CLIENT: HMEL CONSULTANT: EIL DT : 18.11.

2017
PROJECT: BS-VI DHT PROJECT CHECKED BY: KEWAL K REV: 0
DESIGNED BY: ASHISH D TAG NO: 607-V-312 APP BY: R.M.A
EQUIPMENT: CLOSED BLOW DOWN DRUM
DESIGN AS PER DENNIS MOSS
NOZZLE "N7"
Design pressure P = 3.5 kg/cm2
Design Temp. T = 190 °C
Flange Material = SA 105
Bolting Material = SA 193 B7
Corrosion Allowance Ca = 3 mm
Allowable stress at Temp. ( Flange ) Sfo = 1707.04 kg/cm2
Allowable stress at ATM. ( Flange ) Sfa = 1407.04 kg/cm2
Allowable stress at Temp. ( Bolting ) Sb = 1753.72 kg/cm2
Allowable stress at ATM. ( Bolting ) Sa = 1753.72 kg/cm2
Joint effecicny of Nozz to blind at opening E = 1

Gasket outside dia Go = 577.9 mm

Gasket inside dia Gi = 525.5 mm
Gasket factor m = 3
Gasket Design Seating Stress y = 703.07 kg/cm2

Flange outside dia. A = 700 mm

Flange inside dia. ( opening dia.) d1 = 163 mm
Flange inside dia. ( opening dia.) d2 = 163 mm
Assume Flange thickness ( including corrosion) t = 45 mm
Bolt circle dia. C = 635 mm
Nominal bolt dia. db = M 30
No. of bolts. n = 20
Bolt root area. ( single bolt) = 5.03 cm2
Reinforcement length ('d' OR 'Greater of d') w = 163.00 mm
Radius of opening Rn = 81.5 mm
Allowable Stress at Temp. Nozz. Neck at opening S = 1202 kg/cm2
Weld size at blind to opening nozz neck. wf = 9 mm
Reinforcement outside dia. Rod = 0 mm
Thickness of reinforcement tp = 0 mm
Co-efficient factor ( Ug-34 fig.) C1 = 0.3 mm

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FLANGE ANALYSIS
Gasket contact width ( Go-Gi) / 2 N = 26.20 mm
Min Gasket contact width (Ab*Sb/(y*P*(Go+Gi))*100 = 7.24 mm
GASKET WIDTH SUFFICIENT
Basic gasket width (N/2) bo = 13.10 mm
Effective gasket width b = 9.05 mm
( b = bo, When bo < 6.35 )
( b = √(bo) / 2, When bo > 6.35 )
Gasket reaction Dia. G = 559.803 mm
( bo < 6.35, G = mean gasket dia.)
( bo > 6.35. G = RF dia or gaskte od - 2*b)

LOAD & BOLT CALCULATION.

Hydrostatic end load due to pressure ((G^2*π*P)/4 )/100 H = 8610.10 kg
Contact load on gasket surfaces (2*b*π*G*m*P )/100 Hp = 3341.80 kg
Operating Bolt load ( Hp + H ) Wm1 = 11951.90 kg
Gasket seating load ( b*π*G*y )/100 Wm2 = 111881.78 kg
Wm2 / Sa = 63.80
Wm1 / Sb = 6.82
Minimum Require bolt area Am = 63.80 cm2
(max of Wm2/Sa or Wm1/Sb)
Provided Bolt area Ab = 100.6 cm2
BOLT SIZE IS SAFE
Radial distance bet. Bolts & the edge (min) = 33.34 mm
Provided radial dist. Bet. Bolt & edge. = 32.5 mm
RADIAL DIST. INSUFFICENT
Flange Design bolt load, Gasket seating Sa*(Am+Ab)/2 W = 144153.00 kg
Distance of gasket load reaction (0.5(C-G)) hg = 37.60 mm

THICKNESS OF FALNGE
Operating G*√((C1*P/Sfo)+(1.9*Wm1*hg/Sfo*G^3))+Ca to = 16.92 mm
Gasket seating G*√((1.9*W*hg)/(Sfa*G^3))+Ca tg = 39.16 mm
(Cal. Thickness using C = 0.6) to = 22.66 mm

