Design Calculation Exchanger E2226

8/16/2019 Design Calculation Exchanger E2226

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Table of Contents

Cover Sheet ............................................................................................................................................................. 3

Title Page ................................................................................................................................................................ 5

Warnings and Errors : ..................................................................................................................................... 6

Input Echo : ........................................................................................................................................................... 7

XY Coordinate Calculations : ........................................................................................................................... 20

Flg Calc [Int P] : FLANGE1 ................................................................................................................ 21

Flg Calc [Int P] : FLANGE1 ................................................................................................................ 31

Internal Pressure Calculations : ......................................................................................................... 41

External Pressure Calculations : ......................................................................................................... 50

Element and Detail Weights : ......................................................................................................................... 55

Nozzle Flange MAWP : ...................................................................................................................................... 59

Wind Load Calculation : .............................................................................................................................. 60

Earthquake Load Calculation : ................................................................................................................ 62

Center of Gravity Calculation : ........................................................................................................... 64

Lifting Lug Calcs : Left Side ................................................................................................................ 67

Lifting Lug Calcs : Right Side .............................................................................................................. 80

Horizontal Vessel Analysis (Ope.) : .................................................................................................. 93

Horizontal Vessel Analysis (Test) : ................................................................................................ 119

Nozzle Calcs. : N02 ...................................................................................................................................... 141

Nozzle Calcs. : N01 ...................................................................................................................................... 154

Nozzle Calcs. : N04 ...................................................................................................................................... 167

Nozzle Calcs. : N03 ...................................................................................................................................... 180

Nozzle Schedule : ........................................................................................................................................... 193

Nozzle Summary : ............................................................................................................................................. 195

MDMT Summary : .................................................................................................................................................. 197

Tubesheet, ............................................................................................................................................................ 199

Vessel Design Summary : ............................................................................................................................ 205


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Cover Page

EMERGENCY COOLER

E-2226

DESIGN CALCULATION

In Accordance with ASME Section VIII Division 1

ASME Code Version : 2010 Edition, 2011a Addenda


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Cover Page

Job File : C:\DOCUMENTS AND SETTINGS\SAS\MY DOCUMENTS\SK\SA

Date of Analysis : Dec 18,2015

PV Elite 2012, January 2012


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Title Page

Note: PV Elite performs all calculations internally in Imperial Units

to remain compliant with the ASME Code and any built in assumptions

in the ASME Code formulas. The customary Imperial database is

used for consistency. The finalized results are reflected to show

the users set of selected units.


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EMERGENCY COOLERE-2226FileName : E-2226--------------------------------------------

Warnings and Errors : Step: 0 3:54p Dec 18,2015

Class From To : Basic Element Checks.

==========================================================================

Class From To: Check of Additional Element Data

==========================================================================

There were no geometry errors or warnings.

PV Elite is a trademark of Intergraph CADWorx & Analysis Solutions, Inc. 2012


7/208

EMERGENCY COOLERE-2226PV Elite 2012 Licensee:FileName : E-2226--------------------------------------------Input Echo : Step: 1 3:54p Dec 18,2015

PV Elite Vessel Analysis Program: Input Data

EMERGENCY COOLER

E-2226

Exchanger Design Pressures and Temperatures

Shell Side Design Pressure 9.9998 kgf/cm²

Channel Side Design Pressure 8.0002 kgf/cm²

Shell Side Design Temperature 350 C

Channel Side Design Temperature 60 C

Type of Hydrotest UG99-b Note [34]

Hydrotest Position Horizontal

Projection of Nozzle from Vessel Top 0.0000 mm

Projection of Nozzle from Vessel Bottom 0.0000 mm

Minimum Design Metal Temperature -5 C

Type of Construction Welded

Special Service None

Degree of Radiography RT 1

Miscellaneous Weight Percent 0.0

Use Higher Longitudinal Stresses (Flag) Y

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 Yes


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User Defined Hydro. Press. (Used if > 0) 0.0000 kgf/cm²

User defined MAWP 0.0000 kgf/cm²

User defined MAPnc 0.0000 kgf/cm²

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 IS-875

Basic Wind Speed for IS-875 170.00 km/hr

Wind Zone Number 4

Base Elevation 30.000 cm

Percent Wind for Hydrotest 33.0

Risk Factor 1.0


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Terrain Category 3

Equipment Class 1

Topography Factor 1.0

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 IS-1893-SCM

Importance Factor for IS-1893 1.000

Soil Factor 1.200

Zone Number 3.000

Percent Seismic for Hydrotest 10.000

Design Nozzle for Des. Press. + St. Head Y

Consider MAP New and Cold in Noz. Design N

Consider External Loads for Nozzle Des. Y

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

Using Metric Material Databases, ASME II D No


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Complete Listing of Vessel Elements and Details:

Element From Node 10

Element To Node 20

Element Type Elliptical

Description Bonnet dish

Distance "FROM" to "TO" 2.5000 cm

Inside Diameter 650.00 mm

Element Thickness 8.0000 mm

Internal Corrosion Allowance 1.6000 mm

Nominal Thickness 10.000 mm

External Corrosion Allowance 0.0000 mm

Design Internal Pressure 8.0000 kgf/cm²

Design Temperature Internal Pressure 60 C

Design External Pressure 0.0000 kgf/cm²

Design Temperature External Pressure 60 C

Effective Diameter Multiplier 1.2

Material Name SA-516 70

Allowable Stress, Ambient 1406.1 kgf/cm²

Allowable Stress, Operating 1406.1 kgf/cm²

Allowable Stress, Hydrotest 1828.0 kgf/cm²

Material Density 0.007750 kgm/cm³

P Number Thickness 31.750 mm

Yield Stress, Operating 2542.3 kgf/cm²

UCS-66 Chart Curve Designation B

External Pressure Chart Name CS-2

UNS Number K02700

Product Form Plate

Efficiency, Longitudinal Seam 1.0

Efficiency, Circumferential Seam 1.0


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Elliptical Head Factor 2.0


Detail Type Insulation

Detail ID Ins: 50

Dist. from "FROM" Node / Offset dist -16.250 cm

Height/Length of Insulation 18.750 cm

Thickness of Insulation 180.00 mm

Density 0.0001100 kg/cm³

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


Element To Node 30

Element Type Cylinder

Description tube side shell
















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Detail ID Ins: 50

Dist. from "FROM" Node / Offset dist 0.0000 cm





Detail Type Nozzle

Detail ID N02


Nozzle Diameter 250.0 mm

Nozzle Schedule 20

Nozzle Class 150

Layout Angle 90.0

Blind Flange (Y/N) N

Weight of Nozzle ( Used if > 0 ) 0.0000 kgf

Grade of Attached Flange GR 1.1

Nozzle Matl SA-106 B


Detail Type Nozzle

Detail ID N01



Nozzle Schedule 20

Nozzle Class 150

Layout Angle -90.0


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


Element To Node 40

Element Type Flange

Description tube Flange


Flange Inside Diameter 650.00 mm










Material Name SA-105









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UNS Number K03504

Product Form Forgings

Perform Flange Stress Calculation (Y/N) Y

Weight of ANSI B16.5/B16.47 Flange 0.0000 kgf

Class of ANSI B16.5/B16.47 Flange

Grade of ANSI B16.5/B16.47 Flange



Detail ID Ins: 50





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


Element To Node 50

Element Type Flange

Description Shel side Flange


Flange Inside Diameter 650.00 mm








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Perform Flange Stress Calculation (Y/N) Y

Weight of ANSI B16.5/B16.47 Flange 0.0000 kgf

Class of ANSI B16.5/B16.47 Flange

Grade of ANSI B16.5/B16.47 Flange



Detail ID Ins: 50





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


Element To Node 60

Element Type Cylinder

Description









16/208










Detail Type Saddle

Detail ID saddle1


Width of Saddle 200.00 mm

Height of Saddle at Bottom 700.00 mm

Saddle Contact Angle 120.0

Height of Composite Ring Stiffener 0.0000 mm

Width of Wear Plate 300.00 mm

Thickness of Wear Plate 10.000 mm

Contact Angle, Wear Plate (degrees) 130.0


Detail Type Saddle

Detail ID Sdl 2 Fr50


Width of Saddle 200.00 mm

Height of Saddle at Bottom 700.00 mm

Saddle Contact Angle 120.0

Height of Composite Ring Stiffener 0.0000 mm

Width of Wear Plate 300.00 mm

Thickness of Wear Plate 10.000 mm


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Contact Angle, Wear Plate (degrees) 130.0



