Equipment Design: Mechanical Aspects

Prof. Shabina Khanam

Lecture 10
Compensation for Opening

Welcome to the fifth lecture of week 2 and here we are continuing the discussion which we have
started in lecture 4, which is on compensation of opening. So what we have observed till now that
compensation for opening is required when whatever material available in the vessel and nozzle
as extra material, if that material will be lesser than the material which I need to compensate, if
that area is less than the area which I need to compensate then only I will provide compensation
otherwise not.

So do I have any method so that I can judge whether compensation is required or not without
performing detailed calculation okay. The answer is yes, I have a criteria and that criteria is
defined or given in terms of a factor and that factor is called K’, if you see.
(Refer Slide Time: 01:26)

𝑃 𝐷
So what is K’, K’is basically defined by this expression, where K’ is equal to 𝐾 ′ = 1.82𝑓(𝑡𝑜 −𝑐)
𝑠

P is basically the design pressure, f is allowable stress, Do outer diameter of shell or where I am
preparing that opening, ts is the standard thickness of shell or the part where I am creating the
opening and c is the corrosion allowance. So based on this expression, first of all we will calculate
K’ value and then based on that K’ we have different criteria. So let us focus on these criteria.
(Refer Slide Time: 02:22)

So the criteria is if K’ is less than or equal to 1, for diameter less than 0.05 m, need not be
compensated. What is the meaning of this? It means that D is basically the diameter, which I need
to compensate. If that diameter is less than 50 mm, I can remain that opening as it is, I do not need
for compensation for that particular opening. So that is the criteria if you are having opening for
50 mm or less than that you can simply say that compensation is not required and therefore whole
calculation you do not need to carry out.

Now if diameter varies from 50 mm to 200 mm, as it is shown over here, in that case it can remain
uncompensated or unreinforced, which depends on the shell diameter, okay. So we have to focus
on shell diameter to decide whether compensation is required or not. Shell diameter means if
opening is made in shell, otherwise whatever component is having opening, diameter of that
particular component we will consider.
(Refer Slide Time: 03:48)
So that diameter we can decide or we can find in this image, which is figure 3.14A in code, this is
given in IS; 2825, that figure you can tally, and second part is 3.14B, these figures are available in
code. So if you consider this figure A, here we have large X-axis, however, for small axis we have
this figure B okay. So how this figure I have to use, that we will discuss.
(Refer Slide Time: 04:24)

Now what happens, reinforcement is basically based on the diameter of component where opening
is made. So for example if I am preparing opening in shell, so that would be the drum diameter,
it means the shell diameter into thickness. So that thickness is basically standard thickness. So
diameter as well as thickness I have to consider in mm and whatever value I am finding over here
okay. Whatever value I am getting on X-axis corresponding to that value and corresponding value
of K’. Here basically instead of K’, K is mentioned, but it is computed based on same expression.

So for example, if I am having this K value as 0.8 and let us say drum diameter into thickness is
50,000, so this we can consider over here and here we can see that this value will come around
138. So Y-axis shows the maximum diameter of opening. It means up to 138 mm, I do not need
any compensation, if this is the condition for drum diameter as well as K’. However, beyond 130
mm whatever opening is present that I need to compensate.

So this graph basically speaks about whether compensation is required or not. And if you see Y-
axis of this diagram goes up to 200 mm. So that is the condition over here also that up to 200 if
condition lies accordingly I will choose whether compensation will require or not required okay.
And value available almost above 50 mm, so therefore below this compensation will not require.
On the other hand, what we can see that beyond 200, okay because this figure speaks only up to
200, so beyond 200 mm or greater than 0.2 m opening compensation must be required.

So let us say your opening is 0.21 or 0.22 and you are asked to examine whether compensation is
required or not, in that case there is no need to calculate K’ value or see this graph, you can directly
say that compensation must be required for this and therefore we need to carry out whole
calculation up to ring pad area as well as thickness of ring pad. So in this way we decide whether
compensation is required or not. And if it is required, then only I need to pursue whole calculation,
otherwise we can stop while computing K dash and see the diameter of opening.