REINFORCEMENT CAL. DUE TO OPENING

Required thickness in nozzle neck ( P.Rn/S.E-0.6P)+Ca trn = 3.24 mm
Provided Nozzle neck thickness tn = 13.00 mm
Area removed from blind ((0.5*d1*to)/100)*2 Ar = 13.79 cm2
Reinforcement Area ((t-to)(2*w - d)/100)*2 A1 = 45.78 cm2
Reinforcement Area (2h(tn-trn))/100 (h=2.5*t) A2 = 1.76 cm2
Reinforcement Area ((2*tn*h)/100)*2 A3 = 0.00 cm2
Area for weld (( 0.5*w*w )/100)*2 A4 = 0.81 cm2
Reinforcement Area (tp(Rod-d))/100 A5 = 0 cm2
Addition of all Reinforcement area ΣA = 48.34 cm2
ASSUMED THICKNESS IS SAFE

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MINIMUM REQUIRED THICKNESS AS PER (UG-34)C.3
Z = 3.4-(2.4*G/A) Z = 1.48 mm
G√(Z *0.3*P/S*E)+CA t = 19.89 mm
ASSUMED THICKNESS IS SAFE
NOTE :-
1) If "t" is greater of "1.414 * to" than no additional Reinforcement is required.
2) If "to" is calculated using value of C1 = 0.6 than no additional Reinforcement is required.
NOW CAL. FOR NOTE (1) & (2).
NOTE 1 ---> NO ADD.AREA REQUIRED
NOTE 2 ---> NO ADD. AREA REQUIRED

ONLY IF REQUIRED BY CLIENT

MOMENT CALCULATIONS
MOMENT AT OPERATING CONDITION
LOADS
Hydrostatic End Froce (HD = π*d^2*P/4 )/100 HD = 730.35 kg
Gasket load at operating (Wm1 - H ) HG = 3341.80 kg
Pressure force on Flange face ( H - HD ) HT = 7879.75 kg
LEVER ARM
0.5 ( C - d ) hD = 236.00 mm
0.5 ( C - G ) hG = 37.60 mm
0.5 ( hD + hG ) hT = 273.60 mm

Moment due to HD MD = 172363.43 kg-mm

Moment due to HG MG = 125646.49 kg-mm
Moment due to HT MT = 2155886.71 kg-mm
Max moment Mo = 2453896.64 kg-mm
MOMENT AT SEATING CONDITION
LOADS
Gasket load at seating ( HG = W ) HG = 144153.00 kg
LEVER ARM
0.5 ( C - G ) hG = 37.60 mm

Moment due to HG Mo' = 5419933.90 kg-mm

SHAPE CONSTANTS
A/d K = 4.29
( From table 2-5 DENNIS MOSS ) Y = 3.24
FLANGE THICKNESS REQUIRED AT OPERATING
√(Mo*Y/Sfo*B)+CA t = 8.35 mm
√(Mo'*Y/Sfo*B)+CA t = 11.75 mm

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18.11.2017

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UG 45 12.22

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 DESIGN OF FLAT HEAD / BLIND FLANGE WITH OPENING
REFERENCE: Mandatory Appendix 2, & Ug-34 , UG-39

Design pressure P = 3.5 kg/cm2

= 0.3432 Mpa
Design Temp. T = 190 °C
Flange Material = SA 105
Bolting Material = SA 193 B7
Corrosion Allowance Ca = 3 mm
Allowable stress at Temp. ( Flange ) Sfo = 138 Mpa
1407.21 kg/cm2
Allowable stress at ATM. ( Flange ) Sfa = 138 Mpa
1407.21 kg/cm2
Allowable stress at Temp. ( Bolting ) Sb = 172 Mpa
1753.91 kg/cm2
Allowable stress at ATM. ( Bolting ) Sa = 172 Mpa
1753.91 kg/cm2
Joint effecicny of Nozz to blind at opening E = 0.85

