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Heritage Energy Operational Services Limited 1

Kokori Surge Vessel 2 Replacement


V-100
PV Elite 2018 SP2 Licensee: OMITI ENGINEERING PVT LTD
FileName : SURGE VESSEL-2 Horizontal Hydrotest_Rounded up i
Input Echo: Step: 1 11:53am Mar 10,2019

ANNEXURE-A
Calculations for SHOP Hydrostatic Test in
Horizontal Condition
PV Elite Vessel Analysis Program: Input Data

Heritage Energy Operational Services Limited


Kokori Surge Vessel 2 Replacement
V-100

Design Internal Pressure (for Hydrotest) 43.512 psig


Design Internal Temperature 50.0 °C
Type of Hydrotest User Entered Pressure
Hydrotest Position Horizontal
Projection of Nozzle from Vessel Top 200 mm.
Projection of Nozzle from Vessel Bottom 1000 mm.
Minimum Design Metal Temperature 0.0 °C
Type of Construction Welded
Special Service Air/Water/Steam
Degree of Radiography RT-1
Use Higher Longitudinal Stresses (Flag) N
Select t for Internal Pressure (Flag) N
Select t for External Pressure (Flag) N
Select t for Axial Stress (Flag) N
Select Location for Stiff. Rings (Flag) N
Consider Vortex Shedding N
Perform a Corroded Hydrotest N
Is this a Heat Exchanger No
User Defined Hydro. Press. (Used if > 0) 70 psig
User defined MAWP 43.512 psig
User defined MAPnc 0 psig

Load Case 1 NP+EW+WI+FW+BW


Load Case 2 NP+EW+EE+FS+BS
Load Case 3 NP+OW+WI+FW+BW
Load Case 4 NP+OW+EQ+FS+BS
Load Case 5 NP+HW+HI
Load Case 6 NP+HW+HE
Load Case 7 IP+OW+WI+FW+BW
Load Case 8 IP+OW+EQ+FS+BS
Load Case 9 EP+OW+WI+FW+BW
Load Case 10 EP+OW+EQ+FS+BS
Load Case 11 HP+HW+HI
Load Case 12 HP+HW+HE
Load Case 13 IP+WE+EW
Load Case 14 IP+WF+CW
Load Case 15 IP+VO+OW
Load Case 16 IP+VE+EW
Load Case 17 NP+VO+OW
Load Case 18 FS+BS+IP+OW
Load Case 19 FS+BS+EP+OW

Wind Design Code ASCE-7 95


Wind Load Reduction Scale Factor 1.000
Basic Wind Speed [V] 162 Km/hr
Surface Roughness Category C: Open Terrain
Importance Factor 1.5
Heritage Energy Operational Services Limited 2
Kokori Surge Vessel 2 Replacement
V-100
PV Elite 2018 SP2 Licensee: OMITI ENGINEERING PVT LTD
FileName : SURGE VESSEL-2 Horizontal Hydrotest_Rounded up i
Input Echo: Step: 1 11:53am Mar 10,2019

Type of Surface Moderately Smooth


Base Elevation 0 mm.
Percent Wind for Hydrotest 33.0
Using User defined Wind Press. Vs Elev. N
Height of Hill or Escarpment H or Hh 0 mm.
Distance Upwind of Crest Lh 0 mm.
Distance from Crest to the Vessel x 0 mm.
Type of Terrain ( Hill, Escarpment ) Flat
Damping Factor (Beta) for Wind (Ope) 0.0100
Damping Factor (Beta) for Wind (Empty) 0.0000
Damping Factor (Beta) for Wind (Filled) 0.0000

Seismic Design Code No Seismic

Design Pressure + Static Head Y


Consider MAP New and Cold in Noz. Design N
Consider External Loads for Nozzle Des. N
Use ASME VIII-1 Appendix 1-9 N

Material Database Year Current w/Addenda or Code Year

Configuration Directives:

Do not use Nozzle MDMT Interpretation VIII-1 01-37 No


Use Table G instead of exact equation for "A" Yes
Shell Head Joints are Tapered Yes
Compute "K" in corroded condition Yes
Use Code Case 2286 No
Use the MAWP to compute the MDMT Yes
For thickness ratios <= 0.35, MDMT will be -155F (-104C) Yes
For PWHT & P1 Materials the MDMT can be < -55F (-48C) No

Using Metric Material Databases, ASME II D Yes


Calculate B31.3 type stress for Nozzles with Loads Yes
Reduce the MDMT due to lower membrane stress Yes

Complete Listing of Vessel Elements and Details:

Element From Node 20


Element To Node 30
Element Type Elliptical
Description BOTTOM HEAD
Distance "FROM" to "TO" 50 mm.
Inside Diameter 3000 mm.
Element Thickness 12 mm.
Internal Corrosion Allowance 3 mm.
Nominal Thickness 14 mm.
External Corrosion Allowance 0 mm.
Design Internal Pressure 43.512 psig
Design Temperature Internal Pressure 50 °C
Design External Pressure 14.999 psig
Design Temperature External Pressure 50 °C
Effective Diameter Multiplier 1.2
Material Name SA-516 70
Allowable Stress, Ambient 138 N/mm²
Allowable Stress, Operating 138 N/mm²
Allowable Stress, Hydrotest 234 N/mm²
Material Density 0.00775 kg./cm^3
P Number Thickness 31.75 mm.
Yield Stress, Operating 255.6 N/mm²
UCS-66 Chart Curve Designation B
External Pressure Chart Name CS-2
Heritage Energy Operational Services Limited 3
Kokori Surge Vessel 2 Replacement
V-100
PV Elite 2018 SP2 Licensee: OMITI ENGINEERING PVT LTD
FileName : SURGE VESSEL-2 Horizontal Hydrotest_Rounded up i
Input Echo: Step: 1 11:53am Mar 10,2019

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 From Node 20


Detail Type Nozzle
Detail ID N6
Dist. from "FROM" Node / Offset dist 0 mm.
Nozzle Diameter 100 mm
Nozzle Schedule 80
Nozzle Class 150
Layout Angle 0.0
Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 60.663 Kgf
Grade of Attached Flange GR 1.1
Nozzle Matl SA-106 B

--------------------------------------------------------------------

Element From Node 30


Element To Node 40
Element Type Cylinder
Description SHELL1
Distance "FROM" to "TO" 2500 mm.
Inside Diameter 3000 mm.
Element Thickness 12 mm.
Internal Corrosion Allowance 3 mm.
Nominal Thickness 12 mm.
External Corrosion Allowance 0 mm.
Design Internal Pressure 43.512 psig
Design Temperature Internal Pressure 50 °C
Design External Pressure 14.999 psig
Design Temperature External Pressure 50 °C
Effective Diameter Multiplier 1.2
Material Name SA-516 70
Efficiency, Longitudinal Seam 1.0
Efficiency, Circumferential Seam 1.0
Weld is pre-Heated No

Element From Node 30


Detail Type Ring
Detail ID SR-1
Dist. from "FROM" Node / Offset dist 1350 mm.
Inside Diameter of Ring 3024 mm.
Thickness of Ring 12 mm.
Outside Diameter of Ring 3244 mm.
Material Name SA-516 70
Height of Section Ring 0 mm.
Using Custom Stiffener Section No

Element From Node 30


Detail Type Nozzle
Detail ID N3
Dist. from "FROM" Node / Offset dist 350 mm.
Nozzle Diameter 300 mm
Nozzle Schedule 40
Nozzle Class 150
Layout Angle 90.0
Blind Flange (Y/N) N
Heritage Energy Operational Services Limited 4
Kokori Surge Vessel 2 Replacement
V-100
PV Elite 2018 SP2 Licensee: OMITI ENGINEERING PVT LTD
FileName : SURGE VESSEL-2 Horizontal Hydrotest_Rounded up i
Input Echo: Step: 1 11:53am Mar 10,2019

Weight of Nozzle ( Used if > 0 ) 67.832 Kgf


Grade of Attached Flange GR 1.1
Nozzle Matl SA-106 B

Element From Node 30


Detail Type Nozzle
Detail ID N4
Dist. from "FROM" Node / Offset dist 350 mm.
Nozzle Diameter 300 mm
Nozzle Schedule 40
Nozzle Class 150
Layout Angle 120.0
Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 67.832 Kgf
Grade of Attached Flange GR 1.1
Nozzle Matl SA-106 B

Element From Node 30


Detail Type Nozzle
Detail ID M1
Dist. from "FROM" Node / Offset dist 550 mm.
Nozzle Diameter 610 mm
Nozzle Schedule None
Nozzle Class 150
Layout Angle 0.0
Blind Flange (Y/N) Y
Weight of Nozzle ( Used if > 0 ) 418.56 Kgf
Grade of Attached Flange GR 1.1
Nozzle Matl SA-516 70

Element From Node 30


Detail Type Nozzle
Detail ID M2
Dist. from "FROM" Node / Offset dist 550 mm.
Nozzle Diameter 610 mm
Nozzle Schedule None
Nozzle Class 150
Layout Angle 220.0
Blind Flange (Y/N) Y
Weight of Nozzle ( Used if > 0 ) 418.56 Kgf
Grade of Attached Flange GR 1.1
Nozzle Matl SA-516 70

Element From Node 30


Detail Type Nozzle
Detail ID J2B
Dist. from "FROM" Node / Offset dist 1515 mm.
Nozzle Diameter 50.8 mm
Nozzle Schedule None
Nozzle Class 300
Layout Angle 280.0
Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 8.0432 Kgf
Grade of Attached Flange GR 1.1
Nozzle Matl SA-105

Element From Node 30


Detail Type Nozzle
Detail ID J7
Dist. from "FROM" Node / Offset dist 350 mm.
Nozzle Diameter 50 mm
Nozzle Schedule 160
Heritage Energy Operational Services Limited 5
Kokori Surge Vessel 2 Replacement
V-100
PV Elite 2018 SP2 Licensee: OMITI ENGINEERING PVT LTD
FileName : SURGE VESSEL-2 Horizontal Hydrotest_Rounded up i
Input Echo: Step: 1 11:53am Mar 10,2019

