SIZING ENGINEERING DESIGN
ENGINEERING DESIGN & FABRICATION
FLOW LOOP DEMO UNIT
Doc No : xx-xx-xx-xx
EQUIPMENT SIZING : SEPARATOR Rev No. : xx
Job No : xx-xx-xx-xx
Table of Contents
Cover Sheet .................................................................................................................................................................................
Title Page ...................................................................................................................................................................................
Input Echo: .................................................................................................................................................................................
Internal Pressure Calculations: .................................................................................................................................
External Pressure Calculations: .................................................................................................................................
Element and Detail Weights: ...........................................................................................................................................
Center of Gravity Calculation:....................................................................................................................................
Vessel Design Summary:.......................................................................................................................................................
SIZING ENGINEERING DESIGN
ENGINEERING DESIGN & FABRICATION
FLOW LOOP DEMO UNIT
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Job No : xx-xx-xx-xx
DESIGN CALCULATION
In Accordance with ASME Section VIII Division 1,Chemical Enggineering Process
ASME Code Version : 2017
Job File : RTI
Date of Analysis : Jun 14,2024
Diameter
Formula :
𝜋
𝑣 𝐿 = %𝑙𝑖𝑞𝑢𝑖𝑑 × × 𝐷 2 × 𝐿 = 𝑞𝑤 × 𝑡𝑟𝑤 + 𝑞𝑜 × 𝑡𝑟𝑜
4
𝑣 𝐿 = 𝑞𝑤 × 𝑡𝑟𝑤 + 𝑞𝑜 × 𝑡𝑟𝑜
𝑣 𝐿 = 5,2 × 10 + 0,6 × 10
𝑣 𝐿 = 58 𝑓𝑡 3
𝐷 ⬚ = 2,45 𝑓𝑡 ⬚ ≫ 29,4 𝑖𝑛 ≫ 39 𝑖𝑛
Lenght
Formula :
𝐿⬚ = 4 × 𝐷
𝐿⬚ = 5 × 39 𝑖𝑛 ft
𝐿⬚ = 156 𝑖𝑛 ≫ 4000 𝑚𝑚
notes :Asumsi nilai L/D awal untuk perhitungan diameter, nilai L/D diambil diantara
nilai optimum yaitu 3<L/D<5 Dipilih asumsi L/D = 4
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Input Data
Element Type Shell
Description
Inside Diameter 1000 mm
Element Thickness 65 mm
Internal Corrosion Allowance 3.175 mm
Nominal Thickness 0 mm
External Corrosion Allowance 0 mm
Design Internal Pressure 9 MPa
Design Temperature Internal Pressure 200 °C
Design External Pressure 0.103 MPa
Design Temperature External Pressure 93 °C
Effective Diameter Multiplier 1.2
Material Name SA-516 70
Allowable Stress, Ambient 138 MPa
Allowable Stress, Operating 138 MPa
Allowable Stress, Hydrotest 179.4 MPa
Material Density 0.00775 kg/cm³
P Number Thickness 31.75 mm
Yield Stress, Operating 225 MPa
UCS-66 Chart Curve Designation B
External Pressure Chart Name CS-2
UNS Number K02700
Product Form Plate
Efficiency, Longitudinal Seam 1.0
Efficiency, Circumferential Seam 1.0
Elliptical Head Factor 2.0
Weld is pre-Heated No
--------------------------------------------------------------------
Element Type Head (Elliptical)
Description
Distance "FROM" to "TO" 4000 mm
Inside Diameter 1000 mm
Element Thickness 65 mm
Internal Corrosion Allowance 3.175 mm
Nominal Thickness 0 mm
External Corrosion Allowance 0 mm