Now, to make you understand the computation more clearly, I am having a few examples, so let
us start with example 1.
(Refer Slide Time: 07:38)
In this example, a pressure vessel we are considering which is operated at maximum pressure of 2
MN/m2 in gauge, outer diameter is 2.5, and length of shell is 6 m, allowable stress at design
temperature and corrosion allowance is 150 MN/m2, and 3 mm.

It is class 2 vessel, where double welded butt joint with full penetration was used for all joints. So
these joints are basically we can use for shell as well as for nozzle. What we need to find is,
determine the thickness of ream pad up to next integer value, if it is required to compensate opening
of 0.2 m diameter in shell. So opening I am having 0.2 m, and I have to examine whether
compensation is required or not because the maximum value of opening is 0.2 available in the
graph, so here we need to examine whether compensation is required or not.

For this calculation following values are given. Allowable stress of nozzle and ring are
150MN/m2. So here you see allowable stress of nozzle and ring pad as well as that of shell is
equal. Nozzle wall thickness is 10 mm, which is nothing but tn, that is the standard thickness of
nozzle. Inside protrusion of nozzle is 0.04 okay. So if you see this image, here basically this
length of the nozzle it is given as 0.04 m. However, length above the nozzle this value is given as
0.05 m. So here we have to first examine whether compensation is required or not, and if required
we will carry out the whole calculation. So let us start the solution of this example.
(Refer Slide Time: 09:48)
Now, in this problem maximum working pressure is given as 2MN/m2, design pressure we are
considering 5% extra than this. So 2.1MN/m2 is the design pressure. Allowable stress 150, joint
efficiency factor 0.85 is given for double welded butt joint with full penetration, diameter 2.5 is
given.

So considering this expression we will calculate minimum thickness of shell and that comes out
as 20.42. Adding corrosion allowance to this, we have thickness 23.42 and then we will refer table
B1 and we can choose 25 mm as standard thickness. So 25 mm is the standard thickness of shell,
in which we have prepared opening of 0.2 m diameter.
(Refer Slide Time: 10:44)
So first of all we will see K’ because I need to examine whether compensation is required or not.
𝑃 𝐷
So K’ is computed like 𝐾 ′ = 1.82𝑓(𝑡𝑜 −𝑐) , considering all these values over here, we can have K’
𝑠

0.874. Outer diameter is 0.2 m, outer diameter of opening okay. So 𝐷𝑜 𝑡𝑠 that is outer diameter
of shell, this is basically 2.5, so 2500 * 25, so that is 62,500 mm2. So now we will see figure 3.14,
where 𝐷𝑜 𝑡𝑠 is 62,500, so here I have having this is 50,060, so somewhere here it will have 62,000
okay.

And this K’ value is coming as 0.87, so here I am having 0.85 and here 0.9. So somewhere value
will lie over here, like this okay. So if you draw this line, corresponding to 62 and here if you see
the value will come around 159 mm. So 159 mm is the value of opening that remain
uncompensated. And as our opening is 200 mm, which is greater than this, so it means that
compensation must be required.

So in this way we have examined whether compensation is required or not and once we have
observed that it is required, we will carry out whole calculation. And if we compute the area
required to be compensated in this, D is basically inner diameter of nozzle, not the opening. So
0.2 m is the opening diameter and inside this I am having the nozzle and thickness of nozzle is 10
mm, so in that case 200 – 20 would be the diameter, which I need to compensate okay, so that
would be value of d. So considering that we can calculate value of d as 180 mm.
(Refer Slide Time: 13:07)
Now we need to calculate area required to be compensated, so that we can calculate through A,
which is given as (𝑑 + 2𝑐)𝑡𝑟 , d is 180 we have just computed, c is 3 mm, so 2c is 6, and tr 20.42
mm we have computed as minimum thickness of shell. So based on these values, 3798.12 mm 2
area I need to compensate. And then we will calculate how much area I am having as area of
additional material. For that case I have to compute As and An, As is basically area of additional
material in shell and An is the area of additional material in nozzle. So let us start the calculation
of As. Expression of 𝐴𝑠 = (𝑑 + 2𝑐)(𝑡𝑠 − 𝑡𝑟 − 𝑐) so putting all these values we can have As as
293.88 mm2. And further for An, we have to calculate Ao as well as Ai. So Ao how I can calculate,
it is equal to 2𝐻1 (𝑡𝑛 − 𝑡𝑟′ − 𝑐). So tr’ is basically the minimum thickness of nozzle. So that I can
compute using standard formula of thickness calculation and where do,nozzle is basically used as
outer diameter of opening.

