FIRETECH EQUIPMENT AND SYSTEMS PVT. LTD.

MANUFACTURER'S DESIGN REPORT

MECHANICAL DESIGN CODE CALCULATIONS

PURCHASER'S NAME : MX SYSTEM INTERNATIONAL PVT. LTD.

PROJECT NAME : XXXXXXXXXXXXXX

PLANT LOCATION : XXXXXXXXXXXXXX

P.O. NUMBER : XXXXXXXXXXXXXX

EQUIPMENT NAME : 1 KL FOAM TANK

ITEM / TAG NUMBERS : XXXXXXXXXXXXXX

VENDOR'S DOC. NO : XXXXXXXXXXXXXX

Client Document Number : XXXXXXXXXXXXXX

R0 22-Mar-21 Rahul N Darshan P Shrikant R

Rev Date Prepared By Checked By Approved By
 RECORD OF REVISION
Rev. no Description Prep. By Chkd. By Appvd. By

R0 First Issue PLD VP ANN

2. INDEX

Sr. No. Description Page No.

1 COVER SHEET 01

2 INDEX 02

3 DESIGN DATA 03

4 NOTES & ASSUMPTIONS 04

5 3D-MODEL FROM PVELITE 05

6 ASME DESIGN CALCULATION 06

7 BOTTOM PLATE CALCULATION 70

8 TOP PLATE CALCULATION 71

 REFERENCE FABRICATION DRAWINGS
DOC REVISION->
Sr
Description Drawing No. R0 R1 R2 R3
no.

GENERAL ARRANGEMENT DWG. + GENERAL

1 XXXXXXXXXXX R0
NOTES + FOUNDATION LOAD DATA

2 NOZZLE DETAILS DWG. XXXXXXXXXXX R0

3 SADDLE SUPPORT DWG. XXXXXXXXXXX R0

8 NAME PLATE DRAWING XXXXXXXXXXX R0

3. DESIGN DATA
Sr.
Description Values Unit Remark
No.
ASME Sec. VIII Div-1,
1 Design & Construction Code
Ed 2019
ATM+
Internal Design Pressure( At Top) FULL OF LIQUID
Kg/cm2(g)
2
Internal Design Temperature 65 0
C

External Design Pressure 0.000 Kg/cm2(g)

3
External Design Temperature 65 0
C

4 Minimum Design Metal Temperature 0 0

C

Operating Pressure ATM Kg/cm2(g)

5
Operating Temperature (MAX) AMB 0
C

Corrosion Allowance (CA)

6 Shells & Heads (Internal CA) 0.0 mm

Nozzles/Body flanges (Internal CA) 0.0 mm

7 Radiography NIL

8 Service FOAM
4. NOTES AND ASSUMPTION
1 Base metal ID has been considered as 1000 mm as per datasheet

2 All dimensions are in mm unless otherwise specified.

3 Internal Design pressure is considered as ATM at top of vessel in design.

4 Below properties for Insulation & Fire proofing are as per Specification

Insulation NA Fire proofing ATM+

FULL OF LIQUID
5 Below wind loads data are considered :
Wind Code:ASCE-7-05

Design Basic Wind speed : 121 kmph

Surface Roughness Category : D
Importance Factor = 1.5
Base Elevation = 300 mm10 KL FOAM TANK
6 Below seismic loads data are considered :
Sesimic Code: NBC 2015

Site Class : E
Component Amplification factor [Rp] : 2.5
Component Force factor [Ar] : 2.5
Acceleration Sa(0.2) :0.1920
Acceleration Sa(0.5) :0.1260
Acceleration Sa(1.0) :0.0720
Acceleration Sa(2.0) :0.0360

7 Top plate is design as per Good Engineering Practice and Roorks Hand
Book. (Refer Page 71 of Design Report)
Bottom Plate is design as per Good Engineering Practice.
8 (Refer Page 71 of Design Report)
9 Fluid Desnity assumed as 1100 Kg/m^3.
 CLIENT NAME

STRESS VALUES FOR MATERIAL OF CONSTRUCTION

Allowable
Allowable Min Yield at
Allowable Yield stress Min UTS at
Material stress at room room Stress Ref. Page no of Code
Component stress at for room
Specification temperature Temperature 40 Ratio :Sec II (D) Metric
90°C Hydrotest 40 Temperature
40°C °C
°C

