DESCON ENGINEERING LIMITED

Lahore Manufacturing Works

COMPRESS Pressure Vessel Design Calculations

Item. : Sulphur Locks (Funnel Internal Vessel) Vessel Tag No. : SRU-V-004 A/B/C/D/E/F Attock Refinery Upgradation Project/Hyundai Contractor / Client. : Engineering Corporation Project Number./Document DM. 13611 / DM.13611-P11-CS-062-A (REV A) (1 OF 7) Number : Designer: S.Z.A. (Syed Zain Ali) Date: Wednesday, January 15, 2014 This Document is the exclusive property of DESCON ENGINEERING LTD. and may not be copied, exploited, duplicated, reproduced or communicated to a third party in any form without the prior written approval of DESCON ENGINEERING LTD.

1/50

Deficiencies Summary Deficiencies for N9 Jacket (N9 Jacket) N9 Jacket: SA-106 B Smls. Pipe: PWHT is mandatory for thicknesses over 32 mm. (nozzle neck UW-40(f)(3)). Deficiencies for Sleeve Cover SA-105: PWHT is mandatory for thicknesses over 32 mm. Warnings Summary Warnings for ASME B16.5/16.47 Blind on 12" x 10 " ANSI Reducing Flange Internal design pressure varies across this chamber. (warning) External design pressure varies across this chamber. (warning) Check the following component(s): (warning) Flange #6 (warning) N9 Jacket (N9 Jacket) (warning) N9 Sleeve (N9 Sleeve ) (warning) Warnings for Flange #6 The hydrostatic end force on this flange cannot be determined until a vessel support component is specified. (warning) Warnings for Sulphur Outlet 2" x 3" (Steam Jacketed) (N10) ASME B16.5: External loads have not been considered in the flange pressure rating. (warning) Warnings for Vessel Inconsistent PWHT: The vessel has one or more components with PWHT, but not all components have PWHT specified. (warning)

ASME B16.5 / B16.47 Flange Warnings Summary ASME B16.5 / 16.47 Flanges with Warnings
Flange Applicable Warnings

12" x 10 " ANSI Reducing Flange Sulphur Outlet 2" x 3" (Steam Jacketed) (N10)

1, 2 1, 2

ASME B16.5 / 16.47 Flange Warnings

No. Warning

1 2

For Class 150 flanges, ASME B16.5 para. 5.4.3 recommends gaskets to be in accordance with Nonmandatory Appendix B, Table B1, Group No. I. For Class 150 flanges when temperature exceeds 200 C, care should be taken to avoid imposing severe external loads and/or thermal gradients or leakage may develop. ASME B16.5 para. 2.5.2.

2/50

Nozzle Schedule
Nozzle mark N10 Service Sulphur Outlet 2" x 3" (Steam Jacketed) Size NPS 2 Sch 80 (XS) DN 50 NPS 3 Sch 80 (XS) DN 80 128.9 ID x 10 Nozzle Nozzle Materials SA-106 B Smls. Pipe SA-106 B Smls. Pipe SA-105 Impact Tested No No Normalized No No Fine Grain No No Flange NPS 2 Class 150 SO A105 N/A App 2 Weld Neck Integral SA-105 Blind No No

N9 Jacket N9 Jacket N9 Sleeve

N9 Sleeve

Nozzle

No

No

No

SA-105

3/50

Nozzle Summary
Shell Nozzle mark OD (mm) t n (mm) Req t n (mm) A1? A2? Nom t (mm) Yes Yes Yes Yes Yes Yes 9.27 40* 9.27 Design t (mm) N/A N/A N/A User t (mm) Reinforcement Pad Width (mm) N/A N/A N/A t pad (mm) N/A N/A N/A

Corr (mm)

A /A a r (%)

N10 N9 Jacket N9 Sleeve

60.33 88.9 148.9

5.54 7.62 10

4.1 7.2 0

1.5 1.5 1.5

Exempt Exempt Exempt

tn: Req tn: Nom t: Design t: User t: Aa: Ar: Corr: *

Nozzle thickness Nozzle thickness required per UG-45/UG-16 Vessel wall thickness Required vessel wall thickness due to pressure + corrosion allowance per UG-37 Local vessel wall thickness (near opening) Area available per UG-37, governing condition Area required per UG-37, governing condition Corrosion allowance on nozzle wall Head minimum thickness after forming

4/50

Pressure Summary Pressure Summary for Chamber bounded by Bottom Dishend (Internal and ASME B16.5/16.47 Blind on 12" x 10 " ANSI Reducing Flange
P Identifier Design ( kg/cm2) 3.5 3.5 3.5 3.5 3.5 3.5 5.6 0 3.5 3.5 3.5 T Design ( C) 220 220 220 220 220 220 220 220 220 220 220 T

MAWP ( kg/cm2)

MAP ( kg/cm2)

MAEP ( kg/cm2)

external ( C) 220 220 220 220 220 220 220 220 220 220 220

MDMT ( C)

MDMT Exemption

Impact Tested

ASME B16.5/16.47 Blind on 12" x 10 " ANSI Reducing Flange Shell 1 Straight Flange on Bottom Dishend (Internal Bottom Dishend (Internal 12" x 10 " ANSI Reducing Flange Sulphur Outlet 2" x 3" (Steam Jacketed) (N10) N9 Jacket (N9 Jacket) N9 Sleeve (N9 Sleeve ) Flange #6 Flange #6 - Flange Hub Sleeve Cover

13.38 46.63 56.91 48.29 13.38 3.5 5.6 N/A 65.36 166.99 49.95

19.99 73.87 83.98 76.21 19.99 3.5 5.6 N/A 65.36 199.6 54.32

N/A 22.73 29.57 20.64 N/A 5.6 3.5 N/A 426.65 91.85 145.03

-48 -105 -105 -105 -48 -48 -105 N/A -48 -105 -105

Note 1, 2 Note 3 Note 5 Note 4 Note 1, 2 Note 6 Note 7 N/A Note 8 Note 9 Note 10

No No No No No No No No No No No

Chamber design MDMT is -28.89 C Chamber rated MDMT is -48 C @ 3.5 kg/cm2 Chamber MAWP hot & corroded is 3.5 kg/cm2 @ 220 C Chamber MAP cold & new is 3.5 kg/cm2 @ 21.11 C This pressure chamber is not designed for external pressure. Notes for MDMT Rating:
Note # 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. UCS-66(b)(3): Coincident ratio = 0.1751 Flange rated MDMT = -105 C Material is impact test exempt to -105 C per UCS-66(b)(3) (coincident ratio = 0.0734) Straight Flange governs MDMT Material is impact test exempt to -105 C per UCS-66(b)(3) (coincident ratio = 0.0599) Flange rating governs: Flange rated MDMT = -105 C Bolts rated MDMT per Fig UCS-66 note (c) = -48 C Nozzle is impact test exempt to -105 C per UCS-66(b)(3) (coincident ratio = 0.0216). UCS-66(b)(1)(b) has been applied. Flange is impact test exempt to -105 C per UCS-66(b)(3) (coincident ratio = 0.0536) Material is impact test exempt to -105 C per UCS-66(b)(3) (coincident ratio = 0.0193) Bolted cover is impact test exempt to -105 C per UCS-66(b)(3) (coincident ratio = 0.0696). Bolts rated MDMT per Fig UCS-66 note (c) = -48 C UCS-66(b)(3): Coincident ratio = 0.1751 Bolts rated MDMT per Fig UCS-66 note (c) = -48 C Exemption Details

Design notes are available on the Settings Summary page.

