Design Cal - Feed Preheater

Table of Contents
Cover Sheet...............................................................................................................................................2
Title Page.................................................................................................................................................3
Warnings and Errors...........................................................................................................................4
Input Echo.................................................................................................................................................5
XY Coordinate Calculations.........................................................................................................11
Flange Calculations FLANGE.........................................................................................................12
Flange Calculations FLANGE.........................................................................................................15
Internal Pressure Calculations...............................................................................................18
External Pressure Calculations...............................................................................................22
Element and Detail Weights.........................................................................................................25
ANSI Flange MAWP.................................................................................................................................27
Horizontal Vessel Analysis (Ope.)........................................................................................28
Nozzle Calcs. T1.................................................................................................................................36
Nozzle Calcs. T2.................................................................................................................................38
Nozzle Calcs. S1.................................................................................................................................40
Nozzle Calcs. S2.................................................................................................................................43
Nozzle Calcs. T3.................................................................................................................................46
Nozzle Calcs. T4.................................................................................................................................48
Nozzle Schedule...................................................................................................................................50
Nozzle Summary.....................................................................................................................................51
Tubesheet,...............................................................................................................................................52
Vessel Design Summary.....................................................................................................................59
Summary of Known Problems/Failures.....................................................................................61
Cover Page 2
MECHANICAL DESIGN CALCULATIONS

FOR HEAT EXCHANGER
ITEM : FEED PREHEATER
DESIGN CALCULATION
In Accordance with ASME Section VIII Div. 1
ASME Code Version : 2004
Analysis Performed by : USER
Job File : D:\PVELITE JOB FILES\AIROX-HE\FEED PREHEATER.PVI
Date of Analysis : Dec 11,2006
PVElite 2005, January 2005

Title Page 3
DESIGNED BY : AIROX NIGEN EQUIPMENT PVT. LTD

CLIENT : INDIAN OIL CORPORATION LTD.
MECHANICAL DESIGN CALCULATIONS 4
FOR HEAT EXCHANGER
PVElite 2005 Licensee: USER
FileName : FEED PREHEATER------------------------------------
Warnings and Errors STEP: 0 2:02p Dec 11,2006
Class From To : Basic Element Checks.

==========================================================================
Class From To: Check of Additional Element Data

==========================================================================
There were no geometry errors or warnings.
PVElite 2005 ©1993-2005 by COADE Engineering Software

FOR HEAT EXCHANGER
Input Echo STEP: 1 2:02p Dec 11,2006
PVElite Vessel Analysis Program: Input Data
MECHANICAL DESIGN CALCULATIONS

FOR HEAT EXCHANGER
Design Internal Pressure (for Hydrotest) 7.5000 KG/CM2

Design Internal Temperature 80.0 C
Type of Hydrotest not Specified
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 10.0 C
Type of Construction Welded
Special Service Air/Water/Steam
Degree of Radiography None
Miscellaneous Weight Percent 3.
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
Use Hydrotest Allowable Unmodified Y
Consider Vortex Shedding N
Perform a Corroded Hydrotest N
Is this a Heat Exchanger Y
User Defined Hydro. Press. (Used if > 0) 0.0000 KG/CM2
Load Case 1 IP+OW

Load Case 2 EP+OW
Load Case 3 HP
Wind Design Code ASCE-7 93

ASCE Design Wind Speed 31.292 m/sec
ASCE Exposure Constant 3
ASCE Importance Factor 1.
ASCE Roughness Factor 1
ASCE Base Elevation 0.0000 mm.
ASCE Percent Wind for Hydrotest 33.
Use Wind Profile (Y/N) N
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 No Seismic
Design Nozzle for Des. Press. + St. Head Y

Consider MAP New and Cold in Noz. Design N
Consider External Loads for Nozzle Des. N
Consider Code Case 2168 for Nozzle Des. N
Material Database Year Current w/Addenda or Code Year
Complete Listing of Vessel Elements and Details:
Element From Node 10

Element To Node 20
Element Type Elliptical
Description
Distance "FROM" to "TO" 50.000 mm.
Inside Diameter 380.00 mm.
FOR HEAT EXCHANGER
Element Thickness 6.0000 mm.

Corrosion Allowance 1.5000 mm.
Nominal Thickness 8.0000 mm.
External Corrosion Allowance 0.0000 mm.
Design Internal Pressure 7.5000 KG/CM2
Design Temperature Internal Pressure 80.0 C
Design External Pressure 0.0000 KG/CM2
Design Temperature External Pressure 80.0 C
Effective Diameter Multiplier 1.2
Material Name SA-516 70
Allowable Stress, Ambient 1406.1 KG/CM2
Allowable Stress, Operating 1406.1 KG/CM2
Allowable Stress, Hydrotest 1828.0 KG/CM2
Material Density 7833.4 KG/CU-M
P Number Thickness 31.750 mm.
Yield Stress, Operating 2477.1 KG/CM2
UCS-66 Chart Curve Designation B
External Pressure Chart Name CS-2
UNS Number K02700
Efficiency, Longitudinal Seam 1.
Efficiency, Circumferential Seam 1.
Elliptical Head Factor 2.

Element To Node 30
Element Type Cylinder
Description
Efficiency, Longitudinal Seam 0.85
Efficiency, Circumferential Seam 0.85

Detail Type Nozzle
Detail ID T1
Dist. from "FROM" Node / Offset dist 100.00 mm.
Nozzle Diameter 76.200 mm.
Nozzle Schedule SCH 40
Nozzle Class 150
Layout Angle 180.
Blind Flange (Y/N) N
Weight of Nozzle ( Used if > 0 ) 6.1150 KG
Grade of Attached Flange GR 1.1
Nozzle Matl SA-106 B

Detail Type Nozzle
Detail ID T2
Nozzle Class 150
FOR HEAT EXCHANGER
Layout Angle 0.

Element To Node 40
Element Type Flange
Description
Flange Inside Diameter 394.00 mm.
Perform Flange Stress Calculation (Y/N) Y
Weight of ANSI B16.5/B16.47 Flange 0.0000 KG
Class of ANSI B16.5/B16.47 Flange None
Grade of ANSI B16.5/B16.47 Flange None

Element To Node 50
Description

Detail Type Saddle
Detail ID Left Saddle
Width of Saddle 140.00 mm.
Height of Saddle at Bottom 450.00 mm.
Saddle Contact Angle 120.
Height of Composite Ring Stiffener 0.0000 mm.
Width of Wear Plate 150.00 mm.
Thickness of Wear Plate 6.0000 mm.
Contact Angle, Wear Plate (degrees) 130.