Design Internal Pressure 9 MPa
Design Temperature Internal Pressure 200 °C
Design External Pressure 0.103 MPa
Design Temperature External Pressure 30 °C
Effective Diameter Multiplier 1.2
Material Name SA-516 70
Efficiency, Longitudinal Seam 1.0
Efficiency, Circumferential Seam 1.0
Elliptical Head Factor 2.0
Weld is pre-Heated No
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Element Thickness, Pressure, Diameter and Allowable Stress :
| | Int. Press | Nominal | Total Corr | Element | Allowable |
From | To | + Liq. Hd | Thickness | Allowance | Diameter | Stress(SE)|
| | MPa | mm | mm | mm | MPa |
----------------------------------------------------------------------------------
10 | 20| 9 | ... | 3.175 | 1000 | 138 |
20 | 30| 9 | ... | 3.175 | 1000 | 138 |
----------------------------------------------------------------------------------
Element Required Thickness and MAWP :
| | Design | M.A.W.P. | M.A.P. | Minimum | Required |
From | To | Pressure | Corroded | New & Cold | Thickness | Thickness |
| | MPa | MPa | MPa | mm | mm |
----------------------------------------------------------------------------------
10 | 20| 9 | 15.7915 | 17.7095 | 65 | 35.9315 |
20 | 30| 9 | 15.7915 | 17.7095 | 65 | 35.9315 |
----------------------------------------------------------------------------------
Minimum 15.792 17.709
MAWP: 15.792 MPa, limited by: Elliptical Head , Straight Flange Governing
Internal Pressure Calculation Results :
ASME Code, Section VIII Division 1, 2017
Elliptical Head From SA-516 70 , UCS-66 Crv. B at 200 °C
Longitudinal Joint: Full Radiography per UW-11(a) Type 1
Material UNS Number: K02700
Required Thickness due to Internal Pressure [tr]:
= (P*D*Kcor)/(2*S*E-0.2*P) Appendix 1-4(c)
= (9*1006*0.992)/(2*138*1-0.2*9)
= 32.7565 + 3.1750 = 35.9315 mm
Max. Allowable Working Pressure at given Thickness, corroded [MAWP]:
= (2*S*E*t)/(Kcor*D+0.2*t) per Appendix 1-4 (c)
= (2*138*1*61.82)/(0.992*1006+0.2*61.82)
= 16.889 MPa
Maximum Allowable Pressure, New and Cold [MAPNC]:
= (2*S*E*t)/(K*D+0.2*t) per Appendix 1-4 (c)
= (2*138*1*65)/(1*1000+0.2*65)
= 17.709 MPa
Actual stress at given pressure and thickness, corroded [Sact]:
= (P*(Kcor*D+0.2*t))/(2*E*t)
= (9*(0.992*1006+0.2*61.82))/(2*1*61.82)
= 73.538 MPa
Straight Flange Required Thickness:
= (P*R)/(S*E-0.6*P) + c per UG-27 (c)(1)
= (9*503.2)/(138*1-0.6*9)+3.175
= 37.328 mm
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Straight Flange Maximum Allowable Working Pressure:
= (S*E*t)/(R+0.6*t) per UG-27 (c)(1)
= (138 * 1 * 61.82 )/(503.2 + 0.6 * 61.82 )
= 15.792 MPa
Factor K, corroded condition [Kcor]:
= ( 2 + ( Inside Diameter/( 2 * Inside Head Depth ))2)/6
= ( 2 + ( 1006/( 2 * 253.2 ))2)/6
= 0.991666
Percent Elong. per UCS-79, VIII-1-01-57 (75*tnom/Rf)*(1-Rf/Ro) 24.074 %
Note: Please Check Requirements of UCS-79 as Elongation is > 5%.
MDMT Calculations in the Knuckle Portion:
Govrn. thk, tg = 65, tr = 57.76, c = 3.175 mm, E* = 1
Thickness Ratio = tr * (E*)/(tg - c) = 0.934, Temp. Reduction = 4 °C
Min Metal Temp. w/o impact per UCS-66, Curve B 23 °C
Min Metal Temp. at Required thickness (UCS 66.1) 19 °C
MDMT Calculations in the Head Straight Flange:
Govrn. thk, tg = 65, tr = 61.82, c = 3.175 mm, E* = 1
Thickness Ratio = tr * (E*)/(tg - c) = 1, Temp. Reduction = 0 °C
Min Metal Temp. w/o impact per UCS-66, Curve B 23 °C
Note:
Post Weld Heat Treatment is required for this Element/Joint and it was
specified as being heat treated.
