Q1.

(a)
 • Design pressure, 𝑃 = 1.1 × 10 = 11 MPa
• Design temperature, 𝑇 = 200 + 10 = 210 °C

• Material properties @ 𝑻 = 𝟐𝟏𝟎 C:

Material Yield Strength, 𝝈𝒚 Maximum Allowable 𝑓𝑟1 = 𝑠𝑛 /𝑠𝑣

Specification * [MPa] Strength, 𝝈𝒂𝒍𝒍 [MPa]
𝟗𝟒. 𝟓
Nozzle-1 SA-106, Grade A 205 94.5 = 𝟎. 𝟔𝟖𝟒𝟕𝟖
𝟏𝟑𝟖
𝟏𝟏𝟖
Nozzle-2 SA-106, Grade B 240 118 = 𝟎. 𝟖𝟓𝟓𝟎𝟕
𝟏𝟑𝟖
Head &
SA-515 Grade 70 260 138 -
Shell

• 𝑆𝑛 = allowable strength for nozzle material

• 𝑆𝑣 = allowable strength for the vessel material

* Refer to “ASME Boiler and Pressure Vessel Code, Sec. II, Part D (Metric), TABLE 1A”
• minimum required thicknesses: @ 𝑷 = 𝟏𝟏 MPa and 𝑻 = 𝟐𝟏𝟎 C:

- From ASME B36.1/ B36.19 table

NPS OD, Thickness 𝑡,
SCH ID = OD − 2𝑡, mm Change of
(inch) mm mm nozzles SCH
5S is required!
Nozzle-1 12 323.8 3.96 (21.44) 𝟑𝟏𝟓. 𝟗𝟖 (280.92)
(100)
10S
Nozzle-2 10 273 4.19 (18.26) 𝟐𝟔𝟒. 𝟔𝟐 (236.48)
(100)

Maximum Allowable Radius or Minimum thickness, Final thickness,

Basic Formula*
Strength, 𝝈𝒂𝒍𝒍 [MPa] Diameter, mm 𝑡min (mm) mm

Nozzle-1 94.5 157.99 (140.46) 19.77 (17.58) 21.44 (SCH100)

𝑡𝑚𝑖𝑛
Nozzle-2 𝑃×𝑅 118 132.31 (118.24) 13.06 (11.68) 18.26 (SCH100)
=
𝑆𝐸 − 0.6𝑃
Shell 138 600 50.23 52

𝑡𝑚𝑖𝑛
Head 𝑃×𝐷 138 1200 48.21 52
=
2𝑆𝐸 − 0.2𝑃

* Formula as per ASME Sec. VIII, Dc. (1). ; Weld joint efficiency, 𝐸 is assumed equal to 1.
• when an opening and its reinforcement are in an ellipsoidal head and
are located entirely within a circle the center of which coincides with
the head and the diameter is equal to 80% of the shell diameter, 𝑡𝑟 is
the thickness required for a seamless sphere of radius 𝐾1 𝐷,
where 𝐷 is the shell I.D.

𝐷 1200
ℎ= = 𝑚𝑚 = 300 𝑚𝑚
4 4

𝐷 1200 𝑚𝑚
= =2
2ℎ 2 × 300𝑚𝑚 𝐾1 = 0.9
 • Sphere radius, 𝑅, and thickness, 𝑡𝑟 : ✓
𝑅 = 𝐾1 𝐷 = 0.9 × 1200𝑚𝑚 = 1080𝑚𝑚

𝑃𝑅 11 𝑀𝑃𝑎 × 1080𝑚𝑚
𝑡𝑟 = = = 43.4𝑚𝑚
2𝑆𝐸 − 0.2𝑃 2 × 138𝑀𝑃𝑎 × 1 − 0.2 × 11𝑀𝑃𝑎

Conclusion: use a nominal thickness of 44 mm.