Detail Type Saddle
Detail ID RIGHT SADDLE
FOR HEAT EXCHANGER
Width of Saddle 140.00 mm.

Height of Saddle at Bottom 450.00 mm.
Saddle Contact Angle 120.
Height of Composite Ring Stiffener 0.0000 mm.
Width of Wear Plate 150.00 mm.
Thickness of Wear Plate 6.0000 mm.
Contact Angle, Wear Plate (degrees) 130.

Detail Type Ring
Detail ID LR
Inside Diameter of Ring 273.00 mm.
Thickness of Ring 5.0000 mm.
Outside Diameter of Ring 383.00 mm.

Detail Type Ring
Detail ID RR
Inside Diameter of Ring 273.00 mm.
Thickness of Ring 5.0000 mm.
Outside Diameter of Ring 383.00 mm.

Detail Type Nozzle
Detail ID S1
Nozzle Class 150
Layout Angle 0.

Detail Type Nozzle
Detail ID S2
Nozzle Class 150
Layout Angle 180.

Element To Node 60
Element Type Flange
Description
Flange Inside Diameter 394.00 mm.
FOR HEAT EXCHANGER

Perform Flange Stress Calculation (Y/N) Y
Weight of ANSI B16.5/B16.47 Flange 0.0000 KG
Class of ANSI B16.5/B16.47 Flange None
Grade of ANSI B16.5/B16.47 Flange None

Element To Node 70
Description

Detail Type Nozzle
Detail ID T3
Nozzle Class 150
Layout Angle 0.
Blind Flange (Y/N) Y

Detail Type Nozzle
Detail ID T4
Nozzle Class 150
Layout Angle 180.
Blind Flange (Y/N) Y

Element To Node 80
Element Type Elliptical
Description
FOR HEAT EXCHANGER

Efficiency, Longitudinal Seam 1.
Efficiency, Circumferential Seam 1.
Elliptical Head Factor 2.

FOR HEAT EXCHANGER
XY Coordinate Calculations STEP: 2 2:02p Dec 11,2006
XY Coordinate Calculations
| | | | | |
From| To | X (Horiz.)| Y (Vert.) | DX (Horiz.)| DY (Vert.) |
| | mm. | mm. | mm. | mm. |
10| 20| 50.0000 | 0.00000 | 50.0000 | 0.00000 |
20| 30| 250.000 | 0.00000 | 200.000 | 0.00000 |
30| 40| 280.000 | 0.00000 | 30.0000 | 0.00000 |
40| 50| 3280.00 | 0.00000 | 3000.00 | 0.00000 |
50| 60| 3310.00 | 0.00000 | 30.0000 | 0.00000 |
60| 70| 3510.00 | 0.00000 | 200.000 | 0.00000 |
70| 80| 3560.00 | 0.00000 | 50.0000 | 0.00000 |

FOR HEAT EXCHANGER
Flange Calculations FLANGE FLNG: 1 2:02p Dec 11,2006
Flange Input Data Values Description: FLANGE :
Item: Node 30 to 40
Description of Flange Geometry (Type) Loose Ring

Description of Flange Analysis Partial, Thickness
Design Pressure P 7.50 KG/CM2
Design Temperature 80.00 C
Internal Corrosion Allowance Fcor 0.0000 mm.
Use Corrosion Allowance in Thickness Calcs. No
Flange Inside Diameter B 394.0000 mm.
Flange Outside Diameter A 510.0000 mm.
Flange Thickness T 30.0000 mm.
Flange Material SA-516 70

Flange Allowable Stress At Temperature SFO 1406.14 KG/CM2
Flange Allowable Stress At Ambient SFa 1406.14 KG/CM2
Bolt Material SA-193 B7

Bolt Allowable Stress At Temperature SBo 1757.68 KG/CM2
Bolt Allowable Stress At Ambient SBa 1757.68 KG/CM2
Length of Weld Leg at Back of Ring WLEG 0.0000 mm.

Number of Splits in Ring Flange NSPLT 0
Diameter of Bolt Circle C 450.0000 mm.

Nominal Bolt Diameter DB 20.0000 mm.
Type of Threads TEMA Metric
Number of Bolts 16
Flange Face Outside Diameter Fod 440.0000 mm.

Flange Face Inside Diameter Fid 394.0000 mm.
Flange Facing Sketch 1, Code Sketch 1a
Gasket Outside Diameter God 436.0000 mm.

Gasket Inside Diameter Gid 394.0000 mm.
Gasket Factor, m, M 2.0000
Gasket Design Seating Stress Y 112.60 KG/CM2
Column for Gasket Seating 2, Code Column II

Gasket Thickness 3.0000 mm.
ASME Code, Section VIII, Division 1, 2004
Code R Dimension, R = (C-B)/2 - G1 28.000 mm.
Gasket Contact Width, N = (GOD-GID) / 2.0 21.000 mm.

Basic Gasket Width, B0 = N / 2.0 10.500 mm.
Effective Gasket Width, BE = SQRT(B0) / 2.0 8.165 mm.
Gasket Reaction Diameter, G = GOD-2.0*BE 419.669 mm.
Basic Flange and Bolt Loads:
Hydrostatic End Load due to Pressure [H]:

= 0.785 * G * G * PEQ
= 0.785 * 419.6690 *419.6690 *7.5000
= 10372.330 KG
Contact Load on Gasket Surfaces [Hp]:
= 2 * BE * PI * G * M * P + 2.0
= 2 * 8.1655 * 3.1416 * 419.6690 * 2.0000 * 7.50
FOR HEAT EXCHANGER
= 3229.020 KG
Hydrostatic End Load at Flange ID [HD]:
= PI * Bcor * Bcor * P / 4
= 3.1416 * 394.0000 * 394.0000 *7.5000 / 4
= 9142.287 KG
Pressure Force on Flange Face [HT]:
= H - HD
= 10372 - 9142
= 1230.042 KG
Operating Bolt Load [WM1]:
= max( H + HP + HPP, 0 )
= max( 10372 + 3229 + 0 , 0 )
= 13601.350 KG
Gasket Seating Bolt Load [WM2]:
= Y * BE * PI * G + Ypart * BEpart * GLPG + HPGY
= 112.60*8.1655*3.141*419.669+0.00*0.0000*0.00+0.00
= 12119.589 KG
Required Bolt Area [Am]:
= Maximum of WM1/SBO, WM2/SBA
= Maximum of 13601 / 1757 , 12119 / 1757
= 774.032 sq.mm.
Bolting Information for TEMA Metric Thread Series:

