nutshell, we want to teach you what you need to know to successfully
apply the ASME Code to pressure vessel design and analysis.

STRUCTURE OF THE SEMINAR

Our approach to this goal will be to look at pressure vessels on a component by component
basis. In other words, we will study separately each of the many pressure vessel compo-
nents-sheils, heads, nozzles, flanges, tubesheets, etc. This approach is widely practiced
by engineers as they design or analyze pressure vessels. It also allows us to start with rela-
tively simple components and progress to more complicated ones. Most of the lecturcs in
the course will have the following fonnat:
Introduction to the theory of analysis for a particular component.
Detailed review of ASME Code rules associated with a particular component.
Design of the component using the CodeCale or PVElile programs.

Seminar Day 1
The first area to cover includes the history nnd structure of the ASME Code, calculation of
nllowable stresses using Code rules, and review of the scope of vessels covered by the
Code.
This section of the seminar also inCludes a discussion of the design of some of the most
basic components of pressure vessels: shells, heads, and nozzles. We will begin with rules
for internal pressure design of shells and heads, along with associated mles for weld effi-
ciency and brittle fracture. We will also learn how to use the CodeC~lc program, espe-
cially the SHELL program for internal pressllre analysis.

Introduction to the Seminar & the Software 1-1

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Abollt the Software Pressure Vessel Design and Analysis· Semin<tr Notes

We will then stndy the mles for external pressnre design of shells and heads. If time per-
mits we will also study nozzle reinforcement and the design of Oal head and conical sec-
tions. This will complete our study of components typically associated with drums.

Seminar Day 2
On day two we will study components associated with heat exch~lI1gers. \\le will extell-
sively study flanges and bolted flanged connections such as those in TEMA channel cov-
ers, ASM E blind flanges, and floating heads ofheat exchangers. We will look at
tubeshccts, including floaling, stationary, and fixed tubesheet designs, as well as metal
bellows expansion joints and flanged and nued expansion joints, commonly lIsed in heat
exchangers to absorb differential thermal stress.

Seminar Day 3
On day three we will focus on tall vertical pressure vessels and vessel supports. We will
review the loadings on tall vessels, such as wind and earthquake. We will also review the
design of vessel skirts and base rings, horizontal vessels on saddle supports, and legs or
support lugs which arc commonly used for smaller yessels and exchangers. We will also
study yessel-shell stresses that arc caused by loads on attachmcnts, including nozzles and
support lugs.

Overall Notes
This notebook is arranged to allow yOll to work step-by-step through the course, and to
work example problems of each type of calculatiou. Plenty of space has been left to take
additional notes.
We want to encourage you to ask questions and make comments during the course so that
we can cover the material you 1110st want to learn. A three day course is really 100 short to
fully explore both the theoretical and the practical aspects of the ASME Code, but we do
want to cover as much of these topics as possible. Your input will make this easier and
more effective.

ABOUT THE SOFTWARE

CodeCalc: The PVElile Component Analysis Program
The CodeCale program is a package of seyenleen applications for the design and analysis
of pressure vessels and heat exchangers. The purpose of the program is to provide the
mechanical engineer with easy 10 use, technically sound, well documented calculations
that will speed and simplify the task ofyessel design or re-rating.
Calculations in the CodeCalc program are based on the latest editions of national codes
such as the ASME Boiler and Pressure Vessel Code, or industry standards such as the Zick
method of analysis for horizontal drums. The CocicCalc program offers exceptional case
of usc, which results in dramatic improvement in efficiency for both design and re-rating.
One expert estimates that the time he needs (0 rcrate an exchanger has been reduced from
eight hours to two hours.

Features
The following arc features of the CorieCalc/PVElile program:

1-2 Introduction to the Seminar & the Softwmc

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Pressure Vessel Design and Analysis. Seminar Notes Abollt the SoOwarc

Thc Windows cnvironmcnt provides cxtcnsive on-line help at a keystrokc, and man-
ages multiple analysis files so that thc USCI' CHn define a whole pressure vcssel in a sin-
gle file.
The USCI' Cfln define his own unit systcm, opening CodeCfllc 10 thc world of metric
and Sf calculations. Internally, however, calculations continuc to be in the English sys-
tcm of units, assuring continued compliance with ASME Code requirements.
The CodeC"le progmm has " complete m"teri"llibmry including over 2000 t"bles of
allowable stress versus temperature and 49 external pressure charts.
The CodcCalc program also includes a component library which contains diameter
and wall thickness for all standard pipc sizes, pressure vs. temperature charts for
ANSI B 16.5 nanges, "nd section properties for AISC beam sections.
A sUlllmary capabi lity allows evaluation of all the components of a pressure vessel or
hcat exchanger. Design pressure, temperature, material, and Maximuill Allowable
Working Pressure are shown for each component.
Printed output from the CodcCalc program is exceptionally clear and complcte, with
user definable headings on each pagc. User comments and additions Illay bc inserted
at any point in the output. The ability to save any analysis to disk m<lkes it easy to
keep records and do revisions.
High quality documentation with complete operating instmctions, tlltorifll, and many
example problems makes the CodeC"1c program suitable for both beginners and
experts.

Summary of Applications
The following applie"tions are avail"ble in the CodeC"le Program:
SHELL-lntern"1 and external pressure design of vessels and exeh"ngers using the
ASME Code, Section VIII, Division I mles. Components include cylinders, coni-
cal sections, elliptical heads, tori spherical heads, nat heads, and spheric"1 shells
and heads. This program calculates required thickncss and maximum allowable
intern<ll prcssure for thc given componcnt. It also calculates the minimum design
metal temperature per UCS-66, and evaluates stiffening rings for external pressure
design.

NOZZLE-Required w"1I thickness and reinforcement under internal pressure for

nozzles in shells and heads, using the ASME Code, Section VIII, Division I mles
and including tables of outside diameter and wall thickness for all nominal pipe
diameters and schcdulcs. The program also calculates the strength of reinforce-
mcnt and evaluates failure paths for the nozzle.

CONICAL-lnternal and external pressure analysis of conical sections and stiffening

rings using the ASME Code, Section VIII, Division I mles. Complete are" of
reinforcement and moment of inertia calculations for the cone under both internal
<lnd cxternal pressure are included.

HALFPIPE-Intcrnal pressure design for vessels with split pipc type j"eketing. The
program calculates the required thickness of the vessel wall as well as the required
thickness of the halfpipej"ekel. l3ased on ASME, Section VIII, Division I,
Appendix EE.

FLOHEAD-Jntern"1 "nd exten,"1 pressure "nalysis of bolted dished heads (/loating

heads) using the ASME Code, Scetion VIII, Division I mles. An "dditional e"leu-

Introduction to the Scminar & the Softwmc 1-3

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About the Sofiwarc Pressure Vessel Design and Analysis - Seminar Notes

lations technique allowed by the Code (Soehren's ealeulation) is also imple-

mented by this program.
FLANGE-Stress analysis and geometry selection for all types of flanges using Ihe
ASME Code, Section VIII, Division I mles. This program bOlh designs and ana-
lyzes the following types of flanges:

Weld neck flanges and all integral flange types

Slip on flanges and all loose flange Iypes with hubs
Ring type flanges and all loose flange types without hubs
Blind flanges, both circular and non~circlliar
TEMA channel covers
Reverse geometry weld neck flanges
Flat faced flanges with full face gaskets

LGCENTER-Stress analysis for flat heads with a large, central circular opening
based on ASME, Section VIII, Division I, Appendix 14. The program calculates
the stresses at both the OD of the head and the location of the opening.

TUI3SHT-Analysis of aillypes of lubesheets using Ihe Seventh Edition of the Stan-

dards of the Tubular Exchanger Manufaelurers Association. The program takes
full account of the effects of tubesheets extended as flanges, and'for fixed
lubesheets also includes the effects of differentialthemlal expansion and the pres-
ence of an expansion joint.
ASMETUI3E-Analysis of several types of tubesheets using the mles from Appendix
AA of the ASME Code, Section VlIl, Division I. This appendix provides alter-
nate mles for tubesheet design, and may result in thinner tubesheets than the
TEMA program.

HORIZVES-Slress analysis of horizontal dmms on saddle supports using the

method of L.P. Ziek. Results include stresses at the saddles, the midpoint of the
vessel, and in Ihe heads. Stiffening rings used inlhe design of the vessel arc also
evaluated.

LEG&LUG-Analysis of vessel support legs, support lugs, and lifling lugs. This anal-
ysis is based on industry standard calculation techniques, and the resulting
stresses are compared to the AISC Handbook of Steel Construction or the ASME
Code. A full table of AlSC beams, channels and angles is included in the program.

PIPE&PAD-Required wall thickness and maximum allowable working pressure for

two pipes, and branch reinforcement rcquirements for the same two pipes consid-
ered as a branch and a header. I3ased on ANSI 1331.3 mles, this program includes
tables of outside diamcter and wall thickness for all nominal pipe diameters and
schedules.

WRC 107-Stresses in cylindrical or spherical shells due to loading on an attachment,

using the method of P.P. I3ijlaard as defined in Welding Research Council Bulletin
107.

I3ASERING-Thickness calculations and design for annular plate base rings, lop
rings, bolting, and gussets. Thesc calculations are performed using industry stan-
(!cud calculation techniques.

1-4 Introduction to the Seminar & the Sofiware

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Pressure Vesscl Dcsign and Analysis - Seminar Notes About the Sofiware

THINJNT-Calculates stress in a metal bellows expansion joint of the type typically

used in piping and heat exchangers. The program does elastic stress analysis for
stresses due to internal pressure and opening or closing of the joint, and calculates
the cycle life of the joint based on the ASME Code, Section VIII, Division I,
Appendix BB.

THICKJNT-Calculates stresses in a heat exchanger expansion joint fabricated from

relatively thick plate, also called flanged and filled expansion joints, using the
mles of the TEMA Seventh Edition, Paragraph RCB-8. The analysis is based on
the equivalent geometry used in "Expansion Joints for Heat Exchangers" by S.
Kopp and M. f. Sayre, with slight modifications.

RECTVES-Perfonns stress calculations and Maximum Allowable Working Pressure

calculations for the rectangular, obround, and circular vessels described in the
ASM E Code, Section VIII, Division I, Appends 13. The calculations arc taken
from Sections 13-6 through 13-13.

SUMMARY-Description and evalnation of all the components ofa pressure vessel

or heat exchanger. Design pressure, temperature, material, actual thickness, and
Maximum Allowable Working Pressure are shown for each component.

Introduction to thc Scminar & thc Software t -5

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About the Software Pressure Vessel Design and Analysis - Seminar Notes

1-6 Introduction to lhe Seminar & the Soflwarc

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Pressure Vessel Design and AllCllysis - SeminClr Notes

Chapter 2: Overview
of the ASME Code

HISTORY OF THE CODE

The Boiler Codc has becn in existence for almost 90 years.
During the 1800's there wcre numerous catastrophic failures of prcssure vessels and boil-
ers, resulting in thousands of deaths.
Public and professional concern resulted in the release of the first mles for power boilers
in 1915.
The first pressure vessel Code was issued by the ASME in 1925.
In 1968 the Code was divided into two subsections:
Section VIII, Division 1 - Rules for Constmction of Pressure Vessels.
Section VIII, Division 2 - Alternative Rules for Pressure Vessels.
The main differences between Division 1 and Division 2 are
Division 2 has higher allowable stresses in most cases - resulting in thinner vessels.
Division 2 also has more sophisticated design requirements, requiring more extensive
stress analysis than is used in Division J.
Division 2 frequcntly requires a fatigue analysis.
Division 2 frequently requires more extensive inspection and record keeping than
Division
In 1992, the Code moved the allowable stress tables and external prcssure charts for mate-
rials from Section VIII, Division 1 to Section II, Part D. This new publication contains all
of the material data from previous editions of Section Vlll, Division I, plus a few new ref-
erence tables from other sections.
Division 3, whieh is a new division intended fOf high prcssufe vessels, has been in prepa-
ration for sevcral years, and is now issued.
Section VIII, Division I is by far the most widely used of the two current divisions.
Almost all the pressure vessels constmeted in the U.S. are constmcted to Division 1.
In this course, unless specifically noted otherwise, "The Code ll is Section VIII, Division I.
ASME approves Code Case 2290 which increases Division I allowable stresses.

Overview orlhe ASME Code 2-1

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Organization of the Code Pressure Vessel Design and Analysis - Seminar Notes

ORGANIZATION OF THE CODE

The Code is divided into three Subseelions, pins Mandatory Appendices and NOl1Jnanda-
tory appendices
Thc three subsections cover
A - General Requiremcnts
B - Requirements Pertaining to Methods of Fabrication of Pressure Vessels
Part UW - Requirements for Pressure Vessels rabricated by Welding
Pari ur - Requirements for Pressure Vessels rabricaled by rorging
Part UB - Requiremenls for Pressure Vessels rabricated by Brazing.
C - Rcquircmcnts Pertaining to Classes of Materials
Part UCS - Carbon and Low Alloy Steels
Part UNr - Nonferrous Materials
Part UCI - Cast lron
Part UCL - Clad and Lined Vessels
Part UCD - Cast Ductile Iron
Part UHT - Heal trealed ferritie steels
ParI ULW - Layered Construclion
Part ULT - Materials with higher allowable stresses at low temperature
Mandatory appendices cover snbjects nol covered in the main body of the Code. The
requirements of these appendices are mandatory when the subject covered is appropriate
10 the eonslmction oflhe vessel.

Nonmandatory appendices provide information and suggest good practices relative to

prcssure vessel construction. They also scrve as a place where new design rules 3rc intro-
duced and tested before moving into the mandatory requirements.

2-2 Overview of the ASME Code

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Pressure Vessel Design and Analysis - Seminar Notes Scope and Limitations of the Code

SCOPE AND LIMITATIONS OF THE CODE

Section VIII, Division I applies to all pressurized containers, but with Ilumerous excep-
tions. Some of the exceptions listed in paragraph U-I include
Vessels within the scope of other sections (i.e. power boilers).
Fired process tubular heaters (furnaces)
Pressure containers that arc part ora machine (i.e. pumps)
Piping or piping components
Pressurized water storage up to 300 psi
Ileated water storage up to 210°F
Vessels with design pressure 15 psi or less
Vessels with a maximum cross section dimension 6 in. or less
Vessels for Human Occupancy
Division I rules are applicable to vessels not exceeding 3000 psi design pressure. You can
usc Division I above 3000 psi, but special precautions to avoid fatigue and other additions
to the mles are recommended.
The scope of Division I includes the nozzles and attachments to the vessel.
Unfired steam boilers may be constmeted to Division 1 or Section I. Some classes, such
as evaporators or vessels in chemical plants fife required to meet Division I.
SOIIle small vessels are exempt from inspection:
Up to 5 cubic feet at 250 psi
Up to 1.5 cubic feet at 600 psi
ANY Vessel that meets ali the requirements of Division I may be stamped with a U stamp
even though exempted by one of the above limitations.

Overview of the ASME Code 2-3

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Allowable Tensile Stress per the Code Pressure Vessel Design anu Analysis - Seminar Notes

ALLOWABLE TENSILE STRESS PER THE CODE

Division I mles arc based on a maximum principle stress failurc theory. While not very
accuratc, this thcory is simple to understand and apply.
By way of contrast, Division 2 is based on a maximum shear stress theory, which is more
accuratc. Somc other Codcs are based on the even more accurate theory of maximum dis-
tortion encrgy (Von mises stress).
The allowable tensile strcss for materials in Division I is the minimnm of the following
stresses:
1/3.5 ofthc specified minimum tensile strength at ambient temperature
1/3.5 of the tensile strength at the design temperature
2/3 of the specified minimum yield strength at ambient temperature
2/3 of the yield strength at the design temperature
100% of the average stress to produce a creep rate of 1% in 10,000 hours.
67% of the average stress to produce rupture in 100,000 hours.
80% of the minimum stress to produce rupture in 100,000 hours.
In 1999, the ASME changed the 1/4 to 1/3.5.
In the temperature range in which tensile strength or yield strength set the allowable
stresses, higher allowable stresses arc permitted for austenitic stainless steels and nickel-
alloy materials where greater defomlation is not objectionable. In this case the critcrion of
2/3 yield strength at temperature may bc increased to 90% of yield strength at temperature.
Bolting materials whose strength has been enhanced by heat treating or strain hardening
are limited to 1/5 of tensile and 1/4 of yield.

2-4 Overview orllle ASME Code

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Pressure Vessel Design <llld Analysis ~ Seminar Notes Internal pressure on shells <Iud heads

INTERNAL PRESSURE ON SHELLS AND HEADS

Cylinders
Theoretical derivation of stress for thin walled cylinder:
Hoop Strcss: (circumferential)

Force ~ PXD;XL

A reo = 2 X / X L

Force I'D; I'D;

-- ~ - orl
Area 21 2S

Axial Stress: (longitudinal)

Force = Pxnx (-iD)2

Area = n x D; X t

Force I'D; I'D;

or 1
Area 4/ 4S

For thick-walled cylinders the theoretical stress is expressed by the Lame equations. The
formulation of the Lame equations is as follows, for internal pressure only. The maximum
stress at the ID surface is:

Hoop Rodial ~ -I'

ASME has a slight variation on the first formula, making it fit fairly closely the rcsult of
thc sccond fommla:

PR
SE - 0.61'

The aD basis form of the samc equation is:

SE + 0041'

The ID and OD formulas do not yicld exactly thc same results: for relatively thick walled
cylinders, the effect can bc noticeable.
The following graph shows the relative accuracy of these three formulas. The Lame equa-
tion is exact for all geometries. Thc simple approximation becomes pretty bad for thick-

Overview of the ASME Code 2-5

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Internal pressure 011 shells and heads Pressure Vessel Design and Analysis - Seminar Notcs

walled cylilHJers. The ASME equation is much closer to the exact solution than the simple
approximation.

2M T

10"0 -

~" "....., -
-

- -- - --
to
"'" ~ -- EO.ls"9l
EQ(8.1

--
~

EO.(s.l)

.10
1.0 ,.5 2.0 2"S 3.0 35 4.0

"~
figure '.6
"
Compori.on ol fom,vlai !of O<x>p Il'ml r. 0 cy!i,*kol Votl ••

The Joint Efficicncy in this (and all othcr) ASME Code formulas is a measure of the
inspeclion quality on Ihe weld seam. In general, weld seams that receive full radiography
have a joint efficicney of 1.0. Weld scams that receive spot radiography have a joint effi-
ciency of 0.85. Weld seams that receive no radiography have a joint efficiency of 0.7.
Seamless components have ajoint efficiency of 1.0.
In addition to the basic mles described above, the Code requires that no two seams in the
same vessel differ in joint efficiency by more than one category of radiography. For exam-
ple, ifcireumferential seams receive no radiography (E=0.7) then longitudinal scams have
a maximum E of 0.85, even if they receive full radiography. The practical outworking of
this is that circumferential seams, which are usually less highly stressed, may be spot
radiographed (E=0.85) while longitudinal seams arc fully radiographed. This provides the
sallle metal thickness at some savings in inspection costs.

2-6 Overview or the ASME Code

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Pressure Vessel Design and Analysis - Seminar Notes Splleres, Elliptical I-leads, Torispherical Heads

SPHERES, ELLIPTICAL HEADS, TORISPHERICAL HEADS

In Basis 00 Basis

~ p(D12 + CAl l' (D/2)

Cylinder
SE- 0.61' SE + 0041'

Elliptical Hcad ~ p[K(D + CAl] f - 1'[ KD ]

2S£ - 0.21' 2SE+2p(K-OI)

DI2 + CA) ~ 1'( D/2 )

Spherical Head f ~ l' ( 2S£-0.2P 2SE+ 0.81'

Torispherical Head f ~ p[M(L + CAl] 1'[ ML ]

2SE-0.lp I ~ 2SE+ 0.785P(M - 02)

In Basis OD Basis

Cylinder
SE(I - ea) Pa ~ SE(f-ea)
Pa
[(D/2 + ea) + 0.6(1 - ea)] [D/2-0A(I-ca)]

2SE(I - ea) 2SE(I- cal

Elliptical Pa Pa
[K(D + 2ea) + 0.2(1 - ea)] [KD-2(1 + ea)(K - 0.1)1

SE(I-ea) SE(I - ea)

Spherical Pa Pa
(DI2 + ea) + 0.2(1 - ea)] [D12 - 0.8(1 - ea)]

Torispherical Pa ~ SE(I-ea) Pa SE(t-ea)

[M(D + ea) + 0.1 (1- ea)] [(MD - (I - ea))(K - 0.2))

The fonnulas for elliptical and torispherical heads are general. The factors M and K are
semi-empirical adaptations of more complicated shell theories. K and M have the follow-
ing fommlas:
Where h ~ depth of head L ~ crown radius
r ~ knuckle radius
For the special case of a 2: I elliptical head, K~1.

For the special case of a nanged & dished (6%) torispherieal head, M ~ 0.885 and the
inside crown radius equals thc outside diameter of the vcssel.
The shape of elliptical and torispherieal heads produces compressive stresses at the knuck-
les.
ror thin torispherical heads the eqliatiol1 in Division I is unconscrvativc-dimpling can
occur even in vesscls that meet the Code requircments. Division 2 contains a more compli-
cated equation that should be checked when the value of rlt is large.

Overview of the ASME Code 2-7

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Important Terms for analyzing cylinders and heads Pressure Vessel Design and Analysis - Seminar Notes

IMPORTANT TERMS FOR ANALYZING CYLINDERS AND HEADS

ALLOWABLE STRESS-Sclect the allowable slrcss from the appropriatc Code table
at thc design temperature.
JOINT Erf'ICIENCY-Sclcct Ihejoinl cfficiency from lable UW-12
DIAMETER (INSIDE OR OUTSIDE)-ID formulas are found in paragraphs UG-27
and UG-32 00 formulas arc found in Appendix I
CORROSION ALLOWANCE-Subtractthc corrosion allowance from the actual
thickncss, and [liso increase the inside diamcter to account for corrosion.

ACTUAL THICKNESS ANDIOR DESIGN PRESSURE-You can calculate maxi-

mum allowable working pressure if you know the thickness of the component.
Otherwisc, use the design pressure to calculate the required componcnt thickness.

ASPECT RATIO f'OR ELLIPTICAL HEADS-This is typically 2:1, but may range
from I: I to 3: I
CROWN RADIUS AND KNUCKLE RADIUS FOR TORISPHER1CAL HEADS-
The ratio ofcTOwn radius to knuckle radius may not bc less than 1 nor grcater than
16.66

GEOMETRY FOR PRESSURE VESSEL HEADS

Elliptical Heads

Major A~is (Head Diameter)

Minor Axis
(1/2) Head Diameler

(Aspect mtio = ratio of major nxis to minor axis, Iypically 2.0)

2-8 Overview oftbe ASME Code

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Pressure Vcssel Design ;:md Analysis - Seminar Notes Geomctry for Pressure Vessel lIeads

Hemispherical Heads

/""""""---
-------- -'-'~-........
/ "

,I
/ """\.
I
I
! \ \
\
I - - HCild Di;nnctcr --~ ---,I

Overview of the ASME Code 2-9

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Geomelry ror Pressure Vesscilleads Pressure Vessel Design and Analysis - Seminar Notes

GEOMETRY FOR PRESSURE VESSEL HEADS

Torispherical Heads

-r------'"
I . . , . . . . --.. . . .
I ). KNUCKLE
IIEAO DIAMETER _/I / \ RADIUS Ir)
I
/
I
I
_I
til
[$1
q I
"I
"'/

i!
",/
vi
I
I
/
I
I
!
I

The typical torispherieal head, also known as Flanged & Dished, has a crown radius equal
to the outside diameter of the cylinder, and a knuckle radius equal to six percent of the cyl-
inder diameter.

2-tO Overview or tile ASME Code

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Pressure Vessel Design and Analysis - Seminar Notes

Chapter 3:
Using the Program-
The Main Menu

CodcCalc always starts with the Vessel Data Input Screen. Across the top of this screen is
a line of itcms that is called the Main Menu. The Main Menu controls the major fUllctiolls
of the program. \Ve will review the functions available in each of these menu items.
The items in the Main Menu - file, Edit, Analyze, Output, Tools, Diagnostics, View, ESL,
and Help - may be selected with a mouse click or by pressing the underlined character
while pressing the Ait key. for example, the Output processor may be selected by pressing
the Ait and 0 keys simultaneously.
First, we will begin by going over each of the Main Menu items.

FILE MENU
The File Menu controls the general operations of CodeCalc files. Options that are dis-
played in the menu with an ellipsis ( ... ) cause a file manage window to appear when
selected.

Figure 1--The File Menu

Using the Program- The Main Menu 3-1

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File Menu Pressure Vessel Design and Analysis ~ Scminar Noles

New
Starts a new file.

[jo t~ 1I4<. {1-,.,J 1""" ObT-rJir.. 1~L '/>e.. lI,t> .' •

o c& "fa I+ 9 At~ ,( 1.< ~1·m8=IlD ri-&'ff .ftOEHD r= ($lUI H H (]) I:ll
nOlO SJo"f, .. dllo<o... .

~1r..."...,.1

",).J"~
;·,.;.......Ii!'.' ;OJ:", J
~'·"i";··"-"'l~·,r •. ~
'I "';'L"'-"~ ,f".:-""..".", ~
,~ ,-(,·r.r~; -,P"", ~,
r,r"';.··;···'ll.·r"~~!.·_'L ~
i'~ h. n~=-",-·.,· .~
rn.J':-~:to."'·i~It--;""~, ~
:'I:rl.i:r).... ~"''' "," J.;!!_... r: ----L....J

Figure 2--File New

Open
Opens a previously created file. When the Open option is chosen, the user is prompted to
select an existing job file. Files ortype '.ee; will be displayed for selection.

~ ?X

Figure 3--0pen Dialog

Save
Saves the current file in its present condition.

3-2 Using the Program- Thc Main Menu

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Pressure Vessel Design and Analysis - Seminar Nolcs file MCIIU

Save As
Saves a file that has not been previously namcd or saves the current file under another
namc.
fW·i

::!:lY.o~_11,cd ~R(le1'tl'~{CCi
I ~ASIIE_ T...t.!hffi-CCI :=l Shls C(I
, t:JChed,lCcl
:=1[~T{"~CO
I ~('/<<'l_O,b,C(l
~t.lMJ~ccci

r,.[':Ir~,

S• .-e<D!>plI: ICOOU:ALCFlesl'.cci) it

Figure 4--Save As Dialog

Print
Sends the current vcsscl graphic image directly to a postscript or laser jet printer.

Print Preview
Displays the page that will be sent to the printer (sec above).

Print Setup
Brings up the standard Windows printer setup screen,

Exit
Exits CodeCalc. A message window will appear to give the user a last opportunity to save
any modifications to the current job.

Previous Four Files

The File Menn also lists the last fOUf vessel inpullilcs accessed from your computer. Any
of these liles may be opened with a mouse click.

Using the Program- The Mnin Menu 3-3

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Edit Menu Pressure Vessel Design and Analysis - Seminar Notes

EDIT MENU
Once a filc is selectcd, the Edit Mcnu indicates the options available for ediling.

A3Irujll'.I."juOnli,Nj 1.i,.l.tmiif.!:·1.it1,3i

.!~ ~r!;.~.O{
11!1~,('" {. l{lnbeo: I[IOOI
Oew'f.olT.nd.s.heaStc6:.'l:I: "'ISPH=rR"'iC.'' "l"'' ' ' ' ' ;'-
Oe:P;nlr~Plenuo: pooocoo ,~
Db.-v.I~~~ ... ~lo;JllrRaoJlPleu ...,": J1OO0C0J

Figure 5-- Tile Edit Menu

Title Page
Allows the user to enler report titles for this group of rep orIs.

Project Data
Allows the user to enler up to 3 Ii tie lines, which appear at Ihe lop of each page of the
prillted reports.

Insert New Item

Inserts a new element after the current element.

Delete Current Item

Deletes the current clement.

Select All
Selects all of the items in the browse window.

Deselect All
Deselects all of the items in the browse window.

3-4 Using the Program- Thc M"in Mcnu

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Pressure Vessel Design illHJ Analysis - Seminar NOles Analyze Menu

ANALYZE MENU
The Analyze options cause the program to quit the input process and enter the analysis
process. CodeCalc will first save the current job to the input file with the same filename;
Ihcn il will process the analysis.

Browse
Allows the seleclion of certain components in Ihe input lile to be analyzed.

Analyze Selected Items

Performs calculations for selecled analysis Iypes. The calculations will be saved in a
binary file and will be ready for display or printing.

Analyze Current Component

Performs calculations for the current analysis type. The analysis program looks for appro-
priate data in the current analysis file and performs calculations, saving the results in a text
file. The results oflhc analysis will then be ready for display or printing.

Summary
Looks through all the data in the current analysis file and prepare a brief summary of cach
analysis.

Choose Analysis Type

Selects Ihe Iype of componenl you wish to work on.

Figure 5--Choose Analysis Type Menu

The analysis types chosen from this menu can also be selected from Ihe Analysis Tool Bar
by simply clicking on the icon.

Figure 7-- The Analysis Types Toolbar

Using the Program- The Main Menu )-5

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Output MCllu Pressurc Vessel Design and Analysis - Scminar Notes

OUTPUT MENU
The Output Menu allows the user to review the analysis results and print (hc graphics of
the vessel. The following option is available under Output:Review - allows the user to
review the analysis results of the clIrrcJ1tjob, if those results are available.

Il8fIU~:~ __ f
OUC1f,6orld~t.eI Sedi:tl: ISPH£RlCAlliEAO

Figure 8--Ti,e Output Menu

}-

3-6 Using the Program~ The Main Menu

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Pressure Vessel Design and Analysis - Seminar Noles Tools Menu

TOOLS MENU
The Tools Menu controls the utility processors as summarized here.Configuration - This
option allows the user to dcfine a variety of system variables for the program. The first
screen of the Configuration mcnu looks like this:

!
pic5lHljlf.lllliS 1i0!!!ij4B H.'i'iMl.• f1r1.i!'. 33.1 .
,De £.li. hWfli .D~ 1m O~lb:.I i,SL ~~ .u~~
! 0 cHi I e;J,' -f:
, 1
1-1 ~U~
'(0:(9'1"L -',: ]-1Il1l3 ill
!

~ Of 3 ~heh" "'~Ur.· ..... •

. t~ ,
t O~ I~WTd",1 ILU/JJ"1iMD.o'l:
, ££IM1H~
}

D~W~cl~t.o,IS·~; ISpm_flI0lH~AO

Figure 9-- Tile Tools Menu

Configuration Options

Computation Control Tab

The Computation Control Tab in thc Configuration dialog leis some specific program
computation control parameters be set. These controls Icl you set some options in some
programs that control the results of some computations.

Figure 1a--Configuration Options

Following is a description of the options:

Computc Increascd Nozzle Thickness? In many cases pressure vessels are designed
and built long before the piping system is attached to them, This means that the nozzle
loadings are unknown. lfthis field is checked, thcn your minimum nozzlc thickness (tm)
will be the maximum of
trn = (.134,trn for internal pressure) less than or equal Nps 18
Irn = (DD/ISO,trn for internal pressure) greater than Nps 18
By using such a requirement in addition 10 UG-45, the piping dcsigners will have some
additional metal to work with to satisfy thermal bending stresscs in systems these vessels
are designed for.

Using the Progral11~ The Main Menu 3-7

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Tools Menu Pressure Vessel Design and Analysis· Seminar Notes

Note These fonnulae are not in the ASME Code. They are used in industry.

You can also specify the minimum wa)) thickness of the nozzle (Tm) in the Nozzle input.
If you do so, that will override this calculation.
Calculate F iu Flohead if the Pressure is Zero? In the design of noating heads, a
factor F is computed. The factor F is a direct function of the internal pressure. If the inter-
nal pressure is 0, then F is equal to 0. However, some interpret the Code to mean that F
should always be computed regardless of which case we arc analyzing. Typically, the case
in question is the flange bolt-up case. When the uni' is being bolted up, it has 110 internal
pressure. That is why the defanlt is not checked.
(fyou wish F to always be considered in the thickness cales, then check this box. This is
the conservative method of calculation.
Use P iustead ofMAWP for UG-99B? The Code paragraph UG-99(b) discusses the
subject of hydrostatic test pressure on vessels. The equation that wonld nonnally be used
is as follows:
Test Pressure = 1.3' MAWP • StestfSdesign
The code in note 34 states that the MAWP may be assumed to be the same as the design
pressure when calculations arc not made to delcnnine the MAWP.
This will allow for lower test pressures. This directive should be used with caution.
Perform Area Calculatious for Small Nozzles? The Code paragraph UG-36 dis-
cusses the requirement of performing aTea placement calculations when srnall nozzles arc
involved. The Code States
Openings in vessels not subject to rapid fluctuations in pressure do not require
reinforcement other than that inherent in the constmetion under the following con-
ditions:
3.5-in. finished opening in a shell or head .375 in. thick or less
2.375-in. finished opening in a shell or head greater than .375 in.
If your geometry meets this criteria and this box is nol checked, then no area of reinforce-
ment calculations will be perfonned.
Priut Water Volume jn Gallons? Normally the volumes computed by the program
arc in diameter units.
]fyou want to use US gallons instead of cubic diameter units, check this directive. Other-
wise, the program will use cubic units as the default value.
Use Calculated Value of M for Torispherical Heads in UG-45 bI? The Code in
paragraph UG-45 requires a calculation of the required head thickness at the location of
the nozzle. This may lead one to believe that the thickness Inay be computed per para-
graph UG-37. However a recent code interpretation states that the thickness should be
computed by the mles of paragraph UG-32 or by the rules in Appendix I.
Thus, this directive should always be checked.
The second screen of the Configuration Menu looks like this:

3-8 Using the Program- The Main Menu

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Pressure Vessel Design and Analysis - Seminar Notes Tools Menu

Miscellaneous Options
The Miscellaneous Options of the Configuration MCllulets the user select some miscella-
Ileous directives. These directives control some printout style options and others.

?Ixl

• ~[>1Jom3!,,·rlWr.RCNn1
nA~~fio~rl~?"-
Oda<.iUr.sfle Kr.;lllhll iJ1
"-

Figure 11--Miscellaneous Options

Following is a description of the options:

Report Content. This directive allows thc uscr to change the length of the printcd
reports. When the summary option is checked. the formulas and substitutions will not be
printed out. Thus, this option will generate less paper and more compact reports.
Whcn thc dctailcd option is chccked, the reports will be the normallcngth.
External Printont in Rows? There are two choices for thc style of printing extemal
pressure results: rows and columns. Printing the values by row tends to reduce the length
of the printouts. This is the default.
If you wish to print by column, do not check this directive.

Set Unit
This option allows the user to change the current job's units system. Once this option is
selected, a File Open dialog will appear and allow the user to select a new units file. Thcsc

Using the Progmm- The Main Menu 3-9

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Tools Menu Pressure Vessel Design and Analysis· Seminar Notes

units files have the extension ,fil. English, Metric and SJ units are available in the system
!
subdirectory. After you select a units file, the following window will appear:

~,lllJfe "SystemUnl' Ctml.v. utt.Unl· II~ . S~UIi Coi'<rt¥l. . UlerlW •

I~ 'lmtth' led "It _'~f J"'- n~Oenr~ ~ 1n:7cuft, "Jl~r Ihled'!.. f
! f«oe pw>dt. 1 IJ. ~ .WrdSpeed .. ~ _' ~t. . lt:"Mf it
H311(~)~ - "11 ~. In -.d "at;oWeO:;H b/sq~ _ '11~·~-=-}-.IblJqll.11
Mil • rq~ '1I:=i~~ ~ h .. l····~~lnu4.....1

it ......... """""" . r=-l} ~ ...... ~< .r;---:J1.1rl1

I~Slim • bthqn • ~l ~''WmLoad brJfql\. 'P"'7l;-IP'f _11'
~ T~~ ,.;,., d<gtt,F • ~ rr::::;:-j ,"'..... 'ttl .' rr-lj- ~I
(Preuue 'p$iQ ... ~ ~ VclnoO utt:i'doe.l' I • }. ,lIn, 't
i £.MocUn !»-'sqn'" ~.·l~ 1, Oi.YMer Wes ' f l i t.. ~,
~ P~O~If)t bl./N-n,· n-J.c;.'~~W6lTt~U r~.1 . ·'--~l.~t
~ ImlkiJonOM ~/t'Ufl . r:-l 1.. b./cull

~. lr::=!Ci
"
Figure 12..Unil Window

If the units selection is acceptable, press the OK bullon; otherwise, press Cancel. When
OK is selected, the current units will be overlayed with the selected units.

Make Unit File

This option allows the creation of a cuslom units file. Simply pull down the appropriate
conversion constant or label and the corresponding unit or label will change accordingly.
If your conversion constant is not one ofthe choices, type in the label and constant for
your particular unit. (The program will continue to use English units internally).

Figure 13..Make Unit Dialog

This window presents a table of items, the internal units used for each item, a conversion
factor, and the user lin its. The conversion factor is used to obtain the user units from the
internal units. The lip and down arrow keys can be used to move lhe selection to the
desired item. If a desired unit conversion is not available as a default program selection, it
can be entered manually by typing it in. Ensure that your conversion constants arc correct
and that your labels go with the constants. Once all units have been set, press OK to exit

3·10 Using the Program- The Main Menu

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Pressure Vessel Design ;lnd Analysis - Seminar Notes Toob Menu

this screen and save the new units file. A safe place to save it would be in the system sub-
directory where Ihe supplied units files arc stored.
After you have saved the new units file, you will need to overlay the current units in your
job file with Ihe new units. This option is Ihe Set Unit option. After you sel your file with
the new units, all of the entered data will be converted into the new set of units immedi-
alely.

Calculator
This option allows the user to perform simple calculations and paste the results in the input
field in which the cursor resides. .

Figure 14--The Calculator Option

You can use the calculator to compute a number and transfer that number into CodeCalc
by using the Edil, Copy fealure. From the desired field, right click and choose the Paste
option. Before pasting, ensure that the field's current contents have been removed.
Import Nozzle Dala - Imports nozzle information from a PVElilc inpul file (.pvi) for
use in the WRC 107 Module.
Edit!Add Materials - This opliou allows the user to add materials 10 Ihe COADE
Material dalabase. The screen appears as follows:

Edit/Add Materials Dialog

To use this processor, fill in all of the values in all cells. If more than one material is to be
entered, usc the Next button to enter the new material. After all materials have been

Using the Program- The Main Menu 3-11

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Tools Mellu Pressure Vessel Design and Analysis - Seminar Notes

entered, save the file with the Save button. Finally, press the Merge key to join the user-
defined material database with the supplied material database.

xl

Figure 15--Ma/erial Editor

•
"

3-t2 Using the Program- The Main Menu

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Pressurc Vessel Design ;lIId Analysis. Scminar Noles Dillgnostics Menu

DIAGNOSTICS MENU
The Diagnostics Menu helps to troubleshoot problem installations.

e'''''j.. ·''iliji'.I:!liWj4 f.!"l.!M\i¥ fI"i,I,,_,!

)
IlemUI.ITbl:'f:~ !
Dtw'~" Shel Sedl«ljSFH[Rl~ HEAD

Figure 16--Diagnoslics Menu

CRC Check
Performs a cyelic redundancy check (CRC) on each of the supplied CodeCale files.

Build Version Check

Checks the revision level of the CodeCalc executablc files.

DLL Version Check

Checks to make sure thc CodcCale .DLL files are currcnl.

Note If the DLLs are not current, the program may behave in an unusual manner or may
not mn at all.

Using the Progralll- The Main Menu 3-13

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View Menu Pressure Vessel Design and Analysis. Seminar Notes

VIEW MENU
The View Menu allows the user to specify the tool bars to be displayed.

.~
.,
Figure 17--The View Menu

The following options are available:

File Toolb.r

Figure 18--File Toolbar

Analysis Toolbar

Figure 19--Analysis Toolbar

Status Bar )
- ~-

Figure 20--8ta/us Bar (a/ the bottom of/he screen)

;
;

3-14 Using the Program- The Main Menu

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Pressure Vessel Design lind Analysis - Seminar Notes E51 Menu

ESL MENU
The ESL Menu provides utilities lhal interact with the Extenlal SoOw",e Lock (ESL).

e .. U1J....\IlIju.':M,'lj.J.!1 1.!@4f.!li',.HI
"",--,:::;->q~p:~=--.:::=:::;,~y_ l:itb
'''''--l''h?MUpd~e
1-'---.:....=-,'----.:....--'-----4l 1i~alfI Fa:< Co.:le-\~'
B~~[rtl'"h;cCode:l

~["lr/"'tM!Ul

Figure 21--ESL Menu

Phone Update
Allows update authorization information or other ESL changes to be obtained over the
phone.

Generate Fax Codes

Provides the uscr with access codes for rcmote ESL updating. These access codes should
be sent to COADE for authorization codes.

Receive and Enter Fax Codes

Allows yOll to enter the remole authorization codes you receivcd from COADE. Each set
of four codes will make one change to the data stored on your ESL.

View ESL Information

Displays the data stored on the ESL.

Using the Program- The Main Menu 3-15

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Ilclp Menu Pressure Vessel Design and Antilysis· Seminar Noles

HELP MENU
The Ilelp Menu displays on-line Help and infonnation on how to obtain technical support
for CodeCale.

II • I

~ . tcir lY",*e QoJpA. IIX4 Obt;Jl~l- ~Sl Y-1m1 1 .'

6 ~. IiH/'f 1 + ... _" I ~ A.-MUf.! pC t<w";'~_

f'lB, 01 3 _ Sho!tuO'Hkadl .r
·1 Ti?cJIt.eOillY_
Irlo~_~
D~;"IG_I f!:l:nJ.axiECAl.C_

H=t:{urbtf: =;'m~]~:jQ~otr<~n~_~';""~'~' ~j,

11-00').) . . . . . . . oiI.

Figure 22--Help Menu

Contents
Starts the Help facility.

Tip of the Day

Provides tips for running CodeCale.

Info
Provides information on the best ways to contact COADE personnel for teclmical support,
and provides a link to COADE's website.

3-16 Using thc Progmm- Thc Main MCllu

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Pressure Vcssel Design and Analysis - Scmin:lr NOlcs

Chapter 4:
Example Problem 1-
A Simple Drum

PROBLEM
The drawing on the following page shows a simple horizontal pressure vessel that we will
use for our first example problem. In this case the preliminary sizing of the vessel and its
attachments has been completed, and we are asked I) to select thicknesses for the pressure
components, nozzles, and reinforcemcnt, and 2) to check the vessel for stresses when it is
full of liquid.

SPECIFICATIONS
Design conditions, as shown on the drawing, arc 230 psig (1.586 N/1l1l11 2) ii;ternal pressure
and fnll vacuum at 450°F (232°C). Materials arc carbon stecl, SA-516, 70, Nonnalized.
The vessel is subject to full radiography, and has a 1/8-in. (3.175 mm) corrosion allow-
ance.
The length of the vessel is 244 in. (6198 mm) between langent lines (the heads have a 2-in.
(51 mm) straight flange, making the weld-to-weld length of the vessel 240 in. (6096 mm)).
We will require the following programs in this analysis:
Internal pressure on shells and heads - SHELL program,
External pressure on shells and heads - SHELL program.
Nozzle thickness and reinforcement - NOZZLE program.
Follow these steps to complete this first example problem:
I. Analyze the cylindrical shell under internal pressure, and pick a design thickness for
it. Next analyze the 2: I elliptical head, using the same basic thickness.
2. Analyze the cylinder under full vacuum conditions. Also,. analyze the heads for exter-
nal pressure.
3. Analyze the nozzle reinforcement using the NOZZLE program. Select appropriate
reinforcing pads for each nozzle.
4. After the entire vessel has been analyzed using CodeCale, model the same vessel
under PYElite and review the results.

Example Problem 1- A Simple Dnllll 4-1

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 i

144.0'10

= F

192"
_ _ _ _ _-----i0 9~
I
J
_ .•

230 PSIG & Full Vacuum

Design Temperature: 450 F NOZZLE SCH!:DULE
MK. :l OTY. SIZE AND SCHED. TYPE RTG. REINFORCING
,
N1 120.0' RF 388:
,
....
N~

nn,..c:
0101 hp Knockout Drum
nilU
~~
.......... II'o'I<.l'C

'~ ........ www.iran-mavad.com

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Pressure Vessel Design and Allalysis· Seminar Noles Specillcnlions

Pressure Vessel Design and Analysis Seminar

Component Design Problem

D-101 Cylindrical Shell:

Design Pressure 230 psi (1.586 N/nlln 2)

Design Temperature 450°F (232°C)

Material SA 516,70

Joint Efficiency

Corrosion Allowance

Inside Diameter

Notes:

Questions:

What is the required thickness?

What thickness will you usc?

DO NOT TURN THE PAGE UNTIL YOU HAVE

COMPLETED YOUR ANALYSIS

Example Problcm 1- A Simplc Drum 4-3

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Spcciliclllions Pressure Vt:sscl Design nnd Annlysis· Scminllr Noles

COAoE Engineering Soft.ware ,

pVEl i t.e 4 . 00 Licensee: COADE I llC., l.oca 1 Hhj te Lock i
PileName : Seminar ----- •••. --- ...••• --------------- .••••• Page 2
Shell Analysis: 0101 CYLINDER Item: 1 9:51il Sep 21,2000

Input Echo, Component Description: 0101 CYLINDER

"
Design Internal Pressure p 230.00 psig
l'empen\ture for Internal Pressure 450.00 p

Include Hydrostatic Ilead Components NO

I'laterial Specification (Normalized) SA-516 70

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 [or Shell Joint g 1. 00

Design Length of Section L 244.0000 in.

Length of Cylinder [or Volume Cales. CYLLEN 244.0000 in.
Inside Diameter of Cylindrical Shell [) 144.0000 in.

f·linimum Thickness of Pipe or Plate T 1.0000 in.

Corrosion Allowance CA 0.1250 in.

Type of Element: Cylindrical Shell

INTERNAL PRESSURE RESULTS, SHELL NUI·IBER 1, Dese.: 0101 CYLINDER

ASHE Code, Section VIII, Division 1, 1998, A-99

Thickness Due to Internal Pressure (TR):

(P*(D/2 .. CA)/(S*E-0.6*P) per UG-27 (c) (1) .•>'
(230.00*(144.0000/2 .. 0.1250))/(20000.00"1.00·0.6*230.00)
0.8352 in.

Nax. All. working Pressure at Given Thickness (HAI1P);

(S*E* (T·CA) 1 (D/2+CA) +0. 6* (T·CA)) per UG-27 (c) (1)
(20000.00*1.00*(0.8750))/«144.0000/2+0,1250)+0.6*0.8750)
240.88 psig

"laximum Allowable Pressure, New and cold Uo1l\PNC):

(SA*EIT)/(D/2.0.6*T) per UG·27 (e) (1)
(20000.00*1.00*1.0000)/(144.0000/2tO.6*1.0000)
275.48 psig

Actual stress at given pressure and thickness (Sact):

(p* ((0/2tCA) to. 6" (T-CA»)) 1 (E· (T·CA»
(230.00'«(144.0000/2+0.1250).0.6*(0.8750))/(1.00*(0 8750)
19096.57 pai

SUJoIlo1ARY OP INTERNAL PRESSURE RESULTS:

Required Thickness plus Corrosion Allowance, Trca 0.9602 in.
Actual Thickness as Given in Input 1.0000 in.
Maximum Allowable Working Pressure '·lAWP 240.88 psig
Design Pressure as Given in Input P 2]0.00 psig

HYDROSTATIC TEST PRESSURES ( f·leasurcd at High Point ):

4-4 Example Problem 1- A Simple Drum

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Pressure Vessel Design and Analysis - Seminar Notes Speci ficilliol1s

eOADE Engineering Software

PVE) ite 4.00 Licensee: eOADE Inc., Local ~Ihite Lock
PileName Seminar ---------- •• --------------------------- page)
Shell Analysis: 0101 CYLINDER Item: 1 9:51a Sep 21,2000

Hydro. per UG-99Ibl; 1.3 ~ HAWP • SalS 313.15 psig

Hydro. per UG- 991el ; 1.3 ~ r·1APNC 358.13 P S1 9

Hin. f·letal Temp. wlo impact per Pig. UeS-66 -30 p

IHn. f·letal Temp. at Req'd thk. (per ues 66.1) -35 F
IHn. f·letal Temp. wlo impact per UG-20 (f) -20 ,-
WEIGHT and VOLUNE RESULTS, ORIGINI\L THICKNESS:
Volume of Shell Component VOLI·lET 111149.8 in.~~3

\'/eight of Shell Component Wf·1ET 31455.4 lb.

Inside Volume of Component VOLIO 3973788.0 in. "'3
I'/eight of I'latel- in Component ImAT 143497.9 lb.

I'/EIGHT AND VOLW1E RESULTS, CORRODED THICKNESS:

Volume of Shell Component, Corroded VOLNETCA 97339.7 in. ~ ~ 3
I'leight of Shell Component, Corroded 1'11·1ETCA 27547.1 lb.
Inside Volume of Component, Corroded VOLIDCA 3987598.0 in .• ~)

~leight of l'later in Component, Corroded HHATCA 14]996.6 lb.

The PV Elite Program, Ie) 1989-2000 by COADE Engineering Software

Example Problem 1- A Simple Drum 4-5

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 ‫‪z‬‬
‫;;‬
‫‪o‬‬
‫"‬

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Pressure Vesscl Design anti Analysis - Scminar Notes Specifications

Pressure Vessel Design and Analysis Seminar

Component Design Problem

D-101 Elliptical Hcad:

Starting from the cylinder analysis, design an elliptica' head for the dnnl1.

Notes:

Qnestions:

WhHt is the aspect ratio of the head?

What is the required thickness?

What thickness will you usc?

As the pressure increases, the required thickness increases:

Linearly Almost linearly As the square

DO NOT TURN THE I'AGE UNTIL YOU HAVE

COMPLETED YOUR ANALYSIS

Example Problem 1- A Simple Drum 4-7

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Specifications Pressure Vcssel Design and Analysis - Scminar Notes

"
COADE Engineering Software
PVElitc 01.00 Licensee: COADE Inc., i.ocal \'Ihite Lock j
FileName: Seminar -----------------.- ... -.- .. ------------ Page 01
Shell Analysis: DIOI ELLIPTICAL ltem: 2 9:51a Sep 21,2000

Input Echo, Component 2, Description: 0101 ELLIPTICAl,

Design Internal Pressure p 230.00 psig

Temperat\lre for Internal Pressure 450.00 F

Include Hydrostatic Head Components NO

"laterial Specification (Normalized) SA-516 70

Allowable Stress At Temperature S 20000.00 psi
Allowable Stress At Ambient SA 20000.00 psi
Curve Name for Chart UCS 66 0
Joint efficiency for Head Joint E 1.00

Inside Diameter of Elliptical Head o 144.0000 in.

f-linimum Thickness of Pipe or Plate

Corrosion Allowance eA
',' 1.0000
0.1250
in.
in.

Aspect Ratio AR 2.0000

i.ength of Straight Flange S1'RTFLG 2.0000 in.

Type of Element: Elliptical Head

INTERNAL PRESSURE RESULTS, SHELL NUI·IBER 2, Dese.: 0101 ELLIPTICAl.

Asr·1E Code, Section VIII, Division 1, 1998, 1\-99

Thickness Due to Internal Pressure (TR):

(P' (D.2 l eAl lK)/ (2·S'E-O.2'P) Appendix 1-4 (c)
(230.00' (144.000012'0.1250)·1.00)/(2·20000.00'1.00-0.2'230.00)
0.B304 in.

r~ax. All. l'lorking Pressure at Given Thickness (t·IAWP):

(2·S·E· (T-CA)) /(K' (Ot2'C/\) +0.2' (T-CA)) per Appendix 1-4 (c)
(2.20000.00·1.00·(0.8750))/(1.00·(144.0000+2'0.1250)+0.2'(0.8750))
242.34 psig

Maximum Allowable Pressure, New and Cold (I·t1\PNC):

(2·SA·E·T)/(K*O.0.2·T) per Appendix 1-4 (c)
(2·20000.00·1.00·1.0000)/(1.00·144.0000tO.2·1.0000)
277.39 psig

Actual stress at given pressure and thickness (Sact):

(P' (K· (O.2 l CA).0. 2' (T-CAl) ) / (2·E· (T-CAl)
(230.00*(1.00·(144.0000t2·0.1250).0.2·(0.8750»)/(2*1.00-(0.8750»
18981.57 psi

Sm~MARY OF INTERNAL PRESSURE RESULTS:

Required Thickness plus corrosion Allowance, Trca 0.9554 in.
Actual Thickness as Given in Input 1.0000 in.
Maximum Allowable Working Pressure I>1AWP 242.34 psig
Design Pressure as Given in Input P 230.00 psig

4-8 Example Problem 1- A Simple Drum

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Pressure Vessel Design and Anillysis - Seminar Notes Specificiltions

COI\DE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local \'Illite Lock
FileName: Seminar ----------------------~---------------- Page 5
Shell Analysis: 0101 ELLIPTICAI~ Item: 2 9:51a Sep 21,2000

HYDROSTATIC TEST PRESSURES ( t,leasured at High Point I,

Hydro. per UG-991b); 1.3 f·1A11P , sals 315.04 p si 9
Hydro. pel' UG-99(c); 1.3' f·1APNC 360.61 psig

Nin. I-letal Temp. wlo impact per r~ig. UCS-66 -30 F

Nin. loIetal Temp. at Req'd thk. (per UCS 66.1) -35 F
IUn. "'etal Temp. wlo impact per UG-20(f) -20 F

\'IEIGllT and VOLUHE RESULTS, ORIGINAL THICKNESS:

Volume of Shell Component VOLI·1ET 26074.9 in.")
Weight of Shell Component Wt'lET 7379.2 lb.
Inside Volume of Component VOLID 390864,4 in. t ' )
Weight of \1atcr in Component \'11'11\1' 14114.5 lb.
Inside vol. of 2.00 in. Straight VOLSCA 32572.0 in.")
Total Volume for Head I Straight VOLTOT 423436.4 in.")

WEIGHT /\NO VOLU1·1E RESULTS, CORRODED THICKNESS:

Volume of Shell Component, Corroded VOLI,lETCA 22815.5 in. ,*)
weight of Shell Component, CO)"roded I'.'NETCI\ 6456.8 lb.
Inside Volume of Component, Corroded VOLIDCA 392903.7 in. '*3
\'Ieight of Water in Component, Corroded WNATCA 14188.2 lb.
Inside Vol. of 2.00 in. Straight, Carr. VOLSCA 32685,2 in." )
Total volume for Head • Straight Corroded VOLTCA 425588.9 in.*')

The PV Elite Program, (c) 1989-2000 by COADE Engineering Software

Example Problem 1- A Simple Dnlln 4-9

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Brilll~ fracture - Minimulll Design f\'lclnl Temperalure Pressure Vessel Design and Analysis - Semillnr Noles

BRITTLE FRACTURE - MINIMUM DESIGN METAL TEMPERATURE )

New niles in Ihe 1987 Addenda to the Code make il imperalive 10 uuderstand brittle frac-
ture and its relationship to material selection.
What is brill/efractllre? It is a sudden and ealastrophie growth of cracks in sleel.
How does brittle/roc/lire occllr? The stress at the tip ofa discontinuity in the stcel (crack,
inclusion, weld, cte.) reaches a critiefll valuc and the crack begins to propagatc. The total
energy ofpropagalion exceeds the energy absorbing capability of the sleel. The crack con-
tinues to grow at the speed of sound.
The requirements for brittle fracture are low toughness, high stress, and a discontinuity.
Carbon and Low Alloy sleels exhibillow toughness allow lemperalure. AI higher lemper-
atures the toughness improves dramatically.
Charpy impact tests arc one way to measure the fracture toughness of steels. Thc follow-
ing chart shows a typical variation of impact energy with tcmperature.
00. 1

~I .----.-------..- - - . - ? I
l.\:IlEr sre

~ 40 f--- .----...--------/-----.--.----.---.----
,;
W ::1)'---------..- ---.
w

Iu 20 1----·--.-.-.. -/.----·..-----···----·.. --..··-..·-·

101----·. --../.-.--------------...--...- ..--.....-

01 I aWEooor
I I I I I
I
-40 -20 o 20 40 fi) 00

TerpEi"Olu'e. De;roos F

Figure 1-- Typical Variation of Impacl Energy with Tempera/ure

As a function of the grain fineness of the steel, fracture toughness also increases dramati-
cally wilh reduced size of the plale.
i\SME has applied Ihesc general principles 10 the impact requiremenls of carbon sleels
using a Minimum Design Metal Tcmperature approach:
The Minimum Design Metal Tcmperature is the lowest design temperature at which a
given steel can be used to construct [\ pressure vessel without impact testing the steel.
Figure UCS-66 shows the variation of minimum design temperatUl'e with plate thick-
ness and material. Each of the four curves (A, B, C, D) correspond to several materi-
als.
,
t

4-10 Example Problelll 1- A Simple DnJlll

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Pressure Vessel Design and Analysis - Seminar Notes Brillic FraclUre - Minimulll Design Mel;!1 TemperalUl'C

For a givclll1latcrial, lhe bnsic MDMT is a function only ofthickncss. Howevcf, the
MDMT can be rcduccd drnmatically by nOfmalizing or normalizing and tempering
many of the carbon stecl materials. (Toughness is rclated to grain size).
The MDMT can be red need if the slress in the malerial is lower than thc allowable
slress. (Remember, briltle fracture requires a certain energy leveL) Usc figure UCS-
66.1 to calculatc the reduction in Minimum Design Metal Tcmperatufe for a givcn
stress level. Most carboll steels lip to I in. are exempt from impact testing down to
-20°F. When impact testing is needed, used UG-84 10 delermine the required energy
levels.
Hydrostatic tesling ofa pressure vessel is Ihe best available method for determining maxi-
mum tolerable defect size. If a thick pressure vesscl is hydrotested al a prcssure that is
50% greater than the design prcssure, the critical KI (fracturc toughncss) is
KIC=sF, whcrc F is a CHICk shape factor
Assuming an intemal circular naw of dimcnsion 3, the maximum KIC immedintely aftcr
successful hydrotesting is
KIC ~ 1.5*Sm*(2*SQRT(a/pi»
Maximum defect size x at the design prcssure is given by
1.5*Sm*(2*SQRT(a/pi)) = Sm*(2*SQRT(x/pi»
or
x = 2.25a
Hence, a crack that is discovcrcd after hydrotesting can grow 2.25 times its original size
before causing failure. This fact illustrates the importance of hydrotesting and is based on
a hydrostatic temperature that is the same as the lowest opcrating temperature of the ves-
sel.

EXllmplc Problcm 1- A Simple Dnnll 4-11

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Brillic Fracture· Minimum Design Metal Temperature Pressure Vessel Design and Allalysis - Seminar Notes

,
}

140
)
I
!
I
120

1--- _
~
!
100 I ......
g. '0
II A/ V __ . ~-- _
I / ~
,~ 60
I / ----- f--
!
:; '0
I /
I /
V
~
cj.--
~
>!
.§.
~ 20 .~! L
V
....
Vr- __
D b-:::~
~I / /V
E

C
~
~ V
i L/
o

- 20 J ./
V r

iV V
- '0 I / _

-65 .r.V_- t= t--.... -- --

-60

_ 60
r-
I
;- '1 "T' "q"IT
PK
•

0.39<1 2 3 , 6

Nomlll.1 Thlckllo».IIl.

Illmll0d 10 .. Ill. for Woldod Consltuclton)

Gonenl Not,s and Nolos tollV'N on nell1 pago

FIG. UCS·66 IMPACT TEST EXEMPTION CURVES [SEE NOTES (1) ANO (2ll [SEE UCS·66(a))

Figure 2--1998 Section VIII, Division 1

.'

4-12 Example Problem I~ A Simple Drum

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Pressure Vessel Design and Annlysis - Seminnr Noles I3rillle Fracture - Minimum Design Mewl TcmpcrallJrc

FIG. UCS-66 (CONT'OJ

GENERAL NOTES ON ASSIGNMENT or MATERIALS TO CURVES:
(a) Curve A applies to:
(1) all carbon and all low alloy steel plates, structural shapes, and bars not listed In Curves B, C, and 0 below;
(2) SA·21b Grades WCB and WCC if normalized and tempered or water-quenched and tempered; SA·217 Grade WCb if
normalized and tempered or waler-quenched and tempered.
(bl Curve 0 applies to:
(1) SA-21b Grade WCA if normalized and tenlpered or water· quenched and tempered
511.·216 Grades WCD and WCC for thicknesses not exceeding 2 In., If produced to fine grain practice and water-quenched
and tempered
511.-217 Grade WC9 if normalized and tempered
511.-205 Grades A and 0
511.-414 Grade A
SA-SIS Grade 60
511.-516 Grades b5 and 70 if not normalized
511.-612 If 1I0t normalized
SA-b62 Grade B if not normalized;
(Zl except fOr cast steels, alt materials of Curve A if produced to fine grain practice and nOrmalized which are not listed In
Curves C and 0 below;
(3l aU pipe, fittings, forglrl9s and tubing not listed fOr Curves C and 0 below;
(4) parts permitted under UG-ll shall be Included In Curve 8 even when fabricated from plate that otherwise would be assigned
to a different curve.
(c) Curve C
(1) SA·182 Grades 21 and 22 If normalized and tempered
511.-302 Grades C and 0
511.-336 F21 and F22 if normalized and tempered
511.-307 Grades 21 and 22 if normalized and tempered
511.-516 Grades 55 and 60 if not nOrmalized
511.·533 Grades Band C
SA-6b2 Grade A;
(2l all material of Curve B If produced to fine grain practice and normalized and not listed for Curve 0 below.
(d) Curve 0
511.·203
511.-500 Grade 1
511.·516 If normalized
511.·524 Classes 1 and 2
511.-537 Classes 1, 2, and 3
SA-bl2 If normalized
SA-bb2 If nOrmalized
SA-nO Grade A
(e) For bolting and nuts, the following Impact lest exemption temperature shaH apply:

Bolting
Impact Test
Spec. No. Grade Exemptlon Temperature, -F
SA·193 85 -20
511.·193 07 (2 1/ 2 In. dla. and under) -55
(Over 2 1/2 In. to 7 In., IncU -40
SA-193 87M -55
511.·193 016 -20
SA-307 o -20
511.·320 L7, L7A, L7M, L43 Impact tested
SA-325 1, 2 -20
511.·354 oe o
SA·354 00 .20
511.·449 -20
51\-540 023n4 .10

GMeral Notes ilnd !loin conl/nue on ned Pd~

Figure 3--General notes on assignment of materials to cUlYes

EXntllplc Problcm 1- A Simplc Dnllll 4-13

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Briltle fracture· Minimulll Design Metal Temperature Pressure Vessel Design fmd Analysis - Seminar Notes

-~ .. --.~-_.~

1001< I I I I I I I I I I I I I I
.g
~
cc
~

.~
~

E 0.80
.1!
<l;

.2
~
~
;;
uc 0.80,
~

E
0
z
~
~
Ul
<; 0.40 '
I
0.35

-'".
~
•
~

.2 0.20 .
;;
cc

0.00 CCC( r (o? ({(CCA c/( ..1//(tl/!~''I/V/4/v///v/c (v(( ( r ( / / l ( ( ( r ( ( ( 4 ( ( / 6

o 20 40 60 80 100 120 140
'F ISee UCS·66(bjJ .,i

Nomenclaturo (Note references to General Notes of Fig. UCS·66.2.)

tr :< required thickness of the component under consideralion In the corroded
condition for ell applicable loadings IGeneral Note (21J. based on tho
applicable joint efficiency E IGeneral Note (311. in.
t n '" nominal thickness of the component under consideration before corrosion
allowance Is deducted. in.
c • corrosion allowance. in.
E' as defined in General Note (3).
AHcrnalive Ratio S· E* divided by the product ollhe maximum allowable stress value
from Table UCS·23 times E. whore S· is tho applied genoral
primary membrane tensile stress and E and E· are as definod in General
N01e(3).

FIG. UCS-66.1 REDUCTION IN MINIMUM DESIGN METAL TEMPERATURE WITHOUT IMPACT TESTING

Figure 4--Reduction in Minimum Design Me/ai Tempera/ure

.'
1
4-14 Example Problem 1- A Simple Drum

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Prcs~urc Vessel Design and Analysis - Seminar NOles Brillle fmClure - Minimum Design Melal Temperature

ESlablish nominallhicknt'lsscs (General Note (111 of welded par1s, nonwelded parts, and allachments
under consideration both before and after corrosion allowance is deducted (In and tn - c, respectively), and
other pertinent data applicable to tho nominal thicknesses such as:

All i1pplicable loadings (General Nolo (2)) and coincident minimum design melal
temperature (MDMTI
Stop 1 Materials of construction
E .. joint etriciency IGoneral Nolo (3)J
.. nominal noncorrodcd thickness IGeneral Note (1)1. in.
" • required thickness in corroded condition for all applicable loadings IGeneral Noto (2)1,
" based on the applicable joint eU;ciency IGenaral NOle f311, in.
Applicable curve(s) 01 Fig, UCS·66
c .. corrosion allowance, in.

l
StOll 2 Select MDMT from Fig, UCS·66 (Genoral Note (4)1 ror each
nominal noncorrodod governi~g thickness lGeneral Note (5)).

r------ -'- ------,

StOll 3 'I Determine Ratio: t,P II
tn-c
I IGeneral Noles 13>, f6), (7), and (8)) J

I
~====== [~~=~~~~I
Using Ratio from Step 3 to cnler ordinate
Stop 4 I of Fig. UCS-66.1, determine reduction in Slep I
I 2 MDMT IGenr.rel NolO (9)1. I
L-------I-------~
r------- -------,
Stop 5 I Delormine adjusted MOMT for governing :
I Ihickness under consideration. I
L-----~-l------~-~

Repest for all governing thicknesses [General Note 1511 and

take warmestvaluo as the lowest allowable MOMT to be
marked on nameplate for Iho zono under consideration
{General Note 11011. Sec UG·116.
Stop 6 See UG·99 Ih) for coldest recommended met'll temperature
during hydrostatic testlGonoral Note (611.
Sec UG·100(c) for coldost motal temperature permitted
during pneumatic tcstlGencral Notc 1611.

legend

I I Requirement ,r----l.
------
Optional General Not6S foflow on noxt pago

FIG. UCS-66.2 DIAGRAM OF UCS-66 RULES FOR DETERMINING LOWEST MINIMUM DESIGN METAL
TEMPERATURE IMDMT) WITHOUT IMPACT TESTING

Figure 5··Diagram of UGS-66 RlIles for Determining Lowest Minimllm

Design Me/al Tempera/lire (MDMT) Wi/holl/lmpac/ Testing

Example Problem 1- A Simple Dnml 4-15

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Brittle Fracturc - Minimulll Design Mclal Tcmperallll"c Prcssme Vcsscl Dcsign and Analysis - Scminar Notes

"

i
Fig. UCS·66.2 1998 SECfION VIU - DIVISION 1

FIG. UCS-66.2 (CONT'O)

GENERAL tWTES:
11) For pipe where a mill undertolerance Is allowed by the material specifIcation, the thickness after mill undertolerance has been deducted
shall Ix> taken as the noncorroded nominal thickness tit for determination of the MDt.n to be stamped on the nanwplate. LIkewise, for
formed heads, the minimum specified thickness after forming shall be used as I".
(2) loadings, Including those listed In UG·22, which result in general primary membrane tensile stress at the coincl~nt MOMT.
()) E is the joint efficiency (Table UW·l2) used In the calculation of tf ; e has a value equal to E exceplthat E" shall not be less than 0.60.
For castings, use quality 'ador or Joint efficiency EYAlichevtr governs design.
(4) The construction of Fig. UCS'66Is such that the MDMT so selected Is considered to occur coincidentally wilh an applied qeoeral primary
membrane tensile stress at the maximum allowable .stress value In tension from Table IA of Section II Part 0, Tabular values for Fig.
UCS-M are shown In Table UCS·6b.
(5) See UCS-bMa)(I), (2), and 0) for definitions of governing thickness.
(6) If the basis for calculated test pressure Is greater than the design pressure (UG·99(c) test], a Ratio based on the I, determined from the
basis for calculated test pressure and associated appropriate value of '" - c shall be used to determine the recommended coldest metal
temperature during hydrost.1tlc tut and the coldest metal temprrature permitled during the pneumatic test. See UG·Q9(h) and UG-100{c).
(7) Alternath-ely, a Ratio of S' ~ divided by the produ<.t of the maximum allowable stress value in tension from Table IA of Section 11 Part
o times E may be used, where ~ is the applied qeneral primary membrane tensile stress and E and e are as defined in General Note (31.
(8) For UCS-6b(b)(IHb) and (1)(2), a ratio of the maximum design pressure at the MOMT to the maKimum allowable pressure (MAP) at
the MOMT shall be used. The MAP 15 defined as the hignest permissible pressute as determined by the design formulas for a component
using the nominal thickness less cOrloslon allowance and the maKlmum allowable stress value from the Table lA of Section II, Part 0
at the MDMT. For ferrille Sleel flanges defined In UCS-6b(c), the flange rating at the warmer of the MOMT or 100"F may be used as
the MAP.
(9) For reductions In MOMT up to and Including 40"F, the reduction can be determined by; reduction in MDMT t= 11 - Ratlo)lOO"F.
no) A colder MDMT may be obtained by selective use of impact tested materials as appropriate lo the llCed (see UG·8tll. See also UCS-6B(c).

