CodeLine – 80U60

Report No:- ASME/----

Rev:- --

FABRICATOR'S DESIGN REPORT

Pentair Water-CodeLine Division

Verna, Goa, India

Glass Filament Wound

Class I Pressure Vessels

Built To The Requirements
Of
Article RD
ASME Section X 2010 Edition & 2011 Addenda

Prepared Date:
By: __________

Checked Date:
By: __________

Approved Date:
By: __________

Reviewed by:

Authorized Inspector Date

ASME/------ 1
 Table of Contents

1. INTRODUCTION.................................................................................................................................3

2. VESSEL DESCRIPTION......................................................................................................................3
A. OPENINGS............................................................................................................................................3
B. OPENING WEIGHT ALLOWANCES.............................................................................................................3
C. OPERATING CONDITIONS........................................................................................................................3
3. DESIGN OF CLASS I PRESSURE VESSELS......................................................................................4
A. DESIGN ASSUMPTIONS...........................................................................................................................4
B. WINDING SPECIFICATIONS......................................................................................................................4
C. ALLOWABLE STRESSES IN GLASS FILAMENTS............................................................................................4
D. EPOXY RESIN SYSTEM...........................................................................................................................5
E. LAMINATE CURE...................................................................................................................................5
F. SIDE PORT FITTING DESCRIPTION............................................................................................................5
G. LOADINGS:..........................................................................................................................................5
H. INSPECTION OPENINGS...........................................................................................................................6
I. CENTRAL BODY OF THE VESSEL..............................................................................................................6
J. HOOP AND AXIAL STRESSE IN INTERNALLY PRESSURISED VESSELS...............................................................6
K. MAXIMUM ALLOWABLE STRESS IN CENTRAL BODY:-.................................................................................7
L. PORT REGION SHELL THICKNESS.............................................................................................................9
M. MAXIMUM ALLOWABLE STRESS IN THE PORT REGION...............................................................................10
4. DESIGN OF METALLIC COMPONENTS OF VESSEL....................................................................12
A. DESIGN OF BEARING PLATE........................................................................................................12
B. FEED / CONCENTRATE PORT (NOZZLE) MINIMUM THICKNESS UG-45.........................................................13
C. DESIGN OF SPIRAL RING......................................................................................................................15
D. DESIGN OF GROOVE FOR SPIRAL RING:-................................................................................................15
5. DESIGN OF END MARGIN:-.............................................................................................................16

6. REFERENCES...................................................................................................................................17

7. SUMMARY OF CHANGES :..............................................................................................................17

ASME/------ 2
 DESIGN REPORT
1. INTRODUCTION

This design report covers the analysis of a cylindrical fiber reinforced plastic
pressure vessel submitted by Pentair Water - CodeLine Division, Verna, Goa, India for
acceptance as certified to Section X, 2010 Edition & 2011 Addenda , ASME Boiler and
Pressure Vessel Code Class I pressure vessels.
The pressure vessels are constructed from uncut glass filaments impregnated with an
epoxy resin and wound over a steel mandrel, from which they are removed after
curing. There is a resin rich polyester barrier, which serves to assure a smooth inner
surface, but is not considered to add to the strength of the vessel.

2. VESSEL DESCRIPTION

Vessels of various lengths are manufactured with an 8-inch inner diameter.

Refer to Design Drawings 99186-REV-J.1(After all successful qualification, If
dimension variation in is there in the vessels then the Rev-J.1 will be revised to Rev-K
with changes, If not it will remain Rev-J) for a complete list of vessel drawings.

A. Openings
The vessels come equipped with side port openings at each end, one end of which is
depicted in Figure 1.

Figure 1

Note: These vessels comply to RG 404.1 as there are no polar boss openings.

B. Opening Weight Allowances

Refer RT 202 of ASME Section X, 2010 Edition & 2011 Addenda for any of the
nozzles or openings in the vessel to be omitted in production after qualified.

C. Operating Conditions

These pressure vessels are intended to contain water or an air cushion over water
at internal operating pressures of 0-600 psi as indicated in the User’s Design
ASME/------ 3
 Specification 99412 REV-D. The following additional service conditions apply to the
use environment of these pressure vessels:

0 The operating temperature range is 20°F to 190°F

0 Sustained exposure of the internals of the vessel to corrosive or abrasive water

is not anticipated.
0 Corrosive environments surrounding the vessel are not anticipated in the design.