5/50

Revision History
No. Date Operator Notes

1/13/2014

Syed.Zain New vessel created ASME Section VIII Division 1 [COMPRESS 2013 Build 7320]

6/50

Settings Summary COMPRESS 2013 Build 7320 Units: MKS Datum Line Location: 0.00 mm from bottom seam Design ASME Section VIII Division 1, 2010 Edition, A11 Addenda Metric Design or Rating: Minimum thickness: Design for cold shut down only: Design for lethal service (full radiography required): Design nozzles for: Corrosion weight loss: UG-23 Stress Increase: Skirt/legs stress increase: Minimum nozzle projection: Juncture calculations for > 30 only: Preheat P-No 1 Materials > 1.25" and <= 1.50" thick: UG-37(a) shell tr calculation considers longitudinal stress: Butt welds are tapered per Figure UCS-66.3(a). Hydro/Pneumatic Test Shop Hydrotest Pressure: Test liquid specific gravity: Maximum stress during test: Required Marking - UG-116 UG-116(e) Radiography: RT1 UG-116(f) Postweld heat treatment: PHT Code Cases\Interpretations Use Code Case 2547: Apply interpretation VIII-1-83-66: Apply interpretation VIII-1-86-175: Apply interpretation VIII-1-01-37: No UCS-66.1 MDMT reduction: No UCS-68(c) MDMT reduction: Disallow UG-20(f) exemptions: UG-22 Loadings UG-22(a) Internal or External Design Pressure : UG-22(b) Weight of the vessel and normal contents under operating or test conditions: Yes No No Yes Yes Yes No No No 1.3 times vessel MAWP 1.00 90% of yield Get Thickness from Pressure 1.5 mm per UG-16(b) No No Design P only 100% of theoretical loss 1.20 1.0 152.4 mm Yes No No

7/50

UG-22(c) Superimposed static reactions from weight of attached equipment (external loads): UG-22(d)(2) Vessel supports such as lugs, rings, skirts, saddles and legs: UG-22(f) Wind reactions: UG-22(f) Seismic reactions: UG-22(j) Test pressure and coincident static head acting during the test: Note: UG-22(b),(c) and (f) loads only considered when supports are present.

No No No No No

8/50

Thickness Summary
Component Identifier Shell 1 Straight Flange on Bottom Dishend (Internal Bottom Dishend (Internal Sleeve Cover Material SA-106 B Smls. Pipe SA-234 WPB SA-234 WPB SA-105 Diameter (mm) 254.51 ID 254.51 ID 254.51 ID 249 OD Length (mm) 323 55.26 71.74 40 Nominal t (mm) 9.27 9.27 9.27 40* Design t (mm) 5.06 5.06 4.77 34.39 Total Corrosion (mm) 3 3 3 1.5 Joint E 1.00 1.00 1.00 1.00 Load External External External External

Nominal t: Vessel wall nominal thickness Design t: Joint E: * Load internal: external: Wind: Seismic: Circumferential stress due to internal pressure governs External pressure governs Combined longitudinal stress of pressure + weight + wind governs Combined longitudinal stress of pressure + weight + seismic governs Required vessel thickness due to governing loading + corrosion Longitudinal seam joint efficiency Head minimum thickness after forming

9/50

Weight Summary
Weight ( kg) Contributed by Vessel Elements Component Metal New* Metal Corroded* Insulation Insulation Supports Lining Piping + Liquid Operating Liquid New ASME B16.5/16.47 Blind on 12" x 10 " ANSI Reducing Flange Shell 1 Bottom Dishend (Internal TOTAL: 36.3 18.2 9 63.5 36.3 12.3 6.1 54.7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Corroded 0 0 0 0 Test Liquid New 0 19.3 5.2 24.5 Corroded 0 19.8 5.5 25.3 0.17 0.26 0.13 0.56 Surface Area m2

* Shells with attached nozzles have weight reduced by material cut out for opening.
Weight ( kg) Contributed by Attachments Component Body Flanges Nozzles & Flanges Tray Packed Ladders & Trays Supports Beds Platforms Rings & Clips 0 0 0 0 Vertical Loads Surface Area m2

New Corroded New Corroded ASME B16.5/16.47 Blind on 12" x 10 " ANSI Reducing Flange Shell 1 Bottom Dishend (Internal TOTAL: 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0

0 0.42 0.04 0.34

19.5 19.5 0 0

36.4 32.8 3.5 3.1

19.5 19.5

39.8 35.9

Vessel operating weight, Corroded: Vessel operating weight, New: Vessel empty weight, Corroded: Vessel empty weight, New: Vessel test weight, New: Vessel test weight, Corroded: Vessel surface area:

110 kg 123 kg 110 kg 123 kg 147 kg 135 kg 0.91 m2

Vessel center of gravity location - from datum - lift condition Vessel Lift Weight, New: 123 kg Center of Gravity: 210.23 mm Vessel Capacity Vessel Capacity** (New): 21 liters Vessel Capacity** (Corroded): 22 liters **The vessel capacity does not include volume of nozzle, piping or other attachments.

10/50

Hydrostatic Test

Shop test pressure determination for Chamber bounded by Bottom Dishend (Internal and ASME B16.5/16.47 Blind on 12" x 10 " ANSI Reducing Flange based on MAWP per UG-99(b) Shop hydrostatic test gauge pressure is 4.55 kgf/cm2 at 21.11 C (the chamber MAWP = 3.5 kgf/cm2) The shop test is performed with the vessel in the horizontal position.

Identifier
12" x 10 " ANSI Reducing Flange (1) Shell 1 Straight Flange on Bottom Dishend (Internal Bottom Dishend (Internal Flange #6 - Flange Hub Sleeve Cover Flange #6 N9 Jacket (N9 Jacket) N9 Sleeve (N9 Sleeve ) Sulphur Outlet 2" x 3" (Steam Jacketed) (N10)

Local test Test liquid UG-99(b) UG-99(b) pressure static head stress pressure kgf/cm2 kgf/cm2 ratio factor
4.58 4.58 4.58 4.58 4.59 4.59 4.59 4.62 4.59 4.57 0.03 0.03 0.03 0.03 0.04 0.04 0.04 0.07 0.04 0.02 1 1 1 1.0073 1.0073 1.0073 1 1.0073 1 N/A 1.30 1.30 1.30 1.30 1.30 1.30 1.30 1.30 1.30 1.30

Notes: (1) 12" x 10 " ANSI Reducing Flange limits the UG-99(b) stress ratio. (2) The zero degree angular position is assumed to be up, and the test liquid height is assumed to the top-most flange. The field test condition has not been investigated for the Chamber bounded by Bottom Dishend (Internal and ASME B16.5/16.47 Blind on 12" x 10 " ANSI Reducing Flange.

11/50

Vacuum Summary
Elevation Component Line of Support above Datum (mm) 362.5 332.27 323 0 0 -55.26 -76.97 -127 Length Le (mm) N/A N/A 409.24 409.24 409.24 409.24 N/A N/A

ASME B16.5/16.47 Blind on 12" x 10 " ANSI Reducing Flange Shell 1 Top Shell 1 Bottom Straight Flange on Bottom Dishend (Internal Top Straight Flange on Bottom Dishend (Internal Bottom Bottom Dishend (Internal

ASME B16.5/16.47 Blind on 12" x 10 " ANSI Reducing Flange 1/3 depth of Bottom Dishend (Internal -

Note For main components, the listed value of 'Le' is the largest unsupported length for the component.

12/50

Engineering Notes 1- Nozzle N11 Has 2" x 3" Reducing Flange 2- Top Flange Shall not Been Considered 3- This Vessel Is Externally Jacketed with Steam Jacket 4- N9 Sleeve is not Considered as Pressure Part 6-

13/50

Shell 1 ASME Section VIII Division 1, 2010 Edition, A11 Addenda Metric Component: Cylinder Material specification: SA-106 B Smls. Pipe (II-D Metric p. 10, ln. 40) Pipe Description: NPS 10 Sch 40 (Std) DN 250 Material is impact test exempt to -105 C per UCS-66(b)(3) (coincident ratio = 0.0734) Internal design pressure: P = 3.5 kg/cm2 @ 220 C External design pressure: Pe = 5.6 kg/cm2 @ 220 C Static liquid head: Pth = 0.03 kg/cm2 Corrosion allowance (SG = 1, Hs = 265.43 mm, Horizontal test head) Inner C = 1.5 mm Outer C = 1.5 mm

Design MDMT = -28.89 C Rated MDMT = -105 C

No impact test performed Material is not normalized Material is not produced to Fine Grain Practice PWHT is not performed

Radiography:

Longitudinal joint Seamless No RT Top circumferential joint N/A Bottom circumferential joint - Full UW-11(a) Type 1

Estimated weight New = 18.2 kg corr = 12.3 kg Capacity New = 16.43 liters corr = 16.82 liters ID = 254.51 mm Length = 323 mm Lc t = 9.27 mm Design thickness, (at 220 C) UG-27(c)(1) t = P*R / (S*E - 0.60*P) + Corrosion = 3.5*128.76 / (1,203.27*1.00 - 0.60*3.5) + 3 = 3.38 mm

Maximum allowable working pressure, (at 220 C) UG-27(c)(1) P = S*E*t / (R + 0.60*t) - Ps = 1,203.27*1.00*5.11 / (128.76 + 0.60*5.11) - 0 = 46.63 kg/cm2

Maximum allowable pressure, (at 21.11 C) UG-27(c)(1) P = S*E*t / (R + 0.60*t) = 1,203.27*1.00*8.11 / (127.26 + 0.60*8.11) = 73.87 kg/cm2