Detail ID Ins: 50






Detail Type Nozzle

Detail ID N04



Nozzle Schedule 20

Nozzle Class 300

Layout Angle 90.0






Detail Type Nozzle

Detail ID N03



Nozzle Schedule 20

Nozzle Class 300


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Layout Angle -90.0





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


Element To Node 70

Element Type Elliptical

Description Shell




















19/208




UNS Number K02700

Product Form Plate



Elliptical Head Factor 2.0



Detail ID Ins: 50







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EMERGENCY COOLERE-2226PV Elite 2012 Licensee: IBI CHEMATUR ENGINEERING & CONSULTANCY LTD.FileName : E-2226--------------------------------------------XY Coordinate Calculations : Step: 2 3:54p Dec 18,2015

XY Coordinate Calculations

| | | | | |

From| To | X (Horiz.)| Y (Vert.) |DX (Horiz.)| DY (Vert.) |

| | cm | cm | cm | cm |

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

Bonnet dis| 2.50000 | ... | 2.50000 | ... |

tube side| 67.5000 | ... | 65.0000 | ... |

tube Flang| 76.0000 | ... | 8.50000 | ... |

Shel side| 90.0000 | ... | 8.50000 | ... |

50| 60| 510.000 | ... | 420.000 | ... |

Shell| 512.500 | ... | 2.50000 | ... |



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EMERGENCY COOLERE-2226PV Elite 2012 Licensee: IBI CHEMATUR ENGINEERING & CONSULTANCY LTD.FileName : E-2226--------------------------------------------Flg Calc [Int P] : FLANGE1 Flng: 7 3:54p Dec 18,2015

Warnings for Flange : FLANGE1 :

Note: Flange Hub Taper 0.3750 is > 0.33. Check Fig. 2-4(6) of Appendix 2.

This warning should not be considered for Standard Flanges as permitted by

ASME VIII in Table U-3 or for non-Code vessels.

Flange Input Data Values Description: FLANGE1 :

tube Flange

Description of Flange Geometry (Type) Integral Weld Neck

Design Pressure P 8.00 kgf/cm²

Design Temperature 60 C

Internal Corrosion Allowance ci 1.6000 mm

External Corrosion Allowance ce 0.0000 mm

Use Corrosion Allowance in Thickness Calcs. No

Flange Inside Diameter B 650.000 mm

Flange Outside Diameter A 830.000 mm

Flange Thickness t 45.0000 mm

Thickness of Hub at Small End go 10.0000 mm

Thickness of Hub at Large End g1 25.0000 mm

Length of Hub h 40.0000 mm

Flange Material SA-105

Flange Material UNS number K03504

Flange Allowable Stress At Temperature Sfo 1406.10 kgf/cm²

Flange Allowable Stress At Ambient Sfa 1406.10 kgf/cm²


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Bolt Material SA-193 B7

Bolt Allowable Stress At Temperature Sb 1757.68 kgf/cm²

Bolt Allowable Stress At Ambient Sa 1757.68 kgf/cm²

Diameter of Bolt Circle C 770.000 mm

Nominal Bolt Diameter dB 20.0000 mm

Type of Threads TEMA Metric

Number of Bolts 28

Flange Face Outside Diameter Fod 725.000 mm

Flange Face Inside Diameter Fid 650.000 mm

Flange Facing Sketch 1, Code Sketch 1a

Gasket Outside Diameter Go 720.000 mm

Gasket Inside Diameter Gi 670.000 mm

Gasket Factor m 4.5000

Gasket Design Seating Stress y 254.93 kgf/cm²

Column for Gasket Seating 2, Code Column II

Gasket Thickness tg 3.0000 mm

ASME Code, Section VIII, Division 1, 2010, 2011a

Hub Small End Required Thickness due to Internal Pressure:

= (P*(D/2+Ca))/(S*E-0.6*P) per UG-27 (c)(1)

= (8.00*(650.0000/2+1.6000))/(1406.10*1.00-0.6*8.00)+Ca

= 3.4646 mm

Hub Small End Hub MAWP:


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= (S*E*t)/(R+0.6*t) per UG-27 (c)(1)

= (1406.10 * 1.00 * 8.4000 )/(326.6000 + 0.6 * 8.4000 )

= 35.615 kgf/cm²

Corroded Flange ID, Bcor = B+2*Fcor 653.200 mm

Corroded Large Hub, g1Cor = g1-ci 23.400 mm

Corroded Small Hub, g0Cor = go-ci 8.400 mm

Code R Dimension, R = ((C-Bcor)/2)-g1cor 35.000 mm

Gasket Contact Width, N = (Go - Gi) / 2 25.000 mm

Basic Gasket Width, bo = N / 2 12.500 mm

Effective Gasket Width, b = Cb sqrt(bo) 8.909 mm

Gasket Reaction Diameter, G = Go - 2 * b 702.181 mm

Basic Flange and Bolt Loads:

Hydrostatic End Load due to Pressure [H]:

= 0.785 * G² * Peq

= 0.785 * 702.1815² * 8.000

= 30979.752 kgf

Contact Load on Gasket Surfaces [Hp]:

= 2 * b * Pi * G * m * P

= 2 * 8.9093 * 3.1416 * 702.1815 * 4.5000 * 8.00

= 14150.538 kgf

Hydrostatic End Load at Flange ID [Hd]:

= Pi * Bcor² * P / 4

= 3.1416 * 653.2000² *8.0000/4

= 26808.443 kgf

Pressure Force on Flange Face [Ht]:

= H - Hd


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= 30979 - 26808

= 4171.310 kgf

Operating Bolt Load [Wm1]:

= max( H + Hp + H'p, 0 )

= max( 30979 + 14150 + 0 , 0 )

= 45130.293 kgf

= 48551.461 kgf , Mating Flange Load Governs

Gasket Seating Bolt Load [Wm2]:

= y * b * Pi * G + yPart * bPart * lp

= 254.93*8.9093*3.141*702.181+0.00*0.0000*0.00

= 50101.949 kgf

Required Bolt Area [Am]:

= Maximum of Wm1/Sb, Wm2/Sa

= Maximum of 48551/1757 , 50101/1757

= 28.505 cm²

ASME Maximum Circumferential Spacing between Bolts per App. 2 eq. (3) [Bsmax]:

= 2a + 6t/(m + 0.5)

= 2 * 20.000 + 6 * 45.000/(4.50 + 0.5)

= 94.000 mm

Actual Circumferential Bolt Spacing [Bs]:

= C * sin( pi / n ) )

= 770.000 * sin( 3.142/28 )

= 86.213 mm

ASME Moment Multiplier for Bolt Spacing per App. 2 eq. (7) [Bsc]:

= max( sqrt( Bs/( 2a + t )), 1 )

= max( sqrt( 86.213/( 2 * 20.000 + 45.000 )), 1 )

= 1.0071


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Bolting Information for TEMA Metric Thread Series (Non Mandatory):

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

Minimum Actual Maximum

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

Bolt Area, cm² 28.505 60.774

Radial distance bet. hub and bolts 31.750 35.000

Radial distance bet. bolts and the edge 23.810 30.000

Circumferential spacing between bolts 52.390 86.213 94.000

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

Min. Gasket Contact Width (Brownell Young) [Not an ASME Calc] [Nmin]:

= Ab * Sa/( y * Pi * (Go + Gi) )

= 60.774 * 1757.68/(254.93 * 3.14 * (720.000 + 670.00 ) )

= 9.596 mm

Note: Recommended Min. Width for Sheet and Composite Gaskets per table 2-4 :

= 25.000 mm

Flange Design Bolt Load, Gasket Seating [W]:

= Sa * ( Am + Ab ) / 2

= 1757.68 * ( 28.5047 + 60.7743 )/2

= 78461.62 kgf

Gasket Load for the Operating Condition [HG]:

= Wm1 - H

= 48551 - 30979

= 17571.71 kgf

Moment Arm Calculations:

Distance to Gasket Load Reaction [hg]:


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= (C - G ) / 2

= ( 770.0000 - 702.1815 )/2

= 33.9093 mm

Distance to Face Pressure Reaction [ht]:

= ( R + g1 + hg ) / 2

= ( 35.0000 + 23.4000 + 33.9093 )/2

= 46.1546 mm

Distance to End Pressure Reaction [hd]:

= R + ( g1 / 2 )

= 35.0000 + ( 23.4000/2.0 )

= 46.7000 mm

Summary of Moments for Internal Pressure:

Loading Force Distance Bolt Corr Moment

End Pressure, Md 26808. 46.7000 1.0071 1261. kgf-m.

Face Pressure, Mt 4171. 46.1546 1.0071 194. kgf-m.

Gasket Load, Mg 17572. 33.9093 1.0071 600. kgf-m.

Gasket Seating, Matm 78462. 33.9093 1.0071 2679. kgf-m.

Total Moment for Operation, Mop 2055. kgf-m.

Total Moment for Gasket seating, Matm 2679. kgf-m.