Elliptical Head From SA-516 70 , UCS-66 Crv. B at 200 °C
Longitudinal Joint: Full Radiography per UW-11(a) Type 1
Material UNS Number: K02700
Required Thickness due to Internal Pressure [tr]:
= (P*D*Kcor)/(2*S*E-0.2*P) Appendix 1-4(c)
= (9*1006*0.992)/(2*138*1-0.2*9)
= 32.7565 + 3.1750 = 35.9315 mm
Max. Allowable Working Pressure at given Thickness, corroded [MAWP]:
= (2*S*E*t)/(Kcor*D+0.2*t) per Appendix 1-4 (c)
= (2*138*1*61.82)/(0.992*1006+0.2*61.82)
= 16.889 MPa
Maximum Allowable Pressure, New and Cold [MAPNC]:
= (2*S*E*t)/(K*D+0.2*t) per Appendix 1-4 (c)
= (2*138*1*65)/(1*1000+0.2*65)
= 17.709 MPa
Actual stress at given pressure and thickness, corroded [Sact]:
= (P*(Kcor*D+0.2*t))/(2*E*t)
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= (9*(0.992*1006+0.2*61.82))/(2*1*61.82)
= 73.538 MPa
Straight Flange Required Thickness:
= (P*R)/(S*E-0.6*P) + c per UG-27 (c)(1)
= (9*503.2)/(138*1-0.6*9)+3.175
= 37.328 mm
Straight Flange Maximum Allowable Working Pressure:
= (S*E*t)/(R+0.6*t) per UG-27 (c)(1)
= (138 * 1 * 61.82 )/(503.2 + 0.6 * 61.82 )
= 15.792 MPa
= ( 2 + ( Inside Diameter/( 2 * Inside Head Depth ))2)/6
= ( 2 + ( 1006/( 2 * 253.2 ))2)/6
= 0.991666
Percent Elong. per UCS-79, VIII-1-01-57 (75*tnom/Rf)*(1-Rf/Ro) 24.074 %
Note: Please Check Requirements of UCS-79 as Elongation is > 5%.
MDMT Calculations in the Knuckle Portion:
Govrn. thk, tg = 65, tr = 57.76, c = 3.175 mm, E* = 1
Thickness Ratio = tr * (E*)/(tg - c) = 0.934, Temp. Reduction = 4 °C
Min Metal Temp. w/o impact per UCS-66, Curve B 23 °C
Min Metal Temp. at Required thickness (UCS 66.1) 19 °C
MDMT Calculations in the Head Straight Flange:
Govrn. thk, tg = 65, tr = 61.82, c = 3.175 mm, E* = 1
Thickness Ratio = tr * (E*)/(tg - c) = 1, Temp. Reduction = 0 °C
Min Metal Temp. w/o impact per UCS-66, Curve B 23 °C
Note:
Post Weld Heat Treatment is required for this Element/Joint and it was
specified as being heat treated.
Hydrostatic Test Pressure Results:
Pressure per UG99b = 1.30 * M.A.W.P. * Sa/S 20.529 MPa
Pressure per UG99b[36] = 1.30 * Design Pres * Sa/S 0.897 MPa
Pressure per UG99c = 1.30 * M.A.P. - Head(Hyd) 23.012 MPa
Pressure per UG100 = 1.10 * M.A.W.P. * Sa/S 17.371 MPa
Pressure per PED = max(1.43*DP, 1.25*DP*ratio) 0.987 MPa
Pressure per App 27-4 = M.A.W.P. 15.792 MPa
UG-99(b), Test Pressure Calculation:
= Test Factor * MAWP * Stress Ratio
= 1.3 * 15.79 * 1
= 20.529 MPa
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Horizontal Test performed per: UG-99b
Stresses on Elements due to Test Pressure (MPa):
From To | Stress | Allowable | Ratio | Pressure |
------------------------------------------------------------------------
10 20 | 160.0 | 179.4 | 0.892 | 20.54 |
20 30 | 160.0 | 179.4 | 0.892 | 20.54 |
------------------------------------------------------------------------
Stress ratios for Pressurized Vessel Elements (MPa):
Description | Ambient | Operating | Ratio |
------------------------------------------------------------------------
| 138.00 | 138.00 | 1.000 |
| 138.00 | 138.00 | 1.000 |
------------------------------------------------------------------------
Minimum 1.000
Elements Suitable for Internal Pressure.
