A4 4303100037 WTP 12 01 (Thickness Calc Pressure Vessels) r5

Calculations for Design Pressure
DM Feed Pump
Degassed water Pump
mwc
mwc
mwc
Head Require
Shutoff head 20% higher
Static Head
64.6
77.520
8.05
Additional 5% margin
Design Pressure
Say
4.2785
89.8485
or
Degassed water Pump
Head Require
Static Head
42
50.4
5.6
R4
Design Pressure
Say
8.99 kg/cm2
2.8
58.8
or
5.9 kg/cm2
mwc
mwc
Head Require
Static Head
R4
Design Pressure
Say
33
39.6
8.05
2.3825
50.0325
or
5.03 kg/cm2
ION EXCHANGE (INDIA) LIMITED

CLIENT
: M/s. JAIPRAKASH POWER VENTURES LTD
CONSULTANT : DEVELOPMENT CONSULTANT PRIVATE LIMITED, KOLKATA
PROJECT
: 2x 660 MW JAYPEE NIGRIE SUPER THERMAL POWER PROJECT
CONTRACT NO. : 4303100037
PAGE : 2 OF 6
Design Calculations for Thickness Of Shell

As Per IS 2825 Code
Sr
No
Vessel
Description
No MATERIAL
Of
Di
CA
TS
MT
TS+CA
+MT
TNOM
Remarks
DM PLANT
DMF-C-A/B
2 IS-2062
3600
5.03
1400
0.7
2.0
9.262546
0.6
11.86
12
DMFA/B/C
3 IS-2062
3800
8.99
1400
0.7
2.0
17.50991
1.1
20.61
22
ACF -A/B/C
3 IS-2062
3400
8.99
1400
0.7
2.0
15.66676
18.67
20
SAC -A/B/C
3 IS-2062
2200
8.99
1400
10.13731
0.6
10.74
12
SBA -A/B/C
3 IS-2062
3400
5.9
1400
0.7
.
0.7
10.2656
0.6
10.87
12
MB-A/B/C
3 IS-2062
1600
5.9
1400
0.7
4.830868
0.3
5.13
1 IS-2062
1000
5.9
1400
0.7
3.019293
0.3
5.32
ALKALI ACF
ARV
1 IS-2062
1600
8.5
1400
0.7
6.968998
0.4
7.37
10
HWT
1 SS 316
2600
1390
0.85
8.832272
0.5
9.33
10
Notes : Applicable Material Code FOR HWT is ASTM A 240
DIA = Unit diameter (mm)

HOS = Vessel height (mm)
P
= Design Pressure (Kgf/cm2)
Design Pressure =( Shut Off Pressure 20 % higher than pump head + Static Head (as applicable))X 5% margin
S
= Allowable stress (Kgf/cm2)
CA = Corrosion allowance (mm)
3
Di
= Inside diameter of shell in corroded condition (mm)
E
= Joint efficiency
MATL = Material for shell
TS = Calculated shell thickness
= P * D/(2*S*E-P)
MT = Mill Tolerance (mm) = 5% OF NOMINAL THICKNESS
CA = Corrosion allowance= 2mm (For Non - Rubberlined Vessels)
T = Design Temperature = 60 deg C
TNOM = Thickness Nominal
CLIENT
PROJECT
R5
PAGE : 3 OF 6
Design Calculations For Thickness Of Torispherical Dished ends

As Per IS 2825 Code (1969) & IS 4049 PART II (1996)
Sr Vessel
MATERIAL
No Description
Di
Do
Ro
ro
hE
hE/Do
t/Do
CA
TA t+CA
assumed
TNOM
+MT+TA
DM PLANT
2 DMF-C-A/B
IS2002 -2B
10
3600
3628
2890
540
915.3041
1.4
1590
0.85
0.250
0.0028
9.40
13.90
14
3 DMF-A/BC
IS2002 -2B
15
3800
3840
3055
570
968.6815
1.2
8.99
1590
0.85
0.250
0.0039
15.33
19.83
20
4 ACF -A/B/C
IS2002 -2B
14
3400
3440
2734
510
867.9678
1.2
8.99
1590
0.85
0.250
0.0041
13.73
18.23
20
5 SAC-A/B/C
IS2002 -2B
8.5
2200
2224
1768.5
330
561.1234
1.2
8.99
1590
0.85
0.250
0.0038
8.88
11.38
12
6 SBA -A/B/C
IS2002 -2B
8.5
3400
3424
2728.5
510
863.845
1.25
5.9
1590
0.85
0.250
0.0025
9.34
11.74
12
7 MB -A/B/C
IS2002 -2B
1600
1616
1284
240
408.0365
1.3
5.9
1590
0.85
0.250
0.0025
4.59
6.99
8 ALAKALI ACF
IS2002 -2B
1000
1016
803
150
256.8819
1.25
5.9
1590
0.85
0.250
0.0030
2.77
7.17
9 ARV
IS2002 -2B
1600
1620
1286
240
408.9504
1.2
8.5
1590
0.85
0.250
0.0037
6.11
8.51
10
10 HWT
SS 316 ASTM A 240
2600
2624
2088
390
662.1248
1.25
1390
0.250
0.0030
9.44
11.94
12
Notes : Applicable Material Code FOR HWT is ASTM A 240
Ro = outside crown radius (mm)

ro = Outside knuckle radius (mm)
hE = Effective ouside height of DE (mm)
=Ro-SQRT((Ro-Do/2) * (Ro+Do/2-2*ro))
c = Shape factor
t
= P *Do*c/2*f*j (mm)
MATL =Material of Dish
f
P = Design pressure (Kgf/cm2)
j
= Joint efficiency
MT = Mill Tolerance (mm) = 0
T = Design Temperature = 60 deg C
TA = Thinning Allowance
CLIENT
CONSULTANT