• Limit parallel to head surface:

𝑑 = (273−2 × 18.26) = 236.48𝑚𝑚
𝑋 = 𝑑 or 0.5𝑑 + 𝑡 + 𝑡𝑛 whichever is larg
= 236.48𝑚𝑚 or (118.24 + 52 + 18.26) = 188.5𝑚𝑚
Conclusion: use 𝑋 = 236.38𝑚𝑚 𝑡𝑛
• Limit perpendicular to head surface:
𝑡
𝑌
𝑌 = 2.5𝑡 or2.5𝑡𝑛 whichever is smaller
= 2.5(52)=130mm or 2.5(18.26)=45.65mm
𝑋 0.8𝐷 = 960

Conclusion: use 𝑌 = 45.65𝑚𝑚

 𝑑 236.48mm
✓ • Reinforcement area required by UG-37© of VIII-1 is 𝑡𝑟 44mm
𝑡𝑛 18.26mm
𝐴𝑟 = 𝑑𝑡𝑟 𝐹 + 2𝑡𝑛 𝑡𝑟 𝐹 1 − 𝑓𝑟1
𝑡𝑟𝑛 11.68mm
= 234.48 × 44 × 1 + 2 × 18.26 × 44 × 1 × 1 − 0.855
𝑡 52mm
= 10,550 𝑚𝑚2 𝑓𝑟1 ** 0.855
𝐹 1
✓ • Reinforcement area available in the head is

𝐴1 = 𝑑(𝐸𝑡 − 𝐹𝑡𝑟 ) − 2𝑡𝑛 𝐸𝑡 − 𝐹𝑡𝑟 1 − 𝑓𝑟1

= 234.48 × 1 × 52 − 1 × 44 − 2 × 18.26 × 1 × 52 − 1 × 44 1 − 0.855
= 1833.5 𝑚𝑚2

✓ • Reinforcement area available in nozzle-2 is

𝐴2 = 2𝑌(𝑡𝑛 − 𝑡𝑟𝑛 )
= 2 × 45.65 18.26 − 11.68
= 600.76 𝑚𝑚2
✓ • Reinforcement area available in fillet welds is A B

𝐴4 = 2 × 0.5 × (𝑡𝑤 )2
= 2 × 0.5 × 152 C D

= 225 𝑚𝑚2

✓ • Total reinforcement area available in head, nozzle, and welds

𝐴 𝑇 = 𝐴1 + 𝐴2 + 𝐴4 Conclusion:
= 1833.5 + 600.76 + 225 • Area available is not enough.
= 2659.26 𝑚𝑚2

✓ • Area needed from reinforcement: ✓ • Assuming a reinforcement thickness , 𝑡𝑒 = 𝑡, the diameter

needed can be calculated from:
𝐴5 = 𝐴𝑟 − 𝐴 𝑇
𝐴5 = (𝐷𝑝 −𝑑 − 2𝑡𝑛 )𝑡𝑒
= 10,550 − 2659.26
𝐴5 7,890.74
= 7,890.74 𝑚𝑚2 ⟹ 𝐷𝑝 = + 𝑑 + 2𝑡𝑛 = + 236.48 + 2 × 18.26
𝑡𝑒 52
= 424.7𝑚𝑚 < 960𝑚𝑚
 𝑑 281mm
𝑡𝑟 50.23mm
𝑡 52 mm
𝑡𝑛 21.44mm
𝑡𝑟𝑛 17.58 mm
𝑓𝑟1 * 0.685
𝐹 1
• Limit parallel to shell surface: ✓
𝑑 = (323.9−2 × 21.44) = 281𝑚𝑚
𝑋 = 𝑑 or 0.5𝑑 + 𝑡 + 𝑡𝑛 whichever is larg
= 281𝑚𝑚 or (140.5 + 52 + 21.44) = 213.94𝑚𝑚
Conclusion: use 𝑋 = 281𝑚𝑚 𝑡𝑛
𝑡
• Limit perpendicular to shell surface:
𝑌
𝑌 = 2.5𝑡 or2.5𝑡𝑛 whichever is smaller
= 2.5(52)=130mm or 2.5(21.44)=53.6mm
𝑋 𝐷𝑝