Figure 6..General Noles (or Fig. UGS-66.2

}

,
,,

4·16 Example Problem 1- A Simple Drum

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Pressure Vessel Design ;md Analysis - Seminar Notes 13rillle fracllIrc - Minimum Design Metal Temperature

Fig. UG·84.1 1998 SECTION VIn - OJVISION 1

! I
0.39'1 In.
I

50
i
I
I
I
40
I Minimum spe-cilied
I ylald J1ranglh

I 65 ksi
:! r
,
•E

•
£ ! /'
/ 55 ksi
•l' 30
,/"
'0 I
I ./ / 60 ks,

1"
,
I

! ./
/""
./ 0 ~
45 ksl

"'u:> '0

~ t.---
<

l:::::::
38 ksi
I
15 I ~

I
'0
!
ir ,
o
: 1.0 '_0 ;> 3.0

Mallimum Nomlnel Thickness of Mal~rlel or Weld. In.

GENERAL NOTES:
Cal Inlarpolallon batwean yield stHlngths shown i, permlltod.
Cbl The minimuM Implcl enolgy for ono spacimon shall nol ba less lhan '1J3 of lhe average energy requlled fOI
th,oo spoclmans.
(cl Malarlals produced and IMpacl tested In accordanco with $A·320. SA·333. SA·334. SA·350, SA·351, SA·,nO
and SA·165 do not havo 10 satisfy lhose onergy valuel. Thoy ara acceptable for use al minimum design motal
tomperalure not colder than lha lest temperatura when lho anergy values loqulred by tho applicablo
spflciflcatlon .ra sllllsliod,
ldl For matorlalJ having I spaclfied mInimum tllnsllo slrength of 95 ksl or more. soe UG·a4IcU'llbl.

FlG_ UG-84_1 CHARPY V-NOTCH IMPACT TEST REQUIREMENTS fOR fULL SIZE SPECIMENS fOR CARBON
ANO LOW ALLOY STEELS, IIAVING A SPECIFIED MINIMUM TENSILE STRENGTH Of LESS TIIAN 95 ks;,
LISTED IN TABLE UCS-23

Figure 7--Charpy V-Notch Impact Test Requirements _

Example Problem 1- A Simple DnUll 4-17

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 ;f
.,.,.
~
Co

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<
~
V.
v.
~
~
~ 0
ov.
'"3
"C ~.
;;-
:r
0 c..
c-
§" >
~
.:;:
'A
I :;:;.
> <r.
<r.
g
-5;;-
~

0 z
2 0
3 ;;
v.
Prcssure Vessel Dcsign and AUillysis - Scminar Noles nrillic Fracture - Minimulll Design Metal Temperature

Pressurc Vessel Design <lnd Analysis Scminar

Component Design Problcm

Minimum Design Met<ll Temperature

Determine the Minimum Design Metal temperature for the vessel in problem I:

MOMT of Cylinder -

MOMT of Ellipse -

What is Ihe MOMT if the sleel is nol normalized?

MOMT of Cylinder -

MOMT of Ellipse-

DO NOT TURN THE I'AGE UNTIL YOU HAVE

COMPLETED YOUR ANALYSIS

EXill1lplc Problem 1- A Simple Drum 4-t9

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OrilLl!.: FrnClure - Minimulll Design Ivklal Temperature Pressure Vessel Dcsign "lid Analysis. Scminar Notes

Answers:

I-ill. SI\-516,70, Ilormolized, MOMT = -30 F (-34 C) Curve 0

I-ill. SI\-516,70, lIollllormolized, MOMT = 30 F Curve 13

bllt per UG20, this COil be -20 F (-29 C)

4-20 Example Problem 1- A Simple Drum

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Pressure Vessel Design and Analysis - Scminar Noles Extern;}1 Pressure on :,hdls and hcnds

EXTERNAL PRESSURE ON SHELLS AND HEADS

Pressure vessels under extern'll pressure buckle r'lther than deforming elastically or yield-
mg.
A cylinder deforms into lobed shapes as shown in Figure 9.

Buckling

Ch~n"cleriIIJcl
Mode

0 f
I
\
,
\

J
-'
I
0.,
--'
,
CJ 0
,
',
- .,'
,

.... , _ .. I ,~ -- ~,

k· Number of lobes (k is the I 2 3 4

number 01 lull sine waves eround
(he periphery)

Pc" Crilical prenure lhe elallic 0 3Et 8Et 15EI

buckling or coll~pse (No elastic buckling
OCCUrl. only side'wile
7 7 --;>
dilpJacemenlof
undislorloo drciel

Fig. 8.2. Buckling or CoU~ple of Cylindriaal Rin.!: Under EXlernal PrCHU[C Showing Various Modes

Figure B--Buckling or Collapse of Cylindrical Ring

The buckling of a cylinder can be predicted based on the strain due to external pressure. A
given thickness, length, and diameter will buckle at a predictable strain.
With an appropriate factor of safety, the Code uses this strain to calculatc the allowable
stress under external pressure.
The Code calls the critical strain factor 'N and the allowable stress 'B'.
For heads or for allowable compressive stresses in shells, A is a function only of the thick-
ness and diameter.
The geometry chIlli in the Codc is derived from the theorctical buckling strain.
Above a certain length/diamcter ratio (typically 10), the result of the buckling calculation
is independent of the Icngth of the cylinder. Thus, decreasing the free length of a cylinder
docs not begin to increase the allowable pressure until the free rength is less than 10 times
the diameter.

Example Problem 1-- A Simple Dnnl1 4-21

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External Pressure on shells and heads Pressure Vcssel Design alUl Analysis - Scminar Noles