-----------------------------------------------------------------------------
Minimum Actual Maximum
-----------------------------------------------------------------------------
Bolt Area, sq.mm. 774.032 3473.031
Radial distance bet. hub and bolts 23.810 28.000
Radial distance bet. bolts and the edge 23.810 30.000
Circumferential spacing between bolts 52.390 87.791 112.000
-----------------------------------------------------------------------------
Min. Gasket Contact Width (Brownell Young) [Not an ASME Calc] [Nmin]:
= AB * SBA/( Y * Pi * (GOD+GID) )
= 3473.031 * 1757.68 /(112.60 * 3.14 * (436.000 + 394.00 ) )
= 20.790 mm.
Flange Design Bolt Load, Gasket Seating [W]:

= SBA * ( AM + AB ) / 2
= 1757.68 * ( 774.0323 + 3473.0312 ) / 2
= 37314.85 KG
Gasket Seating Force [HG]:
= WM1 - H
= 13601 - 10372
= 3229.02 KG
Moment Arm Calculations:

Distance to Gasket Load Reaction [hG]:
= (C - G ) / 2
= ( 450.0000 - 419.6690 ) / 2
= 15.1655 mm.
Distance to Face Pressure Reaction [hT]:
= ( hD + hG ) / 2
= ( 28.0000 + 15.1655 ) / 2
= 21.5827 mm.
Distance to End Pressure Reaction [hD]:
= ( C - Bcor )/ 2
= ( 450.0000 - 394.0000 ) / 2
= 28.0000 mm.
Summary of Moments for Internal Pressure:

Loading Force Distance Bolt Corr Moment
FOR HEAT EXCHANGER
End Pressure, MD 9142. 28.0000 1.0000 256. KG-M

Face Pressure, MT 1230. 21.5827 1.0000 27. KG-M
Gasket Load, MG 3229. 15.1655 1.0000 49. KG-M
Gasket Seating, MA 37315. 15.1655 1.0000 566. KG-M
TOTAL MOMENT FOR OPERATION, RMO 331. KG-M

TOTAL MOMENT FOR GASKET SEATING, RMA 566. KG-M
Effective Hub Length, H0 = 0.000 mm.

Hub Ratio, HRAT = Defined as 0.0 0.000
Thickness Ratio, GRAT = Defined as 0.0 0.000
Factors from Figure 2-7.1 K = 1.294
T = 1.800 U = 8.427
Y = 7.668 Z = 3.961
Tangential Flange Stress, Operating [Sto]:

= ( Y * RMO )/( TH * TH * Bcor )
= ( 7.6682 *331 )/( 30.0000 *30.0000 *394.0000 )
= 717.02 KG/CM2
Tangential Flange Stress, Seating [STa]:
= ( Y * RMA )/( TH * TH * Bcor )
= ( 7.6682 *565 )/( 30.0000 *30.0000 *394.0000 )
= 1224.00 KG/CM2
Bolt Stress, Operating [BSo]:

= ( WM1 / AB )
= ( 13601 / 3473.0312 )
= 391.73 KG/CM2
Bolt Stress, Seating [BSa]:
= ( WM2 / AB )
= ( 12119 / 3473.0312 )
= 349.06 KG/CM2
Stress Computation Results: OPERATING GASKET SEATING

Actual Allowed Actual Allowed
Tangential Flange 717. 1406. 1224. 1406. KG/CM2
Bolting 392. 1758. 349. 1758. KG/CM2
Minimum Required Flange Thickness 27.990 mm.

Estimated M.A.W.P. ( Operating ) 14.7 KG/CM2
Estimated M.A.W.P. ( Gasket Seating ) 13.6 KG/CM2
Estimated Finished Weight of Flange at given Thk. 19.4 KG
Estimated Unfinished Weight of Forging at given Thk 19.4 KG
Flange Rigidity Based on Required Thickness:
APP. S Flange Rigidity Index for Seating Case 2.665

APP. S Flange Rigidity Index for Operating Case 1.592
Flange Rigidity Based on Given Thickness:

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

Min Metal Temp. at Rqd thickness (UCS 66.1)[rat 0.87] -36 C

FOR HEAT EXCHANGER
Flange Input Data Values Description: FLANGE :
Item: Node 50 to 60
Description of Flange Geometry (Type) Loose Ring

Description of Flange Analysis Partial, Thickness
Design Pressure P 7.50 KG/CM2
Design Temperature 80.00 C
Internal Corrosion Allowance Fcor 0.0000 mm.
Use Corrosion Allowance in Thickness Calcs. No
Flange Inside Diameter B 394.0000 mm.
Flange Outside Diameter A 510.0000 mm.
Flange Thickness T 30.0000 mm.
Flange Material SA-516 70

Flange Allowable Stress At Temperature SFO 1406.14 KG/CM2
Flange Allowable Stress At Ambient SFa 1406.14 KG/CM2

Bolt Allowable Stress At Temperature SBo 1757.68 KG/CM2
Bolt Allowable Stress At Ambient SBa 1757.68 KG/CM2
Length of Weld Leg at Back of Ring WLEG 0.0000 mm.

Number of Splits in Ring Flange NSPLT 0
Diameter of Bolt Circle C 450.0000 mm.

Nominal Bolt Diameter DB 20.0000 mm.
Type of Threads TEMA Metric
Number of Bolts 16
Flange Face Outside Diameter Fod 440.0000 mm.

Flange Face Inside Diameter Fid 394.0000 mm.
Flange Facing Sketch 1, Code Sketch 1a
Gasket Outside Diameter God 436.0000 mm.

