CALCULATION OF MAXIMUM PERMISSIBLE HYDROTEST PRESSURE

FOR CYLINDRICAL SHELL (CORRODED HYDROTEST CONDITION)

Input Data

Hydrotest Pressure (At Top) (FROM CODEWARE) Pd

Liquid Density ρ

Static Liquid head Hs

Pressure due to Liquid Static Head Ps

Resultant Hydrotest Pressure (at bottom) Ph

Vessel Inside Diameter D

Vessel outside Diameter Do

Vessel Corrosion allowance C

Hydrotest temperature (min)

Material of Construction

Joint Efficiency of Head E

Yield Strength at Hydrotest Temp Sy

Allowable stress intensity Value 0.95*Sy

Corroded Vessel Inside Diameter Dc

Corroded Vessel Inside Radius Rc

Provided Thickness tp

Calculations:

Induced Maximum General Primary Membrane Stress (Pm)

Pm = P/E (R/t + 0.6) Pm

As per Part 4.1.6.2 (a) (1) , Eqn 4.1.3 [Pm ≤ 0.95 * Sy]

Hence provied shell thickness is safe for Hydrotest in corroded condition

Maximum permissible Hydrotest Pressure (In Corroded Condition)

Ph = S*E*ln[Do / D] (At Bottom) Ph

(At top) Ph
 DROTEST PRESSURE
OTEST CONDITION)

296.43 psi

0.03613 lb/inch3

191.874 in

6.9324 psi

303.3624 psi

168 inch

169.890 inch

0.126 inch

71.6 º F

SA 516 GR 70N

38000 psi

36100 psi

168.252

84.126

0.9448818898 inch

27150.94 psi
27151 ≤ 36100 psi
349.70 psi

356.63 psi
 CALCULATION OF MAXIMUM PERMISSIBLE HYDROTEST PRESSURE
FOR 2:1 ELLIPSOIDAL HEAD (CORRODED HYDROTEST CONDITION)
Input Data
Hydrotest Pressure (At Top) (FROM CODEWARE) Pd
Liquid Density ρ
Static Liquid head Hs
Pressure due to Liquid Static Head Ps
Resultant Hydrotest Pressure (at bottom) P
Head Inside Diameter D
Head Inside Diameter (Corr) Dc
Inside height of the head (Corr) h
Head Ratio (k = Dc/2h) k
Vessel Corrosion allowance C
Min provided thk of head (Corr) t
Min provided uncorroded Thk
Nominal provided thk of head tp
Hydrotest temp (min)
Material of Construction
Joint Efficiency of Head E
Yield Strength at Hydrotest Temp. C3 = Sy
Allowable stress intensity Value 0.95*Sy
Modulus of Elasticity at Des.Temp. ET

Calculations:
Inside Knuckle Radius of Head (Corr) ( where r/Dc = 0.170374) r
r = Dc * [(0.5/k)-0.08]
Inside Crown Radius of Head ( where L/Dc = 0.90003) L
L = Dc * (0.44 k + 0.02)

L/Dc = 0.8987 where 0.7 ≤ (L/Dc) ≤ 1

r/Dc = 0.1704 where (r/Dc) ≥ 0.06
L/t = 184.6486 where 20 ≤ (L/t) ≤ 2000

Calculating Geometrical Constaints:

ßth = arccos ((0.5*Dc-r)/(L-r))
Øth= sqrt(L*t)/r
Since Øth < ßth, Rth = ((0.5*Dc-r)/Cos(ßth-Øth))+r
C1 = 0.692 * (r/Dc) + 0.605
C2 = 1.46 - 2.6*(r/Dc)

Calculating internal pressure expected to produc e elastic bucking of Knuckle

Peth = (C1*ET*t^2)/(C2*Rth*((Rth/2)-r))

Calculating internal pressure resulting in Stress in the Knuckle equal to material Yield Strength
Py= C3*t / {C2*Rth*(Rth / (2*r) - 1)}
Ratio G = (Peth / Py) = (Since G > 1.0)

Calculating internal pressure result ing in Bucklin g failure of Knuckle

Pck = {(0.77508*G - 0.20354*G2 + 0.019274*G3) / (1 + 0.19014*G - 0.089534*G2 + 0.0093965*G3)} * Py

Allowable pressure based on buckling failure of the knuckle

Pak = Pck / 1.5

Allowable pressure based on rupture of the crown

Pac = 2*S*E / (L / t + 0.5)

Hence Maximum Allowable Hydrotest Pressure (At Bottom)

Pa = min (Pak , Pac)

Hence Maximum Allowable Hy drotest Pressure (At Top)