-.
~~
~
0" I r ~ 4 0" ,l ~
~

o· •
0" 1 f • 5 ____ y'r': • o· ~

Do /t • 6 V 1/
•
M
/

0~/tl'8 I-' I,
N
V V
o I" 10 I--' V v
V-
Il' ~
~
~

00 1/ • IS •
~

I I I /
•
D: ,,'.,), / V :/ V
" M

D:/,'·,l V
V
/ / N

D:"'. JO V V'" "V

f- "
<
I I I L../ "
°0/r.40
/
III
~
a "« 0
u
, <
• "
I- 0 9 11 -50 ~

V V /
l- V •
Oolf ~ 60 V / /
M
V
o~lIl.sb V V l.-
N
V V V
V'"
f

.100 V V-
0 0 1/
I/ V ",V
~ §
00lt o l25 ~
,
0~1I1. ,~ L-
~

1 f V
V i" •
D~,.I. ,&, L.- V /' V- M
/ 1/

~~~/
D~"I:,~ N

~,,'. ,:" 001 001 00 0 01 ~

g 'l: 0.
~ ~
C!
~ ~ ~~ ~
C!
~
0.
~
~ ~ ~. ~ ~ :;l- 0.
•
II!
M
C!
M
~

"
owoo-.
N": ..: ..:
N
..: ~
°0 /7 .. maW9!O 0PISlno ... lll6u81

Figure g··Geometric Chart for Factor A

4·22 Examplc Problcm J- A Simplc Drum

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Pressure Vessel Dcsign and Analysis - Seminar Noles Extern<ll Pressure on shells <ll1d hC<lds

OO~~'~Z~£~f~y
m
<
): ~.,o
·,,•
<
::...t 1\\ 1\:,A--,\* \\* 1\* 1\* \\* \\* .:§J
pO
ol
~ 0/ ~ o~ 0' QO \\ * I
~

,o·.'~
~

V 1/ '/

w-:M
•
..- / V '/ / / V ~~~
7 1...- ./
1/
./
1/10'"
QO\\ ,4';
·
~

, <
N

V V V /' V V~I
0' d'
.- V V
l...- v"" VVV /VV' V
0' ~<J;, 0'
< ~
•<
...- V V
~d'L 1\*/
·,,
~

V V V o'-j-- 'd' •
V l...- V ...- V l/
1/
...- V(~
0'. ;p;
,
~

..-
1/
V
V V V V/ Y V ~
° ,:~
,
N

V V
V
yl/v V V V Vr-rM 0
0
* \~ <
C7>
m
"
~ ~
•
~

·,, •
< U
~

°
~
"
~

...- /' / /
.-
/'
/

/'
...-
V
..-' /
...-..-
/
...-v V
•-
-"
0
,

.-
...- /
""
..-'
V
/ -2
.2
<!J
<

/...- /'
""...- /'
·•• •
-"
I-
•
.;
•
0
<
<
•,
§

/' (/) > ,

.- Ui
.- V "" I-
0
z
--'
,
~
0: <
w
Z
w
<!J

-
N ~ ~ ~ ~ ~ ~ ~ :1 ~ ~
om~'N°2RO~~
t'!-:~. -: -: .... ~~ q ~ ~
~
°0 / 1 .. JalawgrO BPIslnO + 416u'll

Figure 10--Geometric ClJart for Components under External or Compressive Loadings

Since B is the stress associated with the strain A for a given material, the materials charts
in the external pressure section (ASME, 1992, Section II, Parl D, Subpart 3) are really
just stress strain diagrams for a given material, adjusted to reflect a specific factor of
safety against buckling.
The Code has also provided a tabular form for the charts in Subpart 3.

Example Problcm 1- A Simple Drum 4-23

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External Pressure Ull shells aud heads Pressure Vessel Design and Analysi:, - Seminar Nute:,

The external pressure charts have a straight section which corresponds to the clastic por-
tion of the stress strain curve. Inlhis straight section, B is always equal to AE/2 where A is
lhc strain and E is Young's modulus for the material.

'~J»O
GENERAL NOTE; See Tablo CS·2101 tGbulil ... 31 Ullt,
1-
J,!
J,,':t!.Ou' ,""00
, 11(;
1 I
I~)', · ,&,(IoXl
L-- .", . ,.~~

V- I-- / ~~I .. ,
.

V
- .
--
.- - -_. --
'-~

OCO:u

""'
•.1.")

· I,(m
:e.- . - -
t= f= - ·1- 1-- --/l!Jf- .
. - .~o

w ...
1-190 .. 10'
f' II/II .
- l- I" 110. 10( · . _,CY.Jl
1.".~.'O·
n,,, 111 1 - ""
t" 71/// - _.
.
rmi'" IiSfVI
· 1,1'"

3 4 5 6 1 III
..",
3 4 5 6 18' 3 456/111 34~'719
, ""
""" ""
,,,crOll " "
FIG. CS-2 WART FOR DETERMINING SUEll TlUCI<NESS OF COMPONENTS UtlDER EXTERNAL PRESSURE
WilEN CONSTRUCTED OF CARBON OR lOW AllOY STEELS (Specified Minimum Yield Strength :30,000 p~i and
Over Except for Materials Within ThIs Rarlge Where Olher Specific Chnts Ate Referenced) AND TYPE 405 AtlD
TYPE 410 STAINLESS STEELS [Noll.' (1))

Figure 11·· Typical Materials Chart for Factor B

Up untillhe 1992 edition of the Code, external pressure charts (and Ihe tabular form) were
in Appendix 5 of Section VllI, Division I, In 1992 these were moved to Part D of Seelion
II (Malerials). They are found in Subparl 3 of Part D. At the same time Ihe names of the
charts were changed. The following table shows the new names, the old names, and all
abbreviated title for each chart:
Table-Garboll Steel Materials
New Name Old Name Title
CS-I UCS-28.1 Carbon and Low Alloy, Sy<30000
CS-2 UCS-28.2 Carbon and Low Alloy, Sy>30000
CS-3 UCS-28,3 Carbon and Low Alloy, Sy>38000.
CS-4 UCS-28.4 SA-537
CS-5 UCS-28.5 SA·508, SA-533, SA-54 I
CS-6 UCS-28.6 SA-562 or SA-620

Table...J4eat-TI'eated Materials
New Name Old Name Title
HT-1 UHT-28.1 SA-517 and SA-592 A, E, and f
HT-2 UHT-28.2 SA-508 Cl. 4a, SA-543,13,C

Table-8lainless Steel (High Alloy) Materials

New Name Old Name Title

4·24 Example Problem 1- A Simple Drum

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Pressure Vessel Design ,1Ild Analysis - Scminnr Notes External Pressure 011 shells ,11ld heads

HA-I UIIA-28.1 Type 304

HA-2 UIIA-28.2 Type 3 16, 321, 347, 309, 310, 430B
IIA-3 UHA-28.3 Type 304L
HAA UHA-28.4 Type 316L, 317L
HA-5 UIIA-28.5 Alloy S31500

Table-l'/{)n Ferrons Materials

New Name Old Name Title
NFA-I UNF-28.2 ALJ003,0 and HI 12
NFA-2 UNF-28.J ALJ003, HJ4
NFA-3 UNF-28.4 ALJ004, 0 and H 112
NFA-4 UNF-28.5 ALJ004, 1134
NFA-5 UNF-28.IJ AL5154,0 and H 112
NFA-6 UNF-28.14 C61400 (Aluminum Bronze)
NFA-7 UNF-28.17 ALl060,0
NFA-8 UNF-28.18 AL5052,0 and HI 12
NFA-9 UNF-28.19 AL5086, 0 and H 112
NFA-IO UNF-28.20 AL5456,0
NFA-II UNF-28.2J AL5083, 0 and H 112
NFA-12 UNF-28.JO AL6061, T6, T65 I, T65 10 and T6511
NFA-13 UNF-28.J I AL6061, T4, T451, T4510 and T4511
NFA-14 UNF-28.J2 AL5454, 0 and H J 12
NFC-I UNF-28.9 Annealed Copper
NFC-2 UNF-28.10 Copper-Silicon A and C
NFC-3 UNF-28.11 Annealed 90-10 Copper Nickel
NFC-4 UNF-28.12 Annealed 70-30 Copper Nickel
NFC-5 UNF-28.4J Welded Copper Iron Alloy Tube
NFC-6 UNF-28.48 SB-75 and SB-Ill Copper Tube
NFN-I UNF-28.1 Low Carbon Niekcl
NFN-2 UNF-28.6 Ni
NFN-3 UNF-28.7 N i Cu Alloy
NFN-4 UNF-28.8 Annealed Ni Cr Fe
NFN-5 UNF-28.15 Ni Mo Alloy B
NFN-6 UNF-28.24 Ni Mo Cr Fe
NFN-7 UNF-28.25 Ni Mo Cr Fe Cu
NFN-8 UNF-28.27 Ni Fe Cr Alloy 800 .
NFN-9 UNF-28.29 Ni Fe Cr Alloy 800H
NFN-IO UNF-28.JJ Ni Moly Chrome Alloy N I0276
NFN-II UNF-28.34 Ni Cr Fe Mo Cu Alloys G and G-2
NFN-12 UNF-28.J6 Cr Ni Fe Mo Cu Co, SB-462, 463, etc.
NFN-13 UNF-28.J7 Ni Fe Cr Si Alloy 330
NFN-14 UNF-28.J8 Ni Cr Mo Grade C-4
NFN-15 UNF-28.J9 Ni Mo Alloy X
NFN-16 UNF-28.40 Ni Mo Alloy B-2
NFN-17 UNF-28.44 Ni Cr Mo Co N06625 (Alloy 625)
NFN-18 UNF-28.45 Ni Mo Cr Fe Cn (Grade G-3)
NFN-19 UNF-28.46 Ni Mo Cr Pe Cu (Grade G-3, >3/4)

Example Problem 1- A Simple DnllTI 4-25

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E.\lt:rnal Pressure 011 shells alld hcruls Pressure Vessel Design and Analysis· St:lllinar Notes

NFN-20 UNF-28.47 Work Hanlcncd Nickel

NI-T-I UNF-28.22 Unalloyed Titaniulll, Grnde I
NFT-2 UNF-28.28 Unalloyed Titanium, Grade 2
NFT-3 UNF-28.42 Til"nium, Gradc I
NFZ-I UNF-28.35 Zirconium, Alloy 702
NFZ-2 UNF-28.41 Zirconium, Alloy 705

t
Moment axis of ring ~~~ h/3
1-'

L -.;..- L - L --+---
00
I
-+-L~-L
I I

1113
h a depth 01 hcad-!4, • • ..j

Ih-- L --,J.,- L-i-l

I
L I

Do
,r ,

Figure 12-- Typical Geometry showing variables used for External Pressure Analysis

4-26 EXClIllJllc Problem 1- A Simple Drum

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Pressure Vessel Design rllld Annlysis - Seminar Noles Stiffening

STIFFENING
/\ section ora vcsscl held ill a circular shape by a stifTening ring will not buckle into lobes,
and will prevent the sections ncar it on either side frolll buckling into lobes.
for a given length of cylinder, the Code requires that the stiffener have a known moment
of incrtia, to cnsure that it will hold the section round for the calculated external load.
The reinforcement required in a stiffener increases as a function of the length between
stiffeners. However, increasing a stiffener size does not change the maximum length
between stiffeners at all.
When calculating available stiffener moment of inertia, the Code allows you to decide
whether or not to take the shell into account in your calculation.
Thc Codc allows you to include a width of shell in the calcutation cqual to
1.1 * SQRT(Do*t). This is the dccay length of the cylinder.

1
0.'
Decay Length:!: 1,56·SQRT{rl)
0.0
0.7
0.6
0.'
0.'
0.'
0.2

_::~H
-0.2
~~ ==+---;' I
-0.3
~O.4

-O.!l
-0.6
-0.7
-0.6
-0 •
~, I I I I '=...",/ I I I

0.00 2.00 04.00 6,00

o (Xp(eX) x COS(BX) v EXP(BX)'COS(8X)

Figure 13--Decay Length for Cylinder Local Bending

The required value of the moment of inertia will be higher when you include the shell in
your actual moment ofincrtia.ln cffect the Code credits something for the shell when you
chose not to use it in your calculation.

Example Problem 1- A Simple DnllJl 4-27

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Stifrening Pressure Vessel Design and Analysis - Seminar Noles

r1rY' i ,"
T
l{J -l,
i ~/ j
,
1_
L

I 'l'
1--11 . I~ - 21 Ibl
I NOIII (II .nd (:Ill Irlol.1311

--l

T r
l~ i L L
L L

1, J
'lc - tI Ie - 21
[Notu OJ 3M l:lll
'Cdl '.1
INoI. (3))
'"
INotll (3)\

'NOTES:
C11 VlII.n 1"'- conl.to-cv'inder Of' thl knuckl"l(~eVnnderJunction I. not, line ollUpport. tho nomln,l thlcknell of Ihe cone.
knuckle. 01 1000ieonlc.t uetlon lh.1I not be 111I1han Ih. minimum reQulre-d thlckneu of Ih. adiKllnl evllndlle.1 ,hill.
121 Calculetlon, ch,U be made u,lng tho dllmeter end cOHupandlrog thlcknen of nch ,e-ctlon ..,llh dlmen.lon L III 'hown.
IJI Vlhln \h. con..to-<Vllnder or Ihe knueklo-to·eylindef junction II' line of .uPpor(. th' momlnt of Inertl' ,h. II 1.>"
pt'ovldloJ In llGCOrd,nCl with 1-8.

Figure 14--Geometry Showing Design Length for External Pressure for Cylinders

What do you need to know to analyze cylinders and heads for external pres-
sure?

External Pressure Chart

The tables of allowable tensile stress fol' materials also give the name of the external pres-
sure c1wrt to use for the analysis. Many external pressure charts have both lower and upper
limits on temperature. If your design temperature is below the lower limit, use values cho-
sen at thc lower limit. If your temperature is above the upper limit thc component should
not be designcd for vacuum conditions.

Diameter
Thc diamclcr for external pressure considcrations is ;]Iways the ollis ide diamcter.

4-28 Example Problem 1-/\ Simple Drum

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Pressurc Vcssel Design and Analysis - Seminar Notes SlilTcning

Actual (or assumed) Thickness

The strain factor is based on the ratio of diameter to thickness. Therefore to find the
required thickness for a given pressure, you have to guess a thickness, calculate the allow-
able pressure associated with that thickness, and keep modifying it until the allowable
pressure is equal to the desired pressure.

Design Length for the Vessel or Vessel Segment

The design length orthe section is typically the length orthe vessel pills one third the
depth of the heads or, alternately, the distance between stinening rings.
For a vessel with 2 elliptical heads nnd no intermediate stiffeners, the design length is the
tangent length plus the diameter/G.
for a vessel with 2 spherical hcads and no intermediate stiffencrs, the design length is the
tangent length plus the diametcr!3.
For a vessel with 2 flanged and dishcd heads and no intermediate stiffeners, the design
length is the tangent length pills the diameterl9.

Width and Thickness of Reinforcing Rings.

Most external pressure stiffcning rings arc a simple flat plate cut (or rolled the hard way)
into the shnpe of a donut. Calculate the momcnt of inertia of the flat plate by combining it
with the shell section.
You can also combine the moment of inertia of a beam section with the shell contribution
using thc parallcl axis transfer theorem.

Example Problem l~ A Simple Drum 4-29

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 ...
w
o

~
n
:~

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www.iran-mavad.com
<
g
n
rn
~
C
§ n
-c;;- "
~.

-0 §
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<:-
;;- >
;; ~

-<
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-c;;-
~

z
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Pressure Vessel Design and Analysis - Seminar Noles Stiffening

Pressure Vessel Design and Analysis Seminar

Component Design Problem

0-101 Shell and Heads - Extemal Pressure:

Using the gCOIllCtlY defined for internal pressurc, eheck the shell and heads for full vac-
UUIll.

Notes:

Questions:

\Vhat is the rcquircd thickness?

Whatthiekness will you use?
What is the M.A. w.p for the Shell?
What is the M.A. w.p. for the Head?
Why are the M.A.W.p for the shell and the head so different?

DO NOT TURN THE PAGE UNTIL YOU HAVE

COMPLETED YOUR ANALYSIS

Example Problem 1- A Simple Drum 4-31

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Stiffening Pressurc Vessel Design ,111(\ Analysis - Seminar Notcs

CQADE Engineering Software

PVEI i te 4 . 00 Li censee: COADE Inc., Loca 1 \'/hi te Lock
F'ileName : Seminar --------------------------------------- P<lgc 6
Shell Analysis: 0101 EXTERNAL Item: 3 9:51<1 Scp "1,2000

Input Echo, Component 3. Description: 0101 EXTERNAL

Design External Pressure PF.:XT 15.00 psig

Temperature for External Pressure 450.00 P
External Pressure Chart Name CS-2

Include Hydrostatic lIead Components NO

I·latedal Specification (Normalized) SI\-516 70

Allow<lble Stress At Temperature S 20000.00 psi
Allowable Stress At Ambient SA 20000.00 psi
Curve Name [or Chart UCS 66 D
Joint efficiency for Shell Joint E .00

Design I~ength of Section L 268.0000 in.

I,ength of Cylinder for Volume Cales. CYLLEN 244.0000 in.
Inside Diameter of Cylindrical Shell D 144.0000 in.

l-1inimum Thickness of Pipe or Plate T 1.0000 in.

Corrosion Allowance CA o . 1250 in.

Type o[ Element: Cylindrical Shell

WEIGHT and VOLUME RESULTS, ORIGINAL THICKNESS:

Volume of Shell Component VOLI·1BT 111149.8 in .• , 3
weight of Shell Component Wl·1ET 31455.4 lb.
Inside Volume of Component VOLID 3973'188.0 in. "3
~Ieight of Water in Component \'111AT 143497.9 lb.

WEIGHT AND VOLUME RESULTS, CORRODED THICKNESS:

Volume of Shell Component, Corroded VOWETCA 97339.7 in." 3
Height of Shell Component, Corroded Wl·1ETCA 27547.1 lb.
Inside Volume of Component, Corroded VOLIDCA 3987598.0 in. "3
Weight of l1ater in Component, Corroded WWATCA 143996.6 lb.

EXTERNAL PRESSURE RESULTS, SHELL NUI·18BR 3, Desc.; 0101 EXTERNAL

ASf.lB Code. Section VIII, Division 1, 1998, A-99

External Pressure Chart CS-2 at 450.00 F

Elastic "lodulus for Material 27500000.00 psi

Results for t·lax. Allowable External Pl"essut·e (Emawp):

Corroded Thickness of Shell TCA 0.8750 in.
Outside Diameter of Shell 00 146.0000 in.
Design Length of Cylinder or Cone SLEN 268.0000 in.
Diameter / Thickness Ratio (0/1') 166.8571
Length / Diameter Ratio LD 1.8356
Geometl·y Factor, A f(DT,LD) l\ 0.0003286
f·laterials Factor, B, f(A, Chart) B 4518.0068 psi
Maximum Allowable Working Pressure 36.10 psig
Ef.lA\'IP .. (4'B)/(3'(D/T)1 """ (4 ' 4518.0068 1/( 3 ' 166.8571 ) .. 36.1028

Results fOl" Reqd Thickness for Ext. Pressure (Tca)

4-32 Example Problem 1- A Simple Drum

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 Pressurc Vcssel Design and Analysis - SCml1l<lr Noles Stiffcning

COADE Engineering Soft\~are

PVElite 4.00 Licensee; COADE Inc., Local I'lhite Lock

rileName Seminar ------------------------ -------------- Page 7
Shell Analysis 0101 EXTERNAL Item; 3 9:51a Sep 21,2000

Corroded Thickness of Shell TCA 0,6158 in.

Outside Diameter of Shell 00 146.0000 in.
Design Length of cylinder or Cone SLEN 268.0000 in.
Diameter / Thickness Ratio (0/1') 237.0924
Length / Diameter Ratio I,D 1.8356
Geometry F'actor, A f(DT,LD) A 0.0001940
r·laterials F'actor, B, f(A, Chart) B 2667.3970 psi
r·laximum AllOl~able \'larking Pressure 15.00 psig
EI1l\\'/P = (4*S)/D*(O/T)) = ( 'I * 2667.3970 )/( 3 * 237.0924 ) = 15.0006

Results for J·laximum Length Bet"'Jeen Stiffeners (Slenl

Corroded Thickness of Shell TeA 0.8750 in.
Outside Diameter of Shell 00 146.0000 in.
Design Length of Cylinder or Cone SLEN 6'1'1.9812 in.
Diameter I Thickness Ratio (0/1') 166.8571
( Length I Diameter Ratio LD 4.4177
Geometry F'actor, A f(DT,LD) A 0.0001365
Materials F'actor, B, f(A, Chart) B 1877.3041 psi
r·laximuffi Allowable l'larking Pressure 15.00 psig
EHA1'IP", (4*8)/(3*(0/1')) '" (4·1877.304) l/( 3 · 166.8571 ) = 15.0013

SUI·1I·1ARY of EXTERNAL PRESSURE RESULTS:

Allowable Pressure at Corroded thickness 36.10 psig
Required Pressure as entered by User 15.00 psig
Required Thickness including Corrosion all. 0.7408 in.
Actual Thickness as entered by User 1.0000 in.
r·laximum Length for Thickness and Pressure 644.981 in.
Actual Length as entered by User 268.00 in.

The PV Elite Program, (c) 1989-2000 by COADE Engineering Software

Example Problem 1- A Simple Drum 4-33

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Stilfenlng Pressure Vessel Design and Analysis - Seminar Notes

e01\DE Engineering Sofl""'are

PV~:1 i t.e 4. 00 Li censee: COAOE r nc ., Loca I \'/hi te Lock
FileName: Seminar ------------------.--.--- •• ------------ rage 8
Shell 1\rwlysis : 0101 EXT HE1\D Item; 4 9:51a Sep 21,2000

Input Echo, Component 4. Description: 0101 EXT HEAD

Design Ext.ernal Pressure PEXT 15.00 psig

Temperat.ure for f:o:xtel'nal Pressure 450.00 ,.
External Pressure Chart. Name CS-2

Include Hydrostatic !lead Components NO

!·latel'ial Specification (Normalized) SA-516 70

1\llowable Stress 1\t Temperature S 20000.00 psi
Allowable Stress At AMbient SA 20000.00 psi
Curve Name [or Chart UCS 66 0
Joint efficiency [or Head Joint r. 1.00

Inside Diameter of Elliptical Head D 144.0000 in.

r·linimum Thickness of Pipe or Plate T 1.0000 in.

Corrosion Allowance CA 0.1250 in.

lI.spect Ratio AR 2.0000

Length o[ Straight Flal:ge STRTFLG 2.0000 in.

Type of Element.: Elliptical Head

WEIGHT and VOLW1E RESULTS, ORIGINAL THICKNESS:

Volume of Shell Component VOLt·1ET 26074.9 in. H3
\'leight of Shell Component wt·IET 7379.2 lb.
Inside Volume of Component vaLID 390864.4 in. * 03
weight of I-Iater in Component WI-I1\T 14114.5 lb.
Inside Vol. of 2.00 in. Straight VOLSCA 32572.0 in. * 03
Total Volume for Ilcad ... Straight VOLTaT 423436.4 in.' 03

WEIGHT AND VOLW~E RESULTS, CORRODED TIIICKNESS:

Volume of Shell Component, Corroded VQUoIETCA 22815.5 in. "3
Weight of Shell component, Corroded WI·IETCA 6456.8 lb.
Inside Volume of Component, Corroded VOLIDC1\ 392903.7 in.' 03
Weight of NateI' in Component, Corroded I'lWATCA 14188.2 lb.
Inside Vol. ot 2.00 in. Straight, Carr. VOLSCA )2685.2 in ... )
Total Volume for Head * Straight Corroded VaLTCA 425588.9 in.' 03

EXTERNAL PRESSURE RESULTS, SHELL NUt·mER 4, Desc.; 0101 EXT HEAD

ASI~ECode, Section VIII, Division 1, 1998, A-99

External Pressure Chart CS-2 at 450.00 F

Elastic 1·lodulu5 for 1·laterial 27500000.00 psi

Results for 11ax. Allowable External Pressure (Emawp)

Corroded Thickness of S~ell TCA 0.8750 in.
Outside Diameter o[ Shell OD 146.0000 in.
Diameter I Thickness Ratio (O/T) 166.8571
Geometry Factor, A f{DT,LD) A 0.0008324
r·laterials Factor, B, f (A, Chart) 10051.5:;n3 psi
r·laximum 1\llo·....able I-Iorking Pressure " 66.93 p5ig

4-34 Example Problem 1- A Simple Drum

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 Pressure Vessel Design and Analysis - Seminar Notes

eOADE Engineering Software

PVF.lite <1.00 Licensee: eOADE fnc., Local l'lllite Lock
PileName : Seminar - ----- --- -- -- - - - - - - - - - - -- - -- ------- -- - - Page 9
Shell Analysis 0101 EXT HEAD Item: 4 9:51a Sep 21,2000

EHANP B/(KO~ (O/T)) = 10051.5273/( 0.9000 • 166.8571 I = 66.9337

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

Corroded Thickness of Shell TeA 0.3882 in.
Outside Diameter of Shell on 146.0000 in.
Diameter / Thickness Ratio (0/1') 376.0957
Geometry Pactor, A [(DT ,I,D) A 0.0003693
'·laterials PactaI', B, f(A, Chart I B 5077.7563 psi
I·laximum Allowable l'lorking Pressure 15.00 psig
Ef·tM1P = B/ (KO· (0/1')) = 5077.7563/ ( 0.9000' 376.0957) = 15.0014

SI.Rolf·IJ\RY of EXTERNAl. PRESSURE RESULTS:

Allowable Pressure at Corroded thickness 66.93 psig
Required Pressure as entered by User 15.00 psig
Reguired Thickness including Corrosion all. 0.5132 in.
Actual Thickness as entered by User 1.0000 in.
(
The PV Elite Program, (cl 1989-2000 by COAOE Engineering Software

Examplc Problcm I-A Simple DnUll 4-35

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Nozzle Reinrorccmcnl 'Illd Failure P"th C:llculations Pressure Vessel Design and Analysis - Seminar Notes

NOZZLE REINFORCEMENT AND FAILURE PATH CALCULATIONS

The Code implements an "area replacement" concept: Near an opening there should be
"extra" metal equal to the area of required metal missing due to the presence of the open-
ing.
This area needs to be replaced because of stress intensification at the hole. A hole in a
fairly large cylinder is roughly the same as a hole ill a flat plate loaded in plane. Stress
intensification factors for this case arc
Axial Load Only 3.00
Cylinder 2.50
Sphere 2.00
A second consideration in the design of the nozzle is making the connection strong enough
so that pressure loads will not pop the nozzle off the vessel.
The Code rules for nozzle reinforcement and failure path calculations arc found in para-
graphs UG-37 to UG-41. The Code takes into account the differing strengths of different
materials (i.e. the nozzle, the reinforcing plate, the shell) by using strength reduction fac-
tors on any area where the material used has a lesser strength thnn the basic shell material.
All vessel and nozzle thickness calculations arc based on seamless components - E is
always equal to I.
If the opening is ill the spherical portion of a torispherical head, the required thickness
is based on a torispherical head with M= 1. This is a result of the lower stress in the
central portion of a head, and the lower stress intensity at a hole in a sphere.
If the opening is in an elliptical head and is inside a circle based on 80% of the diame-
ter, the required thickness is based on a seamless sphere with a radius of90 percent of
the vessel diameter.
For external pressure, the Code requires that only one half of the required area removed be
replaced. The required area is based on the niles for external pressure.
For nat heads (Paragraph UG-39), the Code requires that only one half of the required area
removed be replaced, because the head is loaded in bending rather than in tension.
Limits of reinforcement (Paragraph UG-40) are intended to assure that the metal used to
replace missing metal is close enough to the hole to be effective. They arc based on the
characteristic length, or decay length of the vessel:

1.56 * SQRT(R *t)

This is an extremely eomlllon expression in pressure-vessel design; it describes the dis-
tance along a vessel shell in which the efTeet of any load will be felt. Beyond this distance,
the effcct of the load has decayed to ncar zero.
The Code approxilnatcs this distance as 2x the corroded inside diameter orthe hole along
the shell, and 2.5 times the thickness of the nozzle radial to the shell (based on rlt ~ 10).
Small openings (Paragraph UG-36) arc exempt from reinforcement requirements:
if t<=3/8, 3 in. and smaller are exempt
if t> 3/8, 2 in. and smaller are exernpt

4-36 Example Problem I-A Simple Drulll

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Pressure Vessel Design nile! Allnlysis * Seminar Notes Nozzle Reinforcement nile! Fnilure Pnlh Calculntiolls

Large openings have special niles which are located in Appendix 1-7. These rulcs required
that more oCthe reinCoreement be placed close to the opening. They apply when one oCthe
Collowing statemenls is tme:
The diameter oClhe nozzle is greater than 20 ill. or greater than D/2 when the vessel is
60 in. or less.

The diameter of the nozzle is greater than 40 in. or greater than D/3 when the vesscl is
more than 60 in.
Bending-end membrane stresses are computed Cor some "large" nozzles per 1-7.
Strength of reinforcement and failure path calculations arc found in paragraphs UG-41,
UW-15, UW-16. The Code requires that the strength of any failure path through the nozzle
and its reinCorcement be grcater than the strength oCa Cailure path through the vessel shell.
There arc two basic placements oC nozzles Cor which the Cailure path becomes an issue: I)
inserted through the shell wall and 2) abUlting the shell wall. Area of reinforcement calcu-
lations arc diITerent Cor the two cases.
Paragraph UW-I 5 (b) exempts many of Ihe commonly used nozzle attachment geometries
Crom strength calculations.

Example Problem I-A Simple Drum 4-37

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Nozzle Reinforccment ma\ Fnilurc Pouh Calculnliulls Pressure Vessel Design and Annlysis - Seminar Notes

11.2 STRESSES AND LOADINGS AT OPENINGS 337

/-67t; Nf'i ""'...

1,0 (axial onlY)
(,)

"
~

Ullj

o.u; ,
IOf£, tnt,
I L
o_~~ 201 (cYlinder)
(b)

r.

11 1 (sphere)
(el

Figure to-Stress Intensification at a Hole

in a Flat Plate under Various Loadings

4-38 Example Problcm I-A Simple Drum

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Pressure Vessel Design ilnd Al1<1lysis - Seminar Notes Nozzle Reinforcement :llld Failure Path Calculmions
"g. UW·16.t 1998 Sr:cnON VIll DIVISION I
r ....
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,
:
Figure 2-- Typical Nozzle Configurations
Example Problem I-A Simple Drum 4-39
 ...
1- z
o o
~
~
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ri
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<:: "Co
il 30 dell. moo. /
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It:lf m ,,, l T ." I I"~
"
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!!C .I. "

~
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=
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ca'
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'
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" or'2 /'lOt I~ rh..n.
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5.
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16 ltlt ,m~H., of 1/4 In.
:>-
!f .s
~ orO.7'.......
"
-<
~

I ~.

>
~
FIG. UW-lb.l SOME ACCEPTABLE TYPES OF WELDED NOZZLES AND OTHER CONNECTIONS TO SHELLS,
HEADS, ETC. (CO NT' D)
'"
~
C/l

~ NOTE: Skdch~s Cal, Cb), (el, Cd), (~), (I-I) througlt (f-4l, (9), {x.ll, (y.ll, and (l-ll Ir~ ~XOlmp!~:; of noull.'S with ~ ~.
intt9ral r~lnforc~mtnL ;;:
"";,- ;:;
~

0 z
o
§
"
~

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Pressurc Vessel Dcsign ;Jnt! Analysis - Scminar Not~s Nozzlc Reinforccmcllt ;Jml F3ilufe P31b Calculations
Fig. U'oV·16.1 1998 SECTION VIJI DIVISION I
.
--",, •
./
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J
>-
~
u ~i
0
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"
:<
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Figure 4-- Typical Nozzle Configurations (continued)
Exal11ple Problem I-A Simple Dnllll 4-41
Nozzle Reinforccment and Failure Path Calculations Pressun: Vessel Dcsign ;llld Analysis - Scminar Notes

PART UG - GENERAL REQUIREMENTS Fig. UG-n.l

U •• lOIOff v.l.... V.. Ill\'l'f walue

Ia< noul. WlllrUo1.d I~'O"~ ,to v ,w.~ -.t.-- 101 1>O1l1. Will .bul1ift9 II',. ......10.-••

wo........ R.InIOl (I .....".

!-,··,,···I
W!a
~ As-o. I,.. hob'. in noul. P",""'.in.]OUI.... "'; ., •
......' .....Iu

=
..!1 D:... ~ ,4., ~ ou,v",d 1>0 •• 1. wold • 1I~12 '" IV...... lob" ill ou" ,d ..... !d
~ [7' • A.) ·w,.... 'dnco"I ......id· (1f9I"" A"" .nillble III i ,d weld

I . . ,.. . ,.A,.A.,.A., >A OP"""'l il l><»qv.alv •• I"'OI~

1t,4, • A 2 ..... , · A., ...... J < .... Optlllng it net ,d1ov.1I1V ul"lo,...,d 10
ni.lo,ci1\9 .llm"I' milt' bot .deled
I<>$,'<>< '~"d" ..... m".1 b' 1t>Cltlud
ffil~ R.;nfo •• ;~ (1 .....,.,I.Add+<I
A • »tnt .. A. Ibo'.. A,u'«I"i..<I

A, ".- .. A,.I01>0'"
• 6(1" - t,,Ifa' "'....... ilobl. In no.." JHOI-:II... oue....'d;
A 2{ _ 2(,., _ ',,,1 f2.!>t,.. '.If" uwllNll., ....
A) • ........ uA,.obovo ........ •,,,itobk in ifW<W nOlllt

L1 ~ -
.Ll ~..
"'iiJ W"
A.,.
A.\ - oulWWd nou;"WlId -I'''ll'f"
ou'" .1"...0" .....1d -11"ll" •• "'to ilJb" In OUt,,_1o:I

m- AU • In.....-clnoul._H _lJf>9 12,,,

AS .rOp -II_2t,,),. f,. Iliot"'l1
"'" ~ .. II In in ..."" w.!O
Areo .."itblt in .l._n.

IIA, .A,'A)' ...U o"'u ''''.]''''S >A

HOTE:
(" Thl, 100m.l. h 'POlo::o~l. lot • 'K""Vulo •• ,0 .....100'ol .r'W>fIl' .,.., 10'... i\hi<> .". 1m", ., ,.inlot..",onl-

FIG. UG·)7.1 fWMENCLATURE AfW rORMULA$ FOR REINFORCED OPENltlG$

" !This Flgurt IIlustrales a Common tlOlllt Confi9uraUon and Is Ilot
Intended to PIohlblt Other Confi9uratlons Permitted by t~ Code.>

Figure 5··Area Replacement Calculations for Typical Nozzle Configurations

4·42 Exmnplc Problem I-A Simple Drul1l

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Prc:-surc Vessel Design and Analysis - Seminar Noles Nozzle Rcinforn:nu:n( and Failure Path Calculations

PART UO - GENERAL REQUIREMENTS Fig. UG41.l

.,

[ =--=-=-=-=-=-=~"ji, Ikd

~ A,
Ll ~ A"

~ A,
Ll ~ A"

m AJ "q 17 A"

IlmI3l A5

w. loltl wtld 10ld IUG-'Ilb)ml

• IA - At. 21..1,,1£,1- FMIS..
VlH • wtkllo~'~ Ilf"I"lh pllh '.IIUG·41lbHlIl
• tAJ. ~. A.l • AllIS..
WH • wtld Iotd fOf Ilrtngth pith 2·2\UG·'llbHllI
• tAJ. A) • A" • AU. 2I"t1'115"
W).) • w.1d Iold lor Ur.nllih pIUl'" IUO..4l1bH III
• tAJ. kt. As· Au • AU • AU • 2/n,r"Is..

GENERAL NOTES:
III ArUI AI. A J• A). ~. rid A.,I" tJ'Iodifiotd by I nt riltlOlJ.
lbl Nomtn<:IUurt Illh.llm.nln UG·)) ud fig. UG-H. I.

101 D.pl<:1. Tvpic.ll NOlll. 0'1.11 Wi1h Nick In.."teI Through 1M VI",,1 Will

FIG. UG-41.1 NOZZLE ATTACHMENT WElD LOADS APID WElD STRENGTH PATHS TO BE COIlSJOEREO

Figure 6--Failure Paths (or Typical Nozzle Configurations

Example Problem I-A Simple Drum 4-43

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Nozzle Rcinfon:emcnt and Failure Path C<llculnlions Prc,:.;surc Vt:ssel Design ami Annlysis - Scminar Notes

Fig. UG·41.1 1998 SECfION vm - DIVISION I

....;:..

~ A,
Ll th A41

~ A, L1 ~ A"

m A5

W ..lOla' wild load IUG·41Ibll211

..
lA-Ails",
wild load rOI sllingth palh l-1IUG·41lbll1l!
W I_, ..
tAl.",· Au • AHIS..
..
WI_I" wild load ror slrlnglh palh 2·2IUQ·4Ublf111
.. (AI. A 41 1S..

GENERAL NOTES:
(al Afeils AI' AI.II~. and AHilfO modified by ',xlaetofs.
(hl Nomenclatufl is the same as in UG·37 ilnd Fig. UG·37.1.

'IM D.pict. TypiClI Nonl' 0.1111 With Nick Abutting lhe Vossel Well

FIG. UG-41.1 NOZZLE ATTACHMENT WELD LOADS AND WELD STRENGTH PATHS TO BE CONSIDERED
lCDNI'D)

Figure T--Failure Paths for Typical Nozzle Configurations (continued)

4-44 Example Problem I~A Simple Drum

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Pressure Vessel Design and Analysis - Scminar Notes Hillside and Orr-Angle Nozzk Anglcs

HILLSIDE AND OFF-ANGLE NOZZLE ANGLES

There are two main categories of ofT-angIe vessel nozzles: those which are off-angle in the
longitudinal planc of the cylinder (Y-angle nozzles, Figure 23), and those which are orr
angle in the circumferential plane ofa cylinder, or in a head (Hillside nozzles, Figure 24).
In order to analyze these kinds of nozzles, CodcCalc asks the user for the angle between
the nozzle centerline and a tangent to the vessel mean radius, as also showll in Figures 23
and 24. However, for hillside nozzles, the determination of this angle can be difficult. This
section provides a few simple equations that can help the user determine the nozzle angle.
The overall goal of this calculation is simple: to find an angle that will make the finished
diameter of the hole fit perfectly within the nozzle. The finished diameter is the dimension
d in Figures 23 and 24, which is called DLII in the CodeCalc print-outs. Ifwe had the
nozzle in front orus and could measure d, thcn we could calculate the input angle vcry
simply lIsing the following equation:

where dn:=: inside diameter of nozzle

d ~ DLR ~ finished diameter of holc

sinn:=: sine of angle betweellllozzic and vessel
Whcn we analyze Y-angle nozzles, this is really all the information we need: the angle is
known and the result is exact:

d ~ DLR ~ !."-
SInn

However, when we analyze hillside nozzles, as shown in Figure 2, the angle is usually not
known. Instead, we may know the offset distance for the nozzle. This distance (L) is the
distance between the centerline of the cylinder or head, and the centerline of the nozzle. A
first approximation to the angle would take thc cosine of the angle as L I rm, where nll is
the mean cylinder or head radius at the point of attachment. However, this approximation
turns out to be too inaccurate for practical use.
The ASME Code has a sample problem (L-7.7) that shows what their preferred method
appears to be. They do not explicitly address this off-anglc problcm in the body of the
Code. Figure 3, taken from ASME (Section VIII, Division I, Addenda An, Page 512),
shows their sample problem. The key to their approacli is the calculation of two angles, al
and a2, and then the calculation of the finished diameter from the difference between these
two angles. You can follow their calculation on Page 512 aml513 of the Code. For our
purposes, we do not need to eany the calculation that far. The angle we are looking for, a
isjust the average of the two Code angles as calculated previously. The following equa-
tions show how to calculate this angle:

a 0: arccos ( L_- _ r,,)

I r
"'
L + ,. )
U
-J =
,.
arccos ( - - "
'"
al + a2
n = arccos--
2

Examplc Problcm I-A Simple DIlJlll 4-45

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Hillside ami On'-Angle Nozzle Angles Pressure Vl~55e1 Design and Annlysis - Semil1nr Noles

Where L ~ offsct distancc cylinder / head ccnterline

rn = inside nozzle radius
rill = mean vessel radius
These three equations can be used without any further information for any hillside nozzle
in a cylinder. However, you need to apply thcm carefully to hillside nozzles in heads.
When a hillside nozzle is in an elliptical or torispherical head, the nozzle may be located in
thc spherical portion of the hcad, the toroidal portion of the hcad, or it may straddle the
two portions. This is shown in Figure 4. Each of these cases requires a slightly different L
and I'm to be used in equations.
When the nozzle lies entircly within the spherical portion of the head (Figure 4(a)), L is
simply the offset from the head ccnterline, and I'm is the spherical radius of the head. For
spherical or torispherical heads, this should be a known radius (Code dimension L in Fig-
ure 1-4 of Appendix I, for example).

Note The Code uses inconsistent terms herc.

For elliptical heads, the spherical portion is taken to be a circle drawn on the head with a
diametcr of 80 percent of the head diameter. The radius of the spherical portion is taken to
be 0,90 times the head diameter. The nozzle offset from the vessel centerline should be
known fr0111 the vessel drawings.
The nozzle can also lie entirely in the knnckle portion of the head (Figure 4(c)). The mean
radius (1'",) is the mean knuckle radius, and the offset (L) is distance from the origin of the
knuckle radius to the centerline of the nozzle. Note that for an elliptical head, the knuckle
is defined as anything outside a circle drawn on the head with a diamcter of 80 percent of
the head diameter. The knuckle radius is 0.17 times the vessel diameter.
Finally, the nozzle may be located so that parI of the nozzle is in the spherical portion, and
part in the knuckle (Figure 4(b)). In this case, the angle at the part of the nozzle in the
spherical portion should be caleulated as described for Figure 4(a), and the angle at the
part in the knuckle portion should be caleulatcd as described for Figure 4(c). That is, cal-
culate the inside angle using the spherical radius of the head and olTset from the ccnterline.

4-46 Example Problem I-A Simple Drum

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Pressure Vessel Design <Inti All<llysis - Seminar Notes Ilillside and Off-Angle Nuzzle Angles

Calcultlte the outside angle using the mean radius of the knuckle and the offset from the
knuckle origin.

Figure 8-- Y-angle Nozzle: Nozzle angled in the longitudinal plane 01 a cylinder

Example Problem I-A Simple Drum 4-47

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Ililiside ant! Olr·l\nglc Nozzle Angles Prc:-;surc Vessel Design ,lilt! AlI:tlysis - Seminar NOles

L = Offset Dislonce

Figure 9--Hillside Nozzle

-....-"'--r---:
,7
_.Y -In in.
/ ! /
1/2 in. lillel_, ... / Rn=2in. ./
/
' .... , ..:
r7'77"?/"
[/ '-
./
. -.-r.--.-t~-._.
/
;.:'
R=15 in. / /
,,,,/
aJ/
j
I
/
a2
" .,
\
\
\i
\ \,
, i
; I 1·1/2 ill.
r -L~12in.---

Figure 10·-ASME Code Figure L-7.7, Example of Reinforced Opening

4-48 Example Problem I-A Simple Drulll

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Pressure Vessel Design and Analysis .. Scminar Noles Ililiside anti Olr-Angle Nozzlc Angles

r-L-l
A'
I ' \
';-i< I II Spherical 1'0l1ion
fI
{ '.L1
~ Knuckle
Radius
\
\ Spherical Radius I--- Lo _ . \29
1~-rll1--1
Tordial
P0I1ioll

Examplc Problcm I-A Simple Drum 4-49

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Hillside and Orr-Angl~ Nozzlc Angles Pressure Vcssel Design lind Analysis· Scminar Notcs

r- L

___ I

'I' oruw
"'1'
Portion

Figure l1--Hiflside nozzles in /leads

What do you need to know to perform nozzle reinforcement calculations?

Required Thickness of Head or Shell and Nozzle

The thickness of an elliptical head is analyzed as "n equivalent spherical head, as speci fied
in the Code, paragraph UG-37 (a), SimilarlY,thc thickness of the spherical portion ofa
torispherical head is analyzed using the same method and code reference.
If your nozzle is outside 80% of the diameter of an elliptical head, or in the toroidal por-
lion of a torispherical head, you must calculate the required IhickJless using the rules of
UG-32 rather than the I1Iles described above (but wilh E= 1.0 in all cases).
You must also calculate the required thickness for a flat head. However, you may reduce
the required area of reinforcement by 50% for a Oat head.
For external pressure, you must calculate the required thickness using the guidelines in
Paragraph UG-28 for cylinders and UG-33 for heads. Once again, however, you may
reduce the required area ofreinforeement by 50 percent for external pressure.

Geometry of Nozzle and Shell

You must know the diameters, thicknesses, and corrosion allowances for both the shell
component (cylinder or head) and the nozzle. Most nozzles are constnicted from pipe or
long weld neck Oanges, bUI occasionally from plate (for large nozzles) or from integrally
reinforced inserts.
The Code slates that metal usually associated with the pipe fabrication tolerance (mill
undertolerance) may be included in lhe calculation of the available area in a nozzle. Sec
paragraph UG-16(b),
The nozzle may be inserted through the vessel wall. Ifso, any metal in the insert, less cor-
rosion, is available for reinforcement.

4-50 Example Problcm I-A Simple Drum

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Pressure Vessel Design and Analysis - Seminar Noles lIillside and Orr.Anglc Nozzle Angles

Diameter Limit, Thickness Limit

Thc diamcter limit is the maximum distance, frolll the centerline of the nozzle along the
vessel wall, that can be calculated to delermine available areas in the shell or a pad. The
Code calculates this limit based 011 the corroded ID oflhe nozzle or the inside radius of the
nozzle plus the shell thickness plus the pad thickness. YOlllllust be conscious orallY phys-
ical obstmctions (other nozzles, welds, the end of the vessel, ctc.) which would prevent the
nozzle from making usc of reinforcement out to this diameter.
The thickness limit is the distance, from the vessel surface along the nozzle axis, that can
be taken credit for when calculating the areas available in the nozzle wall and the pad. The
Code calculates Ihis limit based on the thickness of the shell and pad or the nozzle wall.
You must be conscious of any physical obstnlctions (no insert, studding pad, welding out-
lei, etc.) that would prevent the nozzle from making use of reinforcement out to this thick-
ness.

Is the Nozzle in a Seam?

Ifso, the seam emcicncy is used in the "area available" calculations to reduce the area
available in the shell. However, for the shell thickness calculations themselves, the seam
efficiency is always 1.0.

Details of Nozzle Welds

The welds that attach the nozzle and the reinforcing pad to the shell are important because
thcy contribute to the arca available for reinforccment and because they frequently control
the failure path calculations. Most nozzles arc attached with full penetration groove welds,
plus required fillet welds. Some of these geometries arc exempt from failure path calcula-
tions. Specifically, UW-15(b) indicates that no strength calculations for nozzle allachment
welds are required for figure UW-16.I, sketches (a), (b), (c), (d), (e), (f-I), (f-2), (f-3),
(f-4), (g), (x-I), (y-I), and (z-I).
Nozzle weld thicknesses are based on Figure UW-16. I. The outward nozzle weld is com-
pared to the cover weld required by the Code. Note that the mii,imum dimension of a weld
is 0.7 times its leg dimension. Note also thaI for cover welds the maximum weld the Code
requires is 0.25 in. The pad weld requirement is typically at least one half of the element
thickness. In addition to the cover welds, the total groove weld plus cover weld for
inserted nozzles must bc at least 1.25 timcs thc minimum c1emcnt thickness.

Large Nozzle Considerations

For large diameter nozzles, the rules of Appendix 1-7 rcquire that two-thirds of the rein-
forccmcnt be within 0.75 of the natural diameter limit for the nozzle. If the calculated
value of the percent within this limit is greater than 66%, the nozzle is adequately rein-
forced for the large diameter rules.

Manway or Access Opening

If this nozzle is a manway or access opening, the code docs not require the minimum noz·
zle ncck thickness calculations per UG-45 be performed.

Example Problcm I-A Simplc Dnllll 4-51

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Ilillside and Olr-Angle Nozzle Allgle~ Pres~urc Vessel Design <lnd All<llysis .. Scmil1<lr Nutes

4-52 Examplc Problcm I-A Simple Drum

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Pressure Vessel Design ;'Iud An;llysis - Seminar Notes Ililiside mul On.. . 1\ngle Nozzle Angles

Pressure Vesscl Design and Analysis Scminar

Component Design Problem

D-IOI Nozzle A:

Location Cylinder
Size 12 in. (300 NS)
Material SA 106, C

Thickness Schedule 80

Flange Class 300

Flange Material 1.1

The Nozzle is inserted into the vessel wall.

There is a .687-in. (17.45 mm) partial penetration groove weld
between the vessel wall and the nozzle neck.

Nozzle Outside Projection is 8.0 in. (203 nun)

No Internal Projections arc allowed in this vessel.

There is a 22-in. (559 mm) diameter reinforcing pad

The Pad material is the same as the Shell material.
There is a full penetration weld between the pad and the nozzlc ncck.
There is a 0.375-in.(9.55 mm) cover weld between the pad and the nozzle
neck.
There is a 0.625-in. (16 mm) weld between the OD of the pad and the vessel.

Notes:

Questions:

What pad thickness (ifany) will you use?

What is the M.A.W.P. for the assembly?
Docs this nozzle limit the M.A. w.P. for the vessel? _

DO NOT TURN THE PAGE UNTIL YOU HAVE

COMI'LETED YOUR ANALYSIS

EX,Hllpic Problem I-A Simple Dnull 4-53

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Ilillside ~lld Orr-Angle Nozzle Angles Pressur~ Vessel Design ~lId Anillysis - Seminar Noles

COMPLETED YOUR ANALYSIS

PVElite 4.00 I~icensee; COADE Inc., Local \'lhite Lock

FileName; Seminar ------------ ... -.---------------------- Page 14
Nozzle Analysis; 0101 Nozzle A Item; 9;Sla Sep 21,2000

Input Echo, Nozzle Item Description: 0101 Nozzle A

Design Internal Pressure Case P 230.00 psig

Temperature for Internal Pressure TEI·IP 450.00 F

Shell Haterial (Normalized) SI\-516 70

Shell Allowable Stress at Temperature S 20000.00 psi
Shell Allowable Stress At Ambient SA 20000.00 psi

Inside Diameter of Cylindrical Shell o 144.0000 in.

Actual Thickness of Shell or Head T 1. 0000 in.
Corrosion Allowance for Shell or Head CAS 0.1250 in.

Angle between Nozzle and Shell or Head ANGLE 90.00 Degrees

~ozzle Haterial (Not Normalized or NI\) SA-I06 C

~ozzle Allowable Stress at Temperature SN 20000.00 psi
Nozzle Allowable Stress At Ambient SNA 20000.00 psi

Diameter Basis for Nozzle BASISN 00

Diameter of Nozzle DIA 12 . 0000 in .

Nozzle Size and Thickness Basis DBN Nominal

~ominal Thickness of Nozzle THKNOi-l 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 Insert

Outward Projection of Nozzle HD 8.0000 in.
Weld leg size between Nozzle and Pad/Shell >1O 0.3750 in.
Groove weld depth between Nozzle and Vessel WGNV 0.6870 in.

Pad t·laterial (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
Diamet.er of Pad along vessel surface DP 22.0000 in.
Thickness of Pad TP 0.7500 in.
Weld leg size between Pad and Shell >lP 0.6'-50 in.
Groove weld depth between Pad and Nozzle Io'IGPN 0.7500 in.

Is this is '·lanway/Access/Inspection Opening No

Skip Iterative Failure Thickness calculations Yes

NOZZLE CALCULATION, NOZZLE NUI·lBER 1, Description: 0101 Nozzle A

ASf·1E Code, Section VIII, Division 1, 1998, A-99, UG-37 to UG·45

Actual Nozzle Diameter used in calculation 12.750 in.

Actual Nozzle Thickness Used in Calculation 0.687 in.

Internal Pressure Results {or SHELL/HEAD

4-54 Example Problem I-A Simple Drum

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Ilressurc Vcsscl Design owl! Analysis - Seminar Noles Ilillside and OlT.Angle Nozzlc Angles

COAOE Engineering SO[Lware

PVElite 4.00 I.icensee: COAOE Inc., Local White Lock
FileName: Seminar -. -_.- -- ---- --- - - -- - - - -. - - - - -- - - Page IS
Nozzle /\nalysis 0101 Nozzle A Item: 9:51a Sep 21,2000

Required thickness per UG-H(a) o[ Cylindrical Shell, Tr CASE 1

Thickness Due to Internal Pressure (TR):

lP·(D/2tCA»/(S'E-0.6'P) per UG-27 (c) (1)
(230.00 t (144.0000/2tO.1250»/(20000.00 t l.00-0.6 t 230.00)
0.8352 in.

InLernal Pressure Results for NOZZLE :

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

Thickness Due to Internal Pressure (TRI:

(P'D/21/(S'EtO.4 t P) per Appendix 1-1 (a) 01
(230.00'12.7500/2)/(20000.00"1.0010.4*230.00)
0.0730 in.

UG-40, Thickness and Diameter Limit Results CASE ,

Effective material diameter limit, DL 2) . 2520 in .
Effective mat.erial t.hickness limit, no pad TLNP 1 .4050 in.
Effective material thickness limit, pad side TLI'/P 2. 1550 in.

RESULTS of NOZZLE REINFORCEr·IENT AREA CAl,CUl,ATIONS:

AREA AVAILABLE, A1 t.o A5 Design External r'lapnc
Area Required AR 9.710 NA NA in
Area in Shell A1 0.463 NA NA in
Area in Nozzle 1'laiI A2 2.108 NA NA in
Area in Inward Nozzle A) 0.000 NA NA in
Area in Helds A4 0.531 NA NA in
Area in Pad AS 6.938 NA NA in
TOTAL AREA AVAILABLE ATOT 10.039 NA NA in

Pressure Case 1 Governs the Analysis

Nozzle Angle Used in Area Calculations 90.00 Oegs.

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: 21.6250 0.7500 in.
Based on given Pad Diameter: 22.0000 0.7500 in.
Based on Shell or Nozzle Thickness: 22.3750 0.6875 in.

Reinforcement Area Required for Nozzle:

AR (DLR'TR-t2·THK·TR'O-FFR1)l UG-37(cl or UG-39
AR (11.6260"0.8352.2*(0.6870-0.1250)·0.8352·(1.0-1.00)
AR 9.710 in

Areas per UG-37.1 but with DL = Diameter Limit, DLR = Corroded 10:
Area Available in Shell (Al):
Al (DL-DLRI· (r:S' (T-CAS) -TRI-2* (THK·CAN) * (ES· (T-CASI-TR)*l1-FFRl)
1\1 '" (23.252-11.626)' 0.00' (l .0000-0.125) -0.835) -2. (0.687-0.125)
• n.oo' 0.0000-0.1250) -0.8352)' (l.0-1.00)

Example Problcm I-A Simple Dnull 4-55

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llillside ;lnd Orr.. Angle Nozzle Angles Pressure Vessel Design ;lnd Analysis .. Seminar NOles

COADE Engineering Software

PVElite 4.00 Licensee: COAOE Inc., Local White Lock
FileName: Seminar --- ----- -- Pilge 16
Nozzle Analysis: DI01 Nozzle A Item: 9:51a Sep 21,2000

Al = 0.463 in

Area Available in Nozzle Hall, no Pad;

A2NP ( 2 • tHN (TLNP, 110) ) • (THK CAN TRN ) " FFR2
fl2NP ( 2 • 1.4050 ) • ( 0.6870 .. 0.1250 0.0730 ) , 1.00
A2NP 1.3"/4 in

Area Available in Nozzle Hall, with Pad:

A21-1P (2'llIN(TLWP,HO))' (THK"CAN .. TRN) 'PFR2
A21'IP ( 2 • 2.1550 ) , ( 0.6870 .. 0.1250 - 0.07301 ' 1.00 )
A2\'IP 2.108 in

Area Available in Welds, no Pad:

MNP \'IO"'2'FF'R2 t ( 1'/I .. CAN/0.707 )"'2'FFR2
MNP 0.3750"'2 • 1. 0000 t ( 0.0000 )"'2 • 1. 0000
A4NP 0.141 in

Area Available in welds, with Pad:

A4HP ~0 ... 2·FFR3t(WI .. CAN/0.707) ... 2·FFR2tWP ... 2·FFR4
A4HP 0.3750·2 • 1.00 • ( 0.0000 )·2 • 1.00 t 0.6250·2 • 1.00
A4\'JP 0.53} in

Area Available in Pad:

AS (lH N (DP, OL) .. (OIlH 2 'TIlK) ) " (Hi n (TP, TLI'IP, TE) ) 'FF'R4
AS (22.0000" 12.7500 ) • 0.7500 ' 1. 00
A5 6.938 in

UG-45 Hinimum Nozzle Neck Thickness Requirement:

'" t·lax (t.Jin (Hax (/·lax (UG4 S81, UG16B) ,Hax (UG4582, VG168) ) , VG4 584) , VG4 sA)
f.lax(t-lin(Nax(f·lax( 0.9602, 0.1875),'·lax( 0.1250,0.1875),0.4531),0.1980)
0.4531 < Minimum Nozzle Thickness 0.6011 in. OK

l-I.A.W.P. RESULTS FOR THIS NOZZLE GEOHETRY

Approximate f<l.A.W.P. for given geometry AHAP 233.8 psig

Weight of Nozzle, with Pad, Vncorroded 119.90 lb.

Weight of Nozzle, with Pad, Corroded 106.49 lb.

/·1 IN If.\UH DESIGN t·lETAL TEI·lPERATURE RESULTS: Nozzle Shell Pad

Hinimum
rHnimurn
Temp. w/o impact per Fig. UCS-66
Temp. at operating stress
11
-129
-30
-35
16
12 ,.
F

/Hnimum Temp. w/o impact per OO .. 20(f) -20 -20 -20 F

Nozzle HOHT Thickness Calc. per UCS-66 l(b), HIN(tn,t,te)

IHn. J.letal Temp. w/o impact per Fig. UCS .. 66 11 P
I·lin. "'etal Temp. at Req'd thk. (per UCS 66.1) ·129 F
l-lin. f·letal Temp. w/o impact per UG .. 20(f) ·20 F

WELD SIZE CALCULATIONS, NOZZLE Nrn.JBER 1, Desc. 0101 Nozzle A

l·linimum thickness for nozzle/shell welds Tmin 0.5620 in.

I·linimum thickness for pad/shell welds TminPad 0.7500 in.

4-56 Example Problem I-A Simple Drum

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Pressure Vessel Design ;md A1l3lysis. Seminar Noles Ilillsidt' anti Orr.. Anglc Nozzle Angles

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., I~ocal i'lhite Lock
PileName Seminar .. --- .. ----- .. ---- .. - .. - .. - .... ------------ Page 17
Nozzle Analysis 0101 Nozzle A Item: 9:51a Scp 21,2000

Results Per UH-16.I, Required Thickness Actual Thickness

Nozzle Held 0.2500 !-lin per Code 0.2625 0 .. 7 WO ill.
Pad weld 0.3750 ::: 0.5'TNINPAD 0.4375 = 0.7 ' WP in.

HELD STRENGTH AND \'IELD LOADS PER UG-41.1, SK~'TCH (al OR (bl
W (AR-Al+2* ITHK-CAN) 'PPR1'(El(T-CASI .. TR)'S
1"1 19.7100 - 0.4627 t 2 ' 10.6870 - 0.1250 I ' 1.0000
I 1.00 ' ( 1.0000 - 0.1250) .. 0.8352 I I ' 20000
\1 185841 .. lb.
\11 IA2tA5tA4-(WII-CAN/.707)A 2 *PPR2)"5
WI (2.1077 t 6.9375 1 0.5312 .. 0.0313 ' 1.00 I ' 20000
m 190904. lb.
W2 (A2tA3tA4t(2'(THK-CAN)'(T-CAS)'Prl)'S
~12 (2.1077 -t 0.0000 t 0.1406 .. 0.9835 ) • 20000
1'/2 64636. lb.
In (A2IA3+A4tA5, (2' (THK-CAN)' (T-CASI'Prll) '5
1'13 (2.1077 t 0.0000 .. 6.93"'5 I 0.5312 .. 0.9835 ) • 20000
1'/3 211199. lb.

STREN"GTll OF CONNECTION ELE1·1ENTS FOR PAl LURE PATH ANAl.YSIS

SHEAR, OUTI'IARD NOZZLE \'IELD:

SONI'I (PI/2) 'OLO'~,'O'0.49'SN\~
SON\'/ (].1416 / 2.0 ) , 12.7500 • 0.3750 ' 0.49' 20000
SONW 13602. lb.

SllEAR, PAD ELEI·IENT \'IELD:

SPEH (PI/2)*OP'WP*0.49*SEW
SPE\~ (3.1416 I 2.0 ) , 22.0000 ' 0.6250 ' 0.49 ' 20000
SPEW 211665. lb.

SHEAR, NOZZLE WALL:

SNW IPI'(DLR-tDLO)/4.0) '(THK-CANI '0.7'SN
SN1~ 13.1416 * 6.0940) , ( 0.6870 - 0.1250 I ' 0 .. 7 ' 20000
S~l 150632. lb.

TENSION, PAD GROOVE WELD:

TPGW (PI/2.0) 'DLO'WGPN'O. 74'5EG
TPG~1 ( 3 . 1 4 1 6 / 2 . 0 ) ' 12.7500 ' 0.7500 ' 0.74 * 20000
TPGW 222307. lb.

TENSION, NOZZLE GROOVE WELD:

TNGW (PI/2)'DLO*(WGNVI·CASI*0.74'SNG
TNml (3.1416 I 2.0 I ' 12.7500 ' 10.6870 - 0.1250) , 0.74 ' 20000
TNGW 166582. lb.

STRENGTH OF FAILURE PATHS:

PATH 11 (SPEI1. SNW 1 '" ( 211664 of 150631 I " 362296 lb.
PATH22 (SO~I -t TPGW of TNGW f SINN I

( 7]601 -t 222306 t 166582 .. 0 I " 462490 lb.

PATIO 3 (SPEI'1 t TNGWt SINlrl I
( 211664 -t 166582 ~ 0 I = 318246 lb.

Examplc Problcm I-A Simple Dnllll 4-57

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Ilillside tlnd Orr.Angle Nozzle Angles Pressure Vessel Design and Analysis - Seminar Notes

COADE Engineering soft.ware

PVElite 4.00 Licensee: COADE Inc., Local \·/hit.e Lock
FileName Seminar -------.--------------------------- Page 18
Nozzle Analysis: 0101 Nozzle A Item: 9:51a Sep 21,2000

SUHt·1ARY OF FAILURE PATH CALCULflTJONS:

Path 1 -1 185841. lb. 0< 190904. lb.
Path 2-2
362297.
462491.
lb. ,
lb .•
must exceed I·j
must exceed I'j
'"
185841. lb. 0< 112 64636. lb.
Path 3·3 318247. lb. must exceed I'j 185841. lb. 0< 113 211199. lb.

The PV Elite Program, (e) 1989-2000 by COAOE Engineering Software

4-58 Example Problem I-A Simple Drum

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Pressure Vessel Dcsign and Analysis - Scmilltlf Nolcs Ilillside nnd Off-Angle Nozzlc Angles

Pressure Vessel Design .11)(1 Analysis Seminar

Component Design Problem

0-101 Nozzle B:

Location Cylinder
Size 8 in. (200 NS)
Material SA 106, C

Thickness Schedule 80

Flange Class 300

Flange Material 1.1

The Nozzle is inserted into the vessel wall.

There is a .500-in. (12.7 mm) partial penetration groove weld
between the vessel wall and the nozzle neck.

Nozzle Outside Projection is 8.0 in. (203 mm)

No Intemal Projections are allowed in this vessel.

There is a 0.75-in. (19 mm) thick reinforcing pad

The Pad material is the same as the Shell material.
There is a full penetration weld belween the pad and the nozzle neck.
There is a 0.375-in. (9.5 mm) cover weld between the pad and the nozzle neck.
There is a 0.625-in.(l6 mm) weld between the 00 of the pad and the vessel.
Notes:

Questions:

What pad diameter (if any) will you use? _

What is the M.A.W.P. for the assembly?

DO NOT TUlm THE PAGE UNTIL YOU HAVE

COMPLETED YOUR ANALYSIS

EXl1ll1plc Problcm I-A Simple Drulll 4-59

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Hillside tllH..I On·.Anglc Noule Angles Pressure Vessel Design <lnd Analysis - Seminar Notes

PVElite 4.00 Licensee: COADE Inc., Local \'lhite Lock

FileName: Seminar _ ... -~-------------------------------- Page 19
Nozzle Analysis: 0101 Nozzle B Item: 2 9:S1a Scp 21,2000

Input Echo, Nozzle Item 2, Description: 0101 Nozzle 13

Design Internal Pressure Case P 230.00 psig

Temperature for Internal Pressure TEf·1P 450.00 F

Shell Haterial (Not Normalized or NAJ $A-516 7.

Shell Allowable Stress at Temperature S 20000.00 psi
Shell Allowable Stress At Ambient SA 20000.00 psi

Inside Diameter of Cylindrical Shell D 144.0000 in.

Actual Thickness of Shell or Head T 1. 0000 in.
Corrosion Allowance for Shell or !lead CAS 0.1250 in.

Angle between Nozzle and Shell or Head ANGLE 90.00 Degrees

Nozzle r·latedal (Not Normalized or NA) SA-51G 7.

Nozzle Allowable Stress at Temperature SN 20000.00 psi
Nozzle Allowable Stress At Ambient SNA 7.0000.00 psi

Diameter Basis for Nozzle BASISN OD

Diameter of Nozzle DlA 8.0000 in.

Nozzle Size and Thickness Basis DBN Nominal

Nominal Thickness of Nozzle THKNO:·1 SCH 8.
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 Insert

Outward projection of Nozzle HO 8.0000 in.
Neld leg size between Nozzle and Pad/Shell 110 0.3750 in.
Groove weld depth between Nozzle and vessel \'IGNV 0.5000 in.

Pad Haterial (Not Normalized or NA) SA~SI6 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 15.5000 in.
Thickness of Pad TP 0.7500 in.
Weld leg size between Pad and Shell I1P 0.6250 in.
Groove weld depth between Pad and Nozzle I'IGPN 0.7500 in.
AS1·IE Code Weld Type per UW~16.1 A

Is this is Hanway/Access/Inspection Opening No

Skip Iterative Failure Thickness Calculations Yes

NOZZLE CALCULATION, NOZZLE Nrn~BER 2, Description: 0101 Nozzle B

ASME Code, Section VIII, Division 1, 1998, A-99, UG-37 to UG-45

Actual Nozzle Diameter Used in Calculation 8.625 in.

Actual Nozzle Thickness Used in Calculation 0.500 in.

Internal Pressure Results for SHELL/HEAD

4-60 Example Problem I-A Simple Drum

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Pressure Vessel Design and Analysis - Seminar Notes Ilil1sidc and OIT-Angle Nozzle Angles

COADE Engineering Software

PVElite 4.00 Licensee: COhDE Inc., Local \'Ihite Lock
PileName Seminar --- .. --------- Page 20
Nozzle Analysis D101 Nozzle B Item: 2 9:51a Sep 21,2000

Required thickness per UG-]7(a) of Cylindrical Shell, 1'1' CASE 1

Thickness Due to Internal Pressure (TR);

(P*(D/2+CA))/(S*E-0.G*P) per UG-?? (c) (1)
(2]0.00*(144.0000/2+0.1250))/(20000.00*1.00-0.6*2]0.00)
0.8]52 in.

Internal Pressure Results for NOZ:t,I... E :

Required thickness per VG-)7(a) of Nozzle \'Iall, 1'1' CASE 1

Thickness Due to Internal Pressure (TR):

(P*D/2)/(S*E-I0.4*P) per Appendix 1-1 (a) (1)
(230.00'8.6250/2)/(20000.00*1.00+0.4*230.00)
0.0491 in.

UG-40, Thickness and Diameter Limit Results , CASE

Effective material diameter limit, DL 15 .7500 in.
Effective material thickness limit, no pad TLNP 0 .9375 in.
Effective material thickness limit, pad side TLI'IP 1 .6875 in.

RESULTS of NOZZI,E REINFORCEl-lENT AREA CALCULATIONS:

AREA AVAILABLE, A1 to AS Design External f·lapnc
Area Required AR 6.577 NA NA in
Area in Shell AI 0.313 NA NA in
Area in Nozzle \~a 11 A2 1.099 NA NA in
Area in Inward Nozzle A3 0.000 NA NA in
Area in \~elds M 0.281 NA NA in
Area in Pad A5 5.156 NA NA in
TOTAL AREA AVAILABLE ATOT 6.850 NA NA in

Pressure Case 1 Governs the Analysis

Nozzle 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: 15.2500 0 .7500 in.
Based on given Pad Diameter: 15.5000 0 .7500 ·in.
Based on the estimated Diameter Limit: 15.6250 0 .7500 in.

Reinforcement Area Required for Nozzle:

AR (DLR'TR+2'THK*TR'(I-PPR1)) UG-37(c) or UG-39
AR ('l. 8'150'0.8352+2' (0.5000-0.1250) '0.8352* (1.0-1.00) )
AR 6.577 in

Areas per UG-37.1 but with DL '" Diameter r.imit, DLR'" Corroded ID:
Area Available in Shell (AI):
A1 (DJ,- DLR) • (ES' (1'- CAS) -TR) .. 2' (THK- CAN) , (ES· (T-CAS) -TR) * (1 - FPRl )
Al '" (15.750-7.875) * (1.00' (1.0000-0.125) -0.835) .. 2* (0.500-0.125)

Example Problem I~A Simple Dnlln 4-61

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I lil1sick alld On'-Angle Nozzle Angles Pressure Vessel Design and Analysis - Seminar Notes

(OADE Engineering Software

PVElite 4.00 Licensee: COADE II~C., Local ~'/hite Lock
FileName Seminar -----------------------.----- Page 7.1
Nozzle Analysis 0101 Nozzle B Item: 7. 9:51a Sep 21,2000

• 0.00' n.0000-0.1250) -0.8352) ' n . 0-1.00)

Al = 0.313 in

A2NP I 2 ..
Area Available in Nozzle NaIl, no Pad:
tuN (TLNP, HO) I
. •
I TIIK - CAN TRN I • FFR2
A2Np ( 2 0.9375 I ( 0.5000 - 0.1250 0.0494 I • l. 00 I
A2NP 0.611 in

Area Available in Nozzle NaIl, with Pad:

A2\'/P (2'IUN(TLI'IP,HO»' (TIlK-CAN-TRN) 'FFR2
A2NP ( 2 • 1.6875 ) ' ( 0.5000 - 0.1250 - 0.0494 ) , 1.00 )
A2\'/P 1.099 in

Area Available in \'/elds, no Pad:

MNP \':O"'2'FfR2 .. ( WI-CAN/O. 707 ) ""2'FFR2
MNP 0.3750"'2 ' 1.0000 + ( 0.0000 )"'2 • 1.0000
MNP 0.141 in

Area Available in Nelds, with Pad:

A'1\'lP ~:O"'2' FFR3 .. (m -CANtO . 707) '"'2' F'FR2+Trap' F'F'R4
A'1WP 0.)750"'2 ' l.00 .. ( 0.0000 )"'2 ' 1.00 .. 0.1406 , 1.00
A4rlP 0.281 in

Area Available in Pad:

A5 (lUN (op, DL) - (OIA. 2 'THK) ) , (f·lin (TP, TL\'/P, TE) ) • FFR'1
A5 (15_5000 - 8.6250 I ' 0.7500 .. 1.00
AS 5.156 in

UG-'15 IHnimum Nozzle Neck Thickness Requirement:

.. !·lax (Min (t,lax (Hax (UG4 581, UGl68) ,!·lax (UG4SB2, UGI6B) ) ,UG4SB<l) ,UG4 SA)
1·laxIHinll>lax(Hax( 0.9602, 0.187S),t-1ax( 0.1250, 0.1875», 0,4068), 0.1744)
0.4068 < Hinimum Nozzle Thickness 0.4)75 in. OK

M.A.W,P. RESULTS FOR THIS NOZZLE GEOHETRY

Approximate M.A.ILP. for given geometry A/otAP 234.7 psig

\'Ieight of Nozzle, with Pad, Uncorroded 60.16 lb.

Height 0'Nozzle, with Pad, Corroded 51.13 lb.

NINIHUM
Hinimum
Ninimum
DESIGN HETAL TEt·1PERATURE RESULTS: Nozzle
Temp. wlo impact per Fig. UCS-66
Temp. at operating stress -146
-. Shell
31
2.
,.
Pad

12
F
F
Hinimum Temp. wlo impact per UG-20(f) -20 -20 -20 F

Nozzle ~lDf·lT Thickness Calc. per UCS·66 l(b), IUN(tn,t,te)

l-lin. l1etal Temp. w/o impact per Fig. UCS-66
rHn. Netal Temp. at Req'd thk. (per ucs 66.1) -146
-. F
F
r,Hn. !·letal Temp. w/o impact per UG-20(f) -20 F

HELD SIZE CALCULATIONS, NOZZLE Nm1BER 2, oesc.: 0101 Nozzle B

IHnimum thickness for nozzle/shell welds Tmin 0.3750 in.

Ninimum thickness for pad/shell welds TminPad 0.7500 in.

4-62 Example Problcm I-A Simplc Drum

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Pressure Vessel Design and Analysis - Seminar Noles Hillside and Orr-Angle Noah: Angles

COl\DE Engineel"ing Softwal-e

PVElite 4.00 Licensee: COADE Inc. Local ~Ihite Lock
FileName Seminar Page 22
Nozzle Analysis DIOI Nozzle B Item: 2 9:51a Sep 21,2000

Results Per V\·1-16.1, Required Thickness Actual Thickness

Nozzle \'Ield 0.2500 I·lin per Code 0.2625 0.7 NO in.
Pad \'Ield 0.3'/50 = O.S·TIUNPAD 0.4375 = 0.1 • NP in.

The PV Elite Program, (c) 1989-2000 by COADE Engineering Software

Example Problem I-A Simple DnHn 4-63

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Ilillsidc tint! Orf-Angle Nozzle Anglcs Pressure Vessel Design tint! Antilysis - Scmintlr Notes

4-64 Example Problem I-A Simple Drum

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Pressure Vessel Design and Analysis - Seminar Noles lIillside and Oll.. Angle Nozzle Angles

Pressure Vessel Design alld Analysis Seminar

Component Design I)roblem

D-I 0 I Nozzle C:

Location Elliptical Head

Size 20 in. (500 NS)
Material SA 516, 70 rolled plate

Thickness .75 (19 mm)

Flange Class 300

Flange Material 1.1

The nozzle is inserted into the vessel wall.

There is a .500-in. (12.7 mm )parlial penetration groove weld
betwecn thc vessel wall and the nozzle neck.

Nozzle outside projection is 8.0 in. (203 mm)

No Internal Projections arc allowed in this vessel.

There is a 0.75-in. (19 mm) thick reinforcing pad.

The pad material is the same as the shell material.
There is a full penetration weld between the pad and the nozzle neck.
There is a 0.375-in.(9.5 mm) cover weld between the pad and the nozzle neck.
There is a 0.625-in. (16 mm) weld between the 00 of the pad and the vessel.

Notes:

Questions:
Why is the required shell thickness different than previously calculated?

What pad diameter (if any) will you use?

What is the M.A.W.P. for the assembly?
Docs this nozzle limitlhe M.A.W.P. for the vessel? _

DO NOT TURN THE PAGE UNTIL YOU HAVE

COMPLETED YOUR ANALYSIS

Example Problem I-A Simple DnJlll 4-65

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I lillsidc and Off-Angle Nozzle Angles Pressure Vcssd Design and Analysis - Seminar Noles

COADE Engineering Software

PVElite 4.00 Licensee: COf\DE Inc., Local I"lhite Lock
PileName : Seminar ------------.- .. -~------ ... ------ .. ---. Page 23
Nozzle Analysis: 0101 Nozzle C Item: 3 9:51a Sep 21,2000

Input Echo, Nozzle Item 3, Description: 0101 Nozzle C

Design Internal Pl'essure Case P 230.00 psig

Temperature for Internal Pressure TEr-1P 450.00 p

Shell J.laterial (Not Normalized or Nf\) SA-516 70

Shell Allowable Stress at Temperature 5 20000.00 psi
Shell Allowable Stress At Ambient 5A 20000.00 psi

Inside Diameter of Elliptical Ilead D 144.0000 in.

Aspect Ratio of Elliptical Head AR 2.00
Actual Thickness of Shell or Head T 1. 0000 in.
Corrosion Allowance for Shell or Head CAS 0.1250 in.

Angle between Nozzle and Shell or Head ANGLE 90.00 Degrees

Is the Nozzle Outside the 80\ diameter Limit NO

Nozzle Material (Not Normalized or NA) SA~S16 70

Nozzle Allowable Stress at Temperature 5N 20000.00 psi
Nozzle Allowable Stress At Ambient 5NA 20000.00 psi

Diameter Basis for Nozzle BASISN OD

Diameter of Nozzle DIA 7.0.0000 in,

Nozzle Size and Thickness Basis DBN Actual

Actual Thickness of Nozzle THK 0.7500 in,
Corrosion Allowance for Nozzle CAN 0.1250 in.
Joint Efficiency of Shell Seam at Nozzle E5 1.00
Joint Efficiency of Nozzle Neck EN 1. 00

Insert or Abutting Nozzle Type NT'fP Insert

Outward Projection of Nozzle HO 8.0000 in.
Weld leg size between Nozzle and Pad/Shell HO 0.3750 in.
Groove weld depth between Nozzle and Vessel HGNV 0.5000 in.

Pad '·later-ial (Not Normalized or NA) SA~516 70

Pad Allowable Stress at Temperature 5N 20000.00 psi
Pad Allowable Stress At Ambient 5NA 20000.00 psi
Diameter of Pad along vessel surface DP 32.0000 in.
Thickness of Pad TP 0.7500·in.
Weld leg size between Pad and Shell HP 0.6250 in.
Groove weld depth between Pad and Nozzle WGPN 0.7500 in.
ASME Code Weld Type per UW-16.1 A

Is this is Hanway/Access/Inspection Opening No

Skip Iterative Failure Thickness Calculations Yes

NOZZLE CALCULATION, NOZZLE NUt·lBER 3, Description: 0101 Nozzle C

Asr·1E Code,
Section VIII, Division 1, 1998, 11..-99, UG-37 to UG-<l5

Aclllal No%%le Diameter used in Calculation 20.000 in.

4-66 Example Problem I-A Simple Drum

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Prel-iSlIrt; Vcsscl Design and Analysis ~ Seminar Notes Ilillsidc and Orr-Angle Nozzle Angles

COADE Engineering So[tl"are

PVElite 4.00 Licensee; COADE Inc .• Local I'/hite Lock
FileName Seminar ------------------------ Page 24
Nozzle Analysis 0101 Nozzle C I tern; ) 9:51a Sep 21,2000

Actual Nozzle Thickness Used in Calculation 0.750 in.

Internal Pressure Results for SHELL/HEAD :

Required thickness per UG-37 (a) of Elliptical Head, TR, CASE 1

Thickness Due to Internal Pressure (TR);

(P'(D+2'CAj'K)/(2'S*E-0.2'P) Appendix l-<1(c)
(230.00'(14<1.0000t2'0.1250)'0.90)/(2'20000.00'1.00-0.2'230.00)
0.7474 in.

Internal Pressure Results for NOZZLE

Required thickness per UG-37(aj of Nozzle l'lall, Tr CASE 1

Thickness Due to Internal Pressure (TR):

(P'O/2)/(S'EtO.<1'P) per Appendix 1-1 (al (1)
~ (230.00'20.0000/2)/(20000.00'1.00tO.4'230.00)

0.1145 in.

UG-<10, Thickness and Diameter Limit Results , CASE

Effective material diameter limit, DL 3".5000 ill.
Effective material thickness limit. no pad TI,NP 1.5625 in.
Effective material thickness I imi t. pad side TLI'IP 2.1875 in.

RESULTS oE NOZZLE REINFORCEI·lENT AREA CALCULATIONS;

AREA AVAILABLE, A1 to A5 Design External /olapnc
At:ea Required AR 14.013 NA NA in
Area in Shell A1 2.393 NA NA in
Area in Nozzle Wall A2 2.23<1 NA NA in
Area in Inward Nozzle A3 O. (100 NA NA in
Area in l'Ields A4 0.531 NA NA in
Area in Pad AS 9. (100 NA NA in
TOTAL AREA AVAILABLE ATOT 14.158 NA . NA in

Pressure Case 1 Governs the Analysis

Nozzle 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 oe POSSIBLE REINF'ORCING PADS: Diameter Thickness

Based on given Pad Thickness: 31. 8750 0.7500 in.
Based on given Pad Diameter: 32.0000 0.7500 in.
Based on Shell or Nozzle Thickness: 31.8750 0.7500 in.

Reinforcement Area Required for Nozzle:

AR (OLR'TR+2'THK'TR' (1-FFRll) UG-37 (c) or UG-39
AR (18.7500*0.7<174 t2' (0.7500-0.1250) '0 . .,474' (l. 0 -1.00) j
AR 1<1.013 in

Areas per UG- 37.1 but wi th DL Diameter Limit, DLR Corroded ID;

Example Problem I-A Simple Dnnll 4-67

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Ilillside lllld Orr-Angle Nozzle Angles Pressure Vessel Design and Analysis - Seminar Noles

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar ---------- ---~.-.----••• ~- ••. ~- Page 25
Nozzle Analysis 0101 Nozzle C Item: 9:51a Sep 21,2000

Area Available in Shell (All:

I'll (DL¥DLR)·(ES·{T-CAS)-TR)-2·{THK-CAN)'(ES·(T-CAS)·TR)·(1-FFR1)
I'll (31.500·18.750)·(1.00'(1.0000-0.125)~0.741)·2·(0.750~0.125)

• (1.00· 11.0000-0.1250) -0.74'/4)" (l.0-1.00)

I'll 2.393 in

Area Available in Nozzle Wall, no Pad:

A2NP ( 2 ' t-lIN{TLNP,HO) ) • ( THK - CAN TRN ) ,. FFR2
A2NP ( 2 • 1.5625 ) • ( 0.1500 - 0.1250 0.1145 ) • 1.00 )
A2NP 1. 595 in

Area Available in Nozzle l'Iall, with Pad:

A2~'IP (2·r·lIN(TU·IP,1I0»)· (THK·CAN-TRN) 'FFR2
A21'IP ( 2 • 2.1815 ) • ( 0.1500 - 0.1250 - 0.1145 ) • 1.00 )
A2~'/P 2.234 in

Area Available in Welds, no Pad:

MNP I'IO"2·FFR2 t ( I'II-CAN/0.70'! ' .... 2·FFR2
MNP 0.3750"2 • 1.0000 • ( 0.0000 )A 2 • 1.0000
MNP 0.141 in

Area Available in Welds, with Pad:

A
MHP 1'I0 2' FFR3 -t (\'/I -CAN/a. 707' "2' FFR2-t\'/P"2' FFR4
MWP 0.3150"2 • 1.00 -t ( 0.0000 )A 2 ,. 1.00 -t 0.6250"2 • 1.00
A4~'IP 0.531 in

Area Available in Pad:

AS <rUN (DP, DL) - (01 Aof 2 'THK) ) • {tolin (TP, TLWP, TE) ) ,. FFR4
1'15 (32.0000 - 20.0000 ) • 0.7500 • 1.00
AS 9.000 in

UG-45 rHnimum Nozzle Neck Thickness Requirement:

Nax U1in (Hax (Hax (UG4 581, UG16B) ,"'ax (UG4 582, UG168) ) ,UG4 584) ,UG4 5A)
l1ax(r-lin(Hax{Max( 0.9554, 0.1875),I·tax( 0.1250, 0.187S»), 0.4531), 0.2395)
0.4531 < Minimum Nozzle Thickness 0.7500 in. OK

r·l.A. W. P. RESUI,TS FOR THIS NOZZLE GEONETRY

Approximate '·1.A. \'1. P. (or given geometry AHAP 231. 2 psig

Weight of Nozzle, with Pad, Uncorroded 219.54 lb.

weight of Nozzle, with Pad, Corroded 198.15 lb.

rHNIHUN
Hinimum
Hinimum
DESIGN r-1ETAL TEr·1PERATURE RESULTS: Nozzle
Temp. w/o impact per Fig. UCS-66
Temp. at operating stress -124
I. Shell
II
1.
Pad
1.
2 ,.
P

Ninimum Temp. w/o impact per UG-20(f) -2. -2. -2. F

Nozzle f1D/olT Thickness Calc. per UCS-66 1 (b) , mN(tn,t,te)

rolin. f.letal Temp. w/o impact per Fig. UCS·66
I·tin. f.letal Temp. at Req'd thk. (per UCS 66.1) -124
,. p
P
'·Iin. Netal Temp. w/o impact per UG-20(f) -20 F

WELD S1 ZE CALCULATIONS, NOZ7,LE NUI·IAER 3, Desc.· 0101 Nozzle C

4-68 Example Problem I-A Simple Drum

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Pr~ssurc Vessel Design and Analysis - Seminar Notes Ililisidc <lnd OnO_Angl~ Nozzl~ Angles

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar --------------.------------------------ Page 26
Nozzle Analysis; 0101 Nozzle C ILem: 3 9:51a Sep 21,2000

fOlinimum thickness for nozzle/shell welds Tmin 0.6250 in.

f·linimum thickness fOl pad/shell welds
o
TminPad 0.7500 in.

Results Pel· UN-16.1, Requil·ed Thickness Actual Thickness

Nozzle \\'eld 0.2500 /·lin per Code 0.2625 0.7 \·/0 in.
Pad weld 0.3750 = O.5·T1UNPAD 0.4375 = 0.7 • WP in.

The PV Elite Program, Ie) 1989-2000 by CQADE Engineering Software

Example Problem I-A Simple Drum 4-69

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Ilillside ilnd Orr-Angle Nozzle Anglcs Prcssurc Vesscl Design and An~lysis * SCl1linar Notes

4-70 Example Problcm I-A Simplc Drum

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 Pressure Vessel Design and Analysis - Seminar Noles

Chapter 5: Cones
and Conical Sections

Cones combine all of the analysis techniques we learned for internal and external pressure.

GUIDELINES FOR CONES

The required thickness of a cone for internal pressure (Paragraph UG-32) is based on the
same design formulas used for cylinders, taking into account the inclination of the cone:
I = PD
2cosa(SE - O.6P)
0; P = 2SEtcosa
D + 1.2/cosa

The external pressure calculations for cones (Paragraph UG-33) arc also based on the cyl-
inder analysis, but with adjustments to the thickness and effective length to account for the
inclination of the cone. The effective length for toriconica! sections is adjusted to include a
fraction of the knuckle in the design length.
Cones are required to have reinforcement at the large and small ends under internal pres-
sure (Appendix 1-5) because of the tendency of the cone/cylinder junction to buckle under
the radial load developed in the cone.
The Code calculates the maximum angle below which buckling will not occur as a func-
tion of the design pressure and allowable stress. This ratio is used because it is an accurate
indication of the diameter thickness ratio for the cylinder, and takes into account the
strength of the material. This approach has the odd effect that when you increase the
allowable stress you decrease the allowable cone angle. However, you will nonnally find
that for a given thickness this effect is offset by the increased area available in the cone for
reinforcement.
(
Given that reinforcement is required, the required area is a function of the radius divided
by the allowable stress. Area available in the shell within one decay length may be
included in the area available for stiffening.
Cones are required to have reinforcement at the large and small ends under external pres-
sure (Appendix 1-7) because of the tendency to buckle under axial external loads.
At both the large and small ends there are requirements for area ofreinforcement and
moment of inertia of the reinforcement. The area of reinforcement is based on consider-
ations similar to those described for internal pressure. The required moment of inertia of
the reinforcement is a function of the strain in the ring at the cone/shell junction, which is
in turn calculated using the Code materials chart from the stress in the ring. See the com-
ments on stiffening rings in the external pressure section for further insight.

Cones <:Ind Conical Sections 5-1

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 Typical Geometry for a Simple Cone Pressure Vessel Design and Analysis - Semiuar NoLes

TYPICAL GEOMETRY FOR A SIMPLE CONE

The following four figures arc provided as examples of simple cones.

r----- FLAT HEAD

HALF" APEX ANGLE

CYLINDER

CORROSION ALLOVANCE

CRO\v'N RADIUS
ACTUAL THICKNESS

TORISPHERICAL HEAD
<OR ELLIPT leAl)
<OR HEMISPHERICAl)

Figure 1··Typical Conical Vessel

-------
DIAMETER OF
LENGTH OF
SHALL END
SMAll END THICKNESS or
SMALL END
-------
I THICKNESS or
HALF APEX I CONE
LENGTH OF I
COOE
ANGLE
r-
I

~ THICKNESS Of
REINfURCING RIIlG

_ .:u..;=::T THlCKNESS Of
LENGTH Of -
LARGE END
LARGE END 'WIDTH OF (
REINFORCING RING

Figure 2--Typical Geometry for a Reinforced Cone

tana = Opposite
Adjacent

(D,-D S)
Opposite = .2

Adjacellt :-= L

(D L - D s )/2
a = a 1"C lanl--"---;L-"--

5-2 Cones and Conical Sections

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 Pressure Vessel Dcsign and An<tlysis - Scminar Noles Typical Geometry for a Simplc Cone
(

Os
\ I
\ I
\ ex /
\ ' I

( \17
\ I

" \I
·1 /

Figure 3--Half Apex Angle Calculation

Cones and Conical Sections· 5-3

(

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Typical Geometry [or a Simple COlle Pressure Vessel Design and Analysis - Seminar NoLes

:---...t~V__.~ .----=t~

Figure 4--Free Body Diagram

5-4 Cones and Conical SecLions

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 Pressure Vessel Design <lnd Analysis - Seminar Noles Whal do you need to know to perform cOile calculations?

WHAT DO YOU NEED TO KNOW TO PERFORM CONE CALCULATIONS?

Dimensions of the Cone and the Cylinders at Either End

The Code calculates areas available not only in the cone itself, but in the cylinders
attaehed to either end of the Cone. If you have no cylinders (i.e. a cone with flanges on
either end) you mu·st make an approximation concerning how much area is available at
either end.

Dimensions of Transition Knuckles (if any exist)

If the cone has a knuckle at the large end and a flare at the small end, area ofreinforcement
and moment ofinertia calculations are not required. However, the thickness ofthe knuckle
and flare must meet the requirements for toriconical sections in Appendix 1-4.

Half Apex Angle of the Cone

For internal pressure calculations without a knuckle or a flare, the half apex angle should
( not be greater than 30 degrees. When there is a knuckle or a flare the calculations can be
used up to 60 degrees.
For external pressure calculations the half apex angle must not be greater than 60 degrees.
Some vessel, such (IS reb oilers, have two different angles associated with the conc. In other
words, the cone is eccentric rather than concentric. For Code analysis, we recommend that
the half apex angle chosen be the larger of the two angles.

Axial Forces on the Cone

The axial force can be either positive or negative. Positive values cause additional com-
pression at the cone/cylinder intersection. Negative values reduce the eompression at the
intersection. Determine the sign for your loading by drawing a free body diagram.

Width and Thickness of Cone Reinforcement

Cone reinforcement is usually a simple flat plate cut in the shape of a donut. The width
and thickness of the flat plate are used to calculate a combined m9ment of inertia for the
plate/shell section. The Code rules specifY how to include the shell in the calculations,
since the conical part ofthe shell is inclined.

Cones and Conical Sections 5-5

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What do you need lo know 10 perfonn cone calculalions? Pressure Vessel Design and Analysis - Seminar Noles

5-6 Cones and Conical Sections

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 Pressure Vessel Design and Analysis - Seminar Noles What do you need 10 know 10 pcrronn cone calculations?

Pressure Vessel Design and Analysis Seminar

Component Design Problem

D-I02 Transition Cone:

The vessel shown on page 74 has the following dimensions:

Lower cylinder ID = 42 in. (1067 mm), thickness ~ 0.375 in. (9.5 mm), length ~
42 in. (1067 mm)
Upper cylinder ID = 18 in. (457 mm), thickness ~ 0.375 in.(9.5 mm), length ~ 18
in. (457 mm)
Cone thickness ~ 0.375 in. (9.5 mm), length = 30 in.(762 mm)
Design pressure ~ 125 psi (.862 N/mm 2), Design temperature ~ 300°F (149°C)
All materials arc SS316 with zero corrosion allowance.
(
Use higher allowable stresses and 100% radiography

Do this analysis for internal pressure only using the SHELL program.
Then do the full analysis including full vacuum at 300°F using the
CONICAL program.

For the full analysis, include reinforcing rings of316SS on the shells at both the large and
small ends. Suggested dimensions for the rings are 2 in. wide and 1/2 in. thick.

Notes:

Questions:

What is the half apex angle?

What is the M.A.w.P. for the Cone?

Are the reinforcing rings adequate?

DO NOT TURN THE PAGE UNTIL YOU HAVE

COMPLETED YOUR ANALYSIS

Cones and Conical Sections 5-7

(

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 What do you need 10 know to perform cone calculations'! Pressure Vessel Design and Analysis - Seminar Noles

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar --------------------------------------- Page 10
Shell Analysis: DI02 Cone Item: 5 9:51a Sep 21,2000

Input Echo, Component 5, Description: DI02 Cone

Design Internal Pressure P 125.00 psig

Temperature for Internal Pressure 300.00 F

Include Hydrostatic Head Components NO

Material Specification SA-240 316H

Allowable Stress At Temperature S 20000.00 psi
Allowable Stress At Ambient SA 20000.00 psi
Joint efficiency for Head Joint E 1.00

Inside Diameter of Conical Head D '2 .0000 in.

Minimum Thickness of Pipe or Plate T 0.3750 in.

Corrosion Allowance CA 0.0000 in.

Cone 1/2 Apex Angle ALPHA 21. 8000 degrees

Type of Element: Conical Head or Shell

INTERNAL PRESSURE RESULTS, SHELL NUMBER 5, Dese.: 0102 Cone

ASME Code, Section VIII, Division I, 1998, A-99

Thickness Due to Internal Pressure (TR):

(P·(D+2*CA»/(2*Coslalpha)*(S*E-0.6*P») per Appendix 1-4 (e)
(125.00+(42.0000+2*0.0000)/(2*0.9285*(20000.00*1.00-0.6*125.00))
0.1419 in.

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

(2*S*E*(T-CA)*COSA)/«(D+2*CA)+1.2*(T-CA)*COSA) per App 1-4(e)
(2*20000.00*1.00·10.3750)*0.9285)/(42.0000+2*0.0000)+1.2*(0.3750)*0.9285
328.34 psig

Maximum Allowable Pressure, New and Cold (MAPNC):

(2*SA*E*T*Cos(alpha»/(D+I.2*T*Cos(alpha») per App 1-4(e)
(2*20000.00*1.00·0.3750*0.9285)/{42.0000+1.2*0.3750*0.9285)
328.34 psig

Actual stress at given pressure and thickness (Sact):

(P*(ID+2*CA)+1.2*(T-CA)*Cos(alpha»)/(2*E*{T-CA)*Cos(alpha»
(125.00*({42.0000+2*0.0000)+1.2*(0.3750)*0.9285)/(2*1.00*(0.3750)*0.9285
7614.16 psi

SUMMARY OF INTERNAL PRESSURE RESULTS:

Required Thickness plus Corrosion Allowance, Trca 0.1419 in.
Actual Thickness as Given in Input 0.3750 in.
Maximum Allowable Working Pressure MAWP 328.34 psig
Design Pressure as Given in Input P 125.00 psig

HYDROSTATIC TEST PRESSURES ( Measured at High Point J:

Hydro. per UG-99(b); 1.3 * MAWP * Sa/S 426.84 psig

5-8 Cones and Conical Sections

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 Pressure Vessel Design and Analysis - Seminar Noles What do yOlI need to know 10 perfonn COlle calculations?

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar -~--------------------------------~---- Page 11
Shell Analysis: 0102 Cone Item: 5 9:51a Sep 21,2000

Hydro. per UG-99{c) i 1.3 .. MAPNC 426.84 psig

WEIGHT and VOLUME RESULTS, NO C.A.

Volume of Shell Component VOLMET 1073.6 in.**3
Weight of Shell Component WMET 300.6 lb.
Inside Volume of Component VOLID 22337.8 in ..... 3
Weight of Water in Component WWAT 806.6 lb.

The PV Elite Program, (c) 1989-2000 by COADE Engineering Software

Cones and Conical Sections 5-9

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What do you need fo kllow lo perronn cone calculatIOns? Pressure Vessel Design and Analysis - Seminar Notes

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName : Seminar ---~----------------------------------- Page 27
Conical Analysis; D102 Cone Item: 1 9:s1a Sep 21,2000

Input Echo, Cone Item 1, Description: D102 Cone

Design Internal Pressure PINT 125.00 psig

Temperature for Internal Pressure TEMP IN )00.00 F
Design External Pressure PEXT 15.00 psig
Temperature for External Pressure TEMPEX 300.00 F
Take Cone as Line of Support for External Pressure; Yes

Cone Material SA-2-40 316H

Cone Allowable Stress at Temperature SAC 20000.00 psi
Cone Allowable Stress At Ambient SOC 20000.00 psi
Longitudinal Joint Efficiency of Cone EC 1.0000
Circumferential Joint Efficiency of Cone ECC 1.0000
Actual Thickness of Cone TC 0.3750 in.
Corrosion Allowance for Cone CAC 0.0000 in.

Diameter Basis for Cone and Cylinders BASIS ID

Diameter of Small End of Cone DS 18.0000 in.
Diameter of Large End of Cone DL 42.0000 in.
Half Apex Angle for Cone ANGLE 21.80 degrees
Axial Length of Cone LC 30.0000 in.

Small End Cylinder Material SA-240 316H

Small Cylinder Allowable Stress at Operating SAS 20000.00 psi
Small Cylinder Allowable Stress At Ambient SOS 20000.00 psi
Joint Efficiency of Small Cylinder ES 1. 0000
Actual Thickness of Small Cylinder TS 0.3750 in.
Corrosion Allowance for Small Cylinder CAS 0.0000 in.
Axial Length of Small Cylinder LS 18.0000 in.

Large End Cylinder Material SA-240 316H

Large Cylinder Allowable Stress at Operating SAL 20000.00 psi
Large Cylinder Allowable Stress At Ambient SOL 20000.00 psi
Joint Efficiency of Large Cylinder EL 1.0000
Actual Thickness of Large Cylinder TL 0.3756 in.
Corrosion Allowance for Large Cylinder CAL 0.0000 in.
Axial Length of Large Cylinder LL 42.0000 in.

Type of Reinforcement at Large End of Cone: Bar

Large End Reinforcing/Knuckle Material SA-240 316H

Large Reinforcing/Knuckle Allowable, Operating 20000.00 psi
Large Reinforcing/Knuckle Allowable, Ambient 20000.00 psi
Location of Reinforcement at Large End of Cone: Shell
Radial width of Reinforcing Bar{Large End) RWLB 2.0000 in.
Axial Thickness of Reinforcing Bar RTLB 0.5000 in.

Type of Reinforcement at Small End of Cone: Bar

Small End Reinforcing/Knuckle Material SA~240 316H

Small Reinforcing/Knuckle Allowable, Operating 20000.00 psi
Small Reinforcing/Knuckle Allowable, Ambient 20000.00 psi

5-10 Cones and Conical Sections

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Location of Reinforcement at Small End of Cone: Shell

Radial width of Reinforcing Bar(Small End) RWSB 2.0'000 in.
Axial Thickness of Reinforcing Bar RTSB 0.5000 in.

INTERNAL PRESSURE RESULTS, CONE NUMBER I, Description: DI02 Cone

ASME Code, Section VIII, Division 1, 1998, A-99

INTERNAL PRESSURE CALCULATIONS for CONE:

Thickness Due to Internal Pressure (TR):

(P*(D+2*CA))/(2*Cos(alpha)*(S*E-0.6*P)) per Appendix 1-4 (e)
(125.00+(42.0000+2*0.0000»)/(2*0.9285*(20000.00*1.00-0.6*125.00»
0.1419 in.

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

(2*S*E*(T-CA)*COSA)/((D+2*CA)+1.2*(T-CA)*COSA) per App 1~4(e)
(2*20000.00*1.00*(0.3750)*0.9285)/{(42.0000+2*0.0000)+1.2*(0.3750)*0.9285
328.34 psig

INTERNAL PRESSURE CALCULATIONS for SMALL CYLINDER:

Thickness Due to Internal Pressure (TR):

(P*(D/2+CA))/(S*E-0.6*P) per UG-27 (c) (1)
(125.00*(18.0000/2+0.0000)/(20000.00*1.00-0.6*125.00)
0.0565 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*1.00*(0.3750»)/«(18.0000/2+0.0000)+0.6*0.3750)
813.01 psig

INTERNAL PRESSURE CALCULATIONS for LARGE CYLINDER:

Thickness Due to Internal Pressure (TR):

(p* (D/2+CA» / (S*'E-O. 6*P) per UG-27 (c) (1)
(125.00*(42.0000/2+0.0000»)/(20000.00*'1.00-0.6*125.00)
0.1317 in.
(
Max. All. Working Pressure at Given Thickness (MAWP):
(S*'E*'(T-CA»/(D/2+CA)+0.6*(T-CA» per UG-27 (c)(I)
(20000.00*1.00*'{0.3750»/«(42.0000/2+0.0000)+0.6*0.3750)
353.36 psig

SUMMARY of INT. PRESSURE RESULTS: Small Cyl Cone Large Cyl

Required Thickness plus CA 0.0565 0.1419 0.1317 in.
Actual Given Thickness 0.3750 0.3750 0.3750 in.
Max. All. Working Pressure 813.01 328.34 353.36 psig
Design Pressure as Given 125.00 125.00 125.00 psig

EXTERNAL PRESSURE RESULTS, CONE NUMBER 1, Description: DI02 Cone

ASME Code, Section VIII, Division I, 1998, A-99

Cones and Conical Sections 5-11

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EXTERNAL PRESSURE CALCULATIONS for CONE~

External Pressure Chart HA-2 at 300.00 F

Elastic Modulus for Material 26600000.00 psi

Results for Maximum Allowable External Pressure:

Corroded Thickness of Shell TCA 0.3750 in.
Outside Diameter of Shell OD 42.7500 in.
Design Length of Cylinder or Cone SLEN 21.58 in.
Diameter I Thickness Ratio DT 122.7805
Length I Diameter Ratio LD 0.5048
Geometry Factor, A f{DT,LD) A 0.0019588
Materials Factor, B, f(A, Chart) B 10835.5977 psi
Maximum Allowable Working Pressure 117.67 psig
EMAWP = (4*Bl/{3*DT) '" { 4 * 10835.598 )/( 3 122.7805 } '" 117.6690

Results for Required Thickness for External Pressure:

Corroded Thickness of Shell TCA 0.1158 in.
Outside Diameter of Shell OD 42.7500 in.
Design Length of Cylinder or Cone SLEN 21.58 in.
Diameter I Thickness Ratio DT 397.5126
Length I Diameter Ratio LD 0.5048
Geometry Factor, A f(DT,LD) A 0.0003363
Materials Factor, B, f(A, Chart} B 4472.1846 psi
Maximum Allowable Working Pressure 15.00 psig
EMAWP", (4*B)/{3*DT) '" ( 4 * 4472.185 )/( 3 * 397.5126 ) '" 15.0006

EXTERNAL PRESSURE CALCULATIONS for SMALL CYLINDER:

External Pressure Chart HA-2 at 300.00 F

Elastic Modulus for Material 26600000.00 psi

Results for Maximum Allowable External Pressure:

Corroded Thickness of Shell TCA 0.3750 in.
Outside Diameter of Shell OD 18.7500 in.
Design Length of Cylinder or Cone SLEN 18.00 in.
Diameter I Thickness Ratio DT 50.0000
Length I Diameter Ratio LD 0.9600
Geometry Factor, A f(DT,LD) A 0.0038380
Materials Factor, B, f(A, Chart) B 12093.H26 psi
Maximum Allowable Working Pressure 322.48 psig (
EMAWP = {4*Bl/{3*DTl '" ( 4 * 12093.143 )/( 3 * 50.0000 ) '" 322.4838

Results for Required Thickness for External Pressure:

Corroded Thickness of Shell TCA _0.0618 in.
Outside Diameter of Shell OD 18.7500 in.
Design Length of Cylinder or Cone SLEN 18.00 in.
Diameter I Thickness Ratio DT 303.4573
Length I Diameter Ratio LD 0.9600
Geometry Factor, A f(DT,LD) A 0.0002567
Materials Factor, B, f(A, Chart) B 3414.0022 psi
Maximum Allowable Working Pressure 15.00 psig
EMAWP ~ (4*Bl/{3*DT) '" ( 4 * 3414.002 )/( 3 ~ 303.4573) '" 15.0005

5-12 Cones and Conical Sections

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EXTERNAL PRESSURE CALCULATIONS for LARGE CYLINDER:

External Pressure Chart HA-2 at 300.00 F

Elastic Modulus for Material 26600000.00 psi

Results for Maximum Allowable External Pressure:

Corroded Thickness of Shell TCA 0.3750 in.
Outside Diameter of Shell OD 42.7500 in.
Design Length of Cylinder or Cone SLEN 42.00 in.
Diameter I Thickness Ratio DT 114.0000
Length I Diameter Ratio LD 0.9825
Geometry Factor, A f(DT,LD) A 0.0010881
Materials Factor, B, f(A, Chart) B 9549.2256 psi
Maximum Allowable working Pressure 111.69 psig
EMAWP = (4*B)/(3*DT) = ( 4 * 9549.226 l/( 3 * 114.0000 ) = 111.6869

Results for Required Thickness for External Pressure:

corroded Thickness of Shell TCA 0.1423 in.
Outside Diameter of Shell OD 42.7500 in.
Design Length of Cylinder or Cone SLEN 42.00 in.
Diameter I Thickness Ratio DT 300.5217
Length I Diameter Ratio LD 0.9825
Geometry Factor, A f(DT,LD) A 0.0002542
Materials Factor, 8, f(A, Chart) B 3381.0564 psi
Maximum Allowable Working Pressure 15.00 psig
EMAWP = (4*B)/(3*DT) = ( 4 * 3381.056 lI( 3 * 300.5217 ) = 15.0008

External Pressure Chart HA-2 at 300.00 F

Elastic Modulus for Large End Reinforcement 26600000.00 psi

External Pressure Chart HA-2 at 300.00 F

Elastic Modulus for Small End Reinforcement 26600000.00 psi

SUMMARY of EXT. PRESSURE RESULTS: Small Cyl Cone Large Cyl

Reqd. Thickness + CA 0.0618 0.1158 0.1423 in.
Actual Given Thickness 0.3750 0.3750 0.3750 in.
Max. All. Working Pressure 322.48 117.67 111.69 psig
( Design Pressure as Given 15.00 15.00 15.00 psig

REINFORCEMENT CALCULATIONS for CONE / LARGE CYLINDER:

REQUIRED AREA of REINFORCEMENT for LARGE END UNDER INTERNAL PRESSURE

Large end ratio of pressure to allowable stress 0.00625
Large end max. half apex angle w/o reinforcement 25.500 degrees
Large end actual half apex angle 21.800 degrees

REQUIRED AREA of REINFORCEMENT for LARGE END UNDER EXTERNAL PRESSURE

Large end ratio of pressure to allowable stress 0.00075
Large end max. half apex angle w/o reinforcement 1.875 degrees
Large end actual half apex angle 21.800 degrees

Area of Reinforcement Required in Large End Shell:

Cones and Conical Sections 5-13

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ARLE (RKLE*QL*RCLQ*TAN(Alpha)*/(SOL*EL))*
(1.0-0.25* ((PEXT*RCLO-QL)/QL)* (Delta/Angle)
ARLE (1.0000 * 160.3125 ,., 21.3750 ,., 0.400/( 20000 * 1.00 )) *
( 1.0 - 0.25 * «( 15.00 ,., 21.3750 - 160.3125 ) I 160.3125 ) *
( 1.8750 I 21.8000 )
ARLE = 0.0671 in

AREA of REINFORCEMENT AVAILABLE in LARGE END SHELL:

AeL .55*( Dl*ts )~ ,., ( ts + tc/CoslAlphal )
AeL .55 * ( 4.2.750 * 0.375 )" * ( 0.375 + 0.375/ 0.928 )
AeL 1.7152 in

SUMMARY of REINFORCEMENT AREA, LARGE END, EXTERNAL PRESSURE:

Area of reinforcement required per App. 1-8(1) 0.0671 in
Area of reinforcement in shell per App. 1-8(2) 1.7152 in
Area of reinforcement in stiffening ring 1. 0000 in
Additional Area needed to satisfy requirements 0.0000 in

REQUIRED MOMENT of INERTIA, LARGE END, EXTERNAL PRESSURE:

Area Available in Cone, Shell, and Reinforcement 14.87 in
Force per Unit Length on Shell/Cone Junction 466.68 lb./in.
Actual Buckling Stress associated with this Force 1005.92 psi
Material Strain associated with this stress 0.000076

REQUIRED MOMENT of INERTIA, LARGE END, EXTERNAL PRESSURE:

ISL AL * DCLO * DCLO * ATL / 10.9
ISL 0.000076 * 42.7500 * 42.7500 * 14.87 / 10.9
ISL 0.19 in.**4

AVAILABLE MOMENT of INERTIA, LARGE END, EXTERNAL PRESSURE:

A
Area Centroid Ar*Ce Dist I Ar*Di 2
Shi 0.826 0.0000 0.000 0.2931 0.010 0.1
Can 0.889 -0.4'104 -0.392 0.1335 0.070 0.5
Sec 1.000 1.1875 1.188 -0.8944 0.333 0.8
TOT 2.715 0.796 0.413 1.3
Centroid of Section 0.2931 Moment of Inertia 1. 76

SUMMARY of LARGE END INERTIA CALCULATIONS

Available Moment of Inertia ( Large End ) 1.762
Required Moment of Inertia ( Large End ) 0.189
(
REINFORCEMENT CALCULATIONS for CONE / SMALL CYLINDER:

REQUIRED AREA of REINFORCEMENT for SMALL END under INTERNAL PRESSURE

Small end ratio of pressure to allowable stress 0.00625
Small end max. half apex angle w/o reinforcement 6.750 degrees
Small end actual half apex angle 21.800 degrees

REQUIRED AREA of REINFORCEMENT, SMALL END, INTERNAL:

ARS ( RKS * QS *" ReSI / ( SAS *" ES ) ) *" {I DELTA/ANGLE ) *" TanAlpha
ARS ( 1.00 *" 562 9.0000/ ( 20000 * 1.00 ) ) *"
( 1.0 - 6.75/21.80) * 0.4000
ARS 0.0699 in

5-14 Cones and Conical Sections

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AREA of REINFORCEMENT AVAILABLE in SMALL END SHELL;

Aes .78. (Rs.Ts) .... «Ts-t) + (Tc-Tr) /Cos (alpha) ) A
Aes .78+{ 9.000* 0.375) .... «( 0.375- 0.056 )+( 0.375- 0.061 )/ 0.93 )
Aes 0.9413 in

SUMMARY of REINFORMENT AREA, SMALL END, INTERNAL PRESSURE:

Area of reinforcement required per App. 1-5(3) 0.0699 in
Area of reinforcement in shell per App. 1-5(4) 0.9413 in
Area of reinforcement in stiffening ring 1.0000 in
Additional Area needed to satisfy requirements 0.0000 in

REQUIRED AREA of REINFORCEMENT for SMALL END under EXTERNAL PRESSURE

Area of Reinforcement Required in Small End Shell:

ARSE (RKSE· QS • RCSI * Tan( Alpha) / (SOS*ES)
ARSE (1.0000·70.3125*9.3750*0.4000/(20000+1.00»)
ARSE 0.0132 in

AREA of REINFORCEMENT AVAILABLE in SMALL END SHELL:

Aes .SS"'(Ds"'ts)A*[(ts-t)+(tc-tr)/Cos(angle))]
Aes .55*( 18.750* 0.375)"'*[( 0.375- 0.062)+( 0.375- 0.070)/ 0.928 »)
Aes 0.9361 in

SUMMARY of REINFORCEMENT AREA, SMALL END, EXTERNAL PRESSURE:

Area of reinforcement required per App. 1-8(1) 0.0132 in
Area of reinforcement in shell per App. 1-8(2) 0.9361 in
Area of reinforcement in stiffening ring 1.0000 in
Additional Area needed to satisfy requirements 0.0000 in

REQUIRED MOMENT of INERTIA , SMALL END, EXTERNAL PRESSURE:

Area Available in Cone, Shell, and Reinforcem~nt 10.37 in
Force per Unit Length on Shell/Cone Junction 409.14 lb./in.
Actual Buckling Stress associated with this Force 554.56 psi
Material Strain associated with this stress 0.000042

REQUIRED MOMENT of INERTIA , SMALL END, EXTERNAL PRESSURE:

ISS AS • DCSO * DCSO * ATS / 10.9
( ISS 0.000042 * 18.7500 * 18.7500 + 10.37 / 10.9
ISS 0.01 in.·*4

AVAILABLE MOMENT of INERTIA, SMALL END, EXTERNAL PRESSURE':'

Area Centroid Ar*Ce Dist I Ar*Di "'2
Shl 0.547 0.0000 0.000 0.6364 0.006 0.221
Can 0.589 0.2916 0.172 .0.3447 0.025 0.070
Sec 1. 000 1.1875 1.188 -0.5511 0.333 0.304
TOT 2.136 1. 359 0.364 0.595
Centroid of Section 0.6364 Moment of Inertia 0.96

SUMMARY of SMALL END INERTIA CALCULATIONS

Available Moment of Inertia ( Small End ) 0.960 in**4
Required Moment of Inertia ( Small End ) 0.014 in**4

Cones and Conical Sections 5-15

(

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Results for Discontinuity Stresses per Bednar p. 236 2nd Edition

Stress Type Stress Allowable Location

----------------------------------------------------------------
Tensile Stress 5004 _14 80000.00 Small Cyl. Long.
Compres. Stress -1941.64 -80000.00 Small Cyl. Long.
Membrane Stress 4974.11 30000.00 Small End Tang.
Tensile Stress 5122.08 80000.00 Cone Longitudinal
Compres. Stress -1823.70 -80000.00 Cone Longitudinal
Tensile Stress 5210.00 30000.00 Cone Tangential

Tensile Stress 15693.52 80000.00 Large Cyl. Long.

Compres. Stress -8631.02 -80000.00 Large Cyl. Long.
Membrane Stress 367.91 30000.00 Large End Tang.
Tensile Stress 15965.51 80000.00 Cone Longitudinal
Compres. Stress -8359.04 -80000.00 Cone Longitudinal
Tensile Stress 911.88 30000.00 Cone Tangential
(
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5-16 Cones and Conical Sections

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Pressure Vessel Design and Analysis - Seminar Noles

Chapter 6:
Welded Flat Heads

Welded flat heads are analyzed as flat plates under unifonn loading.

GUIDELINES FOR WELDED FLAT HEADS

The Code fonnula for welded flat plates is
t ~ dJzCPlSE

Z, a factor accounting for non-circularity of the plate, is based on the ratio of the large and
small diameters. Lowercase d is the small diameter, and z ranges from 1.0 for circular
plates to 3.4 for plates with very large ratios of Did:
Z ~ 34- 2.4d
. D
C is an attachment factor that ranges from 0.17 for configurations that closely approximate
fixed-end conditions to 0.50 for plates that are simply supported. A typical value of Cis
0.3. For the special CaSe of a formed flat head with a straight flange, C can go as low as
0.100. In this case, the Code has taken into account the smaller effective diameter of the
flat plate due to the bend radius at the edges.
The C factor has a multiplier of 1.5 built into it because the stress in a flat head is bending,
not membrane, and the allowable stress in bending is nonnally 1.5 times higher than the
allowable stress in tension. Notice how the Code factors compare to those in theoretical
solutions of the flat plate problem:

Welded Flal Heads 6-1

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Guidelines for Welded FlaL Heads Pressure Vessel Design and Analysis - Seminar Notes

SIMPLY SUPPORTED FIXED EDGE

Il1c!m'

" ~ O.309p(dlt)' " ~ O.188p(dlt)'

Code (Max C~O.33) Code (Min C~O.13)

" ~ d'CPISE " ~ d'CPlSE

SE ~ CP(dllJ' SE ~ CP(dll)'

SE ~ O.33P(dll)' SE ~ O.13P(dlt)'

1.5SE ~ O.50P(dlt)' I.5SE ~ O.20P(dlt)'

(conservative) (conservative)

The thickness is linear with the diameter, but is a function of the square root of the pres-
sure (and the attachment factor). This means that as you increase the thickness, you dra-
matically increase the M.A.W.P.

6-2 Welded Flal Heads

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 Pressure Vessel Design alld Analysis - Seminar NoLes Guidelines Cor Welded Flat Ileads

'.,ttm .,-o,rnl.. .
PART UG _ GENERAL REQ1..IIR.HMENTS

,t.- c.n\.r of I"",

',m'... - 2'. L Iyt-T~

~~ft.r;:"~
- o.376In.

,·3,
100- ' . 0< '-'/2 In" T . ,-3,
...."". . ,. - 3.,- d . 'mIn." 0.. 2.'.10' ., __ ." m'n.
-1--"':\iJ=t -
." min. . ---- _
'. > I.in In.
bul'-nota,. _ _•
C .. 0.30
c"
~1'
0.17 C-O.33Ih-
C ......... O.20
1b-2)
",.,,3/41".
...
C" 0.20 w"O. 13

- n '
d
·""..

,.,
C· 0.'3
-
-
,
'''In.

c.,
c.,
'"
s.. Fig. UW·13.:I.k-u"-t (0 CIII. e.) ..... Flo- UW·13.2 ..... ~ I.) 10 C111.
Indu....... fordoI_n. of -'dMI1o.m ,............
_ _ Iolon lor doIteJl 01 ouuldoo

. :rr:m-
I...... t '-,~ 1.215',
"0
:¥.~
~ dJ
( --'---- --j _-.l'

l~-j ~.,t1 . •
r d
.---- I
·C"O.33 e-o.:»", C-O.3 e-O.3
C mlo>. - 0.20 IU.. Eq. (2) 0' Jell
c", IU", Eq, !:II 0' (6))

C",
'"
R'h'nl"'il ""II

,-,
C-O.30
c_,
C- 0.30
c.,
C-O.:JO

~~=.;;;;:~ :~-
, t ......
.+.. -"',,-,-.
O.Br.mln.

-~ u...,. _~
mln.r'l".or... J
e_O..,6 .. ;:t'~= .. .,- r.
NOTE'Wh... plpo!lh.....,._ c" 0.33 Coo 0.;J3
C .. O.2~ T_ UG-43 ,~
IpJ
'0> '"
FIG. UG-34 SOME ACCEPTABLE TYPES OF UNSTAYED FLAT HEAPS AND COVERS
The Above IlIllStraUons A~ Diagrammatic: Only. Other Designs Thai Meet.
Ute kequlremenb of UG-34 Are AoeepLable.

Figure 1--Typical Flat Head Atlachment Delails and C Values

Welded Flal Heads 6-3

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Whm do yOll need 10 know la anf1lyzc welded Oal heads? Pressure Vessel Design and Analysis - Seminar Noles

WHAT DO YOU NEED TO KNOW TO ANALYZE WELDED FLAT HEADS?

Attachment Details
Figure UG-34 shows typical head attachment delails, characteristic diameters, and values
of the attachment factor.

Required and Actual Thickness of the Shell

C is frequently a function of 01, the ratio of required to aclual shell thickness.
C = 0.33 but not less than 0.20
tr
m=-
ts
Ir ~ Required thickness of seamless shell (E = 1.0)
ts ~ Actual thickness of shell, exclusive of corrosion allowance

Large and Small Dimensions for the Head

If the head is non-circular yon need to know both the large and the small dimensions of the
head in order to calculate Z.

6-4 Welded Ftat Heads

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 Pressure Vessel Design and Analysis - Seminar NoLes What do you need 10 know to analyze welded nat heads?

Pressure Vessel Design and Analysis Seminar

Component Design Problem

D-102 Flat Head:

The vessel shown on Page 5-2 and analyzed in the previous examplc also has an
inserted flat head in the upper cylinder. The head is welded with a fillet weld
above and below the head. What is the required thickness of this head?

Upper cylinder 1D ~ 18 in. (457 mm), thickness ~ 0.375 in. (9.5 mm), length = 18
in. (457 mm)
Design pressure ~ 125 psi .862 (N/mm2), Design temperature ~ 300°F (149°C)
All materials arc SS316 with zero corrosion allowance.
Use higher allowable stresses and 100% radiography.
(
Do this analysis for internal pressure only using the SHELL program.

Notes:

Questions:

How do you calculate C (~F)?

What is the required thickness?

(
What is the MAWP for External Pressure?

DO NOT TURN THE PAGE UNTIL YOU HAVE

COMPLETED YOUR ANALYSIS

Welded Flat Heads 6-5

(

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What do you need 10 know to analyze welded nal heads? Pressure Vessel Design and Analysis - Seminar Noles

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Input Echo, Component 6, Description; 0102 Flat

Design Internal Pressure p 125.00 psig

Temperature for Internal Pressure 300.00 F

Include Hydrostatic Head Components NO

Material Specification SA.-240 316H

Allowable Stress At Temperature S 20000.00 psi
Allowable Stress At Ambient SA 20000.00 psi
Joint efficiency for Head Joint E 1.00

Diameter of Flat Head D 18.0000 in.

Minimum Thickness of Pipe or Plate T 1.0000 in.

Corrosion Allowance CA 0.0000 in.

Attachment Factor CF 0.2000

Large Diameter of Flat Head DL 0_0000 in.
(
Type of Element: Flat Head

INTERNAL PRESSURE RESULTS, SHELL NUMBER 6, Desc.; 0102 Flat

ASME Code, Section VIII, Division 1, 1998, A-99

Thickness Due to Internal Pressure (TR):

(D+2ei-CA) *SQRT(Zei-CFei-p/ (S*E)) per UG-34 Ie) (3)
(18.0000+2*0.0000)*SQRT(1.00*0.20*125.00/120000.00*1.00))
0.6364 in.

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

(T-CA) / (D+2:lCA) ) "'2* ((S-E) / ICP*Z» per UG-34 (c) (3)
(1.0000)/(18.0000+2*O.0000))*ei-2*((20000.00*1.00)/(0.20*1.00))
308.64 psig

Maximum Allowable Pressure, New and Cold (MAPNC):

IT/D) "'2* ((S*E) / (Cp*Z») per UG-34 Ie) (3)
(1.0000/18.0000)772*((20000.00*1.00)/(0.20*1.00»)
308.64 psig

Actual stress at given pressure and thickness (Sact):

(Z*CP-P) / ( ( ( (T-CA) / (D+2*CA) ) .... 2) *E)
(1.00*0.20-125.00)/«((1.0000)/(18.0000+2*0.0000)**2)*1.00)
8100.00 psi

SUMMARY OF INTERNAL PRESSURE RESULTS:

Required Thickness plus Corrosion Allowance, Trca 0.6364 in.
Actual Thickness as Given in Input 1.0000 in.
Maximum Allowable Working Pressure MAWP 308.64 psig
Design Pressure as Given in Input P 125.00 psig

HYDROSTATIC TEST PRESSURES ( Measured at High Point );

6-6 Welded Fla' Heads

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 Pressure Vessel Design and Analysis - Seminar Noles \Vilal do you need 10 know Lo analyze welded Oal heads?

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FileName: Seminar --------------------------------------- Page 13
Shell Analysis; 0102 Flat Item: 6 9:51a Sep 21,2000

Hydro. per UG-99 (bl : 1.3 * MAWP It Sa/S 401.23 psig

Hydro. per UG- 99 (c) i 1.3 • MAPNC 401.23 psig

WEIGHT and VOLUME RESULTS, NO C.A.

Volume of Shell Component VOLMET 254.5 in.**3
Weight of Shell Component WMET 71.3 lb.

The PV Elite Program, (c) 1989-2000 by COADE Engineering Software

Welded Flal Heads 6-7

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6-8 Welded Flat Heads

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Pressure Vessel Design and Analysis - Seminar Noles

Chapter 7:
Half-Pipe Jackets

Half-pipe jackets are frequently used on vessels as heating or cooling coils around the out-
side of a cylindrical shel1, as shown in Figurc I.

GUIDELINES FOR HALF-PIPE JACKETS

Appendix EE of the Code gives rules for the required thickness of the jacket and the
required thickness of the shel1 under the combination of internal pressure and shel1 pres-
sure.

Figure 1--Half-Pipe Jacket

The required thickness of the shen is first calculated using the normal rules ofUG-27(b).
A half-pipe jacket introduces bending stresses in the shen in the longitudinal direction.
Therefore, the anowable stress for the additional pressure in the jacket is
F~1.5S-S',

where S' is the actual longitudinal stress due to internal pressure:

S' ~ Pr/2t
The Code does not givc an explicit formula for the actual bending stress in the shen due to
internal pressure. Instead, it includes three graphs (EE-l, EE-2, and EE-3) that plot the
stress factor (stress/unit pressure) as a function of the shen diameter. Thus the anowable
pressure in the jacket as limited by shen bending is the anowable stress (F) divided by the
stress factor (K).
The required thickness of the half-pipe jacket is calculated from the standard internal pres-
sure formula for a cylinder, but taking E = 0.85.
The finet weld attaching the half-pipe jacket to the vessel shan have a throat thickness not
less than the smaner of thc jacket or shell thickness. When a vessel is in cyclic service, a
penetration weld plus a fil1et weld should be used to attach the jacket to the vessel.

Half-Pipe laekets 7-1

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Guidelines for Half· Pipe Jackcls Pressure Vessel Design and Analysis - Seminar Notes

7-2 Half-Pipe lackets

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 Pressure Vessel Design and Analysis - Seminar Notes Guidelines for Half-Pipe Jackels

Pressure Vessel Design and Anal)'sis Seminar

Componenl Design Problem

Half Pipe Jacket:

What is the required thickness of a cylindrical shell subjected to an inside pressure of

190 psi (UI N/mm2)and a half-pipe jacket pressure of300 psi (2.06 N/mm2 )?
The jacket is in non-cyclic service.
J.D. of shell = 40 in. (1016 mm)
Allowable stress of shell = 16,000 psi (110.316 N/mm 2)
Joint efficiency of shell ~ 1.0
Half-pipe jacket is NPS 3
Allowable stress ofjacket material ~ 12,000 psi (83 N/mm 2)
Corrosion allowance = 0.0

Using the HALFPIPE program, do this analysis for internal pressure only.

Notes:

Questions:

What is the required thickness of the shell?

What is the required thickness of the jacket?

DO NOT TURN THE PAGE UNTIL YOU HAVE

COMPLETED YOUR ANALYSIS

Half-Pipe Jackels 7-3

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Guidelines for Half-Pipe Jackets Pressure Vessel Design and Analysis - Seminar Notes

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar --------------------------------------- Page 103
Half Pipe Analysis; JACKETED Item: 1 9:51a Sep 21,2000

Input Echo, Half-Pipe Item I, Desc~iption; JACKETED

Inside Diameter of Shell DIN 40.0000 in.

Thickness of Shell TS 0.3125 in.
Internal Pressure in Shell P 190.00 psig
Temperature for Internal Pressure 300.00 F
Shell Section Material SA-516 65
Shell Allowable Stress, Design Temp S 18600.00 psi
Shell Allowable Stress, Ambient SA 18600.00 psi
Corrosion Allowance of Shell CA 0.0000 in.
Joint efficiency for Shell Joint E 1.00

Nominal Pipe Size of Half-Pipe Jacket NPS 3.0000 in.

Minimum Thickness of Half-Pipe Jacket TJCK 1. 0000 in.
Design Pressure in Jacket PI 300.00 psig
Design Temperature for Jacket 300.00 F
Jacket Material Name SA-53 S/A
Jacket Allowable Stress, Design Temp Sl 13'700.00 psi
Jacket Allowable Stress, Ambient SIA 13700.00 psi
Corrosion Allowance of Jacket CM 0.0000 in.

Half-Pipe Jacket Results per ASME App. EE, 1998, A-99

SHELL THICKNESS CALCULATIONS:

Required Thickness of Shell per UG-27 Eqn(l) (Includes CA);

Tr (P '" R ) / ( S '" E - 0.6 ... P ) + ( CA + CAJ )
Tr (190.00'" 20.000 )/( 18600.00 '" 1.00 - 0.6 '" 190.00 ) + 0.000
Tr 0.2056 in.

Required Thickness of Shell to Withstand Jacket Pressure:

Trj = 0.2500 in.

PRESSURE CALCULATIONS FOR INPUT SHELL THICKNESS:

Input Value of Shell Thickness:

Ts = 0.3125 in.

Chart Used to Find the K-Factor:

FIG. EE 2

K-Factor Read from Chart:

K = 46.5000

Longitudinal Stress in Shell due to Internal Pressure (Includes CAl:

SPrime (P '" R ) / ( 2 '" Ts )
Sprime (190.0000 * 20.0000 ) / ( 2 ... 0.3125 )
Sprime 6080.0000 psi

Permissible Jacket Pressure per Appendix EE-l, Equation {Il:

Pprime 0= 1.5 * S - Sprime ). I K
(

7-4 Half-Pipe Jackels

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 Pressure Vessel Design and Analysis - Scminar Nolcs Guidelines for Half-Pipe Jackets

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName; Seminar --------------------------------------- Page 104
Half Pipe Analysis : J~CKETED Item: 1 9:51a Sep 21,2000

Pprime ( 1.5 ~ 18600.00 6080.0000 ) / 46.50

Pprime 469.2473 psig

HALF-PIPE JACKET THICKNESS CALCULATIONS:

Input Half-Pipe Jacket Thickness:

Tj '" 1.0000 in.

Req'd Half-Pipe Jacket Thickness per App. EE-l, Eqn. (2) {Includes CAl:
T (PI '" R ) / ( . 85 ~ SI .6 '" PI 1 + CAJ
T {300. 0000 * 0.7500 1 / ( .85 '" 13700.00 - .6 ,. 300.0000 ) + 0.0000
T 0.0196 in.

MINIMUM FILLET WELD SIZE CALCULATIONS:

Minimum Fillet Weld Size (Based on Shell Thickness) :

Fillet Ts· 1.414
Fillet 0.3125 * 1.414
Fillet 0.4419 in.

SUMMARY OF RESULTS;

Input Thickness of Shell 0.3125 in.

Req.d Thickness of Shell due to Internal P. 0.2056 in.
Req.d Thickness of Shell due to Jacket P. 0.2500 in.

Pressure Used for Jacket Design 300.0000 psig

M.A.W.P. of Jacket for Input Thickness 469.2473 psig
M.A.W.P. of Jacket for Required Thickness 338.3333 psig

Input Thickness of Half-Pipe Jacket 1.0000 in.

Required Thickness of Half-Pipe Jacket 0.0196 in.

Minimum Acceptable Fillet Weld Size 0.4419 in.

The PV Elite Program, (e) 1989-2000 by COADE Engineering Software

Half-Pipe Jackets 7-5

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 Guidelines for Half-Pipe Jackets Pressure Vessel Design and Analysis - Seminar Noles

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

r :
CHANNEL COVER
I I I
I
CHANNEL _
TIllCKNESS
"r-- I
I
-
I
CHANNEL ill -OR-
I
,,
C HANNEL
MEAN GASKET DIA.
TIlB ESIDE I
CORROSION
ALLOWANCE
I-J r-- I
/ : I
I I II , I I II I
-
l' -.< STATIONARY TUBEFRONT

I I I I I IJJ~l~~ I_~~_II II \,l--W-J SHELL FLANGE

\, SHELL GASKET DIA. X
/\
SHELL L DOLT CIRCLE
TIDCKNESS-- f-- DIAMETER

• SHELL
SHELLSIDE I
CO RROSION _
f-- f--
ALLOWANCE
I NOTRA FIXED TUBESHEET
EXCIIANGERHASTWO
,
STATIONARY ENDS
(NOFLOATINO TIlBESIIEEl)
, ,
I
!
!
!

\~
I
,- : I
I I FLOATING TUBESHEET

\
C~,

'~
..J l
/1-
"/ .
FLOATINGHEAD

SHELL COVER

Figure 2--Typical Geometry for a TEMA Heat Exchanger

7-6 Half-Pipe Jackets

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 Pressure Vessel Design Clnd Analysis - Seminar Noles Fl,mgc Design and Analysis

FLANGE DESIGN AND ANALYSIS

Flange design rules were first published by Tay lor Forge in 1937. These nt les were
included in Ihe Code in 1942 and are essenlially unchanged. They are found in Appendix
2. The Taylor Forge bulletin is also still available, and is still one oflhe most uscfullools
for flange analysis. The flange design sheels in Ihis section arc modeled after Ihe Taylor
Forge analysis. .

Gaskets
A key eomponenl in Ihe design and practical applicalion of flanges is Ihe gasket. There are
many differenllypes of gaskel malerials, useful in differenl services and al differenllem-
peralures.
The Code defines Iwo gasket factors:
y Gasket seating stress, minimum stress 10 seat the gasket
m = Multiple of pressure needed as a slress on the gasket surface to keep it from
leaking
( Unfortunately, these factors are not reliable as measures of gasket behavior. First of all,
they arc not constant; they vary with such Ihings as applied load, temperature, leakage
rate, and size. Second, they do not by themselves adequately predict leakage rate for a
flanged joint. The Pressure Vessel Research Council is working on improving these design
factors, and has published preliminary findings for the past two years at the annual piping
and pressure vessel conference.
Gasket types and their associated m and y factors are found in Table 2-5.1, shown on the
following two pages. Some typical dimensions for gaskets are also shown on Ihe follow-
ing two pages.
In some cases additional gaskel material is used 10 seal partilions. These partition gaskets
are used for channel flanges and also for channel covers, which seal a channel partition.
Include Ihe area of Ihe gasketed partitions in caleulalions for seating forces and overall
loads.

Half-Pipe Jackets 7-7

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Flange Design <HHJ Analysis Pressure Vessel Design and Analysis - Seminar NoLes

Gasket Materials and Gasket Factors

T.ble 2-5.1 1998 SECTION VIn OlVlSION

TABLE 2·5.1
GASKET MATERIALS AND CONTACT FACINGSI
Gasket Factors m ror Operaling Condilions and Minimum Design Seating Stress y

MIn.
Dellgn
SeaUng Fa<:lng Skelth

Gasket Malerlal ,,,

SIIHST,
Skekhes
;lAc! Column
in Table 2·5.2
SeIf-eMrlllllng typei fO rinlls, metallic, elaslo~, other o o
gul(el lypes tOMJdtrtd n stlf'Malll19J

Elastomer$ wilhoYl fabric or high perce"l of aweslos fiber:

B~IO¥t 75A SOOlt Dwomet.er 0.50 o lllll,(lbl,llel,(ldl,
751>. or higher Sl'>ore Durometer 1.00 200 1-41,C5l; Colu,.", II

Asbul.OS with roltablr birder for- operalillg cOllditlOfJ':

V.ln. Wcic 2.00 11:>00
( la),(lbl,llel,Cld),
Vl6 In. thick 2.75 )100
V» In.. Ihlck 3.50 6500
141,151; CoIUIIVI II

Elastomer$ WfUl canon fabrk IMtrt.lon l.25 '00 (lill,() bl,nel,( ldl,
141,(51; Celu,.", II

flastonms with .uOeslos labrlc Instr1ron (willi or

without wire relnfon:emtn(J:

2.25 2200
~
~
(la),Ubl,lld,CldJ,
2-ply
2." 2.'100
(4),(51; Column II

2.75 )700 ~

aoo
~
Ve9tlable fiber 1.75 (laJ,flb),(leI,nd),
f4mli Colllll1l'1 II.

Sprral-wolHld metal, asbestos filled:

Carbon 2.50 10,000 nlll,lIbl; Column II
Stalo1JtsS, MOt'leI, and nlckel·bast '.00 10,00<1
all0)'5

Conug.altd rnffiJJ, a:sbestos Inserted, or torrugaled metal,

Jacketed asbe110$ filltd:
Soft ah,rnll'l\.ltrl 2.50 2900
Soft topper 01' bran 2.75 3100
Iron or ~ Jlrer '.00 <500 na),( IbJi CollII'M II
Monel or 4%-0% ,hr(llM 3.25 5500
Stalnltss steels and nrckel-base aJJOI'S 3.50 60500

Figure 3--Gasket Materials and Conlact Facings

7-8 Half-Pipe Jackets

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 Pressure Vessel Design and Analysis - Seminar Notes Flange Design and Analysis

Gasket Materials and Gasket Factors (Continued)

APPENDIX 2 - MANDATORY

TABlE 2·5.1ICONT'D}
GASKET MATERIAlS AND CONTACT FACINGSl
Gasket Factors n1 for Operallng Condition' and Minimum Design Seating Stress y

MI".
Des19"
Gasht Sealing Fae!"; SktlCh

Gas\;et MaterIal
Factor
• ,.,
Stress .r.-
Skelchu
and ColllM
In Table 2·52
Corh/96kd mm.l:
Soft ahllllinurn 2.75 )700 ~
Soft e~r or btan ).00 4500
lroo or 50ft stffl 3.25 Ual,Ubl,llcl,lldl;
5500
MON!I or 4%-6% chrome ).50 6500 Colt.m11\ II
Stainless fleels and I\kkel-ba!oe 11110)"5 ).75 7600

Flill metal, Jacketed asbestos filled:

Soft Ill,I1linl.m ~

==
3.25 5500
SolI copper or btau 3.50 6500
llal,f1b),Ue),l
tron or soft Sleel 3.75 7600 ~
"-,
4%-{)% chrome
3.50
3.75
BOOO
90(>0 <SP
Ild)'!;12J 1;
Column II
Stainless sleels III>d nlchl-base alloys 3.75 9000

GroO'o'to mel..l:
Soft alurnlm,m 3.25 5500
Soft copptor' or brass 3.50 6500
(U),() bJ,()cl,()d),
Iron or soft metal 3.15 noo
Monel or 4%-6% chrome 3.15 m,U); Column II
'000
Slalnlns sleels and "lckel-base alloys 4.25 10,100

Solid Rat mnal;

Soft alurnlt'lUm '.00 8800
Soft copper or tnss 4.75 n,OOO (laJ,()bl,llc),11 !fl,
Iron Of'" 50ft $letl 5." 18,000 f21,(3),14l,{5J;
MOM! or 4%-6% worne '.00 21,800 COrllllVl1
$liI.1n1m JI.~ls aIId nickel-base alloys 6.50 26,000

RIII9 ./OInt:
1rOll or soft steel 5.50 18,000
Monet or 4%-6% chrome 6.00 21,800
Slalnless s1~rs and nlckel-base allO)'S' 6.50 26,000 (61; Colum" I

HOTES:
H) ThIs T~e gives a list of manr convnonlyllsed 9l»:et matfrlills -.nd conLact liKings V<ltb SIli9fsted cleslgo val~ 01 m ilId y that hal'e
( geltfraJly Pl'ovr-d saUsfattory I" actual service wnen ~1r19 effective QilIke.l sealll'l9 wldl.h b glytn In Table 2,5.2. Tile desilln yaliles and other
t1tlalls giwn In this Table an ~ d only and an not mandalory.
(2) The ~lIrlace 01 a lIiIsket havh9 II lap ~Id not be against tile rAlbblrt

Figure 4--Gasket Materials and Contact Facings (Continued)

Half-Pipe Jackels 7-9

(

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Fhmgc Design and Analysis Pressure Vessel Design and Analysis - Seminar Noles

USEFUL TECHNICAL DATA

BOLTING DATA FOR ASME/ANSI B 16.5 & BS 1560 FLANGES

Class 150 ClassJOO Class 400 Clm 600

N...
p~, RAN" NO
RAN" NO BOLT B.r RAN" NO BOLT B.r RAN" NO BlICY B.r BOLT B.r
Sil:e llA 0' llA llA llA 0' llA IIA llA OF llA llA BIA OF llA llA
BOLll BOLll BOW BOLT<
\\ 3% 4 y, 2\\ 3% 4 Yi 2\\ 3% 4 Yi 2\\ 3% 4 y, 2\\
y, 3Y, 4 V, 2% 3% 4 V, 2% 3% 4 Y, 2% 3% 4 V, 2%
% 3Y. 4 V, 2% 4% 4 % 3\\ 4% 4 % 3\\ 4% 4 % 3\\
1 4V. 4 V, 3V. 4% 4 % 3V, 4% 4 % 3V, 4% 4 % 3V,
IV. 4% 4 V, 3V, 5\\ 4 % 3Y. 5V. 4 % 3% 5\\ 4 % 3Y.
W, 5 4 V, 3Y, 6V. 4 % 4V, 6V. 4 % 4% 6V. 4 % 4%
2 6 4 % 4% 6'(, 8 % 5 6% 8 % 5 6% 8 % 5
2% 7 4 % 5V, 7% 8 % 5Y, 7V, 8 % 5% 7\\ 8 % 5%
3 7V, 4 % 6 8\\ 8 % 6% 8V. 8 % 6% 8\\ 8 % 6%
3Y, 8Y, 8 % 7 9 8 % 7V. 9 8 % 7V. 9 8 Y. 7\\
4 9 8 % 7% 10 8 % 7Y. 10 8 Y, 7% 10% 8 Y, 8V,
5 10 8 % 8% II 8 % 9\\ II 8 % 9V. 13 8 I 10%
6 11 8 % 9% 12% 12 % 10% 12Yi 12 % 10'/, 14 12 1 llY,
8 nv, 8 % 11% 15 12 % 13 15 12 I 13 16V, 12 IV. 13%
10 16 12 Y, 14\\ 17V, 16 1 15\\ 17% 16 IV. 15\\ 20 16 1\\ 17
12 19 12 % 17 20% 16 1% 17% 2OY, 16 1\\ 17% 22 20 IV. 19V.
14 21 12 I 18% 23 20 1% 20v. 23 20 1\\ 20\\ 23% 20 1% 20%
16 23V, 16 I 21V. 25V, 20 1\\22V, 25V, 20 Pis 22% 27 20 W, 23%
18 25 16 IV. 22% 28 24 1\\24% 28 24 1% 24% 29V. 20 1% 25%
20 27V, 20 1% 25 3OY, 24 IV.27 3OY, 24 IY, 27 32 24 1% 28V,
24 32 20 1% 29V, 36 24 W, 32 36 24 IV. 32 J7 24 1% 33
.

. Figure 5--Bolling Data

7-10 Half-Pipe Jackels

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 Pressure Vessel Design rlllrJ Analysis - Seminar Notes Flange Design ,llld Analysis

USEFUL TECHNICAL DATA

BOLTING DATA FOR ASME/ANSI B 16.5 & BS 1560 FLANGES
- -- - - .. __'N"' ___ - - -~ _._'-~

.
'~~'._- ---"'-~.~

Class 900 Class 1500 Class 2500

NollliAal -
Pipt
Siu
n",,,, NO .ou H
.u. .u. ""''''
ou
NO
.u.
"', •.e.
ou.
n ...",
.u
NO
0'
."',
.u.
H
,u.
'" 0'
."'" "
""" """
v, 4% 4 * 3v. 4% 4 * 31' 5!h 4 'I. 3Y2
'I. 5Va 4 'I. 3Y, 5Yo 4 * 31'2 5Y, 4 'I. 3%
Ph Sl'a 4 Y. 4 5V! 4 Y. 4 6Y.i 4 Y. 4y"
1 6Y4 4 V. 4% 6lh 4 V. 4% 7Y4 4 I 51's
lYi 7 4 1 4% 7 4 I 41's 8 4 tva 5*
2 81'2 8 V. W, 8Y, 8 Y. 61'2 9'h 8 I 6'1.
2Y, 9% 8 1 7Y, 9% 8 1 71'2 lOY:! 8 tVa 7%
3 9Y2 8 V. 7Y, 10\12 8 tVa 8 12 8 lY.i 9
4 IlVl 8 JY. 9!1.l 12Y4 8 l!1.i 9Y2 14 8 lY1 lQJ'A
5 13¥.& 8 llh 11 14% 8 jy, llY2 16Yl 8 1% 120/4
6 15 12 lY. 12 15\12 12 1% 121'2 19 8 2 141'1
8 181'2 12 1% Y, 19 12 1% 15lh 21% 12 2 17Y.&
15
Y,
10 21Y2 16 1% 18 23 12 1% 19 261'2 12 2Y, 21Y4
12 24 20 m Y, 261'2 16 2 22Y2 30 12 2% 24%
14 2jy., 20 Iv.i 21 29112 16 2y., 25 - - - -
16 27% 20 1% 22 321'2 16 21'2 27% - -
24
I'
18 31 20 1% 27 36 16 2% 301'2 - - -
20 33% 20 2 29 38% 16 3 32Jh - - - -
24 41 20 2V, Y, 46 16 314 39 - -
35
Y,

Figure 6-- Bolling Data Continued

Half-Pipe Jackels 7-11

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Flange Design and Analysis Pressure Vessel Design and Analysis - Seminar Notes

Other Gasket Types

The following gasket types arc not pictured in the Code tables, but are also acceptable gas-
ket materials and geometries:

~nprel8ullzed ~res~rized \'enled

" I '\ . Venl7

rrorJto
~. Y
I1IJ ~
1/· 1)1IJ
;
JJ JI I I
1/ 'I

C-Rlng J1 J

~ ,i

lens 0'11. Doubl, Cone Brldg,"'n

Figure 7-Olher Gasket Types

Facing Sketches
There are several types of flange facing types. The flange facing is simply the metal sur-
face against which the gasket seats. The Code shows several sketches of typical facing
types in Table 2-5.2. This table also shows how to calculate the basic and effective gasket
seating widths and the diameter of the gasket load reaction. (
Two common mistakes in gasket design (and even ill some computer programs we have
seen) are, (I) to use the basic gasket seating width instead of the effective gasket seating
width in the flange calculations, and, (2) 10 use the mean diameter of the gaskel as the
diameter of the gasket load reaction in all cases.
A special type of gaskel geometry, which is not included in the Code sketches, nor even in
the Code design rules, is the flange with a flat face and a gasket that extend from the ID of
the flange to the OD, beyond the bolt circle. The gaskets used with this type of flange are

7-12 Half-Pipe Jackets

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 Pressure Vessel Design and Analysis - Seminar Notes Flange Design and Analysis

usually quite soft. These flanges can be analyzed using the Taylor Forge calculation
sheets.
Table 2-5.2 1998 SECTlON vm - DMSION 1

TABLE 2-5.2
EFFECTIVE GASKET WIDTHl

BAsic Cuket Seating WkIlh bQ

Facing Skelch
IEu99tr.. ted) Column I Co/umn II
{lal
"«'UUe cul' f
vct/ u "'"

~ ~
=
lIb) '(
fu
¢N'<4 '«UtUC" , "-, ,"
=
7""~~
Set! Hote (I)
=
J>'tN:J';; r
Uel :'f:g0i';'
'" t'ii jI" .," w+ r (w+ N
-.- m") -,-;
. . T ( -.-m"
.. " )
=> r"
--,--:
•'"'5'&
lId)
T
( '7t2k~'
Ste Note III W<"
,2l
1/... III. nubbin
t~ ~
•
~
•
"W"" wSN/l

'" II... In. IIIJbbln

¢',:::[t..,
!1'"
~
N
cry
...
. wS Nn •" '",
,<)

See Note (II ' tN'J

= !."-
•
7"
16

"\

'"
See NtJtt UI
=
~ZI"'"
N

• '",
'M -j 1-- •
~
...
•
Effecti~ GMktt Sealing Wi6lh. b
b - b" when b,.s: ".t. in.; b = 0.5 ~ when b. > 1/. In.
LoutJon. of Gasll:tlload Reaction

G
~
-I~ hG -1
" G..,kCl
F~
(

NOTE:
(11 Whefl! ~lTaUom do not e~utd V"" In. c1tpthand '/jl In. wldlh 5paCln9, sketches UbI ~ Cld) ~I be used.
(2) Tile: gaSh! factlm listed lmly apply 10 flanged )<lInts in whkh tilt gasket Is (ontalflt(i enUrtly w1lhln the Irroer edges of the bolt Iloles.
J«)

Figure B--Facing Sketches and Gasket Seating Calculations

Flange Types
There are essentially only two categories of flanges for purposes of analysis. These are
integral type flanges, where the flange and the vessel to which it is attached behave as a
unit, and loose types, where the flange and the vessel do not behave as a unit. Within these
categories, however, there are several additional subdivisions.

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Flange Design and Analysis Pressure Vessel Design and Analysis - Seminar Notes

Weld Neck FJanges-These have a hub that is butt-welded to the vesseL

Slip-on Flanges-These have hubs, and are normally analyzed as loose type flanges. To
qualify as integral type flanges they required a penetration weld between the flange and
the vesseL
Ring Flanges-These do not have a hub, though they frequently have a weld at the back of
the flange. They are normally analyzed as loose, but may be analyzed as integral if a pen-
elration weld is used between the flange and the vessel.
Lap Joint Flanges-These flanges mayor may not have a hub, but they are completely
disconnected from the vessel, bearing only on a vessel "lap." They are always analyzed as
loose.
Reverse geometry flange-Here the gasket seat is on the inside of the shell diameter.
These use integral flange rules, which arc suitably modified for the reversal of the bending
moments. Sec Appendix 2-13.
Loose-type flanges, especially Jap joints, may be split. A split is used when it is required to
have the flange completely removable from the vessel. If the flange is split into two pieces
by a single split, the design moment for the flange is mnltiplied by 2.0. If the flange con-
sists of two separate split rings, each ring shall be designed as ifit were a solid flange
(without splits) using 0.75 times the design moment. The pair of rings shall be assembled
so that the splits in one ring shall be 90 deg. from the splits in the other.
2-5 1998 SECTION vm - DIVISION l 1-5

Guk~t
Slope
1:3 ima>l.l

Slope 1;3 (max.)

Whet'& hUb lIop!! adiillC81t
(0 f111'1ge ex«Bdl I :J, L.....ILL:;:r I.S go
151 UI. tJ<elehes 1611 or 1Gb) (min.)

181

- --1--,i----''+I'-'
0.2590 but nOt Ius tharI 114 In .. 1hl minimum l6bl ......
for lither leg. This ,"';!Id mil,!, be mee/'llned
til 8 cOUM!r ,..Jius os petmilled in
sketch (51 in which ease 91 ~ 9 0
GENERAL NOTES ILoow lind Integ,.l Type Fr.ngoell:
fll FHle\ flIdiU$ r to be II lean 0.25.91 bUI mit I~$ than 3/16 in.

~
"-j;""::'-t~::!~~t:J~ lbiFiKin91hlcknttWl or llfOQYll'dlePttll9'"eall!r lIlan 1116 In. ,hall be
i . - . HD In uons of Ihl required minimum 1l9nte thlckn.eu I; IhoI'lI
~T G ~uIIIO or Ins lhan 1116 in. m.lIV be intluded In Ihl overall fiar>Qt1hlckOffi.
gQ ,'.
8 .,12
Figure 9--ASME Code Flange Types

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 Pressure Vessel Design and Analysis - Seminar Notes Fl<mge Design and Analysis

2-5 APPENDIX 2 - MANDATORY

Full pene1f81lon weld,

r:+:~
lingl.. Of" double. The
full penc'UlItion _ld
A may biI throVOh the hI>
lIJI« through thl
, D C
t I.
wall (tn ),

~~=-==-~·HD T 11~~=*_"
To be taken IIl1 midpoint or COotlel bl!tweln " , min,"0.7r;
This Mk:I may be meehined to. com".. radius ScrlM'Qd F.~ Wilfl Hub
flatlge end IIlP lndepeodlnt 01 gallr.cl location
to luit It5'ldmIlap jolnl "eng..

III 121

(
u
Selrwtd FIa~
WiI'hout HUb
Jt~
m .... ~
• 0_7 t: ~~
_0" (_ ...
.....j
1/2'
I-
(tneX.I
min.
~ Q,7r;

r;" 1/4 in t: + 1f4 In.

1211 (Not. Ill] 131lNoie (2)1 11I11N01.121) 14J INol1 1211 {4111 (Noli 12)1
NOTES (LOO$8 Type FI.~I:
III For hubtl~ 6 de9- or lnl, Ulego • "I'
12) Loedinfj end dlmtn,lOllllor Skttctlel {2,1. (31,13.1. {41, and (4a) tlO1lho.... n Ir. lIle SIlITle U 101 sketch (21.

Lo~T.,.~FI ..~

Figure 10-·ASME Code Flange Types (Continued)

Half-Pipe Jackels 7-15

(

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Flange Design and Analysis Pressure Vessel Design and Analysis - Seminar Noles

APPENDIX 2 - MANDATORY ng. 24

,~~~,;;~ t}. .~ 101

FilII PIIl'It1l1liOn and backchlp

110) [lte Fig. UW·13.2 ,ketUt.. Iml
.ocI 1111 and 00.93 Idl UJ I

(11)
GENERAL NOTES (Optional Typa Flenges),
fal Optiona. type flanges m.y b. calellialed u ,ither loole or integ.allype. S" 2-4
Ibllo.dlngs .nd dimenSIO", nol1hown In sk,tchlll UI).18.).19j.1ge).1101, .nd 110011 are Ihe "me u ,hown III Iketch (21
wtlen lhe nang. II clllcllial.d 81 8 loose type lI.nga and as ehown ill ,k.leh (7) when lhe lI,nge Is nlellialed II en
Integrellyp. lIeng'_
(el The groove and lill.1 weld, behyeen Ih. lIanga blck lacI 'nd the shell given in sketch Ie) also apply 10 ,kelches (8.).
(91.190).110). lind (1081_
Opllof\ll Typ. FI."V'<

4-llllide
~gl"" di!lmeler

FOI illttglllllY ,-%In. )

r.infOl'm
1l0UI".
!-31'''" Subtype 1.1
~In. -nut !1I16In.
Sllbl""':lbJ
he19ht .. 1f4 In:.
SllblyPt lei t
All Oillet" dll.il. 'I
(,-- , I+- shOWn In shIeh 1121
SulMvpe fdl .../"lJ I.~ 0
Nul f10pdllmetH"

1121

GENERAL NOTE If...,..Wilh NIlI SI0PtJ:

For wbl:yP8I fd Ind fbl"o II the Ihicltn.u ollhe hub.1 the ...... 11 .nd. For Jubtypet 1(11nd Idl. 90 .91'

FlingM \'tlln Hut Stops

FIG. 2-4 TVPES OF flANGES (CONT'D)

Figure 11--ASME Code Flange Types (Continued)

Flange Behavior
The flange design rules incorporated in the Code were based on a paper written in 1937 by
Waters, Westrom, Rossheim, and Williams. This paper assumes linear behavior of all the
components-flanges, bolts, and gaskets.
The Code rules do not take into account external piping loads or Ihennal stresses due to
thermal gradients. In most cases, the flange rules result in a good flange, except Ihat the
bolts must be stressed higher than the Code allowable to get a leak-free seat.

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Pressure Vessel Design and Analysis - Seminar Noles Flange Design and Analysis

The flange model assumes that the flange can be modeled as stiff clements (the flange and
hub) and springs (the bolls and gaskets). The initial boll load compresses Ihe gasket. This
load needs to be high enough to seat (deform) the gasket, and high enough to seal even
when pressure is applied. The pressure load adds to the boll load and unloads the gasket.
When pressure is applied, Ihe flange rolates around the gasket, thus decreasing the bolt
load. However, the pressure end load tends to unload the gasket and load the bolts. The
degree of decrease of the gasket load is a function of the gasket stiffness. Real configura-
tions can go either way.
If the gasket is stiff relative to the bolt, the gasket unloads preferentially, and the bolt
load stays relatively constant.
If the bolt is stiff relative to the gasket, the boll loads preferentially, and the gasket
load slays relatively constant.
The Code assumes that if excess balling is provided a propensity exists for prcloading the
bolls in excess of the calculated required bolt load, and it makes an approximation to take
this into consideration so as not to overstress the flanges. The Code also recognizes
(Appendix S) that it is usually advantageous to load the bolt to a higher value than the
allowable stress. Typical values range from 40,000 to 50,000 psi, or up to 90 percent of
yield.
There are several methods of achieving uniform and high boll loads. From simplest to
most complicated these include:
Cross tightening
Torque wrenching
Pneumatic Tensioning
Pneumatic Tensioning with ultrasonics
Pneumatic Tensioning with strain gaging

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Flange Design (lnd Analysis Pressure Vessel Design <Iud Analysis - Seminar Noles

The following table shows typical torque values for various bolt sizes.

I TORQUE REQUIRED TO PRODUCE BOLT STRESS I

The torque or turning effort required to produce a certain stress in bolting is'dependent
upon a number of condilions. some of which are:
I. Diameter of Bolt.
2. Type and number of threads on bolt.
3. Materialofbo!t.
4. Condition OfllUt bearing surfaces.
5. Lubrication of bolt threads and nut bearing surfaces.
Generally. standard Flexitallic spiral-wound gaskets will require that standard AS ME
flange bolting be stressed to 30,000 psi for proper gasket seating. However, it is the
users responsibility to follow ASME Code calculations, and to ensure thaI sufficient
pre-load is applied to withstand infernal pressure. properly seat the gaskel, and com-
pensate for the effects of bolt relaxation.

The table below reflects the results of many tests to determine the relation between
torque and bolt stress. Values are based on sleel bolting welliubricaled with a graphite
(
and oil mixture.

TORQUE DATA FOR USE WITH ALLOY STEEL STUD BOLTS

Load in Pounds on SLud Bolts when Torque Loads are applied

NO.IIN.\L
,,~

OFBOLT
(bo<1I<.»
.....ffi
ornou:.ws

(porLod)
Ow.<rnR
ATROOTOr
~
(bI<1I<.)
-
ATROOr
0'
n ......
St·""\
T,,,..
,~.

,
30.000 PSI
..,
C..." .....
" ...
To"...
"""
45POOPSI
C. . .
u.
""Io. To"...
r~u.
llO)lOOUI
..,
C........Io.

'" 2. .185 .027 .1. 6 1215

• 1620
5/16
" .240 .<>1,
• 1350 12 2025 16 2700
318
7/16
16
l'
.294
.34'
.06'
.093
12
2.
2<>1.
2790 "
30
3060
4185
5670
,.
2'

60
'.80
'''0
7560
1/2
,n6
13
II
.400
..154
.126
.162
30

"60
3780
'860 "
6' 7290 90 ono
'"
314
11

,
10
.507
.620
.202
.302 100
6060
9060
90
150
9090
moo
120
200
12120
18120
7"
1
• .."
.731 .'119
.551
160
24'
12570
115530
2'0
36'
18SS5
24795
320
'90
25L40
33060

•••
1· 118 .963 .728 3" 21840 533 32760 710 '3680
75. 41'805 1000
1·1/4
1·3/8
1.088
1.213
92'
1.155 "'"
600
27870
34650 1020 51975 1360
55740
69300
1·111
1· 518
•• 1.338
1.463
1.405
L.6W
000
1100
42150
'Q400
1200
1650
63225
75600
1600
2200
84300
100800
1· 3/4
1·718 ,• 1.58S
1.713
1.980
2.304
1500
2000 "'"'"
69120
225.
3000
89100
103680
3000
'000
118SOO
138240 (
2
,• 1.838 2.652 2200 79560 3300 110340 4400 ]59120

,,,
2·114 2.088 3An 3180 102690 4770 154035 6360 205380
2·1/1 2.338 4.292 4400 128760 6600 193140 '800 257520
2-314 2.588 5.259 '920 157770 "00 2366" 11840 315540
3 2.108 6.324 7720 189720 11580 284580 15440 379440

Figure 12--Torque Required to Produce Bolt Stress

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 Pressure Vessel Design Clnd Analysis - Seminar Noles Flange Design and Analysis

BOLnNG DATA-R.ECOM,M£NDED MINIMUM

(All Dimensions In Inche'S unleS5 (llhei"fl'ise stated)

IYt 8 0.128 IIVIl 2.0)2 i m Hi Iii m H.

I--"'-J----'---t-==--+---'C.II---cc,.,-+
HI 8 i1929 1 nl9;
~-
2'~i m 1'14 m l% 1'14
~--'-+--'-+':=+-c-+-~_cc-'--'-+--'-+---'----1-c-- ._- -- - f -
lY.. 8 '-155 2V" .'.'.16 __ ~ _ J~l"'+_'~;"'--j_~I~"--i_~"~'-l--=J~"--i,-'~":...j
Hi 8 1.405 m tEn i jl'o l Ph I 1\1- 3Y. m
Hi 8 1.680: ll~. 2.828 I 3\:\ ni ,
8 1.9&:1 [ ...::'Yo~,+.J~_O~":_I-.:~ 2Yo IY.
8 2-J:l4: 2"Ai 3.m ~ m
(
8 2.652 I 3% 1m ~% 2\i
lY. 8 H23 I ]~ H.62 ~y, 2Y.
lYo 8 4.m i ]~ 4.215 511 rYi,
2M 8 5259! 4% 4-688 SY. Wi
L __ . _._.- f---C~'---'~-:=':+-"'-.I--='--
3 8 6.324 4~ 5.102 f,y, j% 7 ,

a I.4-31!
8.749
IO.lM
l
I
5
SY.
5y'
5.515
5.923
6..341
6~

7Y.
/11.
J%
4y!
]'/,
./'t.. 3'h

'"
1I.S66 ." '"

t~·~
D.C.

I
( Nut dimensions are based on American Nalional Standard 818.2.2· (1972)

Figure 13--80Iting Data-Recommended Minimum

Half-Pipe Jackels 7-19

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Flange Stresses Pressure Vessel Design and Analysis - Seminar NoLes

FLANGE STRESSES
Stresses on the flange are determined entirely by the bending moment on the flange. All
the loads on the flange produce bending in the same direction (i.e., counterclockwise) and
this bending is resisted by the ring behavior of the flange, and in integral flanges by the
reaction of the pipe.
The flange design moments differ from the norm for external pressure, reverse flanges,
and flat flanges. Under external pressure only the end load and flange pressure are
included in the design, and their sense is reversed.
For reverse flanges all the moments are present, but the moment arm h o is negative, mak-
ing M u negative. The load H T is negative, and the moment arm h, may be either positive or
negative. The absolute value of the moment is used in the calculations.
For flat faced flanges an alternate value ofhg (h"g) is used to calculate a reverse moment
at the bolt circle. No calculations for seating conditions for full faced flanges arc required.

Figure 14--Calculating the Reverse Moment at the Boll Circle

Stress Analysis
(
The stresses produce by the bending moment were calculated by Waters Rossheim,
Wesslrom, and Williams using a complicated combination of elasticity and discontinuity
equations.
These equations have been simplified for Code use into curves, formulas, and tables that
contain constants depending on the geometry of the flange assembly.
The form of the stress equations is

a = K(geOmelry)~
I

That is, a constant (dependant on the flange geometry) times the bending moment, divided
by some thickness squared, either the thickness of the flange or the thickness of the hub.
The Code provides formulas so that computer programs can consistently arrive at the
answers that are normally select from charts in the appendix.

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 Pressure Vessel Design and Analysis - Seminar Noles flange Slrcsscs

Below and on the following pages are the Taylor Forge calculation sheets widely used for
flange analysis calculations.
Flanges are frequently subject to external forces and moments, in addition to internal pres-
sure. Using the following fonnula, you may calculate a roughly approximate equivalent
pressure for flanges loaded axially and/or in bending:

P eq = P des -,+-,
+ 4F
nG
t6M
nG

Where:
Equivalent Pressure
Design Pressure
Axial foree, lb
Bending moment, in.-Ib
Diameter of gasket load reaction, in.

There are two commonly used tables of bolt area, which also show spacing required for
the bolts. These spacings frequently govern the geometric design of the flange. The
TEMA table is based on Table D-S in the TEMA Standards. The UNC table is the Unified
National Course thread series, found in many places, stich as Mark's handbook.
Sometimes the mating flange strongly influences the design. For instance, ifyou are
designing two flanges bolted to one another in such a way as to sandwich a tubesheet in
between them, you would have to analyze both flanges and detennine which one had the
maximum bolt loads, then examine the mating flange under those loads.

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Flange Stresses Pressure Vessel Design rl1ld Analysis - Seminar Noles

TYPE 1: WELD NECK FLANGE DESIGN (INTEGRAL)

1 DESIGN CONDITIONS
AlIo".ble SII.....
prllsaure. P
Dllalgn lempenllule
flallQII1N1ot18I [)e,lgn lomp.. s",
F_
De&lgl'l I(Jll1lP•• ~
.......
~log malGl'ial "«Ill. temp., s.. AIm. 'emp., s.
Conoelotl ;1II1owanol!I I I
2 OASKET AHD ~ING DETAILS
Oaskel
"do"
3 TABLES 2-3 AND 2-4 4 LOAD AND 80U CAlCULATIONS
W~ .. b.oy A", - gl&llillf of
b H,. c. ~.omP W....¥S.OfW.. t~
G H. .P/. ",
Y Wm,-Hp+H W• .6(A", .. ,ys.
m

5 MOMENT CAlCULATIONS
Coo. , lww m - """"",
OplA!lng --
Ho .. ,,9 f>/4
Ha .. Wm,-H
ho~R+.5g..
110 ...6{C - G)
Mo·_
~-Ho~ :;".
.-
HT~H-Ho hI ... 6(fl .. III .. hnl
...
u,. .. H1h-r
-
",.W ha - .5{C G}
S...""
...
6 K AND HUB fACTORS

11-~"
K_MI
T
1
"'"
F
V
Y
u
s.,.,
I
II_FIh" t
~F7",~1F:':
d .. ~tJ..g.,~
ho",..reg;
7
, STRESS FORMULA FACTORS

0'_18 .. 1

~+-h,~
" ....1319+1
, . ofT
, .. I'/d
~~., .. 6 I"
H,
m" -
mc-M,;IB
MJB I C

If bon tpacll"lO txcuds :2a .. t. rnukiply

~~
In" 8nd rna in abeNe ~Iinn by: 2a+1

lBo/IS t::+f HG
G"

FIgure 2·10. Dimensional dala and torces fOt a weld

neck nange (integral),
B STRESS CALCULATIONS
"lloWI~ Str...
1.5 St, 1"ong_IJdiFlII hUb.
Operellng
,. ...
Allowable 81r...
Longitudinal hub,
Se.t''''II

... SH ,"Mg,·
Ratialllatlgs• ... SH =-lrncI).g,~
Radia.lI\ar1~.

... SA .. o1mJ).f2
... ~-~t2

. ~~~J~St.
Grealer or .5CSt! + ~
or .6($" -+ 8,

Adilpled from Tayloi' FOIOO Inll9lnab~:H1a1. Irx:. by pelml$$icm

... ~~~~
GreSler 01 .~S,I + ~
~. 5,,+5, . .

Figure 15--Type 1: Weld Neck Flange Design (Inlegral)

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Pressure Vessel Design Clnd Anlllysis - Seminar Noles Fl<mge Stresses

TYPE 2: SLIP·ON FLANGE DESIGN (LOOSE)

1
Do$lgrl P'OMUle, P
Deeigl'llemperatore
Flange "",,,,1&1
BoI\ng meterilll
D9a1gl temp., s..
DESIGN CONDITIONS

FJong.
AJlo'QbIo SlnlUH

Deaigtll&mp.6t.
Alrn. lamp., S.
....,.
AIm. 1811'9.. Sso
COHosion llJoMInee

2 QASI<U AND FAClHQ DETAILS

Gu... Facing
3 TABlES 24 ,\NO 2-4 4 LOAD AND DOLT CALCULATIONS

..
N W"", .. b Y "- .. glllalK of
b H,. .. 2brllmP WrdS.or W.A
0 H.G .,P,4
Y Wml",Hp+H W ... 5<A." ... 1<lJS.
m
5
lood . M~ENT CALCUlATIONS
Levltr Ann
- Momon'

~ ....B 14
Ho. ~ W... H
ho .. R+g,
ho .. .5(C-GI
"". ..... ""'"
.... -""'"
HJ= H
'" hI"= .6(f1 ... ; .... hal

Stlldng
...
Mr .. HI'"

W to· -'<G OJ u,;

'"6
...
K AND HUll FACTORS

~
K=NB
T F,
~A.
z
V
u
v,

5.
1 !lo-

0"
i w
"".... ..mg; '"
d=~Mol h- j.-E. -+f4-Ro -. ~g,"

,7
a.l, + I
~"'413I.+-t

......
T ofT
STReSS FORMULA FACTORS

t-
,.
I
1--8.
C.
),"'Y.'
... -M,IB
I!IG" M;.1B
H boll. spadng elCO&O(Is 23. + I, rnlltiply
rno and me n above equlillion by:
~"""'"
28 ... 1 ~~ 1. G·

~ Bolls : Ho
Figure 2-11. Dimensional data and lorees for a slip.on
lIanga (loose).

8 STRESS CALCULATIONS .

Allowable Sireu Openllng !1ow"I)IeStreM S..llng

1.5s", loIlWfucf1f1ll1 hUb. 1.6 s.. lOOQlludlnll Ixb,
~ =mJ).g,' 8H _ "'<'Ag,z
s" Retial Aanw,
S~ ~ tJrnJl..l~
s" s,,-_
Radial RaIl",

s"
s"
........ "'''~
Sr~ m,Y/I'-
Gt'88191' 01 _~s.. + SlIl
oc. 5H+S,.)
Adapted Irom laylor Forgo Inlernationill, loc., by perrrus.slon.
.
s" T........ ~
Sr maY/l2
GUlaiet 01 .5(SH + S~
or·~+St

Figure 16--Type 2: Slip-On Flange Design (Loose)

Half-Pipe Jackels 7-23

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flange Stresses Pressure Vessel Design and Analysis - Seminar Notes

TYPE 3: RING FLANGE DESIGN

1 DESIGN CONDITIONS
ptll9SUlli. P AIJoW/lbl. Strlll.lI11
[)e.slgo lempBfal"ne
RatI{Ill malOfie}
8oI1i1lg rna\Orial
DeaIgn 'Imp., s..
Aim. t~ .• St.
R"",
Desigtllomp.•
Aim. lernp_. S.
s" """"
C«roslQn a11o'wance

2 OASKET AND FACJNQ DETAILS

Ge$l<lIl rw",
3 TABLES 2-3 AND 2-4 4 LOAD AND BOLT CALCULATIONS

.
N Wrrd--hG)' A... .. 9'••ler of
b H,.-=2brllmP W.dSIOfWlfJ~

,
0 H .. G'rP,",
W.., .H,+H w .. M..... -+AtJS.
m

5
...., ,
MOMENT tALC!JL.ATIONS
Lever Arm . """"',
~r.llng
Hg .. ,BPf4 Ito" .5{C - B) Mo - Hoho
Ho-wm,-H hG- .~C -0) Ma~liGha
H,-H "- tit ~ ,5(1ID+ ho) M, = Hrhl
M"
Slitting
",.W ha '" .S(C - 0) M"
6 SHAPE CONSTANTS

+
W
IA'r.-C~
K. AlB Y