Gasket outside dia Go = 1376.4 mm

Gasket inside dia Gi = 1333.5 mm
Gasket factor (App -,Table 2-5.1) m = 3
Gasket Design Seating Stress (App -,Table 2-5.1) y = 703.07 kg/cm2
69 Mpa
Flange outside dia. A = 1495 mm
Opening for Nozzle B1 d1 = 88.9 mm
Opening for Nozzle V1 d2 = 60.3 mm
Opening for Nozzle P1 d3 = 60.3 mm
Total Opening Area d = 209.50 mm
Assume Flange thickness ( corroded) t = 82 mm
Bolt circle dia. C = 1436.7 mm
Nominal bolt dia. (Metric) db = M 30
No. of bolts. n = 52
Bolt root area. ( single bolt) = 5.03 cm2
Reinforcement limit allong fl ('d1' OR 'Greater of Rn+tn+t) w = #REF! mm
Radius of opening Rn = 104.75 mm
Allowable Stress at Temp. Nozz. Neck at opening S = 118 Mpa
1203.27
Weld size at blind to opening nozz neck. wf = 8 mm
Reinforcement outside dia. Rod = 0 mm
Thickness of reinforcement tp = 0 mm
Co-efficient factor ( UG-34 fig.j]) C1 = 0.6 mm

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FLANGE ANALYSIS
Gasket contact width ( Go-Gi) / 2 N = 21.45 mm
Min Gasket contact width (Ab*Sb/(y*P*(Go+Gi))*100 = 75.16 mm
GASKET WIDTH INSUFFICIENT
Basic gasket width (N/2) bo = 10.73 mm
Effective gasket width b = 8.19 mm
( b = bo, When bo 6 )
( b = √(bo) / 2, When bo 6.00 )
Gasket reaction Dia. G = 1360.025 mm
( bo < 6, G = mean gasket dia.)
( bo > 6, G = RF dia or gaskte od - 2*b)

LOAD & BOLT CALCULATION. (App- 2-5)

Hydrostatic end load due to pressure [ 0.785 * G^2 * P ] H = 498323.11 N
Contact load on gasket surfaces [( 2*b) x 3.14 G*m*P ] Hp = 71996.91 N
Operating Bolt load ( Hp + H ) Wm1 = 570320.02 N
Gasket seating load [ 3.14*b*G*y ] Wm2 = 2412484.00 N
Wm2 / Sa = 14026.07
Wm1 / Sb = 3315.81
Minimum Require bolt area Am = 14026.07 mm2
(max of Wm2/Sa or Wm1/Sb)
Provided Bolt area Ab = 26156 mm2
BOLT SIZE IS SAFE
Flange Design bolt load, Operating W1 = Wm1 W1 = 570320.02 N
Flange Design bolt load, Gasket seating Sa*(Am+Ab)/2 W2 = 3455658.00 N
Distance of gasket load reaction (0.5(C-G)) hg = 38.34 mm

THICKNESS OF FALNGE
Operating G*√((C1*P/Sfo)+(1.9*W1*hg/Sfo*G^3))+Ca to = 57.60 mm
UG- 34( c )(2)

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Gasket seating G*√((1.9*W*hg)/(Sfa*G^3))+Ca tg = 39.62 mm

Opening in Blind Flange does not exceed 1 half the head diameter i.e 747.5 mm
as per UG-39(d)(2) the thickness of blind flange is calculated double the value of C

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 DESIGN OF FLAT HEAD / BLIND FLANGE WITH OPENING
REFERENCE: Mandatory Appendix 2, & Ug-34 , UG-39

Design pressure P = 3.5 kg/cm2

= 0.3432 Mpa
Design Temp. T = 190 °C
Flange Material = SA 105
Bolting Material = SA 193 B7
Corrosion Allowance Ca = 3 mm
Allowable stress at Temp. ( Flange ) Sfo = 138 Mpa
1407.21 kg/cm2
Allowable stress at ATM. ( Flange ) Sfa = 138 Mpa
1407.21 kg/cm2
Allowable stress at Temp. ( Bolting ) Sb = 172 Mpa
1753.91 kg/cm2
Allowable stress at ATM. ( Bolting ) Sa = 172 Mpa
1753.91 kg/cm2
Joint effecicny of Nozz to blind at opening E = 0.85