0 All piping connections to the vessel are required to be flexible. Therefore, no

additional stresses are imparted on vessel.

3. DESIGN OF CLASS I PRESSURE VESSELS

A. Design Assumptions

The analysis of the stresses in the continuous glass reinforcements will be

based on "netting" theory, where it is assumed that the resin matrix carries no
load and serves primarily to keep the glass fibers in position.

A.1.Cylindrical Shell Analysis

As described in chapter IV-3 of the Handbook of Reinforced Plastics (1), the girth
strength of the cylinder is proportional to the sin 2 θ of the helix angle, and the
longitudinal strength is proportional to the cos 2 θ of the helix angle.

B. Winding Specifications

The load bearing constituents of this vessel are the continuous glass filaments
and interlaminate mats as described in winding specification 99644 REV-C.
It is important to define that in addition to the information in winding specification,

0 The helical winding is done with 40 strands 236-yield corrosion resistant

Type E glass.
0 DB120 mat is a Bi-directional mat with areal density of 13.2 oz/yd 2 approx.
0 D155 mat is a unidirectional mat with areal density of 14.747 oz/yd 2

approx. C. Allowable Stresses in Glass Filaments

A substantial quantity of experimental evidence and field experience at Pentair

Water Treatment indicates that a stress in the glass of less than 270,000 psi in
helical winding will provide a design capable of meeting the required ASME
qualification tests of both fatigue life and burst strength. Thus, it will be appropriate
ASME/------ 4
 to demonstrate that the stress reached at six times the maximum operating
pressure does not exceed this level.

D. Epoxy Resin System

The epoxy system used for qualification is Dow D.E.R*750 blended resin and
the hardener is pre-promoted Lindride 6V liquid. Use of any other resin system
Will require requalification.
E. Laminate Cure
The curing of the resin is to be effected per Cure Cycle as specified in
Procedure Specification, General and verified per the Barcol Hardness test
specified in General Procedure Specification .

F. Side Port Fitting Description

Vessels are equipped with metallic side port fittings, which are made from cast 2-
3% molybdenum alloy, SA-351 Gr. CF3M or SA-479 Gr.316L stainless steel as
alternate material in accordance with requirements of ASME Section VIII Div I.
G. Loadings:

(i) RD-120 (a) Internal and External Design Pressure as defined in RD-111:

Design Pressure plus Static Head is not exceeding 1500psi as specifed in

RD111. Static Head for 1 ft is .433 psi & for 8” it is .299 psi aprox. This is taken
care in design.
(ii) RD-120(b) Impact loads:
Not Applicable. Vesel is not subjected to impact Load.
(iii) RD-120(C) weight of the vessel and normal contents under operating
& test conditions.
Taken care As per RD111.
(iv) RD-120(d) Superimposed Loads
Not Applicable. Vesel is not subjected to Superimposed Loads.
(v) RD-120(e) Live Loads
Not Applicable
(vi) RD-120(f) Snow & Ice Loads
Not applicable
(vii) RD-120(g) Wind Loads & Earth QuakeLoads
Not applicable.
ASME/------ 5
 (viii) RD-120(h) reactions of Supporting lugs,rings,saddles and other types of
supports.
Not Applicable
(ix)RD-120(i) Loads due to Thermal expansion and thermal gradients.
Not Applicable
(x) RD-121 Stress due to combined Loadings
Not Applicable since RD-120 is Not applicable.Since Vessel is not subjected to
Bending & Shearing .
(xi) RD-130 Design Restriction.
Not Applicable. Since Vessel is not subjected to Bending & Shearing .
(xii) RD-140 Design Allowances for Degradation
Not Applicable. Since this specification is not applicable for our Vessel.
H. Inspection Openings

RD-1001 Requirements for vessel 12”(300 mm) in Diameter and Smaller

Diameter of vessel is 8” which lesser than 12” and also vessel is having
openings of dia 8.02” approx on both end which is not less than ¾” .Thus
no separate openings required for inspection.

