REFERENCE SYSTECH CONSULTANCY SERVICES PAGE

SCS/RFPAD/REV.1 1
SYSTECH CONSULTANCY SERVICES, 21 & 22 AASRA APT., ST. ANTHONY STREET, VAKOLA, SANTACRUZ (E), MUMBAI -400 055
PHONE: 91-22-2667-4506 or 2667-4787, FAX: 91-22-2667-2737, E-Mail: dhrawalsystech@yahoo.com

TECHNICAL BASIS FOR REINFORCING PADS REQUIREMENTS ON NOZZLES

Reinforcing Pads are required to comply with API-618 (4th ed., 1995), Clause 3.9.3 Pulsation Suppression Devices, Sub-
clause 3.9.3.5, which requires that Reinforcement to be provided with metal area =cut-way area regardless of the nozzle
thickness i.e., ASME Section VIII Div. 1 may not need it for internal pressure design.

Standard
/ Edition
/ Section
Question Reply
API 618,
4th Ed. -
J une
1995,
Section
3.9.3.5
What method of
design calculations of
the connections are
used to satisfy ASME
Section VIII, Division
1, and API 618?
This paragraph of API 618 requires a reinforcing pad of an area equal to the area
of metal cutaway from the shell. Extra area in the branch connection wall, such as
through the use of heavy wall nozzles, is not acceptable even though reinforcement
calculations in accordance with ASME Section VIII, Division 1 or 2 may satisfy the
requirements for internal pressure. Pulsation suppression devices operate in a
pulsating, vibration-rich environment. Deflection in the shell or head wall from
external loads is a concern. The API 618 modification is intended to add
stiffness to the vessel at branch connections which may transmit external
loads and thereby provides structural integrity against dynamic stresses and
fatigue.

All equipment nozzles of following equipments for Reciprocating Compressor Services will require Reinforcing Pads (R. F.
Pads) on cylindrical Shell or D'end to have safe local stresses:
- Volume Bottles
- Moisture Separators
- Suction Filters
- Discharge Dryer Vessels
- Shell and Tube Type Heat Exchangers (Inter Coolers / After Coolers)

All nozzles must be provided with reinforcing pad of matching material of volume bottle shell / Dend, matching
thickness and pad O.D. = 2 x pipe NB to meet API-618 Clause 3.9.3.5; for controlling Stress Intensification Factor
(SIF) and avoiding fatigue failure under dynamic loading (mechanical) even though ASME section VIII, Div. 1, may
not recommended reinforcing pads for internal pressure design.
Higher the SIF, higher the dynamic stress and higher the likely hood of fatigue failure due to pulsating loads.
For example 6"S40 pipe nozzle to inter cooler / volume bottle / separator shell of 12"S30 will have following SIF:
Without R.F. Pad Out of Plane (max) SIF value =6.37
With matching R.F. Pad Out of Plane (max) SIF value =3.24.
Hence, with matching R.F. Pad, SIF reduces by 51%.
Hence, Systech Consultancy Services strongly recommend R.F. Pads on all equipment nozzles for Reciprocating
Compressors and so also SWRI and others.
Small size fittings / valves on volume bottles must be rigidly fixed. Provide gussets (minimum 4 numbers) to avoid cracks and
failures.
1. Computer Aided Piping Stress Services and analog study for 2 Nos. 'Linde' Reciprocating Oxygen Compressors
PC1 and PC2 installed in Integrated Offsites Plant [Model: 1VK 160-2P, Cylinders=2, Discharge Pressure=28
Kg/cm2, RPM=735].
For this study done by us for a Petrochemical Plant done in 1985 to reduce vibration and frequent failures, we have
come across failure of cooling water inlet / outlet nozzles of intercoolers which were not provided with reinforcing
pads prior to our recommending R. F. Pads. After implementation of our recommendations, failure of nozzles on
Intercooler was eliminated.
2. Computer Aided Acoustical Pulsation and Mechanical Manifold Analysis for Sulzer Ethylene Gas Mixture
Compressor [Model: 4K165-2E, Cylinders=4, Discharge Pressure=25.5 Kg/cm2, HP =1006, RPM=750] done for
a Petrochemical Plant [2005].
Small bore PSV connection failures were observed [e.g. N3/1-150#Sch. 40 Vent on Separator 1st Stage Suction.
After implementation of our recommendations, failure of nozzle was eliminated.
3. Computer Aided Engineering Analysis and Pulsation Study for C-420 F Reclaim Compressor, Dresser Rand Model
No. (2) 23.5 & 18.5 & 11 x 10 4HHE FB3 NL2. Cracks / failures on 3rd stage discharge volume bottle nozzles and
small bore connections were observed due to fatigue failure resulting from high stress concentration done for a
Petrochemical Plant done in 2007.
Hence our analysis +experience [25 +years] requires R.F. Pads.
Hence we strongly recommend you to make R. F. Pads as standard requirement to your equipment vendors (heat
exchangers / separators / volume bottles / Suction Filters) of reciprocating compressor.