: DEVELOPMENT CONSULTANT PRIVATE LIMITED, KOLKATA
R5
PROJECT
PAGE : 4 OF 6
Design Calculations for Thickness Of Shell - TANKS

As Per IS 2825 Code
Sr
No
Vessel
Description
Qty.
BAT
BCT
BAT CW
MATERIAL
Di
P
(max)
CA
TS
MT
TS+CA +MT
THK
THK PROVIDED
IS-2062
3400
1400
0.7
5.2121
0.5
5.71
10
IS-2062
3200
1400
0.7
4.9055
0.5
5.41
10
IS-2062
2000
1400
0.7
3.0659
0.5
3.57
10
As per Calculations the thickness is much lower but , minimum Thickness of 10 mm has been provided as per Tender Specs for Bulk Storage Tanks.
BAT : BULK ACID STORAGE TANK
BCT: BULK CAUSTIC STORAGE TANK
BAT CW : BULK ACID STORAGE TANK CW TREATMENT
Notes :
DIA = Unit diameter (mm)

S
CA

= Corrosion allowance (mm)
Di
E
= Inside diameter of shell in corroded condition (mm)

= Joint efficiency
MATL = Material for shell

TS = Calculated shell thickness
= P * D/(2*S*E-P)
MT = Mill Tolerance (mm) = 5 % 0f Nominal Thickness.
CA = Corrosion allowance= 2.0mm (For Non - Rubberlined Vessels) & 0 mm (for Rubberlined Vessels)
T
= Design Temperature = 60 Degrees C (MAX)

CLIENT
PROJECT
PAGE : 5 OF 6
Design Calculations For Thickness Of Torispherical Dished ends - TANKS

As Per IS 2825 Code (1969) & IS 4049 PART II (1996)
Sr Vessel
No Description
MATERIAL
t
assumed
Di
Do
Ro
ro
hE
hE/Do
t/Do
CA
TA
t+CA
REQD.
+MT+TA THICK.
1 BAT
IS2062
3400
3420
2726
510
863.03
1.25
1400
0.7
0.2523 0.0018
6.54
9.04
10
2 BCT
IS2062
3200
3220
2566
480
812.576 1.25
1400
0.7
0.2524 0.0019
6.16
8.66
10
3 BAT CW
IS2062
2000
2020
1604
300
510.238 1.25
1400
0.7
0.2526 0.0019
3.86
8.36
10
As per Calculations the thickness is much lower but , minimum Thickness of 10 mm has been provided as per Tender Specs.
Hence the calculation is submitted only for ref and information
Notes :
D - Inside Diameter of Shell in Corroded Condition (mm)
BAT : BULK ACID STORAGE TANK
L - Crown Radius in Corroded Condition (mm)
BCT: BULK CAUSTIC STORAGE TANK
R - Knuckle Radius in Corroded Condition (mm)
BAT CW : BULK ACID STORAGE TANK CW TREATMENT
NOTE :
Do = Outside diameter of dish (mm)
Ro = outside crown radius (mm)
ro = Outside knuckle radius (mm)
hE = Effective ouside height of DE (mm)
=Ro-SQRT((Ro-Do/2) * (Ro+Do/2-2*ro))
c = Shape factor
t
= P *Do*c/2*f*j (mm)
MATL =Material of Dish
f
P = Design pressure (Kgf/cm2)
j
= Joint efficiency
TD= Calculated D.E.Thickness
MT = Mill Tolerance (mm) = 0.3 mm for plate upto 6 mm
= 0.5 mm for plates 8 mm & above.
T = Design Temperature = 60 Degrees C (MAX)
CLIENT
PROJECT
PAGE : 6 OF 6

A4 4303100037 WTP 12 01 (Thickness Calc Pressure Vessels) r5

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Calculations for Design Pressure

Degassed water Pump

Degassed water Pump

ION EXCHANGE (INDIA) LIMITED

Design Calculations for Thickness Of Shell

Notes : Applicable Material Code FOR HWT is ASTM A 240

DIA = Unit diameter (mm)

Design Calculations For Thickness Of Torispherical Dished ends

SS 316 ASTM A 240

Notes : Applicable Material Code FOR HWT is ASTM A 240

Ro = outside crown radius (mm)

ION EXCHANGE (INDIA) LIMITED

Design Calculations for Thickness Of Shell - TANKS

DIA = Unit diameter (mm)

= Allowable stress (Kgf/cm2)

= Inside diameter of shell in corroded condition (mm)

MATL = Material for shell

= Design Temperature = 60 Degrees C (MAX)

TNOM = Thickness Nominal

Design Calculations For Thickness Of Torispherical Dished ends - TANKS

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