14/50

External Pressure, (Corroded & at 220 C) UG-28(c) L / Do = 409.24 / 273.05 = 1.4988 Do / t = 273.05 / 2.06 = 132.5420 From table G: A = 0.000578 From table CS-2 B = 556.6739 kg/cm2 Metric: Pa = 4*B / (3*(Do / t)) = 4*556.67 / (3*(273.05 / 2.06)) = 5.6 kg/cm2

Design thickness for external pressure Pa = 5.6 kg/cm2 = 5.06 mm Maximum Allowable External Pressure, (Corroded & at 220 C) UG-28(c) ta = t + Corrosion = 2.06 + 3 L / Do = 409.24 / 273.05 = 1.4988 Do / t = 273.05 / 5.11 = 53.4452 From table G: A = 0.002271 From table CS-2 B = 910.9851 kg/cm2 Metric: Pa = 4*B / (3*(Do / t)) = 4*910.99 / (3*(273.05 / 5.11)) = 22.73 kg/cm2

15/50

ASME B16.5/16.47 Blind on 12" x 10 " ANSI Reducing Flange This is an ASME B16.5/16.47 rated blind flange. ASME B16.5-2009 Flange Description: Bolt Material: Blind included: Rated MDMT: (UCS-66(b)(3): Coincident ratio = 0.1751) (Flange rated MDMT = -105 C Bolts rated MDMT per Fig UCS-66 note (c) = -48 C) Liquid static head: MAWP rating: MAP rating: Hydrotest rating: External fillet weld leg (UW-21): Internal fillet weld leg (UW-21): PWHT performed:

NPS 10 Class 150 SO A105 SA-193 B7 Bolt <= 64 (II-D Metric p. 334, ln. 32) Yes -48C

0 kgf/cm2 13.38 kgf/cm2 @ 220C 19.99 kgf/cm2 @ 21.11C 30.59 kgf/cm2 @ 21.11C 10.92 mm (10.92 mm min) 8.14 mm (8.14 mm min) No

16/50

Straight Flange on Bottom Dishend (Internal ASME Section VIII Division 1, 2010 Edition, A11 Addenda Metric Component: Straight Flange Material specification: SA-234 WPB (II-D Metric p. 10, ln. 42) Material is impact test exempt to -105 C per UCS-66(b)(3) (coincident ratio = 0.0599) Internal design pressure: P = 3.5 kg/cm2 @ 220 C External design pressure: Pe = 5.6 kg/cm2 @ 220 C Static liquid head: Pth = 0.03 kg/cm2 Corrosion allowance (SG = 1, Hs = 265.43 mm, Horizontal test head) Inner C = 1.5 mm Outer C = 1.5 mm

Design MDMT = -28.89 C Rated MDMT = -105 C

No impact test performed Material is not normalized Material is not produced to Fine Grain Practice PWHT is not performed Seamless No RT Full UW-11(a) Type 1

Radiography:

Longitudinal joint Circumferential joint -

Estimated weight New = 3.3 kg corr = 2.2 kg Capacity New = 2.81 liters corr = 2.88 liters ID = 254.51 mm Length = 55.26 mm Lc t = 9.27 mm Design thickness, (at 220 C) UG-27(c)(1) t = P*R / (S*E - 0.60*P) + Corrosion = 3.5*128.76 / (1,203.27*1.00 - 0.60*3.5) + 3 = 3.38 mm

Maximum allowable working pressure, (at 220 C) UG-27(c)(1) P = S*E*t / (R + 0.60*t) - Ps = 1,203.27*1.00*6.27 / (128.76 + 0.60*6.27) - 0 = 56.91 kg/cm2

Maximum allowable pressure, (at 21.11 C) UG-27(c)(1) P = S*E*t / (R + 0.60*t) = 1,203.27*1.00*9.27 / (127.26 + 0.60*9.27) = 83.98 kg/cm2

External Pressure, (Corroded & at 220 C) UG-28(c) L / Do = 409.24 / 273.05 = 1.4988 Do / t = 273.05 / 2.06 = 132.5420 From table G: A = 0.000578

17/50

From table CS-2 Metric: Pa

B = 556.6739 kg/cm2

= 4*B / (3*(Do / t)) = 4*556.67 / (3*(273.05 / 2.06)) = 5.6 kg/cm2

Design thickness for external pressure Pa = 5.6 kg/cm2 = 5.06 mm Maximum Allowable External Pressure, (Corroded & at 220 C) UG-28(c) ta = t + Corrosion = 2.06 + 3 L / Do = 409.24 / 273.05 = 1.4988 Do / t = 273.05 / 6.27 = 43.5645 From table G: A = 0.003107 From table CS-2 B = 966.2584 kg/cm2 Metric: Pa = 4*B / (3*(Do / t)) = 4*966.26 / (3*(273.05 / 6.27)) = 29.57 kg/cm2

18/50

Bottom Dishend (Internal ASME Section VIII, Division 1, 2010 Edition, A11 Addenda Metric Component: NPS and Schedule: Material Specification: Straight Flange governs MDMT ASME B16.9 Pipe Cap (modified) NPS 10 Sch 40 (Std) DN 250 SA-234 WPB (II-D Metric p.10, ln. 42)

Internal design pressure: P = 3.5 kgf/cm2 @ 220 C External design pressure: Pe = 5.6 kgf/cm2 @ 220 C Static liquid head: Ps= 0 kgf/cm2 (SG=1, Hs=0 mm Operating head) Pth= 0.03 kgf/cm2 (SG=1, Hs=265.43 mm Horizontal test head) Corrosion allowance: Inner C = 1.5 mm Outer C = 1.5 mm

Design MDMT = -28.89C Rated MDMT = -105C

No impact test performed Material is not normalized Material is not produced to fine grain practice PWHT is not performed Do not Optimize MDMT / Find MAWP Seamless No RT Full UW-11(a) Type 1 corr = 6.1 kg corr = 5.1 liters

Radiography:

Category A joints Head to shell seam -

Estimated weight*: new = 9 kg Capacity*: new = 5 liters * includes straight flange Inner diameter Nominal head thickness Minimum head thickness Overall length E Straight flange length Lsf Nominal straight flange thickness tsf Results Summary = = = = = =

254.51 mm 9.27 mm 8.11 mm 127 mm 55.26 mm 9.27 mm

The governing condition is external pressure. Minimum thickness per UG-16 Design thickness due to internal pressure (t) Design thickness due to external pressure (te) Governing straight flange design thickness Maximum allowable working pressure (MAWP) Maximum allowable pressure (MAP) Maximum allowable external pressure (MAEP)

= = = = = = =

1.5 mm + 3 mm = 4.5 mm 3.37 mm 4.77 mm 5.06 mm 48.29 kgf/cm2 76.21 kgf/cm2 20.64 kgf/cm2

K (Corroded) K=(1/6)*[2 + (D / (2*h))2]=(1/6)*[2 + (257.51 / (2*65.13))2]=0.984723

19/50

K (New) K=(1/6)*[2 + (D / (2*h))2]=(1/6)*[2 + (254.51 / (2*63.63))2]=1 Design thickness for internal pressure, (Corroded at 220 C) Appendix 1-4(c) t = = = P*D*K / (2*S*E - 0.2*P) + Corrosion 3.5*257.51*0.984723 / (2*1,203.26*1 - 0.2*3.5) + 3 3.37 mm

The head internal pressure design thickness is 3.37 mm. Maximum allowable working pressure, (Corroded at 220 C) Appendix 1-4(c) P = = = 2*S*E*t / (K*D + 0.2*t) - Ps 2*1,203.26*1*5.11 / (0.984723*257.51 +0.2*5.11) - 0 48.29 kgf/cm2

The maximum allowable working pressure (MAWP) is 48.29 kgf/cm2. Maximum allowable pressure, (New at 21.11 C) Appendix 1-4(c) P = = = 2*S*E*t / (K*D + 0.2*t) - Ps 2*1,203.26*1*8.11 / (1*254.51 +0.2*8.11) - 0 76.21 kgf/cm2

The maximum allowable pressure (MAP) is 76.21 kgf/cm2. Design thickness for external pressure, (Corroded at 220 C) UG-33(d) Equivalent outside spherical radius (Ro) Ro = Ko*Do = 0.8564*273.05 = 233.84 mm A = = = 0.125 / (Ro / t) 0.125 / (233.84 / 1.76) 0.000943 = 742.117 kgf/cm2

From Table CS-2 Metric: B Pa = = =

B / (Ro / t) 742.117 / (233.84 / 1.76) 5.6 kgf/cm2

t = 1.76 mm + Corrosion = 1.76 mm + 3 mm = 4.77 mm Check the external pressure per UG-33(a)(1) Appendix 1-4(c) t = = = 1.67*Pe*D*K / (2*S*E - 0.2*1.67*Pe) + Corrosion 1.67*5.6*257.51*0.984723 / (2*1,203.26*1 - 0.2*1.67*5.6) + 3 3.99 mm

The head external pressure design thickness (te) is 4.77 mm.