Nozzle Class 300


Layout Angle 290.0
Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 5.9 Kgf
Grade of Attached Flange GR 1.1
Nozzle Matl SA-106 B

Element From Node 30


Detail Type Nozzle
Detail ID N7A
Dist. from "FROM" Node / Offset dist 1920 mm.
Nozzle Diameter 50 mm
Nozzle Schedule 160
Nozzle Class 150
Layout Angle 170.0
Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 4.7308 Kgf
Grade of Attached Flange GR 1.1
Nozzle Matl SA-106 B

Element From Node 30


Detail Type Nozzle
Detail ID N7B
Dist. from "FROM" Node / Offset dist 1920 mm.
Nozzle Diameter 50 mm
Nozzle Schedule 160
Nozzle Class 150
Layout Angle 245.0
Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 4.7308 Kgf
Grade of Attached Flange GR 1.1
Nozzle Matl SA-106 B

Element From Node 30


Detail Type Nozzle
Detail ID J9
Dist. from "FROM" Node / Offset dist 350 mm.
Nozzle Diameter 50 mm
Nozzle Schedule 160
Nozzle Class 300
Layout Angle 245.0
Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 5.9 Kgf
Grade of Attached Flange GR 1.1
Nozzle Matl SA-106 B

Element From Node 30


Detail Type Nozzle
Detail ID J10
Dist. from "FROM" Node / Offset dist 350 mm.
Nozzle Diameter 50 mm
Nozzle Schedule 160
Nozzle Class 300
Layout Angle 75.0
Blind Flange (Y/N) Y
Weight of Nozzle ( Used if > 0 ) 9.6088 Kgf
Grade of Attached Flange GR 1.1
Nozzle Matl SA-106 B

Element From Node 30


Detail Type Nozzle
Detail ID J4B
Heritage Energy Operational Services Limited 6
Kokori Surge Vessel 2 Replacement
V-100
PV Elite 2018 SP2 Licensee: OMITI ENGINEERING PVT LTD
FileName : SURGE VESSEL-2 Horizontal Hydrotest_Rounded up i
Input Echo: Step: 1 11:53am Mar 10,2019

Dist. from "FROM" Node / Offset dist 1515 mm.


Nozzle Diameter 50 mm
Nozzle Schedule 160
Nozzle Class 300
Layout Angle 270.0
Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 5.9 Kgf
Grade of Attached Flange GR 1.1
Nozzle Matl SA-106 B

--------------------------------------------------------------------

Element From Node 40


Element To Node 50
Element Type Cylinder
Description SHELL2
Distance "FROM" to "TO" 2500 mm.
Inside Diameter 3000 mm.
Element Thickness 12 mm.
Internal Corrosion Allowance 3 mm.
Nominal Thickness 12 mm.
External Corrosion Allowance 0 mm.
Design Internal Pressure 43.512 psig
Design Temperature Internal Pressure 50 °C
Design External Pressure 14.999 psig
Design Temperature External Pressure 50 °C
Effective Diameter Multiplier 1.2
Material Name SA-516 70
Efficiency, Longitudinal Seam 1.0
Efficiency, Circumferential Seam 1.0
Weld is pre-Heated No

Element From Node 40


Detail Type Ring
Detail ID SR-2
Dist. from "FROM" Node / Offset dist 550 mm.
Inside Diameter of Ring 3024 mm.
Thickness of Ring 12 mm.
Outside Diameter of Ring 3244 mm.
Material Name SA-516 70
Height of Section Ring 0 mm.
Using Custom Stiffener Section No

Element From Node 40


Detail Type Ring
Detail ID SR-3
Dist. from "FROM" Node / Offset dist 1930 mm.
Inside Diameter of Ring 3024 mm.
Thickness of Ring 12 mm.
Outside Diameter of Ring 3244 mm.
Material Name SA-516 70
Height of Section Ring 0 mm.
Using Custom Stiffener Section No

Element From Node 40


Detail Type Nozzle
Detail ID J2A
Dist. from "FROM" Node / Offset dist 340 mm.
Nozzle Diameter 50.8 mm
Nozzle Schedule None
Nozzle Class 300
Layout Angle 280.0
Heritage Energy Operational Services Limited 7
Kokori Surge Vessel 2 Replacement
V-100
PV Elite 2018 SP2 Licensee: OMITI ENGINEERING PVT LTD
FileName : SURGE VESSEL-2 Horizontal Hydrotest_Rounded up i
Input Echo: Step: 1 11:53am Mar 10,2019

Blind Flange (Y/N) N


Weight of Nozzle ( Used if > 0 ) 8.0599 Kgf
Grade of Attached Flange GR 1.1
Nozzle Matl SA-105

Element From Node 40


Detail Type Nozzle
Detail ID J1B
Dist. from "FROM" Node / Offset dist 440 mm.
Nozzle Diameter 50.8 mm
Nozzle Schedule None
Nozzle Class 300
Layout Angle 310.0
Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 8.0599 Kgf
Grade of Attached Flange GR 1.1
Nozzle Matl SA-105