Effective Hub Length, ho = sqrt(Bcor*goCor) 74.073 mm

Hub Ratio, h/h0 = HL / H0 0.540

Thickness Ratio, g1/g0 = (g1Cor/goCor) 2.786

Flange Factors for Integral Flange:

Factor F per 2-7.2 0.804

Factor V per 2-7.3 0.159

Factor f per 2-7.6 2.239


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Factors from Figure 2-7.1 K = 1.271

T = 1.810 U = 9.057

Y = 8.242 Z = 4.254

d = .29821E+06 mm ³ e = 0.0109 mm ^-1

Stress Factors ALPHA = 1.488

BETA = 1.651 GAMMA = 0.822

DELTA = 0.306 Lamda = 1.128

Longitudinal Hub Stress, Operating [SHo]:

= ( f * Mop / Bcor ) / ( L * g1² )

= (2.2388*2054/653.2000)/(1.1280*23.4000²)

= 1140.27 kgf/cm²

Longitudinal Hub Stress, Seating [SHa]:

= ( f * Matm / Bcor ) / ( L * g1² )

= (2.2388*2679/653.2000)/(1.1280*23.4000²)

= 1486.91 kgf/cm²

Radial Flange Stress, Operating [SRo]:

= ( Beta * Mop / Bcor ) / ( L * t² )

= (1.6512*2054/653.2000)/(1.1280*45.0000²)

= 227.41 kgf/cm²

Radial Flange Stress, Seating [SRa]:

= ( Beta * Matm/Bcor ) / ( L * t² )

= (1.6512*2679/653.2000)/(1.1280*45.0000²)

= 296.54 kgf/cm²

Tangential Flange Stress, Operating [STo]:

= ( Y * Mo / (t² * Bcor) ) - Z * SRo

= (8.2422*2054/(45.0000²*653.2000))-4.2542*227

= 312.97 kgf/cm²


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Tangential Flange Stress, Seating [STa]:

= ( y * Matm / (t² * Bcor) ) - Z * SRa

= (8.2422*2679/(45.0000²*653.2000))-4.2542*296

= 408.11 kgf/cm²

Average Flange Stress, Operating [SAo]:

= ( SHo + max( SRo, STo ) ) / 2

= (1140+max(227,312))/2

= 726.62 kgf/cm²

Average Flange Stress, Seating [SAa]:

= ( SHa + max( SRa, STa ) ) / 2

= (1486+max(296,408))/2

= 947.51 kgf/cm²

Bolt Stress, Operating [BSo]:

= ( Wm1 / Ab )

= (48551/60.7743)

= 798.88 kgf/cm²

Bolt Stress, Seating [BSa]:

= ( Wm2 / Ab )

= (50101/60.7743)

= 824.40 kgf/cm²

Stress Computation Results: Operating Gasket Seating

Actual Allowed Actual Allowed

Longitudinal Hub 1140. 2109. 1487. 2109. kgf/cm²

Radial Flange 227. 1406. 297. 1406. kgf/cm²

Tangential Flange 313. 1406. 408. 1406. kgf/cm²

Maximum Average 727. 1406. 948. 1406. kgf/cm²

Bolting 799. 1758. 824. 1758. kgf/cm²


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Minimum Required Flange Thickness 32.614 mm

Estimated M.A.W.P. ( Operating ) 14.8 kgf/cm²

Estimated Finished Weight of Flange at given Thk. 84.3 kgm

Estimated Unfinished Weight of Forging at given Thk 137.8 kgm

Flange Rigidity Based on Required Thickness [ASME]:

Flange Rigidity Index, Seating (rotation check) per APP. 2 [Js]:

= 52.14 * Ma / Bsc * Cnv_fac * V / ( Lambda * Eamb * go 2 * ho * Ki )

= 52.14 * 2679.5/1.0896 * 100000.023 * 0.159/( 0.864 * 2067025 *

8.400 2 * 74.073 * 0.300 )

= 0.727 (should be


30/208


= 52.14 * Mo / Bsc * Cnv_fac * V / ( Lambda * Eop * goc 2 * ho * Ki )

= 52.14 * 2054.8/1.0071 * 100000.023 * 0.159/( 1.128 * 2044314

* 8.400 2 * 74.073 * 0.300 )

= 0.467 (should be


31/208






Flange Input Data Values Description: FLANGE1 :

Shel side Flange

Description of Flange Geometry (Type) Integral Weld Neck

Design Pressure P 10.00 kgf/cm²

Design Temperature 350 C

Internal Corrosion Allowance ci 1.6000 mm

External Corrosion Allowance ce 0.0000 mm

Use Corrosion Allowance in Thickness Calcs. No

Flange Inside Diameter B 650.000 mm

Flange Outside Diameter A 830.000 mm

Flange Thickness t 45.0000 mm

Thickness of Hub at Small End go 10.0000 mm

Thickness of Hub at Large End g1 25.0000 mm

Length of Hub h 40.0000 mm

Flange Material SA-105

Flange Material UNS number K03504

Flange Allowable Stress At Temperature Sfo 1241.39 kgf/cm²

Flange Allowable Stress At Ambient Sfa 1406.14 kgf/cm²


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Bolt Material SA-193 B7

Bolt Allowable Stress At Temperature Sb 1757.68 kgf/cm²

Bolt Allowable Stress At Ambient Sa 1757.68 kgf/cm²

Diameter of Bolt Circle C 770.000 mm

Nominal Bolt Diameter dB 20.0000 mm

Type of Threads TEMA Metric

Number of Bolts 28

Flange Face Outside Diameter Fod 725.000 mm

Flange Face Inside Diameter Fid 650.000 mm

Flange Facing Sketch 1, Code Sketch 1a

Gasket Outside Diameter Go 720.000 mm

Gasket Inside Diameter Gi 670.000 mm

Gasket Factor m 2.5000

Gasket Design Seating Stress y 203.88 kgf/cm²

Column for Gasket Seating 2, Code Column II

Gasket Thickness tg 3.0000 mm


Hub Small End Required Thickness due to Internal Pressure:

= (P*(D/2+Ca))/(S*E-0.6*P) per UG-27 (c)(1)

= (10.00*(650.0000/2+1.6000))/(1241.39*1.00-0.6*10.00)+Ca

= 4.2437 mm

Hub Small End Hub MAWP:


33/208


= (S*E*t)/(R+0.6*t) per UG-27 (c)(1)

= (1241.39 * 1.00 * 8.4000 )/(326.6000 + 0.6 * 8.4000 )

= 31.443 kgf/cm²

Corroded Flange ID, Bcor = B+2*Fcor 653.200 mm

Corroded Large Hub, g1Cor = g1-ci 23.400 mm

Corroded Small Hub, g0Cor = go-ci 8.400 mm

Code R Dimension, R = ((C-Bcor)/2)-g1cor 35.000 mm

Gasket Contact Width, N = (Go - Gi) / 2 25.000 mm

Basic Gasket Width, bo = N / 2 12.500 mm

Effective Gasket Width, b = Cb sqrt(bo) 8.909 mm

Gasket Reaction Diameter, G = Go - 2 * b 702.181 mm

Basic Flange and Bolt Loads:

Hydrostatic End Load due to Pressure [H]:

= 0.785 * G² * Peq

= 0.785 * 702.1815² * 10.000

= 38724.695 kgf

Contact Load on Gasket Surfaces [Hp]:

= 2 * b * Pi * G * m * P

= 2 * 8.9093 * 3.1416 * 702.1815 * 2.5000 * 10.00

= 9826.765 kgf

Hydrostatic End Load at Flange ID [Hd]:

= Pi * Bcor² * P / 4

= 3.1416 * 653.2000² *10.0000/4

= 33510.559 kgf

Pressure Force on Flange Face [Ht]:

= H - Hd


34/208


= 38724 - 33510

= 5214.136 kgf

Operating Bolt Load [Wm1]:

= max( H + Hp + H'p, 0 )

= max( 38724 + 9826 + 0 , 0 )

= 48551.461 kgf

Gasket Seating Bolt Load [Wm2]:

= y * b * Pi * G + yPart * bPart * lp

= 203.88*8.9093*3.141*702.181+0.00*0.0000*0.00

= 40070.398 kgf

= 50101.949 kgf , Mating Flange Load Governs

Required Bolt Area [Am]:

= Maximum of Wm1/Sb, Wm2/Sa

= Maximum of 48551/1757 , 50101/1757

= 28.505 cm²

ASME Maximum Circumferential Spacing between Bolts per App. 2 eq. (3) [Bsmax]:

= 2a + 6t/(m + 0.5)

= 2 * 20.000 + 6 * 45.000/(2.50 + 0.5)

= 130.000 mm

Actual Circumferential Bolt Spacing [Bs]:

= C * sin( pi / n ) )

= 770.000 * sin( 3.142/28 )