EST PRESSURE
T CONDITION)

296.43 psi
0.0361273 lb/inch3
191.874 in
6.9319 psi
303.3619 psi
168 inch
168.252 inch
42.126 inch
1.997
0.126 inch
0.819 inch
0.945 inch
1.102 inch
71.6 º F
SA 516 GR 70N
1
38000 psi
36100 psi
28,650,000 psi

28.6658 inch

151.2054 inch

Hence, dimensions satisfied

Hence, dimensions satisfied
Hence, dimensions satisfied

1.101129
0.388177
101.98
0.7229
1.0170

5997.5 psi

385.21 psi
 15.57

771.0678 psi

514.0452 psi

389.9571 psi

389.9571 psi

383.0252 psi
 CALCULATION OF MAXIMUM PERMISSIBLE HYDROTEST PRESSURE
FOR CYLINDRICAL SHELL (CORRODED HYDROTEST CONDITION)

Input Data

Hydrotest Pressure (At Top) (FROM CODEWARE) Pd

Liquid Density ρ

Static Liquid head Hs

Pressure due to Liquid Static Head Ps

Resultant Hydrotest Pressure (at bottom) Ph

Vessel Inside Diameter D

Vessel outside Diameter Do

Vessel Corrosion allowance C

Hydrotest temperature (min)

Material of Construction

Joint Efficiency of Head E

Yield Strength at Hydrotest Temp Sy

Allowable stress intensity Value 0.95*Sy

Corroded Vessel Inside Diameter Dc

Corroded Vessel Inside Radius Rc

Provided Thickness tp

Calculations:

Induced Maximum General Primary Membrane Stress (Pm)

Pm = P/E (R/t + 0.6) Pm

As per Part 4.1.6.2 (a) (1) , Eqn 4.1.3 [Pm ≤ 0.95 * Sy]

Hence provied shell thickness is safe for Hydrotest in corroded condition

Maximum permissible Hydrotest Pressure (In Corroded Condition)

Ph = S*E*ln[Do / D] (At Bottom) Ph

(At top) Ph
 OTEST PRESSURE
EST CONDITION)

296.43 psi

0.03613 lb/inch3

191.874 in

6.9324 psi

303.3624 psi

168 inch

170.2048 inch

0.126 inch

71.6 º F

SA 516 GR 70N

38000 psi

36100 psi

168.252

84.126

1.1024 inch

23297.44 psi
23297 ≤ 36100 psi
416.58 psi

423.51 psi
 CALCULATION OF MAXIMUM PERMISSIBLE HYDROTEST PRESSURE
FOR RADIAL NOZZLE ON CYLINDRICAL SHELL
NOZZLE MARK:
Description

Nominal Nozzle Size

Offset from center line

Hydrotest Pressure (Inclusive of Liq. Hd.)

Hydrotest Temp.

Corrosion Allow. (Int)

MATERIAL

Allow. Stress at Hydrotest Temp. (1.43 * Sy)

Inside Diameter of opening (Corr)

Nozzle Inside Radius (Corr)

Increased thickness of Nozzle (Corr)

Nozzle Neck thickness (Corr)

External Reinforcement Pad Thk

Reinforcement Pad Width

Nozzle Projection from Outside of vessel wall

Nozzle Projection from Inside of vessel wall

Height of increased nozzle thk

Height of Taper section from tn to tn2

Height of increased nozzle thk + Taper Height to tn2

Lx3 = Lpr3 + t (4.5.121)

Lx4 = Lpr4 + t (4.5.123)

WELD DETAILS

Fillet size of outside nozzle weld

Throat dimension of outside nozzle weld (=0.7071* L41)

Fillet size of pad to vessel weld

Throat dimension of pad to vessel weld (=0.7071* L42)

Fillet size of inside nozzle weld

Throat dimension of inside nozzle weld (=0.7071* L43)

Nozzle to Shell groove weld depth

Nozzle to pad groove weld depth

SHELL DATA

MATERIAL

Allowable stress

Allow. Stress at Hydrotest Temp. (1.43 * Sy)

Shell Inside Diameter (Corr)

Effective pressure radius of Shell (Corr) Reff = 0.5*Di

(4.5.3)

Nominal Thickness of vessel wall (Corr)

Effective Thickness of vessel Shell (Corr) teff = t + ((A5*frp) / LR) (4.5.25)

frn = min ((Sn / S),1) = (4.5.21)

Allowable stress from Annex 3-A for the pad at the design temperature.

frp = min ((Sp / S),1) = (4.5.22)

As per Part 4.5.2.1 –

a) Nozzle is circular in shape ; hence OK.