External Pressure Calculation Results :
External Pressure Calculations:
| | Section | Outside | Corroded | Factor | Factor |
From| To | Length | Diameter | Thickness | A | B |
| | mm | mm | mm | | MPa |
-----------------------------------------------------------------------------
10| 20| No Calc | 1130 | 61.825 | 0.0075989 | 122.731 |
20| 30| No Calc | 1130 | 61.825 | 0.0075989 | 122.731 |
-----------------------------------------------------------------------------
External Pressure Calculations:
| | External | External | External | External |
From| To | Actual T. | Required T.| Design Pressure | M.A.W.P. |
| | mm | mm | MPa | MPa |
-----------------------------------------------------------------------
10| 20| 65 | 6.09477 | 0.103 | 7.46101 |
20| 30| 65 | 6.09477 | 0.103 | 7.46101 |
-----------------------------------------------------------------------
Minimum 7.461
External Pressure Calculations:
| | Actual Length | Allowable Length | Ring Inertia | Ring Inertia |
From| To | Bet. Stiffeners | Bet. Stiffeners | Required | Available |
| | mm | mm | mm**4 | mm**4 |
--------------------------------------------------------------------------------
10| 20| No Calc | No Calc | No Calc | No Calc |
20| 30| No Calc | No Calc | No Calc | No Calc |
--------------------------------------------------------------------------------
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FLOW LOOP DEMO UNIT
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Elements Suitable for External Pressure.
ASME Code, Section VIII Division 1, 2017
Elliptical Head From 10 to 20 Ext. Chart: CS-2 at 93 °C
Elastic Modulus from Chart: CS-2 at 93 °C : 0.200E+06 MPa
Results for Maximum Allowable External Pressure (MAEP):
Tca OD D/t Factor A B
61.825 1130.00 18.28 0.0075989 122.73
EMAP = B/(K0*D/t) = 122.7/(0.9 *18.28 ) = 7.461 MPa
Results for Required Thickness (Tca):
Tca OD D/t Factor A B
2.920 1130.00 387.02 0.0003589 35.88
EMAP = B/(K0*D/t) = 35.88/(0.9 *387 ) = 0.103 MPa
Check the requirements of UG-33(a)(1) using P = 1.67 * External Design
pressure for this head.
Material UNS Number: K02700
Required Thickness due to Internal Pressure [tr]:
= (P*D*Kcor)/(2*S*E-0.2*P) Appendix 1-4(c)
= (0.172*1006*0.992)/(2*138*1-0.2*0.172)
= 0.6220 + 3.1750 = 3.7970 mm
Max. Allowable Working Pressure at given Thickness, corroded [MAWP]:
= ((2*S*E*t)/(Kcor*D+0.2*t))/1.67 per Appendix 1-4 (c)
= ((2*138*1*61.82)/(0.992*1006+0.2*61.82))/1.67
= 10.113 MPa
Maximum Allowable External Pressure [MAEP]:
= min( MAEP, MAWP )
= min( 7.461, 10.11 )
= 7.461 MPa
Thickness requirements per UG-33(a)(1) do not govern the required
thickness of this head.
Elliptical Head From 20 to 30 Ext. Chart: CS-2 at 30 °C
Elastic Modulus from Chart: CS-2 at 30 °C : 0.200E+06 MPa
Results for Maximum Allowable External Pressure (MAEP):
Tca OD D/t Factor A B
61.825 1130.00 18.28 0.0075989 122.73
EMAP = B/(K0*D/t) = 122.7/(0.9 *18.28 ) = 7.461 MPa
Results for Required Thickness (Tca):
Tca OD D/t Factor A B
2.920 1130.00 387.02 0.0003589 35.88
EMAP = B/(K0*D/t) = 35.88/(0.9 *387 ) = 0.103 MPa
Check the requirements of UG-33(a)(1) using P = 1.67 * External Design
pressure for this head.