= 86.213 mm

ASME Moment Multiplier for Bolt Spacing per App. 2 eq. (7) [Bsc]:

= max( sqrt( Bs/( 2a + t )), 1 )

= max( sqrt( 86.213/( 2 * 20.000 + 45.000 )), 1 )

= 1.0071


35/208


Bolting Information for TEMA Metric Thread Series (Non Mandatory):

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

Minimum Actual Maximum

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

Bolt Area, cm² 28.505 60.774

Radial distance bet. hub and bolts 31.750 35.000

Radial distance bet. bolts and the edge 23.810 30.000

Circumferential spacing between bolts 52.390 86.213 130.000

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

Min. Gasket Contact Width (Brownell Young) [Not an ASME Calc] [Nmin]:

= Ab * Sa/( y * Pi * (Go + Gi) )

= 60.774 * 1757.68/(203.88 * 3.14 * (720.000 + 670.00 ) )

= 11.998 mm

Note: Recommended Min. Width for Sheet and Composite Gaskets per table 2-4 :

= 25.000 mm

Flange Design Bolt Load, Gasket Seating [W]:

= Sa * ( Am + Ab ) / 2

= 1757.68 * ( 28.5047 + 60.7743 )/2

= 78461.62 kgf

Gasket Load for the Operating Condition [HG]:

= Wm1 - H

= 48551 - 38724

= 9826.77 kgf

Moment Arm Calculations:

Distance to Gasket Load Reaction [hg]:


36/208


= (C - G ) / 2

= ( 770.0000 - 702.1815 )/2

= 33.9093 mm

Distance to Face Pressure Reaction [ht]:

= ( R + g1 + hg ) / 2

= ( 35.0000 + 23.4000 + 33.9093 )/2

= 46.1546 mm

Distance to End Pressure Reaction [hd]:

= R + ( g1 / 2 )

= 35.0000 + ( 23.4000/2.0 )

= 46.7000 mm

Summary of Moments for Internal Pressure:

Loading Force Distance Bolt Corr Moment

End Pressure, Md 33511. 46.7000 1.0071 1576. kgf-m.

Face Pressure, Mt 5214. 46.1546 1.0071 242. kgf-m.

Gasket Load, Mg 9827. 33.9093 1.0071 336. kgf-m.

Gasket Seating, Matm 78462. 33.9093 1.0071 2679. kgf-m.

Total Moment for Operation, Mop 2154. kgf-m.

Total Moment for Gasket seating, Matm 2679. kgf-m.

Effective Hub Length, ho = sqrt(Bcor*goCor) 74.073 mm

Hub Ratio, h/h0 = HL / H0 0.540

Thickness Ratio, g1/g0 = (g1Cor/goCor) 2.786

Flange Factors for Integral Flange:

Factor F per 2-7.2 0.804

Factor V per 2-7.3 0.159

Factor f per 2-7.6 2.239


37/208


Factors from Figure 2-7.1 K = 1.271

T = 1.810 U = 9.057

Y = 8.242 Z = 4.254

d = .29821E+06 mm ³ e = 0.0109 mm ^-1

Stress Factors ALPHA = 1.488

BETA = 1.651 GAMMA = 0.822

DELTA = 0.306 Lamda = 1.128

Longitudinal Hub Stress, Operating [SHo]:

= ( f * Mop / Bcor ) / ( L * g1² )

= (2.2388*2154/653.2000)/(1.1280*23.4000²)

= 1195.31 kgf/cm²

Longitudinal Hub Stress, Seating [SHa]:

= ( f * Matm / Bcor ) / ( L * g1² )

= (2.2388*2679/653.2000)/(1.1280*23.4000²)

= 1486.91 kgf/cm²

Radial Flange Stress, Operating [SRo]:

= ( Beta * Mop / Bcor ) / ( L * t² )

= (1.6512*2154/653.2000)/(1.1280*45.0000²)

= 238.38 kgf/cm²

Radial Flange Stress, Seating [SRa]:

= ( Beta * Matm/Bcor ) / ( L * t² )

= (1.6512*2679/653.2000)/(1.1280*45.0000²)

= 296.54 kgf/cm²

Tangential Flange Stress, Operating [STo]:

= ( Y * Mo / (t² * Bcor) ) - Z * SRo

= (8.2422*2154/(45.0000²*653.2000))-4.2542*238

= 328.08 kgf/cm²


38/208


Tangential Flange Stress, Seating [STa]:

= ( y * Matm / (t² * Bcor) ) - Z * SRa

= (8.2422*2679/(45.0000²*653.2000))-4.2542*296

= 408.11 kgf/cm²

Average Flange Stress, Operating [SAo]:

= ( SHo + max( SRo, STo ) ) / 2

= (1195+max(238,328))/2

= 761.70 kgf/cm²

Average Flange Stress, Seating [SAa]:

= ( SHa + max( SRa, STa ) ) / 2

= (1486+max(296,408))/2

= 947.51 kgf/cm²

Bolt Stress, Operating [BSo]:

= ( Wm1 / Ab )

= (48551/60.7743)

= 798.88 kgf/cm²

Bolt Stress, Seating [BSa]:

= ( Wm2 / Ab )

= (50101/60.7743)

= 824.40 kgf/cm²

Stress Computation Results: Operating Gasket Seating

Actual Allowed Actual Allowed

Longitudinal Hub 1195. 1862. 1487. 2109. kgf/cm²

Radial Flange 238. 1241. 297. 1406. kgf/cm²

Tangential Flange 328. 1241. 408. 1406. kgf/cm²

Maximum Average 762. 1241. 948. 1406. kgf/cm²

Bolting 799. 1758. 824. 1758. kgf/cm²


39/208


Minimum Required Flange Thickness 32.614 mm

Estimated M.A.W.P. ( Operating ) 15.6 kgf/cm²

Estimated Finished Weight of Flange at given Thk. 84.3 kgm

Estimated Unfinished Weight of Forging at given Thk 137.8 kgm

Flange Rigidity Based on Required Thickness [ASME]:

Flange Rigidity Index, Seating (rotation check) per APP. 2 [Js]:

= 52.14 * Ma / Bsc * Cnv_fac * V / ( Lambda * Eamb * go 2 * ho * Ki )

= 52.14 * 2679.5/1.0896 * 100000.023 * 0.159/( 0.864 * 2067025 *

8.400 2 * 74.073 * 0.300 )

= 0.727 (should be


40/208


= 52.14 * Mo / Bsc * Cnv_fac * V / ( Lambda * Eop * goc 2 * ho * Ki )

= 52.14 * 2154.0/1.0071 * 100000.023 * 0.159/( 1.128 * 1819582

* 8.400 2 * 74.073 * 0.300 )

= 0.550 (should be


41/208

EMERGENCY COOLERE-2226PV Elite 2012 Licensee: IBI CHEMATUR ENGINEERING & CONSULTANCY LTD.FileName : E-2226--------------------------------------------Internal Pressure Calculations : Step: 5 3:54p Dec 18,2015

Element Thickness, Pressure, Diameter and Allowable Stress :

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

From| To | + Liq. Hd | Thickness | Allowance | Diameter | Stress(SE)|

| | kgf/cm² | mm | mm | mm | kgf/cm² |

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

Bonnet dis| 8.0000 | 10.000 | 1.6000 | 650.00 | 1406.1 |

tube side| 8.0000 | 10.000 | 1.6000 | 650.00 | 1406.1 |

tube Flang| 8.0000 | 45.000 | 1.6000 | 650.00 | 1406.1 |

Shel side| 10.000 | 45.000 | 1.6000 | 650.00 | 1241.4 |

50| 60| 10.000 | 10.000 | 1.6000 | 650.00 | 1241.4 |

Shell| 10.000 | 10.000 | 1.6000 | 650.00 | 1310.0 |

Element Required Thickness and MAWP :

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

From| To | Pressure | Corroded | New & Cold | Thickness | Thickness |

| | kgf/cm² | kgf/cm² | kgf/cm² | mm | mm |

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

Bonnet dis| 8.00000 | 27.6797 | 34.5277 | 8.00000 | 3.44714 |

tube side| 8.00000 | 35.6157 | 42.4816 | 10.0000 | 3.46450 |

tube Flang| 8.00000 | 14.7975 | 18.2587 | 45.0000 | 32.6136 |

Shel side| 10.0000 | 15.5779 | 20.5029 | 45.0000 | 32.6136 |

50| 60| 10.0000 | 31.4426 | 42.4816 | 10.0000 | 4.24371 |

Shell| 10.0000 | 25.7875 | 34.5277 | 8.00000 | 4.07883 |

Summary of Heat Exchanger Maximum Allowable Working Pressures :

Note: The MAWPs and MAPs for the Exchanger elements all appear to


42/208


be zero or some could not be calculated. Please fill these

values in on the main tubesheet tab.