I. Central Body of the Vessel

Ø7.955
7.945

Ø8.52±.06

11.90± .10

Figure 2
Central body of the vessel is the portion of the vessel excluding approximate bell
length from both ends.Refer to Figure 2,
J. Hoop and Axial Stresse in Internally Pressurised Vessels

Using classic equations for determination of hoop and axial stresses in the wall of an
internally pressurized vessel with a wall thickness to diameter ratio of less than 0.1
yields the following:

σ  P
r
 h ………………………..
t (1)

ASME/------ 6
 P
r

a  2 ……………………….
t (2)
D O 
r ………………….
= di  (3)
4
t D O − di …………………..
=  (4)
2
P = 6 PO
do=Outside
diameter, 8.46 in
7.95
di=inside diameter, 5 in
Po=operating
pressure, 600 psi

AS Per equations (1) and (2), stress in body of vessel is:

(6x600) 8.46+7.955
σ
h= 4 = 58508.911 psi
8.46-7.955
2

(6x600) 8.46+7.955
σ
a= 4 = 29254.455 psi
2* 8.46 –
7.955
2
Assume epoxy matrix does not carry any load.
Therefore, compensate wall stress levels to
accommodate only fiberglass. Converting glass
percentage by weight, found in the General
Procedure Specification, to a percentage by
volume, yields the fact that the glass represents
only 51% of the wall. Thus, the effective stress
on glass is at maximum operating pressure is:
σ 58508.9
11
……………
H   114723.355 psi (5)
 0.51
σ 29,254.4
55
…………….
A   57,361.677 psi (6)
0.51
Now we need to verify that imposed stress in
the vessel is below maximum allowable stress.
K. Maximum Allowable Stress in Central Body:-
Laminate is constructed per winding spec. Laminate
construction is composed of gel liner (non load bearing)
first circ, high angle helical, helical, circ for mat interlay,
and last circ.

ASME/------ 7
A

LAST CIRC

XXXXXXXXXXXXXXX
B TRANS CIRC

C HELICAL 4 LAYERS

XXXXXXXXXXXXXXX
D
XXXXXXXXXXXXXXX HIGH ANGLE HELICAL

E 1ST CIRC
F GEL LAYER

XXXXXXXXXXXXXXX

XXXXXXXXXXXXXXX

FIGURE 3
Stress in laminate is calculated individual layers
and their contribution as shown in table 1.
Table 1
LAYER THICKNESS
A 0.022”
B 0.022”
C 0.043”
D 0.034”
E 0.022”
F 0.033”
Contribution to stress is a function of both wind
angle and layer thickness refer to Handbook(1).

Stress in Hoop is given by: σh = σallowable x sin2 θ

Stress in Axial is given by: σa = σallowable x cos2 θ

Where
θ = angle made between fiberglass and
axis of vessel.
σallowable = maximum allowable stress in glass

σallowable = 270,000 psi based on testing

data, fiberglass technical data as per Allowable
stress in the glass filaments.

Therefore:
σHoop = Σ
contributi
on x
σallowable x
sin2 θlayer
 σAxial = Σ
contributi
on x
σallowable x
cos2 θlayer
t
t
cir last

c 2 circ 2
σ
σallowable x θcirc θlast
H  sin + σallowable x sin circ
t t
t
t
H

A HE

H L 2
σallowable x θHAH σallowable x
+ sin + sin θHEL
t t
AND

ASME/------ 8
 t

ci

t
r last

c 2 circ
2
σ
σallowable x θcirc
Ax  cos + σallowable x cos θlast circ
t t
t t

HA HE

H σallowable x θHAH L σallowable x

+ cos + cos θHEL
t t
Tabulated
Calculations:-
Table
2
t t
la
l
ye

ay t layer x r x
2θ
er 2 2 Sin 2

C
Sin co o
LAYER θ θ s θ s θ

t t t
0.022 0.087 0.030
CIRC * 1 = 1 80 0.9698 2 0.0845 0.0026
0.252
5

0.034 = 0.134 59.6 0.255

HEL * 1 7 3 0.7444 6 0.1002 0.0344
0.252
5

0.043 0.510 51.3 0.389

HEL 0.252 * 3 = 9 8 0.6104 6 0.3119 0.1990
5

0.043 0.170 0.377

HEL 0.252 * 1 = 3 52.1 0.6227 3 0.1060 0.0643
5

0.022 0.174 0.030

CIRC * 2 = 3 80 0.9698 2 0.1690 0.0053
0.252
5
0.305
0.7716 6

Substituting:
σh = 0.7716 σallowable = 0.7716 * (270,000) = 2,08,0332.000 psi
Therefore maximum allowable hoop stress is 2,08,332.000 psi, and from
 (5) actual is 1,14,723.355 psi
and
σa = 0.3056 σallowable = 0.3056 *(270,000) = 82,512.000 psi.