b) Di / t = 67.7297 ≤ 400 ; Hence OK

c) Nozzle is raidal to Shell , Ratio of Major / Minor Nozzle Diameter = 1.0 <=1.5 ; hence OK

Calculation for Reinforcement Limits

Reinforcement Limit along vessel wall

LR = min ((sqrt(Reff*t)), (2*Rn)) (4.5.89)

Reinforcement Limit along nozzle wall projecting outside

Thickness of the reinforcing pad

LH1 = min (1.5 * t , te) + Sqrt (Rn * tn) (4.5.11)

LH2 = Lpr1 (4.5.12)

LH3 = 8 * (t + te) (4.5.13)

LH = min (LH1 , LH2 , LH3) + t (4.5.14)

Reinforcement Limit along nozzle wall projecting inside

LI1 = Sqrt (Rn * tn) (4.5.16)

LI2 = Lpr2 (4.5.17)

LI3 = 8 * (t + te) (4.5.18)

LI = min (LI1 , LI2 , LI3) (4.5.19)

Total available area near the nozzle opening

Area contributed by vessel wall

A1 = (t*LR)*max(((λ/5)^0.85),1.0) (4.5.23)

Where λ = min (((dn+tn)/sqrt((Di+teff)*teff)),12) (4.5.24)

Area contributed by nozzle outside the vessel wall

A2 = tn*LH (Since LH < Lx3) (4.5.27)

Area contributed by nozzle Inside the vessel wall

A3 = tn * LI (4.5.38)

Areas contributed by nozzle welds =0.5*L41^2 (4.5.39)

=0.5*L42^2 (4.5.40)

=0.5*L43^2 (4.5.41)

Area conributed by external reinforcement pad

Total area contributed

AT = A1 + frn*(A2 + A3) + A41 + A42 + A43 + frp*A5 (4.5.20)

Determining the applicable forces :

Nozzle radius for Force calculation

Rxn = tn / ln ((Rn+tn) / Rn) (4.5.51)

Shell radius for Force calculation

Rxs = teff / ln ((Reff+teff) / Reff) (4.5.52)

Force from Int Pr in the nozzle outside of the vessel D

fN = P*Rxn * LH (4.5.46)

Force from internal pressure in the Shell

fS = P*Rxs*(LR+tn) (4.5.48)

Discontinuity force from internal pressure

fY = P*Rxs*Rnc (4.5.50)

Calculation for Induced Stresses : D

Average local Primary Membrane Stress

savg = (fN + fS + fY) / AT (4.5.53)

General Primary Membrane Stress

scirc = (P * Rxs) / teff (4.5.54)

Maximum local primary membrane stress

PL = max((2savg-scirc),scirc) (4.5.55)

Allowable Stress

Sallow = 1.5 * S * E (4.5.57)

Since Maximum Induced Stresses are less than Allowable Stress , nozzle construction is SAFE

Calculating Maximum Permissible Hydrotest Pressure of Nozzle

Pmax1 = Sallow / ((2*Ap/AT)-(Rxs/teff)) (4.5.59)

Where

Ap = ((fN+fS+fY)/P) (4.5.62)

Pmax2 = S * (t/Rxs) (4.5.60

Pmax = min (Pmax1 , Pmax2) (4.5.61)

Since Maximum permissible hydrotest Pressure is more than actual hydrotest Pressure , nozzle
construction is SAFE
HYDROTEST PRESSURE
RICAL SHELL
N1,N2,N3
Symbol Unit Details

3" (80 NB)

DR mm 0
P N/mm2 5.951
T Deg.C 20
Ci mm 3

SA 105M
Sn N/mm2 357.5
dn mm 73
Rn=Rnc mm 36.5
tn mm 22
tn2 mm 7.95
te mm 0
W mm 0
Lpr1 mm 274
Lpr2 mm 0
Lpr3 mm 157

mm 14
Lpr4 mm 171
Lx3 mm 194
Lx4 mm 208

L41 mm 16
L41T mm 11.3136
L42 mm 0
L42T mm 0
L43 mm 0
L43T mm 0
tw1 mm 37
tw2 mm 0

SA 516M Gr 485 (N)

Sy N/mm2 260
S N/mm2 371.8
Di mm 2506
Reff mm 1253

t mm 37
teff mm 37

frn = 0.9615
Sp = 371.8
frp = 1.00

67.7297297

LR mm 73
 te mm 0
LH1 mm 28.3373
LH2 mm 274
LH3 mm 296
LH mm 65.34
Lpr3 + t mm 194