Internal Pressure Calculation Results :


Elliptical Head From 10 To 20 SA-516 70 , UCS-66 Crv. B at 60 C

Bonnet dish

Material UNS Number: K02700

Required Thickness due to Internal Pressure [tr]:

= (P*D*Kcor)/(2*S*E-0.2*P) Appendix 1-4(c)

= (8.000*653.2000*0.994)/(2*1406.14*1.00-0.2*8.000)

= 1.8471 + 1.6000 = 3.4471 mm

Max. Allowable Working Pressure at given Thickness, corroded [MAWP]:

= (2*S*E*t)/(Kcor*D+0.2*t) per Appendix 1-4 (c)

= (2*1406.14*1.00*6.4000)/(0.994*653.2000+0.2*6.4000)

= 27.680 kgf/cm²

Maximum Allowable Pressure, New and Cold [MAPNC]:

= (2*S*E*t)/(K*D+0.2*t) per Appendix 1-4 (c)

= (2*1406.14*1.00*8.0000)/(1.000*650.0000+0.2*8.0000)

= 34.528 kgf/cm²

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

= (P*(Kcor*D+0.2*t))/(2*E*t)


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= (8.000*(0.994*653.2000+0.2*6.4000))/(2*1.00*6.4000)

= 406.403 kgf/cm²

Straight Flange Required Thickness:

= (P*R)/(S*E-0.6*P) + c per UG-27 (c)(1)

= (8.000*326.6000)/(1406.14*1.00-0.6*8.000)+1.600

= 3.465 mm

Straight Flange Maximum Allowable Working Pressure:

= (S*E*t)/(R+0.6*t) per UG-27 (c)(1)

= (1406.14 * 1.00 * 8.4000 )/(326.6000 + 0.6 * 8.4000 )

= 35.616 kgf/cm²

Factor K, corroded condition [Kcor]:

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

= ( 2 + ( 653.200/( 2 * 164.100 )) 2)/6

= 0.993516

Percent Elong. per UCS-79, VIII-1-01-57 (75*tnom/Rf)*(1-Rf/Ro) 6.494 %

Note: Please Check Requirements of UCS-79 as Elongation is > 5%.

MDMT Calculations in the Knuckle Portion:

Govrn. thk, tg = 8.000 , tr = 3.624 , c = 1.6000 mm , E* = 1.00

Stress Ratio = tr * (E*)/(tg - c) = 0.566 , Temp. Reduction = 26 C

Min Metal Temp. w/o impact per UCS-66 -29 C

Min Metal Temp. at Required thickness (UCS 66.1) -48 C

MDMT Calculations in the Head Straight Flange:


44/208






Cylindrical Shell From 20 To 30 SA-516 70 , UCS-66 Crv. B at 60 C

tube side shell



= (P*R)/(S*E-0.6*P) per UG-27 (c)(1)

= (8.000*326.6000)/(1406.14*1.00-0.6*8.000)

= 1.8645 + 1.6000 = 3.4645 mm


= (S*E*t)/(R+0.6*t) per UG-27 (c)(1)

= (1406.14*1.00*8.4000)/(326.6000+0.6*8.4000)

= 35.616 kgf/cm²


= (S*E*t)/(R+0.6*t) per UG-27 (c)(1)

= (1406.14*1.00*10.0000)/(325.0000+0.6*10.0000)

= 42.482 kgf/cm²


= (P*(R+0.6*t))/(E*t)


45/208


= (8.000*(326.6000+0.6*8.4000))/(1.00*8.4000)

= 315.848 kgf/cm²

Percent Elongation per UCS-79 (50*tnom/Rf)*(1-Rf/Ro) 1.515 %

Minimum Design Metal Temperature Results:





Cylindrical Shell From 50 To 60 SA-105 , UCS-66 Crv. B at 350 C



= (P*R)/(S*E-0.6*P) per UG-27 (c)(1)

= (10.000*326.6000)/(1241.39*1.00-0.6*10.000)

= 2.6437 + 1.6000 = 4.2437 mm


= (S*E*t)/(R+0.6*t) per UG-27 (c)(1)

= (1241.39*1.00*8.4000)/(326.6000+0.6*8.4000)

= 31.443 kgf/cm²


= (S*E*t)/(R+0.6*t) per UG-27 (c)(1)

= (1406.14*1.00*10.0000)/(325.0000+0.6*10.0000)


46/208


= 42.482 kgf/cm²


= (P*(R+0.6*t))/(E*t)

= (10.000*(326.6000+0.6*8.4000))/(1.00*8.4000)

= 394.810 kgf/cm²

Minimum Design Metal Temperature Results:





Elliptical Head From 60 To 70 SA-516 70 , UCS-66 Crv. B at 350 C

Shell



= (P*D*Kcor)/(2*S*E-0.2*P) Appendix 1-4(c)

= (10.000*653.2000*0.994)/(2*1310.01*1.00-0.2*10.000)

= 2.4788 + 1.6000 = 4.0788 mm


= (2*S*E*t)/(Kcor*D+0.2*t) per Appendix 1-4 (c)

= (2*1310.01*1.00*6.4000)/(0.994*653.2000+0.2*6.4000)

= 25.787 kgf/cm²


47/208



= (2*S*E*t)/(K*D+0.2*t) per Appendix 1-4 (c)

= (2*1406.14*1.00*8.0000)/(1.000*650.0000+0.2*8.0000)

= 34.528 kgf/cm²


= (P*(Kcor*D+0.2*t))/(2*E*t)

= (10.000*(0.994*653.2000+0.2*6.4000))/(2*1.00*6.4000)

= 508.004 kgf/cm²

Straight Flange Required Thickness:

= (P*R)/(S*E-0.6*P) + c per UG-27 (c)(1)

= (10.000*326.6000)/(1310.01*1.00-0.6*10.000)+1.600

= 4.105 mm

Straight Flange Maximum Allowable Working Pressure:

= (S*E*t)/(R+0.6*t) per UG-27 (c)(1)

= (1310.01 * 1.00 * 8.4000 )/(326.6000 + 0.6 * 8.4000 )

= 33.181 kgf/cm²

Factor K, corroded condition [Kcor]:

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

= ( 2 + ( 653.200/( 2 * 164.100 )) 2)/6

= 0.993516

Percent Elong. per UCS-79, VIII-1-01-57 (75*tnom/Rf)*(1-Rf/Ro) 6.494 %

Note: Please Check Requirements of UCS-79 as Elongation is > 5%.

MDMT Calculations in the Knuckle Portion:


48/208






MDMT Calculations in the Head Straight Flange:





Hydrostatic Test Pressure Results:

Exchanger Shell Side Hydrostatic Test Pressures:

Pressure per UG99b = 1.3 * M.A.W.P. * Sa/S 0.000 kgf/cm²

Pressure per UG99b[34] = 1.3 * Design Pres * Sa/S 13.954 kgf/cm²

Pressure per UG99c = 1.3 * M.A.P. - Head(Hyd) 0.000 kgf/cm²

Pressure per UG100 = 1.1 * M.A.W.P. * Sa/S 0.000 kgf/cm²

Pressure per PED = 1.43 * MAWP 0.000 kgf/cm²

Exchanger Channel Side Hydrostatic Test Pressures:

Pressure per UG99b = 1.3 * M.A.W.P. * Sa/S 0.000 kgf/cm²

Pressure per UG99b[34] = 1.3 * Design Pres * Sa/S 10.400 kgf/cm²

Pressure per UG99c = 1.3 * M.A.P. - Head(Hyd) 0.000 kgf/cm²


49/208


Pressure per UG100 = 1.1 * M.A.W.P. * Sa/S 0.000 kgf/cm²

Pressure per PED = 1.43 * MAWP 0.000 kgf/cm²

UG-99(b) Note 34, Test Pressure Calculation [Shell Side]:

= Test Factor * Design Pressure * Stress Ratio

= 1.3 * 10.000 * 1.073

= 13.954 kgf/cm²

UG-99(b) Note 34, Test Pressure Calculation [Channel Side]:

= Test Factor * Design Pressure * Stress Ratio

= 1.3 * 8.000 * 1.000

= 10.400 kgf/cm²

Horizontal Test performed per: UG-99b (Note 34)

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 Hydrostatic Test Pressure:

From To Stress Allowable Ratio Pressure

Bonnet dish 426.2 1828.0 0.233 10.46

tube side shell 346.4 1828.0 0.189 10.46

50 60 464.0 1828.0 0.254 14.02

Shell 570.9 1828.0 0.312 14.02

Elements Suitable for Internal Pressure.