20/50

Maximum Allowable External Pressure, (Corroded at 220 C) UG-33(d) Equivalent outside spherical radius (Ro) Ro = Ko*Do = 0.8564*273.05 = 233.84 mm A = = = 0.125 / (Ro / t) 0.125 / (233.84 / 5.11) 0.002731 B = 944.6632 kgf/cm2

From Table CS-2 Metric: Pa = = =

B / (Ro / t) 944.6632 / (233.84 / 5.11) 20.6394 kgf/cm2

Check the Maximum External Pressure, UG-33(a)(1) Appendix 1-4(c) P = = = 2*S*E*t / ((K*D + 0.2*t)*1.67) - Ps2 2*1,203.26*1*5.11 / ((0.984723*257.51 +0.2*5.11)*1.67) - 0 28.92 kgf/cm2

The maximum allowable external pressure (MAEP) is 20.64 kgf/cm2.

21/50

12" x 10 " ANSI Reducing Flange ASME B16.5-2009 Flange Description: Bolt Material: Blind included: Rated MDMT: (UCS-66(b)(3): Coincident ratio = 0.1751) (Flange rated MDMT = -105 C Bolts rated MDMT per Fig UCS-66 note (c) = -48 C) Liquid static head: MAWP rating: MAP rating: Hydrotest rating: External fillet weld leg (UW-21): Internal fillet weld leg (UW-21): PWHT performed:

NPS 10 Class 150 SO A105 SA-193 B7 Bolt <= 64 (II-D Metric p. 334, ln. 32) Yes -48C

0 kgf/cm2 13.38 kgf/cm2 @ 220C 19.99 kgf/cm2 @ 21.11C 30.59 kgf/cm2 @ 21.11C 10.92 mm (10.92 mm min) 8.14 mm (8.14 mm min) No

22/50

Flange #6

ASME VIII-1, 2010 Edition, A11 Addenda Metric, Appendix 2 Flange Calculations

Flange is attached to: Flange type: Flange material specification: Bolt material specification: Bolt Description: Internal design pressure, P: Required flange thickness, tr: Maximum allowable working pressure, MAWP: Maximum allowable pressure, MAP: External design pressure, Pe Maximum allowable external pressure, MAEP: Corrosion allowance: Bolt corrosion (root), Cbolt: Design MDMT: Rated MDMT:

N9 Sleeve (N9 Sleeve ) Weld neck integral SA-105 (II-D Metric p. 18, ln. 5) SA-193 B7 Bolt <= 64 (II-D Metric p. 334, ln. 32) 0.75 in Series 8 Thread 3.5 kgf/cm2 @ 220 C 32.57 mm 65.36 kgf/cm2 @ 220 C 65.36 kgf/cm2 @ 21.1111 5.6 kgf/cm2 @ 220 C 426.65 kgf/cm2 @ 220 C Bore = 1.5 mm 0 mm -28.89 C -48 C Flange = 0 mm No impact test performed Flange material is not normalized Material is not produced to fine grain practice PWHT is performed corroded = 10.8 kg C (bolting limits) (bolting limits)

Estimated weight:

New = 11.02 kg

Flange dimensions, new flange OD bolt circle gasket OD gasket ID flange ID thickness bolting hub thickness hub thickness length gasket factor seating stress Gasket thickness A = 249 mm C = 207 mm = 167 mm = 141 mm B = 129 mm t = 38 mm = 8- 0.75 in dia g1 = 10 mm g0 = 10 mm e = 50 mm m = 3.75 y = 632.762 kgf/cm2 T = 3.2 mm Flat metal, jacketed mineral fiber filled gasket description Stainless steels and nickel-base alloys

Note: this flange is calculated as an integral type. Determination of Flange MDMT

23/50

UCS-66(b)(1)(b) has been applied. Flange is impact test exempt to -105 C per UCS-66(b)(3) (coincident ratio = 0.0536) Bolts rated MDMT per Fig UCS-66 note (c) = -48 C The rated flange MDMT is -48 C

Flange calculations for Internal Pressure + Weight Only

Gasket details from facing sketch 1(a) or (b), Column II Gasket width N = 13 mm b0 = N/2 = 6.5 mm Effective gasket seating width, b = 2.5*b01/2 = 6.37 mm G = gasket OD - 2*b = 167 - 2*6.37 = 154.25 mm hG = (C - G)/2 = (207 - 154.25)/2 = 26.37 mm hD = R + g1/2 = 29 + 8.5/2 = 33.25 mm hT = (R + g1 + hG)/2 = (29 + 8.5 + 26.37)/2 = 31.94 mm Hp = 2*b*3.14*G*m*P = 0.01*2*6.37*3.14*154.25*3.75*3.5 = 810.27 kgf H = 0.785*G2*P = 0.01*0.785*154.252*3.5 = 653.75 kgf HD = 0.785*B2*P = 0.01*0.785*1322*3.5 = 478.74 kgf HT = H - HD = 653.75 - 478.74 = 175.01 kgf Wm1 = H + Hp = 653.75 + 810.27 = 1,464.02 kgf Wm2 = 3.14*b*G*y = 0.01*3.14*6.37*154.25*632.7621 = 19,531.79 kgf Required bolt area, Am = greater of Am1, Am2 = 11.1361 cm2 Am1 = Wm1/Sb = 1,464.02/1,753.911 = 0.8347 cm2 Am2 = Wm2/Sa = 19,531.79/1,753.911 = 11.1361 cm2 Total area for 8- 0.75 in dia bolts, corroded, Ab = 15.5871 cm2

24/50

W = (Am + Ab)*Sa/2 = (11.1361 + 15.5871)*1,753.911/2 = 23,435.07 kgf MD = HD*hD = 478.74*0.0332 = 15.9 kgf-m MT = HT*hT = 175.01*0.0319 = 5.6 kgf-m HG = Wm1 - H = 1,464.02 - 653.75 = 810.27 kgf MG = HG*hG = 810.27*0.0264 = 21.4 kgf-m Mo = MD + MT + MG = 15.9 + 5.6 + 21.4 = 42.9 kgf-m Mg = W*hG = 23,435.07*0.0264 = 618 kgf-m

25/50

Hub and Flange Factors h0 = (B*g0)1/2 = (132*8.5)1/2 = 33.49 mm From FIG. 2-7.1, where K = A/B = 249/132 = 1.8863 T = 1.55 g1/g0 = 1 F = 0.9089 V = 0.5501 e = F/h0 = 0.2714 d = (U/V)*h0*g02= (3.546/0.5501)*3.3494*0.84992 = 15.595 cm3 Stresses at operating conditions - VIII-1 Appendix 2-7 f=1 L = (t*e + 1)/T + t3/d = (3.8*0.2714 + 1)/1.55 + 3.83/15.595 = 4.829 SH = f*Mo/(L*g12*B) = 1e5*1*42.9/(4.829*8.52*132) = 93.123 kgf/cm2 SR = (1.33*t*e + 1)*Mo/(L*t2*B) = (1.33*38*0.0271 + 1)*1e5*42.9/(4.829*382*132) = 11.047 kgf/cm2 ST = Y*Mo/(t2*B) - Z*SR = 1e5*3.2268*42.9/(382*132) - 1.7818*11.047 = 52.902 kgf/cm2 Allowable stress Sfo = 1,397.01 kgf/cm2 Allowable stress Sno = 1,397.01 kgf/cm2 ST does not exceed Sfo SH does not exceed Min[ 1.5*Sfo, 2.5*Sno ] = 2,095.515 kgf/cm2 SR does not exceed Sfo 0.5(SH + SR) = 52.085 kgf/cm2 does not exceed Sfo 0.5(SH + ST) = 73.012 kgf/cm2 does not exceed Sfo Stresses at gasket seating - VIII-1 Appendix 2-7 SH = f*Mg/(L*g12*B) = 1e5*1*618/(4.829*8.52*132) = 1,342.349 kgf/cm2 SR = (1.33*t*e + 1)*Mg/(L*t2*B) = (1.33*38*0.0271 + 1)*1e5*618/(4.829*382*132) = 159.235 kgf/cm2 ST = Y*Mg/(t2*B) - Z*SR = 3.2268*1e5*618/(382*132) - 1.7818*159.235 = 762.568 kgf/cm2 Z = 1.7818 Y = 3.2268 U = 3.546

26/50

Allowable stress Sfa = 1,407.207 kgf/cm2 Allowable stress Sna = 1,407.207 kgf/cm2 ST does not exceed Sfa SH does not exceed Min[ 1.5*Sfa, 2.5*Sna ] = 2,110.811 kgf/cm2 SR does not exceed Sfa 0.5(SH + SR) = 750.792 kgf/cm2 does not exceed Sfa 0.5(SH + ST) = 1,052.458 kgf/cm2 does not exceed Sfa Flange rigidity per VIII-1 Appendix 2-14 J = 52.14*V*Mo/(L*E*g02*KI*h0) = 1e5*52.14*0.5501*618/(4.829*20.52E+05*8.52*0.2*33.49) = 0.3697 The flange rigidity index J does not exceed 1; satisfactory.