Element From Node 40


Detail Type Nozzle
Detail ID J1A
Dist. from "FROM" Node / Offset dist 1765 mm.
Nozzle Diameter 50.8 mm
Nozzle Schedule None
Nozzle Class 300
Layout Angle 310.0
Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 8.0599 Kgf
Grade of Attached Flange GR 1.1
Nozzle Matl SA-105

Element From Node 40


Detail Type Nozzle
Detail ID J5
Dist. from "FROM" Node / Offset dist 2095 mm.
Nozzle Diameter 100 mm
Nozzle Schedule 80
Nozzle Class 300
Layout Angle 280.0
Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 18.642 Kgf
Grade of Attached Flange GR 1.1
Nozzle Matl SA-106 B

Element From Node 40


Detail Type Nozzle
Detail ID J3A
Dist. from "FROM" Node / Offset dist 1765 mm.
Nozzle Diameter 50.8 mm
Nozzle Schedule None
Nozzle Class 300
Layout Angle 330.0
Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 8.0599 Kgf
Grade of Attached Flange GR 1.1
Nozzle Matl SA-105

Element From Node 40


Detail Type Nozzle
Detail ID J3B
Dist. from "FROM" Node / Offset dist 440 mm.
Nozzle Diameter 50.8 mm
Heritage Energy Operational Services Limited 8
Kokori Surge Vessel 2 Replacement
V-100
PV Elite 2018 SP2 Licensee: OMITI ENGINEERING PVT LTD
FileName : SURGE VESSEL-2 Horizontal Hydrotest_Rounded up i
Input Echo: Step: 1 11:53am Mar 10,2019

Nozzle Schedule None


Nozzle Class 300
Layout Angle 330.0
Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 8.0599 Kgf
Grade of Attached Flange GR 1.1
Nozzle Matl SA-105

Element From Node 40


Detail Type Nozzle
Detail ID J4A
Dist. from "FROM" Node / Offset dist 340 mm.
Nozzle Diameter 50 mm
Nozzle Schedule 160
Nozzle Class 300
Layout Angle 270.0
Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 5.9 Kgf
Grade of Attached Flange GR 1.1
Nozzle Matl SA-106 B

Element From Node 40


Detail Type Nozzle
Detail ID J8
Dist. from "FROM" Node / Offset dist 1765 mm.
Nozzle Diameter 100 mm
Nozzle Schedule 80
Nozzle Class 300
Layout Angle 320.0
Blind Flange (Y/N) Y
Weight of Nozzle ( Used if > 0 ) 31.111 Kgf
Grade of Attached Flange GR 1.1
Nozzle Matl SA-106 B

--------------------------------------------------------------------

Element From Node 50


Element To Node 60
Element Type Cylinder
Description SHELL3
Distance "FROM" to "TO" 900 mm.
Inside Diameter 3000 mm.
Element Thickness 12 mm.
Internal Corrosion Allowance 3 mm.
Nominal Thickness 12 mm.
External Corrosion Allowance 0 mm.
Design Internal Pressure 43.512 psig
Design Temperature Internal Pressure 50 °C
Design External Pressure 14.999 psig
Design Temperature External Pressure 50 °C
Effective Diameter Multiplier 1.2
Material Name SA-516 70
Efficiency, Longitudinal Seam 1.0
Efficiency, Circumferential Seam 1.0
Weld is pre-Heated No

Element From Node 50


Detail Type Nozzle
Detail ID N1
Dist. from "FROM" Node / Offset dist 450 mm.
Nozzle Diameter 200 mm
Nozzle Schedule 80
Heritage Energy Operational Services Limited 9
Kokori Surge Vessel 2 Replacement
V-100
PV Elite 2018 SP2 Licensee: OMITI ENGINEERING PVT LTD
FileName : SURGE VESSEL-2 Horizontal Hydrotest_Rounded up i
Input Echo: Step: 1 11:53am Mar 10,2019

Nozzle Class 150


Layout Angle 270.0
Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 56.305 Kgf
Grade of Attached Flange GR 1.1
Nozzle Matl SA-106 B

--------------------------------------------------------------------

Element From Node 60


Element To Node 70
Element Type Elliptical
Description TOP HEAD
Distance "FROM" to "TO" 50 mm.
Inside Diameter 3000 mm.
Element Thickness 12 mm.
Internal Corrosion Allowance 3 mm.
Nominal Thickness 14 mm.
External Corrosion Allowance 0 mm.
Design Internal Pressure 43.512 psig
Design Temperature Internal Pressure 50 °C
Design External Pressure 14.999 psig
Design Temperature External Pressure 50 °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

Element From Node 60


Detail Type Nozzle
Detail ID J6
Dist. from "FROM" Node / Offset dist 610 mm.
Nozzle Diameter 80 mm
Nozzle Schedule 160
Nozzle Class 300
Layout Angle 270.0
Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 19.491 Kgf
Grade of Attached Flange GR 1.1
Nozzle Matl SA-106 B