~~~r.Pa:.v~u2a~~1:Ulliply J8oJ1 spIocing ho B~

20 .. I

7 FLANGE THICKNESS REQUIREO

I '" gf8lIler 01
[II r+'~ ~h H(jl HT
G.

, Bolls
""""'" ScKlliog 1

,.~
... 1- ~
~
Agure 2-12. Dlmensk>nal data and forces ror a ring
nange.

1/4 In.~
.25g.
> 1T'"~90
~=90 1,.,"'90
h ,
h ' g,
-IA
g,
hl-l; -g,

I ~; I ~ ~<+"'i"
I T
"'"
I· • B
~. B I. • B

.7cmin
Figure 2·13. Various allachmenls of ring flanges. (All olher dimensions and loadings per Figure 2·11.)

8 NmES

I g, sM h. BIg. s3CKl, p~ j
la. <1-5t.lI'ldh<9•• de$Ic)'lllo! IrI!aglIll-Kg. > 1.$1. &rdh>il"•. ~sq, ... ~
p!!illt>dClWgtl *'1:>. < TCIO". o..q, Il$ ml<q3lorb>lu.

e"'''"",,<:(I~"'I-=:~. bulro1 loss Ihan I/~ In.

Figure 17--Type 3: Ring Flange Design

7-24 Hair-Pipe Jackels

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 Pressure Vessel Design and Analysis - Seminar Noles Flange Stresses

TYPE 5: SLIP-ON FLANGE, FLAT FACE, FULL GASKET

I
lIign pressln, P
DeaIgn lempereh"e
fIange rnalorial
BolIng material
Cotros;on aIowlll'C9
()e$ign temp..
Aim. lOmP-. s..
s..
,-
DESIGN CONomONS

T
Ioweble Str.....

De~" tomp.• St.

Alm.lelnj)., S.
-""
2 GASKET AND FACJHO DETAILS
GB$lI:;eI Facing

3 TABLES 2~ AND 2-4 4 LOAD AND BOLT CAlCULATIONS

G C

,
b

m
~{C-B""
""
W...:I. -
H,.
•I
~

H. • P/4
b~Gr
+ HQy
21numP

W.,_H+H,.+Ht\
.
A", .. grealCO" or
W,dS. 01 W",,1SD

w-.5(A.+~.
H6,v .. (halh6)brGy

5
..,.. •
MOMENT CALCULATIONS
"",,,Am> . Momenl
Operallftg

(
Ho" TB'PJ4
Hr-H-Ho

"o",(C-9X2BtC)
ho .. A +111
1lr-.6(AtQ,+11G)

levlr Arrrl.
hir._l..... CK2A+C)
.
Mo" Hollo
IMr _H,h,

6(9 + C) 6(C + A'J

Rev&l'loIl Moment

Ha .. W-H hO .. hohQ '-"G = He.1IG

ha+hG
6 K AND HUB FACTORS
Ho
, • AlII
T
z """"
V,
~A. }-9O~
y
U
g,,.,
• F,

d .. U h"g.,a
1
". ,mg;
,7
STRESS fORMULA FACTORS
v,
i ~E~ .~ho B.

•l,--,t'
Id h·
I-- A~ 4
0 "+. + I
jl .. .(f31e
,-ofT
" bo-. ~ IlCeed:s 2a ... I. nVtIpty
m" In 1\ equalion by:
m,. M,III

4Bo1l2a$p&Cino
of t
t-I~
W

\
4 I-g.~

Co
B
Allowable SIre..
STRESS CALCuLATIONS
OperlUng
L --,-
!
- - ---
.. s" longitvcJ:nalllub.
Sw EO rnJ),g,Z H'G
~h,
HtH
., G r
s" ~~~a,r.
s"
s"
s"
~;'~Il~I~s..
Grtlll8r ol.5<Stt + ~
or.5{s" + Sy
Radial $(l8M at
boll drc18
-- h'o

4 Bolls
f4-- h G
G~

"",. 6Mo Figure 2~15. Dimensional data and rorces lor a sJip-on
"he - nd,) nange. flat face. full gasket.

... apt od from Ta y\Ol Forge 1~18mahof'lal. Int.• by pefmlulon

Figure IB--Type 5: Slip-On Flange, Flal Face, Full Gasket

Half-Pipe Jackels 7-25

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Flange Stresses Pressure Vessel Design and Analysis - Seminar Notes

TYPE 4: REVERSE FLANGE DESIGN

1 DESIGN CONOmONS

"-
Design pressu-e. P Allowable Str","
DesIgo tempetAlu,.
Flange mel,riaJ Design tomp., So, Design temp_. s.. """""
Bolting maloriill Aim. temp., Ss. AIm.lemp., S.
Corroalon alCM'anoe
2 OASKET AND FACING DETAILS
Ga~E'1 Facing

3 TABLES 2-3 AND 2·" 4 lOAD AND BOLT CALCULATIONS

..
N W,.z .. bl'6), A", .. grealef of
b H,. "" 2/nGmP WrdSa 01 W.,,!St.

,
G H .. OaT P/4
W.,.H... +H W-.l)(A,.,'tA.)S.
m

-
5 MOMENT CALCUl...ATtON$

""" • Lever Afm

OperllJng
- 01

Ho- .8 14 hI)" .5(C+g,-~-8J .... Hob,

Ho~W
Hr~H-IlD
.., H
I
ha ...5(C -
Illy - .5(C
0)
(8 i-O}f2) ,
I .....
M,- "" Hrllr
Add moment. Ilgabralcalty. "'on UN Ihe absolute voJue 1M,1 in ..1 subsequent caleU'aliorls.
....,ng '.... '
.... W ho" .5(C - 0) 1M;
6 K AND HUB FACTORS
K .. AlB'
T "'"
F
H, W ... G.
l
,
V
't-"':l. ,
~J". .,.
V
I"
•.
u

h, •
",
.n;g;
8 .. FIh"

d .. ~~1 'I
~B'"

v~ .. ORY UR - "AU c.
<rfl-
_111
W + ~-+lK1-·)1
rV
bI
L '-oJ+ H.
TA_l!...!:.!)...",T
~-'I --. . +--8.

7 STRESS fORMULA FACTORS , BoIlS

, a_ 11d
~A.

Q- _10+ 1 ). ... 7+6 FIgure 2·14. DimensIonal dala and forces for a (everse
,8.41'310 + 1 11\0" "VB' Nange.
't- afT" ""-MOm'
8
.... ~
• u... u_•
STRESS CALCULATIONS
Allow.bI. Str... , ...Ung
,us,..
... longiWdinll hb,
SIi" 1mJ).9,t

~-~' . ...
1.5s..,
~:~;~\AI.
Radial ftlflg!,
s... ...
~tr

....
~"al~,

..
iWlQ8ntillll fI{l.nge•
S, .. m.,y"p! - zs.. maY~ -
Sr .. zs..
(0.(1710" 1)'.8 (uno + 1lr'.8
a...IBf 01 ~8tl + t;i GI'lNll." oI.6(Stt + ~
Of SH+S, 01" ·5(SH +
~'lIialt~ iangenl\ell ~ngo
SI! rB')
Sr{".e') .. ~
-il'
Iv "'H"lj
(kt I~
~_ "'H"l! (l<.Z-I)).

Figure 19--Type 4: Reverse Flange Design

7-26 Half-Pipe Jackets

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 Pressure Vessel Design and Analysis - Seminar Noles Flange Stresses

Pressure Vessel Design and Analysis Seminar

Componenl Design Problem

Body flange for a heat exchanger - Weld neck type.

A body flange (SA350,LF2) has been designed with the following dimensions:

Flange inside diameter ~ 40.000 in. (1016 mm)

Flange outside diameter = 47.650 in. (1210 mm)
Flexitallic gasket, 40.5-in. (1029 mm)!D, 41.5-in. (1054 mm) OD, .5-in. (12.7
mm) ring
56 I-in. (25.4 mm) bolts on 45.5-in. (1156 mm) bolt circle
Bolt material is SA-193, B7
Shell thickness 0.750 in. (19 mm)
( Hub thickness 1.250 in.(32 mm)
Hub length 2.5000 in. (63.5 mm)
Flange thickness 3.500 in. (89 mm)
No corrosion allowance

Is this flange acceptable for conditions of 500 psi (3.45 N/mm 2) at 300°F (149°C).

Notes:

Questions:

What arc the m and y factors for the giveu gasket? _

What is the required thickness for the given conditions?

DO NOT TURN THE PAGE UNTIL YOU HAVE

COMPLETED YOUR ANALYSIS

Half-Pipe Jackets 7-27

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flange Slresses Pressure Vessel Design and Analysis - Seminar Notes

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar --------------------------------------- Page 39
Flange Analysis: EX-2 Channel F1 Item: 1 9:51a Sep 21,2000

Input Echo, Flange Item I, Description: EX-2 Channel F1

Description of Flange Geometry (Type) Integral Weld Neck

Description of Flange Analysis Analysis Only
Design Pressure P 500.00 psig
Design Temperature 300.00 F
Corrosion Allowance FCOR 0.0000 in.

Flange Inside Diameter B 40.0000 in.

Flange Outside Diameter A 47.6500 in.
Flange Thickness T 3.5000 in.
Thickness of Hub at Small End GO 0.7500 in.
Thickness of Hub at Large End G1 1. 2500 in.
Length of Hub HL 2.5000 in.
Perform thickness cales. based on rigidity No

Flange Material (Not Normalized) SA-350 LF2

Flange Allowable Stress At Temperature SFO 20000.00 psi
Flange Allowable Stress At Ambient SFA 20000.00 psi

Bolt Material SA-l93 B7

Bolt Allowable Stress At Temperature ssa 25000.00 psi
Bolt Allowable Stress At Ambient SBA 25000.00 psi

Diameter of Bolt Circle C 45.5000 in.

Nominal Bolt Diameter DB 1.0000 in.
Type of Threads TEMA Thread Series
Number of Bolts 56

Flange Face Outside Diameter FOD 42.5000 in.

Flange Face Inside Diameter FlO 40.0000 in.
Flange Facing Sketch I, Code sketch 1.

Gasket Outside Diameter GOD 41.5000 in.

Gasket Inside Diameter GID 40.5000 in.
Gasket Factor, m, M 3.0000
Gasket Design Seating Stress Y 10000.00 psi

Column for Gasket Seating 2, Code Column I I

FLANGE ANALYSIS, FLANGE NUMBER I, Description: EX-2 Channel Fl

ASME Code, Section VIII, Division 1, 1998, A-99

Corroded Flange lO, BCOR B+2.0*FCOR 40.000 in.

Corroded Large Hub, G1COR G1-FeaR 1.250 in.
Corroded Small Hub, GOCOR GO-FCOR 0.750 in.
Code R Dimension, R ({C-BCOR)/2.0)-G1COR 1.500 in.

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

Basic Gasket Width, BO N / 2.0 0.250 in.
Effective Gasket Width, BE BO 0.250 in.
Gasket Reaction Diameter, G (GOD+GID) / 2.0 41.000 in.

7-28 Half-Pipe Jackels

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 Pressure Vessel Design and Analysis. Seminar NoLes Flange Stresses

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar --------------------------------------- Page 40
Flange Analysis: EX-2 Channel F1 Item: 1 9:51a Sep 21,2000

BASIC FLANGE AND BOLT LOADS:

Hydrostatic End Load due to Pressure:
H 0.785 * G • G • PEQ
H; 0.7854 * 41.0000 * 41.0000 • 500.0000
H ;; 660127. lb.
Contact Load on Gasket Surfaces:
HP 2 * BE * PI • G • M PEQ +
HP ;; 2 • 0.2500 • 3.1416 * 41.0000 • 3.0000 * 500.00
HP;; 96604. lb.
Hydrostatic End Load at Flange ID:
HD 0.785 * Bear * Bear * PEQ
HD;; 0.785 * 40.0000 * 40.0000 * 500.0000
HD ;; 628319. lb.
Pressure Force on Flange Face:
HT H - HD
HT ;; 660127 - 628318
HT ;; 31809. lb.
Operating Bolt Load:
WM1 H + HP + HPP
WM1 ;; ( 660127 + 96603 + 0 )
WM1 ;; 756731. lb.
Gasket Seating Bolt Load:
WM2 y * (( BE * PI * G ) + (BEPG * GLPG)) + HPGY
WM2 10000.00*«(0.2500*3.141*41.000)+(0.00*0.0000))+0.00
WM2 322013. lb.
Required Bolt Area:
AM Maximum of WM1!ABSTR, WM2!ABASTR
AM Maximum of 756731 ! 25000 , 322013 ! 25000
AM 30.2692 in

Bolting Information for TBMA Thread Series:

Total Area of Bolts, AD 30.856 in
Minimum radial distance between hub and bolts 1.375 in.
Minimum radial distance between bolts and edge 1.063 in.
Minimum circumferential spacing between bolts 2.250' in.
Actual circumferential spac;:ing between bolts 2.551 in.
Maximum circumferential spacing between bolts 8.000 in.

( Min. Gasket Contact Width (Brownell Young):

Nmin AS * ABASTR!(GDSTR • PI • (GOD+GID)
30.856 * 25000.00!( 10000.00 * 3.14 ,. ( 41.50 + 40.50) )
Nmin 0.299 in.

Flange Design Bolt Load, Gasket Seating:

W ABASTR * ( AM + AB ) ! 2.0
W ; 25000.00 * ( 30.2692 + 30.8560 ) ! 2.0
W ;; 764065.56 lb.
Gasket Seating Force:
HG WM1 - H
HG 756731 - 660127
HG 96604.00 lb.

Half-Pipe Jackels 7-29

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Flange Stresses Pressure Vessel Design and Analysis - Seminar Notes

COADE Engineering Software

PVElite 4.00 Licensee; COADE Inc .. Local White Lock
FileName: Seminar --------------------------------------- Page 41
Flange Analysis: EX-2 Channel F1 Item: 1 9:51a Sep 21,2000

MOMENT ARM CALCULATIONS;

Distance to Gasket Load Reaction:
DHG (C-G)/2.0
DRG '" ( 45.5000 - 41.0000 ) /2.0
DHG = 2.2500 in.
Distance to Face Pressure Reaction:
DHT ( R + G1COR + DHG ) / 2.0
DHT = ( 1.5000 + 1.2500 + 2.2500 I I 2.0
DHT '" 2.5000 in.
Distance to End Pressure Reaction:
DRO R + ( G1COR / 2.0 )
DRO 1.5000 + ( 1.2500 / 2.0 )
DHD 2.1250 in.

SUMMARY OF MOMENTS FOR INTERNAL PRESSURE:

LOADING Force Distance Bolt Corr Moment (
End Pressure, MD 628319. 2.1250 1.0000 111265. ft.lb.
Face Pressure, MT 31809. 2.5000 1.0000 6627. ft. lb.
Gasket Load. MG 96604. 2.2500 1. 0000 18113. ft. lb.
Gasket Seating, MA 764066. 2.2500 1.0000 143262. fLIb.

TOTAL MOMENT FOR OPERATION, RMO 136005. ft.lb.

TOTAL MOMENT FOR GASKET SEATING, RMA 143262. ft.lb.

Effective Hub Length, HO SQRT(BCOR*GOCOR) 5.477 in.

Hub Ratio, HRAT HL / HO 0.456
Thickness Ratio, GRAT (GICOR/GOCOR) 1. 667

Flange Factors for Integral Flange:

Factor F per 2-7.2 0.846
Factor V per 2-7.3 0.287
Factor f per 2-7.6 1.000
Factors from Figure 2-7.1 K 1.191
T 1.842 U 12.295
y 11.188 2 5.772
d 131.819 in. "3 e 0.154 in. "'-1
Stress Factors ALPHA 1.541
BETA -L721 GAMMA 0.836
DELTA 0.325 LAMBDA 1.161

Longitudinal Hub Stress, Operating~

SHO ( f * RMO / BOOR ) / ( Rlambda * GlOOR"'2 )
SHO = { 1.0000 * 0.163E+07 / 40.0000 / ( 1.1615 * 1.2500"'2 )
SHO = 22482. psi
Longitudinal Hub Stress, Seating:
SHA ( f * RMA / BCOR ) / ( Rlambda * G1COR"'2 )
SHA = ( 1.0000 * 0.172E+07 /40.0000 ) / ( 1.1615 * 1.2500"'2 )
SRA = 23682. psi
Radial Flange Stress, Operating:
SRO (BETA * RMO / BeaR ) / ( Rlambda * TH"'2 )
SRO (1.7210 * a .163E+07 / 40.0000 ) / ( 1.1615 * 3.5000"'2 )
SRO 4935. psi

7-30 Half-Pipe lackets

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Pressure Vessel Design and Analysis - Seminar Noles Flange Stresses

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName : Seminar -~------------------------------------- Page 42
Flange Analysis: EX-2 Channel FI Item: I 9;51a Sep 21,2000

Radial Flange Stress, Seating:

SRA (BETA*RMA/BCOR) / ( Rlambda*TH~2 )
SRA "'- ( 1.7210 * 0.172E+07/ 40.0000 l / ( 1.1615 * 3.5000'"'2 )
SRA = 5199. psi
Tangential Flange Stress, Operating:
STO (Y·RMO I (TH*TH*BCOR) ) - Z*SRO
STO",- ( 11.1883 * 0.163E+07 / ( 3.5000'"'2 • 40.0000) ) - 5.7724 * 4935
STO "'- 8777. psi
Tangential Flange Stress, Seating:
STA (Y*RMA / (TH'"'2*SCORl) Z·SRA
STA = { 11.1883 " 0.I72E+07 / ( 3.5000'"'2 * 40.0000) ) - 5.7724 * 5198
STA "'- 9246. psi
Average Flange Stress, Operating:
SAO (SHO + MAX( SRO, STO ) ) / 2
SAO = ( 22482 + MAX ( 4935, 8777 ) / 2
SAO "'- 15630. psi
Average Flange Stress, Seating;
SAA (SHA + MAX( SRA, STA ) ) / 2
SM = ( 23681 + MAX ( 5198, 9245 ) l/ 2
SAA = 16464. psi
Bolt Stress, Operating:
SBO (WM1 / AS )
SSO "'- ( 756731 / 30.8560
SBO = 24525. psi
Bolt Stress, Seating:
SBA (WM2 / AB )
SBA {322013 / 30.8560
SSA 10436. psi

Stress Computation Results: OPERATING GASKET SEATING

Actual Allowed Actual Allowed
Longitudinal Hub 22482. 30000. 23682. 30000. psi
Radial Flange 4935. 20000. 5199. 20000. psi
Tangential Flange 8777. 20000. 9246. 20000. psi
Maximum Average 15630. 20000. 16464. 20000. psi
Bolting 24525. 25000. 10436. 25000. psi

Estimated M.A.W.P. ( Operating) 509.7 psig

Estimated M.A.W.P. {Gasket Seating 716.9 psig
Estimated Finished weight of Flange 612.8 lb.
Estimated Unfinished weight of Forging 894 c.2 lb.
APP. S Flange Rigidity Index for Seating Case 0._827
APP. S Flange Rigidity Index for Operating Case 0.785

The PV Elite Program, (c) 1989-2000 by COADE Engineering Software

H.lf-PipeJ.ckels 7-31

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Flange Stresses Pressure Vessel Design and Analysis - Seminar Noles

,
J

7-32 Half-Pipe Jackets

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 Pressure Vessel Design and Analysis - Seminar Notes Flange Slrcsses

Pressure Vessel Design and Analysis Seminar

Component Design Problem

Body flange for a heat exchanger - Ring Flange

Redesign the flange in pmblem I as a ring type flange.

Notes:

Questions:

Which flange is lighter?

Which flange is easier to fabricate?

DO NOT TURN THE PAGE UNTIL YOU HAVE

COMPLETED YOUR ANALYSIS

Half-Pipe Jackets 7-33

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Flange Stresses Pressure Vessel Design and Analysis - Seminar Noles

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar --------------------------------------- Page 43
Flange Analysis; EX-2 Channel Fl Item; 2 9:51a Sep 21,2000

Input Echo, Flange Item 2, Description: EX-2 Channel Fl

Description of Flange Geometry (Type) Loose Ring

Description of Flange Analysis Design, Geometry
Design Pressure P 500.00 psig
Design Temperature 300.00 F
Corrosion Allowance FCOR 0.0000 in.

Flange Inside Diameter B 41.5000 in.

Perform thickness calcs. based on rigidity No

Flange Material (Not Normalized) SA-350 LF2

Flange Allowable Stress At Temperature SFO 20000.00 psi
Flange Allowable Stress At Ambient SFA 20000.00 psi

Bolt Material SA-I93 87

Bolt Allowable Stress At Temperature SBO 25000.00 psi
Bolt Allowable Stress At Ambient SBA 25000.00 psi

Length of Weld Leg at Back of Ring WLEG 0.3750 in.

Number of splits in Ring Flange NSPLT o
Type of Threads TEMA Thread Series

Flange Face Outside Diameter FOD 44.0000 in.

Flange Face Inside Diameter FID 41.5000 in.
Flange Facing Sketch I, Code Sketch la

Gasket Outside Diameter GOD 43.0000 in.

Gasket Inside Diameter GID 42.0000 in.
Gasket Factor, ro, M 3.0000
·Gasket Design Seating Stress Y 10000.00 psi

Column for Gasket Seating 2, Code Column II

Geometry Selection for Flange Design Option:

Number of Bolts Selected for Flange 36
Diameter of Bolts Selected for Flange 1.2500 in.
Bolt Circle Diameter Selected for Flange 45.7500 in.
Outside Diameter Selected for Flange 4B.2500 in.
Initial Thickness Given for Flange 5.0000 in.

FLANGE ANALYSIS, FLANGE NUMBER 2, Description: EX-2 Channel Fl

ASME Code, Section VIII, Division 1, 199B, A-99

Corroded Flange ID, BCOR B+2.0~FCOR 41.500 in.

Corroded Large Hub, GlCOR Gl-FCOR 0.000 in.
Corroded Small Hub, GOCOR GO-FCOR 0.000 in.
Code R Dimension, R ((C-BCOR)/2.0)-GICOR 2.125 in.

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

Basic Gasket Width, BO N / 2.0 0.250 in.
Effective Gasket Width, BE BO 0.250 in.

7-34 Half-Pipe Jackets

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 Pressure Vessel Design and Analysis - Seminar Noles Flange Siresses

COADE_Engineering Software
PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar --------------------------------------- Page 44
Flange Analysis: EX-2 Channel Fl Item: 2 9:51a Sep 21,2000

Gasket Reaction Diameter, G = (GOD~GID) / 2.0 42.500 in.

BASIC FLANGE AND BOLT LOADS:

Hydrostatic End Load due to Pressure:
H 0.785" G ,., G ,., PRQ
H = 0.7854 ., 42.5000 ., 42.5000 * 500.0000
H = 709313. lb.
Contact Load on Gasket Surfaces:
HP 2" BE * PI * G * M * PRQ ~
HP = 2 ,., 0.2500 * 3.1416 * 42.5000 ., 3.0000 * 500.00
HP = 100138. lb.
Hydrostatic End Load at Flange ID:
HD 0.785 * Bear * Bear * PEQ
HD = 0.785 ., 41.5000 ., 41.5000 * 500.0000
HD = 676326. lb.
Pressure Force on Flange Face:
HT H - HD
HT = 709312 - 676326
\ HT = 32987. lb.
Operating Bolt Load:
WM1 H ~ HP + HPP
WM1 = ( 709312 ~ 100138 + 0 )
WM1 = 809451. lb.
Gasket Seating Bolt Load:
WM2 y * «( BE * PI * G ) + (BEPG ., GLPG») ~ HPGY
WM2 10000.00*(0.2500*3.141o,42.500)+(0.00*0.0000)~0.00
WM2 333794. lb.
Required Bolt Area:
AM Maximum of WM1/ABSTR, WM2/ABASTR
AM Maximum of 809451 / 25000 , 333794 / 25000
AM 32.3780 in

Bolting Information for TEMA Thread Series:

Total Area of Bolts, AS 33.444 in
Minimum radial distance between hub and bolts 1. 750 in.
Minimum radial distance between bolts and edge 1.250 in.
Minimum circumferential spacing between bolts 2.813 in.
Actual circumferential spacing between bolts 3.987 in.
Maximum circumferential spacing between bolts 11. 229 in.
Distance Across Corners for Nuts 2.209 in.
Circular Wrench End Diameter a 3.250 in.

Min. Gasket Contact Width (Brownell Young) :

( Nmin AS * ASASTR/(GDSTR • PI * (GOD~GID)
33.444 * 25000.00/( 10000.00 * 3.14 * ( 43.00 ~ 42.00) )
Nmin 0.313 in.