Conclusion: use 𝑌 = 53.6𝑚𝑚

 𝑑 281mm
✓ • Reinforcement area required by UG-37© of VIII-1 is 𝑡𝑟 50.23mm
𝑡 52 mm
𝐴𝑟 = 𝑑𝑡𝑟 𝐹 + 2𝑡𝑛 𝑡𝑟 𝐹 1 − 𝑓𝑟1
𝑡𝑛 21.44mm
= 281 × 50.23 × 1 + 2 × 21.44 × 50.23 × 1 × 1 − 0.685
𝑡𝑟𝑛 17.58 mm
= 14,793 𝑚𝑚2 𝑓𝑟1 * 0.685
𝐹 1
✓ • Reinforcement area available in the shell is

𝐴1 = 𝑑(𝐸𝑡 − 𝐹𝑡𝑟 ) − 2𝑡𝑛 𝐸𝑡 − 𝐹𝑡𝑟 1 − 𝑓𝑟1

= 281 × 1 × 52 − 1 × 50.23 − 2 × 21.44 1 × 52 − 1 × 50.23 1 − 0.685
= 473.3 𝑚𝑚2

✓ • Reinforcement area available in nozzle-1 is

𝐴2 = 2𝑌(𝑡𝑛 − 𝑡𝑟𝑛 )
= 2 × 53.6 21.44 − 17.85
= 384.8 𝑚𝑚2
✓ • Reinforcement area available in fillet welds is A B

𝐴4 = 2 × 0.5 × (𝑡𝑤 )2 C D
2
= 2 × 0.5 × 18
= 324 𝑚𝑚2

✓ • Total reinforcement area available in head, nozzle, and welds

𝐴 𝑇 = 𝐴1 + 𝐴2 + 𝐴4 Conclusion:
= 473.3 + 384.8 + 324 • Area available is not enough.
= 1182.1 𝑚𝑚2

✓ • Area needed from reinforcement: ✓ • Assuming a reinforcement thickness , 𝑡𝑒 = 𝑡, the diameter

needed can be calculated from:
𝐴5 = 𝐴𝑟 − 𝐴 𝑇
𝐴5 = (𝐷𝑝 −𝑑 − 2𝑡𝑛 )𝑡𝑒
= 14,793 − 1182.1
𝐴5 13,611
= 13,611 𝑚𝑚2 ⟹ 𝐷𝑝 = + 𝑑 + 2𝑡𝑛 = + 281 + 2 × 21.44
𝑡𝑒 52
= 585.63𝑚𝑚
Q1.(b)
 𝑫𝒐
= 𝟐𝟑
(i) Shell Thickness: Trial #1
𝒕

• Assumption: shell length,

𝐿𝑠 = 1.5 × 𝐷 = 1.5 × 1.2 = 1.8𝑚

• Effective length w/o stiffening rings:

1
𝐿 = 2 × × 1.2 + 1.8 = 2.6 𝑚
3
• Assume 𝑡𝑚𝑖𝑛 = 52𝑚𝑚 for internal
pressure and

• Calculation of ratios:
𝐿 2.6𝑚
= = 2.167 𝑳
𝐷𝑜 1.2𝑚 = 𝟐. 𝟏𝟕
𝑫𝒐

and
𝐷𝑜 1200𝑚
= = 23.1
𝑡 52𝑚𝑚 ⟹ 𝑨 = 𝟎. 𝟎𝟎𝟓
DF:Design Factor = 1
𝐵 = 102

4𝐵
𝑃𝑎 =
3(𝐷𝑜 /𝑡) × DF
4 × 102
=
3 × 23.1 × 1
= 5.887 𝑀𝑝𝑎;

Conclusion:

• Must increase thickness

𝑨 = 𝟎. 𝟎𝟎𝟓
 𝑫𝒐
= 𝟏𝟐
Trial #2 𝒕

• Double the thickness, 𝑡𝑚𝑖𝑛 = 100𝑚𝑚

• Calculation of ratios:
𝐿 2.6𝑚
= = 2.167
𝐷𝑜 1.2𝑚

and
𝐷𝑜 1200𝑚
= = 12
𝑡 100𝑚𝑚
𝑳
= 𝟐. 𝟏𝟕
𝑫𝒐

⟹ 𝑨 = 𝟎. 𝟎𝟏𝟓
DF:Design Factor = 1
𝐵 = 102

4𝐵
𝑃𝑎 =
3(𝐷𝑜 /𝑡) × DF
4 × 102
=
3 × 12 × 1
= 11.33 𝑀𝑝𝑎;

Conclusion:

• Acceptable!