Element From Node 60


Detail Type Nozzle
Detail ID N2
Dist. from "FROM" Node / Offset dist 0 mm.
Nozzle Diameter 150 mm
Nozzle Schedule 80
Nozzle Class 150
Layout Angle 0.0
Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 37.292 Kgf
Grade of Attached Flange GR 1.1
Nozzle Matl SA-106 B

Element From Node 60


Detail Type Nozzle
Detail ID N5
Dist. from "FROM" Node / Offset dist 610 mm.
Nozzle Diameter 100 mm
Nozzle Schedule 80
Heritage Energy Operational Services Limited 10
Kokori Surge Vessel 2 Replacement
V-100
PV Elite 2018 SP2 Licensee: OMITI ENGINEERING PVT LTD
FileName : SURGE VESSEL-2 Horizontal Hydrotest_Rounded up i
Input Echo: Step: 1 11:53am Mar 10,2019

Nozzle Class 150


Layout Angle 90.0
Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 22.981 Kgf
Grade of Attached Flange GR 1.1
Nozzle Matl SA-106 B

PV Elite is a trademark of Intergraph CADWorx & Analysis Solutions, Inc. 2018


Heritage Energy Operational Services Limited 11
Kokori Surge Vessel 2 Replacement
V-100
PV Elite 2018 SP2 Licensee: OMITI ENGINEERING PVT LTD
FileName : SURGE VESSEL-2 Horizontal Hydrotest_Rounded up i
Internal Pressure Calculations: Step: 3 11:53am Mar 10,2019

Element Thickness, Pressure, Diameter and Allowable Stress :

| | Int. Press | Nominal | Total Corr | Element | Allowable |


From | To | + Liq. Hd | Thickness | Allowance | Diameter | Stress(SE)|
| | psig | mm. | mm. | mm. | N/mm² |
----------------------------------------------------------------------------------
BOTTOM HEAD| 43.512 | 14 | 3 | 3000 | 138 |
SHELL1| 43.512 | 12 | 3 | 3000 | 138 |
SHELL2| 43.512 | 12 | 3 | 3000 | 138 |
SHELL3| 43.512 | 12 | 3 | 3000 | 138 |
TOP HEAD| 43.512 | 14 | 3 | 3000 | 138 |
----------------------------------------------------------------------------------

Element Required Thickness and MAWP :

| | Design | M.A.W.P. | M.A.P. | Minimum | Required |


From | To | Pressure | Corroded | New & Cold | Thickness | Thickness |
| | psig | psig | psig | mm. | mm. |
----------------------------------------------------------------------------------
BOTTOM HEAD| 43.5123 | No Calc | No Calc | 12 | 6.25967 |
SHELL1| 43.5123 | No Calc | No Calc | 12 | 6.2719 |
SHELL2| 43.5123 | No Calc | No Calc | 12 | 6.2719 |
SHELL3| 43.5123 | No Calc | No Calc | 12 | 6.2719 |
TOP HEAD| 43.5123 | No Calc | No Calc | 12 | 6.25967 |
----------------------------------------------------------------------------------

Internal Pressure Calculation Results :

ASME Code, Section VIII Division 1, 2017

Elliptical Head From 20 To 30 SA-516 70 , UCS-66 Crv. B at 50 °C

BOTTOM HEAD

Longitudinal Joint: Full Radiography per UW-11(a) Type 1


Circumferential 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)
= (43.51*3006*0.997)/(2*138*1-0.2*43.51)
= 3.2597 + 3.0000 = 6.2597 mm.

Actual stress at given pressure and thickness, corroded [Sact]:


= (P*(Kcor*D+0.2*t))/(2*E*t)
= (43.51*(0.997*3006+0.2*9))/(2*1*9)
= 50.000 N/mm²

Straight Flange Required Thickness:


= (P*R)/(S*E-0.6*P) + c per UG-27 (c)(1)
= (43.51*1503)/(138*1-0.6*43.51)+3
= 6.272 mm.

Straight Flange Maximum Allowable Working Pressure:


= (S*E*t)/(R+0.6*t) per UG-27 (c)(1)
= (138 * 1 * 11 )/(1503 + 0.6 * 11 )
= 145.837 psig
Heritage Energy Operational Services Limited 12
Kokori Surge Vessel 2 Replacement
V-100
PV Elite 2018 SP2 Licensee: OMITI ENGINEERING PVT LTD
FileName : SURGE VESSEL-2 Horizontal Hydrotest_Rounded up i
Internal Pressure Calculations: Step: 3 11:53am Mar 10,2019

Factor K, corroded condition [Kcor]:


= ( 2 + ( Inside Diameter/( 2 * Inside Head Depth ))2)/6
= ( 2 + ( 3006/( 2 * 753 ))2)/6
= 0.997347

Percent Elong. per UCS-79, VIII-1-01-57 (75*tnom/Rf)*(1-Rf/Ro) 2.031 %

MDMT Calculations in the Knuckle Portion:

Govrn. thk, tg = 12, tr = 3.26, c = 3 mm., E* = 1


Thickness Ratio = tr * (E*)/(tg - c) = 0.362, Temp. Reduction = 69 °C

Min Metal Temp. w/o impact per UCS-66, Curve B -23 °C


Min Metal Temp. at Required thickness (UCS 66.1) -48 °C
Min Metal Temp. w/o impact per UG-20(f) -29 °C