A B C 0.9*C E B/A
Line No./Table
MPa (g) MPa (g) MPa (g) MPa (g) MPa (g) No./Page No.
10/1A/17-19
Shell SA 106 GR B 118.0 118.0 241.0 216.9 415.0 1.000 &
44/Y1/658-660

Standard Flanges / 19/1A/20-23

Couplings SA 105 138.0 138.0 248.0 223.2 485.0 1.000 &
11/Y1/666-669

10/1A/17-19
Nozzle Neck Pipe SA 106 GR B 118.0 118.0 241.0 216.9 415.0 1.000 &
44/Y1/658-661

12/1A/16-19
Head / Pipe Fittings /
SA 234 Gr.WPB 118.0 118.0 241.0 216.9 415.0 1.000 &
Elbow
46/Y1/658-661

33/1A/20-23
Saddle Support SA 516 Gr. 70 138.0 138.0 262.0 235.8 485.0 1.000 &
24/Y1/666-669

28/3/398-401
External Bolting & SA 193 Gr. B7 /
130.0 138.0 517.0 465.3 690.0 1.062 &
Nuts SA 194 Gr. 2H
12/Y1/636-638
Lowest stress ratio(LSR)= 1.000 (Except Bolting)
 0

CHECK FOR REINFORCEMENT REQUIREMENTS

AS PER UG - 36
Description Symbol Values Unit
Corroded Shell I.D D1 490.95 mm
Corroded Shell Thickness t1 7.3343 mm
Max. size of unreinforced opening allowed
Dmax. 89 mm
in the shell (As per UG-36 (c)(3)(a)(1))
Max. size of unreinforced opening provided D 52.63 mm
CONCLUSION :
1) Reinforcement calculation are Not Required. (Small Opening)

CHECK FOR MULTIPLE OPENING (UG-42)

The pair of Nozzles N6 & N3 are closest distance than any other nozzle pairs.
Hence, As per UG-42 (a), The minimum distance between pair of N6 & N3 openings shall
be ( 52.63+ 26.34)/2 =78.97 mm.
-Actual distance between pair of Nozzle N6 & N3 is 150 mm as per drawing.
Conclusion:
Nozzle N6 & N3 are well apart & doesn't fall in to multiple opening.

CHECK FOR INSPECTION OPENINGS (UG-46)

Requirement: As per UG-46(f-2), All vessels 18in.(450mm) to 36in.
(900mm),inclusive,I.D.shall have a manhole or atleast two hand-holes or two
plugged,threaded inspection openings of not less than NPS2(DN50).
Conclusion:
Required Inspection Opening, To comply Code Requirement.

CHECK FOR DRAIN OPENINGS (UG-25)

Requirement: As per UG-25(f) Openings for Drain. Vessels subject to corrosion
shall be supplied with a suitable drain opening at the lowest point practicable in the
vessel; or a pipe may be used extending inward from any other location to within 1/4 in.
(6 mm) of the lowest point.
Conclusion:
Vessel has Drain(Liquid outlet) Connection N3 (2" Size) at BTM Side as per datasheet.
 IMPACT TEST REQUIREMENT (UCS-66)

CONDITION APPLICABILITY

1) Thickness of P No. 1, Gr. No. 1 or 2 materials less than 13 mm for Yes

materials listed in Curve-A & less than 25 mm for materials listed in
Curve-B,C or D (Refer Column)

Yes
2) The completed vessel shall be hydrostatically tested per UG-99( b ).

3) i)Design Temp. 93 , Which is not warmer than 345°C Yes

ii) MDMT 21.0 , Which is not colder than -29°C Yes

Yes
4) Themal & Mechanical loadings are not a controlling design requirement.

Yes
5) Cyclical loading is not a controlling design requirement.

Conclusion : Impact test is exempted as per UG-20( f ).

Exemp.
Sr. Material P. No./ Applicable Governing
Temp.