Flange Design Bolt Load, Gasket Seating:

W ABASTR * ( AM + AB ) / 2.0
W = 25000.00 ., ( 32:3780 + 33.4440 ) / 2.0
W = 822775.50 lb.
Gasket Seating Force:

Half-Pipe Jackels 7-35

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Flange Stresses Pressure Vessel Design and Analysis - Seminar Noles

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar --------------------------------------- Page 45
Flange Analysis : EX-2 Channel FI Item: 2 9:51a Sep 21,2000

HG WMl - H
HG 809451 - 709312
HG 100138.25 lb.

MOMENT ARM CALCULATIONS;

Distance to Gasket Load Reaction:
DBG (C - G ) I 2.0
ORG ~ ( 45.7500 - 42.5000 ) I 2.0
OHG ; 1.6250 in.
Distance to Face Pressure Reaction:
DHT (DRD + DHG ) I 2.0
DRT ~ ( 2.1250 + 1.6250 l I 2.0
DHT = 1.8750 in.
Distance to End Pressure Reaction:
DRD (C - BCOR )/ 2.0
DRO (45.7500 - 41.5000 ) /2.0
DRO 2.1250 in.

SUMMARY OF MOMENTS FOR INTERNAL PRESSURE:

LOADING Force Distance Bolt Corr Moment
End Pressure, MD 676326. 2.1250 1.0000 119766. ft. lb.
Face Pressure, MT 32987. 1. 8750 1.0000 5154. it .lb.
Gasket Load, MG 100138. 1.6250 1.0000 13560. ft .lb.
Gasket Seating, MA 822775. 1.6250 1.0000 111418. it.lb.

TOTAL MOMENT FOR OPERATION, RNO 138481. it.lb.

TOTAL MOMENT FOR GASKET SEATING, RMA 111418. ft.lb.

Effective Hub Length, HO 0.000 in.

Hub Ratio, HRAT Defined as 0.0 0.000
Thickness Ratio, GRAT Defined as 0.0 0.000
Factors from Figure 2-7.1 K 1.163
T := 1.854 U 14.231
Y := 12.950 Z 6.686
Tangential Flange Stress, Operating;
STO (Y*RMO / (TH*TH+BCOR) ) - Z+SRO
STO = ( 12.9500 * 0.166E+07 / ( 5.0919~2 + 41.5000) ) - 6.6B58 + 0
STO = 20000. psi
Tangential Flange Stress, Seating:
STA (Y+RMA / (TH~2+BCOR») Z+SRA
STA:= (12.9500 + 0.134E+07 / (5.0919"-2 + 41.5000) ) - 6.6858'" 0
STA = 16091. psi
Bolt Stress, Operating:
SBO (WM1 / AB )
SRO = ( 809451 / 33.4440
SBO := 24203. psi
Bolt Stress, Seating~
SBA (WM2 / AB )
SBA (333794 / 33.4440
SEA 9981. ps~

Stress Computation Results: OPERATING GASKET SEATING

Actual Allowed Actual Allowed

7-36 Half-Pipe Jackels

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 Pressure Vessel Design and Analysis - Seminar Noles Flange Stresses

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar --------------------------------------- Page 46
Flange Analysis: EX-2 Channel FI Item: 2 9:51a Sep 21,2000

Tangential Flange 20000. 20000. 16091. 20000. psi

Bolting 24203. 25000. 9981. 25000. psi

Minimum Required Flange Thickness 5.092 in.

Estimated M.A.W.P. ( Operating) 500.0 psig

Estimated M.A.W.P. ( Gasket Seating 7-46.9 psig
Estimated Finished Weight of Flange 685.6 lb.
Estimated Unfinished Weight of Forging 1022.3 lb.
APP. S Flange Rigidity Index for Seating Case 1. 268
APP. S Flange Rigidity Index for Operating Case 1.575

The PV Elite Program, (c) 1989-2000 by CQADE Engineering Software

Half-Pipe Jackets 7-37

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Blind Flanges and Channel Covers Pressure Vessel Design and Analysis - Seminar Noles

BLIND FLANGES AND CHANNEL COVERS

Blind flange design is a mixture of the flange analysis we have just been studying and the
flat head design we reviewed previously.
The ASME Code formula for a circular blind flange is

I ~ "JCP/SE+ 1.9Wh/SEd'

The first term in this formula is the bending of a flat plate under pressure.
The second term is the bending of the plate due to an edge moment.
The stress is limited to 1.5 times the allowable stress, but the 1.5 factor is already built
into the equation, as with welded flat plates.
For bolt-up conditions the first term is zero-the thickness of the flange depends only
on the edge bending.
For non-circular blind flanges the formula is modified as follows:

(~ "JZCP/SE+6Wh/SELd'

Where Zis the samc nou-circularity factor used in welded flat plates, and the factor 1.9/d
has been replaced by 6/L. L is the perimeter of the non-circular head, measured through
the centers of the bolt holes. Notice, therefore, that for a circular head, d is equal to LI
3.14159, as you would expect.
It is interesting to note that the Code coverS non-circular blind flanges, but no other type of
non-circular flange (not even in the rectangular vessel appendix).
Chaunel Covers designed to TEMA must meet at least the minimum thickness require-
ments of the Code. In addition, if there is a pass partition groove, the cover deflection is
limited.
The formula for flange deflection limitation is found in paragraph 9.21 ofTEMA:

y ~ E~(O.0435G3p+0.5SeABhg)

The deflection is, of course, a function of (J and GJ. Thus, a very small increase in flange
thickness will decrease the deflection significantly.
One implication of using the TEMA formula to check a channel cover is that when the (
program selects thickness based on TEMA, the stresses in the channel cover may be Jess
than the Code allowable. The following graph shows how the required thickness of a
channel cover varies with pressure for both the TEMA and ASME requirements. Notice

7-38 Half-Pipe Jackets

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 Pressure Vessel Design and Analysis - Seminar Notes Blind Flanges <Iud Channel Covers

thai the required thickness for TEMA can be higher than AS ME for some pressures, and
lower for others (because ASME is a function of d', and TEMA a function of </3).

Cha.nnel Cover Thickness

lou. y,. J&,I£
u

"
j
",
,.
~ ,.
,..
J "
,"..
,..
"
,~ ,~ '00
D<>lt., P,......

Figure 20--Channel Cover Thickness

Note The Seventh Edition ofTEMA also gives recommended deflection as a function
of flange size. The previous editions hid the actual deflection you were working
toward in a thickness equation.

Half-Pipe Jackels

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Blind Flanges and Channel Covers Pressure Vessel Design and An<llysis - Seminar Noles

7-40 Half-Pipe Jackels

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 Pressure Vessel Design and Analysis - Seminar Noles Blind Flanges and Chmlllci Covers

Pressure Vessel Design and Analysis Seminar

Component Design Problem

Channel Cover Design

Analyze a channel cover 10 mate wilh Ihe flange designed in Ihe previous examples.

Geomelry for Ihe channel cover should be as follows;

Thickness ~ 5.0 in. (127 mm)

Outside Diameter ~ 47.375 in. (1203.3 mm)
Diameter of Bolt Circle ~ 45.125 (1146.17)
48 1.125-in. (28.5750) diameter bolts
Flange Face 10 ~ 41.5 in. (1054.1 mm)
Flange Face OD ~ 44.0 in. 1117.6 mm)
( Gasket 10 = 42.0 in. (1066.8)
Gaskel OD ~ 43.0 in. (1092.2)
Flexitalic Gasket (m~3.000, y=IOOOO.O) (68.94 N/mm2 )

Notes;

Questions;

Whal is the required thickness of the flange?

Why arc the slresses less than the allowable slresses at the required thickness?

DO NOT TURN THE PAGE UNTIL YOU HAVE

COMPLETED YOUR ANALYSIS

Half-Pipe lackets 7-41

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Blind Flanges and Channel Covers Pressure Vessel Design and Analysis - Seminar Noles

COADE Engineering Software

PVElite 4.00 -Licensee: COADE Inc., Local White Lock
FileName: Seminar --------------------------------------- Page 47
Flange Analysis: EX-2 ChannelCV Item: 3 9:51a Sep 21,2000

Input Echo, Flange Item 3, Description: EX-2 Channel cv

Description of Flange Geometry (Type) TEMA Channel Cover

Description of Flange Analysis Analysis Only
Design Pressure p 500.00 psig
Design Temperature 300.00 p
Corrosion Allowance FeOR 0.0000 in.

Flange Inside Diameter B 0.0000 in.

Flange Outside Diameter A 47.3750 in.
Flange Thickness T 5.0000 in.
Perform thickness cales. based on rigidity No

Flange Material (Not Normalized) SA-350 LF2

Flange Allowable Stress At Temperature SFO 20000.00 psi
Flange Allowable Stress At Ambient SFA 20000.00 psi

Bolt Material SA-193 B7

Bolt Allowable Stress At Temperature SBO 25000.00 psi
Bolt Allowable Stress At Ambient SBA 25000.00 psi

Diameter of the Load Reaction, Long Span DL 47.3750 in.

Diameter of the Load Reaction, short Span OS 47.3750 in.
Perimeter along the Center of the Bolts L 141.7644 in.
Youngs Modulus for Blind Flange MatI. YMOD 28500000.00 psi
Allowed Channel Cover Deflection CVDLT 0.0300 in.

Diameter of Bolt Circle C 45.1250 in.

Nominal Bolt Diameter DB 1.2500 in.
Type of Threads TEMA Thread Series
Number of Bolts
••
Flange Face Outside Diameter FOD 44.0000 in.
Flange Face Inside Diameter FID 41.5000 in.
Flange Facing Sketch 1, Code Sketch la

Gasket Outside Diameter GOD 43.0000 in.

Gasket Inside Diameter GID 42.0000 in.
Gasket Factor, m, M 3.0000
Gasket Design Seating Stress Y 10000.00 psi

Colunm for Gasket Seating 2. Code Colunm I I

FLANGE ANALYSIS, FLANGE NUMBER 3, Description: EX-2 Channel CV

ASME Code, Section VIII, Division 1, 1998, A-99

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

Basic Gasket Width, BO N / 2.0 0.250 in.
Effective Gasket Width, BE BO 0.250 in.
Gasket Reaction Diameter, G (GOD+GIDl / 2.0 42.500 in.

7-42 Half-Pipe Jackels

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 Prcssure Vessel Design and Analysis - Seminar Noles Blind Flanges and Channcl Covers

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName : Seminar --------------------------------------- Page 48
Flange Analysis: EX-2 Channel CV Item; 3 9:51a Sep :n,2000

BASIC FLANGE AND BOLT LOADS:

Hydrostatic End Load due to Pressure:
H 0.785 * G ... G ... PEQ
H ~ 0.7854 * 42.5000 ... 42.5000 * 500.0000
H = 709313. lb.
Contact Load on Gasket Surfaces:
HP 2 * BE * PI ... G ... M * PEQ +
HP = 2 * 0.2500 ... 3.1416 * 42.5000 ... 3.0000 * 500.00
HP ~ 100138. lb.
Hydrostatic End Load at Flange ID:
liD 0.3*G*G*PEQ
liD ~ 0.3 • 42.5000 * 42.5000 • 500.0000
liD ~ 270937. lb.
Pressure Force on Flange Face:
HT 0.0 For Blind Flanges
HT = 0.0 For Blind Flanges
HT=O.lb.
Operating Bolt Load:
( WM1 H + HP + HPP
WM1 ~ ( 709312 + 100138 + 0 )
WM1 = 809451. lb.
Gasket Seating Bolt Load:
WM2 Y'" «( BE ... PI * G ) + (BEPG * GLPG)) + HPGY
WM2 10000.00*(0.2500*3.141*42.500)+(0.00*0.0000))+0.00
WM2 333794. lb.
Required Bolt Area:
AM Maximum of WM1/ABSTR, WM2/ABASTR
AM Maximum of 809451 / 25000 , 333794 / 25000
AM 32.3780 in

Bolting Information for TEMA Thread Series:

Total Area of Bolts, AS 44.592 in
Minimum radial distance between hub and bolts 1.750 in.
Minimum radial distance between bolts and edge 1.250 in.
Minimum circumferential spacing between bolts 2.813 in.
Actual circumferential spacing between bolts 2.951 in.
Maximum circumferential spacing between bolts 11: 071 in.

Min. Gasket Contact Width (Brownell Young):

Nmin A8 * ABASTR/fGDSTR * PI * (GOD+GID)
44.592 * 25000.00/( 10000.00 * 3.14 ( 43.00 + 42.00) )
Nmin 0.417 in.

(
Flange Design Bolt Load, Gasket Seating:
W ABASTR * (AM. + AS ) / '.0
W = 25000.00 ... ( 32.3780 + 44. 5920 ) / 2.0
W = 962125.56 lb.
Gasket Seating Force:
HG WMl
HG 809451
HG 809451. 00 lb.

Half-Pipe Jackels 7-43

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Blind Flanges and Channel Covers Pressure Vessel Design and Analysis - Seminar Noles

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar --------------------------------------- Page 49
Flange Analysis: EX-2 Channel CV Item: 3 9:51a Sep 21,2000

MOMENT ARM CALCULATIONS;

Distance to Gasket Load Reaction:
DHG (C - G ) I 2.0
DHG ~ ( 45.1250 - 42.5000 ) / 2.0
DHG = 1.3125 in.
Distance to Face Pressure Reaction:
DHT 0.0 for blind flange
DHT = 0.0 for blind flange
DHT = 0.0000 in.
Distance to End Pressure Reaction:
DHD G/4.0
DHD 42.5000 / 4.0
DHD 10.6250 in.

SUMMARY OF MOMENTS FOR INTERNAL PRESSURE:

LOADING Force Distance Bolt Carr Moment
End Pressure, MD 270937. 10.6250 1.0000 239893. ft.lb.
Face Pressure, MT 0. 0.0000 1.0000 0. ft.lb.
Gasket Load, MG 809451. 1. 3125 1. 0000 88534. ft.lb. (
Gasket Seating, MA 962126. 1. 3125 1.0000 105232. ft.lb.

TOTAL MOMENT FOR OPERATION, RMO 328426. ft.lb.

TOTAL MOMENT FOR GASKET SEATING, RMA 105232. ft .lb.

Tangential Flange Stress, Flat Head, Operating:

.o. .o.
1.9 to WMl"'DHGtoBCORR/(TH 2 to G) + CtozRAT*PEQtoG 2/(TH 2)
A
STO
STO 1.9 to 809451 * 1.3125 * 1.0000/( 5.0000.0. 2 to 42.5000 ) +
0.30 * 1.0000 to 500.00 * 42.5000"'2 )/( 5.0000.0. 2 )
STO 12737. psi
Tangential Flange Stress, Flat Head, Seating:
.o.
STA 1.9*W to DHG*BCORR/(TH 2 to G» + 0
STA .. 1.9 * 962125 * 1.3125 * 1.0000 /( 5.0000 2 * 42.5000 ) + 0
A

STA : 2258. psi

Bolt Stress, Operating:
sao (WM1/AB)
SBO = ( 809451 / 44.5920
SBO = 18152. psi
Bolt Stress, Seating:
SSA (WM2/AB)
SSA (33)794 / 44.5920
SSA 7486. psi

Stress Computation Results: OPERATING GASKET SEATING

Actual Allowed Actual Allowed
Tangential Flange 12737. 20000. 2258. 20000. psi
Bolting 18152. 25000. 7486. 25000. psi

TEMA Channel Cover Deflection Calculations:

Actual deflection at center per TEMA formula 0.0286 in.
Allowed deflection at center of Cover 0.0300 in.

Estimated M.A.W.P. ( Operating) 534.0 psig

7-44 Half-Pipe Jaekels

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 Pressure Vessel Design and Analysis - Seminar Noles Blind Flanges and Channel Covers

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName : Seminar -----------------------------~--------- Page 50
Flange Analysis: EX-2 Channel CV Item: 3 9:51a Sep 21,2000

Estimated M.A.W.P. (Gasket Seating 3281.1 psig

Estimated Finished weight of Flange 2494 .3 lb.
Estimated Unfinished Weight of Forging 2494.3 lb.

The PV Elite Program, (el 1989-2000 by COADE Engineering Software

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 Large Cenlral Openings Pressure Vessel Design and Analysis - Seminar NoLes

LARGE CENTRAL OPENINGS

.'
Some flat heads have large nozzle openings. A special modification ofthc flange rules is
providcd in Appendix 14 in order to analyze the stresscs in thesc hcads. The opening in the
head may have a nozzle or may be a simple hole, as shown:
14-3 1998 SECTION VIII - DMSION I 14-'

Tl'li' haU depiell Thll"_IfdvpielS

opMlng wilh noule. "'9'0 loon leI op!oingwilhoul noule.

9 0 hheUI 1 . - - - - - - - - . , -1----- --1

1+--1------ A----jf--------++J

Figure 21--lntegral Flat Head with Large Cenlral Opening

Notice that these rules apply only to an integral head. A flat head with a large nozzle in it
may be analyzed using the normal rules for flat heads and nozzles. Only when the flat
head is welded or otherwise integral to the shell do these rules apply.
The design procedure begins with the calculation of the normal bending moments for a
flanged connection, taking the point of bending to be not the gasket, but the inside diame-
ter of the vessel wall.
The next step is to calculate the slresses at this point (the OD of the head). These are used
to calculate an equivalent moment and geometry for the head with the large opening. (The
equivalent moment is M JI" the equivalent geometry is expressed by (Eg)' andXj ).
The equivalent geometry and loading are used to calculate the stresses at the Head/Shell
Juncture and at the Opening/Head Juncture. In each case longitudinal, radial, and tangen-
tial stresses are calculated. These stresses are then compared to the standard ASME Code
allowables from Appendix 2-8.

7-46 Half-Pipe JackeLs

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 Pressure Vessel Design and Analysis - Seminar Notes Large Central Openings

Pressure Vessel Design and Analysis Seminar

Component Desigll Problem

Large Central Circular Opening.

A flat head designed for 75 psi. (5 I 7N/mm 2) internal pressure at 500°F (260°C) has a 12-
in. (305 mOl) centrally located nozzle. Determine the stresses for the head and the nozzle
openillg. The following additional data is available:

Corrosion Allowance ~ 0.0625 in. (1.6 mm)

Flat head thickness = 1.0 ill. (25.4 mm)

Flat head outside diameter ~ 20.0 in. (508 mm)

SheH thickness ~ 0.25 in. (6.35 mOl)

( Shell hub thickness, large end ~ 0.5 in. (12.7 mOl)
Shell hub length = 3.0 ill. (76.2 mOl)

Flange and nozzle are both SAI06 B.

Nozzle hub thickness (wall thickness) at small end ~ 0.25 in. (6.35 mm)
Nozzle hub thickness at large end ~ 0.6 in. (15.24 mm)
Nozzle hub length = 2.8 in. (71.12 mm)

Notes:

Questions:
( What is the longitudinal stress in the head at the shell?

What is the longitudinal stress in the head at the nozzle?

DO NOT TURN THE PAGE UNTIL YOU HAVE

COMPLETED YOUR ANALYSIS

Half-Pipe Jackels 7-47

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Large Cenlral Openings Pressure Vessel Design and Analysis - Seminar Notes

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName ; Seminar --------------------------------------- Page 105
Lgcenter Analysis: HAND CHECK Item: 1 9:51a Sep 21,2000

Input Echo, Large Opening Item 1, Description: HAND CHECK

Design Temperature TEMP 500.00 F

Design Pressure P 75.00 psig
Integral Flat Head Thickness T 1.0000 in.

Opening Inside Diameter B 12.0000 in.

Flat Head Outside Diameter A 20.0000 in.

Shell Side Hub Thickness, Small End SGO 0.2500 in.

Shell Side Hub Thickness, Large, End SGl 0.5000 in.
Shell Side Hub Length 3.0000 in.
Corrosion Allowance FCOR 0.0625 in.

Flange and Nozzle Material SA-I06 B

Allowable Stress at Design Temperature SFO 17100.00 psi
Allowable stress at Ambient Temperature SPA 17100.00 psi

Nozzle Side Hub Thickness, Small End NGO 0.2500 in.

Nozzle Side Hub Thickness, Large End NGl 0.6000 in.
Nozzle Side Hub Length NHL 2.8000 in.

ASME VIII App. 1. A-99 FLANGE RESULTS 1, Desc.; HAND CHECK

Diameter of the Load Reaction G ~ C per App. 14

G FLGOD - 2.0 * SGI + 2.0 * FCOR
G ~ 20.0000 - 2.0 * 0.2500 + 2.0 * 0.0625
G ~ 19.6250 in.
The Flange K Factor
K Flange 00 / Flange ID
K = 20.0000 ! 12.1250
K ~ 1.6495
The Flange Radial Distance Dimension R
R 0.5 * ( G - FLGCID ) - ( SG1 - FCOR )
R ~ 0.5 * ( 19.6250 - 12.1250 ) - ( 0.5000 - 0.0625 )
R ~ 3.3125 in.
The Hydrostatic End Force Hd
Hd PI/4. Flange 10 A 2 ,., P
Hd = PI/4 * 12.1250 A 2 * 75.0000
Hd = 8659.9355 lb.
The Moment Md
Md HD * ( R + 0.5 * ( SGI - FCOR ) )
Md '" 8659.94 * ( 3.3125 + 0.5 * ( 0.5000 - 0.0625 ) )
Md '" 2548.3665 ft.lb.
The Total Hydrostatic End Force H
A
H PI!4 * G 2 * P
H", PI/4 * 19.6250 A 2 * 75.0000
H '" 22686.6562 lb.
The Differential End Force Ht
Ht H - Hd
Ht 22686.66 - 8659.94
Ht 14026.7207 lb.

7-48 Half-Pipe Jackels

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 Pressure Vessel Design tlod Analysis - Seminar Noles Large Cenlral Openings

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar ~-------------------------------------- Page 106
Lgcenter Analysis; HAND CHECK Item; 1 9:51a Sep 21,2000

The Moment Mt
Mt 0.5 ~ Ht * ( R + SGI )
Mt = 0.5 * 14026.72 * ( 3.3125 + ( 0.5000 - 0.0625 ) )
Mt = 2191.6750 it.lb.
The Total Moment Mo
Mo Md -t Mt
Mo 2548.37 + 2191.68
Mo 4740.0415 it.lb.

Flange Factors ( Opening

Factors from Figure 2-7.1 K 1.649

T 1.647 U 4.455
Y 4.054 Z 2.162

( Effective Hub Length, 110 SQRT(S*GZERO) 1.508 in.

Hub Ratio, BRAT HBLNG / HO 1.857
Thickness Ratio, GRAT (GONE/GZERO) 2.867

Flange Factors for Integral Flange;

Factor F per 2-7.2 0.604
Factor V per 2-7.3 0.058
Factor f per 2-7.6 1.000
A
d 4.067 in. 3 A e 0.400 in. _l
Stress Factors ALPHA 1.375
BETA 1. 501 GAMMA 0.835
DELTA 0.203 LAMBDA 1.038

Longitudinal Hub Stress, Operating:

A
SH~ ( F . RMO / B ) / ( RLAMBDA • GONE 2 )
A
SHy ~ ( 1.0000 ~ 56880 / 12.1250 ) / ( 1.0379 • 0.4375 2 )
SHy = 23613. psi
Radial Flange Stress, operating:
A
SR. (BETA * RMO / B ) / ( RLAMBDA • TH 2 )
SR. ~ ( 1.5006 * 56880 / 12.1250 ) /
A
1.0379· 0.9375 2 ')
SR~ = 7716. psi
Tangential Flange Stress, Operating:
( ST* (Y.RMO / TH*TH*B ) - Z·SRO
STy (4.0541.56880/ 0.9375 A 2 ~·12.1250 ) - 2.1623 • 7716
ST~ 4954. psi

The Value for E Theta Star ( Integral Nozzle )

Et* 0.91. (NGl/NGOI A 2·Bl*V*Sh*/{f*ho)
Et* 0.91*{ 0.538 / 0.188 )A2 ~ 12.312 * 0.058 * 23613/( 1.000 * 1.508)
Et* 83723.1953 psi

Flange Factors ( Shell ) :

Effective Hub Length, 110 SQRT(B*GZERO) 1.936 in.

Hub Ratio, IlRAT HBLNG / HO 1.549
Thickness Ratio, GRAT (GONE/GZERO) 2.333

Half-Pipe Jackels 7-49

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Large Central Openings Pressure Vessel Design and Analysis - Seminar Notes

COADE Engineering Software

PVElite 4.00 Licensee; COADE Inc .. Local White Lock
FileName : Seminar --------------------------------------- Page 107
Lgcenter Analysis HAND CHECK Item; 1 9:51a Sep 21,2000

Flange Factors for Integral Flange:

Factor F per 2-7.2 0.663
Factor V per 2-7.3 0.095
Factor f per 2-7.6 1.000
e • 0.343 in .... -1

Moment Acting at the Shell to Plat Head Juncture

Mh Et*/C(1.74*ho*V/(SGO"'3*B1»+Et*/Mo*(1+Pt/ho»)
Mh 83723 /[{1.74 * 1.9365 * 0.0947 /( 0.1875"'3 * 19.9375 »+ 83723 /
56880 * ( 1 + 0.6633 * 0.9375 / 1.9365 )
Mh 1595.8574 ft.lb.

The Xl Factor
Xl (Mo - Mh ( 1 + Ft/ho ) ) / Mo
Xl (56880 - 19150 ( 1 + 0.6633 * 0.9375 I 1.9365 ) ) / 56880
Xl 0.5552
(
Stress Results for the Head/Shell Juncture

Longitudinal Hub Stress in the Shell :

Shs (Xl) (E*) (l.lO*ho*fj / ((gl/g0) "'2*Bs*V)
Shs (0.56){ 83723) (1.10 * 1.936 * 1.0001/(( 5.444)"'2 * 19.62) 0.095)
shs 9788.3799 in.

Radial Stress at the Outside Diameter ;

A
srs 1.91*Mh(1+F*t/ho)/(Bs*t 2) + 0.64*F*Mh/{Bs*ho*t)
1.91 * 1595{ 1 + 0.663 * 0.938 I 1.936 1/( 19.625 * 0.879 2 ) +
A
Srs
0.64 * 0.663* 1595/( 19.625 * 1.936 * 0.938 )
Srs ~ 3029.7085 psi

Tangential Stress at the Outside Diameter :

A
Sts X1*Etheta**t/Bs - .57 {1+P*t/ho)Mhl (Bs*t 2) + .64*P*Z*Mh/(Bs*ho*t)
Sts = 0.555 * 83723.195* 0.938 / 19.625 -
.57( 1 + 0.663 * 0.938 / 1.936) 1595 /( 19.625 * 0.8789"'2 ) +
.64 * 0.663 * 2.162 * 1595 I( 19.625 * 1.936 * 0.938 )
Sts = 1877.8865 psi

where Z = (K"'2+1)/(K A 2-1) = ( 2.721 + 1 )/( 2.721 - 1 ) 2.162

Stress Results for the Opening Head Juncture

Longitudinal Hub Stress in Central Opening :

sho = Xl * Sh* = ( 0.555 * 23613.205 ) = 13110.363 psi

Radial Stress at Central Opening

Sro = Xl * Sr* = ( 0.555 * 7716.479 ) = 4284.292 psi

Tangential Stress at Diameter of Central Opening

Sto X1*St* + .64*P*Zl*Mh/(Bs*ho*tl
Sto 0.555 * 4953.979 +
.64 * 0.6633 * 3.162 * 1595 I ( 19.625 * 1.936 * 0.938 )
Sto 3472.0491 psi

7-50 Half-Pipe lackets

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 Pressure Vessel Design and Analysis - Seminar Noles Large Central Openings

CQADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar --------------------------------------- Page 108
Lgcenter Analysis: HAND ~HECK Item: 1 9:51a Sep 21,2000

where Zl = 2*K~2/(KA2-1) = (2* 2.721 + 1/12.721 - 1 = 3.162

Flange Stress Results per Appendix 14

Head/Shell Allowed Opening Allowed
Long. Hub 9788 25650 13110 25650 psi
Radial 3029 17100 4284 17100 psi
Tangential 1877 17100 3472 17100 psi

M.A.W.P. for the given Geometry 146.735 psig

Estimated Finished Weight of Forging 69.3 lb.
Approximate Minimum Flange Thickness 0.5444 in.

The PV Elite Program, (c) 1989-2000 by CQADE Engineering Software

Half-Pipe Jackets 7-51

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Large Central Openings Pressure Vessel Design ilnd Analysis - Seminar Notes

7-52 Half-Pipe Jackels

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Pressure Vessel Design <llld Analysis - Seminar Noles

Chapter 8:
Floating Heads and
Spherically Dished Covers

Floating hcads and spherically dished covers are discussed in Appendix 1-6.

TYPES OF SPHERICALLY DISHED COVERS

There arc four types of spherically dishcd covers:
Type A covers are evaluated using nomlal head rules. Only the other three rcquire spe-
cial analysis.
The Type B head has a thin spherical section extended across the flange face, with a
flange ring behind the plate.
Type C heads arc made from a single piccc of steel the thicknesses of the flange with
the centcr portion dished.
Type D heads, very commonly used as floating heads for heat exchangers, consist of a
flange ring with the spherical cap welded to the inside of the ring. Type D heads are
the most intcresting, because of the inward reaction of the head to internal pressure
(and outward to external pressure, sincc these are usually found inside heat exchang-
ers).
An additional analysis techniquc, called Soehren's calculation, takes into account the rota-
tion of the flange and head at thc attachment point. This calculation may be used as a
design basis.

DESCRIPTION
Thcse heads always have a flange, which must be designed using modified flange rules,
and frequently a backing ring which is designed as a ring flange .
.Backing rings usually have slightly larger diameters than the flange ring. The backing ring
may be a split ring. If the ring has one split, then it has been split along a diameter, into
two pieces. The bending moment on the ring is multiplied by 2.0 for this case. A ring with
two splits has been sliced in half like a bagel, and then each half has been split along a
diameter. The ring is assembled with the diametral splits offset by 90 degrees. For this
case, enter the thickncss of one half of the original ring, since cach half is required to sup-
port 75 percent of the original design momcnt.
The attachment point of the head to the flange is measured by two diffcrent values.
Q is the distance from the bolting face of the flange to the intcrsection of the head
inside diamctcr and the flange. This dimension is uscd in Soehren's calculation.
HR is lhe distance from the flangc ccntroid to the intcrscction of the head centerline
and the flange. HR is positive if it is above the flange centroid, and negative if it is
below thc flange centroid. HR is used in the Code calculation.

Floating Heads and Spherically Dished Covers 8-t

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Example Pressure Vessel Design and Analysis - Seminar Notes

A slolled flange hns bolt holes that extend radinlly to the onter edge of the flange. Slotted
flanges are allowed by the Code for floating heads.
A full face gasket extends from the 10 of the flange 10 the OD, enclosing the bolt holes.
These gaskets are nsually soft malerials such as rubber or nn elastomer, so that the bolt
stresses do not go too high during gasket seating. The Code takes into account the use of
full face gaskets for floating heads.
The tubeside pressure is internal to the flange, creating a typical flange bending moment,
to which is added the moment caused by the pressure on the head acting to rotate the
flange. If the head is allached above the centerline of the flange, this will result in a
moment that is opposite to the olher flange bending moments. Ifthe head is allached
below the centerline, this moment will have the same sign.
The shellside pressure is external to the flange. The rules in Appendix 2 of the Code for
flanges under external pressure are used by the program to calculate the bending moment
on the flange. Note that because the sign of the pressure on the head is also reversed, the
head component of the flange bending will always have the same effect that it does for
internal pressure.

EXAMPLE
The following figure shows typical geometry for floating heads and spherically dished
heads.
,oJ Al'PENDD.: I - MANDATORY 1..
NotL.qn.....
'tend 1/1 No
CtM IMt: T'htn
Il2itl. ..-~"9

It- ~~. L\

a....ft·
IIl~F""T'r'fIt
1,1

Figure 1--Typical Geometry for Floating Heads and Spherical Caps

8-2 Floating Heads and Spherically Dished Covers

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 Pressure Vessel Design and AIl<Jlysis - Seminar Noles Example

Pressure Vessel Design and Analysis Seminar

Component Design Problem

Special Design Problem-Floating Head

Design Pressure 275 psi shell side . 1.89 N/sqmm

215 psi tube side 1.48 N/sqmm

Design temperature 300°F 149°C

Corrosion allowance 0.125 in. 3.175 mm

Head Material SA5l6,70

Flange and backing ring SAlO5
Bolting SA193, Grade B7
Gasket ID 45.125 in. II 46mm
Gasket OD 45.688 in. 1160 mm
Spiral Wound SS/Asbestos Gasket
Number of Bolts 52
Bolt size 314-in. 19mm
Backing ring ID 45.6875 in. 1160 mm
Backing ring thickness 3.75 in. 95mm

0.675 in_ \hick

Centroid
Hr
T rC\
1
'5.00
7500 in thick

I '5.125 ---j
( I '6.750
I
'9.375

Questions:

What is the required head thickness?

What are the required flange thicknesses? _
What are the required ring thicknesses?

DO NOT TURN THE PAGE UNTIL YOU HAVE

COMPLETED YOUR ANALYSIS

Floating Heads and Spherically Dished Covers 8-3

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Example Pressure Vessel Design and Analysis - Seminar Notes

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
)
FileName; Seminar --------------------------------------- Page 34
Plohead Analysis; EX-2 PLOHEAD Item: 1 9:51a Sep 21,2000

Input Echo, Floating Head Item 1, Description: EX-2 FLOHEAD

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 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 CA.sS 0.1250 in.

Flange Material SA-lOS

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 FlO 45.1250 in.
Flange Thickness TC 7.7500 in.

Bolt Material SA-I93 B7

Bolt Allowable Stress At Temperature SBO 25000.00 psi
Bolt Allowable Stress At Ambient SBA 25000.00 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 -45.7500 in.

Flange Face Inside Diameter FlO 45.1250 in.
Gasket Outside Diameter GOD 45.6880 in.
Gasket Inside Diameter GIO 45.125~ in.

Gasket Factor, m, M 3.0000

Gasket Design Seating Stress Y10000.00 psi
Flange Facing Sketch I, Code Sket.ch la
Column for Gasket Seating 2, Code Column I I
Gasket Thickness 0.0000 in.
Flange Face Nubbin Width 0.0000 in.
Length of partition Gasket 0.0000 in.
Width of Partition Gasket 0.0000 in.

Distance from Head Centerline to Flange centroid 1.5000 in.

The Flange is not Slotted.

8-4 Floating Heads and Spherically Dished Covers

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 Pressure Vessel Design and Analysis - Seminar Noles Example

COADE Engineering Software

PVElite 4.00 I.icensee: COADE Inc .• Local White Lock
FileName: Seminar --------------------------------------- Page 35
Flohead Analysis; EX-2 FLOHEAD Item: 1 9:51a Sep 21,2000

Backing Ring Material Specification SA-IDS

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 3.7500 in.
Number of Splits in Backing Ring NSPLIT 1

INTERNAL PRESSURE RESULTS FOR SPHERICAL HEADS

ASME Code, Section VIII, Div. 1, 1998, A-99 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-CatsJ / 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, 1998, A-99

External Pressure Chart CS-2 at 300.00 F

Elastic Modulus for Material 29000000.00 psi

Results for Maximum Allowable External Pressure:

Corroded Thickness of Shell TCA 0.875Q in.
Outside Crown Radius of Shell 00/2 46.0000 in.
Crown Radius / Thickness Ratio (00/2) /T 52.5714
Geometry Factor, A f(D/T,LD) A 0.0023777
( Materials Factor, B, f(A, Chart) B 15586.9805 psi
Maximum Allowable Working Pressure 296.49 psig
EMAWP = B/( (OD/T)! 2 ) = 15586.9805 /( 105.1429/2.0) = 296.4915

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

Corroded Thickness of shell TCA 0.B217 in.
Outside Diameter of Shell OD 92.0000 in.
Diameter / Thickness Ratio (O/T) 111.9651
Geometry Factor, A f(DT.LD) A 0.002232B
Materials Factor, B, f(A, Chart) B 15397.0B9B psi

Floating Heads and Spherically Dished Covers 8-5

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Example Pressure Vessel Design and Anslysis - Seminar Notes

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName; Seminar --------------------------------------- Page 36
Flohead Analysis: EX-2 FWHEAD Item: 1 9:51a Sep 21,2000

Maximum Allowable Working Pressure 275.03 psig

EMAWP = B!((D!T)!2) = 15397.0898!< 111.9651 ! 2 275.0337

INTERMEDIATE CALCULATIONS FOR FLANGED PORTION:

ASME Code, Section VIII, Div. 1, 1998, A-99 App. 2

Gasket Contact Width, N (GOD-GID) ! 2 0.281 in.

Basic Gasket Width, BO N ! 2.0 0.141 in.
Effective Gasket Width, BE BO 0.141 in.
Gasket Reaction Diameter, G (GOD-tGID) I 2.0 45.407 in.

Bolting Information for TEMA Thread Series :

Total Area of Bolts 15.704 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 14 _786 in.

BASIC FLANGE AND BOLT LOADS:

Hydrostatic End Load due to Pressure H 348148.4 lb.
Contact Load on Gasket Surfaces HP 25900.4 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 374048.8 lb.
Gasket Seating Bolt Load WM2 200778.0 lb.
Required Bolt Area AM 14.962 in

Flange Design Bolt Load W 383324.4 lb.

Gasket Seating Force HG 25900.4 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 25900. 0.6'717 1. 0000 1450. ft. lb.
Floating Hd. Load, Mh 609473. 1.5000 1.0000 -76184. ft.lb.
Gasket Seating, Ma 383324. 0.6717 1.0000 21458. ft.lb.

TOTAL MOMENT FOR OPERATION ( Internal Pressure ) 54789. ft. lb.

TOTAL MOMENT FOR GASKET SEATING ( Int. Pressure) 21458. ft.lb.

BASIC FLANGE AND BOLT LOADS;

Hydrostatic End Load due to Pressure H 445306.1 lb.
Contact Load on Gasket Surfaces HP 33128.4 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: >lMl 374048.8 lb.

8-6 Floating Heads and Spherically Dished Covers

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 Pressure Vessel Design and Analysis - Seminar Noles Example

COADF. Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar --------------------------------------- Page 37
Flohead Analysis: EX-2 FLOHEAD Item: 1 9:51a Sep 21,2000

Gasket Seating Bolt Load WM2 200778.0 lb.

Required Bolt Area l\M 14 .962 in

Flange Design Bolt Load W 383324.4 lb.

Gasket Seating Force 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 o. ft.lb.
Floating Hd. Load, Mh 779559. 1.5000 1.0000 -97445. ft. lb.
Gasket Seating, Ma 383324. 0.6717 1. 0000 21458. ft.lb.

TOTAL MOMENT FOR OPERATION I External Pressure ) 96861. it.lb.

TOTAL MOMENT FOR GASKET SEATING I Ext. Pressure ) 214.58. ft. lb.
(
Required thickness for Main Flange, internal operating conditions:
T F+SQRT{F* F + J ) per 1-6{g)
T 1.273 + SQRT( 1.273 * 1.273 + 18.257 )
T 5.7316 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 + 7.150
T 2.6740 in.

Required thickness for Main Flange, external operating conditions:

T F+SQRT(F* F + J ) per 1-6(g)
T 1.628 + SQRT( 1.628 * 1.628 + 32.276 )
T 7.5385 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 + 7.150
T 2.6740 in.

Required thickness for Backing Ring, internal operating conditions:

T SQRT( M Y / S B ) Per App 2-7(b) (9)
T SQRT( 397426.9 * 24.888 / ( 20000.0 * 45.687 ) )
T 3.2901 in.
(
Required thickness for Backing Ring, internal bolt-up conditions:
T SQRT( M Y / S B ) Per App 2-7 (b) (9)
T SQRTI 407282.2 * 24.888 / ( 20000.0 * 45.687 ) )
T 3.3306 in.

SUMMARY OF REQUIRED THICKNESSES: Head Flange Backing Ring

Tubeside (Internal) Pressure 0.4042 5.7316 3.2901 in.
Shells ide (External) Pressure 0.8217 7.5385 in.
Tubeside Gasket Seating Load 2.6740 3.3306 in.

FloaLing Heads and Spherically Dished Covers 8-7

(

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 Example
Pressure Vessel Design and Analysis - Seminar Notes

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar --------~-------------------___________ Page 38
Flohead Analysis: EX-2 FLOHEAD Item: 1 9:51a Sep 21,2000

Shells ide Gasket Seating Load 2.6740 in.

Maximum + Corrosion Allowance l.0717 7.7885 3.3306 in.
Actual Thickness as Given 1.1250 7.7500 3.7500 in.
WEIGHT OF HEAD AND FLANGE:
Weight of Spherical Head, Uncorroded WHO 544.9 lb.
Weight of Spherical Head, Corroded WHOCA 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, Un corroded WBR 292.2 lb.
Weight of Backing Ring, Corroded WBRCA 252.6 lb.

The PV Elite Program, (c) 1989-2000 by COADE Engineering Software

8-8
Floating Heads and Spherically Dished Covers

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Pressure Vessel Design and Analysis - Seminar Noles

Chapter 9: Heat Exchanger

Tubesheets

lEMA TUBESHEETS
Tubesheets are usually analyzed using the TEMA Standards (Standards of the Tubular
Exchanger Manufacturers Associalion). The 7th Edition ofTEMA was issued in 1988,
with addenda.
The following TEMA tubeshcet types are illustrated in Figure 9-1:
A stationary tubesheets, gasketed on both sides.
B stationary tubesheets, integral with the shell.
C stationary tubcshecls, integral with the channel.
N stationary tubeshccts, integral on both sides.

U U-tube tubesheets gaskelcd on both sides.

V U-tube tubesheets integral with the channel.
P floating tubesheets, outside packed floating head.
S floating tubeshects, head with backing device.
T floating tubesheets, pull through floating head.
W floating head, externally sealed floating tubesheet.
D Divided floating tubeshee!.

F Fixed tubesheet exchanger - two stationary tubcsheets.

The TEMA Standard has a very simple equation for lhe thicknes~ of the tubeshee!. The
equation in bending (which controls far more often than shear) is

T is the required thickness.

F is a correction faclor taking into account the fixity of the shell support for the
tubeshee!. It is 1.0 for simply supported (gaskeled) tubesheets.
G is the characteristic diameter of the tubesheel support point-either the 1D of the
shell or the mean diameter of the gasket.
Lowercase h is the ligament efficiency of the tubcsheet. The value ofh depends on the
tube pattern, tube pitch and tube OD. This term was added to the equation (in place of
a constant) in the Seventh edition ofTEMA.
S is the allowable stress.

Heat Exchanger Tubcsheets 9-1

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TEMA Tubesheets Pressure Vessel Design and Analysis - Seminar NoLes

Pis Ihe pressure. But P is really a wild card. TEMA aeeounls for the complexities of
fixed lubesheet geometry and tubes heels extended as flanges by developing multiple
eandidales for an equivalenl design pressure on each side oflhe tubeshee!. These can-
didates lake inlo aeeounlthe loading on Ihe lubesheet from differenliallhermal expan-
sion, Ihe loading due to bolling, and Ihe aelual pressure loads.

fRONT INO lEAl INO

SHIll rnu HEAD lYPU
"AT1OHA.lJ HEAD rn£5

~ TT
~r
A
,...- E

ONf 'ASS SHnL

I~ L
~IT
UKE
flX£D rUBHmn
~10- STAIIONAIlY HEAD

~r- ~~_._ ..__ ... -

AND REM Aau COVER F
- ~ M
~
e
mefO TUBESHUT
TWO p.us SHEll liKE ·B~ nAflONAJiY H£AO
WITH lONGITUDINAl aAFflE

8
~ --m-l----- ~ C~
,:~
G N
flXfD TUUSHEET
':'_~'. LIKE Y S'Al1ON101l'Y HEAD
80NNET (INTEGRAL COVER) !>f'l.1T F\OW

~ '-i- + I] ,jP ~ 50"

C ~~

&
:1: .....
CHANNEl INTEGRAl WITH TUBE-
SHEeT AND RfMOVABl£ COVER
H

J
~I
DOUBLE SPlIT nOW'

I~
5
OUTSIN '.0.0£0 1l0ATlIiG HEAOI

~'.:~f4 .
flOATING HE100
WITH IAO:ING D[VlCf

t· N
Q: K
~
OMOfD flOW

T '~\'\. r .... Jl.

~~gf'~...!~....
POll TtUIOUGH fLOAflN(; HE"'O

~
(HANNU INTfGIAL wnH lUU-
SHEet AND REMOVABLE (OVER
U
D
~
KETTlE TYPE REBOILER

:
U·TUBE BUNDlE

.. ~ ~ ~
~ X
(
:L~
w "
ClOSS flOW UlUNAUY SfAUO
SPfCIAl HIOH 'RfSSURf: CIOSUIl£' nOAlING IOBESHUT

Figure 1--Standards of the Tubular Exchanger Manufacturers Association

One of the most difficult areas of fixed tubesheet design is deciding on the actual metal
temperature for the components.
The most conservative approach is to choose metal temperatures which are based on the
maximum difference belween Ihe shellside and tubeside fluids. For example, if the shell-
side fluid enters the exchanger a1450°F and leaves Ihe exchanger al 340°F, then the shell-
side mclaltemperature would be assumed 10 be 450°F. Ifthe tubeside fluid enlers at 180°F
and leaves al 250°F, then the tube metallemperature would be taken at 180°F. This would

9-2 HeaL Exchanger Tubesheers

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 Pressure Vessel Design and Analysis - Seminar Noles TEMA Tubcsheets

result in a 270°F temperature difference between the shell and the tubes, which would
almost certainly require an expansion joint.
An approach that is one step Icss conservative takes thc metal temperatures at the mean of
the inlet and outlet temperatures for the fluids. In the case described above, this results in a
shell metal temperature of 395°F and a tube metal temperature of 215°F.
The best approach is to know something about the actual metal temperatures through heat
transfer considerations. We recommended asking a process engineer what the process
design implies about the metal temperatures. Alternately, if you can find out the approxi-
mate shellside and tubeside heat transfer coefficients, you can estimate the tube metal tem-
perature using a simple weight average as
HsTsF + HrTrF
TrM ~ H +H
s r

In the case above, if the shellside fluid has a heat transfer coefficient that is five times
greater than the tubeside fluid, then, starting from the average temperature for each side,
the tube metal temperature would be 365°F. The shell metal temperature would remain
( 395°F. Thus it would be likely that the exchanger could be built with no expansion joint.

Note Typically a metal temperature difference of up to 50°F can be tolerated with no

expansion joint. Note also that there may be operating scenarios (such as a loss of
fluid) where the temperature difference is much higher. These must be taken into
account in the design.

TEMA allows differenlial pressure design. The differential pressure is used as the design
pressure on both the tubeside and the shellside. The exception to this rule is fixed
tubesheet exchangers, which have special differential design pressure rules.
When a tubesheet may be controlled by shear stress, TEMA requires the perimeter and
area of the tubesheet for the shear calculation. The perimeter is the distance covered when
stepping around all of the tubes on the periphery of the bundle. The area is the area
enclosed by this process.
It is difficult to empirically evaluate the perimeter and area. You will be conservative if
you overestimate the area and underestimate the perimeter.
TEMA calculates a pressure below which shear calculations need not be considered. How-
ever, even above this pressure, bending may control the tubesheet thickness.
Fixed tubesheet heat exchangers frequently require expansion joints. For TEMA evalua-
tion, all you need to know about the expansion joint is its spring constant and inside diam-
eter. If you have a flanged and flued expansion joint-that is, one that is relatively stiff-
you will have to know the exact spring constant. For metal bellows expansion joints you
only need to know that the spring rate is below a certain value prescribed by TEMA.
When a tubesheet is extended as a flange, additional bending moments may be imposed
on the tubesheet. TEMA transforms these moments into an equivalent pressure.
The bending moments on the tubesheet extension are calculated assuming the extension is
a ring-type flange, and using the typical Code flange analysis.
TEMA also provides rules for longitudinal stresses, both in the shell and in the tubes.
You need to know the baille spacing and tube physical and material properties to deter-
mine the buckling stress in the tube.

Heat Exchanger Tubesheets 9-3

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TEMA Tubeshects Pressure Vessel Design and Analysis - Seminar Notes

The following table shows lhe tube joinl reliability factor used by TEMA to compare the
actual to the maximum tube pull-au I load.
IS98 SECTION VII DIVISION 1

TABLEA-2
EFPICIENCIESfr

Dew:iption (l) No ...

9-4 Heal Ex.changer Tubesheets

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 Pressure Vessel Design and Analysis - Seminar Noles TEMA Tubesheels

Pressure Vessel Design and Analysis Seminar

Component Design Problem

Floating TubesllCet Design

Determine the required thickness for the following floating tubesheet.

Tubesheet type - Floating tubesheet with backing ring, SA-105 Forging

Gasket diameter for tubesheet - 38 in. (965 mm)
Design pressure - 250-psi (1.72 N/mm 2) shell at 480°F (249°C), 525-psi channel at
200°F (93°C)
3/4-in. tubes on 15116 pitch, triangular
Shell: SA-516,70, 37-in. diameter, 0.5-in. thick, 0.125-in. CA
Channel: SA-5 I 6,70, 37-in. diameter, 0.5-in. thick, 0.125-in. CA

Gasket between Channel and Tubesheet

Flange Face OD ~ 38.5 in. (978 mm)
Flange Face ID ~ 37.5 in. (953 mm)
Gasket OD ~ 38.5 in. (978 mm)
Gasket ID ~ 37.5 in. (953 mm
m ~ 2.75, y = 3700.0-psi (2.55 N/mm 2)

Notes:

Questions:
(
What is the required thickness of the tubeshect?
What is the maximum pressure allowed on the tubeside
for a 4-in.(102 mm) thick tubesheet?

DO NOT TURN THE PAGE UNTIL YOU HAVE

COMPLETED YOUR ANALYSIS

Heal Exchanger Tubeshecls 9-5

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TEMA Tubesheels Pressure Vessel Design and Analysis - Seminar Noles

COADE Engineering Software

PVElite -4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar --------------------------------------- Page 51
Tubesheet Analysis: EX-) Float TS Item: 1 9:51a Sep 21,2000

Input Echo, TubeSheet Item 1, Description: EX-) Float TS

Shell Design Pressure PS 250.00 psig

Shell Temperature for Internal Pressure TEMPS 480.00 F
Shell Material SA-516 70
Shell Allowable Stress at Temperature SOS 20000.00 psi
Shell Allowable Stress at Ambient SAS 20000.00 psi
Shell Thickness TS 0.5000 in.
Shell Corrosion Allowance CAS 0.1250 in.
Inside Diameter of Shell OS 37.0000 in.

Channel Design Pressure PC 525.00 psig

Channel Temperature for Internal Pressure TEMPC 200.00 F
Channel Material SA-516 70
Channel Allowable Stress at Temperature SOC 20000.00 psi
Channel Allowable Stress at Ambient SAC 20000.00 psi
Channel Thickness TC 0.5000 in.
Channel Corrosion Allowance CAC 0.1250 in.
Inside Diameter of Channel DC 37.000Q in.

TUBESHEET TYPE: Floating, Backing Ring

Tube Outside Diameter DT 0.7500 in.
Tube pitch (Center to Center Spacing) FT 0.9380 in.
Tube Layout Pattern Triangular
Tubesheet Design Metal Temperature TEMPTS -480.00 F
Tubesheet Material (Not Normalized) SA-lOS
Tubesheet Allowable Stress at Temperature SOTS 19680.00 psi
Tubesheet Allowable Stress at Ambient SATS 20000.00 psi
Thickness of Tubesheet TTS 4.0000 in.
Tubesheet Corr. Allowance (Shell side) CATS 0.0000 in.
Tubesheet Corr. Allowance (Channel side) CATC 0.0000 in.
Depth of Groove in Tube Sheet GROOVE 0.0000 in.

ADDITIONAL DATA FOR GASKETED TUBESHEETS:

Flange Face Outside Diameter FOD 38.5000 in.
Flange Face Inside Diameter FID 37.5000 in.
Flange Facing Sketch 1, Code Sketch la
Gasket Outside Diameter GOD 38.5000 in.
Gasket Inside Diameter GID 37.5000 in.
Gasket Factor, m, M 2.7500
Gasket Design Seating Stress y 3700.00 psi
Column for Gasket Seating 2, Gode Column II
Tubesheet Gasket on which Side SIDE BOTH

INTERMEDIATE CALCULATIONS FOR GASKETED TUBESHEETS:

ASME Code, Section VIII, Div. I, 199B, A-99 Appendix 2

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

Basic Gasket Width, BO N I 2.0 0.250 in.
Effective Gasket Width, BE BO 0.250 in.
Gasket Reaction Diameter, G (GOD+GID) / 2.0 38.000 in.

9-6 Heat Exchanger Tubesheets

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 Pressure Vessel Design and Analysis - Seminar Notes TEMA Tubesheets

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar --------------------------------------- Page 52
Tubesheet 1\Ilalysis: EX-3 Float TS Item: 1 9:51a Sep 21,2000

TUBESHEET ANALYSIS, TUBESHEET NUMBER l,Description:EX-3 Float TS

TEMA Standards, Eighth Edition, 1999, RCB-7 Tubesheets

TEMA R-I.131 Minimum Tubesheet Thickness for R-type:

THIN MAX ( DT, CONST - ( CATS ~ CATC ) )
TMIN =: MAX ( 0.750, 0.750 - ( 0.000 + 0.000) )
TMIN = 0.7500 in.
Min. Thickness + CATS + MAX (CATC, GROOVE)
TREQMIN = 0.7500 in.

Shellside Fixity Factor, F, per RCB 7.132 FS 1. 0000

Shellside Effective Diameter, per RCB 7.132 GS 38.0000 in.
Tubeside Fixity Factor, F, per RCB 7.132 FC 1.0000
Tubeside Effective Diameter, per RCB 7.132 GC 38.0000 in.
TEMA Eta factor used in calculation ETA 0.4201

Shells ide Effective Pressure, Bending, PSU 250.0000 psig

Tubeside Effective Pressure, Bending, PTU 525.0000 psig

TEMA RCB-7.132 Required Thickness for Shellside Pressure:

TRS FS I GS I SQRT { PSU / ( ETA I SOTS) ) / 3.0
TRS = 1.0000 I 38.0000 I SQRT( 250.00 / ( 0.4201 I 19680 ) ) / 3.0
TRS = 2.2025 in.
TEMA RCB-7.132 Required Thickness for Tubeside Pressure:
TRC FC I GC I SQRT { PTU / ( ETA I SOTS) ) / 3.0
TRC = 1.0000 I 38.0000 I SQRT( 525.00 / ( 0.4201 I 19680 ) ) / 3.0
TRC = 3.1918 in.
TEMA RCB-7.132 Required Thickness for Bending + CATS + MAX ( CATC,GROOVE):
TREQ = 3.1918 in.

No Shear Calculation, since Pressure is less than 1264.8911 psig

SUMMARY of RESULTS for Tubesheet calculations

Reqd Tubsheet Thk. + CATS + MAX(CATC,GRV)TREQ 3.1918 in.
Actual Tubsheet Thickness as Given TTS 4.0000 in.

The PV Elite Program, (c) 1989-2000 by COADE Engineering Software

Heat Exchanger Tubesheets 9-7

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 TEMA Tubeshcets Pressure Vessel Design and Analysis. Seminar Notes

9-8
Heal Exchanger Tubeshcels

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 Pressure Vessel Design and Analysis - Seminar Noles TEMA Tubesheets

Pressure Vessel Design and Analysis Seminar

Component Design Problem

Fixed tubesheet design

Determine the required thickness for the following fixed tubesheet.

Tubesheettype - SA-lOS Forging

Design pressure - 250 psi shell at 480°F (249°C), 525-psi channel at 480°F (274°C)
3/4-io.( 19 mm) tubes on 15/16 (24 mm) pitch, triangular

Shell- SA-516,70 - 40.5lD (1029 mm) by 0.5 (12.77 mm) thick, 0.125 (3.175 mm)
corrosion allowance
Channel- SA-516,70 - 40.5 lD (1029 mm) by 0.5 (12.77 mm) thick, 0.125 (3.175
mm) corrosion allowance

( Tubesheet is welded to shell, extended as flange, and gasketed to channel.

aD of extension is 47.65 (1210 mm), thickness of extension is 3.5 in. (89mm)
56 I-in. bolls on 45.5-in.(1156 mm) boll circle, SA-193, B7
40.5-in. (1029 mm) gasket lD, 41.5-in. (1054 mm) aD, flexitallic (m~3.0,
y~10000.)
40.5-in. (1029 mm) face lD, 42.5-in. (l080 mm) face aD.

Tubes (SA-214, allowable ~IO ksi (69N/mm 2), yield=23 ksi (159 N/mm2»
Tube metal temperature 241°F (116°C)
Shell metaltemperalure 259°F (126°C)
Tubesheet melal temperature 250°F (121°C)

No expansion joint
1511 tubes, 0.075-in. (1.9056 mm) thick, 96-in. (2438 mm) overall length
44-in.(l1I8 mm) spacing all baillles
Tube to tubesheet joinl factor (ASME) 0.65

Notes:
(

Questions:

What is the required thickness of the tubcsheet?

What is the maximum pressure allowed on the tubeside for a 4-in.(l02 mm)
thick tubesheet?

DO NOT TURN THE PAGE UNTIL YOU HAVE

COMPLETED YOUR ANALYSIS

Heal Exchanger Tubesheels 9-9

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TEMA Tubesheels Pressure Vessel Design and Analysis - Seminar Notes

CQADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar --------------------------------------- Page 53
Tubesheet Analysis; EX-3 f-'ixed TS Item: 2 9~51a Sep 21, 2000

Input Echo, TubeSheet Item 2, Description: EX-3 Fixed TS

Shell Design Pressure PS 250.00 psig

Shell Temperature for Internal Pressure TEMPS 480.00 F
Shell Material SA-516 70
Shell Allowable Stress at Temperature SOS 20000.00 psi
Shell Allowable Stress at Ambient SAS 20000.00 psi
Shell Thickness TS 0.5000 in.
Shell Corrosion Allowance CAS 0.1250 in.
Inside Diameter of Shell OS 40.5000 in.

Channel Design Pressure PC 525.00 psig

Channel Temperature for Internal Pressure TEMPC 480.00 F
Channel Material S1I-516 70
Channel Allowable Stress at Temperature SOC 20000.00 psi
Channel Allowable Stress at Ambient SAC 20000.00 psi
Channel Thickness TC 0.5000 in.
Channel Corrosion Allowance CAC 0.1250 in.
Inside Diameter of Channel OC 40.5000 in.

TUBESHEET TYPE: Fixed Tubesheet Exchanger

Tube Outside Diameter OT 0.7500 in.
Tube Pitch (Center to Center Spacing) PT 0.9380 in.
Tube Layout Pattern Triangular
Tubesheet Design Metal Temperature TEMPTS 480.00 F
Tubesheet Material (Not Normalized) SA-lOS
Tubesheet Allowable Stress at Temperature SOTS 19680.00 psi
Tubesheet Allowable Stress at Ambient SATS 20000.00 psi
Thickness of Tubesheet TTS 4.0000 in.
Tubesheet Corr. Allowance (Shell side) CATS 0.0000 in,
Tubesheet Corr. Allowance (Channel side) C/l,TC 0.0000 in.
Depth of Groove in Tube Sheet GROOVE 0.0000 in.

ADDITIONAL DATA FOR FIXED TUBESHEET EXCHANGERS

Actual Metal Temperature for Shell ACTUALl 259.00 F
Actual Metal Temperature for Tubes ACTUAL2 241.00 F
Actual Metal Temperature for Tubesheet ACTUAL3 250.00 F
Number of Tubes TNU>lT .1511
Length of Tubes TLENT 96.0009 in.
Tube Material SA-214
Tube Allowable Stress at Temperature SOT 1l400.00 psi
Tube Allowable Stress At Ambient SAT 11400.00 psi
Tube Yield Stress At Operating Temperature SYT 21400.00 psi
Tube Wall Thickness TT 0.0750 in.
ASME Tube Joint Reliability Factor Fl\SME 0.6500
Expansion Joint Spring Rate SJF 0.00 lbs./in.
Expansion Joint Inside Diameter at Bellows OJ 40.5000 in.
Maximum Unsupported Tube Length SL 44.0000 in.
Tube Span Between Baffle and Tubesheet SLT 44.0000 in.
Is this a Kettle-type configuration No

ADDITIONAL DATA FOR TUBESHEETS EXTENDED AS FLANGES:

9-10 Heal Exchanger Tubesheets

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 Pressure Vessel Design and Analysis - Seminar Notes TEMA Tubesheets

COADE Engineering Software

PVElite 4.00 Licensee: COhOE Inc., Local White Lock
FileName: Seminar --------------------------------------- Page 54
Tubesheet Analysis: EX-3 Fixed TS Item: 2 9:51a Sep 21,2000

Outside Diameter of Flanged Portion OF 47.6500 in.

Diameter of Bolt Circle DB 45.5000 in.
Thickness of Extended Portion of Tubesheet TF 3.5000 in.
Nominal Bolt Diameter DBOLT 1.0000 in.
Type of Threads (Thread Series TEMA Thread Series
Number of Bolts NUMBER 56
Bolt Material SA-193 B7
Bolt Allowable Stress At Temperature SBO 25000.00 psi
Bolt Allowable Stress At Ambient SB' 25000.00 psi
Weld between Flange and Shell/Channel WLDH 0.0000 in.

ADDITIONAL DATA FOR GASKETED TUBESHEETS;

Flange Face Outside Diameter FOD 42.5000 in.
Flange Face Inside Diameter FID 40.5000 in.
Flange Facing Sketch 1, Code Sketch 1a
Gasket Outside Diameter GOD 41.5000 in.
Gasket Inside Diameter GID 40.5000 in.
Gasket Factor, m, M 3.0000
( Gasket Design Seating Stress Y 10000.00 psi
Column for Gasket Seating 2, Code Column. II
Tubesheet Gasket on which Side SIDE CHANNEL

INTERMEDIATE CALCULATIONS FOR TUBESHEETS EXTENDED AS FLANGES:

ASME Code, Section VIII, Div. 1, 1998, A-99 Appendix 2

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

Basic Gasket Width, BO N / 2.0 0.250 in.
Effective Gasket Width, BE BO 0.250 in.
Gasket Reaction Diameter, G (GOD+GID) / 2.0 41.000 in.

BASIC FLANGE AND BOLT LOADS:

Hydrostatic End Load due to Pressure:
H 0.785*G*G*PEQ
H = 0.7854 * 41.0000 * 41.0000 * 525.0000
H = 693134. lb.
Contact Load on Gasket Surfaces:
HP 2 * BE * PI • G * M * PEQ +
HP = 2 * 0.2500 • 3.1416 • 41.0000 * 3.0000 • 525.00
HP = 101434. lb.
Hydrostatic End Load at Flange 10:
HD 0.785 * Bear * Bcor * PEQ
HD = 0.785 * 40.7500 * 40.7500 * 525.0000
HD = 684706. lb.
( Pressure Force on Flange Face:
HT H - HD
HT = 693133 - 684706
HT = 8427. lb.
Operating Bolt Load:
WMI H + HP + HPP
WM1 = ( 693133 + 101434 + 0 )
WMI = 794568. lb.
Gasket Seating Bolt Load:
WM2 = y * (t BE • PI * G ) + (BEPG * GLPG) + HPGY

Heat Exchanger Tubesheets 9-11

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 \

TEMA Tubesheets Pressure Vessel Design ~U1d Analysis - Seminar Notes

\

COADE Engineering Software \

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar ------------------------~-------------- Page 55
Tubesheet Analysis: EX-3 Fixed TS Item: 2 9:51a Sep 21,2000

WM2 ~ lOOOO_OO·((O.2S00~).141*41.000>~10.00*O.OOOO)}+O.OO
\
WM2 ~ 32201J. lb.
Required Bolt Area:
AM ~ Maximum of WMl/ABSTR, WM2/ABASTR
AM
AM
Maximum of 794567 I 25000
31.7821 in
I 322013 I 25000 \
Bolting Information tor TEMA Thread Series:
Total Area of Bolts, AS 30.356 in \
** WARNING ** Required Bolt Area > Actual Bolt Area

Minimum radial distance between hub and bolts 1. 375 in.

Minimum radial distance between bolts and edge 1.063 in. \
Minimum circumferential spacing between bolts 2.250 in.
Actual circumferential spacing between bolts 2.551 in.
Maximum circumferential spacing between bolts 6.000 in.
\
Flange Design Bolt Load, Gasket Seating:
1I.BlI.STR * ( AM + AB ) I 2.0
"~ 25000.00 * ( 31.7827 + 30.6560 ) I 2.0
" \
""" 7e298J.BB lb.
Gasket Seating Force:
HG WMI - H
HG 794567 - 69)133
HG 101434.19 lb.
\
MOMENT ARM CALCULATIONS:
Distance to Gasket Load Reaction:
DHG (C - G ) j 2.0
DHG "" ( 45.5000 - 41.0000 ) I 2.0 _-I
\
DHG "" 2.2500 in.
Distance to Face Pressure Reaction:
nUT '" I R + GleOR + DHG ) I 2.0
DHT '" ( 2.0000 + 0.3750
DHT "" 2.3125 in.
~ 2.2500 l I 2.0 \
Distance to End Pressure Reaction:
DHD R + ( GICOR I 2,0 I
DHD '" 2.0000 + < 0.3750
DHD 2.1875 in.
I 2.0 ) \
SUMMARY OF MOMENTS FOR INTERNAL PRESSURE:
LOADING
End Pressure, MD
Force
684706.
Distance
2.1875
Bolt Carr
1.0000
Moment
124.816. ft. lb. (
\
Face Pressure. MT 8427. 2.3125 1.0000 1624. ft.lb.
Gasket: Load, MG 101434. 2.2500 1.0000 19019 . ft.lb.
Gasket Seating, MA 2.2500
782984. 1.0000 146809. it.lb.
\
TOTAL MOMENT FOR OPERATION, RMO 1<15459. ft .lb.
TOTAL MOMENT FOR GASKET SEATING, RNA 14.6809. ft-Ib.

TUBESHEET ANALYSIS, TUBESHEET NUMBER 2.Descriptian:EX-3 Fixed TS \

TEMA Standards, Eighth Edition, 1999, RCB-7 Tubesheets

9-12 Heal Exchanger Tubesheels

\

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 Pressure Vessel Design and AIl<\lysis - Seminar Notes TEMA Tubesheets

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Tubesheet Analysis: EX-3 Fixed TS Item; 2 9:51a Sep 21,2000

TEMA R-7.131 Minimum Tubesheet Thickness for R-type:

TMIN MAX( DT, CONST - ( CATS + CATC ) )
TMIN;; MAX( 0.750, 0.750 - ( 0.000 + 0.000 ) )
TMIN ;; 0.7500 in.
Min. Thickness + CATS + MAX(CATC,GROOVE)
TREQMIN;; 0.7500 in.