Gasket Inside Diameter Gid 394.0000 mm.
Column for Gasket Seating 2, Code Column II

Gasket Thickness 3.0000 mm.
ASME Code, Section VIII, Division 1, 2004
Code R Dimension, R = (C-B)/2 - G1 28.000 mm.
Gasket Contact Width, N = (GOD-GID) / 2.0 21.000 mm.

Gasket Reaction Diameter, G = GOD-2.0*BE 419.669 mm.
Basic Flange and Bolt Loads:
Hydrostatic End Load due to Pressure [H]:

= 0.785 * G * G * PEQ
= 0.785 * 419.6690 *419.6690 *7.5000
= 10372.330 KG
Contact Load on Gasket Surfaces [Hp]:
= 2 * BE * PI * G * M * P + 2.0
= 2 * 8.1655 * 3.1416 * 419.6690 * 2.0000 * 7.50
FOR HEAT EXCHANGER
= 3229.020 KG
Hydrostatic End Load at Flange ID [HD]:
= PI * Bcor * Bcor * P / 4
= 3.1416 * 394.0000 * 394.0000 *7.5000 / 4
= 9142.287 KG
Pressure Force on Flange Face [HT]:
= H - HD
= 10372 - 9142
= 1230.042 KG
Operating Bolt Load [WM1]:
= max( H + HP + HPP, 0 )
= max( 10372 + 3229 + 0 , 0 )
= 13601.350 KG
Gasket Seating Bolt Load [WM2]:
= Y * BE * PI * G + Ypart * BEpart * GLPG + HPGY
= 112.60*8.1655*3.141*419.669+0.00*0.0000*0.00+0.00
= 12119.589 KG
Required Bolt Area [Am]:
= Maximum of WM1/SBO, WM2/SBA
= Maximum of 13601 / 1757 , 12119 / 1757
= 774.032 sq.mm.

-----------------------------------------------------------------------------
-----------------------------------------------------------------------------
Bolt Area, sq.mm. 774.032 3473.031
-----------------------------------------------------------------------------
Min. Gasket Contact Width (Brownell Young) [Not an ASME Calc] [Nmin]:
= AB * SBA/( Y * Pi * (GOD+GID) )
= 3473.031 * 1757.68 /(112.60 * 3.14 * (436.000 + 394.00 ) )
= 20.790 mm.
Flange Design Bolt Load, Gasket Seating [W]:

= SBA * ( AM + AB ) / 2
= 1757.68 * ( 774.0323 + 3473.0312 ) / 2
= 37314.85 KG
Gasket Seating Force [HG]:
= WM1 - H
= 13601 - 10372
= 3229.02 KG

Distance to Gasket Load Reaction [hG]:
= (C - G ) / 2
= ( 450.0000 - 419.6690 ) / 2
= 15.1655 mm.
Distance to Face Pressure Reaction [hT]:
= ( hD + hG ) / 2
= ( 28.0000 + 15.1655 ) / 2
= 21.5827 mm.
Distance to End Pressure Reaction [hD]:
= ( C - Bcor )/ 2
= ( 450.0000 - 394.0000 ) / 2
= 28.0000 mm.
Summary of Moments for Internal Pressure:

Loading Force Distance Bolt Corr Moment
FOR HEAT EXCHANGER


Effective Hub Length, H0 = 0.000 mm.

Hub Ratio, HRAT = Defined as 0.0 0.000
Thickness Ratio, GRAT = Defined as 0.0 0.000
Factors from Figure 2-7.1 K = 1.294
T = 1.800 U = 8.427
Y = 7.668 Z = 3.961
Tangential Flange Stress, Operating [Sto]:

= ( Y * RMO )/( TH * TH * Bcor )
= ( 7.6682 *331 )/( 30.0000 *30.0000 *394.0000 )
= 717.02 KG/CM2
Tangential Flange Stress, Seating [STa]:
= ( Y * RMA )/( TH * TH * Bcor )
= ( 7.6682 *565 )/( 30.0000 *30.0000 *394.0000 )
= 1224.00 KG/CM2
Bolt Stress, Operating [BSo]:

= ( WM1 / AB )
= ( 13601 / 3473.0312 )
= 391.73 KG/CM2
Bolt Stress, Seating [BSa]:
= ( WM2 / AB )
= ( 12119 / 3473.0312 )
= 349.06 KG/CM2
Stress Computation Results: OPERATING GASKET SEATING

Actual Allowed Actual Allowed
Tangential Flange 717. 1406. 1224. 1406. KG/CM2
Bolting 392. 1758. 349. 1758. KG/CM2
Minimum Required Flange Thickness 27.990 mm.

Estimated M.A.W.P. ( Operating ) 14.7 KG/CM2
Estimated M.A.W.P. ( Gasket Seating ) 13.6 KG/CM2
Estimated Finished Weight of Flange at given Thk. 19.4 KG
Estimated Unfinished Weight of Forging at given Thk 19.4 KG
Flange Rigidity Based on Required Thickness:

Flange Rigidity Based on Given Thickness:



FOR HEAT EXCHANGER
Internal Pressure Calculations STEP: 5 2:02p Dec 11,2006
Element Thickness, Pressure, Diameter and Allowable Stress :
| | Int. Press | Given | Corrosion | Element | Allowable |

From| To | + Liq. Hd | Thickness | Allowance | Diameter | Stress(SE)|
| | KG/CM2 | mm. | mm. | mm. | KG/CM2 |
10| 20| 7.50000 | 6.00000 | 1.50000 | 380.000 | 1406.14 |
20| 30| 7.50000 | 8.00000 | 1.50000 | 380.000 | 1195.22 |
30| 40| 7.50000 | 30.0000 | 0.00000 | 394.000 | 1406.14 |
40| 50| 10.0000 | 8.00000 | 1.50000 | 380.000 | 1195.22 |
50| 60| 7.50000 | 30.0000 | 0.00000 | 394.000 | 1406.14 |
60| 70| 7.50000 | 8.00000 | 1.50000 | 380.000 | 1195.22 |
70| 80| 7.50000 | 6.00000 | 0.00000 | 380.000 | 1406.14 |
Element Required Thickness and MAWP :
| | Design | M.A.W.P. | M.A.P. | Actual | Required |