So this P is the design pressure because nozzle will have the same design pressure as that is used
Pdo,nozzle
for shell. So, do,nozzle that will be 200 mm/(2fJ+P) ( 𝑖. 𝑒. ). So values we will put over
2fJ+P

here and then 1.6336 mm will be the minimum thickness of nozzle. So considering t r dash, so
further for Ao expression along with tr’ I also have to find out H1 value, H1 is given by this
expression and the value comes as 36.08 mm.

And H1 final would be 36.08 mm. If you remember H1 is basically the boundary decided over the
vessel okay. So that will be compared with the outer length of the nozzle. Outer length of the
nozzle in this case is 50 mm. Now H1 is less than 50 mm, so H1 we will consider as 36.08.
Considering these values, Ao we can find at 387.27 mm2. And in the similar line I will calculate
H2 and that will be compared with the protrusion part, which is 40 mm. So 27.276 is less than 40
mm, so H2 will be considered as 27.276 mm.
(Refer Slide Time: 16:13)
Once I am having H2 value, I will find out value of An, which comes out as 218.21 okay. So
considering Ao and Ai, I will find An and then As we have already computed as 293.88 okay. So
A’ would be 𝐴𝑠 + 𝐴𝑛 . Now I will compare A’ with A and I can found A’ will be significantly
less than A, therefore I need to calculate Ar, that is area of ring pad and that would be 𝐴 − 𝐴′. So
this would be the area of ring pad.

So once I am having the area of ring pad, I will put that in the given expression, and then I will
calculate thickness of ring pad and it comes out as 16.85 mm. Though in the problem we have to
find out (tn)s as next higher value than this, but this value we have taken from table B1, which is
18 mm. In that case no need to add corrosion allowance that is the main point to discuss. That
16.85 is the minimum thickness of ring pad. I have not added corrosion into this and directly I
have taken next value than this available in table B1.

Why I am doing so because ring pad is placed over the vessel, are you getting? Ring pad is
basically placed over the vessel. It means ring pad is in contact with the metal. It is not coming
directly into the contact of the liquid or the fluid, which is filled inside the vessel, and therefore
material of ring pad will not be wasted due to corrosion and therefore corrosion allowance will not
be added to this. So whatever minimum thickness of ring pad I have computed, directly I have
taken next value available than this in table B1 okay.
So in this way we calculate the thickness of ring pad. So till now whatever problem I have solved,
in that case allowable stress of ring, nozzle as well as for shell, all these allowable stresses are
equal. Now we will see if these value differ.
(Refer Slide Time: 18:45)

So we have to find thickness of ring pad if allowable stress of nozzle and ring pad are 140MN/m2
and 130MN/m2 respectively; however, for shell allowable stress value is given as 150MN/m2.

In that case, this is An, this is As and here we have the value of A. Now how I can find A’, which
𝑓
is equal to 𝐴𝑠 + 𝐴𝑛 𝑓𝑛 , fn is the allowable stress of nozzle and fs is the allowable stress of shell
𝑠

okay. Considering this, As I have already calculated, An I have already calculated, putting all these
value we can calculate A’ as 0.000858986 okay. And 𝐴 − 𝐴′ will be equal to
𝑓
𝐴𝑟 𝑓𝑟 , fr is the allowable stress of the ring pad and fs is the allowable stress of shell material. A I
𝑠

know, A’ I know, all these two values I know already.

So from these I can compute Ar. So Ar will come as 0.0033913 and using the expression of Ar as
a function of tp I can compute tp as 19.72 mm and next value to this is 20 mm without adding
corrosion allowance. So in this way we can calculate the ring pad thickness if allowable stress
values vary for each section.
(Refer Slide Time: 20:25)
And here I am having second example, through which you will have more idea how to carry out
compensation for opening. So in this diagram pressure vessel with outer diameter of 4 m and
length 10 m is considered. And it is operated at maximum working pressure of 2MN/m2, allowable
stress is 150 and corrosion is 2 mm, and this is again class 2 vessel with single welded butt joint
with backing strip.