𝑨 = 𝟎. 𝟎𝟏𝟓
 𝑫𝒐
= 𝟏𝟒. 𝟕𝟐
(ii) Nozzle-1: 𝒕

• Assumption: nozzle length,

𝐿 = 1.5 × 𝐷 = 1.5 × 323.8 = 485.7𝑚

• Assume 𝑡𝑚𝑖𝑛 = 22 𝑚𝑚

• Calculation of ratios:

𝐿 485.7𝑚𝑚
= = 1.5
𝐷𝑜 323.8𝑚𝑚
and
𝐷𝑜 323.8𝑚𝑚
= = 14.72
𝑡 22𝑚𝑚
𝑳
= 𝟏. 𝟓
𝑫𝒐

⟹ 𝑨 = 𝟎. 𝟎𝟏𝟔
 DF:Design Factor = 1

4𝐵
𝑃𝑎 =
3(𝐷𝑜 /𝑡) × DF 𝐵 = 130
4 × 130
=
3 × 14.72 × 1
= 11.775 𝑀𝑃𝑎;

Conclusion:
• Acceptable!

𝑨 = 𝟎. 𝟎𝟏𝟔
 𝑫𝒐
= 𝟏𝟒. 𝟗𝟓
(iii) Nozzle-2: 𝒕

• Assumption: nozzle length,

𝐿 = 1.5 × 𝐷 = 1.5 × 273 = 409.5𝑚

• Assume 𝑡𝑚𝑖𝑛 = 18.26 𝑚𝑚

• Calculation of ratios:

𝐿 409.5𝑚𝑚
= = 1.5
𝐷𝑜 273𝑚𝑚
and
𝐷𝑜 273𝑚𝑚
= = 14.95
𝑡 18.26𝑚𝑚
𝑳
= 𝟏. 𝟓
𝑫𝒐

⟹ 𝑨 = 𝟎. 𝟎𝟏𝟔
 DF:Design Factor = 1

4𝐵
𝑃𝑎 =
3(𝐷𝑜 /𝑡) × DF 𝐵 = 130
4 × 130
=
3 × 14.95 × 1
= 11.59 𝑀𝑃𝑎;

Conclusion:
• Acceptable!

𝑨 = 𝟎. 𝟎𝟏𝟔
(iv) Ellipsoidal Head:

• Design pressure as per ASME code:

𝑃 = 1.67 × 𝑃 = 1.67 × 11 = 18.37𝑀𝑃𝑎

𝑃×𝐷 18.37 × 1200

𝑡1 = =
2𝑆𝐸 − 0.2𝑃 2 × 138 × 1 − 0.2 × 18.37
= 80.95𝑚𝑚

• Let 𝑡2 = 100 𝑚𝑚
𝐵 = 118

• Calculation of constant, 𝐴:

0.125 0.125
𝐴= = = 0.021
𝑅𝑜 /𝑡 600/100
• Calculation of allowable pressure:
𝐵 118
𝑃𝑎 = = = 19.67𝑚𝑚
(𝑅𝑜 /𝑡) (600/100)

• Calculation of final thickness:

𝑡 = max 𝑡1 , 𝑡2 = max 80.95,100 = 100𝑚𝑚 𝑨 = 𝟎. 𝟎𝟐𝟏
 DF:Design Factor = 1

4𝐵
𝑃𝑎 =
3(𝐷𝑜 /𝑡) × DF 𝐵 = 130
4 × 130
=
3 × 14.95 × 1
= 11.59 𝑀𝑃𝑎;

Conclusion:
• Acceptable!