Gasket outside dia Go = 1376.4 mm

Gasket inside dia Gi = 1333.5 mm
Gasket factor (App -,Table 2-5.1) m = 3
Gasket Design Seating Stress (App -,Table 2-5.1) y = 703.07 kg/cm2
69 Mpa
Flange outside dia. A = 1495 mm
Opening for Nozzle B1 d1 = 88.9 mm
Opening for Nozzle V1 d2 = 60.3 mm
Opening for Nozzle P1 d3 = 60.3 mm
Total Opening Area d = 209.50 mm
Assume Flange thickness ( corroded) t = 82 mm
Bolt circle dia. C = 1436.7 mm
Nominal bolt dia. (Metric) db = M 30
No. of bolts. n = 52
Bolt root area. ( single bolt) = 5.03 cm2
Reinforcement limit allong fl ('d1' OR 'Greater of Rn+tn+t) w = 209.50 mm
Radius of opening Rn = 104.75 mm
Allowable Stress at Temp. Nozz. Neck at opening S = 118 Mpa
1203.27
Weld size at blind to opening nozz neck. wf = 8 mm
Reinforcement outside dia. Rod = 0 mm
Thickness of reinforcement tp = 0 mm
Co-efficient factor ( UG-34 fig.j]) C1 = 0.3 mm

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FLANGE ANALYSIS
Gasket contact width ( Go-Gi) / 2 N = 21.45 mm
Min Gasket contact width (Ab*Sb/(y*P*(Go+Gi))*100 = 75.16 mm
GASKET WIDTH INSUFFICIENT
Basic gasket width (N/2) bo = 10.73 mm
Effective gasket width b = 8.19 mm
( b = bo, When bo 6 )
( b = √(bo) / 2, When bo 6.00 )
Gasket reaction Dia. G = 1360.025 mm
( bo < 6, G = mean gasket dia.)
( bo > 6, G = RF dia or gaskte od - 2*b)

LOAD & BOLT CALCULATION. (App- 2-5)

Hydrostatic end load due to pressure [ 0.785 * G^2 * P ] H = 498323.11 N
Contact load on gasket surfaces [( 2*b) x 3.14 G*m*P ] Hp = 71996.91 N
Operating Bolt load ( Hp + H ) Wm1 = 570320.02 N
Gasket seating load [ 3.14*b*G*y ] Wm2 = 2412484.00 N
Wm2 / Sa = 14026.07
Wm1 / Sb = 3315.81
Minimum Require bolt area Am = 14026.07 mm2
(max of Wm2/Sa or Wm1/Sb)
Provided Bolt area Ab = 26156 mm2
BOLT SIZE IS SAFE
Flange Design bolt load, Operating W1 = Wm1 W1 = 570320.02 N
Flange Design bolt load, Gasket seating Sa*(Am+Ab)/2 W2 = 3455658.00 N
Distance of gasket load reaction (0.5(C-G)) hg = 38.34 mm

THICKNESS OF FALNGE
Operating G*√((C1*P/Sfo)+(1.9*W1*hg/Sfo*G^3))+Ca to = 43.02 mm
UG- 34( c )(2)

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Gasket seating G*√((1.9*W*hg)/(Sfa*G^3))+Ca tg = 39.62 mm
As the distance between two nozzle openings is more than mm
twice or average diameter. Hence as per UG-39.c (2) "to" = 1.414x43.02
shall be multiplied by 1.414 to required thickness t = 60.83 mm
Further reinforcement calculation in not required because opening are isolated
REINFORCEMENT CAL. DUE TO OPENING (As per UG-37)
Required thickness in nozzle neck ( P.Rn/S.E-0.6P)+Ca trn1 = 6.73 mm
Nozzle neck thickness as per UG-45 (t+ca) trn2 = 6.42
Further calculation use Max (trn1,trn2) MAX(6.42,6.73) Max = 6.73
Provided Nozzle neck thickness (Min Thk) tn = 8.74 mm
Area removed from blind ((0.5*d*to)/100) Ar = 45.06 cm2
Reinforcement Area ((t-to)(2*w - d)/100) A1 = 81.66 cm2
Reinforcement Area (2h(tn-trn))/100 (h=2.5*t) A2 = 8.24 cm2
Reinforcement Area ((2*tn*h)/100) A3 = 35.83 cm2
Area for weld (( 0.5*w*w )/100)*2 A4 = 0.64 cm2
Reinforcement Area (tp(Rod-d))/100 A5 = 0 cm2
Addition of all Reinforcement area ΣA = 126.38 cm2
ASSUMED THICKNESS IS SAFE

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2456.8

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