Shells ide Fixity Factor, F, per RCB 7.132 FS 1.0000

Shellside Effective Diameter, per RCB 7.132 GS 40.7500 in.
Tubeside Fixity Factor, F, per RCB 7.132 FC 1.0000
Tubeside Effective Diameter, per RCB 7.132 GC 40.7500 in.
TEMA Eta factor used in calculation ETA 0.4201

MATERIAL PROPERTIES FOR THERMAL EXPANSION ANALYSIS:

Shell - TEMA : C-Mn-Si, 1-1/4Cr-1!2Mo & 3Cr-1Mo
Coeff. of Thermal Exp. at Metal Temp. 0.6108E-05 / deg F
Elastic Modulus at Metal Temp. 0.2870E+08 psi
Tubes - TEMA : Plain Carbon Stl & C-Mn Stl.
Coeff. of Thermal Exp. at Metal Temp. 0.6752E-05 / deg F
Elastic Modulus at Metal Temp. 0.2829E+08 psi
TubeSheet - TEMA : C-SI, C-1/2Mo & Cr-l/2Mo
Coeff. of Thermal Exp. at Metal Temp. 0.6260E-05 ! deg F
Elastic Modulus at Metal Temp. 0.2825E'l-08 psi

TEMA RCB-7.161 K Factor for Thermal Expansion 0.2045

TEMA RCB-7.161 Fq Factor for Thermal Expansion 3.7930
TEMA RCB-7.161 Differential Expansion / Length -0 .12E-06
TEMA RCB-7.161 Equivalent Differential Thermal Expansion Pressure:
PD 4 * RJ * ELAS * TSCA * DLL /
( DOS - 3.0*TSCA ) • ( 1.0 + RJ * RK ,., FO l
FD 4 * 1.0000 * 0.287E+08 * 0.3750 * 0.0000 /
( 41.5000 - 3.0 * 0.3750 ) * ( 1.0 + 1.0000 ., 0.2045 • 3.7930 )
PD;; -0.07 psig

RCB 7.162 Equivalent Shellside Bolting Pressure:

PBS 6.2. RMA / ( F*.2 * G**3 )
A h
PBS = 6.2 * 0.176E+07 / ( 1.0000 2 * 40.7500 3
PBS = 161.42 psig
RCB 7.162 Equivalent Tubeside Bolting Pressure:
PST 6.2. RMO / ( F**2 * G**3 )
A
PBT 6.2 * 0.175E+07 / ( 1.0000 A 2 * 40.7500 3
PBT 159.93 psig
(
TEMA RCB 7.163 Effective Shellside Design Pressure:
TEMA RCB-7.163 Fs Factor for Shells ide Design 0.4882
PSP1 0.4 * RJ * ( 1.5 + RK * (1.5 + FFS ) )
0.4 * 1.0000 * ( 1.5 + 0.2045 • (1.5 + 0.4882 ) )
PSP2 « 0.5 - RJ / 2.0 ) * ( DJ**2 / G**2 - 1.0 )
( ( 0.5 - 1.0000 / 2.0 ) * ( 40.7500**2 / 40.7500**2 - 1.0 )
PSP3 1. 0 + RJ * RK * FQ
1.0 + 1.0000 * 0.2045 * 3.7930
PSP PS * ( ( PSPI - PSP2 ) / PSP3 )

Heal Exchanger Tubcsheets 9-13

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 TEMA Tubes/wets

Pressure Vessel Design and Analysis _Seminar Notes

COADE Engineering Software

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FileName 'Seminar ------------------_____________________ Page 57
Tubesheet Analysis, EX-3 Fixed TS Item, 2 9,51a Sep 21,2000

250.00 ,0; ( ( 0.7627 - 0.0000 ) /1.7758

PSP 107.37 psig

TEMA RCB-7.163 Eff. Shell Side Design Pressure:

PSU = Max (absolute) of PSP 107.37

or or PBS
161.42
or ( PSP PSP - PD) / 2 (107.37 -0.07
PD - PBS) /2 (107.37 -0.07 / 2.0
or ( PBS + PD ) / 2(161.42 + -0.07 161.42 ) / 2.0
psu '" or ( PSP - PBS) (107.37 161.42 ) / 2.0
)
TEMA RCB 161.42 psig
PSS 7.163 Shellside Shear Design Pressure,
: 107.37 psig
RCB 7.164 Effective Tubeside Design Pressure:
TEMA RCB-7.164, Ft Factor for Tubeside Design 0.6724
PTPI 1.0 ~ 0.4 * RJ * RK .. ( 1.5 + FFT )

PTP2 1.0 ++ RJ
1.0 ,0; FQ .. 0.2045 * ( 1.5 + 0.6724 )
0.4 * *RK1.0000

1.0 + 1.0000 * 0.2045 ... 3.7930

PTP PT * PTP1 / PTP2
525.00 ... 1.1777/1.7758
PTP 348.19 psig

TEMA RCB-7.164 Effective Tube

PTU = Max (absolute) of Side Design Pressure:
( PTP + PBT + PD ) / 2
or ( PTP + PBT ) ( 348.19 ~ 159.93 + -0.07 ) / 2.0
PTP - PSP + PBT + PO) / 2 ( 348.19 + 159.93
or ( PTP - PSP + PBT ) (348.19 107.37 + 159.93 + -0.07 ) / 2.0
PTU (348.19 107.37 + 159.93
RCB 508.12 psig
7.164 Tubeside Shear
PTS Design Pressure (PBT=O):
: 348.19 psig

TEMA RCB-7.132 Required Thickness for Shellside Pressure:

TRS FS'" GS ,0; SQRT ( PSU / ( ETA * SOTS) ) / 3.0
TRS '== 1.
TRS 1.0000 < 40.7500 < SQRTI 161.42 / I 0.4201 < 19680 ) ) / 3.0
8979 in.
TEMA RCB-7.132 Required Thickness for Tubeside Pressure:
TRC FC,o; GC ... SQRT ( PTU / ( ETA" SOTS) ) / 3.0
TRC '"= 3.3673
TRC 1.0000 in.
< 40.7500 < SQRTI 508.12 / I 0.4201 < 19680 ) / 3.0

TENA = 3.367] Required

TREQRCB-7.132 in. Thickness for Bending < CATS + MAxI CATC, GROOVE) ,

No Shear Calculation, since Pressure is less than 1264.8971 psig

TENA RCB-7.134 Required Thickness for Tubesheet Flanged Extension,

TPREQ .98* SQRT( (RM* fR"'2 - 1 + 3.71'" R"'2 ... LN IR»)
/ ( SOTS .. ( DF - G -' .. ( 1.0 + 1.86 ... R.. . 2 »)
TFREQ .98< SQRTII 0.176E+07<1 1.17'2 I + 3.71< 1.17'2<LNI 1.17)))
TFREQ = / 2.0204 in. ( 47.65 - 40.75 ) * ( 1.0 + 1.86 ... 1.17"'2 »J
( 19680,0;

9-14

Heat Exchanger Tubesheels

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Pressure Vessel Design and Analysis - Seminar Notes TEMA Tubesheets

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FileName Seminar --------------------------------------- Page 58
Tubesheet Analysis; EX-3 Fixed TS Item; 2 9:51a Sep 21,2000

RCB-7.22 Shell Longitudinal Stress:

Max. Effective Pressure for Longitudinal Stress, 284.18 psig

TEMA RCB-7.22 Maximum Shell Longitudinal Stress:

STSMAX PSSMAX * CS * ( DOS - TSCA )/( 4 * TSCA )
STSMAX ~ 284.18 * 1.00 * ( 41.5000 - 0.3750 ) / ( 4 * 0.38 )
STSMAX ~ 7791. psi
TEMA RCB-7.22 Allowable Shell Longitudinal Stress
STSALL ~ 20000. psi

RCB-7.23 Tube Longitudinal Stress Results:

Max. Effective Pressure for Longitudinal Stress, 255.12 psig
Min. Effective Pressure for Longitudinal Stress, -75.27 psig

TEMA RCB-7.23 Maximum Tube Long. Stress (Tension):

STTMAX ~ PTTMAX*CT*FO*G*G /(4*TNUMT*TT*(DT-TT)
STTMAX ~ 255.12* 1.00* 3.79*-40.7500* 40.7500
/ ( 4* 1511* 0.0750*( 0.7500- 0.0750) )
STTMAX ~ 5251.62 psi

TEMA RCB-7.23 Allowable Tube Long. Stress (Tension):

STSALL = 11400.00 psi

TEMA RCB-7.23 Minimum Tube Camp. Longitudinal Stress

STTMIN = PTTMIN*CT*FO*G*G/{4*TNUMT*TT*(DT-TT»)
STTMIN = -75.27* 1.00* 3.79* 40.7500* 40.7500
/ ( 4* 1511* 0.0750*( 0.7500- 0.0750) )
STTMIN -1549.40 psi

Modulus of Elasticity of Tubes at Mean Tube Temperature

External Pressure Chart CS-l at 300.00 F
Elastic Modulus for Tube Material, ET 29000000.00 psi

TEMA RCB-7.24 Allowable Tube Compressive Stress

STTCOM -PI**2 * ET / ( FSAF * RKLR**2 )
STTCOM - 3.14**2 * 0.290E+08 / ( 1.35 * 183.24**2
STTCOM -6297.79 psi

RCB-7.25 Tube-To-Tubesheet Joint Load:

Effective Pressure for Tube-to-Tubesheet Load 255.12 psig

TEMA RCB-7.25 Actual Tube-To-Tubesheet Load

WJ PI * FQ * PTLOAD * G * G / ( 4.0 * TNUMT )
WJ = 3.14 * 3.79 * 255.12 * 40.75 • 40.75 / ( 4.0 * 1511 )
WJ = 835.23 lb.
TEMA RCB-7.25 Allowable Tube-To-Tubesheet Load:
A
WJA (PI/4.0)* (DT 2-(DT-2*TT) **2)*SOT*FASME
WJA (3.14/4.0)*( 0.7500 A 2-( 0.7500-2.0 * 0.0750)**2) *
WJA 11400 * 0.65
WJA 1178.51 lb.

LONGITUDINAL TUBE STRESS SUMMARY Actual Allowable

Heat Exchanger Tubesheels 9-15

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 TEMA Tubesheels
Pressure Vessel Design and Analysis - Seminar NOles

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar ---------------------__________________ Page 59
Tubesheet Analysis; EX-3 Fb-:ed TS Item: 2 9:51a Sep 21,2000
Shell Long. Stress (Tens.+J
Tube Long. Stress (Tens.+) 7791.29 20000.00 psi
Tube Long. Stress (Comp.-) 5251.62 114 00.00 psi
Tube-to-Tubesheet Load. -1549.40 -6297.79 psi
935.23 1179.51 lb.
SUMMARY of RESULTS for Tubesheet Calculations
Reqd Tubsheet Thk. + CATS + MAx(CATC.GRV)TREQ
Actual Tubsheet Thickness as Given TTs 3.3673 in.
Required Thickness for the Flanged Portion TFREQ 4.0000 in.
Actual Thickness for the Flanged Portion TF 2.0204 in.
Equivalent Differential Ther. Expansion Pressure 3.5000 in.
Shells ide Prime Pressure -0.0740 psig
Tubeside Prime Pressure 107.3695 psig
349.1878 psig
The PV Elite Program, (c) 1989-2000 by COADE Engineering Software

':c.
}
. ;t
."

9-16

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 Pressure Vessel Design and Analysis - Seminar Notes ASME Tubesheels

ASME TUBESHEETS
Beginning in 1989, the ASME Code began to include rules for some kinds of tubesheels.
These rules have now been expanded 10 include bolh U-Iube exchangers and mosl kinds of
fixed tubesheet exchangers. These are located in appendix AA of the Code, an oplional
appendix, and most people continue to use the TEMA rulcs for most exchangers. How-
ever, there are many occasions in which the ASME rules can result in a thinner tubeshcct,
at the expense of a slightly more complicated analysis.

0,

(til Typkil Sholl.Sldo Inleg';l1 ;lnd ChannQI·SldG G;I~hlQd TypQ Tld>II~hwl ConHnxllon
Wrth Twuhul £:t'ond~d n a Flango

Figure 2--Typical Fixed Tubesheet Type Constructions

The design considerations and calculations for ASME tubesheets are similar 10 those for
TEMA tubesheets which we have already considered. Notice, however, the following
additional considerations:
The ASME method requires a specific and independent calculation of each design
case (temperature plus pressure, pressure only, temperature only). The TEMA method
takes these cases into account by means of the various candidates for design tempera-
ture and pressure.
The ASME method uses a model in which the tubesheet is considered to be a flat plate
on an elastic foundation. This model typically results in a thinner tubesheet than caleu-
( lated by the TEMA melhod.
In cases where the stresses at the junetion between the tubesheet and the shell are high,
the ASME method allows the introduction of plastiticity at this joint. Recalculating
using a reduced stiffness al the joint typically results in a significant reduction in the
stresses. The CodeCalc program performs this type of recalculation automatically.
This Appendix was rewritten in 1989.

Heat Exchanger Tubeshecls 9-17

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ASME Tubeshee.s Pressure Vessel Design and Analysis - Seminar Notes

9-J8 Heat Exchanger Tubesheels

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 Pressure Vessel Design and Analysis - Selllll1ar Noles ASME Tubesheels

Pressure Vessel Design and Analysis Seminar

Component Design Problem

ASME Tubesheet Calculation:

Recalculate the required thickness of the fixed tubeshcet analyzed using lhe ASME pro-
gram.

Tubesheel type - SA-105 Forging.

Design pressure - 250-psi shell at 480°F (249°C), 525-psi channel at 480°F (249°C)
3/4-in.(19mm) tubes on 15116 (24mm) pitch, triangular

Shell - SA-516,70 - 40.5 (I 029mm) !D by 0.5 (12.7mm) thick, 0.125 (3.175mm) cor-
rosion allowance
Channel- SA-516,70 - 40.5 (l029mm)!D by 0.5 (l2.7mm) thick, 0.125 (3.175mm)
corrosion allowance

Tubeshect welded to shell, extended as flange and gasketed to channel.

aD of extension is 47.65 (1210 mm), thickness of extension is 3.5 in. (89mm)
56 I-in. bolts on 45.5-in. (1156 mm) bolt circle, SA-193, B7
40.5-in. (1029 mm) gasket!D, 41.5-in. (1054 mm) aD, flexitallic (m~3.0,
y=IOOOO)
40.5-in. (1029 mm) facc!D, 42.5-in. (1080 mm) face aD.

Tubes (SA-214, allowable ~10 ksi (69N/mm 2 , yield~23 ksi (159 N/mm 2 )
Tube metal temperature 241°F (116°C)
Shell metal temperature 259°F (126°C)
Tubesheet metal temperature 250°F (121°C)

No expansion joint
1511 tubes, 0.075 thick (1.9050 mm), 96-in.(2438 mm) overall length.
44-in.(l118 mm) spacing all barnes.
Tube to tubesheet joint factor (ASME) 0.65

(
Notes:

Questions:
What is thc rcquircd thickness oflhe tubeshect?
How does this requircd thickness compare to the rcquired thickness
calculated using the TEMA program?

DO NOT TURN THE PAGE UNTIL YOU HAVE

COMPLETED YOUR ANALYSIS

Hettl Exchanger Tubesheets 9-19

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 \

ASME Tubesheels Pressure Vessel Design and Ana!ysis - Seminar Notes

\
coADE Engineering Software
PVElite 4.00 Licensee; COADE Inc., Local White Lock
FileName; Seminar -----------------------~--------------- Page 93
ASMETube Analysis: EX-2 FIXED COM Item~ 1 9:51a Sep 21,2000

INPUT ECHO, TUBESHEET NUMBER Description: EX-2 FlXED COM

shell Design Pressure Ps 250.00 psig

Shell Thickness Hs 0.5000 in.
Shell Corrosion Allowance CAS 0.1250 in.
Inside Diameter of Shell Os -40.5000 in.

Channel Design Pressure Pt 525.00 psig

\
Channel Thickness HC 0.5000 in.
Channel Corrosion Allowance CAC 0.1250 in.
Inside Diameter of Channel DC 40.5000 in.

Tubesheet Design Metal Temperature TEMPTS 480.00 F

\
Tubesheet Material Specification S1\-105
Tubesheet Allowable Stress at Temperature S 1.96BQ.OO psi
Tubesheet ~llowable Stress at Ambient S1\TS 20000. 00 psi
Thickness of Tubesheet H 4.0000 in.
in.
\
Tubesheet Carr. Allowance (Shell side) CATS 0.0000
Tubesheet Carr, Allowance (Channel side) CATS 0.0000 in.
(
TUBESHEET TYPE: Fixed Tubesheet Exchanger
\
ADDITIONAL DATA FOR fIXED TUBESHEET EXCHANGERS
Shell Temperature for Internal Pressure DELTs 4BO.00
shell Material S1\-516 70
Shell Allowable Stress at Temperature Ss 20000.00 psi
Shell Allowable Stress at Ambient SAS 20000. 00 psi \
Channel Temperature for Internal Pressure DELTC 480.00 F
Channel Material SA-516 70
Channel Allowable Stress at Temperature So 20000.00 psi
Channel Allowable Stress at Ambient SAC 20000.00 psi
Length of 'I'tJbes RL 96.00 in. \
Tube Fixity condition k O.QO
Tube Yield Stress At Operating Temperature SYT 2HOO.00 psi
Expansion Joint Spring Rate ( Ibs./in. ) Sj o. lbs./in.
Expansion Joint Projection from Shell 00 wj 0.0000 in.
Maximum Unsupported Tube Length SL 44.00 in. \
Tube Span Between Baffle and Tubesheet SLT 4.4.0000 in.
Mean Shell Metal Temp. along Shell len. TEMPSM 0.00 F
Mean Tube Metal Temp. along Tube length TEMPTM 0.00 F
Tubesheet Metal Temp. at Rim TDASH 0.00
Shell Metal Temp. at Tubesheet TDASHS 0.06
F
F \
Ch~nnel Metal Temp. at Tubesheet TDASHC 0.00 F
ASME Tube Joint Reliability Factor FASME 0.65
Classification for Tube Joint Type TJNT r

Number of Tubes RNTUBS 1511 ( \

Tube Wall Thickness t 0.0,50 in.
Tube Outside Diameter D 0.7500 in.
Design Temperature of the Tubes 480.00 F
Tube Layout Pattern
Tube Material
Triangular
SA-214 \

\
"-.c.;"'-

9-20 Heal Exchanger Tubesheets \

\
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 Pressure Vessel Design and Analysis - Seminar Notes ASME Tubesheets

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ASMETube Analysis: EX-Z FIXED COM Item: 1 9:51a Sep 21/2000

Tube Allowable Stress at Temperature SOT 11400.00 psi

Tube Allowable Stress At Ambient SAT 11400.00 psi
Tube Pitch (Center to Center Spacing) P 0.9375 in.
Radius to Outermost Tube Hole Center rc 18.0000 in.
Tube-side pass partition groove depth hg 0.0000 in.
Largest Center-to-Center Tube Distance Ul 0.0000 in.
Length of Expanded Portion of Tube Pedd 0.0000 in.

ADDITIONAL DATA FOR TUBE SHEETS EXTENDED AS FLANGES:

Flanged Tubesheet Outside Diameter DF 47.6500 in.
Diameter of Bolt Circle DB 45.5000 in.
Flange Thickness TF 3.5000 in.
Nominal Bolt Diameter DBOLT 1.0000 in.
Type of Threads TEMA Thread Series
Number of Bolts 56
Bolt Material SA-193 87
Bolt Allowable Stress At Temperature SBO 25000. 00 psi
Bolt Allowable Stress At Ambient SBA 25000.00 psi
Weld between Flange and Shell/Channel WLDH 0.0000 in.

ADDITIONAL DATA FOR GASKETED TUBESHEETS;

Flange Face Outside Diameter FOD 42.5000 in.
Flange Face Inside Diameter FID 40.5000 in.
Flange Facing Sketch I, Code Sketch 1a
Gasket Outside Diameter GOD 41.5000 in.
Gasket Inside Diameter GID 40.5000 in.
Gasket Factor, m, M 3.00
Gasket Design Seating Stress y 10000.00 psi
Column for Gasket Seating 2, Code Column II
Tubesheet Gasket on which Side SIDE CHANNEL

Installation Temperature of Assembly 70.00 F

ASME TubeSheet Results per APP. AA. 1998 Addenda A-99

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

Basic Gasket Width, 80 N I 2.0 0.250 in.
Effective Gasket Width, 8E 80 0.250 in.
Gasket Reaction Diameter, G (GOD+GID) I 2.0 41. 000 in.
Flange Design Bolt Load W 782983.88 lb.

Note: Since ASHE does not provide an explicit formula for flanged
extensions, the TEMA formula will be used.

Req. Thk. of Flanged Extension for Fixed Tubesheet Per TEMA 8th Edition
( FTREQ .98ISQRT((RMICRAZ-l+3.71IRA2ILN(R»)/((S*(A-G)I(1+1.86*RA2»
FTREQ .98+SQRT( 0.176E+07+( 1.1693 A2-1+3.71* 1.1693 A2 I LN( 1.1693»)/
( 19680+( 47.6500- 40.7500)*(1+1.86* 1.1693 A Z»
FTREQ 2.0204 in.

Elasticity/Expansion Material Properties

Heal Exchanger Tubcshccts 9-21

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ASME Tubesheels Pressure Vessel Design and Analysis - Seminar Notes

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ASMETube Analysis EX-2 FIXED COM Item; 1 9:51a Sep 21,2000

Shell - TEMA C-Mn-Si, 1-1/4Cr-1/2Mo & 3Cr-1Mo

Coeff. of Thermal Exp. at Metal Temp. along Length 0.5530E-05 / deg F
Elastic Modulus at Design Temp. 0.2758E+08 psi
Channel - TEMA : C-Mn-Si, 1-1/4Cr-l/2Mo & 3Cr-lMo
Coeff. of Thermal Exp. at Metal Temp. at Tubesheet 0.5530E-05 / deg F
Elastic Modulus at Design Temp. 0.2758E+08 psi
Tubes - TEMA : Plain Carbon Stl & C-Mn Stl.
Coeff. of Thermal Exp. at Metal Temp. along Length 0.6076E-05 / deg F
Elastic Modulus at Design Temp. 0.2708E+08 psi
TubeSheet - TEMA : C-SI, C-1/2Mo & Cr-1/2Mo
Coeff. of Thermal Exp. at Metal Temp. at Rim 0.5666E-05 / deg F
Elastic Modulus at Design Temp. 0.2708E+08 psi
Shell - TEMA : C-Mn-Si, 1-1/4Cr-l/2Mo & 3Cr-lMo
Coeff. of-Thermal Exp. at Metal Temp. at Tubesheet 0.5530E-05 / deg F

Results for ASME Fixed Tubesheet Calculations,

Per 1998 Revisions, Original Thickness :

Results for Step 1

rho Pedd / h
rho 0.0000/ 4.0000
rho 0.0000 ( must be 0 <~ rho <= 1

d* MAX ( dt 2tt'" ( Et/E ) ( St/S ) ( rho), dt - 2tt)

d* MAX ( 0.7500-2* 0.0750*( 0.271E+08/ 0.271E+08)*
( 11400/ 19680 )"'( 0), 0.7500-2* 0.0750 )
d* 0.7500 in.

ao ro + dt / 2
ao 18.0000 + 0.7500 / 2
ao IB.3750 in.

pstar p I sqrt{ 1 - 2*ro*UL/(Pi '* ao~2) )

pstar 0.9375 / sqrt( 1 - 2* 18.0000* 0.0000/
( 3.142 * 18.3750~2) )
pstar 0.9375 In.

mustar 1 - dstar / pstar

mustar 1 - 0.7500 / 0.9375
mustar 0.2000

Ks as / ao
Ks 20.5625 / 18.3750
Ks 1.1190 (
Kc ac / ao
Kc 20.5000 / 18.3750
Kc 1.1156

xt 1 - Nt*{ (dt - 2*tt) / (2*ao) )'2

9-22 Heat Exchanger Tubesheets

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 Pressure Vessel Design and Analysis - Seminar Noles ASME Tubesheets

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ASMETube Analysis: EX-2 FIXED COM Item: 1 9:51a Sep 21,2000

xt 1 - 1511""( ( 0.7500 - 2"- 0.0750)/(2"- 18.3750) )"2

xt 0.5972

xs 1 - Nt*( dt/(2.ao) l"2

xs 1 - 1511*( 0.7500/(2"- 18.3750) )"2
xs 0.3707

Results for Step 2

Ks Pi * ts( Ds + ts )Es/t
Ks 3.14"- 0.3750( 40.7500 + 0.3750 ) 0.276£+08/ 96.000
Ks 13919066.0000 psi * in.

Kt Pi"- tt( Dt - tt )Et/L

Kt 3.14"- 0.0750( 0.7500 0.0750) 0.271E+08/ 96.000
Kt 44863.4180 psi * in.

Kst Ks / ( Nt ,.- Kt )
Kst 0.139E+08 / ( 1511 * 44863.4180 1
Kst 0.2053

s ( ( 3 * (l rnus A2) )A O • 25 ) /
0; ( (Os + ts)/2 * ts ) .... 0.5
s ( ( J * (l - 0.30"2) )"0.25 ) /
( { 40.7500 + 0.3750)/2. * 0.3750) .... 0.5
s 0.4629 (= 0.0 if Gasketed 1

c ( ( 3 * (1 - rouc""2l )""0.25 ) /
= ( (Dc + tc)/2 • tc lA O. 5
c ((3"- (1 - 0.30""2) )""0.25 ) /
( ( 40.7500 + 0.3750l/2. * 0.3750)""0.5
c 0.0000 (= 0.0 if Gasketed )

Results for Step 3 :

J 1 / ( 1 + Ks/Kj )
J 1 / ( 1 + 0.139E+08/ 0.0000 )
J 1.000000000 ( = 1.0 if No Exp. Joint)

Lambdas rnus*as/ts + Es/Et * ( (rnut*dt)/(2"-tt) +

ao""2"- xs/( Nt * tt "-(dt-tt) )
Lambdas 0.3* 20.5625/ 0.3750 + 0.276E+08/ 0.271E+08 ,.-
( ( 0.3* 0.7500)/(2* 0.0750) + 18.3750""2 • 0.3707/
( 1511 ,.. 0.0750 ,.. ( 0.7500 - 0.0750) )
,
( Lambdas 19.6441

Lambdat rnut*( dt - 2*tt )/( 2*tt ) +

ao A2 * xt/( Nt * tt *(dt-tt) )
Lambdat 0.3*( 0.7500 - 2* 0.0750 l/{ 2* 0.0750 ) +
18.3750....2 * 0.5972/( 1511 * 0.0750 *
( 0.7500 - 0.0750))

HeaL Exchanger Tubesheets 9-23

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 ASME Tubesheels
Pressure Vessel Design and Analysis - Seminar Noles

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ASMETube Analysis: EX-2 FIXED COM Item: 1 9:51a Sep 21,2000
Lambdat = 3.8361

gamma {alphatm*( Ttm - Tarnb - alphasm*( Tsm - Tamb ))* L

gamma ( 0.608E-05*( 0 - 70) 0.553£-05*( 0 - 70)"
96.00
gamma -0.0037 in.

Qe = J*gamma/L + J*Lambdas " (Ps/Es) _

(Pt/Et) * (J*Lambat + Et"as/ (2"Es*ts»)
PS*(1~J)/2 * hj* (Ds + hj)/(Es*ts*Os)
Qe 1.0000* -0.0037/ 96.00 + 1.0000* 19.6441*{ 250.00/ 0.276E+08)
( 525.0/ 0.271E+08)*( 1.0000* 3.8361 + 0.271E+08* 20.5625/
(2* 0.276E+08* 0.3750») - 250.0*(1 - 1.0000)/2 * 0.00*
( 40.7500 + 0.00)/( 0.276E+08* 0.3750* 40.7500)
Qe -0.000456451

Results for Step 4

eta ( E*/E ) * ( 1 A
nu 2)/( 1 - nu*A 2 )
eta ( 0.1553 )" ( 1 - 0.3000 A2 )/( 1 _ 0.4586*A 2
eta 0.1790

Xa ({24 * (1 rnu*"'2) "Nt * Et* tt+ (dt - tt)" aO"'2) /

A
( E* " L * H 3 ) )A O . 25
A
Xa (24 *(1 0.459 2)* 1511* 0.271E+08" 0.0750"
(0.7500 0.0750)* 18.3750 A2)/( 0.421E+07 *
96.00 * 4.000 A3 ))A O . 25
Xa = 4.7588
A A
v = 2/(E * h 3)* ( s" ts 3* Es* as/(1 _ rnus A2)*
(1 + s*h + SA2 * h A2 /2) + c* tc A3* Ee* ac/
(1 - rouc"'2)* (1 + c*h + c A2* h A2 /2) )
A
V 2/( 0.271E+09*
A 4.0000 3)* ( 0.463* 0.3750 A3 * 0.276E+08* 20.5625/
(1 - 0.300 2)*(1A + 0.463* 4.0000 + 0.463 A2* 4.0000 A2 /2) +
( 0.000* 0.3750 3 * 0.276E+08* 20.5000/
(1 - 0.300"'2)*(1 + 0.000* 4.0000 + O.OOOA Z * 4.0000 A2 /Z)
V = 0.08015467Z

gamastars A
SAZ * Ats 2 * Ks"'3 *(1 + s*h)/(6*(1 _ rnus"'Z»
A
gamastars 0.463 Z * 0.3750 Z * 1.119 A3* (1 + 0.463* 4.0000)/
( 6* ( 1 - 0.300 A2 ) )
gamastars 0.022053536

gamas A
(Ks 2 - 1) * (Ks -1)/4 - gamastars
gamas ( 1.119"'2 - 1) * ( 1.119 - 1)/4 - 0.OZ21
gamas -0.014545569

gamastarc
(
CAZ * te"'2 " KC"'] *(1 + c*h)/(6*(1 _ rnuc A2l)
gamastarc A
0.000A 2 " 0.3750 2 * 1.116"'3* (1 + 0.000* 4.0000)/
( 6* ( 1 - 0.300 A2 ) )
gamastarc 0.000000000

9-24
Heat Exchanger Tubesheets

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 Pressure Vessel Design and Analysis - Seminar Noles ASME Tubesheels

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FileName; Seminar --------------------------------------- Page 98
ASMETube Analysis: EX-2 FIXED COM Item: 1 9:51a Sep 21,2000

gamac (Kc A 2 _ 1) w (Kc -1)/4 - (Kc A 3 Ks)/2 gamastarc

gamac ( 1.119 A 2 - 1) w ( 1.119 - 1)/4
( 1.116 A 3 - 1.119)/2 - 0.0000 .
gamac -0.005373001

Results for Step 5 :

Values from Table AA-2.4

Zd 0.013938
ZV 0.043256
Zm 0.296594

(1 - rnu A 2)!eta * ( In( A/{2*ao) ) ~ V)

(1 - 0.3000 A 2)/ 0.1790 * (In( 47.65/(2* 18.3750) ) ~
0.0802 )
1. 727864861

Q1 (Ks - 1 - * Zv) / ( l + * Zm)

Q1 (1.1190 - 1 - 1.7279* 0.0433)/(1 . ,. 1.7279* 0.2966)
Q1 0.029294359

Tr (T + Ts + Tc)/3
Tr (0.0 + 0.0 + 0.0) / 3
Tr 0.0000 F

T*s (Ts + Tr)/2

T*s (0.0 + 0.0) / 2
T*s 0.0000 F

T""c (Tc ~ Tr) /2

TIC (0.0..,. 0.0) / 2
T*c 0.0000 F

Pstars Es*ts/as * ( alphas * (TIs Tamb)-

alpha ..,. (Tr - Tamb) )
Pstars 0.276E+08* 0.3750/ 20.5625 * ( 0.553E-05 "" ( 0.0 - 70.0) -
0.567E-05 * ( 0.0 - 70.0) ]
Pstars 4.8049 psig

Pstarc Ec*tc/ac * ( alphac "" (Tirc Tamb)-

alpha * (Tr - Tamb) )
Pstarc 0.276E+08* 0.3750/ 20.5000 * [ 0.553E-05 * ( 0.0 70.0) -
0.567E-05 * ( 0.0 - 70.0) )
Pstarc 4.8196 psig
(
Q2 (ao A 2*( Pt*gamac + Pstarc*gamastarc ~ Ps""gamas -
pstars,o,gamastars) + W*gamab!(2*Pi) ) ! (1 + *Zm)
Q2 (18.3750 2*( 525.00* -0.00537 + 4.82* 0.00000..,.
A

250.00* -0.01455 4.80* 0.02205) + 782983.9* -0.12245/

(2* 3.14) ) / (1 + 1.7279* 0.2966)
Q2 -11549.908203125

Heat Exchanger Tubesheets 9-25

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ASME Tubesheets Pressure Vessel Design and Analysis - Seminar Noles

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc .• Local White Lock
FileName: Seminar --------------------------------------- Page 99
ASMETube Analysis: EX-2 FIXED COM Item: 1 9:51a Sep 21,2000

Results for Step 6 :

QZl (Zd + Ql*Zv) /2 "Xa"'4

Qzl (0.01394 + 0.02929* 0.04326)/2 * 4.75884"'-4
Qzl 3.8992

A
Qz2 (Zv + Ql*Zm) /2 *Xa 4
Qz2 (0.04326 + 0.02929· 0.29659)/2 * 4.75884 ....4
Qz2 13.3203

A
Ux (Zv + (Ks - 1) *Zm) ·Xa 4/2
Ux (0.0433 + ( 1.1190 - 1)* 0.2966)* 4.75884"'4/2
Ux 20.1466

Pe 2/ao"'2" (as*Es*ts*Qe - J*Kst*Q2*Ux

O.5*(Ps - Pt)*ao"'2*(Ks"'2 - 1»/(1 + J*Kst*
(Qzl + (Ks -I)*Qz2) )
Pe 2/ 18.3750"'2 * ( 20.5625* O.276E+OB* 0.3750* -0.0005 -
1.0000* 0.2053* -11549.91* 20.15 - 0.5*( 250.00 - 525.00)*
18.37s0~2*( 1.119~2 - 1)/(1 + 1.0000* 0.2053*{ 3.899 +
( 1.119 - 1)* 13.320) )
Pe -104.6997 psig

Q3 Q1 + 2*Q2/{pe*ao A2)
Q3 0.02929 + 2*-0.115E+Os/( -104.700* 18.3750 A2)
Q3 0.6827

Results for Step 7 :

Curve Value from Table AA-2.4

Fro '" 0.360388

hmin h (For pressure plus thermal case and thermal only case)
hmin 4.0000 in.

The Tubesheet Bending Stress - original Thickness:

Sigma (1.5*Fm/mustar) * (2*ao/hmin)A 2 * Pe
Sigma (1.5* 0.3604/ 0.2000) * (2* 18.3750/ 4.0000)A 2 ... -104.70
Sigma -23887.5625 psi

The Allowable Tubesheet Bending Stress ;

Sigma allowed 1.5 * Omega * S
Sigma allowed 1.5 * 2.6667 * 19680.00
Sigma allowed 78720.0000 psi

The Tubesheet Bending Stress - Final Thickness:

Sigmaf (l.s*Fm/mustar) * (2*ao/hmin) AZ * Pe
Sigmaf (1.5* 0.1963/ 0.2000) * {2* 18.3750/ 1.9270)A 2 * 147.01
Sigmaf 78719.8125 psi

Required Tubesheet Thickness, for bending stress :

9-26 Heat Exchanger Tubesheels

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 Pressure Vessel Design and Analysis - Seminar Noles ASME Tubesheels

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ASMETube Analysis: EX-2 FIXED COM Item: 1 9:51a Sep 21,2000

(Including CATS and CATC)

H reqd _ bend. H + CATS + CATC
H reqd. bend. 1. 9270 + 0 _0000 + 0.0000
H reqd. bend. 1.9270 in.

mu (p - dt) /p
mu (0.9375 0.7500)/0.9375
mu 0.2000

The Tubesheet Avg. Shear Stress - Original Thickness:

Tau (1/ (2*mu) ) * { ao/h l • Pe
Tau (1/{2* 0.200) ) * ( 18.3750/4.000 1 * -104.700
Tau -1202.4100 psi

The Allowable Tubesheet Shear Stress

Tau allowed 0.8 * S
Tau allowed 0.8 * 19680.00
Tau allowed 15744.0000 psi

The Tubesheet Shear Stress - Final Thickness:

Tauf (1/ (2*mu) ) * ( ao/h ) * Pe
Tauf (1/ (2* 0.200) ) * ( 18.3750/ 0.976 ) * 333.879
Tauf 15715.6035 psi

Required Tubesheet Thickness, for shear stress :

(Including CATS and CATC)
H reqd. shear H + CATS + CATC
H reqd. shear 0.9759 + 0.0000 + 0.0000
H reqd. shear 0.9759 in.

Required Tubesheet Thickness for Given Loadings,

(Including CATS and CATC)
H reqd. Max{ H_re'L-bend, H~reqd_shear
H reqd. Max{ 1.9270, 0.9759)
H reqd. 1.9270 in.

Results for Step 8 ;

A
Fq (zd + Q3*Zv)*Xa 4/2
A
Fq (0.0139 + 0.6827* 0.0433)* 4.7588 4/2
Fq 11.1474

The Tube Stress in the outermost Tube row.

Sigmato ( (Ps*xs - Pt*xt) - pe*Fq) / (xt - xs)
sigmato ( ( 250.00* 0.3707 525.00* 0.5972) -104.70* 11.147)/
( 0.5972 - 0.3707)
( Sigmato 4176.6797 psi

The Allowable Tube Stress

Sigmato allowed omegat * Sot
Sigmato allowed 2 * 11400.00
Sigmato allowed 22800.0000 psi

Heat Exchanger Tubesheets 9-27

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ASME Tubesheets Pressure Vessel Design and Analysis - Seminar Noles

COADE Engineering Software

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ASMETube Analysis: EX-2 FIXED COM Item: 1 9:51a Sep 21,2000

The Force on the Outermost Tube ;

TubeForce TubeStress * Tube Area
TubeForce 4176.68 * 0.15904
TubeForce 664.2722 lb.

The Allowable Tube Force Per Appendix A VIII 1

Force Allowed 0.1590 * 11400.00 * 0.65 * 1.00 * 1.00
Force Allowed = 1178.5096 lb.

Results for Step 9

Qz2star ( (Zv + Q3*Zm)*Xa A 4 )/2

Qz2star ( ( 0.0433 + 0.6827* 0.2966)* 4.7588 A 4 )/2
Qz2star 63.0190

The Shell Membrane stress due to joint interaction

A
Sigmasm ao 2*Pe/(2*as*ts) + Pt*as/(2*ts) +
(Ps - Pt)/2 * ao*(Ks A 2 - 1)/(Ks*ts)
Sigmasm 18.3750 A 2* -104.70/(2* 20.5625* 0.3750) +
525.0* 20.5625/(2* 0.3750) + ( 250.0 - 525.0)/2 * (
18.3750*( 1.119 A 2 - 1)/( 1.119* 0.3750)
Sigmasm = 10582.6562 psi

The Shell sending stress due to joint interaction

Sigmasb = 12* (1 + s*h/2)* (Es/E)* (s*ts/eta) *
A A
(ao 3/(h 3*Xa A 4»)* Pe*Qz2star +
1/(1 - rnus A 2)*(Ps - rnus*Sigmasm*ts/as +
Pstars)* SA 2 * as A 2
Sigmasb 12* (1 + 0.463* 4.000/2)* ( 0.276E+08/ 0.271E+08)*
( 0.463* 0.3750/ 0.179) + { 18.3750 A 3 /
( 4.000 A 3* 4.7588 A 4))* -104.700* 63.019 +
0.30* 10582.7 *
A
1/(1 - 0.30 2)* (250.0
A
0.3750/20.5625 + 4.80) * 0.4629 A 2* 20.S62S 2
Sigmasb = -8859.6250 psi

SHELL STRESS SUMMATION VS. ALLOWABLE

ISigmasm/ + ISigmasbl =< 1.5 * Omega * Ss
I 10582 I + I -8859 I =< 1.5 * 2.6667 • 20000
19442.28 must be < or = 80000.0000

Computations completed for ASME Tubesheet configuration b

Summary of stress/force comparisons

Stress Description Stress Value Allowable

Tubesheet bending stress 23887.6 <~ 78720.0 psi

Average Tubesheet shear stress 1202.4 <~ 15744.0 psi
Tube stress in the outermost tube 4176.7 <~ 22800.0 psi
Force on the outermost tube 664.3 <~ 1178.5 lb.
Shell stress due to j t. inter. 19442.3 <~ 80000.0 psi

9-28 Heat Exchanger Tubesheets

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 Pressure Vessel Design and Analysis - Seminar Noles ASME Tubesheels
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SUMMARY of RESULTS for ASHE Tubesheet Calculations

Reqd Tubsheet Thickness + CATS + CATC HREQ 1.9270 in.
Actual Tubsheet Thick. as Given H 4. 0000 in.
Required Thickness for the Flanged Portion FI'REQ 2.0204 in.
Actual Thickness for the Flanged Portion TF 3.5000 in.

The PV Elite Program, (c) 1989-2000 by COADE Engineering Software

Heat Exchanger Tubeslleets 9-29

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ASME Tubcshects Pressure Vessel Design and An'alysis - Seminar NOles

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9-30 Heal Exchanger Tubesheets

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Pressure Vessel Design amI Analysis - Seminar Notes

Chapter 10:
Expansion Joints

FLANGED AND FLUED EXPANSION JOINTS

These are also commonly called "thick-walled" expansion joints. They are characterized
by having a small number of large bellows with relatively thick walls on the order of 0.25
m.
Thick-walled expansion joints are analyzed using "Expansion Joints for Heat Exchang-
ers," by S. Kopp, American Locomotive Company, Alco Products Division, and M.F.
Sayre, Union College, Schenectady, N.Y. This method is commonly referred to as the
"Kopp and Sayre" method.
TEMA has modified the Kopp and Sayre method to reflect the use of plate and shell the-
ory, and has implemented it as paragraph RCB-8. This is also the method that is imple-
mented in the CodeCalc program.
Evaluation of the stresses calculated by this method is based on the ASME Code, Section
VJII, Division I, Appendix CC, Paragraph CC-3.
The formnlas contained in the program are applicable based on the following assumptions:
Applied loadings are axial.
Torsional loads are negligible.
The flexible elements are snfficiently thick to avoid instability.
The flexible elements are axisymmetric.
The sequence of calcnlation used by the program is as follows:
I. Select a geometry for the flexible clement per RCB-8.21 (user input).
2. Determine the effective geometry constants per RCB-8.22.
3. Calculate the flexibility factors per RCB-8.3.
4. Calculate the flexible element geometry factors per RCB-8A.
5. Calculate the overall shell spring rate with all contributions from flexible shell ele-
ments per RCB-8.S.
6. Calculate Fax for each condition as shown in Table RCB-8.6. This requires that you
run the CodeCalc Tubesheet program to determine the differential expansion and
shellside and tubeside equivalent pressures.
? Calculate the flexible element stresses per RCB-8.?
8. Compare the flexible element stresses to the appropriate allowable stresses per the
Code, for the load conditions as noted in Step 6.
9. Modify the geometry and rerun the program if necessary.

Expansion Joints to-t

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Flanged and Flued Expansion Joints Pressure Vessel Design and Analysis - Seminar Noles

Figure lO-1 shows geomelry for the THICKJNT program. (TEMA Figure RCB-8.2l and
RCB-8.22) Both the input geomelry and the equivalent geometry used for the analysis are
shown. The discussion of input data below uses the nomenclature shown on this figure.

I. I. t. I.

t.

<:l
C
t,
2r~ I,
<:l
C
I,
1 1.-0 / ... 0
r." 0 r.-O
I, I, I,
"

til. I, I,
I.)

(--"
I, -
Ii -
TI
_. -Ir +
.
I.

-
.Q

~
y, Y. a
~X+

Figure 1--Geomelry for Flanged and Flued Expansion Joints

The Kopp and Sayre Method uses continuity considerations '0 elastically calculate equiv-
alent stresses in the expansion joint.
The bellows outside diameter, inside depth, and the radius of the inside and oulside cor-
ners are shown in the sketch on the following page. The analysis technique also applies to
joints with a square comer (zero radius) at either 'he inside diameter or the outside diame-
ter.
When a flanged-only expansion joint or a square expansion joinl is analyzed, the bellows
thickness should be the same as the shell thickness, and the web thickness should be the
thickness of the annular plate.

10-2 Expansion Joints

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 Pressure Vessel Design and AnCllysis - Seminar Noles Flanged and Flued Expansion Joints

For fully flanged and flued joints, thc bellows web thickncss is typically a lillie bit less
than thc nominal bcllows thickness due 10 thinning in the forming operation.
The Kopp and Sayre method analyzcs a square cornercdjoint, and approximatcs radiused
corners by substituting the length of a square corner wilh the samc stiffness. Thus Ihe
method produces an equivalcntlcngth and span for use in the analysis.
Allowable stress for internal and external pressure are based on the ASME Code, Section
VIII, Appendix CC, Paragraph CC-3, and is 1.5 limes the basic material allowable stress
in Ihe flat pari of the annulus and 3.0 times the basic allowable slress near the corners.
Individual stress intcnsitics are based on the algcbraic addition ofthc various cases,
including differential expansion pressure, shellside and lubeside design pressurc, and the
equivalent pressures due 10 othcr loadings. All ofthesc loads are found in the output of the
CodeCale Tubesheet Program.
Since thc CodeCale Tubesheel program is separate from the flanged and flued expansion
joinl program, a new expansion joint design requires an iterative approach:
I. Select expansion joint geometry using the expansion joint program based only on
shcllside and tubeside pressure. Detcrmine the spring constant for this joint.
2. Run Ihe Tubeshcet program with this spring constant and determinc the required
tubesheet Ihickness plus thc differential and equivalent pressures.
3. Enter the differential and equivalcnt pressures into the cxpansionjoinl program and
determine if the joint is adequate from a strcss standpoint. If il is nOI, rcsize the joinl
and repeal from Stcp I.
The stress resulting from intcrnal pressure (shellside pressure) lends 10 increase as the
joint OD increases, and decrease as the joint thickness increases. The stress due to differ-
cnlial cxpansion and tubeside pressure lends to decrease as joint OD increases and
increase as joint thickness increases. Workable designs will adequately balance Ihesc com-
peting demands.
The maximum stress range is automatically calculated for each design case by the TEMA
procedures.
The cycle lifc is bascd on the material category, using the fonnulas given in the ASME
Code, Section VIII, Division I, Appendix CC, Paragraph CC-4. This paragraph includes a
power law formula for fatigue evaluation as follows:
( 2.17

< 2.2
- ( 14.2Kg Sn )
E 0.03
b

for series 3XX high alloy steels, nickel-chromium iron alloy, nickel-iron chromium alloy
and nickel-copper alloy.
2."
< 2.0
- [ 15K S )
+-0.011
b

for carbon, low alloy, series 4XX, and high alloy steels.
N is the number of cycles, the cycle life.
Sn is the maximum stress range resulting from the analysis.

Expansion Joints 10-3

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Flanged and Flued Expansion Joints Pressure Vessel Design and Analysis - Seminar Noles

E b is the elastic modulus for the material at the temperature under consideration.
Kg is the fatigue strength reduction factor. Use a fatigue strength reduction factor of
1.0 if both thc inside and the outside comcr radii are greater than 3 times the joint
thickness. If either radius is 0.0 usc a factor of4.0. Ifboth radii arc greaterthan 0.0 but
less than 3.0 times the thickness, use a value of2.5.

10-4 Expansion Joints

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 Pressure Vessel Design and Analysis - Seminar Noles Pressure Vessel Design and Analysis Seminar Componenl

PRESSURE VESSEL DESIGN AND ANALYSIS SEMINAR

COMPONENT DESIGN PROBLEM

. Flanged and Flued Expansion Joint Analysis

Evaluate the stresses in the following expansion joint:

10-1\ (3048mm) tit shell, 0.375-in. (9.5 mm) thickness, 25.25-in.(641 mm)!D, SA-
516-70 at 200°F (93°C)
34-in. 00, 33-in.!D Expansion Joint, 0.4375 thick, SA-240 316 SS at 200°F
At the joint!D there is a I-in. (25.4 mm) straight flange and 1.5-in. (38.1 mm) radins
bend.
At the joint 00 there is a l-in.(25.4 mm) straight flange and 1.5-in. (38.1 mm) radius
bend.
There is a short I-in. (25.4 mm) outer cylinder connecting the two halves of
the expansion joint.
The outer cylinder thickness is 0.5 in. (12.7 mm), SA-240 316 SS.

From the Tubesheet Program you learn the following Information:

PO = 515.9200 psi (3.55 Nmm2)
PS ~ 200.0000 psi (1.372 Nmm2)
PSP ~ -38.7500 psi (-0.267 N/mm2)
PT ~ 100.0000 psi (0.689N/mm2)
PTP = 86.9000 psi (0.559 Nmm2)

Notes:

Questions:

What is the minimum cycle life for the bellows? _

DO NOT TURN THE PAGE UNTIL YOU HAVE

COMPLETED YOUR ANALYSIS

Expansion Joints 10-5

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Input Echo, Thick Joint Item I, Description: EX-4 JOINT 1

Design Temperature for Expansion Joint TEMP 200.0000 F

Inside Diameter of Expansion ~oint RID 33.0000 in.
Outside Diameter of Expansion Joint ROD 34.0000 in.
Wall thickness of Expansion Joint TE 0.4375 in.
Corrosion Allowance for Expansion ~oint CAE 0.0000 in.
Material for Expansion Joint SA-240 316
Operating Allowable Stress, Expansion Joint SOE 20000.00 psi
Ambient Allowable Stress, Expansion Joint SAE 20000.00 psi

Inside Diameter of Shell G 25.2500 in.

Wall thickness of Shell TS 0.3750 in.
Corrosion Allowance for Shell CAS 0.0000 in.
Length of Shell Cylinder RLI 40.0000 in.
Material for Shell SA-516 70
Operating Allowable Stress, Shell SOS 20000.00 psi
Ambient Allowable Stress, Shell SAS 20000.00 psi

Length of Straight Flange, Joint ID FA 1. 0000 in.

Radius of Knuckle, Joint ID RA 1. 5000 in.
Length of Straight Flange, Joint 00 FB 1. 0000 in.
Radius of Knuckle, Joint 00 RB 1.5000 in.

Thickness of Outer Cylinder TO 0.5000 in.

Corrosion Allowance for Outer Cylinder CAO 0.0000 in.
Length of Outer Cylinder RLa 1. 0000 in.
Outer Cylinder Material Name SA-240 316
Operating Allowable Stress, Outer Cylinder SOO 20000.00 psi
Ambient Allowable Stress, Outer Cylinder SAO 20000.00 psi
Differential Expansion Pressure PD 515.9200 psig
Shells ide Design Pressure PS 200.0000 psig
Shellside Prime Design Pressure PSP -38.7500 psig
Tubeside Design Pressure PT 100.0000 psig
Tubeside Prime Design Pressure PTP 86.9000 psig

Analyze for Differential Expansion y

Analyze for Shellside Pressure y
Analyze for Tubeside Pressure y
A.nalyze for Shellside + Tubeside Pressure y
Analyze for Shellside + Differential Expansion y
Analyze for Tubeside + Differential Expansion N
Analyze for Shells ide + Tubeside + Differential N (
Results per TEMA 1999

TEMA Paragraph RCB B.22 Effective Geometry Constants:

Ta IF(RA<>O,Te,Ts) 0.4375 in.
Tb IF (MoO, Te, To) 0.4375 in.
A ( G + TA ) / 2.0 12.B437 in.
B (ROD-TB)/2 16.7B12 in.

10-6 Expansion Joints

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H I B - A) 3.9375 in.
RLA FA + RA+ TE I 2.0 2.7188 in.
RLB FB + RB I 4.0 + TE I 2.0 2.7188 in.
RADASH " RA + o. 5 TE • 1.7l88 in.
RBDASH " RB + 0 .5 • TE 1.7188 in.
YA MIN I RLA + RLI, 2 SQRT A TA 4.7409 in.
YB "" MIN I RLB + RLO, 2 • SQRT B • TB 3.7188 in.

TEMA Paragraph ReB 8.30 Element Flexibility Factors:

Elastic Modulus for Expansion Joint Material EE 0.273E+08 psi
Elastic Modulus for Shell Material ES O. 290E+08 psi
Elastic Modulus for Outer Cylinder MatI. EO 0.273E+08 psi

EA IF (RA <> 0, EE, ES) 0 .273E+08 psi

EB IF (RB <> 0, EE, EO) 0 .273&+08 psi
Ba 1.285 / SQRT( A * TA 0.5421 l/in.
Bb 1. 285 / SQRT! B * TB 0.4742 l/in.
Da 0.0916 • EA • TA**3 209407.53 in. lb.
Db 0.0916 EB * TB**3 209407.53 in. lb.
De 0.0916 • EE * TE .... 3 209407.53 in. lb.

Wa BA • YA 2.5700
RJIA SIN( WA • SINH { WA 3.5134
RJ2A COS ( WA * COSH ( WA -5.5266
ZZA RJIA**2 + RJ2A**2 42.8877
RKOA SINH{ WA ) + SIN ( WA 7.0356
RKIA COSH { WA ) + COS ( WA I RKOA 0.8144
RK2A SINH( WA ) SIN{ WA I RKOA 0.8462
RK3A COSH! WA ) COS { WA I RKOA 1.0535

wb
RJIB
RJ2B
BB • YB
SIN( WB ) .
SINH{ WB
COS( WB ) '* COSH{ we
1.7636
2.7785
-0.5753
ZZB RJIB*"'2 + RJ2B"'·2 8.0511
RKOB SINH{ we ) + SIN( WB 3.8124
RKIB COSH( we ) + COS ( WB I RKOB 0.7373
RK2B SINH{ WB ) SIN ( HB I RKOB 0.4851
RK3B COSH( WB ) COS I WB I RKOB 0.8378

TEMA paragraph RCB 8.31 Cylinder Flexibility Factors:

CIA (RLA / SQRT ( A • TA ) ) 1.1469
C2A (TS / TA ) 0.8571
C3A (EA / ES ) 0.9414
C4A -0.364661+{0.338172/C2A)-(O.0366351/C2A**2 -0.0200
C5A -1.06871+(1.01164/C2A)-(0.122627/C2A··2) -0.0554
C6A 0.0696709+(1.76415*C2A)-(S.46103"'C2A"''''3) -1. 8572
C7A -0.142734+{0.918656*C2A)-(2.00749"'C2A**3) -0_:6195
C8A (C5A/C1A'*·2-C6A/CIA"'*3+C7A/CIA*"'4-C4A)
/(C3A H O.2) 0.8612
EAA 2.718"''''C8A 2.3658

CIB RLB / SQRT( B • TB ) ) 1.0034

C'B TO / TB ) 1.1429

Expansion Joints 10-7

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C3B ( EB I EO I 1.0000
C4B (3.3731-1.707962*C2B+0.226216*C2B**2)/1000 0.0017
C'B -0.403287+0.3200J7*C2B-0.0307508*C2B**2 -0.0777
CGB -0.684978+0.582549*C2B-0.0547812*C2B**2 -0.0908
C7B -0.201334+0.168201*C2B-0.015728*C2B**2 -0.0296
C'B (CSB/C1B**2-C6B/C1B**3+C7B/C1B**4-C4B)
/ (C3B H O.2) -0.0183
EBB 2.718**C8B 0.9819

TEMA paragraph RCB 8.40 Element Geometry Factors:

RYl (EAA* (RK3A-RK2A H 2/ (2*RK1A)) / (DA*BA)) 12.7948 I 10-"6
RY2 (EBB* (RK3B-RK2B H 2/ (2*RK1B)) / WB*BB)) 6.7051 I 10"'6
C {A**2/ (B**2 - A**2») 1.4142
D ( B / A ) 1.3066
RXI -A * C * (0.769 + 1.428 * D * D) / DE -278.1458 I 10"'6
RX2 2.2 * A * C * D * D / DE 325.7556 I 10"'6
RX3 -A*A*(1.538+LN(D)*{2+C*(2+3.714*D*D)))
/ (4*OE) -1.0294 I 10"'3
RX4 ( -2.2 * B * C ) / DE -249.3214 I 10"'6
RX' {B * C * (0.769 * D * D + 1.428) / DE) 310.6066 I 10"'6
RXG (-A*B*{1.538 + 5.714*C*ln(D)) / (4*DE») -951.7537 I 10-"6
XBOT (RX1 RY1) * (RX5 + RY2) - (RX2 * RX4) -0.0111 I 10"6
RX7 (RX2 * RX6 RX3 * RXS RX3 * RY2) / XBOT -1.4941
RX' (RXJ * RX4 - RX1 * RX6 + RX6 * RY1) / XBOT 1.8255

RQ1 0.38S * A * A + 1.429 * C * B * B * In{D) 215.6894

RQ2 (-0.385 - 1.429 * C * In(D)) * B * B -260.5991
RQ3 .2S*A*B*B*(1.269/fC*D*D)+3.714*C*ln(D)"'2) 814.9036
GG (A/B) 0.7654
GST (GG**4 * In(GG) / (1-GG**2)) -0.2215
RM1 0.51 - 0.635 * GG**2 + GST -83.4889 I 10"'3
RM2 0.635 (1 - GG**2 ) + GST 41.5111 I 10"'3
RM3 2.357 * GG**2 + 3.714 * GST 0.5580

TEMA Paragraph RCB 8.50 Stiffness Multiplier:

TEMA Paragraph ReB 8.51 Y Geometrical Parameters:

YA IF( YA/G >00 0.075) YA 1.0 1. 0000
YB 00 IF( YB/G >'" 0.075) YB = 1.0 1. 0000

TEMA Paragraph RCB 8.52 Equal Knuckle Radii Case {RA RB) :
M = Fig RCB-8.51 ( RADASH, H, TE ) 1.6949
ALPHA '" IF{G/TE < 160) ALPHA '" 4.3*(G/TE)"'-0.287 1.3427
K '" ALPHA * M * YA * YB 2.2758

TEMA RCB 8.60 Flexible Element Stiffness :

SJ 2*PI*A*DE*K/{ RX7*RQl + RX8*RQ2 + RQ3 2272059.250 lb./in.
SJF", {1.0 / (1.0/ SJ + 1.0 / SJ)) 1136029.625 lb./in.

Analysis of Differential Expansion

TEMA Paragraph RCB 8.70 Induced Axial Force:

Tubeside Equivalent Pressure for this case, PIC 0.000 psig

10-8 Expansion Joints

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Shellside Prime Pressure for this case, PSPC 0.000 psig

Differential Expansion Pressure for this Case, PDC 515.920 psig
Shellside Pressure for this Case, PSC 0.000 psig
Equivalent Pressure, PSS PIC + PSPC - PDC -515.920 psig
Induced Axial Force, FAX = A + PSS / 2.0 -3313.174 lb. in.

TEMA Paragraph RCB S.80 Flexible Element Moments

THA «(Ps+S"3) / (8·DE) ) •
(-2+GG+RM2-RM3/GG-GG"J/2-2 I GG"J·LN(GG)) 0.0000 I 10"'6
THB (Ps·B++J)+{-2·RM2-RM3+0.5-GG++2)/(S+DE) 0.0000 I 10.... 6
ZA (pS·A++2-0.J·1'.+FAX)/(EA·TA) 1. 0688 I 10.... 3
ZB (PSIS "'2- 0.3 + (A+FAX+ { (B ....2 -A "2) /2) IPS 1)
/ (ES+TB) 1.0688 I 10.... 3
MTlA (RXS+RY2)·(-THA-FAX·RX3-BA·ZA) -1.0823 I 10"'3
MT21'. RX2*(FAXIRX6+THB-(BS*RK2B+ZB/RK1B») 1. 0271 I 10.... 3
RMA (MTlA+MT21'.)/XBOT 4976.483 in.lb./in.
MT1B (RYl-RX1) +
(THB+FAX*RX6-(BB*RK2B*ZB/RKlB)) 917.3J31 I 10 .... 6
MT2B RX4 * (FAX·RX3+THA+BA*ZA) -850.4341 I 10 ....6
RMB (MTlB+MT2B)/XBOT -6026.405 in.lb./in.

TEMA paragraph RCB 8.82 Flexible Element Moments

RAIl -C*RMA+C*O*O·RMB+0.65*A+C*FAX*ln(GG) -11.1267 • 10"3
RA12 PSS*(0.32S.RM2*B*B+0.412S*A*Al 0.0000 I 10"6
RA1 (RA1D1-RAI2) -11.1267 10"3
RA21 C*RMA-C*RMS-0.6S.A*C*FAX*ln(GG) 5.1003 10 ....3
RA22 0.087S*RM3*PSS*B*B 0.0000 I 10.... 6
RA2 B*B.(RA21+RA22) 1. 4363 • 10.... 6
RA3 O. 206*PSS 0.0000 I 10.... 6
RA4 0.65*A*(FAX-0.S*A*PSS) -27.6598 • 10.... 3

Stress in Expansion Joint Flange:

SBX(R) = (6.0 / TE+*2) * (RAI + RA2/(R*R) + RA3*R*R + RA4 I ln{R/S»)
Stress Suounary:
Location: (A) 12.8437 in. , 155997.55 psi
Location: (B) 16.7812 in., -188909.36 psi

TEMA Paragraph RCB 8.83 Cylindrical Element Stresses

For the Inner Cylinder at X = YA

DEA +RRA*(PSS*RRA-0.3*F2A)/(EA*TYA) 1.2470 I 10.... 3
BIA (l/ZZA)* {RJ21'.IRMA/{2*8A"'2*EAA*OA)-RJIA*DEA -2.3046 I 10.... 3
B2A (1/ZZA)*(-RJIA*RMA/(2*BA*BA*EAA*OA)
-RJ2A*DEA) -1.2395 I 10.... 3
UlA +BA* (YA-YA) 0.0000 I 10"'6
U2A 811'.*SIN(U1A)*SINH(UI1'.)+B21'.*COS{UIA)
*COSH(Ul1'.) -1.2395 I 10"'J
SMYA EAI(OEA+U2A)/RRA 16.003 psi

For the Inner Cylinder at X = LA

DEA RRA*{PSS*RRA-0.J*F2A)/(EA*TY1'.) 1.2470 I 10"'3
BIA (1/ZZA1*{RJ2A*RMA/(2*BA"'2*EAA*OA)-RJ1A*OE1'. -2.J046 I 10"'3
B2A (1/ZZA)·(-RJIA·RMA/(2*BA"'2 I EAA*OA)-RJ2A*DE -1. 2395 I 10.... 3

Expansion Joints 10-9

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DIA BA*(YA-LA) -0.9317

D2A BIA*SIN(UIA) *SINH (UIA) +B2A*COS (UIA) *COSH (U -3.0679 / 10.0. 3
SMYA EA*(DEA+U2A)/RRA -3870.467 psi

For the Outer Cylinder at X = YB

DEB RRB*(PSS*RRB-O.3*F2Bl!(EB*TYB) 1. 0688 / 10"'3
BIB (1/ZZB)*(RJ2B*RMB!C2*BS"'2*EBS*DB)-RJlS*OEB 4.2870 / lOA)
B'B (1/ZZB)*(-RJlS*RMB/(2*Ss"'2*E8B*DB)-RJ2S*DE 22.5635 / lOA)
DIB BB*(YB-YB) 0.0000 / 10"'6
D'B BIB*SIN(UIBj*SINH(UIB)+B2B*COS(UIB)
A
·COSH(UIB) 22.5635 / 10 3
SMYB EB·(DEB+U2B)/RRB 38445.434 psi

For the Outer Cylinder at X '" LB

DEB RRS*(PSS*RRB-0.3*F2B)/(ES*TYB) 1.0688 / 10....)
BIB (1/ZZB)·(RJ2B*RMB/(2*BB ....2*EBB*DB)-RJIB*DEB 4.2870 / 10 .... 3
B2B (1/ZZB)*(-RJIB*RMB/(2*BB*BB*EBB*DB)-RJ2B*O 22.5635 / 10 .... 3
UlB BB*(YB-RLB) -0.8151
D2B BIB*SIN(U1B)·SINH(U1B)+B2B*COS(U1B)
*COSH(U1B) 23.7395 / 10 .... )
SMLB EB*(DEB+U2B)/RRB 40358.613 psi

TEMA Paragraph RCB 8.84 Maximum Cyclic Stresses

Evaluated per ASME A-99 Appendix CC, Paragraph CC-3(C):

For the Inner Cylinder:

SCLA = ABS(6.0*RMA/ (T*T)) + ABS(F2A/T) 163570.484 psi
RNA= 47.11*EXP«(ln(SCLA*28.3E6/EB)-14.12)**2/1.023 3.2217 * 10 .... 3

For the Outer Cylinder:

SCLB = ABS(6.0*RMB/ (T*T) + ABS(F28/T) 194705.406 psi
RNB= 47.11*EXP«ln{SCLB*28.3E6/EB)-14.12)*·2/1.023 1.6345 * 10....3

Analysis of Shellside Pressure

TEMA Paragraph RCB 8.70 Induced Axial Force:

PIC 0.000 PSPC= -38.750 PDC 0.000
PSC '" 200.000 PSS '" -38.750 FAX -248.848

TEMA pa-ragraph RCB 8 .80 Flexible Element Moments

THA -0.438 THB -0.410
2A 2.843 /10 .... 3 ZB 4.503 /10 ....3
A
MT1A 57.324 /10 .... 6 MT2A -56.875 /10 6 RMA -40.404
A
MT18 -50.797 /10 .... 6 MT2B 45.041 /10 6 RMB 518.487
(
TEMA Paragraph RCB 8.82 Flexible Element Moments
A
RAIl 2.094 *10 3 RA12 14.369 *10 3 HAl -12.275 *10 3
RA21 -1.576 ·10 3 RA22 2.750 *10 3 HA2 0.331 0010 .... 6
A
RA3 41.200 RA4 -12.800 *10 3

Stress in Expansion Joint Flange:

SBX(R) '" (6.0/ TE·*2) • (RAI + RA2/(R*R) + RA3*R*R + RA4*ln(R/B»
Stress Summary:

10-10 Expansion Joints

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Location: (A) 12.8437 in., -1621.83 psi

Location: (R) 14. 0081 in .• -6070.31 psi
Location: (B) 16.7812 io., 15717 _07 psi

TEMA Paragraph RCB 8.83 Cylindrical Element Stresses

For the Inner Cylinder at X = YA

DEA 3.316 /10 ....3 BIA -253.799 /10"'6 B2A 438.722 /10"6
OlA 0.000 /10"'6 U2A 438.722 /10"'6 SMYA 7.982 *10"'3

For the Inner Cylinder at X = LA

DBA 3.316 /10"'3 BIA -253.799 /10"'6 B2A 438.722 /10"'6
UIA -0.932 U2A 165.245 /10"'6 SMLA 7.400 *10"'3

For the Outer Cylinder at X YB

DEB 4.503 /10"'3 BIB -1.955 /10"'3 B2B -1.613 /l0"'3
UlB 0.000 /10"'6 U2B -1.613 /10"'3 SMYB 4.701 *10"'3

For the Outer Cylinder at X LB

DEB 4.503 /10"'3 BIB -1.955 /10"'3 B2B -1 .613 /10"'3
UIB -0.815 U2B -2.787 /10"'3 SMLB 2 .792 *10"'3

TEMA Paragraph RCB 8.64 Maximum Cyclic Stresses

Evaluated per ASME A-99 Appendix CC , paragraph CC-3fc):

For the Inner Cylinder:

SCLA 1. 635 *10"'3 RNA 1.000 *10"'6

For the Outer Cylinder:

SCLB 17.406 *10"'3 RNB 1.000 *10"'6

Analysis of Tubeside Pressure

TEMA Paragraph RCB 8.70 Induced ;r>.xial Force:

PIC 13.100 PSPC= 0.000 PDe 0.000
PSC ':0 0.000 PSS = 13.100 FAX 84.127

TEMA paragraph RCB 8.80 Flexible Element Moments

THA 0.000 /10"'6 THB 0.000 /10"'6
ZA -27.140 /10"'6 ZB -27.140 /10"'6
MT1A 27.482 /10 .... 6 MT2A -26.080 /10"'6 RMA -126.361
MT1B -23.292 /10 .... 6 MT2B 21.594 /10"'6 RMB 153.020

( TEMA Paragraph RCB 8.82 Flexible Element Moments

RAll 282.523 RAl2 0.000 /10"'6 RAI 282.523
RA21 -129.504 RA22 0.000 /10"'6 RA2 -36.470 "'10"'3
RAJ 0.000 /10"'6 RA4 702.325

Stress in Expansion Joint Flange:

SBX(R) = (6.0/ TE*"'2) * (RA1 + RA2/(R"'R) + RA3*R*R + RA4*ln(R/B»)
Stress Summary:
Location: (A) 12.8437 in. , -3961.02 psi
Location: (B) 16.7812 in. , 4796.70 psi

Expansion Joints 10-11

(

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TEMA Paragraph RCB 8.83 Cylindrical Element Stresses

For the Inner Cylinder at X Y~

DEA -31.663 /10 .... 6 BIA 58.517 /10"'6 B2A 31.472 /10"'-6
UIA 0.000 /10"'6 U2A 31.472 /10"'6 SMYA -0.406

For the Inner Cylinder at X LA

DEA -31.663 /10"'6 BIA 58.517 /10"'-6 B2A 31.472 /10"'6
UIA -0.932 U2A 77.899 /10""6. SMLA 98.277

For the Outer Cylinder at X YB

DEB -27.140 /10"'6 BIB -108.853 /10"6 B2B -572.921 /10 .... 6
UIB 0.000 /10"6 U2B -572.921 /10"'6 SMYB -976.188

For the Outer Cylinder at X = LB

DEB -27.140 /10 .... 6 BIB -108.853 /10"-6 B2B -572.921 /10"-6
UIB -0.815 U2B -602.782 /10.0. 6 SMLB -1.025 ... 10 .... 3

TEMA paragraph RCB 8.84 Maximum Cyclic Stresses

Evaluated per ASME A-99 Appendix CC , Paragraph CC-3(c):

For the Inner Cylinder:

seLA 4.153 ... 10 .... 3 RNA 1.000 ... 10.... 6

For the Outer Cylinder:

SCLB 4 _944 ... 10.... 3 RNB

Analysis of Shellside + Tubeside Pressure

TEMA Paragraph RCB 8.70 Induced Axial Force:

PIC 13 .100 PSPC= -38.750 PDC 0.000
PSC = 200.000 PSS = -25.650 FAX -164.721

TEMA paragraph RCB 8.80 Flexible Element Moments

THA -0.438 THB -0.410
2A 2.815 /loA] ZB 4.476 /10 .... 3
MT1A 84.806 /10.... 6 MT2A -82.955 /10.... 6 RMA -166.764
MTIB -74.089 /10 ....6 MT2B 66.635 /10.0. 6 RMB 671. 506

TEMA Paragraph RCB 8.82 Flexible Element Moments

RAll 2.377 "'10.0. 3 RA12 14.369 ... 10 .... 3 RAI -11.992 ~10A3
RA2l -1.705 "'10"-3 RA22 2.750 '""10.0. 3 RA2 0.294 "'10.0. 6
RA3 41. 200 RA4 -12.098 "'10"-3

Stress in Expansion Joint Flange:

SBX(R) = (6.0/ TE...... 2) ... (RAI + RA2/(R"'R) + RA3"'R'""R + RA4"'ln(R/B))
Stress Summary:
Location: (A) 12.8437 in. I -5582.82 psi
Location: (R) 13.6136 in. , -7494.45 psi
Location: (B) 16.7812 in .. 20513.79 psi

TEMA paragraph RCB 8.83 Cylindrical Element Stresses

10-12 Expansion Joinls

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For the Inner Cylinder at X = YA

DEA 3.285 /10"'3 BIA -195.282 /10 ..... 6 B2A 470.194 /10"'6
UlA 0.000 /10"'6 U2A 470.194 /10"'6 SMYA 7.981 ·10"'3

For the Inner Cylinder at X = LA

DEA 3.285 /10"'3 BIA -195.282 /10..... 6 B2A 470.194 /10"'6
UIA ~O. 932 U2A 243.144 /10"'6 SMLA 7.499 *10"'3

For the Outer Cylinder at X YB

DEB 4.476 /10 ..... 3 BIB -2.063 /10"'3 B2B -2. lB6 /10"'3
UIB 0.000 /10 ..... 6 U2B -2.186 /10"'3 SMYB 3. 725 ·10"'3

For the Outer Cylinder at X LB

DEB 4.476 /10 .... 3 BIB -2.063 /10 ....3 B2B ~2.186 /10..... 3
UIB -0.815 U2B -3.389 /10"'3 SMLB 1.767 *10"'3

TEM~ Paragraph RCB 8.84 Maximum Cyclic Stresses

Evaluated per ASME A-99 Appendix CC, Paragraph CC-3(c);

For the Inner Cylinder:

SCLA 5.604 *10"'3 RNA 1.000 *10"'6

For the Outer Cylinder:

seLB 22.350 *10"'3 RNB 1.000 ·10"'6

Analysis of Sh~~lside + Differential Expansion

TEMA Paragraph RCB 8.70 Induced Axial Force:

PIC 0.000 PSPC= -38.750 PDC 515.920
PSC = 200.000 PSS = -554.670 FAX -3562.022

TEMA paragraph RCB 8.80 Flexible Element Moments

THA -0.4 3 8 THB -0.410
ZA 3.911 /10"'3 ZB 5.572 /10 ..... 3
MT1A -1. 025 /10"'3 MTZA 970.229 /10 ..... 6 RMA 4.936 *10 ..... 3
MT1B 866.536 /10"'6 MT2B -805.393 /10"'6 RMB -5.508 *10"'3

TRMA Paragraph RCB 8.82 Flexible Element Moments

RAll -9.032 *10"'3 RA12 14.369 *10 .....3 RAI ~23.401 ·,.10"'3
RA2l 3.524 *10 ..... ) RA22 2.750 ·10"'3 RA2 1.767 ·10 .... 6
RA3 41.200 RA4 -40.460 *10"')

Stress in Expansion Joint Flange:

SBX(R) = (6.0/ TE**2) * (RA1 + RA2/{R·R) + RA3*R*R + RA4*ln(R/B)
Stress Summary:
Location: (A) 12.8437 in. I 154375.70 psi
Location: (8) 16.7812 in. , -173192.11 psi

TEMA paragraph RCB 8.83 Cylindrical Element Stresses

For the Inner Cylinder at X YA

DEl'. 4.563 /10"'3 B1A -2.558 /10 ..... 3 B2A -800.740 /10"'6

Expansion Joints 10-13

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UtA 0.000 /loA 6 U2A -800.740 /loA 6 SMYA 7.998 *10.0.)