𝑨 = 𝟎. 𝟎𝟏𝟔
After this, complete the reinforcement calculation
following the same step from part (a).
Q1.(C)
 • Manway calculation:

𝑎 = 200 𝑚𝑚 and 𝑏 = 150 𝑚𝑚

𝑃𝑎2 𝑏2
𝑡𝑟𝑚 =
𝑆𝐸 𝑎2 𝑠𝑖𝑛2 (𝜙) + 𝑏2 𝑐𝑜𝑠 2 (𝜙) 3/2

11 × 2002 × 1502
=
138 × 1 × 2002 𝑠𝑖𝑛2 (0) + 1502 𝑐𝑜𝑠 2 (0) 3/2

= 21.25 𝑚𝑚

Conclusion: use 𝑡𝑟𝑚 = 22 𝑚𝑚

 𝑑 400 mm
• Limit parallel to head surface: 𝑡𝑟 50.23 mm
𝑑 = 2𝑎 = 2 × 200 = 400𝑚𝑚 𝑡 52 mm
𝑋 = 𝑑 or 0.5𝑑 + 𝑡 + 𝑡𝑚 whichever is larg 𝑡𝑚 22 mm
= 400𝑚𝑚 or (200 + 52 + 22) = 274𝑚𝑚 𝑡𝑟𝑚 21.25 mm
Conclusion: use 𝑋 = 400𝑚𝑚 𝑓𝑟1 0.685
𝐹 1
• Limit perpendicular to head surface:

𝑌 = 2.5𝑡 or 2.5𝑡𝑚 whichever is smaller

= 2.5(52)=130mm or 2.5(22)=55mm

Conclusion: use 𝑌 = 55𝑚𝑚

• Reinforcement area required by UG-37© of VIII-1 is

𝐴𝑟 = 𝑑𝑡𝑟 𝐹 + 2𝑡𝑚 𝑡𝑟 𝐹 1 − 𝑓𝑟1

= 400 × 50.23 × 1 + 2 × 22 × 50.23 × 1 × 1 − 0.685
= 20,788.2 𝑚𝑚2
✓ • Reinforcement area available in the shell is

𝐴1 = 𝑑(𝐸𝑡 − 𝐹𝑡𝑟 ) − 2𝑡𝑛 𝐸𝑡 − 𝐹𝑡𝑟 1 − 𝑓𝑟1

= 400 × 1 × 52 − 1 × 50.23 − 2 × 22 1 × 52 − 1 × 50.23 1 − 0.685
= 683.5 𝑚𝑚2
𝑑 400 mm
✓ • Reinforcement area available in the man-way nozzle is
𝑡𝑟 50.23 mm
𝐴2 = 2𝑌(𝑡𝑛 − 𝑡𝑟𝑛 ) 𝑡 52 mm
= 2 × 55 22 − 21.25
𝑡𝑚 22 mm
= 82.5 𝑚𝑚2
𝑡𝑟𝑚 21.25 mm
✓ • Reinforcement area available in fillet welds is 𝑓𝑟1 0.685

𝐴4 = 2 × 0.5 × (𝑡𝑤 )2 𝐹 1
= 2 × 0.5 × 192
= 361 𝑚𝑚2
✓ • Total reinforcement area available in head, nozzle, and welds

𝐴 𝑇 = 𝐴1 + 𝐴2 + 𝐴4
= 683.5 + 82.5 + 361 Conclusion:

= 1127 𝑚𝑚2 • Area available is not enough.

✓ • Area needed from reinforcement:

𝐴5 = 𝐴𝑟 − 𝐴 𝑇
= 20,788.2 − 1127
= 19,661.2 𝑚𝑚2

✓ • Assuming a reinforcement thickness , 𝑡𝑒 = 𝑡, the diameter

needed can be calculated from:
𝐴5 = (𝐷𝑝 −𝑑 − 2𝑡𝑛 )𝑡𝑒
𝐴5 19,661.2
⟹ 𝐷𝑝 = + 𝑑 + 2𝑡𝑛 = + 400 + 2 × 22
𝑡𝑒 52
> 822𝑚𝑚