From| To | Pressure | Corroded | New & Cold | Thickness | Thickness |
| | KG/CM2 | KG/CM2 | KG/CM2 | mm. | mm. |
10| 20| 7.50000 | 32.9650 | 44.2646 | 6.00000 | 3.88125 |
20| 30| 7.50000 | 39.7591 | 49.0850 | 8.00000 | 3.88125 |
30| 40| 7.50000 | 14.7082 | 14.7082 | 30.0000 | 27.9897 |
40| 50| 10.0000 | 39.7591 | 49.0850 | 8.00000 | 3.88125 |
50| 60| 7.50000 | 14.7082 | 14.7082 | 30.0000 | 27.9897 |
60| 70| 7.50000 | 39.7591 | 49.0850 | 8.00000 | 3.88125 |
70| 80| 7.50000 | 44.2646 | 44.2646 | 6.00000 | 2.38125 |
Minimum 13.218 14.708
Note : The M.A.W.P is Governed by an ANSI Flange !
Internal Pressure Calculation Results :
ASME Code, Section VIII, Division 1, 2004 Code
Elliptical Head From 10 To 20 SA-516 70 , UCS-66 Crv. B at 80 C
Thickness Due to Internal Pressure [Tr]:

= (P*(D+2*CA)*K)/(2*S*E-0.2*P) Appendix 1-4(c)
= (7.50*(380.0000+2*1.5000)*1.00)/(2*1406.14*1.00-0.2*7.50)
= 1.0220 + 1.5000 = 2.5220 mm.
Note: The thickness required was less than the Code Minimum, therefore
the Code Minimum value of 2.3812 mm. will be used.
Max. All. Working Pressure at Given Thickness [MAWP]:

= (2*S*E*(T-Ca))/(K*(D+2*Ca)+0.2*(T-Ca)) per Appendix 1-4 (c)
= (2*1406.14*1.00*(4.5000))/(1.00*(380.0000+2*1.5000)+0.2*(4.5000))
= 32.96 KG/CM2
Maximum Allowable Pressure, New and Cold [MAPNC]:

= (2*Sa*E*T)/(K*D+0.2*T) per Appendix 1-4 (c)
= (2*1406.14*1.00*6.0000)/(1.00*380.0000+0.2*6.0000)
= 44.26 KG/CM2
Actual stress at given pressure and thickness [Sact]:

= (P*(K*(D+2*CA)+0.2*(T-CA)))/(2*E*(T-CA))
= (7.50*(1.00*(380.0000+2*1.5000)+0.2*(4.5000)))/(2*1.00*(4.5000))
= 319.92 KG/CM2
Percent Elongation per UCS-79 ( 75*tnom / Rf(1-Rf/Ro) ) 9.096 %

FOR HEAT EXCHANGER
Cylindrical Shell From 20 To 30 SA-516 70 , UCS-66 Crv. B at 80 C

= (P*(D/2+Ca))/(S*E-0.6*P) per UG-27 (c)(1)
= (7.50*(380.0000/2+1.5000))/(1406.14*0.85-0.6*7.50)
= 1.2062 + 1.5000 = 2.7062 mm.

= (S*E*(T-Ca))/((D/2+Ca)+0.6*(T-Ca)) per UG-27 (c)(1)
= (1406.14*0.85*(6.5000))/((380.0000/2+1.5000)+0.6*6.5000)
= 39.76 KG/CM2

= (SA*E*T)/(D/2+0.6*T) per UG-27 (c)(1)
= (1406.14*0.85*8.0000)/(380.0000/2+0.6*8.0000)
= 49.08 KG/CM2

= (P*((D/2+CA)+0.6*(T-CA)))/(E*(T-CA))
= (7.50*((380.0000/2+1.5000)+0.6*(6.5000)))/(0.85*(6.5000))
= 265.25 KG/CM2


= (P*(D/2+Ca))/(S*E-0.6*P) per UG-27 (c)(1)
= (10.00*(380.0000/2+1.5000))/(1406.14*0.85-0.6*10.00)
= 1.6103 + 1.5000 = 3.1103 mm.

= (1406.14*0.85*(6.5000))/((380.0000/2+1.5000)+0.6*6.5000)
= 39.76 KG/CM2

= (SA*E*T)/(D/2+0.6*T) per UG-27 (c)(1)
= (1406.14*0.85*8.0000)/(380.0000/2+0.6*8.0000)
= 49.08 KG/CM2

= (P*((D/2+CA)+0.6*(T-CA)))/(E*(T-CA))
= (10.00*((380.0000/2+1.5000)+0.6*(6.5000)))/(0.85*(6.5000))
= 353.67 KG/CM2

FOR HEAT EXCHANGER

= (P*(D/2+Ca))/(S*E-0.6*P) per UG-27 (c)(1)
= (7.50*(380.0000/2+1.5000))/(1406.14*0.85-0.6*7.50)
= 1.2062 + 1.5000 = 2.7062 mm.

= (1406.14*0.85*(6.5000))/((380.0000/2+1.5000)+0.6*6.5000)
= 39.76 KG/CM2

= (SA*E*T)/(D/2+0.6*T) per UG-27 (c)(1)
= (1406.14*0.85*8.0000)/(380.0000/2+0.6*8.0000)
= 49.08 KG/CM2

= (P*((D/2+CA)+0.6*(T-CA)))/(E*(T-CA))
= (7.50*((380.0000/2+1.5000)+0.6*(6.5000)))/(0.85*(6.5000))
= 265.25 KG/CM2

Elliptical Head From 70 To 80 SA-516 70 , UCS-66 Crv. B at 80 C

= (P*(D+2*CA)*K)/(2*S*E-0.2*P) Appendix 1-4(c)
= (7.50*(380.0000+2*0.0000)*1.00)/(2*1406.14*1.00-0.2*7.50)
= 1.0140 + 0.0000 = 1.0140 mm.