For the Inner Cylinder at X LA

DEA 4.563 /10"'3 BIA -2.558 /10""'3 B2A -800.740 /10"'6
UIA -0.932 U2A -2.903 /l0"3 SMLA 3.530 *10")

For the Outer Cylinder at X YB

A
DEB 5.572 /10"'3 BIB 2.332 /10 ) B2B 20.951 /10""'3
UIB 0.000 /10"'6 U2B 20.951 /10.0. 3 SMYB 43.147 ·10"'3

For the Outer Cylinder at X LB

DEB 5.572 /10.0.) BIB 2.332 /10"3 B2B 20.951 /10"'3
UIB -0.815 U2B 20.953 /l0") SMLB 43.151 "'10""3

TEMA Paragraph RCB 8.84 Maximum Cyclic Stresses

Evaluated per ASME A-99 lI.ppendix CC, Paragraph CC-3(c);

For the Inner Cylinder:

SCLA 0.163 *10"'6 RNA 3.278 *10 .... )

For the Outer Cylinder:

SCLB 0.177 *10"'6 RNB 2.337 *10"'3

STRESS SUMMARY: Analysis of Differential Expansion

Inside Junction Outside Junction
Actual Allowed Actual Allowed
Annular Element 155998. (Fatigue) -188909. (Fatigue) psi
Annular Ring at R 16.781 188909. (Fatigue) psi
CyL at point Y 16. (Fatigue) 38445. (Fatigue) psi
CyL at point L -3870. (Fatigue) 40359. (Fatigue) psi
Max. Cycle Stress 163570. (Fatigue) 194705. (Fatigue) psi
Max. Cycle Life 3222. Cycles 1635. Cycles

STRESS SUMMARY; Analysis of Shells ide Pressure

Inside Junction Outside Junction
Actual Allowed Actual Allowed
Annular Element -1622. 60000. 15717. 60000. psi
Annular Ring at R 14.008 -6070. 30000. psi
CyL at point y 7982. 20000. 4701. 20000. psi
CyL at point L 7400. 20000. 2792 . 20009· psi
Max. Cycle Stress 1835. (Fatigue) 17406. (Fatigue) psi
Max. Cycle Life 999999. Cycles 999999. Cycles

STRESS SUMMARY: Analysis of Tubeside Pressure

Inside Junction Outside Junction
Actual Allowed Actual Allowed
Annular Element -3961. (Fatigue) 4797. (Fatigue) psi
Annular Ring at R 16.781 4797. (Fatigue) psi
CyL at point y o. (Fatigue) -976. (Fatigue) psi
Cyl. at point L 98. (Fatigue) -1025. (Fatigue) psi
Max. Cycle Stress 4153. (Fatigue) 4944. (Fatigue) psi
Max. Cycle Life 999999. Cycles 999999. Cycles

10-14 Expansion Joints

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STRESS SUMMARY: Analysis of Shellside ~ Tubeside Pressure

Inside Junction Outside Junction
Actual Allowed Actual Allowed
Annular Element -5583. (Fatigue) 20514 _ (Fatigue) psi
Annular Ring at R 13.614 -7494. (Fatigue) psi
Cyl. at point Y 7981. (Fatigue) 3725. (Fatigue) psi
Cyl. at point L 7499. (Fatigue) 1767. (Fatigue) psi
Max. Cycle Stress 5604. (Fatigue) 22350. (Fatigue) psi
Max. Cycle Life 999999. Cycles 999999. Cycles

STRESS SUMMARY: Analysis of Shellside + Differential Expansion

Inside Junction Outside Junction
Actual Allowed Actual Allowed
Annular Element 154376. (Fatigue) -173192. (Fatigue) psi
Cyl. at point Y 7998. (Fatigue) 43147. (Fatigue) psi
Cyl. at point L 3530. (Fatigue) 43151. (Fatigue) psi
Max. Cycle Stress 162873. (Fatigue) 171299. (Fatigue) psi
Max. Cycle Life 3278. Cycles 2337. Cycles

The PV Elite Program, (e) 1989-2000 by COADE Engineering Software

Expansion JoinLs 10-15

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Metal Bellows Expansion Joints Pressure Vessel Design and Analysis - Seminar NOles

METAL BELLOWS EXPANSION JOINTS

These arc also called "thin-walled" expansion joints. They characteristically have multiple
bellows with thin walls on the order of 0.05 in.
There arc several ways to analyze metal bellows expansion joints. Many of them use clas-
tic analysis of an equivalent structure, constrained by continuity effect. The most widely
used method is the one presented in the standards of the Expansion Joint Manufacturers
Association (EJMA).
The method we will usc is the one presented in the ASME Code, Section VIII, Division I,
Appendix 26. (This used to be Appendix BB, but it was moved up in the An revision to
the Code.) These formulas take into account both internal pressure and axial joint move-
ment. They do not include lateral or angular joint movements. The appendix covers expan-
sionjoints up to liS-in. thick, with multiple convolutions, and includes both reinforced
and unreinforced expansion joints.
Circumferential and meridional stresses are calculated in the bellows for both the rein-
forced and unreinforced geometries. In addition, for reinforccd expansion joinls the stress
in the reinforcing clement and in any bolted fastener that may be on the reinforcing ele- (
ment arc calculated.
The ASME approach calculates the maximum stress for the worst combination of internal
pressure andjoinl opening, and uses this value to calculate the maximum cycle life for the
joint.
Notice that the thickness you use in the analysis is the thickness of the sheet from which
the bellows is formed, measured before the forming process occurs. The method itself cal-
culales the thinning due to forming.
The method in the Code also calculates stresses in a reinforcing ring and in a bolted fas-
lener for the reinforcing ring. {Sec the sketch on the next page for details of this geome-
try.}
The faclor q/2w is used to identify the location on the X axis of curves 26-3, 26-4, and
26-5. In the same way the factor q/(2.2* SQRT«d+w)-*t» is used to select the curve on
these figures. Figure 26-3 is then interpolated linearly for Cpo Figures 26-4 and 26-5 arc
interpolated logarithmically for Cf and Cd respectively.
The meridional membrane plus bending stress due to pressure (Smmp+-Smbp) is com-
pared to 1.5 times the basic allowable stress for unreinforced bellows and 3.0 times the
basic allowable stress for reinforced bellows. The sum of the meridional stresses (
(Smmp+Smbp+Smmd+Smbd) is compared to the allowable stress (Sn) at the givennum-
ber of design cycles for the given material type.
The actual stresses in the reinforcement arc compared to the basic allowable stress for the
reinforcement. The actual stresses in the bolt (fastener) arc compared to the allowable
stress in the bolt. These values arc only calculated if AR and/or AF are greater than zero.
The stress amplitude for cycle life evaluation is the sum of all the meridional stresses. This
value is used with the appropriate formula in Paragraph 26-3 to calculate lhe cycle life.

10-16 Expansion Joints

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 Pressure Vessel Design and Analysis - Seminar NoLes Metal Bellows Expansion Joints

The cycle life calculation should be ba.sed on the fonnulas in the ASME Code, Section
VIII, Division I, Appendix 26. These formulas implement a power law for fatigue life as
follows:

]
~.oo

N< 2.5
- [ _I4_.2_K--",-s'.::.. _ 0.02
E.

for series 3XX high alloy steels, nickel-chromium iron alloy, nickel-iron chromium alloy,
and nickel-copper alloy.

N~[15K ;.0 ]"1

_..!'~. -0.011
E.

for carbon, low alloy, series 4XX, and high alloy steels.
N is the number of cycles, the cycle life.
S. is the maximum stress range resulting from the analysis.
Eb is the elastic modulus for the material at the temperature under consideration.
K, is the fatigue strength reduction factor. Use a fatigue strength reduction factor of
1.5 for lInreinforeed bellows, and 3.0 for reinforced bellows. Alternative factors may
be used if substantiated by test data, for example by hudrotes for design temperatures
below the creep range.
The nominal bellows thickness must be greater than the thickness required for pressure as
calculated by the ASME method.

Expansion Joints 10-17

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Melal Bellows Expansion Joints Pressure Vessel Design and Analysis Seminar NOles R

The knuckle radius for the bellows must be grcater than threc limcs tm, the minimum
unformed thickness. If r<3 'tm you should increase the K factor for fatigue and stress cal-
culations from 1.0 to 4.0, usually resulting in unacceptably high slresses or low cycle life.

n
Li-L
drt ~-------L---------.J
(ill Unrelnfarced BellowJ

~A ~A'
A-A
/ - - .....

f
I
V
\
EqU3Iilir>g"ng

L.A I I
E,.u t'<.!ualiling ring

~h
GENERAL NOTE'
Nominal t ;0 :3'm . (b! Reinlor..,.Q' 8flllows
t d'''m.

Figure 2--Geometry for Melal Bellows Expansio'n Joints

10-18 Expansion Joints

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Pressure Vessel Design and Analysis - Seminar Noles Pressure Vessel Design and Analysis Seminar Componenl

PRESSURE VESSEL DESIGN AND ANALYSIS SEMINAR

COMPONENT DESIGN PROBLEM

Metal Bellows Expansion Joint Analysis

Evaluate the following expansion joint for a design life of 1800 cycles.

Pressure is 150 psi (1.034 Nmm2) at 200°F (93°C).

The joint opens .125 in. (3.175 mm) per convolution.
Bellows ID is 24 in. (610 mm) The joint is fabricated from SA-240-304.
The convolutions are I-in. (25.4 mm) deep on a 1.l25-in. (28.57 mm) pitch.
The thickness of the bellows before forming is 0.05 in. (1.27 mm)
This is an unreinforced bellows.
There is no provision for corrosion.

Notes:

The elastic modulus for SA-240-304 at ambient temperature is 28.3e6 (195121)

The elastic modulus for SA-240-304 at 200°F is 27.7e6 (190984)

Questions:

What is the cycle life for the bellows?

DO NOT TURN THE PAGE UNTIL YOU HAVE

COMPI~ETED YOUR ANALYSIS

Expansion Joinls 10-19

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Input Echo, Thin Joint Item 1, Description: EX-4, JOINT 2

Design Cycle Life, Number of Cycles NCYC 1800

Design Temperature of Expansion Joint TEMP 200.0 F
Design Internal Pressure P 150.0 psig
Expansion Joint Opening Per Convolution E 0.1250 in.

Material of Expansion Joint Bellows MATI SA-240 304

Bellows Operating Allowable Stress ALLST1 20000.0 psi
Bellows Elastic Modulus at Design Temp. EMOD1 . 27700E+08 psi
Bellows Elastic Modulus at Ambient Temp. EAMBI 0.2830E+08 psi

Material Category for Cycle Life Evaluation AUSTENITIC STAINLESS

Inside Diameter of Bellows D 24.0 in.

Convolution Depth W 1.0000 in.
Convolution pitch Q 1.1250 in.
Bellows Minimum Thickness before Forming TM 0.0500 in. (
Fatigue Strength Reduction Factor Kg 1. 0000

THIN JOINT RESULTS, ASME VIII DIV. I App.26, 1998, A-9B

Nominal Bellows Thickness Based on given Minimum
T (TM ~ SQRT ( D/ ( D + W ) ) )
T (0.0500 ~ SQRT( 24.00/( 24.00 + 1.0000 ) ) )
T 0.0490 in.

Cross Sectional Area of Bellows

AS (0.571 * Q + 2. 0 ~ W ) * T
AB (0.571 ~ 1.1250 + 2.0 * 1.0000 ) ~ 0.0490
AB 0.1294 in

Final Reinforcement Ratio ~ 1.0000

Minimum Required Thickness for Unreinforced Bellows

Tu P~(D+W)/(ALLST1*(1.14+4.0*W/Q»
Tu 150.0*( 24.0+ 1.0000)/( 20000.0~(1.14+4.0* 1.0000/ 1.1250»
Tu 0.0399 in.

Required Bellows Thickness for Pressure = 0.0399 in.

Actual Knuckle Radius for one Convolution

RKN (Q/4-TM/2)
RKN (1.1250 / 4 - 0.0500 / 2 )
RKN 0.2562 in.

Allowed Knuckle Radius for one Convolution

TM3 = 3.0 * TM = 0.1500 in.

Stiffening Factor for Bellows Under Pressure

RKS 0.3-( 100.0/( 0.6 * P**1.5 + 320.0 ) )**2
RKS 0.3-( 100.0/( 0.6 ~ 150.0**1.5 + 320.0) )**2
RKS 0.2951

10-20 Expansion Joints

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SUMMARY for PRESSURE CALCULATIONS ;

Nom. Bellows Thickness based on given Minimum T 0.0490 in.
Required Bellows Thickness for Pressure TREQ 0.0399 in.
Actual Knuckle Radius for One Convolution RKN 0.2562 in.
Allowed Knuckle Radius for One Convolution 3"*TM 0.1500 in.
Cross-Sectional Area for One Convolution Ab 0.1294 in
Fraction of Pressure Resisted by Bellows R 1.0000
Stiffening Factor for Bellows under Pressure RKS 0.2951

SUMMARY of FIGURES B8-3, 8B-4, BB-5

Horizontal Figure Factor q/2W 0.56250
Vertical Figure Factor q/(2.2«(d+w)* t) "'* .5) 0.46207
Value Interpolated from Figure B8-3, Cp Cp 0.63207
Value Interpolated from Figure 88-4, Cf Cf 1.74880
Value Interpolated from Figure B8-4, Cd cd 1. 78330

STRESS RESULTS for UNREINFORCED BELLOWS

Circumferential Stress in the Bellows
SCMPU P*(D+W)/(T*(1.14+4.0*W/Q)
SCMPU 150.0*( 24.0+ 1.0000)/( 0.0490*(1.14+4.0* 1.0000/ 1.1250))
SCMPU 16301.9 psi

Meridional Membrane Stress due to Pressure

SMMPU (P*W )/( 2.0*T )
SMMPU (150.0 * 1.0000 )/( 2.0 * 0.0490 )
SMMPU 1530.9 psi

Meridional Bending Stress due to Pressure

5MBPU (p * W "* W * CP ) / ( 2.0 * T * T )
5MBPU (150.0. 1.0000* 1.0000* 0.63207 )/( 2.0 "* 0.0490 * 0.0490 )
5MBPU 19752.2 psi

Meridional Membrane Stress due to Deflection

SMMDU (EAMB1*T*T*E )/(2.0*W"3*Cf )
SMMDU (0.283E+08* 0.0490* 0.0490* 0.1250 )/(2.0* 1.0000.. . 3* 1.74880 )
SMMDU 2427.4 psi

Meridional Bending Stress due to Deflection

5MBDU 5.0·EAMB1"*T*E/(J.0*W*W*CD)
5MBDU 5.0* 0.283E+08* 0.0490"* 0.1250/(3.0* 1.0000"* 1.0000* 1.78330)
5MBDU 161967.2 psi

Summation of all Meridional Stresses

STOTU = (SMBDU+SMMDU+SMBPU+SMMPU) = 185677 psi

The Total Cycle Life

CYCU (FM/ (FN*RKG*STOTU/EMOD1) -FO») ** 2.00
CYCU ( 2.5/« 14.2* 1.0000* 1856771 0.277E+08)- 0.020»)**2
CYCU n06.

Maximum Stress for Given Cycle Life

Expansion Joints 10-21

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SMAXC (FM/{RNCYC**(1/2.00)+FO)*(EMODl/FN*RKG)
SMAXC ( 2.S!( 1800**(1/2.00))+ 0.020)*( O.277E+08/ 14.2* 1.0000)
SMAXC 153960.4 psi

STRESSES in BELLOWS, psi Actual Allowed

Circumferential membrane, pressure Scmp 16301 20000
Meridional Membrane, pressure Smmp 1530 20000
Meridional Bending , pressure 5mbp 19752
Meridional Membrane, deflection Smmd 2427
Meridional Bending , deflection 5mbd 161967

Meridional Membrane + Bending , pressure 21283 30000

Summation of all Meridional Stresses 185677 153960

Stress Amplitude for Cycle Life Evaluation 185677

Cycle Life for Bellows 1105

The PV Elite Program, Ie) 1989-2000 by CQADE Engineering Software

(

10-22 Expansion Joints

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Pressure Vessel Design and Analysis - Seminar Noles

Chapter 11:
Stresses

STRESSES IN SHELLS DUE TO LOADS ON ATTACHMENTS

This analysis is based on "Local Stresses in Spherical and Cylindrical Shells due to Exter-
nal Loadings," Welding Research Council Bulletin 107, August 1965, based on the prior
work ofP.P. Bijlaard, and with revisions through 1979.
In this section, you will calculate slrcsses at eight points around the periphery of an exter-
nally loaded attachment to a shell. You will analyze two shell types-cylinders and
spheres. All head types are approximated as spheres.
You will also evaluate several attachment types. On spheres, attachments can be round or
square, hollow or solid. On cyUndcrs, attachments can be round, square, or rectangular,
but all are considered solid.
IThe program does not calculate stresses in attachments, only in the shell of the vessel.
, Stresses in attachments can, in fact, be higher than the stresses in the shell.
liThe WRC107 analysis does not specifically address reinforced nozzles. An approach that
I we believe to be eonservative is to analyze the nozzle at the nozzle OD and the vessel plus
\ pad thickness, and then to analyze the nozzle at the reinforcing pad OD and the vessel
· thickness. Ifboth of these analyses yield reasonable stresses, then the nozzle is OK. If this
1,approach does not work, a more sophisticated analysis is required.
Loads for analysis of cylinders include the following:
Design pressure on the cylinder
Radial load on the cylinder (axial load on the nozzle)
Cireumferential shear, dragging the attachment around the vessel
Longitudinal shear, dragging the attachment along the vessel
Torsional moment, twisting the attachment
Circumferential moment, tipping the attachment around the vessel
Longitudinal moment, tipping the attachment along the vessel
The ratio of cylinder radius to wall thickness (the shell parameter, gamma) must be in the
range 5 < RMITH < 300 or the analysis willllot work. In other words, the analysis is not
valid for very thick or very thin vessels.
The ratio of attachment radius to cylinder radius (the attachment parameter, beta) must be
in the range 0.0571 < RO/RM < 0.571 or the program wiII give an error message. In other
words, the program is not valid for very small or very large attachments.
The value beta must be adjusted when calculating several of the figures for rectangular
attachments. Thus, the error for a beta greater than 0.571 may occur even when the nomi-
nal beta is less than 0.571.

Slresses It-I

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 Stresses in Shells due to Loads 011 Allachmcllls Pressure Vessel Design and Analysis - Seminar Notes

The analysis e~lculales stresses at four points around the periphery of the allaehment, and
at the inside of the cylinder and the outside of the cylinder at each point.
The computer program makes the following modification:
The last page of Appendix A (to WRC-107) indicates that curves IC and 2C were uneon-
servalive by as much as a factor of three, and were truncated for that reason. Now, how-
ever, instead ofjust using the values that exisl at the end of the truncated curves, we
compared those points to the same point in Figure IC-I and 2C-I, multiplied by 3.0. For
example, if the value from IC-I is more than three times less than the truncated value
from IC, the value of IC-I multiplied by 3.0 will be used.
The typical allowable stress for the combined stresses is 1.5 times the basic material
allowable stress. If all your results are less than 1.5*SA then the configuration and loading
are acceptable. If the load is self-relieving (that is, if it would disappear after only a small
rotation or translation of the attachment), then the allowable stresses may be increase to
3*SA.
Loads for the analysis of spheres include the following:
Design pressure on the cylinder. (
Radial load, along the axis of the attachment.
Shear from point A to point B.
Shear from point C to point D.
Torsional moment, twisting the attachment.
Moment tipping point A toward point B.
Moment tipping point C toward point D.
The shell parameter for spheres is Upsilon, the radius allachment divided by the decay
length of the sphere.
The ratio of sphere thickness to allaehment thickness must be in the range 0.25 < TslTn <
10.0 or the analysis will not work.
The ratio of allachment radius to allachmentthiekness must be in the range 5 < RnlTn <
50.0 or the analysis will not work.
If the above two parameters for a hollow allachment are out of range, the attachment can
probably still be analyzed as a solid allachment.
' The analysis yields stress at both the inside of the sphere and the outside of the sphere at
) four points around the periphery of the nozzle. Stresses are not calculated in the nozzle
wall. . (

11-2 Stresses

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 Pressure Vessel Design and Analysis - Seminar Noles Discussion of Results

DISCUSSION OF RESULTS
WRC107 Stress Calculations
CodeCale computes stress intensities in accordance with WRCI07 and includes the
effects of longitudinal and hoop stresses due to internal pressure. If the geometry includes
a circular reinforcing pad, CodeCale will perform two analyses on the geometry. The first
analysis will compute the stresses at the edge of the nozzle. The second stress analysis will
be at the edge of the reinforcing pad.
CodeCale uses the Lame equation to determine the exact hoop stress at the upper and
lower surface of the cylinder around the edge of the altaclunenl. The hoop stress equa-
tions, as well as the longitudinal stress equation, are as follows:

SHoop(Upper) = 2Sl.ong

Where P Design Pressure

r; Inner diameter of shell
ro Outer diameter of shell
For spherical shells the program uses the following equation:

SHoop = SLong

For each run performed, a table of dimensionless stress factors for each loading will be
displayed for review. Any table figure followed by an exclamation point (!) means that the
curve figure for that loading has been exceeded.

Why are the Stresses at Edge of the Pad the Same as at the Edge of the
Nozzle?
Since the stress is a direct product of the stress factor, the stresses computed at the edge of
the pad may be same as those at the edge of the nozzle ifthe curve parameter for that type
of stress has been exceeded.

What are the Allowable Stresses?

The stress intensities computed should typically be between 1.5 and 3.0 times the hot
allowable stress for the vessel material at operating temperature. If the results arc less than
1.5 Sa then the configuration and loading are acceptable. If the load is self-relieving (that
is, if it would relax or disappear after only a small rotation or translation of the attach-
ment), the allowable stress intensity would increase to 3.0 Sa.

Stresses 11-3
(

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Discussion of Results Pressure Vessel Design and Analysis - Seminar NoLes

Since many geometries do not fall within the acceptable range of what WRClO7 will
accept, it may be necessary to use a more sophisticated 1001 to solve the problems where
the diameter of the vessel is very large in comparison with the nozzle or where the thick-
ness of the vessel or nozzle is small. An example of a more sophisticated tool would be a
FEA (finite elemeut analysis) program.

SPHERICAL SHELLS CYLINDRICAL SHELLS

To Define WRC Axes: To Define WRC Axes:

I. P-axis: Along the Nozzle centerline and posi- I. P-axis: Along the Nozzle centerline and posi-
tive entering the vessel. live enleTing the vessel.
2. M I-axis: Perpendicular to the nozzle center- 2. Me-axis: Along the vessel centerline and pasi-
line along convenient global axis. live to correspond with any parallel global axis.
3. M2-axis: Cross the P-axis into the MI axis and 3. M2-axis: Cross the P-axis with the Me axis and
the resull is the M2-axis. the result is the ML-axis.

To Define \VRC Stress Points: To Define WRC Stl"CSS Points:

u-upper, means stress on outside ofvesscl wall at u-upper, means stress on outside of vessel wall at
junction. junction.
I-lower, means stress 011 inside of vessel atjunc- I-lower, means stress on inside of vessel a!junc-
tion. tion.
A-Position on vessel at junction, along negative A-Position on vessel at junction, along negative
Ml axis. MCaxis.
B-Position on vessel atjunclioll, along posilive B-Position on vessel at junction, along positive
M2 axis. MCaxis.
C-Position on vessel at junction, along positive C-Position on vessel at junction, along positive
M2 axis. MLaxis.
D-Position on vessel at junction, along negative D-Position on vessel aljunction, along negative
M2 axis. ML axis.

Note: Shear axis "VC" is parallel, and in the same

direction as the bending axis "ML." Shear
axis "VL" is parallel, and in the opposite
direction as the'bending axis "MC."

11-4 Stresses

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Pressure Vessel Design and Analysis - Seminar Noles Discussion or Results

WRC107 Stress Summations

ASME Seclion VIII, Division 2, provides for a fairly elaborate procedurc to analyzc the
local stresses in vesscls and nozzles (Appendix 4-1 "MandatOlY Design Based On Stress
Analysis"). Only the elastic analysis approach will bc discussed here. The user should
always refer to the applicable code if any of the limits described in this seclion arc
approached, or ifany unusual material, weld, or stress situation exists, or thcre are non-lin-
ear concerns such as the material's operation in the creep range.
The first step in the procedure is to determine if the clastic approach is satisfactory. Sec-
lion AD-160 contains the exact method and basically states that if all of the following con-
ditions are met, then fatigue analysis need not be done:

a) The expected design number offull-range pressure cycles does not exceed the
number of allowed cycles corrcsponding to an S, value ons m(4S mfor non-inte-
gral allachments) on the material fatigue curve. The Sm is the allowable stress
intensity for the material at the operating temperature.

b) The expected design range of pressure cycles other than startup or shutdown must
be less than 1/3 (1/4 for non-integral attachments) the design pressure times (S,I
Sm), where S, is the value obtained on the material fatigue curve for the specificd
number of significant pressure fluctuations.

c) The vessel does not experience localized high stress due to heating.

d) The full range of stress intensities due to mechanical loads (including piping reac-
tions) does not exceed S, from the fatigue curve for the expecled number of load
fluctuations.

Once the user has decided that an elastic analysis will be satisfactory, either a simplified or
a comprehensive approach may be taken to the vessel stress evaluation. Both melhods will
be described in detail below, after a discussion of the Section VIII Div. 2 Requirements.

Stresses 11-5

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Discussioll of Results Pressure Vessel Design and Analysis - Seminar Notes

ASME Section VIII Division 2-Elastic Analysis of Nozzle

Ideally in order to address the local allowable stress problem, the user should have the
endurance curve for the material of construction and complete design pressure / tempera-
ture loading information. If any of the elastic limits are approached, or ifthere is anything
out of the ordinary about the nozzlelvessel connection design, the code should be carefully
consulted before performing the local stress analysis. The material Sm table and the
endurance curve for carbon steels are given in this section for illustration. Only values
taken directly from the code should be used in design.
There are essentially three criteria that must be satisfied before the stresses in the vessel
wall due to nozzle loads can be considered within the allowables. These three criteria can
be summarized as

Where Pm. P r, Pb' and Q are the general primary membrane stress, the local primary mem-
brane stress, the local primary bending stress, and the total secondary stresses (membrane
plus bending)} respectively; and K, Smh' and Smavg are the occasional stress factor, the hot
material allowable stress intensity, and the average material stress intensity (Smh + Sm,) / 2.
Because of the stress classification defined by Section VIII, Division 2, in the vicinity of
nozzles, as given in the Table 4-120. I, the bending slress terms caused by any external
load moments or internal pressure in the vessel wall ncar a nozzle or other opening, should
be classified as Q, or the secondary stresses, regardless of whether they were caused by
sustained or expansion loads. This causes P b to disappear, and leads to a much more
detailed classification:

Pm General primary membrane stress (primarily due to internal pressure)

PI Local primary membrane stress, which may include the following:

Membrane stress due to internal pressure

Local membrane stress due to applied sustained forces and moments
(
Q Secondary stresses, which may include the following:

Bending stress due to internal pressure

Bending stress due to applied sustained forces and moments
Membrane stress due to applied expansion forces
Bending stress due to applied expansion forces and moments
Membrane stress due to applied expansion moments
Each of the stress terms defined in the above classifications contain three parts: two stress
components in nonnal directions and one shear stress component. To combine these
stresses, the following rules apply:
Compute the normal and shear components for each of the three stress types, i.e. Pm,
PI, and Q.
Compute the stress intensity due to the Pm and compare it against kSmh.

tl-6 Stresses

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 Pressure Vessel Design c1nd Analysis - Seminar Noles Discussion ofResulls

Add Ihe individual normal and shear stress components due 10 Pmand PI, compute Ihe
resullant slress intensily, and compare ils value against 1.5kSmh.
Add Ihc individual normal and shear slress componenls due to Pm, PI, and Q, compute
Ihe resuhant slrcss inlensity, and compare ils value 10 against 3Smavg.
If Ihere is an occasional load as well as a suslaincd load, Ihese Iypes may be repeated
using a k value of 1.2.
These criteria can be readily found from Figure 4-130.1 of Appendix 4 of ASME Seclion
Vl1l, Division 2 and the surrounding lexl. Nole Ihallhe primary bending slress lerm (Pb) is
not applicable 10 the shell stress evalualion, and Iherefore disappears from Ihe Scclion
Vl1l, Division 2 requirements. Under Ihc same analogy, Ihe peak slress limil may also be
written as

PI + P b + Q + F < S,

The above equation need not be salisfied, provided Ihe elaslic limit crileria of AD-160 is
met based on the slalement explicitly given in Seclion 5-100:
( "If the specified operation ofthe vessel meets all ofthe conditions ofAD-160, no analysis
for cyclic operatioll is required and it may be assumed that the peak stress limit discussed
in 4-135 has been satisfied by compliance with the applicable requirements for materials,
design,jabricafion, testing and inspection afthis division. "

,"
~'"
II) E - 30" to'poi.
1211tl1.'~.lo<UTSIlO-I15bi_
131 Tlbhl5-110.1 ~ ......
J... buI .."" ...... _ •
I
Iooonul.ofor.n
I
l«u,,'.",I.'~,IionQl"'"'' ........ 0-

.,
~ ~~
/_'OfUTs" eo ...

,,,. "'--
!"<0-
------- ---
r... UTS Il!-UOb'

I- ~

..•.. , , ,
' , ,,, '" ..' , ;- "':;;"
,
'"

FIG. s-nO.1 DE-SICH fAll(,UE CURVES fOR CARBON. LOW AllOY, SERIES 4XlC, HleH ALLOY STEELS AHD
HleH TENSILE STEELS FOR TEM~ERATURES NOT EXCEEDINC 100'F

Figure 1--Example Fatigue Curve (For Values of Sa)

The equations used in CodeCale to qualify the various stress components can be summa-
rized as follows:

Pm(SUS) < Smh

Pm(SUS + acC) < I.2S mh

Stresses 11-7

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Discussion of Resulls Pressure Vessel Design and Analysis - Seminar Noles

Pm(SUS + OCC) + Pj(SUS + OCC) < 1.5( 1.2)Smh

Pm(SUS + OCC) +NSUS + OCC) + Q(SUS + EXP + OCC) < 1.5(Sm, + Smh)

If some of the conditions listed in AS ME VIII Div.2 (in which AD-I 60 is not satisficd),
you probably need to perfonn the fonnal fatigue analysis. Peak stresses are required to be
calculated or estimated. You may consider using AD-560 "Alternative Rules for Nozzle
Design" instead of Article 4-6 "Stresses in Openings for Fatigue Evaluation" to calculate
the peak pressure stress for the opening.
Ifall conditions of AD-560.1 through AD-560.6 are satisfied, the stress indices given in
Table AD-560.7 may be used. Ifuser says "Yes" to indicate the conditions have been satis-
fied, the program will use these pressure stress indices to modify the primary stress due to
internal pressure (hoop and longitudinal stresses). For external loads, the highest peak
stresses are usually localized in fiIlets and transitions. If the user decides to use WRCI07
stress concentration factors (Kn, Kb), the fillet radius between the Vessel and Nozzle is
required. (If a reinforcing pad is used, the program assumes the same pad fillet radius.)
The program will make a crude approximation and use WRCI07 Appendix-B equations
(3) and (4) to estimate Kn and Kb. The tension and bending stresses are thus modified
using Kn and Kb respectively. The program outputs the local stresses for 4 pairs of points
(upper and lower) at the intersection.

Note The user should 1101 direct the program to perform the stress summations. Instead
the user should detennine which stresses should be added based on locations in
order to obtain the peak stress level, then use Appendix-4 & 5 rules and fatigue
curves depending on operation cycles.

Based on comparisons with finite element analysis, it is known that the top tip of the fiIlet
weld on the nozzle usually experiences the highest peak stress due to external loads. So it
is conservative to add all the peak stresses after including both pressure stress indices and
concentration factors.

Note The stress summation may ollly be used to check stress intensities, not stress !ev-
els.

You need the peak stress level to perform fatigue analysis. The current stress summation
routine does not compare stress level with fatigue allowables per Appendix-5. However,

J 1-8 Stresses

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 Pressure Vessel Design and Analysis - Seminar Noles Discussion of Results

you may find the stress summation results useful to compare the combined effect due to
the stress concentration factor and pressure stress indices.

""------"'Ll:%'lOITUOIN.'<L ~
TORSION....L IJOl.1ENT

GEOMETRY
o
POINTS FOR STRESS RECOVERY

Figure 2--Geometry for Local Stresses in Cylindrical Shells

Stresses 11-9

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Discussion ofResulls Pressure Vessel Design and Analysis - Seminar NoLes

NOZZLE
Do
I. ""pl•., Lud,' ,. P.,_OI."
DL
Ilooli.1 Lood. , r __
'b.
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vl~_ _ lb,
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V III __ A••;~ •• Il..~ _ _ : •. .. _~ ..... I... d.IC .. "' _ _ HOLLOW ATTACHMENT
~ I. TMd".... • .. _ _ :,.- • b",lin.I..d. llo ...- _ _
.......1. lol.uR.d;y., '",= _ _ ;f.. "'OTE, I!ftlo •• n IOU Iuoo I.. Rm
.....,.I.OuIJ;d. Rd;u •• I.=- __ i". u .... donee -<lh "tn II.ft

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COKBINEO STP.E:SS INTmSJrY - S.

11. When '( "I- o. s .. laraC!.':t llbsoll.lte 1l\.1'lnltuc1C! of eithC!r

S .. 1/2 [Ox+Oy! {lOll: Oy)2 .. 4Tl)or {(all. - Oy)2~

2) When t ~ O. S .. lIIrqest Abi!;Ol\Ite Illaqnitude of either

S .. 0.:c' 0y or (Ox - a I •
7

Figure 3--AII Attachments to a Spherical Shell

ll-JO Stresses

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 Pressure Vessel Design and Analysis - Seminar NOles Discussion of Results

1. ",,,11'" 1. ..1.'
••iIl.II.. ,. ,. =---1'"
CI ....... ,~'.
101.", _ _ 1... 1",
1..",.101_.". l1li1.:: _ _ 1•• 1\,
T...I..........,.
Sh... L.. ~.
I f . : - - I... I",
v. =__ " {J tUJSl -it ;:--
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............••
",,,,,"-. .1,,,11 ••• '" 'HOT(, (", n 10 lwII I.
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CYLINDRICAL SHELL
, ..1.·
nIlE~U~ _ "1. . 4 ..., ....11. ,h•• t.o .... ,........., .........

". .."....4_ •• , ..
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10
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-11.1 ••
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IIL/•• ·U
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COMBINED STRESS INTENSITY - S

1) When T # 0, S ;; largest absolute ma~nitude of either

( S;; 1/2 [Ox+04l ~ .,t(Ox - 0tP)2 + 4T 2 Jor I(a~ - 0'41)2 +

2) When ~ ;; 0, S = largest absolute magnitude of either

S'-D ox' o~ or (ax - °41)

Figure 4--AII Attachments to a Cylindrical Shell

( Slresses 1t -11

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 Discussion of Results Pressure Vessel Design (lnd Analysis - Seminar Notes

11-12 Stresses

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 Pressure Vessel Design and Analysis - Seminar Notes Discussion of Results
(

Pressure Vessel Design and Analysis Seminar

Component Design Problem

Stresses in a Cylinder due to Loads on a Nozzle

Analyze the cylinder for Drum D-IOI under the following loads:
Design pressure is 200 psi (1.378N/mm 2)
Radial load is 5,400 lbs (24021 N)
Longitudinal shear load is 2, I00 Ibs (9342 N)
Longitudinal bending moment is 3500 ft-Ibs (4.74e6Nmm)

The cylinder is 144 in. (3658 mm) ID and I-in. (25.4 mrn) thick
The attachment is ronnd and has an OD of 12.75 in. (324 mm)
(

Notes:

Questions:

( What is the highest stressed point?

Is the stress at Ihis point acceptable?

DO NOT TURN THE PAGE UNTIL YOU HAVE

COMPLETED YOUR ANALYSIS

Stresses 11-13
(

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Discussion of Results Pressure Vessel Design and Analysis ~ Seminar NOles

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar --------------------------------------- Page 71
WRCI07 Analysis: Nozzle/Cylinder Item: 1 9;51a Sep 21,2000

Input Echo, WRC107 Item Description: Nozzle/Cylinder

"
Diameter Basis for Vessel VBASIS ID
Cylindrical or Spherical Vessel CYLSPH Cylindrical
Corrosion Allowance for Vessel CAS 0.0000 in.
Vessel Diameter DV 14-<1.000 in.
Vessel Thickness TV 1.000 in.

Attachment Type TYPE Round

Diameter Basis for Nozzle N8ASIS ID

Corrosion Allowance for Nozzle CAN 0.0000 in.
Nozzle Diameter
Nozzle Thickness
D"
TN
12.000
1.000
in.
in.

Design Internal Pressure DP 200.00 psig

External Forces and Moments in WRC 107 Convention:

Radial Load P 5400.00 lb.
Circumferential Shear VC 0.00 lb.
Longitudinal Shear VL 2100.00 lb.
Circumferential Moment MC 0.00 ft.lb.
Longitudinal Moment ML 3500.00 n .Ib.
Torsional Moment MT 0.00 ft.lb.

Compute Maximum Radial Force Yes

Compute Maximum Circumferential Moment "0
Compute
Compare
Maximum
Maximum
Longitudinal Moment
Stress Intensity to
"0
26250.00 psi

Global Force (SUS) Fx -LOI lb.

Global Force (SUS) Fy 0.00 lb.
Global Force (SUS) Fz 44.00 lb.
Global Moment (SUS) Mx 44 .00 ft.lb.
Global Moment (SUS) My 0.00 ft .lb.
Global Moment (SUS) Mz 0.00 fLlb.
Internal Pressure (SUS) P 0.00 psig
Include Pressure Thrust "0
Use Interactive Control
WRCI07 Version
INTACT
VERSION
"0
March 1979 ( 81 & B2 )

Include WRC107 SIF(Kn,Kb)--concentration factors

Include Pressure Stress Indices per Div. 2
"0
No

Dimensionless Parameters used: Gamma = 72.50

Dimensionless Loads for Cylindrical Shells

Curves read for Beta Figure value

N{PHI) / ( P/Rm 0.084 4C 12.282

M(PHI) / ( P ) 0.084 2C1 0.078

11-14 Slresses

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 Pressure Vessel Design and Analysis - Seminar Noles Discussion ofResulls
(

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PlJElite 4.00 Licensee: COADE Inc. , Local White Lock
FileName , Seminar --------------------------------------- Page 72
WRC107 Analysis ,
Nozzle/cylinder Item: 1 9:51a Sep 21,2000

N (PHI) I MC/(Rm**2 Beta) 0.084 3A 2.280

H(PHI) I MC/ (Rm Beta) 0.084 1A 0.093
N(PHI) I ML/(Rm**2 Beta) 0.084 3B 8.115
M(PHI) I ML! (Rm • Beta) 0.084 1B 0.043

N(x) I P/Rm ) 0.084 3C 10.437

M(x) I p ) 0.084 1C1 0.118
N(x) I MC!(Rm**2 • Beta) 0.084 4A 3.410
M(x) I MC! (Rm • Beta) 0.084 2A 0.051
N(x) I ML!(Rm**2 • Beta) 0.084 4B 2.289
M(x) I ML! (Rm • Beta) 0.084 2B 0.063

STRESS POINTS C & 0 (MARCH 1979)

N(PHI) I ( P!Rm ) 0.084 3C 10.437
M{PHI) I ( p ) 0.084 1C 0.115
M(PHI) I ( ML/ (Rm
· BETA) ) 0.084 1B1 0.042

( N(x) I P!Rm ) 0.084 4C 12.282

M(x) I p ) 0.084 2C 0.078
M(x) I ML/ (RID • BETA) 0.084 2B1 0.064

Stress Concentration Factors Kn = 1.00, Kb 1.00

Stresses in the Vessel at the Attachment Junction

[ Stress Values at
Type of [ (psi)
---------------1--------------------------------------------------------
Stress Load I Au Al Bu Bl Cu Cl Du D1
---------------1--------------------------------------------------------
Circ. Memb. DP I 14300 14500 14300 14500 14300 14500 14300 14500
Cire. Memb. P I -914 -914 -914 -914 -777 -777 -777 -777
Cire. Bend. P I -2523 2523 -2523 2523 -3711 3711 -3711 3711
Cire. Memb. MC I 0 0 0 0 0 0 0 0
Cire. Bend. MC I 0 0 0 0 0 0 0 0
Cire. Memb. ML I -767 -767 767 767 0 0 0 0
Cire. Bend. ML I -1739 1739 1739 -1739 0 0 0 0
I
Tot. Circ. Str.[ 8357 17081 13369 15137 9812 17434 9812 17434

Long. Mernb. OP 1 7150 7150 7150 7150 7150 7150 7150 7150
Long. Mernb. P 1 -777 -777 -777 -777 -914 -914 -914 -914
Long. Bend. P 1 -3817 3817 -3817 3817 -2541 2541 -2541 2541
( Long. Memb. 1 MC 0 0 0 0 0 0 0 0
Long. Bend. 1 MC 0 0 0 0 0 0 0 0
Long. Memb. 1 ML -216 -216 216 216 0 0 0 0
Long. Bend. 1 ML -2648 2648 2648 -2648 0 0 0 0
1
Tot. Long. Str·1 -308 12622 5420 7758 3695 8777 3695 8777

Shear VC o o o o o o o o
Shear VL o o o o -95 -95 95 95
Shear MT o o o o o o o o

Stresses 11-15

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Discussion of Results Pressure Vessel Design and Analysis - Seminar Notes

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Semiriar --------------------------------------- Page 73
WRCI07 Analysis: Nozzle/Cylinder Item: 1 9:51a Sep 21,2000

I
Tot. Shear I o o o o -95 -95 95 95

Str. Int. I 8665 17081 13369 15137 9813 17435 9813 17435

With the Given Forces and Moments the

Maximum Radial Force (Edge of Nozzle) is ..... 21621.90 lb.

The PV Elite Program, (c) 1989-2000 by COADE Engineering Software

11-16 Siresses

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 Pressure Vessel Design and Analysis - Seminar Noles Discussion of Results

Pressure Vessel Design and Analysis Seminar

Component Design Problem

Stresses in a sphere due to Loads on a Nozzle

Analyze the elliptical head for Drum D-IOI under the following loads:
.Design pressure is 200 psi. (1.378 N/mm2)
Radial load is 5,400 Ibs. (24021 N)
Longitudinal shear load is 2,100 lbs. (9342 N)
Longitudinal bending moment is 35,000 ft-lbs. (4745 N-m)

The elliptical head is 144 in. (3658 mm) ID and I-in. (25.4 mm) thick.
The attachment is round and has an OD of 12.75 in. (324 mm)
(

Notes:

Questions:
( What is the highest stressed point?
Is the stress at this point acceptable?

DO NOT TURN THE PAGE UNTIL YOU HAVE

COMPLETED YOUR ANALYSIS

Stresses 11-17

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 Discussion or Results Pressure Vessel Design and Analysis - Seminar NOles

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar --~------------------------------------ Page 74
WRCI07 Analysis: Nozzle/Head Item: 2 9:51a Sep 21,2000

Input Echo, WRCI07 Item 2, Description: Nozzle/Head

Diameter Basis for Vessel VBASIS 10

Cylindrical or Spherical Vessel CYLSPH Spherical
Corrosion Allowance for Vessel CAS 0.0000 in.
Vessel Diameter OV 259.200 in.
Vessel Thickness TV 1.000 in.

Attachment Type TYPE Round

Diameter Basis for Nozzle NBASIS 10

Corrosion Allowance for Nozzle CAN 0.0000 in.
Nozzle Diameter ON 12.750 in.
Nozzle Thickness TN 0.6B7 in.

Design Internal Pressure OP 200.00 psig

External Forces and Moments in WRC 107 Convention:

Radial Load P 5400.00 lb.
Circumferential Shear (VC) V2 0.00 lb.
Longitudinal Shear (VL) V1 2100.00 lb.
Circumferential Moment (MC) Ml 0.00 it.lb.
Longitudinal Moment (ML) M2 3500.00 it.lb.
Torsional Moment MT 0.00 ft.lb.

Compute Maximum Radial Force Yes

Compute Maximum Circumferential Moment No
Compute Maximum Longitudinal Moment No
Compare Maximum Stress Intensity to 26250.00 psi

Use Interactive Control INTACT No

WRCI07 Version VERSION March 1979 ( Bl & B2 )

Include WRCI07 SIF(Kn,Kb)--concentration factors No

Include Pressure Stress Indices per Div. 2 No

Dimensionless Parameters: U ; 0.62 TAU 9.78 RHO 1.46

Dimensionless Loads for Spherical Shells

Curves read for Figure Value

N(x) • T / p SP 2 0.05315
M(x) / P SP 2 0.0598B
N{x) • T • SQRT(Rm * T / MC SM 2 0.10030
M(x) • SQRT(Rm • T / MC SM 2 0.13465
N(x) • T • SQRT(Rm • T / ML SM 2 0.10030
M(x) • SQRT(Rm T / ML SM 2 0.13465

N(y) • T / P SP 2 0.15573
M(y) / P SP 2 0.03152
N(y) • T • SQRT(Rm
• T ) / MC SM 2 0.14582

II-IS Stresses

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 Pressure Vessel Design and Analysis - Seminar Noles Discussion of Resulls

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WRCI07 Analysis : Nozzle/Head Item: 2 9: 51a Sep 21,2000

M(y) ,.. SQRT(Rm T I MC SM 2 0.09009

N(y) ... T ... SQRT(Rm T I ML SM 2 0.14582
M(y) SQRT(Rm ... T I ML SH 2 0.09009

Stress Concentration Factors Kn = 1.00, Kb == 1. 00

Stresses in the Vessel at the Attachment Junction

I Stress Values at
Type of I (psi)
---------------1--------------------------------------------------------
Stress Loadl Au Al Bu 81 Cu Cl Du Dl
---------------1--------------------------------------------------------
Rad. Memb. DP I 12%0 12960 12960 12960 12960 12960 12960 12960
Rad. Mernb. P I -287 -287 -287 -287 -287 -287 -287 -287
Rad. Bend. P I -1940 1940 -1940 1940 -1940 1940 -1940 1940
Rad. Memb. MC I 0 0 0 0 0 0 0 0
Rad. Bend. MC I 0 0 0 0 0 0 0 0
Rad. Memb. ML I ~369 -369 369 369 0 0 0 0
Rad. Bend. ML 1 -2974 2974 2974 -2974 0 0 0 0
1
Tot. Rad. Str.1 7390 17218 14076 12008 10733 14613 10733 14613

Tang. Memb. DP 1 12960 12960 12960 12960 12960 12960 12960 12960
Tang. Memb. P 1 -840 -840 -840 -840 - 840 -840 -840 -840
Tang. Bend. P 1 -1021 1021 -1021 1021 -1021 1021 -1021 1021
Tang. Memb. MC 1 0 0 0 0 0 0 0 0
Tang. Bend. MC I 0 0 0 0 0 0 0 0
Tang. Memb. ML I -536 -536 536 536 0 0 0 0
Tang. Bend. ML I -1990 1990 1990 -1990 0 0 0 0
I
Tot. Tang. Str·1 8573 14595 13625 11687 11099 13141 11099 13141

shear VC I 0 0 0 0 0 0 0 0
Shear VL 1 0 0 0 0 -9' -9' 9' 9.
Shear MT I 0 0 0 0 0 0 0 0
1
Tot. Shear I 0 0 0 0 -9' -9' 9. 9'
Str. Jnt. I 8573 1721B 14076 1200B 11121 14618 !11121 14618

(
With the Given Forces and Moments the
Maximum Radial Force (Edge of Nozzle J is 0.0" 34893.37 lb.

The PV Elite Program, (cl 19B9-2000 by COADE Engineering Software

( Slresses 11-19

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Stresses in Horizontal Pressure Vessels Pressure Vessel Design and Analysis - Seminar Noles

STRESSES IN HORIZONTAL PRESSURE VESSELS

The Zick analysis method calculates stresses in horizontal pressure vessels created by the
combination of internal pressure and the weight of the vessel and its contained liquid. The
method is based on "Stresses in Large Horizontal Cylindrical Pressure Vessels on Two
Saddle Supports," The Welding Journal Research Supplement, J95 I, and subsequent
interpretations of that work.
The geometry analyzed by the Zick method is a horizontal cylinder with torispherical,
hemispherical, or spherical heads, supported at two locations on saddles. The saddles
extend between 100 degrees and 180 degrees around the shell and mayor may not have
wear pads separating them from the shell.
The melhod calculates the stresses at several points in a horizontal vessel, including the
following:
Longitudinal stresses at the top and bottom of the shell near the saddles, including
pressure stresses
Longitudinal stresses at the top and bottom of the shell at the midspan, including pres-
sure stresses (
Tangential shear stresses in the shell
Tangential shear stresses in the head
Circumferential stress above the saddle, including pressure stresses
Stress in the head if it is used as a stiffener
Compressive stress in the shell
The method also analyzes additional stiffening rings that may be required to reduce the
stresses to acceptable levels.
The saddle is generally located close 10 the head in order to take advantage of the stiffen-
ing effect of the head. In general, 'A' should be less than 0.2*L.
Acceptable bearing angles are between 100 and 180 degrees. If you enter a value greater
than or equal to 180 you will not be able to compute the result. The most typical value is
120 degrees, except for very small vessels, and the maximum is generally f50 degrees.
If the dimensions of the wear pad and the saddle are appropriate, this method allows sum-
ming the thicknesses of the shell and pad for circumferential membrane stress calcula-
tions. For circumferential bending stress calculations the method will use the square root
of the sum of the squares of the wear pad and shell thicknesses.
If the wear pad extends above the horn orthe saddle more than R110 in., and if the saddle
is within O.5R of the head, then the wear pad thickness may be included in the caleulation
for the circumferential stress at the horn of the saddle. If the wear pad width is more than
1.56*SQRT(R*TS) then the wear pad thickness may be included in the calculation for the
circumferential stress at the bottom of the vessel.
This type of vessel may have a full encirclement stiffener either on the ID or the OD. The
purpose of the stiffener is to keep the shell round, just as in external pressure caleulations.
Several different kinds of stiffeners may be analyzed. These include simple plate stiffen-
ers, tees, double plate stiffeners, and beam sections.
Longitudinal stresses at the saddle include both the bending stresses across the vessel, and
the longitudinal pressure stress (SLP+-SLS). The allowable stress in tension is the shell
allowable stress times the shell joint efficiency. The allowable stress in compression is the
allowable compression per the ASME Code, Paragraph UG-23 , using the materials chart

11-20 Stresses

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 Pressure Vessel Design and Analysis. Seminar Noles Stresses ill Horizontal Pressure Vessels

associated with the given material. If you entered alternate stresses for the material, then
the allowable compressive stress is based on chart CS-2. The top section of the shell for an
unstiffened vessel is ineffective as a beam. Therefore, except for the stiffened case, the
section modulus of the shell is lower at the saddles than away from them.
Longitudinal stresses at the mid-span include both the bending stresses across the vessel,
and the longitudinal pressure stress (SLP+-SLM). The allowable stress in tension is the
shell allowable stress times the shell joint efficiency. The allowable stress in compression
is the allowable compression per the ASME Code, Paragraph UG-23, using the materials
chart associated with the given material. If you entered alternate stresses for the material,
then the allowable compressive stress is based on chart CS-2.
The tangential shear in the shell varies depending on whether the shell is stiffened or the
head acts as a stiffener, or neither of these cases. Tangential stress in the head only exists if
the head is close enough to the saddle to be used as a stiffener. The allowable stress in
shear is 80% of the allowable tensile stress.
The stress at the hom of the saddle depends on the location of the saddle and the equiva-
lent thickness of the saddle and wear pad. It is zero if the shell is stiffened by rings. This
stress is always compressive and the allowable stress is -1.5 times the allowable tensile
stress.
Use of a head as a stiffener creates additional tensile stress in the head. The allowable
additional stress in the vessel head is limited to 0.25 times the allowable tensile stress. If
you add the pressure stress in the head (not shown) to this value, the resulting stress must
be less than 1.25 times the allowable tensile stress.
The ring compressive stress in the shell is the compression at the bouom of the saddle due
to the weight of the vessel. The allowable membrane compressive stress is taken to be one
half the yield stress or 1.5 times the tension allowable, whichever is less.
If the stiffening ring is internal then the maximum stress in the shell is compressive. If the
ring is external, the stress in the shell is tensile, and internal pressure adds to this stress.
The slress should be limited to +/- 1.5 times the shell allowable stress.

POINTS FOR STRESS RECOVERY

..." LONG! TUOINAl. smESS

l3 SHEAR STRI::SS

! C1RCVUFERENT'~L STRESS

Figure 5--Geometry for the Analysis of Horizontal Vessels on Saddle Supports

Stresses 11-21
(

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Stresses in Horizontal Pressure Vessels Pressure Vessel Design and Analysis Seminar Notes
R

11-22 Stresses

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 Pressure Vessel Design and Analysis - Seminar Notes Stresses in Horizonlal Pressure Vessels

Pressure Vessel Design and Analysis Seminar

Component Design Problem

Horizontal Vessels on Saddle Supports (Zick Analysis).

Analyze Drum D-I 0 I for stresses as a horizontal drum:

Design pressure 230 psi (1.585 Nmm 2 ) at 450°F (232°C)
SA-516,70 (shell and heads) with 0.125-in. (3.175 mm) corrosion allowance
144-in. (3658 mm) ID with I-in. (25.4 mm) wall, full radiography
2:1 elliptical heads, I-in. (25.4 mm) thick, full radiography

Vessel is 20 ft 6096 tangent to tangent.

Saddle is 30 in. (762 mm) from the vessel tangent, and 12 in. (304.8 mm) wide.
( The saddle has an arc of 120 degrees.

The wear pad, 0.375, 9.5 extends only a small amount outside the saddle.
There is no reinforcing ring.

Weight of attachments and appurtenances ~ 40,000.0 lbs. 177934N

Notes:

Questions:

What happens if you extend the wear pad?

DO NOT TURN THE PAGE UNTIL YOU HAVE

COMPLETED YOUR ANALYSIS

Stresses 11-23

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Stresses in lIorizontal Pressure Vessels Pressure Vessel Design and Analysis - Seminar Notes

COADE Engineering Software

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FileName: Seminar --------------------------------------- Page 60
Horizves Analysis; 0101 Zick Item: 1 9:51a Sep 21,2000

Input Echo, Horizontal Vessel Item I, Description: 0101 zick

Design Internal Pressure 200.00 psig

Design Temperature 450.00 F
Corrosion Allowance for Vessel 0.1250 in.

Shell Material SA-516 70

Shell Operating Allowable Stress 20000.00 psi
Shell Ambient Allowable Stress 20000.00 psi
Head Material SA-516 70
Head Operating Allowable Stress 20000.00 psi
Head Ambient Allowable Stress 20000.00 psi

Density of Shell and Head Material 0.2830 lb. lin

Liquid Height in vessel 144.2500 in.
Density of Stored Liquid 0.2830 lb. 1ft
Extra Weight 40000.000 lb.

Baseplate Length 168.0000 in.

Baseplate Thickness 1.0000 in.
Baseplate Width 12.0000 in.
Number of Ribs ( inc. outside ribs ) 3
Rib Thickness 1.0000 in.
Web Thickness 1.0000 in.
web Location Center
Height of Center Web 12.0000 in.

Design Temperature of Base Structure 100.00 F

Saddle\Baseplate\Rib\Web Material SA-516 70
Operating Allowable Stress 20000.00 psi
Ambient Allowable Stress 20000.00 psi

Use ASCE 7-95 No

Force Coefficient 0.500
Extra Area 2880.0000 in
Importance Factor 1.050
Wind Velocity 110.000 mile/hr
Exposure Category C
Height above Grade 7.0000 ft.
Distance from Center of Vessel to Support- 84.0000 in.

Seismic Loads Present N

(
Diameter Basis for Vessel ID
Shell Diameter 144.0000 in.
Shell Length Tangent to Tangent 20.0000 ft.
Thickness of Shell 1. 0000 in.
Shell Joint Efficiency 1.0000

Head Type Elliptical

Head Thickness 1. 0000 in.
Head Joint Efficiency 1.0000

11-24 Stresses

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Pressure Vessel Design and Analysis - Seminar Notes Stresses in Horizontal Pressure Vessels

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Horizves Analysis: 0101 zick Item: 1 9:51a Sep 21,2000

Distance from Saddle to Vessel Tangent 30.0000 in.

Saddle Width 12.0000 in.
Saddle Bearing Angle 120.0000 degrees
Wear Pad Thickness 0.3750 in.
Wear Pad Extension above Horn of Saddle 0.0000 in.
Wear Pad Width O. 0000 in.

Stiffening Ring Present N

Results for HORIZVES Number 1, Description: 0101 Zick

Shell Allowable Stress used in calculation 20000.00 psi

Shell Compressive Yield used in Calculation 31750.00 psi
Head Allowable Stress used in Calculation 20000.00 psi

Volume of Vessel 2722.20 ft.**3

Weight of Vessel, Empty 83924.85 lb.
Weight of Vessel, Full 84695.23 lb.

Required Actual
Shell Thickness, Reqd. VS. Actual 0.851 1.000 in.
Head Thickness, Reqd. VS. Actual 0.847 1.000 in.
Shell M.A.W.P. Reqd. VS. Actual 200.00 240.88 psig
Head M.A.W.P. Reqd. VS. Actual 200.00 2'12.3'1 psig

Actual Allowable
Long. Stress at Top of Saddles 824].46 20000.00 psi
Long. Stress at Bottom of Saddles 8162.25 20000.00 psi
Long. Stress at Top of Midspan 8116.58 20000.00- psi
Long. Stress at Bottom of Midspan 8289.13 20000.00 psi

Tangential Shear in Shell 642.27 16000.00 psi

Tangential Shear in Head 642.27 16000.00 psi
circ. Stress at Horn of Saddle -3360.27 -28575.00 psi
Addl. Stress in Head as Stiffener 292.74 5000.00 psi
Ring Compressive Stress in Shell -1044.44 -15875.00 psi

WIND ( ASeE #7 J and SEISMIC RESULTS

Transverse Wind Load Component Ft

Ft {AFT '" CF '" GH * QZ 1 * 0.5
Ft {391.311 * 0.5000 * 1.3967 '" 27.3514 1 * 0.5
Ft 3737.1382 lb.

Saddle Reaction Force due to Wind Ft

Fwt 1.5 * Ft * B / E
Fwt 1.5 * 3737.1 * 84.0000 / 126.6562
Fwt 3717.7756 lb.

Longitudinal Wind Load Component Fl

FI {AFL"'CF*GH*QZl
Fl ~ { 159.671 * 0.5000 '" 1.3967 '" 27.3514

Stresses 11-25

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 Slresses in Horizontal Pressure Vessels Pressure Vessel Design and Analysis - Seminar Notes

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Horizves Analysis: 0101 Zick Item: 1 9:51a Sep 21,2000

FI ~ 3049.8240 lb.

Saddle Reaction Force due to Wind pI

Fwl FI * B I La
Fwl 3049.8240 '* 84.0000 / 180.0000
Fwl 1423.2512 lb.

Load Combination Results for Q + Wind or Seismic

Q WO!2 + Max( Fwl, Fwt, FsI, Fst )
Q 42347 + Max( 1423, 3717, 0, 0 )
Q 46065.3945 lb.

FORMULAS and SUBSTITUTIONS for ZICK ANALYSIS RESULTS

Shell and Head Required Thickness and MAWP :

TR (PI (D/2+CA)) / (S*E-O. 6,o,P) per UG-27 (c) (1) Shell

TR ( 200.00 '* ( 144.0000 ! 2 + 0.1250 )) /
( 20000 '* 1.00 - 0.6 * 200.00 ) + CA
TR 0.851 in.

MAWP (S'*E* (T-cA) ) ! ( (D!2+CA) +0.6* (T-CA)) per UG-27 (c) (1) : Shell
MAWP ( 20000 '* 1.00 * ( 1.0000 - 0.1250 ») I
«( 144.0000 I 2 + 0.1250 ) + 0.6 '* ( 1.0000 - 0.1250 ))
MAWP 240.9 psig

TR (p* (D+2*CA) '*K) / (2·S·E-0. 2·P) per App. 1-4 (c) Elli. Hd.
TR (200.00 '"' ( 144.0000 + 2 * 0.1250 ) * 1.00 ) I
( 2 * 20000 * 1.00 - 0.2 * 200.00 ) + CA
TR 0.847 in.

MAWP (2*S*E·(T-CA)!(K,o,(D+2*CA)+0.2'*(T-CA.)I per App. 1-4 (c) ; Elli. Hd.