MDMT Calculations in the Head Straight Flange:

Govrn. thk, tg = 14, tr = 3.272, c = 3 mm., E* = 1


Thickness Ratio = tr * (E*)/(tg - c) = 0.297, Temp. Reduction = 78 °C

Min Metal Temp. w/o impact per UCS-66, Curve B -18 °C


Min Metal Temp. at Required thickness (UCS 66.1) -104 °C
Min Metal Temp. w/o impact per UG-20(f) -29 °C

Cylindrical Shell From 30 To 40 SA-516 70 , UCS-66 Crv. B at 50 °C

SHELL1

Longitudinal Joint: Full Radiography per UW-11(a) Type 1


Circumferential Joint: Full Radiography per UW-11(a) Type 1

Material UNS Number: K02700

Required Thickness due to Internal Pressure [tr]:


= (P*R)/(S*E-0.6*P) per UG-27 (c)(1)
= (43.51*1503)/(138*1-0.6*43.51)
= 3.2719 + 3.0000 = 6.2719 mm.

Actual stress at given pressure and thickness, corroded [Sact]:


= (P*(R+0.6*t))/(E*t)
= (43.51*(1503+0.6*9))/(1*9)
= 50.283 N/mm²

% Elongation per Table UG-79-1 (50*tnom/Rf*(1-Rf/Ro)) 0.398 %

Minimum Design Metal Temperature Results:

Govrn. thk, tg = 12, tr = 3.272, c = 3 mm., E* = 1


Thickness Ratio = tr * (E*)/(tg - c) = 0.364, Temp. Reduction = 68 °C

Min Metal Temp. w/o impact per UCS-66, Curve B -23 °C


Min Metal Temp. at Required thickness (UCS 66.1) -48 °C
Min Metal Temp. w/o impact per UG-20(f) -29 °C

Cylindrical Shell From 40 To 50 SA-516 70 , UCS-66 Crv. B at 50 °C

SHELL2
Heritage Energy Operational Services Limited 13
Kokori Surge Vessel 2 Replacement
V-100
PV Elite 2018 SP2 Licensee: OMITI ENGINEERING PVT LTD
FileName : SURGE VESSEL-2 Horizontal Hydrotest_Rounded up i
Internal Pressure Calculations: Step: 3 11:53am Mar 10,2019

Longitudinal Joint: Full Radiography per UW-11(a) Type 1


Circumferential Joint: Full Radiography per UW-11(a) Type 1

Material UNS Number: K02700

Required Thickness due to Internal Pressure [tr]:


= (P*R)/(S*E-0.6*P) per UG-27 (c)(1)
= (43.51*1503)/(138*1-0.6*43.51)
= 3.2719 + 3.0000 = 6.2719 mm.

Actual stress at given pressure and thickness, corroded [Sact]:


= (P*(R+0.6*t))/(E*t)
= (43.51*(1503+0.6*9))/(1*9)
= 50.283 N/mm²

% Elongation per Table UG-79-1 (50*tnom/Rf*(1-Rf/Ro)) 0.398 %

Minimum Design Metal Temperature Results:

Govrn. thk, tg = 12, tr = 3.272, c = 3 mm., E* = 1


Thickness Ratio = tr * (E*)/(tg - c) = 0.364, Temp. Reduction = 68 °C

Min Metal Temp. w/o impact per UCS-66, Curve B -23 °C


Min Metal Temp. at Required thickness (UCS 66.1) -48 °C
Min Metal Temp. w/o impact per UG-20(f) -29 °C

Cylindrical Shell From 50 To 60 SA-516 70 , UCS-66 Crv. B at 50 °C

SHELL3

Longitudinal Joint: Full Radiography per UW-11(a) Type 1


Circumferential Joint: Full Radiography per UW-11(a) Type 1

Material UNS Number: K02700

Required Thickness due to Internal Pressure [tr]:


= (P*R)/(S*E-0.6*P) per UG-27 (c)(1)
= (43.51*1503)/(138*1-0.6*43.51)
= 3.2719 + 3.0000 = 6.2719 mm.

Actual stress at given pressure and thickness, corroded [Sact]:


= (P*(R+0.6*t))/(E*t)
= (43.51*(1503+0.6*9))/(1*9)
= 50.283 N/mm²

% Elongation per Table UG-79-1 (50*tnom/Rf*(1-Rf/Ro)) 0.398 %

Minimum Design Metal Temperature Results:

Govrn. thk, tg = 12, tr = 3.272, c = 3 mm., E* = 1


Thickness Ratio = tr * (E*)/(tg - c) = 0.364, Temp. Reduction = 68 °C

Min Metal Temp. w/o impact per UCS-66, Curve B -23 °C


Min Metal Temp. at Required thickness (UCS 66.1) -48 °C
Min Metal Temp. w/o impact per UG-20(f) -29 °C

Elliptical Head From 60 To 70 SA-516 70 , UCS-66 Crv. B at 50 °C

TOP HEAD
Heritage Energy Operational Services Limited 14
Kokori Surge Vessel 2 Replacement
V-100
PV Elite 2018 SP2 Licensee: OMITI ENGINEERING PVT LTD
FileName : SURGE VESSEL-2 Horizontal Hydrotest_Rounded up i
Internal Pressure Calculations: Step: 3 11:53am Mar 10,2019

Longitudinal Joint: Full Radiography per UW-11(a) Type 1


Circumferential 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)
= (43.51*3006*0.997)/(2*138*1-0.2*43.51)
= 3.2597 + 3.0000 = 6.2597 mm.