Therefore maximum stress in is 82,512.000 psi, and from (6) actual axial
stress is 57,361.677 psi.
Conclusion:
Imparted stress at 3600 psi are less than maximum allowable stress.

L. Port Region Shell Thickness

11. i
do=Outside diameter, 8 n
8.7 i
di=inside diameter, 10 n
p
P =Internal Design 60 s
Pressure, 0 i

As per equations (1) and (2), stress in body of vessel is:

(6x600)
*(11.8+8.71 )
= 11,947.573
σh = 4 psi
(11.8-8.71)
2
ASME/------ 9
 (6x600)
*(11.8+8.71)
= 5,973.786
σa = 4 psi
2*(11.8-8.71)
2

Assume epoxy matrix does not carry any load. Therefore, compensating wall stress
levels to accommodate only fiberglass. Converting glass percentage by weight,
found in the General Procedure Specification in Appendix B, to a percentage by
volume, yields the fact that the glass represents only 51% of the wall.

Thus, the effective stress on glass is at maximum operating pressure is:

σ 11,947.5
73  23,426.613 …………………..
H  psi (7)
0.51
σ 5,973.7
86 …………………...
A   11,713.307 psi (8)
0.51

M. Maximum Allowable stress In The Port Region

Laminate is constructed per winding specification. Laminate construction is

composed of gel liner (non load bearing) first circ, high angle helical, helical, circ for
mat interlay, and last circ. Stress in laminate is calculated based on individual
layers and their contribution. Table 1 lists layer data for port area found in Figure 2.

Contribution to stress is a function of both wind angle and layer thickness refer
to Handbook(1).

Stress in Hoop is given by: σh = σallowable x sin2 θ

Stress in Axial is given by: σa = σallowable x cos2 θ
Where
θ = angle made between fiberglass and axis of vessel.
σallowable = maximum allowable stress in glass

σallowable = 270,000 psi based on testing data, fiberglass technical data

as per Allowable stress in the glass filaments.
ASME/------ 10
 Therefore:-
σHoop = Σ contribution x σallowable x sin2 θlayer
σAxial = Σ contribution x σallowable x cos2 θlayer
t
t
cir last

c 2 circ 2
θ
σ σallowable x ci
H  sin rc + σallowable x sin θlast+ mil circ
t t
t
t
H

A HE

H 2 L 2
σallowable x θHAH
+ sin + σallowable x sin θHEL
t t
A
N
D
t
t
ci last

rc circ 2
σ θ
σallowable x cir
Ax  cos c + σallowable x cos θlast+ mil circ
t t
t
t
H

A HE

H σallowable x θHA L σallowable x θH

+ cos H+ cos EL
t t
Calculation Table
s: 3
tl
a
y θ θ
er 2 2 t layer x Sin2 t layer x Cos2
c
Sin o
LAYER θ θ s θ
t t t
0.02
2 0.01 0.96 0.030
CIRC * 1 = 42 80 98 2 0.0138 0.0004
1.54
5

0.03
HEL 4 * 3 = 0.06 59.63 0.74 0.255 0.0491 0.0169
 1.54 60 44 6
5

0.04
3 0.08 0.61 0.389
HEL * 3 = 35 51.38 04 6 0.0510 0.0325
1.54
5

0.04
3 0.05 0.62 0.377
HEL * 2 = 57 52.1 27 3 0.0347 0.0210
1.54
5

0.02
2 0.02 0.96 0.030
CIRC * 2 = 85 80 98 2 0.0276 0.0009
1.54
5

0.01
MAT 76 1 0.19 0.50 0.500
* 7 = 37 45 00 0 0.0968 0.0968
1.54
DB-120 5

0.02
MAT 3 0.13 0.00 1.000
* 9 = 40 0 00 0 0.0000 0.1340
1.54
DB-155 5
0.302
0.2730 5

Substituting
:-
σh = 0.2730 σallowable = 0. 2730 * (270,000) = 73,710.000 psi
a
n
d
σa = 0.3025 σallowable = 0.3025 * (270,000) = 81,675.000 psi
Add Stress Risers caused by
ports:
Kt is stress riser resulting from port
hole
L = distance between
holes
D = diameter of
hole
From handbook(2) figure
6.10
For a circular hole Kt =
2.5
σ
h = 73,710.000 = 29,484.000 psi …………(9)
2.5