MAWP ( 2 * 20000 • 1.00 '* ( 1. 0000 - 0.1250 )) I
( 1.00 * ( 144.0000 + 2 * 0.1250 ) + 0.2 *( 1.0000 - 0.1250 »)
MAWP 242.3 psig

Longitudinal Bending (+-) at Midspan

( 3 '"' Q * L '* K.2 / ( PI * R~2 '* ( TS - CA »))
( 3 * 46065 * 20.00 * 0.4464 ) I
( PI * 72.1250 * 72.1250 * ( 1.0000 - 0.1250 I))
86.27 psi

Longitudinal Bending (+-) at Saddle

( 3 * Q * L '"' K.l / { PI '* R 2 * (TS
A
CA I))
( 3 * 46065 * 20.00 * 0.2101 ) /
( PI * 72.1250 * 72.1250 '* ( 1.0000 - 0.1250 I)) (
40.60 psi

Tangential Shear in Shell near Saddle

Q '"' K.5 / ( R * ( TS - CA I»)
46065 * 0.8799 / ( 72.1250 • ( 1.0000 - 0.1250 )
642.27 psi

Tangential Shear in Head used as Stiffener

11-26 Stresses

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 Pressure Vessel Design and Analysis - Seminar Noles Stresses in Ilorizontal Pressure Vessels

COADE Engineering Software

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Q .., K.5 I ( R ... ( TH - CA »)

46065 * 0.8799 / ( 72.12 ... ( 1.0000 - 0.1250 )
642.27 psi

Circumferential Stress at Horn of Saddle

_Q!(4*TEM*(SADWTH+l.56*SQRT(R*CA»)-12*Q*R*K.7!(12*L*TEB)
-46065!1 4'" 0.8750 ... ( 12.00 + 1.56 ... SQRT( 72.1250 ,.. 0.8750 »))
-12.0 ... 46065 ... 72.12 ... 0.0130 I ( 12 .., 20.0000 ... 0.7656 )
-3360.27 psi

Additional Tension in Head used as Stiffener

(Q/(R*(HDTHK_CA»)*(3/8)*(SIN(AL)A 2 /(PI-AL+SIN(AL"*COS(ALI)~
( 46065 I ( 72 .1250 ... ( 1. 0000 - 0.1250 )))"* (3/8)"* ( SIN ( 1.99 ) -"-2) I
( PI - 1.99 + SIN{ 1.99 ) ... COS ( 1.99 )))
292.74 psi

Circumferential Compression at Bottom of Shell

(Q*( K.9/( TEM9"*( B+1.56 "* SQRT( R * TEM9 I)~)
( 46065*( 0.7603/( 1.2500*( 12.00+1.56*SQRT( 72.25* 1.2500))))
-1044. 44 psi

Longitudinal Pressure Stress

DP"*«SID/2+CA)-0.4"'(TS-CA»/{2.0*(TS-CA))
200.0'" « 144.00 I 2 + 0.1250 - 0.4 '" ( 1.000 - 0.1250 )) /
( 2.0 * ( 1.000 - 0.1250 ))
8202.86 psi

RESULTS for VESSEL RIBS, WEB and BASE

Moment of Inertia of Saddle Lateral Direction

Y A AY Ay"'2 10
Shell 0.4375 10.8438 4.7441 2.0756 0.6919
wearplate 1.0625 0.0000 0.0000 0.0000 0.0000
Web 6.1250 9.7500 59.7187 365.7773 77.2383
BasePlate 11.5000 12.0000 138. 0000 1587.0000 1.0000
Totals 19.1250 32.5937 202.4629 1954.8529 78.9301

Value C1 SumQfAy/SumOfA 6.2117 in.

Value I SumQfAy"'2 + SumOfIo - C1*SumOfAy 776.1425 in*"'4
Value As SumOfA - Ashell 21.7500 in

K1 (1+Cos(b)-.5*Sin(b)A 2 >/(pi-b+Sin(b)"'Cos(b)) 0.2035

Fh (K1*Q)= 9375.3076 lb.

Tension Str .. St ( 2.0 ... Fh/As ) 862.0974 psi

Allowed Str .• Sa .6 * Yield Stress 22800.0000 psi

Bending Mom. , M Fh d 19124.1465 ft.lb.

Bending Str., Shnd ( M C1 I I ) 1836.6779 psi

Allowed Str. , Sa .66 Yield Str. 25080.0020 psi

Stresses 11-27
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 Stresses in Horizonlal Pressure Vessels Pressure Vessel Design and Analysis - Seminar Noles

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar --------------------------------------- Page 64
Horizves Analysis: 0101 Zick Item: 1 9:51a Sep 21,2000

Minimum Thickness of Baseplate

Baseplate Min .. ~ (3*Q*F/{4*A*SA»)A. 5 0.3137 in.

Calc. of Axial Load, Inter. Values and Compo Stress

e BPLEN - 1 ) / ( NRIBS - 1)
e 168.0000 - 1 ) / ( 3 - 1 ) 83.5000 in.

AP e * BPWID / 2
AP 83.5000 * 12.0000 / 2 501. 0000 in

P AP * SF
P 501.0000 * 22.8499 = 11447.7988 lb.

AR BPWID - 1 - WEBTK ) * RIBTK + e/2 * WEBTK

AR 12.000 - 1 - 1.000 ) * 1.000 + 83.5000/2 * 1.000 51.750 in

se P/AR
se 11447.7988/ 51.7500 221.2135 psi

Check of Outside Ribs

Inertia of Saddle, Outer Ribs - Axial Direction
Y A AY Ay.... 2 10
Rib 6. 0000 10.0000 60.0000 0.0000 143.9167
Web 6.0000 41.7500 250.5000 0.0000 6.9583
Values 6.0000 51.7500 310.5000 0.0000 150.8750

KL/R < Cc ( 27.8921 < 122.7360 ) per AISC E2-1 9th Edition
Sea (1-(Klr) .... 2/(2*Cc.... 2))*Fy/{5/3+3*(Klrl/(8*Cc)-(Klr"'3)/(8*Cc"'3l
Sea (1-( 27.89 )"'2/(2 * 122.74"'2 ») * 38000 /
( 5/3+3*( 27.89)/(8. 122.74)-( 27.89 .... 3)/{8* 122.74"'3)
Sea 21148.51 psi

AISC Unity Check on Outside Ribs ( must be <= 1.0 )

Check Sc/Sca + Sb/Sba
Check 221.21 / 21148.51 + 334.94 / 250S0.00
Check 0.02

Check of Inside Ribs

Inertia of Saddle, Inner Ribs - Axial Direction
Y A AY Ay"'2 10
Rib 5.5000 10.0000 55.0000 0.0000
Web 5.5000 83.5000 459.2500
110.8333 (
0.0000 6.9583
Values 5.5000 93.5000 514.2500 0.0000 117.7917

KL/R < Cc { 9.5776 < 122.7360 1 per AISC E2-1 9th Edition
Sea (1- (Klr) ....2/ (2*Cc"'2) 1*Fy/ (5/3+3* (Klr) / (S*Cc) - (Klr .... 3) / (S*CC .... 3)
Sea (1-( 9.58 ) .... 2/(2 * 122.74 .... 2 )) * 38000 /
( 5/3+3*( 9.581/(8* 122.74)-{ 9.58"'31/(8* 122.74"'3)
Sea 22339.15 psi

11-28 Stresses

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 Pressure Vessel Design and Analysis - Seminar Noles Stresses in Horizonlal Pressure Vessels

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PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName; Seminar --------------------------------------- Page 65
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~ISC Unity Check on Inside Ribs ( must be <= 1.0

Check Se/Sea + Sb/Sba
Check 244.87/ 22339.15 + 177.54 / 25080.00
Check 0.02

The PV Elite program, (cl 1989-2000 by COADE Engineering Software

Stresses 11-29

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Siresses in JIorizonlal Pressure Vessels Pressure Vessel Design and Analysis - Seminar Notes

11-30 Stresses

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Pressure Vessel Design and Analysis - Seminar Notes

Chapter 12:
Tall Vertical Towers
ENGINEERING SOfTWARE

ALLOWABLE STRESSES ON TALL TOWERS

The allowable stress for the hoop direction is the same as always-the labulated stress for
thc material.
The allowable stress for longitudinal tension can be increased when calculaling cases Ihal
include wind or earthquakc loads. The factor for this increase is 1.2
The allowable compressive stress (which may also be multiplied by the above factor) is
calculated as follows:
I. Allowable strain, A, is O.125/(RO/t).
2. Allowable stress, B, is taken from the appropriatc external pressure chart.
3. Joint efficiency for butt-welded joints is taken as unity.
The temperature limitations on the external pressure charts also apply 10 the compressive
allowable.

Tall Vertical Towers t2-1

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 Analyzing Tall Vertical Process Towers Pressure Vessel Design and Analysis - Seminar NOles

ANALYZING TALL VERTICAL PROCESS TOWERS

The analysis ofta]] vertical process towers is somewhat more complicated than that for
simple pressure vessels. There are several reasons for this additional complication:
Pressure - Internal
- External
- Hydrotest
Dead Loads - Vessel Weights
- Equipment & Appurtenances
- Contents
Thermal - Temperature Effects
Moments - Wind
- Earthquake
- Piping
- Erection

Internal External Dead Wind!

Load Case Pressure Pressure Loads Seismic Thermal

Erection X X
Operating x X X x
Operating X X X X

t2-2 Tall Vertical Towers

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 Pressure Vessel Design and Analysis - Seminar Noles Design Procedure

DESIGN PROCEDURE
In light of the various loadings found on towers, a very carefully thought out design proce-
dure must be followed. The following list shows typical steps in a procedure of this kind:
I. Analyze vessel geometry and determine the X and Y coordinate for elements.
2. Analyze or design the vessel for internal pressure-determine initial thickness esti-
mates.
3. Analyze or design the vessel for external pressure-verify original thickness esti-
mates, and modify if necessary. When thicknesses are modified, return to Step 2.
4. Calculate the weights of elements and details. This would include shells and heads,
nozzles, flanges, skirts, baserings, insulation, internals, platforms, fireproofing, pack-
ing, liquid, trays, and other miscellaneous items. This turns out to be one of the most
tedious steps you will perform, even ifusing a computer program, since the geometry
of each of these items must be determined.
5. Determine the support forces and/or moments. Based on the weights of each compo-
( nent, determine the force and moment at the support point (or, in a more sophisticated
analysis, the support points.)
6. Calculate the cumulative weight and bending moment for the vessel. In the case of a
tower, this is calculated both for the upright and the horizontal position, since the hor-
izontal weight and bending moment diagram is used to determine the natural fre-
quency.
7. Determine the natural frequency for the vessel. This is most often done using a numer-
ical method such as Freese's method. In a more sophisticated analysis, this might be
done with a finite element or finite difference analysis.
8. Calculate the wind load on the vessel. This is done using the rules found in national
standards such as American Society of Civil Engineers, Standard 7, the National
Building Code of Canada, or the Uniform Building Code.
9. Calculate the earthquake load on the vessel. THis is done with the same national stan-
dards described above.
10. Calculate the cumulative weight and bending moments for the various load cases.
These include the various combinations of wind, earthquake, internal pressure, exter-
nal pressure and weight described above, plus hydrotest cases.
(
I I. Calculate the stresses and required thicknesses for the various load cases. It may be
that the designer will have to increase the thickness of one or more vessel components
at this point. If so, then the designer will have to begin all over with his calculations,
starting from Step 2.

Wind load Computations

Most wind load calculations will be done using a national standard such as the American
Society of Civil Engineers, Standard 7, the National Building Code of Canada, or the Uni-
form Building Code.
The ASCE Standard contains the following formula for wind load computation:
Where:
F force on each segment of the vessel
q, ~ wind pressure

Tall Vertical Towers 12-3

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Design Procedure Pressure Vessel Design and Analysis· Seminar NOles

gust response factor

structural force coefficient

Wind Pressure Computation

Where:
KZ Exposure Coefficient
qz Wind Pressure
I Importance Factor
V Wind Velocity

Where:
zg Gradient Height
a Power Law Coefficient
z Elevation

I. "Category" classification
Structure . Category
All Structures Not Covered Below I
Primary Occupancy Of Over 300 11
Essential Facilities 1Il
~inor Structures IV

2. "Importance" Factor
Category 100 Miles F/ Hurricane At Hurricane Line
I 1.00 1.05
11 1.07 1.11
III 1.07 1.11
IV 0.95 1.00

3. "Exposure" Constants
Category Alpha : Zg
A - Large Cities 3.0 1500
B - Suburban Areas 4.5 1200
C - Open Terrain 7.0 900 (
D - Flat, Coastal 10.0 700
When the wind pressure has been calculated, the gust and structural factors for each ele-
ment must be determined. The gust response factor can be either static or dynamic. The
static just response factors are given in tables similar to those above, evaluated at the
building or structural height h. The dynamic gust response factor is calculated based on
the natural frequency of the vessel, various damping factors, and the design wind speed.
Calculations for this factor can be found in the commentary to ASCE-7. The dynamic gust
response factor must be used when the natural frequency of the structure is less than 1hz.
If the natural frequency is unknown, then a guideline given by ASCE is to use the dynamic
gust response factor when the height to width ratio of the vessel is greater than 5.
The structural force factor is also found in tabular form. The most commonly used table in
ASCE 7 looks like this:
Force Coefficients Jar Chimneys, Tanks, and Similar Structures, CJ

12-4 Tall Vertical Towers

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 Pressure Vessel Design and Analysis - Seminar Notes Design Procedure

CHar hiD values of

Shape Type of Surface I 7 25
Square (wind normal) All 1.3 1.4 2.0
Square (wind diagonal) All 1.0 l.l 1.5
Hexagonal or octagonal All 1.0 1.2 1.4
Round, highly loaded Moderately smooth 0.5 0.6 0.7
Rough 0.7 0.8 0.9
Very RoughO.8 1.0 1.2
Round, lightly loaded All 0.7 0.8 1.2

Earthquake Load Computation

ASCE-7 and several of the other standards have a relatively simple calculation for the lat-
eral force imposed by an earthquake:
Where:
Z Seismic Zone Coefficient
I Importance Factor
C
T Fundamental Natural Frequency
K Horizontal Force Factor
S Soil Profile Coefficient

Note C' S need not exceed 0.14 for profile 3 in zones 3 and 4; C need not exceed 0.12.

'Z''Seismic Zone Coefficient

Zone Z
4 I
( 3 3/4
2 3/8
I 3/16
o 1/8

'l''Gccupancy Importance Factor

Category
I 1.0
11 1.25
III 1.5
IV N/A

Tall Vertical Towers 12-5

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Design Procedure Pressure Vessel Design and Analysis - Seminar Noles

'S''Soil Profile Coefficient

Profile Type S
Rock, Stiff Soil SILO
Deep Cohesionless, Stiff Clay S2 1.2
Soft - Medium Clay S3 1.5

'K'!Horizontal Force Factor

Structure Type K

Unreinforced Masonry Walls NlA

Reinforced Masonry Walls 1.33
Light Wood or Metal Walls 1.0
Building Frame Systems 1.0
Moment Resisting, Concrete N/A
Moment Resisting, Ordinary Steel 1.0
(
Moment Resisting, Special Frames 0.67
Dual Systems 0.80
Elevated Tanks 2.5
Other (Pressure Vessels) 2.0

12-6 Tall Vertical Towers

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 Pressure Vessel Design and Analysis - Semill<lT Notes Design Procedure

Tall Vertical Towers 12-7

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Design Procedure Pressure Vessel Design and Analysis - Seminar Noles

Pressure Vessel Design and Analysis Seminar

Component Design Problem

Tall Vertical Process Towers

Use PVElite to analyze the tower shown on the following page.

(You need not perform nozzle calculalions)
Assume the tower full of liquid 10 the bottom of the cone (s.g. ~ .9)

Notes:

'<
j

Questions:

Arc the thicknesses adequate?

What arc the dimensions of the basering? _

12-8 Tall Vertical Towers

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 Pressure Vessel Design and Analysis ~ Seminar Notes Design Procedure

T101 LIQUID PHASE REACTOR

lCOO FT LBS
DESIGN PRESSURE = 225 PSIG
250 LBS EXTERNAL PRESSURE = 15 PSIG
2'1 ELLJPTlCAL DESIGN TEMPERATURE ~ 350 F
• .,,5' CORRISION ALLOWANCE = 0.125

1
11 ...0000
JOINT EFFICIENCY:
LONGITUDINAL ~ 100%
CIRCUMFERENTIAL ~ 85%

t-f------l MATERIALS:
SHELL & SKIRT
HEADS
BASE PLATE
SA516.70
SA516.70
SA285.C

"~1----1
REINFORCEMENT SA516.70
FORGINGS SA105
NOZZLE NECKS PIPE SA106.C
NOZZLE NECKS PLATE SA516.70
(
NOZZLE SCHEDULE:

l-
MARK SIZE PURPOSE
A-D 20" MANWAY
E 18" INLET
F 32" OUTLET
I-----------l
H"'WOO o.~375·

----~~----""T~ .2\1 ELLlPTlCAL

O.~375·

0.625'

Figure 1--Geometry for Tower Design Example English

Tall Vertical Towers 12-9

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Design Procedure Pressure Vessel Design and Analysis· Seminar Noles

101 LIQUID PHASE REACTOR

1112 N
1.62.691e+006 N-I'lM DESIGN PRESSURE = 1.55 N/mm'
2'1 ELLlPTICAL EXTERNAL PRESSURE = 0.103 N/mm'
16 MH DESIGN TEMPERATURE = 177 C
CORRISION ALLOWANCE = 3.175 mm
JOINT EFFICIENCY:
LONGITUDINAL = 100%
CIRCUMFERENTIAL = 85%

MATERIALS:
SHELL & SKIRT SA516.70
HEADS SA516.70
BASE PLATE SA285.C
REINFORCEMENT SA516.70
FORGINGS SA105
NOZZLE NECKS PIPE SA106.C
NOZZLE NECKS PLATE SA516.70
'''''
NOZZLE SCHEDULE:
MARK SIZE PURPOSE
A-D 20" MANWAY
E 18" INLET
2-4 t-iN F 32" OUTLET

2.1 ELLIPTICAL
24 I~M

16 MM

Figure 2-Geamelry for Tower Design Example Metric

12-10 Tall Vertical Towers

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 Pressure Vessel Design and Analysis - Seminar Noles Skirl and BaseRing Design
(

SKIRT AND BASERING DESIGN

Basering Thickness Calculations
Thickness of basering under compression: The equalion for the thickness of the basering is
Ihe equalion for a simple cantilever beam. The beam is assumed to be supported al the
skirt, and loaded with a uniform load caused by the compression ofthe concrete due to the
combined weight of the vessel and bending moment on the down-wind I down-earthquake
side of the vessel. The equation for the cantilever is found in most of the common vessel
design textbooks, including Jawad & FaIT, Structural Analysis and Design of Process
Equipment, page 434, formula 12.12:

Where:

fc bearing stress on the concrete

(
J cantilever length of basering

J allowable bending stress of basering (typically 1.5 times Code allow-

able).
There are two commonly accepted methods of determining the bearing stress on the con-
crete. The approximate method simply calculates the compressive load on the concrete,
assuming that the neutral axis for the vessel is at the centerline. Thus the load per unit area
of the concrete is, from Jawad & FaIT equation 12.1, equal to·

Where:

W Weight of vessel (worst case).

M Bending moment on vessel (worst case).

( A Cross sectional area of basering on foundation

c Distance from the center of the basering to the edge

J Moment of inertia of the basering on the foundation

However, when a steel skirt and basering are supported on a concrete foundation, the
behavior of the foundation is similar to that of a reinforced concrete beam. If there is a net

Tall Vertical Towers 12-11

( I

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Skirt and BaseRing Design Pressure Vessel Design and Analysis - Seminar Notes

bending moment on the foundation, then the force upward on the bolls must be balanced
by the force downward on the concrete.

T
11'---"
'~

.. ~
•
•
. . .. ~

'WL!
(. ) fll t i
I C

ICI

Ie

, d

d
( b)

Figure 3--Neutral Axis Shift

Because the concrete and the steel have different elastic moduli, and because the strain in
the concrete cross section must be equal to the strain in the basering at any specific loca-
tion, the neutral axis of the combined bolt/concrete cross section will be shifted in the
direction of the concrete. Several authors, including Jawad & FaIT (pages 428 to 433) and
Megyesy (Pages 70 to 73) have analyzed this phenomenon. In the program, we have used
the formulation of Singh and Soler, Mechanical Design of Heat Exchangers and Pressure
Vessel Components, Pages 957 to 959. This formulation seems to be the most readily
adaptable to computerization, as there are no tabulated constants. Singh and Soler provide
the following description of their method:

In this case a neutral axis parallel to the y axis exists. The location ofthe neutral axis is
identified by the angle a. The object is to determine the peak concrete pressure p and
the angle a.

For narrow base plate rings, an approximate solution may be constructed using numer-
ical iteration. It is assumed that the concrete annulus under the base plate may be
trcated as a thin ring of mean diameter c. Assuming the foundation to be linearly elas-
tic, and the base plate to be relatively rigid, Brownnell and Young have developed an
approximate solution that can be cast in a form suitable for numerical solution.

Let the total tensile stress area of all foundation bolts be A. Within the limits of accu-
racy sought, it is permissible to replace the bolls by a thin shell of thickness f and
mean diameter equal to the bolt circle diameter c, such that t ~ A / pc. We assume that

/2-12 Tall Vertical Towers

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 Pressure Vessel Design and Analysis - Seminar Noles Skirt and BaseRing Design

the discrete tensile bolt loads, acting around the ring, are replaced by a line load, vary-
ing in intensity with the distance from the neutral plane.

Let n bc the ratio of Young's moduli oflhe bolt material to that oflhe concrete; II nor-
mally varies bctwcen 10 and 15. Assuming that the concrete can take only comprcs-
sian (non-adhesive surface) and that thc bolts are effective only in tension (untapped
holes in base plate), an analysis [similar to that given above) yields the following
results:

2W+ P21ca
p ~ -:p'-,(7:,-,_-=-:.,)-c

a ~ 2(M - Wp,c)
2
P2 P)/C

ex::: c o as -"~-'
( a+n -

(
Where:

I, width of basering (similar to I in Jawad & Farr's equations above)

c bolt circle diamctcr

p four constants based on the neutral axis angle, and defined in Singh &
Soler equations 20.3.12 through 20.3.17, not reproduced here.
These equations give the required 7 non-linear equations to solve for 7 unknowns,
namely p, s, a, and thc r; (i = 1,4) parameters. The simple iteration scheme described
below converges rapidly. The iterative solution is started with assumed values of sand
p; say So and Po' [the program takes thesc from the approximate analysis it has just per-
formed). Then a is determined via the above equation, and then the dimensionless
parameters Tj, T2' T)) and £4 are computed. This enables computation of corrected val-
ues ofp and s (say Po' and so'). The next iteration is started with s, andp, where we
choose the following:
l71 ::; 05 ( l70 + l7n
( P, = 05 (PO + pi)

This process is continued until the errors e; and e; at the ith iteration stage are within
specified tolerances, (e; = e; = 0.005 is a practical value), where

Actual numerical tests show that thc convergence is uniform and rapid regardless of
the starting values of So and Po'

( Tall Vertical Towers 12-13

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Skin and BaseRing Design Pressure Vessel Design and Analysis - Seminar Notes

Once the new values of bolt slress and bearing pressure are calculated, the thickness of the
basering is calculated again using the same fonnula given above for the approximate
method.

Thickness of Basering under Tension

On the tensile side, ifthere is no top ring but there are gussets, there is disagreement on
how to do the analysis. For example, Brown & Root does not look at the tensile side at all,
Megyesy uses a "Table F" to calculate an equivalent bending moment, Dennis R. Moss
uses the same approach but gives the table (Page 126-129), and Jawad & FaIT use a "yield-
line" theory (Page 435-436). Since Jawad & FaIT is both accepted and explicit, Ihe pro-
gram uses their Equation 12.13:

3.91F
t=
S, 2b,,21~
+ - d(~ + ..!.-)
,,2/

Where:
F Boll Load = Allowable Stress * Area
a Distance between gussets
b Width of base plate that is outside of the skirt
I Dislance from skirt to bolt circle
d Diameler of bolt hole

Thickness of Top Ring under Tension

Ifthere is a top ring or plate, its thickness is calculated using a simple beam fonnula. Tak-
ing the plate to be a beam supported between two gussets with a point load in the middle
equal to the maximum bolt load, we derive the following equation:

t=lM ,7

Where:
M Bending moment from Megyesy, beams, case II, fixed beam.

2 F, e.
80
FI Bolt Load ~ Allowable Stress time Area
s Allowable stress, 1.5 * plate allowable
z Seclion Modulus, from Megyesy, Properties of Seclions

( Do2 _D,2. _d.)

Wt Width of Section

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 Pressure Vessel Design and Analysis - Seminar Noles Skirt and BaseRing Design

Required thickness of gussets in tension: Iflhere are gussets, they must be analyzed for
both tension and compression. The stress fonnuJa in tension is just the force over the area,
where the force is taken to be the allowable bolt stress times the boll area, and the area of
the gusset is the thickness of the gusset times one half the width of the gusset (because
gussets normally taper).
. Required thickness of gussets in compression: In compression (as a column) we must iter-
atively calculate the required thickness. Taking the actual thickness as the starting point,
we perfonn the calculation in AISC 1.5.1.3. The radius of gyration for the gusset is taken
as 0.289 t per Megyesy (Fifth edition, Page 404). The actual compression is calculated as
described above, then compared to the allowed compression per AISC. The thickness is
then modified and another calculation performed until the actual and allowed compres-
sions are within one half of one percent of each other.

Basering Design Selections

Selection of Number of Bolls: This selection is made on the basis of Megyesy's table in
Pressure Vessel Handbook (Table C, Page 67 in the fifth edition). Above the diameter
shown, the selection is made to keep the anchor boll spacing at about 24 in.
(
Calculation of Load per Boll: This calculation is made per Jawad& Farr, Equation 12.3:

W 2M
p= - - - -
N NR
Where:

W Weight of vessel
N Number of bolls
R Radius of boll circle
M Bending moment

Calculation of Required Area for Each Bolt

This is just the load per boll divided by the allowable stress.

Selection of the Bolt Size

The program has a table of boll areas, and selects smallest boll with area greater than the
area calculated above.
(
Selection of Preliminary Basering Geometry
The table of bolt areas also contains the required clearances in order to successfully
tighten the selected boll (wrench clearances and edge clearances). The program selects a
preliminarybasering geometry based on these clearances. Values selected at this point arc
the boll circle, basering outside diameter, and basering inside diameter.

Analysis of Preliminary Basering Geometry

Using the methods described above for the analysis section, the program determines the
approximate compressive stress in the concrete for the preliminary geometry.

Selection of Final Basering Geometry

If the compressive stress calculated above is acceptable, then the preliminary geometry
becomes the final geometry. lfnot, then the boll circle and bascring diameters arc scaled

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Skirt and BttseRing Design Pressure Vessel Design and Analysis - Seminar Noles

up to the point where the compressive stress will be acceptable. These become the final
basering geometry values.

Analysis of Basering Thicknesses

The analysis then continues through the thickness calculation described above, determin-
ing required thicknesses for the basering, top ring, and gussets.

Skirt Thickness Calculations

Basic Skirt Thickness

The required thickness of the skirt under tension and compression loads is determined
using the same formula used for the compressive stress in the concrete, except using the
thickness of the skirt:
W Me
lZ = - - - -
, A I

Where:

W Weight of vessel (worst case)

M Bending moment on vessel (worst case)
A Cross sectional area of skirt
c Distance from the center of the basering to the skirt
(radius of skirt)
1 Moment of inertia of the skirt cross section

In tension this actual stress is simply compared to the allowable stress, and the required
thickness can be calculated directly by solving the formula for t. In compression, the
allowable stress must be calculated from the ASME Code, per paragraph UG-23, where
the geometry factor is calculated from the skirt thickness and radius, and the materials fac-
tor is found in the Code external pressure charts.
As with all external pressure chart calculations, this is an iterative procedure. A thickness
is selected, the actual stress is calculated, the allowable stress is determined, and the origi-
nal thickness is adjusted so that the allowable stress approaches the actual stress.

Stress in Skirt due to Gussets or Top Ring

If there are gussets or gussets and a top ring included in the base plate geometry, there is
an additional load in the skirt. Jawad & Farr have analyzed this load and determined that
the stress in the skirt due to the boll load on the base plate is calculated as follows:

Where:
F Total load in one bolt ~ load on one gusset
b Width of the gusset at the base
thickness of the skirt

12-16 Tall Vertical Towers

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 Pressure Vessel Design and Analysis· Seminar Notes Skirt and BaseRing Design

h height of the gusset

Jawad & Farr note that this stress should be combined wilh the axial stress due to weight
and bending moment, and should then be less lhan three times the allowable stress. They
thus categorize this stress as secondary bending. The program performs the calculation of
this stress, and then repeats the iterative procedure described above to determine the
required thickness of the skirt at the lop of the basering.
Generally the skirt/head/shell weld is a non-inspectable weld detail. Frequently the joint
efficiency oflhis weld is taken to be as Iowa 0.45, sometimes 0.55 (See UW-12). Thus the
skirt thickness may very well be governed by the loads at the top, even though the bending
moment is higher at the bottom.

r TTA

•I
HG I DS
-L I
I
II I DC

-rl. ! .. DC
DO

Ih-'~--BND
I I

1-=
TGA
l- I
I
I I I
I

Figure 4--Geometry for Baserings and Bolt Chairs

Tall Vertical Towers 12-17

(

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Skirl and BaseRing Design Pressure Vessel Design and Analysis - Seminar Noles

12-18 Tall Vertical Towers

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Pressure Vessel Design and Analysis - Seminar Noles Skirl and BnseRing Design

Pressure Vessel Design and Analysis Seminar

Component Design Problem

Baserings:

Use the Basering program to analyze the support for tower shown on Page 198.

You will need the following additional information:

Basering ID ~ 118 in. (2997 mm.), OD~128 in. (3251 mm.), Thickness ~ I in.
(25.4 mm), SA-516 70 at 100°F (37.7°C)
Top Ring Thickness ~ I in. (25.4 mm), SA-193 B7 on a 124 in. (3150 mm) Bolt
Circle
Compressive strength of concrete, 3,000 psi (20.68 N/mm 2)
Gussets, I in.(25.4 mm) thick by 12 in. (304.8 mm) tall, 2 per bolt. (locate 3 in.
(76.2 mm) to cach side of bolts)
Gussets arc SA-516 70 at 100°F (37.7°C), Elastic Modulus ~ 29,000,000 (19947
N/mm 2).
Skirt is 0.625 in. (15.9 mm) thick, 121.875 in.(3096 mm) OD, SA 516 70 at
100°F (37.7"C)

From PYElite, get the weights and moments for the tower:
(thcse have been increased to make the problem more interesting)
Dead weight ~ 200,000 Ib (839672 N)
Operating weight ~ 250,000 Ib (1.I1e 6 N)
Test weight = 400,000 Ib (1.77e6 N)
Operating Moment = 1,000,000 ft Ib (1.335e 9 Nmm2)
Test Moment ~ 1,000,000 ft Ib (1.335e9 Nmm2)

Notes:

Questions:

Are thc thicknesses chosen adequatc?

Tall Vertical Towers 12-19

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Skirt and BaseRing Design Pressure Vessel Design and Analysis - Seminar Notes

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar --------------------------------------- Page 76
Basering Analysis: PVD&A Item: 1 9:51a Sep 21,2000

Input Echo, Sasering Item 1, Description: PVD&A

Analyze or Design the Sasering AORD AM

Design Temperature for sasering RNGTMP 100.00 F
Thickness of Sase ring TBA 1.0000 in.
Sasering Material 8A-516 70
Sasering Operating Allowable Stress BASOPE 20000.00 psi
Sasering Ambient Allowable Stress SASAMB 20000.00 psi
Inside Diameter of sasering Dr 118.0000 in.
Outside Diameter of sasering DO 128.0000 in.

Nominal Diameter of Bolts BND 0.8750 in.

Bolt Material 81\-193 87
Bolt Operating Allowable Stress SA 25000.00 psi
Salt Ambient Allowable Stress SAHAMB 25000.00 psi
Number of Bolts NGIV 20
Diameter of Bolt Circle DC 124.0000 in.

Nominal Compressive Stress of Concrete FPC 3000.0 psi

Thickness of Gusset Plates TGA 1.0000 in.

Temperature for Gusset plates GUSTMP 100.0000 F
Average Width of Gusset Plates AVGWDT 2.0000 in.
Material for Gussets 8A-516 70
Gusset Plate Elastic Modulus E 29000000.0 psi
Gusset Plate Yield Stress SY 38000.00 psi
Height of Gussets HG 12.0000 in.
Distance from Bolts to Gussets CG 3.0000 in.
Number of Gussets per bolt NG 2

Thickness of TOp Ring/Plate TTA 1.2500 in.

Radial Width of the Top Ring/Plate TOPWTH 4.0000 in.

External Corrosion Allowance 0.0000 in.

Skirt Thickness TS 0.6250 in.

Skirt Temperature SKTTEM 100.0000 p
Skirt Material SA-516 70
Skirt Operating Allowable Stress SKTOPE 20000.00 psi
Skirt Ambient Allowable Stress SKTAMB 20000.00 psi
Outside Diameter of Skirt at Base DS 121. 8750 in.
Outside Diameter of Skirt at Bottom Head SKTHED 121.8750 in.
Joint Efficiency of Skirt Weld ARCJNT 0.7070

Dead Weight of Vessel DW 200000.0 lb.

Operating Weight of Vessel ROW 250000.0 lb.
Test Weight of Vessel TIl 400000.0 lb.
Operating Moment on sasering ROM 1000000.0 ft.lb.
Test Moment on Sasering TM 1000000.0 ft.lb.

RESULTS FOR BASERING ANALYSIS : ANALYZE OPTION

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 Pressure Vessel Design ami Analysis - Seminar Noles Skirl and BnseRing Design

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName : Seminar --------------------------------------- Page 77
Basering Analysis: PVD&A Item: 1 9:51a sep 21,2000

Calculation of Load per Bolt, Dead Weight Condition:

W/Bolt ({ 4 • M/De ) - W ) / RN per Jawad Farr, Eq. 12.3
W/Bolt ({ 4 * 0.120E+08 / 124.000) - 200000 ) / 20
W/Bolt 9354.8389 lb.

Required Area for Each Bolt, Based on Max Load 0.3742 in

Area Available in a single Bolt 0.4190 in
Area Available in all the Bolts 8.3800 in
Bolt Stress Based on Approximate Analysis 22326.58 psi

Concrete Contact Area of Base Ring 1932.08

Concrete Contact Section Modulus of Base Ring 57185.03

Calculation of Concrete Load, Test Weight Condition:

SC ((ABT*SA+W)/CA) + M/CZ per Jawad & Farr Eq. 12.1
SC {( 8.3800· 25000+ 400000)/ 1932.08) + 0.120E+08/ 57185.03
SC 525.31 psi
(
Calculation of sasering Thickness, (Simplified):
TB RW * SQRT( 3 • SC / S ) + CA per Jawad & Farr Eq. 12.12
TB 3.0625 * SQRT{ 3 • 525 / 30000 ) + 0.0000
TB 0.7019 in.

Results of Neutral Axis shift Calculation:

Searing Pressure on Concrete 412.50 psi
Stress in Bolt 0.00 psi

Calculation of Sasering Thickness, (N.A. Shift):

TBNA RW * SQRT{ 3 • SCNA / S) + CA per Jawad & Farr Eg. 12.12
TBNA 3.0625 * SQRT( 3 • 412 / 30000 ) + 0.0000
TBNA 0.6220 in.

Required Thickness of Top Ring/Plate in Tension:

(Calculated as a fixed beam per Megyesy)
FT (SA*ABSS) , Bolt Allowable Stress * Area
RM (FT*2.0*CG)/B.0. Bending Moment
SS (1.5*BASOPE), Allowable stress· 1.5
WT (TOPWTH BND), Width of Section

T SQRT ( 6 • RM / ( SB * WT » + CA
T SQRT( 6 .7856 / ( 30000 • 3.1250 )) + 0.0000
T 0.7091 in.

Required Thickness of Gusset in Tension:

T = ( SA*ABSS )/( NG*S*( AVGWDT ») + CA
Required thickness based on average cross-section 0.1309 in.
Actual thickness as entered by user 1.0000 in.

Required Thickness of Gusset in Compression, per AISC E2-1 9th Ed.

1. Allowed Compression at Given Thickness:
Factor KI/r Per E2-1 83.0450
Factor Cc Per E2-1 122.7360
All. Buckling Str. per E2-1 15572.10 psi

Tall Vertical Towers 12-21

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Skirt ami BaseRing Design Pressure Vessel Design and Analysis - Seminar Noles

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar --------------------------------------- Page 78
Sasering Analysis: PVD&A Item: 1 9:51a Sep 21,2000

Act. Buckling Str. at Given Thickness 2618.75 psi

Required Gusset thickness, + CA 0.4931 in.

2. Allowed Compression at Calculated Thickness:
Factor KI/r Per E2-1 168.4202
Factor Cc Per E2-1 122.7360
All. Buckling Str. per E2-2 5264.57 psi
Act. Buckling Str. at Calculated Thickness 5310.98 psi

SUMMARY OF BASERING THICKNESS CALCULATIONS

Required Basering Thickness (simplfied) 0.7019 in.
Required Basering Thickness (N.A. Shift) 0.6220 in.
Actual Basering Thickness as entered by user 1. 0000 in.

Required Top Ring/Plate Thickness as a Fixed-Beam 0.7091 in.

Actual Top Ring Thickness as entered by user 1.2500 in.

Required Gusset thickness, + CA 0.4931 in.

Actual Gusset Thickness as entered by user 1. 0000 in.

TENSILE STRESS CALCULATIONS FOR SKIRT AT TOP HEAD:

S 0
Mil PI*R"2*T I - F/ (2*PPR*T)
Operating Dead Load Test Load
Skirt Rad. Given by User 60.9375 60.9375 60.9375 in.
Skirt Thkn. Given by User 0.6250 0.6250 0.6250 in.
Bndg. Mom. Given by User 1000000.0 1000000.0 1000000.0 ft. lb.
Axial Force Given by User 250000.0 200000.0 400000.0 lb.
Actual Stress in Skirt 601.1 810.1 -25.7 psi
Allowed Stress in Skirt 11312.0 11312.0 16968.0 psi

THICKNESS CALCULATION FOR SKIRT:

Required Thickness 0.0332 0.0448 N/A in.
Actual Thickness as Given 0.6250 0.6250 0.6250 in.

COMPRESSIVE STRESS CALCULATIONS AT BASE OF SKIRT:

S = M/IPIrR"2*T) + F/(2*PIrRrT)
Operating Dead Load Test Load
Skirt Rad. Given by User 60.9375 60.9375 60.9375 in.
Skirt Thkn. Given by User 0.6250 0.6250 0.6250 in.
Bndg. Mom. Given by User 1000000.0 1000000.0 1000000,0 ft.lb.
Axial Force Given by User 250000.0 200000.0 400000.0 lb.
Actual Stress in Skirt 2690.5 2481. 6 3317.4 psi
Allowed Stress in Skirt 13426.0 13426.0 20139.0 psi

THICKNESS CALCULATION FOR SKIRT AXIAL COMPRESSION:

Required Thickness 0.2378 0.2284 0.2156 in.
Actual Thickness as Given 0.6250 0.6250 0.6250 in.

SUMMARY OF SKIRT THICKNESS: Operating Dead Load Test Load

Req. Thickness, Tension 0.0332 0.0448 N/A in.
Req. Thickness, Camp. 0.2378 0.2284 0.2156 in.
Actual Thickness as Given 0.6250 0.6250 0.6250 in.

The PV Elite Program, {cl 1989-2000 by COADE Engineering Software

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Pressure Vessel Design and Analysis· Seminar Noles

Chapter 13:
Vessel Legs, Support Lugs,
and Lifting Lugs

These design caleulations are done with simple hand methods. It is useful to review the
origin of the calculations.

VESSEL LEGS
The loading for vessel legs is the weight of the vessel, including operating weight or
weight of water for hydrotest, plus the horizontal shear and overturning moment due to
wind, earthquake, or external loads.
A vessel must have at least three legs. A vessel on two legs develops unacceptably high
bending stresses in the legs under even small horizontal loadings.
For the column furthest away from the neutral bending axis, the axial force in the column
due to these loads, per Jawad & Farr 12.3, is

W 2M
p= - - - - -
N NR
Where:
W Weight of vessel and contents
N Number oflegs (columns)
R Radius of column circle
M Bending moment due to wind or earthqu~ke loads

Note Because the bending moment is only effectively carried by legs that are quite far
removed from the neutral axis, the total number of legs is divided by two in this
equation.

To generate the stress in the leg, simply divide the force by the cross sectional area of the·
leg.
For the column closest to the neutral axis, the axial force does not contain the bending
moment term. However, the axial load may be increased by cross-bracing of the legs.
Cross bracing resolves the shear at the top of the legs into an axial load.
The shear at the top of one leg is the horizontal load divided by the number oflegs which
support the shear load. As implemented in Codecale, the number ofeffective legs for shear
is the integer part of the number of legs divided by two, rounded up. For example, if you
have 4 legs, the number oflegs effective for shear is two, but if you have three legs the
number of effective legs is still two.

Vessel Legs, Support Lugs, and Lifting Lugs 13-1

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Vessel Legs Pressure Vessel Design and Analysis - Seminar Noles

The axial force can be computed from the horizontal force by resolving the force vectors.
First, the horizontal force, assumed to be tangential to the vessel, is resolved into a force
into the vessel and a force in the plane from one leg to the next. The angle between the two
legs is alpha, and the force X in that plane is

H
X=--
sin it

Where:
H Horizontal force at top of one leg
a Angle between tangent and next leg
180N -360
a =
2N

This horizontal force in the plane of the legs is further resolved into an axial force in the
cross bracing and an axial force in the leg (F):

X
F=-
tantl'
Where:
X Horizontal force in plane of legs
P Angle between top and bollom of legs

,.vDIN
atan---
L
P
D Diameter of leg circle
L Length oflegs
When you have many legs, or if the legs are quite tall, the angle of the cross bracing will
be high, and even a small horizontal load will require a large vertical component in the
brace and leg to resist it.
The leg closest to the neutral axis carries the weight of the vessel and the additional axial
compression caused by the cross bracing:

p=---p
w
N

Vessel legs are generally a simple structural shape - an I beam, a channel, an angle, or a
structural tube. I-beams and channels have a strong and a weak orientation. If the beam is
allached such that the tangent to the vessel is parallel to the beams strong axis use the
strong axis beam properties. Otherwise use the weak axis properties. '
For angles, iflhe angle is allached with one leg welded to the vessel or one flat welded 10
the vessel, use the strong axis properties. If the angle is attached with both legs welded 10
the vessel (like an upside down V), use the properties of the angle in a diagonal direction.

13-2 Vessel Legs, Support Lugs, and Lifting Lugs

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 Pressure Vessel Design and Analysis - Seminar NoLes Support Lugs

These leg loads are compared to the allowable leg comprcssion per the AISC Stcel Con-
struction Manual, paragraph 1.5.1.3:

KI
Wmn-<C,
r

F. = 5 3( ~) (~r
-+------
3 gC, 8C;
Wmre:

C =
,
l,,i'E
F
( >
K Effective length factor
Length
,. Least radius of gyration
E Young's Modulus of column material
F, Yicld strength of column material
If you cross brace the legs, there will be no bending at the bottom. OthelWise the bending
at the bottom will be equal to the length ofthe leg times the shear at the top of the leg clos-
est to the neutral axis.
The combination of bending and compressive stress is compared to the allowable per
AISC 1.6.1 (unity check).

SUPPORT LUGS
The lug support point should be set as close to the vesscl OD as possible, to reduce bend-
ing moments on the lugs and the vessel.
Most support lug calculations also assume a minimum of three lugs, so that the lugs do not
have to carry a bending moment. However, some vessels are supported on two wide lugs
that can carry transverse bending.
The force on one lug is the weight of the vessel divided by the number oflugs, plus the
bending moment at the lug support point divided by the radius to the lug and the number
of effective lugs. This is thc same fonnula shown above for the force on a leg far away
from the neutral axis of the bending moment.
Most support lugs have two gussets, equally spaced about a bolt hole. The distance
between the gussets is used to calculate the bending in thc support plate.

Vessel Legs, Support Lugs, and Lifting Lugs t3-J

(

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Lining Lugs Pressure Vessel Design and Analysis - Seminar Noles

The bending stress in the bottom plate of a vessel support lug is calculated using a simple
beam formula for a beam (the plate) on two simple supports (the gussets):

M
17=-
Z
Wmre:

2
= W,lf,l
z 6
F = Force on one lug
D gp =Dist.ance between gussets
Wpi = Width of supportlugboLlotn plaLe
f pi = Thicknessof support plaLe

Bending stress in Lhe bottom plate ofa vessel support lug is compared to the AISC allow-
able bending stress.
The stress in the gusset is one half the lug force divided by the gusset area. This compres-
sion is compared Lo the AISC allowable compression. If the gussets arc angled (as they
would be iffor cases with no top plate), ealeulate the mean gusset widlh and usc that value
in the gusset compression calculations.
Compressive stresses in support lug gussets arc compared to AISC compressive allow-
able, which is caleulaled using the same formulas given above for the legs as columns.
The loads on the vessel shell should also be checked. These can be checked using the
WRC- I 07 analysis technique.

LIFTING LUGS
There are two orientations of lifting lugs: flat to the vessel and perpendicular to the vessel.
Flat lugs arc generally welded below the top head scam and extend far enough above the
scam for the lifting cables to clear the head and its nozzles. Perpendicular lugs (cars) are
used to clear some obstruction at or ncar the top head (such as a l;>ody flange) by moving
the support point away from the vessel shell. They arc also used as tailing lugs.
Lifting lugs are normally subject to forces that arc "horizontal" in the natural coordinate
system of the vessel during the early part of the lift, and then to purely vertical forces. For
lifting lugs that are flat to the vessel shell, these tangential forces are usually not a prob- (
lem. However, for lifting lugs that are perpendicular to the shell (ears), these forces can
easily bend the lug, and should be avoided.
Forces normal to (away from) the shell should be avoided on lifting lugs that arc flat to the
shell, since these will tend to peel the lug off the shell. In other words, don't pull on the lug
in its weak direction.
The most significant stresses in the lug usually occur in the welds which attach the lug to
the vessel. You need to know the minimum leg width and the location of these welds.
Then you need to calculate the cross sectional area and the shear stress on the welds that
attach the lug to the vessel. The load for the direct shearing stress may calculated as the

13-4 Vessel Legs, Support Lugs, and Lifting Lugs

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 Pressure Vessel Design and Analysis - Seminar Notes Lining Lugs

square root oflhe squares of all Ihe loads on Ihe lug (W, Nand T). This is only slightly
cOIlservativc.
WeldArea =(2 L\Uld + BWeld )( Twdi )
Wmre:
LWld = Length of weld on sides of support
B wl1 = Widlh of weI d on boltom of support
TWld "" Thickness of welds

Load = lw' + N' + T'

Wmre:
W = WeighlLo.d
N =Horizontal force nonn at to the vessel
T = Horizon.tal force tangent to the vessel

In addition to the direct shear stress, the shear stress at the ends of the welds due to the
(
bending on the lifting lug is must be calculated for each load. First, calculate the section
modulus of the weld group. Then calculate the shear stresses:
Bending Stress Due to Normal Force:

Bending Stress Due to Weight:

Bending Stress Due to Tangential Force:

Hlif Height of Lifting Lug

L,'dd Length of weld on sides of support
O'if Offset vessel OD to center of hole
Z" Section Modulus, Longitudinal Direction
Z/c Section Modulus, Circumferehtial Direction
Tensile, bending and shear loads are combined to calculate the stresses in vessel lifting
lugs. The stresses in the lugs arc compared to ASME allowable for base material shear and
fillet weld shear.
Most lifting lugs have a circular hole located in a semi-circular arc of meta I. Shear across
this section may control the lug design.
The bending load on a flat lifting lug is caused by the force N that you entered normal to
the vessel. The bending load on perpendicular lifting lugs is caused by the combination of

Vessel Legs, Support Lugs, and Lifting Lugs 13-5

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 Lifting Lugs Pressure Vessel Design and Analysis - Seminar Notes

Ihe vessel weight (W) and Ihe force you entered in Ihe tangential direclion. Nole Ihallhis
combinalion calculates the slress only allhe highest slressed corner of the weld group.

_ / OFFSET OF UFllNG lOO

~IU
flATUFTllm
_-__'LU'G\ ARC Of'S£[
RADIUS

F'f:RF'ENDlC
LUG
o
SlDEFU..1ET
WELD

LEGs----+-<.1
CROSS BRAaNG-+-I-<~

LEG ORlENTATJON;
__=:::- WEAK

-SlRONG.

Figure 1--Geometry for Vessel Legs, Support Lugs, and Lifting Lugs

13-6 Vessel Legs, Support Lugs, and Lifting Lugs

I.

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 Pressure Vessel Design find Analysis - Seminar Noles Lining Lugs

Pressure Vessel Desigu and Analysis Seminar

Component Design Problem

Vessel Legs

Design vessel support legs for the following vessel:

The design pressure is 200 psi (1.37 N/mm2), design temperature is 300°F 149°C.
The diameter of the vessel is 42 in. (1067 mm)
The height of the vessel itself is about 14.3 ft. (4359 mm)
The weight of the vessel is 30,000 lbs. (133451 N)
The wind load is 40 psf (0.002 N/mm 2)
The centroid of the vessel area is 10 ft (3048 mm) above grade.

( The vessel has 4 legs

Each leg is a W6x25 beam, oriented with the axis in the strong direction.
The leg material is SA-285, C
The vessel legs are 5 ft (720 mm) tall and are not cross-braced.

Notes:

Questions:

What is the result of the AISC unity check?

DO NOT TURN THE PAGE UNTIL YOU HAVE

COMPLETED YOUR ANALYSIS

Vessel Legs, Support Lugs, and Lifting Lugs 13-7

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Lining Lugs Pressure Vessel Design and Analysis - Seminar NoLes

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar --------------------------------------- Page 66
Leg & Lug Analysis 0102 Legs Item; 1 9:51a Sep 21,2000

Input Echo, Leg & Lug Item Description: 0102 Legs

Design Internal Pressure 200.00 psig

Design Temperature for Attachment TEMP 300.00 F
Vessel Outside Diameter OD 42.0000 in.
Tangent to Tangent Length of Vessel TANTAN 14 .3000 ft.
Height of Bottom Tangent Above Grade 5.0000 ft.

Operating weight of Vessel (vertical load ) W 30000.00 lb.

Erection Weight of Vessel (Lifting Analysis) W 30000.00 lb.

Force Coefficient Cf 0.500

Additional Area 2880.00 in
Importance Factor I 1.050
Wind Velocity V 110.000 mile/hr
Exposure Catagory Expcat C
Use ASCE 7-95 Wind Code No

Additional Horizontal Force on Vessel FF 0.00 lb.

Location of Horizontal Force above Base Point FH 0.00 ft.

Number of Legs
Length of Legs
NLEG
LLEG
•
5.0000 ft.
Effective Leg End Condition Factor K 1.00
Material for Legs SA-285 C
Yield Stress of Leg Material 26500.00 psi
AIse Member Designation W6X25
Leg Orientation to vessel Axis ORIENT Strong
Are the Legs Cross-Braced XB NO

Occasional Load Factor (AISe A5.2) OCCFAC 1 .33

COMPUTED pARAMETERS:
Effective Wind Area of Vessel AREA 13962.21 in
Wind Pressure on Vessel ( ASCE #7 or User PWIND 38.02 psf
Location of Centroid above Base Point WH 12.15 ft.

RESULTS FOR LEGS : Description:D102 Legs

Section Properties for the selected Member
Cross Sectional Area for W6X25 7.340 in
Radius of Gyration ( strong axis ) 2.700 in.
Section Modulus (strong axis ) 16.700 in. **3
Overturning Moment at top of Legs 13179.9 ft.lb.
Weight Load at top of one Leg 7500.0 lb.
Additional force in Leg due to Bracing 0.0 lb.

Shear at top of one Leg

Vleg (V + FF '" ( Imax / Itot )
Vleg (1843.3 + 0.0 ) '" ( 53.5 / 140.93 )
Vleg 699.86 lb.

Axial Compression, Leg futhest from N.A.

13-8 Vessel Legs, Support Lugs, and Lifting Lugs

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 Pressure Vessel Design and Analysis - Seminar Noles Lining Lugs

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName : Seminar ------------~-------------------------- Page 67
Leg & Lug Analysis DI02 Legs Item; 1 9:51a Sep 21,2000

Sma «(W/Nleg) + (Mleg/{Nlegm*Rn) I I . 0000) / (Aleg I 1. 0000»)

Sma «( 30000/4) + ( 13179 /( 2 .., 2.02 I) .., 1.00001/
( 7.340 .., 1. 0000) )
Sma 1466.92 psi

Allowable Compo for the Selected Leg (KL/r <·Cc )

Sa (1- (kl/r) "2/ (2*Cc"2») *Fy /
{ 5/3+3"'(KI/r)/(8*Cc)-(KI/r~3)/(8*Cc~31
Sa (1-( 39.47 )"2/(2 ... 146.97'''2 I) ... 26500 /
( 5/3+3*( 39.47 1/(8* 146.97 )-( 39.47"3)/(8* 146.97"3)
Sa 19249.06 psi

Bending at the Bottom of the Leg closest to the N.A.

S {Vleg * Rlngth 12.0000 / Smdsa )
S (699.86 * 5.00 • 0.0000 / 16.70 )
S 2514.48 psi

Sb (0.6 * Fy * Occfac )
Sb (0.6 * 26500 * 1.33 )
Sb 21147.00 psi

AISC Unity Check ( must be < or = to 1.00 )

Sc (Sma/Sa)+(0.85·S)/«1-Sma/spex)*Sb)
Sc ( 1466/ 19249 )+( 0.85 .., 2514.476 1/«( 1 - 1466/ 127463 ) * 21147 )
Sc 0.1785

Additional Results
Forces/Moments for WRC107 Analysis: Weight only
Radial Load Max. Shear/leg o. lb.
Circumferential Shear Max. Shear/leg o. lb.
Longitudinal Shear Load / Leg 7500. lb.
Longitudinal Moment Moment/ Nlegs 1994. it.lb.
Circumferential Moment Max. Shear/leg* Dist. o. ft.lb.

Forces/Moments for WRC107 Analysis: Occasional

Radial Load Max. Shear/leg ..700. lb .
Circumferential Shear Max. Shear/leg 700. lb.
Longitudinal Shear Load / Leg 10767. lb.
Longitudinal Moment Moment/ Nlegs 2862. ft.lb.
Circumferential Moment Max. Shear/leg· Dist. ;186. ft.lb.

The PV Elite Program, (cl 1989-2000 by COADE Engineering Software

Vessel Legs, Support Lugs, and Lifting Lugs 13-9

(

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Lining Lugs Pressure Vessel Design and Analysis - Seminar Notes

COAOE Engineering Software

PVElite 4.00 Licensee: COAOE Inc., Local White Lock
FileName: Seminar ----------------------------------- Page 68
Leg & Lug Analysis 0102 Lugs Item: 2 9:51a Sep 21,2000

Input Echo, Leg & Lug Item 2, Description: 0102 Lugs

Design Internal Pressure 200.00 psig

Design Temperature for Attachment TEMP 300.00 F
Vessel Outside Diameter 00 42.0000 in.

Operating Weight of Vessel (vertical load ) W 30000.00 lb.

Erection Weight of Vessel (Lifting Analysis) W 30000.00 lb.

Force Coefficient Cf 0.500

Additional Area 2880.00 in
User defined Wind Pressure 34.490 psf
Use ASCE 7-95 Wind Code No

Additional Horizontal Force on Vessel FF 3000.00 lb.

Location of Horizontal Force above Base Point FH 0.00 ft.

Horizontal Force Normal to the Vessel N 3000.00 lb.

Horizontal Force Tangent to the vessel T 15000.00 lb.
Lifting Lug Material SA-516 70
Lifting Lug Yield Stress YIELD 33600.00 psi
Lifting Lug Orientation to Vessel Flat
Width of Lifting Lug WLIF 6.0000 in.
Thickness of Lifting Lug TLIF 1.0000 in.
Diameter of Hole in Lifting Lug DLIP 1. 5000 in.
Radius of Semi-Circular Arc of Lifting Lug RLIF 3.0000 in.
Height of Lug from bottom to Center of Hole HLIF 15.0000 in.
Offset from Vessel 00 to Center of Hole OLIF 0.5000 in.
Minimum thickness of Fillet Weld around Lug TWELD 0.5250 in.
Length of weld along sides of Lifting Lug LWELD 8.0000 in.
Length of Weld along Bottom of Lifting Lug BWELD 6.0000 in.

Occasional Load Factor (AISC A5.2) OCCFAC 1.33

COMPUTED PARAMETERS:
Effective Wind Area of Vessel AREA 13962.21 "in
Wind Pressure on Vessel ( ASCE #7 or User PWIND 34.49 psi
Location of Centroid above Base Point WH 12.15 it.

RESULTS FOR LIFTING LUGS : Description:D102 Lugs

Held Group Inertia in the Longitudinal Direction 86.50 io**4
Weld Group Centroid distance in the Long. Direction 5.16 in.
Weld Group Inertia in the Circumferential Direction 108.41 in I *4
Weld Group Centroid Distance in the Circ. Direction 3.53 in.
(
Primary Shear Stress in the Welds due to Shear Loads:
A A
Ssll SQRT(W 2+T 2+N A 2)/(2*Lweld+Bweld)*Tweld)
A
Ssll SQRT( 30000 2+ 15000 A 2+ 3000 A 2)/((2* 8.0+ 6.0)* 0.5250)
Ssll 2915.5B psi

Shear Stress in the Welds due to Bending Loads ;

Shlf = (N*IHlif-Lweld/2»*YLL/ILL+fW*OLIF*YLL/ILL)+(T*OLIP*YLC/ILC)

13-10 Vessel Legs, Support Lugs, and Lining Lugs

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Pressure Vessel Design and Analysis - Seminar Notes Lifting Lugs

COADE Engineering Software

PVElite 4.00 Licensee; COADE Inc., Local White Lock
FileName; Seminar --------------------------------------- Page 69
Leg & Lug Analysis 0102 Lugs Item; 2 9:51a Sep 21,2000

Shlf ~ 3000*( 15.000- 8.000/2)* 5.162/ 86.496 +

30000* 0.500* 5.162/ 86.496) +
( 15000* 0.500* 3.525/ 108.405)
Sblf ~ 3108.76 psi

Total Shear Stress vs. allowable Shear for Combined Loads

St (Ssll + sbU )
St (2915.577 + 3108.760 )
St 6024.34 psi

Sta (0.4 * Yield * Occfac ) AISC Shear All.

Sta (.4 * 33600 * 1.33 )
Sta 17875.20 psi

Secondary Shear Stress in the Welds due to Shear Loads:

Unit Weld Section Modulus ( Uwsm )
(2*LWELD+WLIF)A 3 / 12 - LWELD A 2(LWELD+WLIF\)A 2 /(2*LWELD+WLIF)
~ 317.15 in .... 3

Loads on Welds due to Torsional Moment

Fth T * (Hlif-(Lweld-Cent) * (Bweld/2J/Uwsm
Fth 1715.56 lb./in.

Ftv T * ( Hlif-(Lweld-Cent») * Cent / Uwsm

Ftv 2911.24 lb./in.

Fsv T / ( 2 * Lweld + Wlif )

Fsv 681.82 lb./in.

Resultant Load on Weld Group

Fr Sqrt( Fth"'2 + ( Ftv+Fsv )A 2 )
Fr = 3981.61 lb./in.

Resultant Secondary Weld Stress

Fws Fr / Tweld
Fws = 7584.02 psi

Allowable Resultant Secondary Weld Stress

Psa ( . 4 " Yield * Occfac )
Psa = 17875.20 psi

shear Stress in Lug above Hole vs. Allowable Base Metal Shear
A
Shs SQRT( W 2 + N A2 + T A2 ) / Sha
Shs SQRT( 30000 A2 + 3000"'2 + 15000 A 2 ) / 4.500
shs 1483.31 psi

Sas (0.4 * Yield * Occfac ) Shear Allowable

Sas (0.4 * 33600 * 1.33 )
Sas 17875.20 psi

Pin Hole Bearing Stress Vs. Allowable Bearing Stress

A
pbs Sqrt( W 2 + NA 2 + T A 2 )/( Tlif * Dlif )
pbs = Sqrt( 30000"'2 + 3000"'2 + 15000 A 2 )/( 1.000 * 1.500

Vessel Legs, Support Lugs, and Lifting Lugs 13-11

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Lifting Lugs Pressure Vessel Design and Analysis - Seminar Noles

COADE Engineering Software

PVElite 4.00 Licensee: COADE Inc., Local White Lock
FileName: Seminar --------------------------------------- Page 70
Leg & Lug Analysis 0102 Lugs Item: 2 9:51a Sep 21,2000

Pbs 22449.94 psi

Pba
Pba
I 0.75
I 0.75
.•
'field
33600
AISC Bearing All.

Pba 25200.00 psi

Bending Stress in Lug at Weld Vs. Allowable Stress

A
Fbs N*(HLIF-LWELD)/(WLIF*TLIF 2/6)
Fbs 3000 *( 15.000 - 8.000 )!( 6.000 ,., I.DOO A 2 / 6)
Fbs 21000.00 psi

Fba ( 0.4 • Yield Occfac ) Shear Allowable

Fba ( 0.4 .., 33600 .., 1. 33 )
Fba 17875.20 psi

The PV Elite Program, (c) 1989-2000 by COADE Engineering Software

13-12 Vessel·Legs, Support Lugs, and Lifting Lugs

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Pressure Vessel Design and Analysis - Seminar Notes

Bibliography

Brief Bibliography of Pressure Vessel Texts and Standards

This bibliography describes several of the commonly available texts and standards used by
the author of CodeCalc to develop and support the program. This list will help you to iden-
tify resources you may need to effectively design or analyze pressure vessels:

ANSI Standard A58.1 - 1982, Building Code Requirements for Minimum Design
Loads in Buildings and Other Structures, American national Standards Institute, New
York,1982.

This standard provides the most commonly used design technique for cDlculating wind loads and
earthquake loads on structures, including pressure vessels.

ANSI Standard Bl6.5, Pipe Flanges and Flanged Fittings, American National Stan-
dards Institute, New York.
This is 1he standard for 'standard' flanges up to 24 inches in diameter. Provides flange geomelries
and allowable pressures for the various classes oftlanges (150, 300, 400, 600, 900, 1500. and 2500)
made from a variety of materials and over a wide range of temperatures.

ASME Boiler and Pressure Vessel Code, SECTION VIII, Division I, Rules for Con-
struction of Pressure Vessels. July 1989. American Society of Mechanical Engineers,
345 East 47th Street. New York, N.Y., 10017.

This is 'lhe Code'. The INTERNAL, EXTERNAL, NOZZLE and CONICAL programs are based
exclusively on this document. The FLOHEAD and FLANGE programs are based primarjly on Ihis
document. All of the allowable stresses used by these programs are also taken from this document.

ASME Code for Pressure Piping, B31, Chemical Plant and Petroleum Refinery Pip-
ing ANSIIASME B31.3, American Society of Mechanical Engineers, 345 East 47th
Street. New York, N.Y., 10017.

This is the piping code for refineries and chemical plants. The PIPE&PAD program is based on this
code. In addition, this document has good tables of elastic modulus and coefficient of thermal
expansion for many classes of materials.

Bednar, H.H., Pressure Vessel Design Handbook, Van Nostrand-Reinhold Co., Prince-
ton, H.J., 1981.

Bibliography

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Drief Bibliography of Pressure Vessel Texis and Standards Pressure Vessel Design and Analysis - Seminar Noles

Bednar provides good calculation techniques for tall process towers and fair coverage ofa variety of
other pressure vessel design problems.

Brownell, L.E. and Young, E.H., Process Equipment Design, John Wiley, New York,
1959.

This is a classic reference on process equipment design, and contains many useful calculation tech-
niques. However, many copies of Ihis book are in an unreviscd format Ihat contains errors in tables
and formulas. We recommend comparing a given technique to some of the other texts before using
it.

Farr, J.R. and Jawad, M.H., Structural Analysis and Design of Process Equipment,
John Wiley & Sons, New York, 1984.

This is lhe best recent book on pressure vessel design and analysis. The book covers a wide scope of
design techniques, and presents the rational and use of the ASME Code techniques beller than any
other pressure vessel textbook. (J.R. FaIT is on many of tile ASME Code commiltees). The book also
provides a good balance of theory, practice, and example problems. Highly recommended.

Harvey, J. F. Theory and Design of Modern Pressure Vessels, 2nd Edition, Van Nos-
trand-Reinhold, Princeton, N.J.

Harvey provides a basic overview of pressure component design, but little information on supports
or other peripherals to the vessel. His sections on thick walled pressure vessels, aUlofretiage, and
thermal stress are especilllly useful.

Manual of STEEL CONSTRUCTION, American Institute of Steel Construction, Chi-

cago, III. Eighth Edition, 1980.

This standard provides tables ofall beam sections and structural tubing, and provides calculations
for allowable compression on columns, allowable stress on beams, and allowable combined loads.
These are vel)' useful for support leg, gusset plate, and even flat plate cldculations. Later editions are
also available.

Megyesy, E.F., Pressure Vessel Handbook,Pressure Vessel Handbook Publishing, Inc.,

Tulsa OK, 74135
(
This is another very widely used book with a good combination of easy- to-usc formulas, examples,
and tables of data, including pipe sizes and schedules, flange dimensions and weights for compo-
nents.

Modern Flange Design. Bulletin 503, 7th Edition, Gulf and Western Taylor-Bonney
Division, Southfield, Michigan.

This is the best known bulletin on design of flanges, and includes all of the f1rmge calculation sheets
commonly used for flange design. It also contains a good pmctical discussion offlange design and
bolting, and a good table of bolt dimensions.

Moss, Dennis R., Pressure Vessel Design Manual, Gulf Publishing Company, HOlls-

2 Bibliography

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Pressure Vessel Design and Analysis - Seminar Noles Brier Bibliography of Pressure Vessel Texis <lnd Standards

ton, TX, 1987.

This relatively new book provides many different calculation procedures, and some calculation
sheets, for most of file common teclmiques in pressure vessel design. A major weakness of the book
is a lack of example problems illustrating the use oftlie leehniques. Some ofthe calculations for sup-
port lugs,lining lugs, and vessel legs in the LEG&LUG program are from this book.

Roark, R.J., and Young, W.C., Formulas for Stress and Strain, 5th Edition, McGraww
Hill, New York, 1795. (Later editions also available).

This well known reference book provides an abundance of [annulas for detennining the stresses in
structural components. The book provides tables for beams, plates, shells, and many other types of
components under many pmcticalloading cOlldifiollS.

Standards of the Tubular Exchanger Manufacturers Association, Seventh Edition,

1988. Tubular Exchanger Manufacturers Association. 25 North Broadway. Tarrytown,
N.Y.,10591.

This is Ihe standard used for tubcsheets (in the TUBESHT program) and channel covers (in the
FLANGE program). This document also contains excellent tables of elastic modulus, coefficient of
Ihennal expansion, thennal conductivity, and the bolt tables used in the FLANGE, TUBESHT, and
FLOHEAD programs.

Shigley, J. E., Mechanical Engineering Design, McGraw Hill, New York, 1972.

This is a 'standard' textbook for mechanical engineering students. It provides many basic fommlns
for beams, plates, shells, bolting, screws, springs, shafts, and olher mechanical components you may
need to analyze from time to time.

Wiclunan, K.R, Hopper, A.G, and Mershon, J. L., "Local Stresses in Spherical and
Cylindrical Shells due to External Loadings," WRC Bulletin 107, Welding Research
Council, New York, 1965 (revisions through 1979).

This is the 'WRC-I07' technique whieh is widely used to detennine stresses in shells due to loads on
nozzles and attachments. This analysis is implemented in the CYLNOZ and SPHNOZ progmms.
Though widely used, the results of this analysis are !lot especially accurate.

Zick, L.P., "Stresses in large Horizontal Cylindrical Pressure Vessels on Two Saddle
Supports," in Pressure Vessel and Piping Design Collected Papers 1927-1959, Amer-
ican Society of Mechanical Engineers, New York, 1960.

This is the 'Zick' analysis, used in the HORIZVES program. The Ziek analysis is very widely used to calculate
stresses in horizontal vessels.

Bibliography 3

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 Brief Bibliography of Pressure Vessel Texts and Standards Pressure Vessel Design and Analysis - Seminar Noles

4 Bibliography

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