50/208

EMERGENCY COOLERE-2226PV Elite 2012 Licensee: IBI CHEMATUR ENGINEERING & CONSULTANCY LTD.FileName : E-2226--------------------------------------------External Pressure Calculations : Step: 6 3:54p Dec 18,2015

External Pressure Calculation Results :


Elliptical Head From 10 to 20 Ext. Chart: CS-2 at 60 C

Bonnet dish

Elastic Modulus from Chart: CS-2 at 60 C : 0.204E+07 kgf/cm ²

Results for Maximum Allowable External Pressure (MAEP):

Tca OD D/t Factor A B

6.400 666.00 104.06 0.0013347 955.24

EMAP = B/(K0*D/t) = 955.2408/(0.9000 *104.0625 ) = 10.1994 kgf/cm²

Check the requirements of UG-33(a)(1) using P = 1.67 * External Design

pressure for this head.



= ((2*S*E*t)/(Kcor*D+0.2*t))/1.67 per Appendix 1-4 (c)

= ((2*1406.14*1.00*6.4000)/(0.994*653.2000+0.2*6.4000))/1.67

= 16.575 kgf/cm²

Maximum Allowable External Pressure [MAEP]:

= min( MAEP, MAWP )

= min( 10.20 , 16.5747 )


51/208


= 10.199 kgf/cm²

Cylindrical Shell From 20 to 30 Ext. Chart: CS-2 at 60 C

tube side shell



Tca OD SLEN D/t L/D Factor A B

8.400 670.00 729.17 79.76 1.0883 0.0017266 1022.94

EMAP = (4*B)/(3*(D/t)) = (4*1022.9390 )/(3*79.7619 ) = 17.0999 kgf/cm²

Results for Maximum Stiffened Length (Slen):


8.400 670.00 729.17 79.76 1.0883 0.0017266 1022.94

EMAP = (4*B)/(3*(D/t)) = (4*1022.9390 )/(3*79.7619 ) = 17.0999 kgf/cm²








52/208




Cylindrical Shell From 50 to 60 Ext. Chart: CS-2 at 350 C




8.400 670.00 4279.17 79.76 6.3868 0.0002515 220.82

EMAP = (4*B)/(3*(D/t)) = (4*220.8170 )/(3*79.7619 ) = 3.6913 kgf/cm²

Results for Maximum Stiffened Length (Slen):


8.400 670.00 4279.17 79.76 6.3868 0.0002515 220.82

EMAP = (4*B)/(3*(D/t)) = (4*220.8170 )/(3*79.7619 ) = 3.6913 kgf/cm²

Elliptical Head From 60 to 70 Ext. Chart: CS-2 at 350 C

Shell



Tca OD D/t Factor A B

6.400 666.00 104.06 0.0013347 629.45

EMAP = B/(K0*D/t) = 629.4528/(0.9000 *104.0625 ) = 6.7209 kgf/cm²

Check the requirements of UG-33(a)(1) using P = 1.67 * External Design

pressure for this head.


53/208




= ((2*S*E*t)/(Kcor*D+0.2*t))/1.67 per Appendix 1-4 (c)

= ((2*1310.01*1.00*6.4000)/(0.994*653.2000+0.2*6.4000))/1.67

= 15.442 kgf/cm²

Maximum Allowable External Pressure [MAEP]:

= min( MAEP, MAWP )

= min( 6.72 , 15.4416 )

= 6.721 kgf/cm²

External Pressure Calculations

| | Section | Outside | Corroded | Factor | Factor |

From| To | Length | Diameter | Thickness | A | B |

| | cm | mm | mm | | kgf/cm² |

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

10| 20| No Calc | 666.000 | 6.40000 | 0.0013347 | 955.241 |

20| 30| 72.9167 | 670.000 | 8.40000 | 0.0017266 | 1022.94 |

30| 40| No Calc | ... | 43.4000 | No Calc | No Calc |

40| 50| No Calc | ... | 43.4000 | No Calc | No Calc |

50| 60| 427.917 | 670.000 | 8.40000 | 0.00025151 | 220.817 |

60| 70| No Calc | 666.000 | 6.40000 | 0.0013347 | 629.453 |



54/208


| | External | External | External | External |

From| To | Actual T. | Required T.|Des. Press. | M.A.W.P. |

| | mm | mm | kgf/cm² | kgf/cm² |

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

10| 20| 8.00000 | 3.10000 | ... | 10.1994 |

20| 30| 10.0000 | No Calc | ... | 17.0999 |

30| 40| 45.0000 | 32.6136 | ... | No Calc |

40| 50| 45.0000 | 32.6136 | ... | No Calc |

50| 60| 10.0000 | No Calc | ... | 3.69127 |

60| 70| 8.00000 | 3.10000 | ... | 6.72088 |

Minimum 3.691


| | Actual Len.| Allow. Len.| Ring Inertia | Ring Inertia |

From| To | Bet. Stiff.| Bet. Stiff.| Required | Available |

| | cm | cm | cm**4 | cm**4 |

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

10| 20| No Calc | No Calc | No Calc | No Calc |

20| 30| 72.9167 | No Calc | No Calc | No Calc |



50| 60| 427.917 | No Calc | No Calc | No Calc |


Elements Suitable for External Pressure.



55/208

EMERGENCY COOLERE-2226PV Elite 2012 Licensee: IBI CHEMATUR ENGINEERING & CONSULTANCY LTD.FileName : E-2226--------------------------------------------Element and Detail Weights : Step: 7 3:54p Dec 18,2015

Element and Detail Weights

| | Element | Element | Corroded | Corroded | Extra due |

From| To | Metal Wgt. | ID Volume |Metal Wgt. | ID Volume | Misc % |

| | kgm | cm³ | kgm | cm³ | kgm |

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

10| 20| 44.4240 | 44244.1 | 37.3161 | 44859.5 | ... |

20| 30| 104.455 | 215690. | 87.9550 | 217819. | ... |

30| 40| 84.3493 | 28353.0 | 82.1916 | 28484.0 | ... |

40| 50| 84.3493 | 28353.0 | 82.1916 | 28484.0 | ... |

50| 60| 674.940 | 1.120E+06 | 568.325 | 1.134E+06 | ... |

60| 70| 44.4240 | 44244.1 | 37.3161 | 44859.5 | ... |

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

Total 1036 1480647.25 895 1498025.38 0

For elements specified as shell side elements, the volume(s) shown

above for those elements, reflects the displacement of the tubes.

Weight of Details

| | Weight of | X Offset, | Y Offset, |

From|Type| Detail | Dtl. Cent. |Dtl. Cent. | Description

| | kgm | cm | cm |

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

10|Insl| 18.2606 | -6.87500 | ... | Ins: 50

20|Insl| 34.4071 | 32.5000 | ... | Ins: 50

20|Nozl| 30.0943 | 32.5000 | 45.5175 | N02

20|Nozl| 30.0943 | 32.5000 | 45.5175 | N01

30|Insl| 6.34622 | 4.25000 | ... | Ins: 50


56/208


40|Insl| 6.34622 | 4.25000 | ... | Ins: 50

50|Sadl| 64.4614 | 40.0000 | 50.2500 | saddle1

50|Sadl| 64.4614 | 320.000 | 50.2500 | Sdl 2 Fr50

50|Insl| 222.323 | 210.000 | ... | Ins: 50

50|Nozl| 49.9064 | 36.5000 | 45.5175 | N04

50|Nozl| 49.9087 | 377.500 | 45.5175 | N03

60|Insl| 18.2606 | 9.37500 | ... | Ins: 50

30|FTsh| 146.557 | 11.7500 | ... | Tube Sheet

30|Tube| 802.569 | 209.000 | ... |

Total Weight of Each Detail Type

Total Weight of Saddles 128.9

Total Weight of Insulation 305.9

Total Weight of Nozzles 160.0

Total Weight of Exchanger Components 949.1

Total Weight of Liquid in Tubes 176.4

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

Sum of the Detail Weights 1720.4 kgm

Weight Summation

Fabricated Shop Test Shipping Erected Empty Operating

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

1036.9 2275.0 1036.9 2275.0 1036.9 2580.9

128.9 1480.0 128.9 ... 128.9 ...

160.0 ... 160.0 ... ... ...

... 176.4 ... 305.9 ... ...

... ... ... ... 305.9 ...


57/208


... ... ... ... ... ...

... ... ... ... ... ...

... ... ... ... 160.0 176.4

949.1 ... 949.1 ... ... ...

... ... ... ... 949.1 ...

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

2275.0 3931.4 2580.9 2580.9 2580.9 2757.4 kgm

Note: The shipping total has been modified because some items have

been specified as being installed in the shop.