= (2*S*E*(T-Ca))/(K*(D+2*Ca)+0.2*(T-Ca)) per Appendix 1-4 (c)
= (2*1406.14*1.00*(6.0000))/(1.00*(380.0000+2*0.0000)+0.2*(6.0000))
= 44.26 KG/CM2

= (2*Sa*E*T)/(K*D+0.2*T) per Appendix 1-4 (c)
= (2*1406.14*1.00*6.0000)/(1.00*380.0000+0.2*6.0000)
= 44.26 KG/CM2

= (P*(K*(D+2*CA)+0.2*(T-CA)))/(2*E*(T-CA))
= (7.50*(1.00*(380.0000+2*0.0000)+0.2*(6.0000)))/(2*1.00*(6.0000))
= 238.25 KG/CM2

MINIMUM METAL DESIGN TEMPERATURE RESULTS :

FOR HEAT EXCHANGER
Minimum Metal Temp. w/o impact per UCS-66 -29. C

Minimum Metal Temp. at Required thickness -48. C
Minimum Design Metal Temperature ( Entered by User ) 10.
Elements Suitable for Internal Pressure.

FOR HEAT EXCHANGER
External Pressure Calculations STEP: 6 2:02p Dec 11,2006
External Pressure Calculation Results :
ASME Code, Section VIII, Division 1, 2004 Code
Elliptical Head From 10 to 20 Ext. Chart: CS-2 at 80 C
Results for Maximum Allowable Pressure (EMAP):

Tca OD D/t Factor A B
4.5000 392.00 87.11 0.0015944 1002.75
EMAP = B/(K0*D/t) = 1002.7493 /(0.9000 *87.1111 ) = 12.7902 KG/CM2
Cylindrical Shell From 20 to 30 Ext. Chart: CS-2 at 80 C

Tca OD SLEN D/t L/D Factor A B
6.5000 396.00 281.67 60.92 0.7113 0.0041825 1194.25
EMAP = (4*B)/(3*(D/t)) = (4*1194.2462 )/(3*60.9231 ) = 26.1367 KG/CM2
Results for Maximum Stiffened Length (SLEN):

6.5000 396.00 0.71E+33 60.92 .1803E+31 0.0002964 302.13
EMAP = (4*B)/(3*(D/t)) = (4*302.1312 )/(3*60.9231 ) = 6.6123 KG/CM2
Cylindrical Shell From 40 to LR Ext. Chart: CS-2 at 210 C

6.5000 396.00 350.00 60.92 0.8838 0.0033090 1005.88
EMAP = (4*B)/(3*(D/t)) = (4*1005.8806 )/(3*60.9231 ) = 22.0142 KG/CM2

6.5000 396.00 0.89E+33 60.92 .2241E+31 0.0002964 290.67
EMAP = (4*B)/(3*(D/t)) = (4*290.6745 )/(3*60.9231 ) = 6.3616 KG/CM2
Cylindrical Shell From LR to RR Ext. Chart: CS-2 at 210 C

6.5000 396.00 800.00 60.92 2.0202 0.0013930 848.27
EMAP = (4*B)/(3*(D/t)) = (4*848.2695 )/(3*60.9231 ) = 18.5648 KG/CM2

6.5000 396.00 0.20E+34 60.92 .5122E+31 0.0002964 290.67
EMAP = (4*B)/(3*(D/t)) = (4*290.6745 )/(3*60.9231 ) = 6.3616 KG/CM2
Cylindrical Shell From RR to 50 Ext. Chart: CS-2 at 210 C

6.5000 396.00 1850.00 60.92 4.6717 0.0005925 581.12
EMAP = (4*B)/(3*(D/t)) = (4*581.1188 )/(3*60.9231 ) = 12.7181 KG/CM2

6.5000 396.00 0.47E+34 60.92 .1184E+32 0.0002964 290.67
EMAP = (4*B)/(3*(D/t)) = (4*290.6745 )/(3*60.9231 ) = 6.3616 KG/CM2
Cylindrical Shell From 60 to 70 Ext. Chart: CS-2 at 80 C

FOR HEAT EXCHANGER

6.5000 396.00 281.67 60.92 0.7113 0.0041825 1194.25
EMAP = (4*B)/(3*(D/t)) = (4*1194.2462 )/(3*60.9231 ) = 26.1367 KG/CM2

6.5000 396.00 0.71E+33 60.92 .1803E+31 0.0002964 302.13
EMAP = (4*B)/(3*(D/t)) = (4*302.1312 )/(3*60.9231 ) = 6.6123 KG/CM2
Elliptical Head From 70 to 80 Ext. Chart: CS-2 at 80 C

Tca OD D/t Factor A B
6.0000 392.00 65.33 0.0021259 1071.67
EMAP = B/(K0*D/t) = 1071.6661 /(0.9000 *65.3333 ) = 18.2256 KG/CM2
External Pressure Calculations
| | Section | Outside | Corroded | Factor | Factor |

From| To | Length | Diameter | Thickness | A | B |
| | mm. | mm. | mm. | | KG/CM2 |
10| 20| No Calc | 392.000 | 4.50000 | 0.0015944 | 1002.75 |
20| 30| 281.667 | 396.000 | 6.50000 | 0.0041825 | 1194.25 |
30| 40| No Calc | 0.00000 | 30.0000 | No Calc | No Calc |
40|Ring| 350.000 | 396.000 | 6.50000 | 0.0033090 | 1005.88 |
Ring|Ring| 800.000 | 396.000 | 6.50000 | 0.0013930 | 848.270 |
Ring| 50| 1850.00 | 396.000 | 6.50000 | 0.00059250 | 581.119 |
50| 60| No Calc | 0.00000 | 30.0000 | No Calc | No Calc |
60| 70| 281.667 | 396.000 | 6.50000 | 0.0041825 | 1194.25 |
70| 80| No Calc | 392.000 | 6.00000 | 0.0021259 | 1071.67 |
| | External | External | External | External |

From| To | Actual T. | Required T.| Des. Press.| M.A.W.P. |
| | mm. | mm. | KG/CM2 | KG/CM2 |
10| 20| 6.00000 | No Calc | 0.00000 | 12.7902 |
20| 30| 8.00000 | No Calc | 0.00000 | 26.1367 |
30| 40| 30.0000 | 27.7105 | 0.00000 | No Calc |
40|Ring| 8.00000 | No Calc | 0.00000 | 22.0142 |
Ring|Ring| 8.00000 | No Calc | 0.00000 | 18.5648 |
Ring| 50| 8.00000 | No Calc | 0.00000 | 12.7181 |
50| 60| 30.0000 | 27.7105 | 0.00000 | No Calc |
60| 70| 8.00000 | No Calc | 0.00000 | 26.1367 |
70| 80| 6.00000 | No Calc | 0.00000 | 18.2256 |
Minimum 12.718
| | Actual Len.| Allow. Len.| Ring Iner.| Ring Iner. |