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Material UNS Number: K02700
Required Thickness due to Internal Pressure [tr]:
= (P*D*Kcor)/(2*S*E-0.2*P) Appendix 1-4(c)
= (0.172*1006*0.992)/(2*138*1-0.2*0.172)
= 0.6220 + 3.1750 = 3.7970 mm
Max. Allowable Working Pressure at given Thickness, corroded [MAWP]:
= ((2*S*E*t)/(Kcor*D+0.2*t))/1.67 per Appendix 1-4 (c)
= ((2*138*1*61.82)/(0.992*1006+0.2*61.82))/1.67
= 10.113 MPa
Maximum Allowable External Pressure [MAEP]:
= min( MAEP, MAWP )
= min( 7.461, 10.11 )
= 7.461 MPa
Thickness requirements per UG-33(a)(1) do not govern the required
thickness of this head.
Element and Detail Weights:
| | Element | Element | Corroded | Corroded | Extra due |
From| To | Metal Wgt. | ID Volume |Metal Wgt. | ID Volume | Misc % |
| | kgm | ltr | kgm | ltr | kgm |
---------------------------------------------------------------------------
10| 20| 812.324 | 190.781 | 772.646 | 194.054 | ... |
20| 30| 7426.1 | 3273.08 | 7063.37 | 3315.62 | ... |
---------------------------------------------------------------------------
Total | 8238 | 3463.86 | 7836 | 3509.67 | 0 |
Weight Summation Results: (kgm)
| Fabricated | Shop Test | Shipping | Erected | Empty | Operating |
---------------------------------------------------------------------------------------------
Main Elements | 8238.4 | 8238.4 | 8238.4 | 8238.4 | 8238.4 | 8238.4 |
Test Liquid | ... | 3461.7 | ... | ... | ... | ... |
---------------------------------------------------------------------------------------------
Totals | 8238.4 | 11700.2 | 8238.4 | 8238.4 | 8238.4 | 8238.4 |
Weight Summary:
Fabricated Wt. - Bare Weight without Removable Internals 8238.4 kgm
Shop Test Wt. - Fabricated Weight + Water ( Full ) 11700.2 kgm
Shipping Wt. - Fab. Weight + removable Intls.+ Shipping App. 8238.4 kgm
Erected Wt. - Fab. Wt + or - loose items (trays,platforms etc.) 8238.4 kgm
Ope. Wt. no Liq - Fab. Weight + Internals. + Details + Weights 8238.4 kgm
Operating Wt. - Empty Weight + Operating Liq. Uncorroded 8238.4 kgm
Oper. Wt. + CA - Corr Wt. + Operating Liquid 7836.0 kgm
Field Test Wt. - Empty Weight + Water (Full) 11700.2 kgm
Note:
The Corroded Weight and thickness are used in the Horizontal
Vessel Analysis (Ope Case) and Earthquake Load Calculations.
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Outside Surface Areas of Elements:
| | Surface |
From| To | Area |
| | mm² |
----------------------------
10| 20| 1654650 |
20| 30| 15584140 |
----------------------------
Total 17238790.000 mm²
Minimum Design Metal Temperature Results Summary :
Curve
Basic Reduced UG-20(f) Thickness Gov E* PWHT
Description MDMT MDMT MDMT ratio Thk reqd
Notes °C °C °C mm
-----------------------------------------------------------------------------------
[10] B 23 19 0.934 65.000 1.00 Yes
[7] B 23 23 1.000 65.000 1.00 Yes
[10] B 23 19 0.934 65.000 1.00 Yes
[7] B 23 23 1.000 65.000 1.00 Yes
-----------------------------------------------------------------------------------
Warmest MDMT: 23 23
Required Minimum Design Metal Temperature -28.9 °C
Warmest Computed Minimum Design Metal Temperature 23.0 °C
Notes:
[ ! ] - This was an impact tested material.
[ 1] - Governing Nozzle Weld.
[ 4] - ANSI Flange MDMT Calcs; Thickness ratio per UCS-66(b)(1)(-c).