Weight Summary

Fabricated Wt. - Bare Weight W/O Removable Internals 2275.0 kgm

Shop Test Wt. - Fabricated Weight + Water ( Full ) 3931.4 kgm

Shipping Wt. - Fab. Wt + Rem. Intls.+ Shipping App. 2580.9 kgm

Erected Wt. - Fab. Wt + Rem. Intls.+ Insul. (etc) 2580.9 kgm

Ope. Wt. no Liq - Fab. Wt + Intls. + Details + Wghts. 2580.9 kgm

Operating Wt. - Empty Wt + Operating Liq. Uncorroded 2757.4 kgm

Oper. Wt. + CA - Corr Wt. + Operating Liquid 2615.7 kgm

Field Test Wt. - Empty Weight + Water (Full) 4237.4 kgm

Exchanger Tube Data

Volume of Exchanger tubes : 176510.4 cm³

Weight of Ope Liq in tubes : 176.4 kgm

Weight of Water in tubes : 176.4 kgm

Note: The Corroded Weight and thickness are used in the Horizontal

Vessel Analysis (Ope Case) and Earthquake Load Calculations.


58/208


Outside Surface Areas of Elements

| | Surface |

From| To | Area |

| | cm² |

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

10| 20| 5392.23 |

20| 30| 13681.6 |

30| 40| 4145.33 |

40| 50| 4145.33 |

50| 60| 88404.4 |

60| 70| 5392.23 |

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

Total 121161.172 cm²



59/208

EMERGENCY COOLERE-2226PV Elite 2012 Licensee: IBI CHEMATUR ENGINEERING & CONSULTANCY LTD.FileName : E-2226--------------------------------------------

Nozzle Flange MAWP : Step: 8 3:54p Dec 18,2015

Nozzle Flange MAWP Results :

Nozzle ----- Flange Rating

Description Operating Ambient Temperature Class Grade|Group

kgf/cm² kgf/cm² C

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

N02 19.3 20.0 60 150 GR 1.1

N01 19.3 20.0 60 150 GR 1.1

N04 38.3 52.1 350 300 GR 1.1

N03 38.3 52.1 350 300 GR 1.1

Shellside Flange Rating

Lowest Flange Pressure Rating was (Ope)[ShellSide]: 38.342 kgf/cm²

Lowest Flange Pressure Rating was (Amb)[ShellSide]: 52.109 kgf/cm²

Channelside Flange Rating

Lowest Flange Pressure Rating was (Ope)[TubeSide ]: 19.273 kgf/cm²

Lowest Flange Pressure Rating was (Amb)[TubeSide ]: 19.987 kgf/cm²

Note: ANSI Ratings are per ANSI/ASME B16.5 2009 Metric Edition



60/208


Wind Load Calculation : Step: 9 3:54p Dec 18,2015

Wind Load Calculations per India Std. IS-875 (Part-3) - 1987, Amd. 1&2 (2003):

Actual Vessel Height to Diameter ratio 0.000

Force Coefficient per IS:875 Table 23, Cf 0.700

User Entered Basic Wind Speed 170.0 km/hr

Base Elevation 0.30 m

Wind Zone Number 4

Risk Factor (k1) 1.0000

Terrain Category 3

Equipment Class A

Topography Factor (k3) 1.0000

Use Gust Response Factor (Dynamic Analysis) No

User entered Beta Value ( Operating Case ) 0.0100

From fo` FO E S G(ope) G(emp) G(tst)

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

10 1048.30 13.98 0.0051 0.0411 1.0000 1.0000 1.0000

20 1048.30 13.98 0.0051 0.0411 1.0000 1.0000 1.0000

30 1048.30 13.98 0.0051 0.0411 1.0000 1.0000 1.0000

40 1048.30 13.98 0.0051 0.0411 1.0000 1.0000 1.0000

50 1048.30 13.98 0.0051 0.0411 1.0000 1.0000 1.0000

60 1048.30 13.98 0.0051 0.0411 1.0000 1.0000 1.0000

Design Wind Speed (Vz):

= Basic Wind Speed * k1 * k2 * k3

Height Factor :

= 0.6 * Vz²


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Wind Load Calculation : Step: 9 3:54p Dec 18,2015

Element Wind Load :

= Wind Area * Cf * Height Factor

From Height k1 k2 k3 Vz Cf

m m/sec

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

10 1.00 1.0000 0.9287 1.0000 43.85 0.7000

20 1.00 1.0000 0.9287 1.0000 43.85 0.7000

30 1.00 1.0000 0.9287 1.0000 43.85 0.7000

40 1.00 1.0000 0.9287 1.0000 43.85 0.7000

50 1.00 1.0000 0.9287 1.0000 43.85 0.7000

60 1.00 1.0000 0.9287 1.0000 43.85 0.7000

Wind Load Calculation

| | Wind | Wind | Wind | Wind | Element |

From| To | Height | Diameter | Area | Pressure | Wind Load |

| | cm | cm | cm² | kgf/m² | kgf |

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

10| 20| 100.000 | 123.120 | 3132.19 | 117.718 | 25.8007 |

20| 30| 100.000 | 123.600 | 8034.00 | 117.718 | 66.1781 |

30| 40| 100.000 | 121.200 | 1030.20 | 117.718 | 8.48602 |

40| 50| 100.000 | 121.200 | 1030.20 | 117.718 | 8.48602 |

50| 60| 100.000 | 123.600 | 51912.0 | 117.718 | 427.612 |

60| 70| 100.000 | 123.120 | 3132.19 | 117.718 | 25.8007 |



62/208

EMERGENCY COOLERE-2226PV Elite 2012 Licensee: IBI CHEMATUR ENGINEERING & CONSULTANCY LTD.FileName : E-2226--------------------------------------------Earthquake Load Calculation : Step: 10 3:54p Dec 18,2015

Seismic Analysis Results per IS-1893 (1984), Seismic Coefficient Method.

Soil Factor ß 1.2000

Importance Factor as Entered by User I 1.0000

Zone Number 3

Value of Alpha o per table 2 and Zone 0.0400

Horizontal Seismic Coefficient (Alpha h):

= ß * I * Alpha o

= 1.2000 * 1.0000 * 0.0400

= 0.0480

Earthquake Element Load, for the first Element:

= Earthquake Weight * Alpha h

= 326.97 * 0.0480

= 15.7 kgf

Earthquake Load Calculation

| | Earthquake | Earthquake | Element |

From| To | Height | Weight | Ope Load |

| | cm | kgf | kgf |

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

10| 20| 32.5000 | 326.965 | 15.6943 |

20| 30| 32.5000 | 326.965 | 15.6943 |

30| 40| 32.5000 | 326.965 | 15.6943 |

40| 50| 32.5000 | 326.965 | 15.6943 |

50|Sadl| 32.5000 | 326.965 | 15.6943 |

Sadl| 60| 32.5000 | 326.965 | 15.6943 |

50| 60| 32.5000 | 326.965 | 15.6943 |


63/208

EMERGENCY COOLERE-2226PV Elite 2012 Licensee: IBI CHEMATUR ENGINEERING & CONSULTANCY LTD.FileName : E-2226--------------------------------------------Earthquake Load Calculation : Step: 10 3:54p Dec 18,2015

60| 70| 32.5000 | 326.965 | 15.6943 |



64/208

EMERGENCY COOLERE-2226PV Elite 2012 Licensee: IBI CHEMATUR ENGINEERING & CONSULTANCY LTD.FileName : E-2226--------------------------------------------Center of Gravity Calculation : Step: 11 3:54p Dec 18,2015

Shop/Field Installation Options :

Insulation is installed in the Shop.

Note : The CG is computed from the first Element From Node

Center of Gravity of Saddles 270.000 cm

Center of Gravity of Insulation 255.796 cm

Center of Gravity of Nozzles 198.446 cm

Center of Gravity of Tubesheet(s) 79.250 cm

Center of Gravity of Tubes 276.500 cm

Center of Gravity of Bare Shell New and Cold 233.562 cm

Center of Gravity of Bare Shell Corroded 229.696 cm

Vessel CG in the Operating Condition 239.410 cm

Vessel CG in the Fabricated (Shop/Empty) Condition 240.430 cm

Rigging Analysis Results:

Total Effective Length of Vessel for this analysis 507.00 cm

Total vessel weight (No Liquid) Twt 2580.94 kgf

Impact weight multiplication factor Imp 1.50

Design lifting weight, DWT = Imp * Twt 3871.41 kgf

Elevation of the Tailing Lug (bottom) 180.00 cm

Elevation of the Lifting Lug (top ) 390.00 cm

Design Reaction force at the tailing lug 2757.36 kgf

Design Reaction force at the lifting lug 1114.05 kgf


65/208


CG Distance from Tailing Lug 60.43 cm

CG Distance from the Nearer Lifting Lug 60.43 cm

Critical Values:

Max Stress Elevation Allowables

kgf/cm² cm kgf/cm²

-----------|-----------|---------------|------------------------

Bending | 82.68 | 168.50 | 1177.55 (UG-23)