No. Component Identifier Spec. No. Group Curve Thk. per rule

( mm ) No. ( mm ) UCS-66(a)

1 Shell SA 516 Gr. 70 1 / 1 Curve B 12 -29

2 Dish Head SA 516 Gr. 70 1 / 1 Curve B 10 -29

3 Saddle Support SA-516 Gr. 70 1 / 2 Curve B 26 -29

Exempted Temp. per Note (c) of UCS-

8 External Bolting SA-193 Gr. B7 --- -48
66
Exempted Temp. per Note (c) of UCS-
9 External Nuts SA-194 Gr. 2H --- -48
66
Conclusion:
Impact testing is not required as per UCS-66 of ASME Sec VIII Div-1.
 0

RADIOGRAPHY REQUIREMENT ( UW-11, UW-12 & UCS-57)

WHETHER FULL
MAX. BUTT WELD
DESCRIPTION MATERIAL P.No RADIOGRAPHY APPLICABLE CLAUSE PROVIDED
THICKNESS (mm)
REQUIRED

Shells 9.53 SA 106 Gr. B 1 NO UW 11(a)(2) 100% (Note-2)

Left head/Right Head 9.53 SA 234 WPB 1 NO UW 11(a)(2) 100% (Note-2)

Nozzle flanges/ Couplings 9.53 SA 105 1 NO UW 11(a)(4) 100% (Note-2)

Notes:
1) As per UW-11 (a) (2) of ASME SEC VIII Div-1, minimum thickness of components above which full radiography of butt welded
joints is mandatory is 38 mm.

2) As per Datasheet sheet 100% RT For Shell & Heads shall be carried out for all butt welded joints.

3) As per Table UW-12 Type No 3

 POST WELD HEAT TREATMENT REQUIREMENT (UCS-56,UCS-79) AND 32-SAMSS-004

PFHT based
PWHT based on Rf % E % E on
Sr. t ID
Component Material P-No P-No & Thickness Elongation Elongation Strain
No. (mm) (mm) (mm) (ASME) (32-SAMSS-004) Elongation.
"B" (Note-2)

1 Head SA 516 Gr.70 P1 10.000 Not Required 1981.0 342 2.194 26.236 Required

2 Shell SA 516 Gr.70 P1 12.000 Not Required 1981.0 997 0.602 0.602 Not Required

Fabricated
5 Pipe for SA 516 Gr.70 P1 10.0 Not required 590.0 305 1.639 1.639 Not required
Nozzle-M1

Notes:
1 As per note (b) (1) Table UCS-56-1 of ASME Sec VIII Div. 1 for P1 materials, PWHT, Postweld heat treatment is mandatory
for welded joints of all thickness above 38 mm.

2 As per UCS-79 of ASME Sec VIII Div. 1,for cold formed components, Stress relieving is required after forming when the
extreme fiber elongation (strain) exceeds 5 % from the as-rolled condition.

Forming Strains Calculation (UCS-79)

For Cylinder formed from plate :
(As per ASME) Where, t = Nominal wall thickness before forming, mm

For Heads formed from plate :

(As per ASME) R0 = Original centerline radius, mm = Infinity

For Cylinder formed from plate :

(32-SAMSS-004) Rf = Final Mean radius after forming, mm

For Heads formed from plate :

(32-SAMSS-004) Db = Diameter of unformed blank plate, mm

Df = Outside diameter of the finished product, mm

3 As Boot Head Material is SA 234 WPB , that is already Heat Treated. So No Need of PWHT And PFHT.

Conclusion:
1 Since, the extreme fiber elongation (strain) is greater than 10%, Stress relieving is required after forming for dishend.
Hence 32-SAMSS-004 requirement is complied.
 POST WELD HEAT TREATMENT REQUIREMENT (UCS-56,UCS-79) AND 32-SAMSS-004
2 As verified above, PWHT is not required as per code.
 EXTERNAL PRESSURE AND MISCELLANEOUS LOADS CALCULATION
(As per Good Engineering Practice)

Sr.No. Descriprtion Symbol Value Unit Remark

1 External Pressure as per Datasheet Ped 0.1034 MPa

2 Tank Outside Diameter OD 2005 mm
3 Total Length of Equipment L 9469 mm
4 TL-TL Length Lt 8458
6 Water Height Above Tank Hw 600 mm

Height Of Liquid From Bottom to Vault

7 2.605
Submerged Level H m
8 Density of Filling Liquid ϱ 1000 kg/m^3
9 External Pressure Due to Static Head Ph 0.02557 MPa
10 Water Force Fh 485517.64 N
11 Voulume of Vessel Vv 28.81 m^3
12 Volume of Shell Vs 26.70 m^3
13 Depth of Dish head h 0.50 m
14 Radius of Shell Ri 1.00 m
15 α 360 Deg
16 Voulume of Dish Head V 2.11 m^3
17 Total Buoyant Force F 282579.22 N
18 External Pressure due to Buoyant Force Pb 0.0149 MPa
19