LI1 mm 28.3373
LI2 mm 0
LI3 mm 296
LI mm 0.00

A1 mm2 2701

λ 0.310
A2 mm2 1437.48

A3 mm2 0

A41 mm2 128

A42 mm3 0
A43 mm4 0
A5 mm2 0
AT mm2 4211.13
 Rxn mm 46.64

Rxs mm 1271.41

fN N 18134.03

fS N 718785.44

fY N 276164.93

savg N/mm2 240.57

scirc N/mm2 204.49

PL N/mm2 276.65

Sallow N/mm2 371.8

Pmax1 N/mm2 8

Ap mm2 170237.67
Pmax2 N/mm2 10.82
Pmax N/mm2 8
CALCULATION OF MAXIMUM PERMISSIBLE HYDROTEST PRESSURE FOR CYLINDRICAL SHELL (CORRODED HYDROTEST CONDIT

Input Data
Hydrotest Pressure (At Top) (FROM CODEWARE) Pd
Liquid Density ρ
Static Liquid head Hs
Pressure due to Liquid Static Head Ps
Resultant Hydrotest Pressure (at bottom) Ph
Vessel Inside Diameter D
Vessel Corrosion allowance C
Hydrotest temperature (min)
Material of Construction
Joint Efficiency of Head E
Yield Strength at Hydrotest Temp Sy
Allowable stress intensity Value 0.95*Sy
Corroded Vessel Inside Diameter Dc
Corroded Vessel Inside Radius Rc
Provided Thickness tp

Calculations:
Induced Maximum General Primary Membrane Stress (Pm)
Pm = P/E (R/t + 0.6) Pm
As per Part 4.1.6.2 (a) (1) , Eqn 4.1.3 [Pm ≤ 0.95 * Sy]
Hence provied shell thickness is safe for Hydrotest in corroded condition

Maximum permissible Hydrotest Pressure (In Corroded Condition)

Ph = S*E*ln[Do / D] pm
Ph = 0.95 * Sy *E*ln[Do / D] Ph

Pm = 1/ [(E/Ph) * ln((1+(2*(tp-c))/Dc))))]
Ph = 0.95 * Sy * E * ln((1+(2*(tp-c))/Dc))))] (At Bootom)
(At Top)
CAL SHELL (CORRODED HYDROTEST CONDITION)

5.916 psi
0.0361273 lb/inch3
191.874 in
0.0350 psi
5.9510 psi
2500 inch
3 inch
22 º F
SA 516 GR 70N
1
260 psi
247 psi
2506
1253
40 inch

190 psi
190 ≤ 247 psi

188.9286295443
7.188081

204.4908790746 psi
7.1880809875 psi
NOZZLE DATA (Integrally Reinforced , Set in Nozzle) -Fig 4.5.13
Determining the applicable forces :
Nozzle radius for Force calculation Rxn
Rxn = tn / ln ((Rn+tn) / Rn) (4.5.51)
Shell radius for Force calculation Rxs
Rxs = teff / ln ((Reff+teff) / Reff) (4.5.52)
Force from Int Pr in the nozzle outside of the vessel D fN
fN = P*Rxn * LH (4.5.46)
Force from internal pressure in the Shell fS
fS = P*Rxs*(LR+tn) (4.5.48)
Discontinuity force from internal pressure fY
fY = P*Rxs*Rnc (4.5.50)
Calculation for Induced Stresses : D
Average local Primary Membrane Stress savg
savg = (fN + fS + fY) / AT (4.5.53)
General Primary Membrane Stress scirc
scirc = (P * Rxs) / teff (4.5.54)
Maximum local primary membrane stress PL
PL = max((2savg-scirc),scirc) (4.5.55)
Allowable Stress Sallow
Sallow = 1.5 * S * E (4.5.57)
Since Maximum Induced Stresses are less than Allowable Stress , nozzle

Calculating Maximum Permissible Hydrotest Pressure of Nozzle

Pmax1 = Sallow / ((2*Ap/AT)-(Rxs/teff)) (4.5.59) Pmax1
Where
Ap = ((fN+fS+fY)/P) (4.5.62) Ap
Pmax2 = S * (t/Rxs) (4.5.60 Pmax2
Pmax = min (Pmax1 , Pmax2) (4.5.61) Pmax
Since Maximum permissible hydrotest Pressure is more than actual hydro
mm 46.64

mm 1271.41

N 18134.03

N 718785.44

N 276164.93

N/mm2 240.57

N/mm2 204.49

N/mm2 276.65

N/mm2 371.8

N/mm2 8

mm2 170237.67
N/mm2 10.82
N/mm2 8