Flange calculations for External Pressure + Weight Only per VIII-1, Appendix 2-11
Gasket details from facing sketch 1(a) or (b), Column II Gasket width N = 13 mm b0 = N/2 = 6.5 mm Effective gasket seating width, b = 2.5*b01/2 = 6.37 mm G = gasket OD - 2*b = 167 - 2*6.37 = 154.25 mm hG = (C - G)/2 = (207 - 154.25)/2 = 26.37 mm hD = R + g1/2 = 29 + 8.5/2 = 33.25 mm hT = (R + g1 + hG)/2 = (29 + 8.5 + 26.37)/2 = 31.94 mm Hp = 2*b*3.14*G*m*P = 0.01*2*6.37*3.14*154.25*3.75*5.6 = 1,296.43 kgf H = 0.785*G2*P = 0.01*0.785*154.252*5.6 = 1,046 kgf HD = 0.785*B2*P = 0.01*0.785*1322*5.6 = 765.99 kgf HT = H - HD = 1,046 - 765.99 = 280.02 kgf Wm1 = H + Hp = 1,046 + 1,296.43 = 2,342.44 kgf Wm2 = 3.14*b*G*y = 0.01*3.14*6.37*154.25*632.7621

27/50

= 19,531.79 kgf Required bolt area, Am = greater of Am1, Am2 = 11.1361 cm2 Am1 = 0.785*G2*(Pm - Pr)/Sb = 0/1,753.911 = 0 cm2 Am2 = Wm2/Sa = 19,531.79/1,753.911 = 11.1361 cm2 Total area for 8- 0.75 in dia bolts, corroded, Ab = 15.5871 cm2 W = (Am2 + Ab)*Sa/2 = (11.1361 + 15.5871)*1,753.911/2 = 23,435.07 kgf Mo = HD*(hD - hG) + HT*(hT - hG) = 765.99*(0.0332 - 0.0264) + 280.02*(0.0319 - 0.0264) = 6.8 kgf-m Mg = W*hG = 23,435.07*0.0264 = 618 kgf-m

28/50

Hub and Flange Factors h0 = (B*g0)1/2 = (132*8.5)1/2 = 33.49 mm From FIG. 2-7.1, where K = A/B = 249/132 = 1.8863 T = 1.55 g1/g0 = 1 F = 0.9089 V = 0.5501 e = F/h0 = 0.2714 d = (U/V)*h0*g02= (3.546/0.5501)*3.3494*0.84992 = 15.595 cm3 Stresses at operating conditions - VIII-1 Appendix 2-7 f=1 L = (t*e + 1)/T + t3/d = (3.8*0.2714 + 1)/1.55 + 3.83/15.595 = 4.829 SH = f*Mo/(L*g12*B) = 1e5*1*6.8/(4.829*8.52*132) = 14.823 kgf/cm2 SR = (1.33*t*e + 1)*Mo/(L*t2*B) = (1.33*38*0.0271 + 1)*1e5*6.8/(4.829*382*132) = 1.758 kgf/cm2 ST = Y*Mo/(t2*B) - Z*SR = 1e5*3.2268*6.8/(382*132) - 1.7818*1.758 = 8.421 kgf/cm2 Allowable stress Sfo = 1,397.01 kgf/cm2 Allowable stress Sno = 1,397.01 kgf/cm2 ST does not exceed Sfo SH does not exceed Min[ 1.5*Sfo, 2.5*Sno ] = 2,095.515 kgf/cm2 SR does not exceed Sfo 0.5(SH + SR) = 8.291 kgf/cm2 does not exceed Sfo 0.5(SH + ST) = 11.622 kgf/cm2 does not exceed Sfo Stresses at gasket seating - VIII-1 Appendix 2-7 SH = f*Mg/(L*g12*B) = 1e5*1*618/(4.829*8.52*132) = 1,342.349 kgf/cm2 SR = (1.33*t*e + 1)*Mg/(L*t2*B) = (1.33*38*0.0271 + 1)*1e5*618/(4.829*382*132) = 159.235 kgf/cm2 ST = Y*Mg/(t2*B) - Z*SR = 3.2268*1e5*618/(382*132) - 1.7818*159.235 = 762.568 kgf/cm2 Z = 1.7818 Y = 3.2268 U = 3.546

29/50

Allowable stress Sfa = 1,407.207 kgf/cm2 Allowable stress Sna = 1,407.207 kgf/cm2 ST does not exceed Sfa SH does not exceed Min[ 1.5*Sfa, 2.5*Sna ] = 2,110.811 kgf/cm2 SR does not exceed Sfa 0.5(SH + SR) = 750.792 kgf/cm2 does not exceed Sfa 0.5(SH + ST) = 1,052.458 kgf/cm2 does not exceed Sfa Flange rigidity per VIII-1 Appendix 2-14 J = 52.14*V*Mo/(L*E*g02*KI*h0) = 1e5*52.14*0.5501*618/(4.829*20.52E+05*8.52*0.2*33.49) = 0.3697 The flange rigidity index J does not exceed 1; satisfactory. Flange #6 - Flange hub ASME Section VIII Division 1, 2010 Edition, A11 Addenda Metric Component: Flange hub Material specification: SA-105 (II-D Metric p. 18, ln. 5) Material is impact test exempt to -105 C per UCS-66(b)(3) (coincident ratio = 0.0193) Internal design pressure: P = 3.5 kg/cm2 @ 220 C External design pressure: Pe = 5.6 kg/cm2 @ 220 C Static liquid head: Pth = 0.04 kg/cm2 Corrosion allowance (SG = 1, Hs = 427.1 mm, Horizontal test head) Inner C = 1.5 mm Outer C = 0 mm

Design MDMT = -28.89 C Rated MDMT = -105 C

No impact test performed Material is not normalized Material is not produced to Fine Grain Practice PWHT is performed

Radiography:

Longitudinal joint Seamless No RT Top circumferential joint N/A Bottom circumferential joint - Full UW-11(a) Type 1

Estimated weight New = 0.4 kg corr = 0.4 kg Capacity New = 0.17 liters corr = 0.18 liters ID = 129 mm Length = 13 mm Lc t = 10 mm Design thickness, (at 220 C) UG-27(c)(1) t = P*R / (S*E - 0.60*P) + Corrosion = 3.5*66 / (1,397.01*1.00 - 0.60*3.5) + 1.5 = 1.67 mm

30/50

Maximum allowable working pressure, (at 220 C) UG-27(c)(1) P = S*E*t / (R + 0.60*t) - Ps = 1,397.01*1.00*8.5 / (66 + 0.60*8.5) - 0 = 166.99 kg/cm2

Maximum allowable pressure, (at 21.11 C) UG-27(c)(1) P = S*E*t / (R + 0.60*t) = 1,407.21*1.00*10 / (64.5 + 0.60*10) = 199.6 kg/cm2

External Pressure, (Corroded & at 220 C) UG-28(c) L / Do = 13 / 149 = 0.0872 Do / t = 149 / 0.6 = 247.4039 From table G: A = 0.005600 From table CS-2 B = 1,039.1024 kg/cm2 Metric: Pa = 4*B / (3*(Do / t)) = 4*1,039.1 / (3*(149 / 0.6)) = 5.6 kg/cm2