[ 5] - ANSI Flange MDMT Calcs; Thickness ratio per UCS-66(b)(1)(-b).
[ 6] - MDMT Calculations at the Shell/Head Joint.
[ 7] - MDMT Calculations for the Straight Flange.
[ 8] - Cylinder/Cone/Flange Junction MDMT.
[ 9] - Calculations in the Spherical Portion of the Head.
[10] - Calculations in the Knuckle Portion of the Head.
[11] - Calculated (Body Flange) Flange MDMT.
[12] - Calculated Flat Head MDMT per UCS-66.3
[13] - Tubesheet MDMT, shell side, if applicable
[14] - Tubesheet MDMT, tube side, if applicable
[15] - Nozzle Material
[16] - Shell or Head Material
[17] - Impact Testing required
[18] - Impact Testing not required, see UCS-66(b)(3)
[20] - Cylinder/Cone Junction MDMT based on Longitudinal Stress considerations
[21] - Bolting Material
UG-84(b)(2) was not considered.
UCS-66(g) was not considered.
UCS-66(i) was not considered.
Notes:
Impact test temps were not entered in and not considered in the analysis.
UCS-66(i) applies to impact tested materials not by specification and
UCS-66(g) applies to materials impact tested per UG-84.1 General Note (c).
The Basic MDMT includes the (30F) PWHT credit if applicable.
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ASME Code, Section VIII Division 1, 2017
Diameter Spec : mm ID
Vessel Design Length, Tangent to Tangent 4076.20 mm
Specified Datum Line Distance 0.00 mm
Internal Design Temperature 93 °C
Internal Design Pressure 0.690 MPa
External Design Temperature 93 °C
External Design Pressure 0.103 MPa
Maximum Allowable Working Pressure 15.792 MPa
External Max. Allowable Working Pressure 7.461 MPa
Hydrostatic Test Pressure 20.529 MPa
Required Minimum Design Metal Temperature -28.9 °C
Warmest Computed Minimum Design Metal Temperature 23.0 °C
Wind Design Code ASCE-93
Earthquake Design Code UBC-94
Materials of Construction:
Component | | | | |Normal | Impact |
Type | Material | Class | Thickness | UNS # | ized | Tested |
----------------------------------------------------------------------------------------------
Head | SA-516 70 | ... | ... | K02700 | No | No |
Normalized is determined based on the UCS-66 material curve selection and Figure UCS-66.
Impact Tested is based on material selection and material data properties.
Element Pressures and MAWP (MPa & mm):
| Design | | | | Str. | In |
Element Description | Pressure | Ext. | Element | Corrosion | Flg. | Creep |
or Type | + Stat. head | Press. | M.A.W.P | Allowance | Gov. | Range |
--------------------------------------------------------------------------------------------
Ellipse | 9.000 | 0.10 | 15.792 | 3.1750 | Yes | No |
Ellipse | 9.000 | 0.10 | 15.792 | 3.1750 | Yes | No |
Element Types and Properties:
Element |"To" Elev | Element | Nominal | Finished | Reqd Thk | Reqd Thk | Long | Circ |
| | Length |Thickness |Thickness | Internal | External | Eff | Eff |
Type | mm | mm | mm | mm | mm | mm | | |
------------------------------------------------------------------------------------------------
Ellipse | 76.2 | 76.2 | ... | 65.0 | 35.9 | 6.1 | 1.00 | 1.00 |
Ellipse | 4076.2 | 4000.0 | ... | 65.0 | 35.9 | 6.1 | 1.00 | 1.00 |
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Weights:
Fabricated - Bare W/O Removable Internals 8238.4 kgm
Shop Test - Fabricated + Water ( Full ) 11700.2 kgm
Shipping - Fab. + Rem. Intls.+ Shipping App. 8238.4 kgm
Erected - Fab. + Rem. Intls.+ Insul. (etc) 8238.4 kgm
Empty - Fab. + Intls. + Details + Wghts. 8238.4 kgm
Operating - Empty + Operating Liquid (No CA) 8238.4 kgm
Field Test - Empty Weight + Water (Full) 11700.2 kgm
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