Actual stress at given pressure and thickness, corroded [Sact]:


= (P*(Kcor*D+0.2*t))/(2*E*t)
= (43.51*(0.997*3006+0.2*9))/(2*1*9)
= 50.000 N/mm²

Straight Flange Required Thickness:


= (P*R)/(S*E-0.6*P) + c per UG-27 (c)(1)
= (43.51*1503)/(138*1-0.6*43.51)+3
= 6.272 mm.

Straight Flange Maximum Allowable Working Pressure:


= (S*E*t)/(R+0.6*t) per UG-27 (c)(1)
= (138 * 1 * 11 )/(1503 + 0.6 * 11 )
= 145.837 psig

Factor K, corroded condition [Kcor]:


= ( 2 + ( Inside Diameter/( 2 * Inside Head Depth ))2)/6
= ( 2 + ( 3006/( 2 * 753 ))2)/6
= 0.997347

Percent Elong. per UCS-79, VIII-1-01-57 (75*tnom/Rf)*(1-Rf/Ro) 2.031 %

MDMT Calculations in the Knuckle Portion:

Govrn. thk, tg = 12, tr = 3.26, c = 3 mm., E* = 1


Thickness Ratio = tr * (E*)/(tg - c) = 0.362, Temp. Reduction = 69 °C

Min Metal Temp. w/o impact per UCS-66, Curve B -23 °C


Min Metal Temp. at Required thickness (UCS 66.1) -48 °C
Min Metal Temp. w/o impact per UG-20(f) -29 °C

MDMT Calculations in the Head Straight Flange:

Govrn. thk, tg = 14, tr = 3.272, c = 3 mm., E* = 1


Thickness Ratio = tr * (E*)/(tg - c) = 0.297, Temp. Reduction = 78 °C

Min Metal Temp. w/o impact per UCS-66, Curve B -18 °C


Min Metal Temp. at Required thickness (UCS 66.1) -104 °C
Min Metal Temp. w/o impact per UG-20(f) -29 °C

Note: Heads and Shells Exempted to -20F (-29C) by paragraph UG-20F

Hydrostatic Test Pressure Results:

Pressure per UG99b = 1.30 * M.A.W.P. * Sa/S 56.566 psig


Pressure per UG99b[36] = 1.30 * Design Pres * Sa/S 56.566 psig
Pressure per UG99c = 1.30 * M.A.P. - Head(Hyd) 369.932 psig
Pressure per UG100 = 1.10 * M.A.W.P. * Sa/S 47.864 psig
Heritage Energy Operational Services Limited 15
Kokori Surge Vessel 2 Replacement
V-100
PV Elite 2018 SP2 Licensee: OMITI ENGINEERING PVT LTD
FileName : SURGE VESSEL-2 Horizontal Hydrotest_Rounded up i
Internal Pressure Calculations: Step: 3 11:53am Mar 10,2019

Pressure per PED = max(1.43*DP, 1.25*DP*ratio) 62.005 psig


Pressure per App 27-4 = 1.30 * M.A.W.P. * Sa/S 56.566 psig
User Defined Hydrostatic Test Pressure at High Point 70.000 psig

Horizontal Test performed per: User Hydro Pressure

Please note that Nozzle, Shell, Head, Flange, etc MAWPs are all considered
when determining the hydrotest pressure for those test types that are based
on the MAWP of the vessel.

Stresses on Elements due to Test Pressure (N/mm² & psig):

From To | Stress | Allowable | Ratio | Pressure |


------------------------------------------------------------------------
BOTTOM HEAD | 64.1 | 234.0 | 0.274 | 74.27 |
SHELL1 | 64.3 | 234.0 | 0.275 | 74.27 |
SHELL2 | 64.3 | 234.0 | 0.275 | 74.27 |
SHELL3 | 64.3 | 234.0 | 0.275 | 74.27 |
TOP HEAD | 64.1 | 234.0 | 0.274 | 74.27 |
------------------------------------------------------------------------

Stress ratios for Nozzle and Pad Materials (N/mm²):