20 Total External Pressure Pe 0.1439 MPa

 0

HYDROTEST PRESSURE CALCULATIONS (AT SITE AND SHOP CORRODED CONDITION)

(UG-99(b))
SR.NO. DESCRIPTION SYMBOL UNIT VALUES REMARK

Maximum Allowable Working Pressure (MAWP) from

1 P MPa (g) 1.8000
(Governed by Bottom Shell) PVELITE
2 Lowest stress ratio of material constructed (ratio of
stress at hydro test temperature to stress at design
temperature. ratio of bolt material is excluded) R - 1.00
(refer stress values of material construction)

Min. hydro test pressure for the vessel at top in Horizontal condition :

Pv= 1.3 X MAWP X Lowest stress ratio

= 1.3 x P x R

= 2.3400 MPa (g)

For induced stresses during hydro test, Refer page-XXX of design report.
 LARSEN & TOUBRO HEAVY ENGINEERING LLC
SOHAR WORKS, OMAN

HYDROTEST PRESSURE CALCULATIONS (AT SHOP IN NEW & COLD CONDITION)

(UG-99(C))

SR.NO. DESCRIPTION SYMBOL UNIT VALUES

1 Maximum Allowable Pressure (MAPnc)
P kg/cm2 (g) 34.8462
(governed by Bottom Shell)
2 Static height of governing element for hydro test
pressure calculation in Horizontal condition(Vessel hg mm 3350
dia+ Nozzle Projection)
3 Pressure head due to water column when equipment
is in horizontal condition (Water density ρ = 1000 static head kg/cm2 (g) 0.335
kg/m3)
4 Height of water column when equipment is in Vertical
condition h' mm 10600

5 Pressure head due to water column when equipment

is in horizontal condition (Water density ρ = 1000 Ph'=ρ*g*h' kg/cm2 (g) 1.060
kg/m3)
6 Lowest stress ratio of material constructed (ratio
of stress at hydro test temperature to stress at R - 1.00
design temperature. ratio of bolt material is
excluded) (refer stress values of material
construction)
Min. hydro test pressure for the vessel at top in Horizontal condition at shop:

Pv= 1.3 X MAPnc X LSR

= 1.3 x P x LSR

= 45.3001 kg/cm2 (g)

For induced stresses during site hydro test, Refer page-41 of design report.
 TEMPLATE SIZE FOR SHELL & HEAD (AS PER UG 80 & 81)

LEFT &
SHELL
SECTION (UG-80)
RIGHT HEAD Remark
(UG-81)

Inside Diameter, Di mm 1981 1981

Nominal Thickness, Ts (mm) 12 10

Nominal thk-Corrosion
allowance 12.00 10.00
Thickness, t (mm)

Unstiffened Length , L (mm) 3675.00 ---

Outer Diameter, D0 (mm) 2005 3585.8

Do/Ts 167.1 358.6

Do/t 167.1 358.6

L/D0 1.8 0.5

e/t From Fig. UG 80.1 0.8 0.9

e = e/t * t (mm) 9.6 9

Arc from Fig. UG 29.2) 0.18 0.081

Arc Length = Arc*Do (mm) 361 290

Template size as per UG 80,

Chord Length = 2* Arc 722 581
length (mm)
5.3D-MODEL FROM PVElite
 0

WIND INDUCE VIBRATION CHECK

SR.NO. DESCRIPTION SYMBOL UNIT VALUES
1 Inside Dia of Vessel Di mm 488.95
2 Thickness of the Vessel T mm 9.525
3 Outside Dia of Vessel Do m 0.508
4 Height of Vessel (including Saddle) H m 0.758
5 Erected Empty Weight of Vessel We Kg 260.2
6 Normal Operating Weight Wo Kg 260.5
7 Hydrotest Conditions Weight Wh Kg 518.6
8 Case A : Check as per height to Diameter Ratio
H/D ratio = 1.49
Since H/D ratio is less than 15. Hence Vortex Shadding is Not Applicable
9 Case B: Check as per W/HD2

W/HD2 = 1330.18
Since W/HD^2 ratio is greater than 400. Hence Vortex shadding is Not Applicable
10 Concusion :
Since H/D ratio is less than 15 and W/HD^2 ratio is greater than 400. Hence
Vortex shadding is Not Applicable
 NODE DESCRIPTION FOR VESSEL

Refer PV Elite Model Sketch

Node Description

10-20 Left Dish Head

20-30 Shell-1

30-40 Right Dish Head