ASME/------ 11
 σa = 81,675.000 _ = 32,670.000 psi ……….(10)
2.5
Conclusion:

Maximum allowable hoop stress is 29,484.000 psi, and actual is 23,426.613 psi. from (7)
Maximum allowable axial stress is 32,670.000 psi and actual is 11,713.307 psi. from (8)
Imparted stress at 3600 psi are less than maximum allowable stress.

4. DESIGN OF METALLIC COMPONENTS OF VESSEL

As per ASME Section X, RM-211, metallic parts for Class I vessels shall comply with
all requirements of Section VIII, Division 1.

A. DESIGN OF BEARING PLATE

INSERT RING

SHEL SPIRAL
RETAINING
RING

BEARING

1.124”
1.25”

Figure 5. Bearing Plate 600psi

II A BEARING PLATE
As per Section-X RD-720 & Section VIII Div 1 UG-39 (a), single openings in flat heads
do not require any reinforcement ,since the opening in the bearing plate does not
exceed ¼”th the Head Diameter.
For material – SB-221Grade 6061-T6 (UNS No A96061)
CP
T min D min. req’d thickness, Section VIII, UG-34.
SE
ASME/------ 12
 inc
t= 1.124 h actual bearing plate thickness, inch
d inc
= 7.92 h bearing plate OD, inch
C Application factor from Section VIII, UG-34, case
= 0.3 (m)
E
= 1 Joint efficiency from Section VIII, UG-34
S
= 10,900 psi allowable stress, @ 190 °F For SB-221 6061 / T6
P
= 600 psi design pressure, psi

Solve for equation 11:

t min = 1.018 minimum required thickness in inches.

CONCLUSION:-
Plate thickness thicker than minimum - OK

B. Feed / Concentrate Port (Nozzle) Minimum Thickness UG-45

The minimum value of nozzle neck is larger of UG-45(a) and UG-

45(b). Nomenclature
t = minimum thickness required, in.
P = Internal design pressure, psi.

R = Inside radius of shell under consideration,

in. S = Minimum allowable stress value, psi.
E = Joint efficiency

Material and Port size considered: CF3M as per SA-351 and 4” ports.
Allowable tensile stress of the material S = 17200 psi @190ºF. (As per UG-24 a
casting quality factor of 80% is to be applied to the allowable stress) Therefore
S=17,200 X 0.80 = 13,760 Psi.

(A) Ug-45(ta) :
Considering nozzle as shell and calculation as per UG-27.

a) UG-27

i) UG-27 (c)(1): (For circumferential stress)

As the thickness of the laminate in the port region does not exceed one-half
of the inside radius , using the formula to calculate thickness
 PR 600  2.013  0.090
T
  in.
(SE − 0.6P) (13760  1 − 0.6  600)

ASME/------ 13
 ii)UG-27(c)(2): (longitudinal stress)
As the thickness of the laminate in the port region does not exceed one-half of
the inside radius , using the formula to calculate minimum thickness


PR 600  2.013 0.043in
T
  .
(2SE  (2  13760 1  0.4 
0.4P) 600)

Higher of UG-27(c )(1) & UG-27(c ) (2)

UG 45 (ta) min = .090 inch………..(x)

(B) UG-45(tb)
UG-tb1.
Because of dissimmilar shell (FRP) and nozzle(SS) material, minimum
thickness is governed by UG-16(b).
Based on Pentair’s burst history data, the minimum thickness is considered as 0.0625 inch
and the same will be proof tested.
Hence,
tb1=.0625 in.

iii)UG-45(tb2):
Not applicable as vessel is not subjected to external
pressure. tb2=0

iii)UG-45(tb3):
minimum nozzle thickness for 4” as per table UG-
45 is tb3=.207”

therefore as per formula

tb = min (tb3, max (tb1, tb2))

tb= .0625 inches ………..(y)

minimum thickness is max (ta, tb)

max (x, y)
 t-UG-45= .090 inches

ASME/------ 14
 Conclusion:
As actual thickness provided in port wall is 0.141 inches which is more than
required, hence the design of port is safe. However this port thickness is
ensured during prototyping.