Shear | -12.76 | 168.50 | 984.30 (0.7*S)

-----------|-----------|---------------|------------------------

Forces and Moments at selected elevations (not all analysis points shown):

Distance Bending Moment Bending Stress Shear Force Shear Stress

cm kgf-m. kgf/cm² kgf kgf/cm²

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

0.00 0.0 0.0 -838.8 -5.1

2.50 52.6 1.6 -903.3 -4.4

67.50 629.3 18.7 -1387.3 -6.7

76.00 745.8 22.1 -1871.2 -9.0

84.50 903.5 26.8 -2355.1 -11.4

504.50 39.7 1.5 64.5 0.4

Unity Check (Actual Stress / Allowable Stress):

Maximum Unity Check is 0.0702 at elevation 168.5000 cm - Must be


66/208


--- Plot data successfully generated ...----



67/208

EMERGENCY COOLERE-2226PV Elite 2012 Licensee: IBI CHEMATUR ENGINEERING & CONSULTANCY LTD.FileName : E-2226--------------------------------------------Lifting Lug Calcs : Left Side Step: 12 3:54p Dec 18,2015

Lifting Lug Calculations: Lug(s) on Left End of Vessel

Input Values:

Lifting Lug Material SA-105

Lifting Lug Yield Stress Yield 2531.05 kgf/cm²

Total Height of Lifting Lug w 150.0000 mm

Thickness of Lifting Lug t 16.0000 mm

Diameter of Hole in Lifting Lug dh 40.0000 mm

Radius of Semi-Circular Arc of Lifting Lug r 45.0000 mm

Height of Lug from bottom to Center of Hole h 75.0000 mm

Offset from Vessel OD to Center of Hole off 230.0000 mm

Lug Fillet Weld Size tw 6.2500 mm

Length of weld along side of Lifting Lug wl 273.0000 mm

Length of Weld along Bottom of Lifting Lug wb 12.5000 mm

Thickness of Collar (if any) tc 0.0000 mm

Diameter of Collar (if any) dc 0.0000 mm

Impact Factor Impfac 1.50

Sling Angle from Horizontal 90.0000 deg

Number of Lugs in Group 1

Lifting Lug Orientation to Vessel: Perpendicular

Lift Orientation : Horizontal Lift

PV Elite does not compute weak axis bending forces on the lugs. It is

assumed that a spreader bar is used.

Computed Results:


68/208


Force Along Vessel Axis Fax 0.00 kgf

Force Normal to Vessel Fn 2757.36 kgf

Force Tangential to Vessel Ft 0.00 kgf

Converting the weld leg dimension (tw) to the weld throat dimension.

Weld Group Inertia Calculations:

Weld Group Inertia about the Circumferential Axis Ilc 1710.992 cm**4

Weld Group Centroid distance in the Long. Direction Yll 140.919 mm

Dist. of Weld Group Centroid from Lug bottom Yll_b 136.500 mm

Weld Group Inertia about the Longitudinal Axis Ill 8.626 cm**4

Weld Group Centroid Distance in the Circ. Direction Ylc 8.000 mm

Note: The Impact Factor is applied to the Forces acting on the Lug.

Primary Shear Stress in the Welds due to Shear Loads [Ssll]:

= sqrt( Fax 2 + Ft 2 + Fn 2 )/(( 2 * (wl + wb) ) * tw )

= sqrt(0 2+0 2+2757 2)/((2*(273.0+12.5))*4.4188)

= 109.28 kgf/cm²

Shear Stress in the Welds due to Bending Loads [Sblf]:

= (Fn*(h-Yll_b)) *Yll/Ilc + (Fax*off *Yll/Ilc) + (Ft*off *Ylc/Ill)

= (2757 *(75.000 -136.500 )) * 140.919/1710.992 +

(0 *0.000 * 140.919/1710.992 ) +

(0 *0.000 * 8.000/8.626 )

= -139.67 kgf/cm²

Total Shear Stress for Combined Loads [St]:


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= Ssll + Sblf

= 109.284 + -139.666

= -30.38 kgf/cm²

Allowable Shear Stress for Combined Loads [Sta]:

= 0.4 * Yield * Occfac (AISC Shear Allowable)

= 0.4 * 2531 * 1.00

= 1012.42 kgf/cm²

Shear Stress in Lug above Hole [Shs]:

= sqrt( Pl 2 + Fax 2 ) / Sha

= sqrt( 2757 2 + 0 2 )/8.000

= 344.67 kgf/cm²

Allowable Shear Stress in Lug above Hole [Sas]:

= 0.4 * Yield * Occfac

= 0.4 * 2531 * 1.00

= 1012.42 kgf/cm²

Pin Hole Bearing Stress [Pbs]:

= sqrt( Fax 2 + Fn 2 ) / ( t * dh )

= sqrt( 0 2 + 2757 2 )/( 16.000 * 40.000 )

= 430.84 kgf/cm²

Allowable Bearing Stress [Pba]:

= min( 0.75 * Yield * Occfac, 0.9 * Yield ) AISC Bearing All.

= min( 0.75 * 2531 * 1.00 , 2277.9 )

= 1898.29 kgf/cm²

Bending Stress at the Base of the Lug [Fbs]:


70/208


= Ft * off/(w * t 2/6) + Fax * off/(w 2 * t/6)

= 0 * 230.000/(150.000 * 16.000 2 /6) +

0 * 230.000/(150.000 2 * 16.000/6)

= 0.00 kgf/cm²

Tensile Stress at the Base of the Lug [Fa]:

= Fn / (w * t)

= 0/(150.000 * 16.000 )

= 114.89 kgf/cm²

Total Combined Stress at the Base of the Lug:

= Fbs + Fa

= 0.0 + 114.9

= 114.89 kgf/cm²

Lug Allowable Stress for Bending and Tension:

= min( 0.66 * Yield * Occfac, 0.75 * Yield )

= min( 0.66 * 2531 * 1.00 , 1898.3 )

= 1670.49 kgf/cm²

Required Shackle Pin Diameter [Spd]:

= sqrt[(2 * sqrt(Fn 2 + Fax 2)/( Pi * Sta))]

= sqrt[2 * sqrt(2757 2 + 0 2)/( Pi * 1012 )]

= 13.1676 mm

WRC 107 Stress Analysis for the Lifting Lug to Shell Junction in

the new and Cold Condition (no corrosion applied).

Note: Since Beta1/Beta2 >= 0.25, C22 (C22p) is adjusted per table 6

in paragraph 4.3 of WRC Bulletin 107.


71/208


Input Echo, WRC107 Item 1, Description: Lift Lug

Diameter Basis for Vessel Vbasis ID

Cylindrical or Spherical Vessel Cylsph Cylindrical

Internal Corrosion Allowance Cas 0.0000 mm

Vessel Diameter Dv 650.000 mm

Vessel Thickness Tv 10.000 mm

Design Temperature 37.78 C

Attachment Type Type Rectangular

Parameter C11 C11 25.00 mm

Parameter C22 C22 100.00 mm

Thickness of Reinforcing Pad Tpad 10.000 mm

Pad Parameter C11P C11p 100.000 mm

Pad Parameter C22P C22p 200.000 mm

Design Internal Pressure Dp 0.000 kgf/cm²

Include Pressure Thrust No

External Forces and Moments in WRC 107 Convention:

Radial Load (SUS) P -2757.4 kgf

Longitudinal Shear (SUS) Vl 0.0 kgf

Circumferential Shear (SUS) Vc 0.0 kgf

Circumferential Moment (SUS) Mc 0.0 kgf-m.

Longitudinal Moment (SUS) Ml 0.0 kgf-m.

Torsional Moment (SUS) Mt 0.0 kgf-m.


72/208


Use Interactive Control No

WRC107 Version Version March 1979

Include Pressure Stress Indices per Div. 2 No

Compute Pressure Stress per WRC-368 No

WRC 107 Stress Calculation for SUStained loads:

Radial Load P -2757.4 kgf

Circumferential Shear VC 0.0 kgf

Longitudinal Shear VL 0.0 kgf

Circumferential Moment MC 0.0 kgf-m.

Longitudinal Moment ML 0.0 kgf-m.

Torsional Moment MT 0.0 kgf-m.

Dimensionless Parameters used : Gamma = 16.75

Dimensionless Loads for Cylindrical Shells at Attachment Junction:

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

Curves read for 1979 Beta Figure Value Location

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

N(PHI) / ( P/Rm ) 0.110 4C 3.124 (A,B)

N(PHI) / ( P/Rm ) 0.110 3C 2.925 (C,D)

M(PHI) / ( P ) 0.066 2C1 0.169 (A,B)

M(PHI) / ( P ) 0.066 1C 0.202 (C,D)

N(PHI) / ( MC/(Rm**2 * B

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Design Calculation Exchanger E2226

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