Design thickness for external pressure Pa = 5.6 kg/cm2 = 2.1 mm Maximum Allowable External Pressure, (Corroded & at 220 C) UG-28(c) ta = t + Corrosion = 0.6 + 1.5 L / Do = 13 / 149 = 0.0872 Do / t = 149 / 8.5 = 17.5318 From table G: A = 0.100000 From table CS-2 B = 1,207.7426 kg/cm2 Metric: Pa = 4*B / (3*(Do / t)) = 4*1,207.74 / (3*(149 / 8.5)) = 91.85 kg/cm2

31/50

N9 Jacket (N9 Jacket) ASME Section VIII Division 1, 2010 Edition, A11 Addenda Metric tw(lower) = Leg41 = Leg43 = hnew = 40 mm 7 mm 9 mm 250 mm

Note: round inside edges per UG-76(c)

Location and Orientation Located on: Orientation: Distance to head center, R: Passes through a Category A joint: Nozzle Access opening: Material specification: Description: Inside diameter, new: Nominal wall thickness: Corrosion allowance: Projection available outside vessel, Lpr: Internal projection, hnew: Local vessel minimum thickness: Liquid static head included: Longitudinal joint efficiency:

Sleeve Cover 0 0 mm No

No SA-106 B Smls. Pipe (II-D Metric p. 10, ln. 40) NPS 3 Sch 80 (XS) DN 80 73.66 mm 7.62 mm 1.5 mm 200 mm 250 mm 40 mm 0 kgf/cm2 1

32/50

Reinforcement Calculations for Internal Pressure

UG-45 Nozzle Wall UG-39 Area Calculation Summary Thickness (cm2) Summary For P = 5.6 kg f/cm2 @ 220 C (mm)
The nozzle passes UG-45 A required A available A1 A2 A3 A5 A welds treq tmin

This nozzle is exempt from area calculations per UG-39(d)

6.3

6.67

UG-41 Weld Failure Path Analysis Summary The nozzle is exempt from weld strength calculations per UW-15(b)(1) UW-16 Weld Sizing Summary
Weld description Nozzle to shell fillet (Leg 41) Required weld throat size (mm) Actual weld throat size (mm) Status weld size is adequate

4.28

4.9

Calculations for internal pressure 5.6 kgf/cm2 @ 220 C Fig UCS-66.2 general note (1) applies. Nozzle is impact test exempt to -105 C per UCS-66(b)(3) (coincident ratio = 0.0216).

Nozzle UCS-66 governing thk: 6.67 mm Nozzle rated MDMT: -105 C Parallel Limit of reinforcement per UG-40 = MAX(d, Rn + (tn - Cn) + (t - C)) = MAX(76.66, 38.33 + (7.62 - 1.5) + (40 - 1.5)) = 82.95 mm Outer Normal Limit of reinforcement per UG-40 = MIN(2.5*(t - C), 2.5*(tn - Cn) + te) = MIN(2.5*(40 - 1.5), 2.5*(7.62 - 1.5) + 0) = 15.3 mm Inner Normal Limit of reinforcement per UG-40 LI = = = MIN(2.5*(t - C), 2.5*(ti - Cn - C)) MIN(2.5*(40 - 1.5), 2.5*(7.62 - 1.5 - 1.5)) 11.54 mm LH LR

33/50

Nozzle required thickness per UG-27(c)(1) trn = = = P*Rn / (Sn*E - 0.6*P) 5.6*38.33 / (1,203.2642*1 - 0.6*5.6) 0.18 mm

Required thickness tr from UG-34 The static head of liquid has not been included in the total design load because the vessel is supported below the flange. W = = = = = = 0.785*G2*P + 2*b*3.14*G*m*P 0.785*154.252*5.6/100 + 2*6.37*3.14*154.25*3.75*5.6/1005.6/100 2,342.44 kgf d*Sqr(2*(C*P / (S*E) + 1.9*W*hg / (S*E*d3))) 154.25*Sqr(2*(0.3*5.6 / (1,397.0101*1) + 1.9*2,342.44*26.37 / (1,397.01 / 100*1*154.253))) 12.89 mm

tr

Gasket seating tr = d*Sqr(2*1.9*W*hG / (S*E*d3)) = 154.25*Sqr(2*1.9*23,435.07*26.37 / (1,407.207 / 100*1*154.253)) = 32.89 mm Opening does not require reinforcement per UG-39(d)

UW-16(c) Weld Check Fillet weld: tmin = lesser of 19 mm or tn or t = 6.12 mm tc(min) = lesser of 6 mm or 0.7*tmin = 4.28 mm tc(actual) = 0.7*Leg = 0.7*7 = 4.9 mm The fillet weld size is satisfactory. Weld strength calculations are not required for this detail which conforms to Fig. UW-16.1, sketch (c-e).

UG-45 Nozzle Neck Thickness Check ta UG-27 = = = = = = = P*R / (S*E - 0.6*P) + Corrosion 5.6*38.33 / (1,203.2642*1 - 0.6*5.6) + 1.5 1.68 mm max[ ta UG-27 , ta UG-22 ] max[ 1.68 , 0 ] 1.68 mm 34.39 mm

ta

tb1

34/50

tb1

= = = = = = = = =

max[ tb1 , tb UG16 ] max[ 34.39 , 3 ] 34.39 mm min[ tb3 , tb1 ] min[ 6.3 , 34.39 ] 6.3 mm max[ ta , tb ] max[ 1.68 , 6.3 ] 6.3 mm

tb

tUG-45

Available nozzle wall thickness new, tn = 0.875*7.62 = 6.67 mm The nozzle neck thickness is adequate.

35/50

Reinforcement Calculations for External Pressure

UG-45 Nozzle Wall UG-39 Area Calculation Summary Thickness (cm2) Summary For Pe = 3.5 kg f/cm2 @ 220 C (mm)
The nozzle passes UG-45 A required A available A1 A2 A3 A5 A welds treq tmin

This nozzle is exempt from area calculations per UG-39(d)

6.3

6.67

UG-41 Weld Failure Path Analysis Summary Weld strength calculations are not required for external pressure UW-16 Weld Sizing Summary
Weld description Nozzle to shell fillet (Leg 41) Required weld throat size (mm) Actual weld throat size (mm) Status weld size is adequate

4.28

4.9

Calculations for external pressure 3.5 kgf/cm2 @ 220 C Parallel Limit of reinforcement per UG-40 = MAX(d, Rn + (tn - Cn) + (t - C)) = MAX(76.66, 38.33 + (7.62 - 1.5) + (40 - 1.5)) = 82.95 mm Outer Normal Limit of reinforcement per UG-40 = MIN(2.5*(t - C), 2.5*(tn - Cn) + te) = MIN(2.5*(40 - 1.5), 2.5*(7.62 - 1.5) + 0) = 15.3 mm Inner Normal Limit of reinforcement per UG-40 LI = = = MIN(2.5*(t - C), 2.5*(ti - Cn - C)) MIN(2.5*(40 - 1.5), 2.5*(7.62 - 1.5 - 1.5)) 11.54 mm LH LR

Nozzle required thickness per UG-28 trn = 0.66 mm From UG-34 required thickness tr = 32.89 mm Opening does not require reinforcement per UG-39(d)

36/50

UW-16(c) Weld Check Fillet weld: tmin = lesser of 19 mm or tn or t = 6.12 mm tc(min) = lesser of 6 mm or 0.7*tmin = 4.28 mm tc(actual) = 0.7*Leg = 0.7*7 = 4.9 mm The fillet weld size is satisfactory. Weld strength calculations are not required for this detail which conforms to Fig. UW-16.1, sketch (c-e).