From| To | Bet. Stiff.| Bet. Stiff.| Required | Available |
| | mm. | mm. | mm**4 | mm**4 |
10| 20| No Calc | No Calc | No Calc | No Calc |
20| 30| 281.667 | 714.1E+30 | No Calc | No Calc |
40|Ring| 350.000 | 887.4E+30 | No Calc | No Calc |
Ring|Ring| 800.000 | 2.028E+33 | No Calc | No Calc |
Ring| 50| 1850.00 | 4.690E+33 | No Calc | No Calc |
60| 70| 281.667 | 714.1E+30 | No Calc | No Calc |
FOR HEAT EXCHANGER
Elements Suitable for External Pressure.

FOR HEAT EXCHANGER
Element and Detail Weights STEP: 7 2:02p Dec 11,2006
Element and Detail Weights
| | Element | Element | Corroded | Corroded | Extra due |

From| To | Metal Wgt. | ID Volume | Metal Wgt. | ID Volume | Misc % |
| | KG | mm. | KG | mm. | KG |
10| 20| 15.1076 | 239072. | 12.2750 | 243933. | 0.45323 |
20| 30| 15.2744 | 421892. | 12.4584 | 428579. | 0.45823 |
30| 40| 19.3509 | 68032.7 | 19.3509 | 68032.7 | 0.58053 |
40| 50| 229.116 | 6.328E+06 | 186.876 | 6.429E+06 | 6.87348 |
50| 60| 19.3509 | 68032.7 | 19.3509 | 68032.7 | 0.58053 |
60| 70| 15.2744 | 421892. | 12.4584 | 428579. | 0.45823 |
70| 80| 15.1076 | 239072. | 15.1076 | 239072. | 0.45323 |
---------------------------------------------------------------------------
Total 328 7786367 277 7904920 9
Weight of Details
| | Weight of | X Offset, | Y Offset, |

From|Type| Detail | Dtl. Cent. | Dtl. Cent. | Description
| | KG | mm. | mm. |
20|Nozl| 6.29850 | 100.000 | 228.100 | T1
20|Nozl| 6.29850 | 100.000 | 228.100 | T2
40|Sadl| 27.7480 | 700.000 | 313.000 | Left Saddle
40|Sadl| 27.7480 | 2300.00 | 313.000 | RIGHT SADDLE
40|Ring| 2.28589 | 350.000 | 0.00000 | LR
40|Ring| 2.28589 | 1150.00 | 0.00000 | RR
40|Nozl| 8.78420 | 2800.00 | 240.800 | S1
40|Nozl| 8.78420 | 125.000 | 240.800 | S2
60|Nozl| 2.55491 | 100.000 | 202.700 | T3
60|Nozl| 2.55491 | 100.000 | 202.700 | T4
30|FTsh| 33.2537 | 55.0000 | 0.00000 | TUBESHEET
30|Tube| 286.586 | 1497.00 | 0.00000 |
30|RTsh| 33.2537 | 2959.00 | 0.00000 |
Total Weight of Each Detail Type
Total Weight of Saddles 55.5

Total Weight of Stiffeners 4.6
Total Weight of Nozzles 35.3
Total Weight of Exchanger Components 353.1
---------------------------------------------------------------
Sum of the Detail Weights 448.4 KG
Fabricated Wt. - Bare Weight W/O Removable Internals 786.9 KG

Shop Test Wt. - Fabricated Weight + Water ( Full ) 1205.2 KG
Shipping Wt. - Fab. Wt + Rem. Intls.+ Shipping App. 786.9 KG
Erected Wt. - Fab. Wt + Rem. Intls.+ Insul. (etc) 786.9 KG
Empty Wt. - Fab. Wt + Intls. + Details + Wghts. 786.9 KG
Operating Wt. - Empty Wt. + Operating Liquid (No CA) 786.9 KG
Oper. Wt. +CA - Corr Wt. + Operating Liquid 734.7 KG
Field Test Wt. - Empty Weight + Water (Full) 1205.2 KG
Note: The Corroded Weight and thickness are used in the Horizontal
Vessel Analysis (Ope Case) and Earthquake Load Calculations.
Outside Surface Areas of Elements
| | Surface
From| To | Area
| | sq.mm. |
10| 20| 402201.
FOR HEAT EXCHANGER
Element and Detail Weights STEP: 7 2:02p Dec 11,2006
20| 30| 248830.

30| 40| 130434.
40| 50| 3.732E+06
50| 60| 130434.
60| 70| 248830.
70| 80| 402201.
--------------------------------
Total 5295374.000 sq.mm.

FOR HEAT EXCHANGER
ANSI Flange MAWP STEP: 8 2:02p Dec 11,2006
ANSI Flange MAWP Results :
ANSI Flange Pressure Rating for: T1 : Class 150 : Grade GR 1.1

Pressure Rating for B16.5 Flange at 80.00 C is 18.702 KG/CM2
ANSI Flange Pressure Rating for: S1 : Class 150 : Grade GR 2.1

ANSI Flange Pressure Rating for: T3 : Class 150 : Grade GR 1.1

Note: ANSI Ratings are per B16.5 1996
Lowest Flange Pressure Rating was (ope) : 13.218 KG/CM2

Lowest Flange Pressure Rating was (Amb) : 19.334 KG/CM2

FOR HEAT EXCHANGER
Horizontal Vessel Analysis (Ope.) STEP: 11 2:02p Dec 11,2006
Zick Analysis: Stresses for the Left Saddle
Horizontal Vessel Stress Calculations : Operating Case
Shell Allowable Stress used in Calculation 1406.14 KG/CM2

Shell Compressive Yield used in Calculation 2274.47 KG/CM2
Head Allowable Stress used in Calculation 1406.14 KG/CM2
Saddle Force Q, Operating Case 472.14 KG
Stress Results for Zick Stresses: Actual Allowable