Vessel has opening diameter of 0.22 m. We need to compute the thickness of ring pad, if
compensation of opening is required. So again I need to examine this. Allowable stress for nozzle
and ring pad are 150, inside protrusion length is 0, there is no protrusion part in this and nozzle
length above the surface is 0.02. So in this case I only know the value of this nozzle length above
the vessel. So let us start the solution of this.
(Refer Slide Time: 21:33)
Here I am having the design pressure 2.1 as we have calculated in example 1, thickness of the shell
comes out as 34.69 mm, this I have already explained how it is coming, there is no need to repeat
that again and again. t with corrosion allowance, it will remain 34.696 mm as this minimum
thickness is greater than 30 mm.

So we have not added corrosion into this, though it is given in the problem. And next value to this
is 36, which is available in table B1, so this we have chosen as standard thickness for shell. Now
outer diameter of nozzle is given as 0.22, so in this case though we are asked to examine whether
compensation is required or not. So in that case there is no need to compute the value of K’ or
refer the graph because it is equal to 0.22 m, and if you remember that graph is available only up
to 200 mm.
(Refer Slide Time: 22:39)
So up to 2 m value we can see whether compensation is required or not through this graph.
However, beyond this we should compensate and therefore in this case without computing I can
say that compensation must be required.

Now in the calculation of area for compensation we need d value, d is the inner diameter of nozzle
and inner diameter of nozzle is not given in this example, so for that purpose we will calculate
minimum thickness of nozzle. Then if required corrosion will be added and then we can see the
standard value available in table B1. So in that way we will proceed for computation of nozzle
thickness.

So let us start this. tr’ we can compute using this same expression, where Do would be opening or
outer diameter of nozzle and that would be equal to 0.22 m. Considering that tr’ we can find out
as 1.908 mm. tr’plus corrosion is 3.908 mm and then next value to this in table B1 is 5 mm. So
standard thickness of nozzle would be 5 mm. So to calculate d we will deduct 2 * 5 that is 10 mm
from 0.22 m. So in that case 0.21 would be value of d.
(Refer Slide Time: 24:17)
So here you can see this is the value of d 0.21. Area to be compensated, it will be calculated by
(𝑑 + 2𝑐)𝑡𝑟 so using the values of different parameters I can calculate A, which is coming out as
0.007425. As will be computed using the expression as (𝑑 + 2𝑐)(𝑡𝑠 − 𝑡𝑟 − 𝑐). Now in this case,
ts is 36 and tr is 34.69 and c we have not added in this standard thickness. So in that case while
computing As value, we will not consider corrosion. So in that case this value would be equal to
0.

So (𝑑 + 2𝑐)(𝑡𝑠 − 𝑡𝑟 − 𝑐), considering that we can find As as 0.000279. However, we have

So if you remember here in this case protrusion part is not given, so we will not compute Ai, we
will only focus on Ao. And for that purpose, first I need to compute value of H1. So H1 is given
as √(𝑑 + 2𝑐)(𝑡𝑛 − 𝑐) , considering that we can find H1 as 0.025338 m, and nozzle length outside
is given as 0.02. So this calculated H1 value is higher than this. So H1 for calculation purpose is
taken as 0.02.
So Ao will be nothing but 4.37E–05 m2, An will only consider Ao, so this value will be same as
that of Ao. So considering this we can find A’ as 0.000323 and then area of ring pad as 0.071, area
of ring pad we can compute using regular expression. And further using expression of Ar as well
as tp we can find tp as 34.14 mm and next standard value of this is 36 mm. So in that way we can
find thickness of ring pad as 36 mm.

Here I have again not added corrosion allowance, and the reason why I am not adding that I have
already explained in example 1. So here we have seen two examples to calculate compensation
for opening and I hope you have the idea how to compute this, how to examine the compensation
requirement and how to compute this okay.
(Refer Slide Time: 27:42)

Here I am having a few references, which we have used to prepare this lecture. You can go through
these references.
(Refer Slide Time: 27:51)
And here I am having summary of the video and this summary is related to the summary of lecture
4 as well as lecture 5. And it goes as requirement of compensation for opening is discussed, types
of compensation along with orientation of nozzle is discussed, design equation for computation of
ring pad thickness used for compensation are described, and further we have solved a few examples
to illustrate design of compensation for opening okay. So that is all for now, thank you.