Description | Pad/Nozzle | Ambient | Operating | Ratio |


------------------------------------------------------------------------
N6 | Nozzle | 118.00 | 118.00 | 1.000 |
N6 | Pad | 138.00 | 138.00 | 1.000 |
N3 | Nozzle | 118.00 | 118.00 | 1.000 |
N3 | Pad | 138.00 | 138.00 | 1.000 |
N4 | Nozzle | 118.00 | 118.00 | 1.000 |
N4 | Pad | 137.90 | 137.90 | 1.000 |
M1 | Nozzle | 137.90 | 137.90 | 1.000 |
M1 | Pad | 137.90 | 137.90 | 1.000 |
M2 | Nozzle | 138.00 | 138.00 | 1.000 |
M2 | Pad | 137.90 | 137.90 | 1.000 |
J2B | Nozzle | 138.00 | 138.00 | 1.000 |
J7 | Nozzle | 118.00 | 118.00 | 1.000 |
N7A | Nozzle | 118.00 | 118.00 | 1.000 |
N7B | Nozzle | 118.00 | 118.00 | 1.000 |
J9 | Nozzle | 118.00 | 118.00 | 1.000 |
J10 | Nozzle | 118.00 | 118.00 | 1.000 |
J4B | Nozzle | 118.00 | 118.00 | 1.000 |
J2A | Nozzle | 138.00 | 138.00 | 1.000 |
J1B | Nozzle | 138.00 | 138.00 | 1.000 |
J1A | Nozzle | 138.00 | 138.00 | 1.000 |
J5 | Nozzle | 118.00 | 118.00 | 1.000 |
J5 | Pad | 138.00 | 138.00 | 1.000 |
J3A | Nozzle | 138.00 | 138.00 | 1.000 |
J3B | Nozzle | 138.00 | 138.00 | 1.000 |
J4A | Nozzle | 118.00 | 118.00 | 1.000 |
J8 | Nozzle | 118.00 | 118.00 | 1.000 |
J8 | Pad | 138.00 | 138.00 | 1.000 |
N1 | Nozzle | 118.00 | 118.00 | 1.000 |
N1 | Pad | 138.00 | 138.00 | 1.000 |
J6 | Nozzle | 118.00 | 118.00 | 1.000 |
N2 | Nozzle | 118.00 | 118.00 | 1.000 |
N2 | Pad | 138.00 | 138.00 | 1.000 |
N5 | Nozzle | 118.00 | 118.00 | 1.000 |
N5 | Pad | 138.00 | 138.00 | 1.000 |
------------------------------------------------------------------------
Minimum 1.000
Heritage Energy Operational Services Limited 16
Kokori Surge Vessel 2 Replacement
V-100
PV Elite 2018 SP2 Licensee: OMITI ENGINEERING PVT LTD
FileName : SURGE VESSEL-2 Horizontal Hydrotest_Rounded up i
Internal Pressure Calculations: Step: 3 11:53am Mar 10,2019

Stress ratios for Stiffening Ring Materials (N/mm²):

Description | Ambient | Operating | Ratio |


------------------------------------------------------------------------
SR-1 | 138.00 | 138.00 | 1.000 |
SR-2 | 138.00 | 138.00 | 1.000 |
SR-3 | 138.00 | 138.00 | 1.000 |
------------------------------------------------------------------------
Minimum 1.000

Stress ratios for Pressurized Vessel Elements (N/mm²):

Description | Ambient | Operating | Ratio |


------------------------------------------------------------------------
BOTTOM HEAD | 138.00 | 138.00 | 1.000 |
SHELL1 | 138.00 | 138.00 | 1.000 |
SHELL2 | 138.00 | 138.00 | 1.000 |
SHELL3 | 138.00 | 138.00 | 1.000 |
TOP HEAD | 138.00 | 138.00 | 1.000 |
------------------------------------------------------------------------
Minimum 1.000

Hoop Stress in Nozzle Wall during Pressure Test (N/mm²):

Description | Ambient | Operating | Ratio |


------------------------------------------------------------------------
N6 | 3.21 | 216.00 | 0.015 |
N3 | 7.84 | 216.00 | 0.036 |
N4 | 7.84 | 216.00 | 0.036 |
M1 | 12.81 | 179.27 | 0.071 |
M2 | 12.81 | 234.00 | 0.055 |
J2B | 1.09 | 225.00 | 0.005 |
J7 | 1.56 | 216.00 | 0.007 |
N7A | 1.56 | 216.00 | 0.007 |
N7B | 1.56 | 216.00 | 0.007 |
J9 | 1.56 | 216.00 | 0.007 |
J10 | 1.56 | 216.00 | 0.007 |
J4B | 1.56 | 216.00 | 0.007 |
J2A | 1.09 | 225.00 | 0.005 |
J1B | 1.09 | 225.00 | 0.005 |
J1A | 1.09 | 225.00 | 0.005 |
J5 | 3.21 | 216.00 | 0.015 |
J3A | 1.09 | 225.00 | 0.005 |
J3B | 1.09 | 225.00 | 0.005 |
J4A | 1.56 | 216.00 | 0.007 |
J8 | 3.21 | 216.00 | 0.015 |
N1 | 4.21 | 216.00 | 0.019 |
J6 | 1.84 | 216.00 | 0.009 |
N2 | 3.72 | 216.00 | 0.017 |
N5 | 3.21 | 216.00 | 0.015 |
------------------------------------------------------------------------

Elements Suitable for Internal Pressure.

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