UG-45 Nozzle Neck Thickness Check ta UG-28 ta = = = = = = = = = = = = = = 2.16 mm max[ ta UG-28 , ta UG-22 ] max[ 2.16 , 0 ] 2.16 mm 34.39 mm max[ tb2 , tb UG16 ] max[ 34.39 , 3 ] 34.39 mm min[ tb3 , tb2 ] min[ 6.3 , 34.39 ] 6.3 mm max[ ta , tb ] max[ 2.16 , 6.3 ] 6.3 mm

tb2 tb2

tb

tUG-45

Available nozzle wall thickness new, tn = 0.875*7.62 = 6.67 mm The nozzle neck thickness is adequate. External Pressure, (Corroded & at 220 C) UG-28(c) L / Do = 200 / 88.9 Do / t = 88.9 / 0.66 From table G: A From table CS-2 B Metric: Pa = 2.2497 = 134.5888 = 0.000368 = 353.2996 kg/cm2

= 4*B / (3*(Do / t)) = 4*353.3 / (3*(88.9 / 0.66)) = 3.5 kg/cm2

Design thickness for external pressure Pa = 3.5 kg/cm2 ta = t + Corrosion = 0.66 + 1.5 = 2.16 mm

37/50

N9 Sleeve (N9 Sleeve )

38/50

Sulphur Outlet 2" x 3" (Steam Jacketed) (N10) ASME Section VIII Division 1, 2010 Edition, A11 Addenda Metric tw(lower) = 9.27 mm Leg41 = 6 mm

Note: round inside edges per UG-76(c)

Location and Orientation Located on: Orientation: End of nozzle to datum line: Calculated as hillside: Distance to head center, R: Passes through a Category A joint: Nozzle Access opening: Material specification: Description: Inside diameter, new: Nominal wall thickness: Corrosion allowance: Projection available outside vessel, Lpr: Projection available outside vessel to flange face, Lf: Local vessel minimum thickness: Liquid static head included: Longitudinal joint efficiency: ASME B16.5-2009 Flange Description: Bolt Material: Blind included: Rated MDMT: (UCS-66(b)(3): Coincident ratio = 0.1751)

Bottom Dishend (Internal 0 -280 mm No 0 mm No

No SA-106 B Smls. Pipe (II-D Metric p. 10, ln. 40) NPS 2 Sch 80 (XS) DN 50 49.25 mm 5.54 mm 1.5 mm 149.24 mm 154.77 mm 8.11 mm 0 kgf/cm2 1

NPS 2 Class 150 SO A105 SA-193 B7 Bolt <= 64 (II-D Metric p. 334, ln. 32) No -48C

39/50

(Flange rated MDMT = -105 C Bolts rated MDMT per Fig UCS-66 note (c) = -48 C) Liquid static head: MAWP rating: MAP rating: Hydrotest rating: External fillet weld leg (UW-21): Internal fillet weld leg (UW-21): PWHT performed:

0 kgf/cm2 13.38 kgf/cm2 @ 220C 19.99 kgf/cm2 @ 21.11C 30.59 kgf/cm2 @ 21.11C 7.8 mm (5.65 mm min) 5.54 mm (5.54 mm min) No

40/50

Reinforcement Calculations for Internal Pressure

UG-45 Nozzle Wall UG-37 Area Calculation Summary Thickness (cm2) Summary For P = 3.5 kg f/cm2 @ 220 C (mm)
The nozzle passes UG-45 A required A available A1 A2 A3 A5 A welds treq tmin

This nozzle is exempt from area calculations per UG-36(c)(3)(a)

3.37

4.85

UG-41 Weld Failure Path Analysis Summary The nozzle is exempt from weld strength calculations per UW-15(b)(2) UW-16 Weld Sizing Summary
Weld description Nozzle to shell fillet (Leg 41) Required weld throat size (mm) Actual weld throat size (mm) Status weld size is adequate

2.83

4.2

Calculations for internal pressure 3.5 kgf/cm2 @ 220 C Fig UCS-66.2 general note (1) applies. Nozzle is impact test exempt per UCS-66(d) (NPS 4 or smaller pipe). External nozzle loadings per UG-22 govern the coincident ratio used.

Nozzle UCS-66 governing thk: 4.85 mm Nozzle rated MDMT: -105 C Parallel Limit of reinforcement per UG-40 = MAX(d, Rn + (tn - Cn) + (t - C)) = MAX(52.25, 26.13 + (5.54 - 1.5) + (8.11 - 3)) = 52.25 mm Outer Normal Limit of reinforcement per UG-40 = MIN(2.5*(t - C), 2.5*(tn - Cn) + te) = MIN(2.5*(8.11 - 3), 2.5*(5.54 - 1.5) + 0) = 10.09 mm Nozzle required thickness per UG-27(c)(1) trn = = = P*Rn / (Sn*E - 0.6*P) 3.5*26.13 / (1,203.2642*1 - 0.6*3.5) 0.0762 mm LH LR

41/50

Required thickness tr from UG-37(a)(c) tr = = = P*K1*D / (2*S*E - 0.2*P) 3.5*0.8896*257.51 / (2*1,203.2642*1 - 0.2*3.5) 0.33 mm

This opening does not require reinforcement per UG-36(c)(3)(a)

UW-16(c) Weld Check Fillet weld: tmin = lesser of 19 mm or tn or t = 4.04 mm tc(min) = lesser of 6 mm or 0.7*tmin = 2.83 mm tc(actual) = 0.7*Leg = 0.7*6 = 4.2 mm The fillet weld size is satisfactory. Weld strength calculations are not required for this detail which conforms to Fig. UW-16.1, sketch (c-e).

UG-45 Nozzle Neck Thickness Check

Interpretation VIII-1-83-66 has been applied. ta UG-27 = = = = = = = = = = = = = = = = = P*R / (S*E - 0.6*P) + Corrosion 3.5*26.13 / (1,203.2642*1 - 0.6*3.5) + 1.5 1.58 mm 2.05 mm max[ ta UG-27 , ta UG-22 ] max[ 1.58 , 2.05 ] 2.05 mm 3.37 mm max[ tb1 , tb UG16 ] max[ 3.37 , 3 ] 3.37 mm min[ tb3 , tb1 ] min[ 4.92 , 3.37 ] 3.37 mm max[ ta , tb ] max[ 2.05 , 3.37 ] 3.37 mm

ta UG-22 ta

tb1 tb1

tb

tUG-45

Available nozzle wall thickness new, tn = 0.875*5.54 = 4.85 mm

42/50

The nozzle neck thickness is adequate.

43/50

Applied Loads Radial load: Circumferential moment: Circumferential shear: Longitudinal moment: Longitudinal shear: Torsion moment: Internal pressure: Head yield stress: Pr = M1 = V2 = M2 = V1 = Mt = P= Sy = 314 8 314 16 314 18 3.5 2,080.22 kgf kgf-m kgf kgf-m kgf kgf-m kgf/cm2 kgf/cm2

Maximum stresses due to the applied loads at the nozzle OD (includes pressure) Mean dish radius Rm = 234.26 mm U = ro / Sqr(Rm*t) = 0.872 Pressure stress intensity factor, I = 1 (derived from PVP-Vol. 399, pages 77-82) Local pressure stress = I*P*Ri / (2*t) =79.376 kgf/cm2 Maximum combined stress (PL+Pb+Q) = -1,527.77 kgf/cm2 Allowable combined stress (PL+Pb+Q) = +-3*S = +-3,609.79 kgf/cm2 The maximum combined stress (PL+Pb+Q) is within allowable limits. Maximum local primary membrane stress (PL) = -177.03 kgf/cm2 Allowable local primary membrane stress (PL) = +-1.5*S = +-1,804.9 kgf/cm2 The maximum local primary membrane stress (PL) is within allowable limits.

44/50

Stresses at the nozzle OD per WRC Bulletin 107 Figure value

SR-2* SR-2 SR-3* SR-3 SR-3* SR-3 0.0778 0.0426 0.0919 0.0968 0.0919 0.0968

Au
-93.578 -307.452 0 0 -162.831 -1,029.082 79.376 -1,513.567 -177.033 -28.896 -92.383 0 0 -49.074 -311.53 79.376 -402.507 1.406 61.659 0 64.893 126.552 -1,527.769

Al
-93.578 307.452 0 0 -162.831 1,029.082 79.376 1,159.501 -177.033 -28.896 92.383 0 0 -49.074 311.53 79.376 405.319 1.406 61.659 0 64.893 126.552 1,180.172

Bu
-93.578 -307.452 0 0 162.831 1,029.082 79.376 870.259 148.629 -28.896 -92.383 0 0 49.074 311.53 79.376 318.701 99.555 61.659 0 -64.893 -3.234 870.259

Bl
-93.578 307.452 0 0 162.831 -1,029.082 79.376 -573.001 148.629 -28.896 92.383 0 0 49.074 -311.53 79.376 -119.592 99.555 61.659 0 -64.893 -3.234 -573.001

Cu
-93.578 -307.452 -81.415 -514.576 0 0 79.376 -917.646 -95.617 -28.896 -92.383 -24.537 -155.73 0 0 79.376 -222.17 25.943 61.659 -64.893 0 -3.234 -917.646

Cl
-93.578 307.452 -81.415 514.576 0 0 79.376 726.411 -95.617 -28.896 92.383 -24.537 155.73 0 0 79.376 274.056 25.943 61.659 -64.893 0 -3.234 726.411

Du
-93.578 -307.452 81.415 514.576 0 0 79.376 274.338 67.213 -28.896 -92.383 24.537 155.73 0 0 79.376 138.364 75.017 61.659 64.893 0 126.552 349.988