C. Design of Spiral Ring

Material under consideration

SA- 479 Type 316: - Minimum allowance strength = 17,300 psi @
190ºF. Allowable shear stress is 80% of minimum tensile strength
……………
Sshear = 17,300 x 0.8 = 13,840 psi. (a)
p 60
= 0, operating pressure, psi
D 8.0
= 2, Shaft or housing diameter,in
0.183, ring thickness, in (in compressed
t= condition)
Normal thrust load at the operating pressure(F)= PxπxD2 4

= 600X3.142X8.02x8.02 4

=30,314.204 lbs.

Shear area (A)= π x Dxt = 3.142x8.02 x .183 = 4.611 in2

Check for induced shear stress “τ”
30,314.2
τ F 04 ………………
= = = 6574.323psi. (b)
A4.611

Conclusion:
From (a) and (b)
Induced shear stress is less than the allowable shear stress.. Hence the design
for spiral ring is safe considering shear loading.

D. Design Of Groove For Spiral Ring:-

The groove for spiral ring is formed in the vessel by a Insert Ring which is a
integral part of the vessel.

Material:- CF8 SA 351 allowable stress = 16,700 psi @ 190ºF.

 Consider Allowable shear stress as 80% of minimum tensile strength

ASME/------ 15
 Sshear = 16,700 x 0.8 = 13,360.00 ……………
psi. (a)

p 60
= 0, operating pressure, psi
0.1
t= 7, Groove depth,in.
D =8.36, groove diameter, in.
d 8.0
= 2, housing diameter, in.

Normal thrust load at the operating =

pressure(F) PxπxD2
4
= 600X3.142X8.36x8.36 4

=32934.698 lbs.

Area of deformation (A)= π x dxt = 3.142 x8.02 x .17 = 4.283 in2

Check for induced shear stress “τ”
F 32934.698
τ    7689.633psi ………………(b)

A 4.283

Conclusion:
From (a) and (b)
Induced shear stress is less than the allowable shear stress. Hence the design of
groove for spiral ring made of Insert Ring is safe considering groove deformation.

5. DESIGN OF END MARGIN:-

The end margin length is provided in the vessel to hold the end
closure components in place.

L= 2.00” , End margin length.

D= 8.625 , Outside diameter of the insert ring
P= 600 psi,

Normal thrust load at the operating pressure(F) = PxπxD2

4
= 600X3.142X8.625x8.625 4

= 35,060.3 lbs.
Shear area (A)= π x DxL = 3.142x8.625 x 2 = 54.1995 in2

Check for induced shear stress “τ” in the laminate,

ASME/------ 16
 F 35060.3
τ    646.875 psi ………………(a)

A 56.1995

Maximum allowable stress in axial is 32,670.000 psi from eqn (10).

Consider Allowable shear stress as 80% of minimum tensile strength

Sshear = 32,670.000 x 0.8 = 26,136.000 psi……..(b)

From (a) and (b)

Induced shear stress is less than the allowable shear stress. Hence the design
of end margin length is safe considering laminate shear.

Conclusion:

For Fiberglass Reinforced Class I pressure Vessels, design shall be considered

qualified by subjecting to 100000 cycles of pressure ranging from atmospheric
to the design pressure follows a destructive testing of a prototype withstand a
pressure not less than six times the specified maximum design pressure
as per RD160- Proof of Design Adequacy.

6. REFERENCES

1. Oleesky, S., Mohr, Gilbert J. Handbook of Reinforced Plastics,

Reinhold Publishing Corporation, New York, 1964, pp. 292-301

2. Harvey, John Theory and Design of Pressure Vessels,

Van Nostrand Reinhold Company, New York, 1985, pp. 384, 399.

7. SUMMARY OF CHANGES :

Summary of Change

Page
No Date Current Nature of Change
Rev

p
ASME/------ 17