Dl
-93.578 307.452 81.415 -514.576 0 0 79.376 -139.911 67.213 -28.896 92.383 24.537 -155.73 0 0 79.376 11.671 75.017 61.659 64.893 0 126.552 295.008

Pressure stress* Total Ox stress Membrane O x stress* SR-2* SR-2 SR-3* SR-3 SR-3* SR-3 0.024 0.0128 0.0277 0.0293 0.0277 0.0293

Pressure stress* Total Oy stress Membrane O y stress* Shear from M t Shear from V 1 Shear from V 2 Total Shear stress Combined stress (PL+Pb+Q)

Notes: (1) * denotes primary stress. (2) The nozzle is assumed to be a rigid (solid) attachment. Longitudinal stress in the nozzle wall due to internal pressure + external loads (hot shut down condition governs) n (Pm) = ABS(Pr / (*(Ro2 - Ri2))) + M*Ro / I = ABS(314 / (*(30.162 - 26.132))*100) + 17,888.5*30.16 / 284,127.8*100 = 233.896 kgf/cm2 The average primary stress Pm (see Division 2 5.6.a.1) across the nozzle wall due to internal pressure + external loads is acceptable ( S = 1,203.264 kgf/cm2) Longitudinal stress in the nozzle wall due to external pressure + external loads n (Pm) = ABS(P*Ri / (2*tn) - Pr / (*(Ro2 - Ri2)) - M*Ro / I) = ABS(-5.6*26.13 / (2*3.34) - 314 / (*(30.162 - 26.132)) - 17,888.5*30.16 / 284,127.8) = 255.773 kgf/cm2 The average primary stress Pm (see Division 2 5.6.a.1) across the nozzle wall due to external pressure + external loads is acceptable ( S = 1,203.264 kgf/cm2)

45/50

Shear stress in the nozzle wall due to external loads shear = (VL2 + Vc2)0.5 / (*Ri*tn)*100 = (3142 + 3142)0.5 / (*26.13*4.04)*100 = 134.047 kgf/cm2 torsion = Mt / (2**Ri2*tn)*100000 = 18 / (2**26.132*4.04)*100000 = 103.986 kgf/cm2 total = shear + torsion = 134.047 + 103.986 = 238.033 kgf/cm2 UG-45: The total combined shear stress (238.033 kgf/cm2) is below than the allowable (0.7*Sn = 0.7*1,203.264 = 842.285 kgf/cm2)

46/50

Reinforcement Calculations for External Pressure

UG-45 Nozzle Wall UG-37 Area Calculation Summary Thickness (cm2) Summary For Pe = 5.6 kg f/cm2 @ 220 C (mm)
The nozzle passes UG-45 A required A available A1 A2 A3 A5 A welds treq tmin

This nozzle is exempt from area calculations per UG-36(c)(3)(a)

3.59

4.85

UG-41 Weld Failure Path Analysis Summary Weld strength calculations are not required for external pressure UW-16 Weld Sizing Summary
Weld description Nozzle to shell fillet (Leg 41) Required weld throat size (mm) Actual weld throat size (mm) Status weld size is adequate

2.83

4.2

Calculations for external pressure 5.6 kgf/cm2 @ 220 C Parallel Limit of reinforcement per UG-40 = MAX(d, Rn + (tn - Cn) + (t - C)) = MAX(52.25, 26.13 + (5.54 - 1.5) + (8.11 - 3)) = 52.25 mm Outer Normal Limit of reinforcement per UG-40 LH = = = MIN(2.5*(t - C), 2.5*(tn - Cn) + te) MIN(2.5*(8.11 - 3), 2.5*(5.54 - 1.5) + 0) 10.09 mm LR

Nozzle required thickness per UG-28 trn = 0.57 mm From UG-37(d)(1) required thickness tr = 1.74 mm This opening does not require reinforcement per UG-36(c)(3)(a)

UW-16(c) Weld Check Fillet weld: tmin = lesser of 19 mm or tn or t = 4.04 mm tc(min) = lesser of 6 mm or 0.7*tmin = 2.83 mm tc(actual) = 0.7*Leg = 0.7*6 = 4.2 mm The fillet weld size is satisfactory.

47/50

Weld strength calculations are not required for this detail which conforms to Fig. UW-16.1, sketch (c-e).

UG-45 Nozzle Neck Thickness Check

Interpretation VIII-1-83-66 has been applied. ta UG-28 ta UG-22 ta = = = = = = = = = = = = = = = 2.07 mm 2.12 mm max[ ta UG-28 , ta UG-22 ] max[ 2.07 , 2.12 ] 2.12 mm 3.59 mm max[ tb2 , tb UG16 ] max[ 3.59 , 3 ] 3.59 mm min[ tb3 , tb2 ] min[ 4.92 , 3.59 ] 3.59 mm max[ ta , tb ] max[ 2.12 , 3.59 ] 3.59 mm

tb2 tb2

tb

tUG-45

Available nozzle wall thickness new, tn = 0.875*5.54 = 4.85 mm The nozzle neck thickness is adequate. External Pressure, (Corroded & at 220 C) UG-28(c) L / Do = 154.77 / 60.33 Do / t = 60.33 / 0.57 From table G: A = From table CS-2 B = Metric: Pa = 2.5656 = 105.4753 0.000461 442.9905 kg/cm2

= 4*B / (3*(Do / t)) = 4*442.99 / (3*(60.33 / 0.57)) = 5.6 kg/cm2

Design thickness for external pressure Pa = 5.6 kg/cm2 ta = t + Corrosion = 0.57 + 1.5 = 2.07 mm

48/50

Sleeve Cover ASME Section VIII Division 1, 2010 Edition, A11 Addenda Metric Component: Bolted Cover Attached to: Flange #6 Material specification: SA-105 (II-D Metric p. 18, ln. 5) Bolted cover is impact test exempt to -105 C per UCS-66(b)(3) (coincident ratio = 0.0696). Internal design pressure: P = 3.5 kg/cm2 @ 220 C External design pressure: Pe = 5.6 kg/cm2 @ 220 C Static liquid head: Pth = 0.04 kg/cm2 (SG = 1, Hs = 427.1 mm, Horizontal test head) Inner C = 1.5 mm Outer C = 0 mm No impact test performed Material is not normalized Material is not produced to Fine Grain Practice PWHT is not performed Seamless No RT corr = 12.8 kg

Corrosion allowance:

Design MDMT = -28.89 C Rated MDMT = -105 C

Radiography: Estimated weight:

Category A joints New = 13.3 kg

Head diameter, d = 154.25 mm Cover thickness, t = 40 mm Note: The quantity under the square root sign has been doubled per UG-39(d) Design thickness, (at 220 C) UG-34 (c)(2), flange operating t = d*Sqr(2*(C*P / (S*E) + 1.9*W*hG / (S*E*d3))) + Corrosion = 154.25*Sqr(2*(0.3*3.5 / (1,397.01*1) + 100*1.9*1,464.02*26.37 / (1,397.01*1*154.253))) + 1.5 = 11.69 mm Design thickness, (at 21.11 C) UG-34 (c)(2), gasket seating t = d*Sqr(2*1.9*W*hG / (S*E*d3)) + Corrosion = 10*154.25*Sqr(2*1.9*23,435.07*26.37 / (1,407.207*1*154.253)) + 1.5 = 34.39 mm Maximum allowable working pressure, (at 220 C ) P = (S*E / (2*C))*(t / d)2 - 1.9*W*hG / (d3*C) - Ps = (1,397.01*1 / (2*0.3))*(38.5 / 154.25)2 - 1.9*100*20,894.19*26.37 / (154.253*0.3) - 0 = 49.95 kgf/cm2 Maximum allowable pressure, (At 21.11 C ) P = (S*E / (2*C))*(t / d)2 - 1.9*W*hG / (d3*C) = (1,407.207*1 / (2*0.3))*(40 / 154.25)2 - 1.9*100*22,719.95*26.37 / (154.253*0.3) = 54.32 kgf/cm2 Design thickness for external pressure, (at 220 C) U-2(g)

49/50

t = d*Sqr(2*C*Pa / (S*E)) + Corrosion = 154.25*Sqr(2*0.3*5.6 / (1,397.01*1)) + 1.5 = 9.07 mm Maximum allowable external pressure, (At 220 C ) U-2(g) Pa = (S*E / (2*C))*(t / d)2 = (1,397.01*1 / (2*0.3))*(38.5 / 154.25)2 = 145.03 kgf/cm2

50/50