Long. Stress at Top of Saddles 338.86 1195.22 KG/CM2
Long. Stress at Bottom of Saddles -48.24 1038.48 KG/CM2
Long. Stress at Top of Midspan 160.69 1195.22 KG/CM2
Long. Stress at Bottom of Midspan 129.93 1195.22 KG/CM2
Tangential Shear in Shell 14.80 1124.91 KG/CM2

Circ. Stress at Horn of Saddle -98.17 -2047.02 KG/CM2
Circ. Stress at Tip of Wear Plate -87.44 -2047.02 KG/CM2
Circ. Compressive Stress in Shell -19.15 -1137.23 KG/CM2
Intermediate Results: Saddle Reaction Q due to Wind or Seismic
Saddle Reaction Force due to Wind Ft

Fwt = Ftr * ( Ft/Num of Saddles + Z Force Load ) * B / E
Fwt = 3.00 * ( 78.0 /2 + 0 ) * 450.0000 / 345.5441
Fwt = 152.3169 KG
Saddle Reaction Force due to Wind Fl or Friction

Fwl = Max( Fl, Friction Load, Sum of X Forces) * B / Ls
Fwl = Max( 5.65 , 95.95 , 0 ) * 450.0000 / 1600.0001
Fwl = 26.9848 KG
Saddle Reaction Force due to Earthquake Fl or Friction

Fsl = Max( Fl, Friction Force, Sum of X Forces ) * B / Ls
Fsl = Max( 0.00 , 95.95 , 0 ) * 450.0000 / 1600.0001
Fsl = 26.9848 KG
Saddle Reaction Force due to Earthquake Ft

Fst = Ftr * ( Ft/Num of Saddles + Z Force Load ) * B / E
Fst = 3.00 * ( 0 /2 + 0 ) * 450.0000 / 345.5441
Fst = 0.0000 KG
Load Combination Results for Q + Wind or Seismic

Q = Saddle Load + Max( Fwl, Fwt, Fsl, Fst )
Q = 319 + Max( 26 , 152 , 26 , 0 )
Q = 472.1364 KG
Formulas and Substitutions for Zick Analysis Results:
Longitudinal Bending (+-) at Midspan

= ( 3 * Q * L/12 * K.2 / ( pi * R² * ( Ts - Ca )))
= ( 3 * 472 * 3000.00 /12 * -0.3252 ) /
( pi * 191.5000 * 191.5000 * ( 8.0000 - 1.5000 )))
= -15.38 KG/CM2
Longitudinal Bending (+-) at Saddle

= ( 3 * Q * L/12 * K.1 / ( pi * R² * ( Ts - Ca )))
= ( 3 * 472 * 3000.00 /12 * 4.0924 ) /
( pi * 191.5000 * 191.5000 * ( 8.0000 - 1.5000 )))
= 193.55 KG/CM2
FOR HEAT EXCHANGER
Tangential Shear in Shell near Saddle

= Q * K.4 * (( L-H-2A )/( L+H ))/( R*(Ts-Ca))
= 472 * 1.1707 * (( 3000.00 - 0.00 - 2 * 1000.00 )/
( 3000.00 + 0.00 ))/( 191.5000 * ( 8.0000 - 1.5000 ))
= 14.80 KG/CM2
Circumferential Stress at Tip of the Wear Plate

= -Q/(4*(TS-CA)*(SADWTH+1.56*Sqrt(R*(TS-CA))))-3.0*Q*K13/(2*(TS-CA)²)
= -472 /( 4 * 6.5000 * (140.00 + 1.56*Sqrt(191.5000 *6.5000 )))
-3 * 472 * 0.0466 / ( 2 * 42.2500 )
= -87.44 KG/CM2
Circumferential Stress at Horn of Saddle

= -Q /(4*TEM*(SADWTH+1.56*Sqrt(R*(TS-CA))))-3.0*Q*K.7/(2*TEB)
= -472 /( 4 * 6.5000 * (140.00 + 1.56*Sqrt(191.5000 *6.5000 )))
-3 * 472 * 0.0530 / ( 2 * 42.2500 )
= -98.17 KG/CM2
Circumferential Compression at Bottom of Shell

= (Q*( K.9/( TEM9 * WPDWTH ) ) )
= ( 472 *( 0.7603 /( 12.5000 * 150.000 ) ) )
= -19.15 KG/CM2
Results for Vessel Ribs, Web and Base:

Baseplate Length Bplen 400.0000 mm.
Baseplate Thickness Bpthk 10.0000 mm.
Baseplate Width Bpwid 150.0000 mm.
Number of Ribs ( inc. outside ribs ) Nribs 3
Rib Thickness Ribtk 10.0000 mm.
Web Thickness Webtk 10.0000 mm.
Web Location Webloc Side
Moment of Inertia of Saddle - Lateral Direction
Y A AY Ay² Io
Shell 3. 1333. 4331. 14077. 4692.
Wearplate 10. 900. 8550. 81225. 2700.
Web 126. 2275. 287219. 36261240. 9812087.
BasePlate 245. 1500. 367500. 90037184. 12500.
Totals 384. 6008. 667600. 126393728. 9831980.
Value C1 = Sumof(Ay)/Sumof(A) = 111. mm.

Value I = Sumof(Ay² ) + Sumof(Io) - C1*Sumof(Ay) = 62040112. mm**4
Value As = Sumof(A) - Ashell = 4675. sq.mm.
K1 = (1+Cos(beta)-.5*Sin(beta)² )/(pi-beta+Sin(beta)*Cos(beta)) = 0.2035
Fh = ( K1 * Q ) = 96.0900 KG
Tension Stress, St = ( Fh/As ) = 2.0558 KG/CM2

Allowed Stress, Sa = 0.6 * Yield Str = 1518.6301 KG/CM2
Bending Moment, M = Fh * d = 27.2008 KG-M
Bending Stress, Sb = ( M * C1 / I ) = 4.8740 KG/CM2

Allowed Stress, Sa = 2/3 * Yield Str = 1687.3668 KG/CM2
Minimum Thickness of Baseplate :

Baseplate Min., = (3*Q*F/(2*A*SA))½ = 3.9677 mm.
Calc. of Axial Load, Inter. Values and Comp. Stress

FOR HEAT EXCHANGER
Effective Baseplate Length (e)

= ( Bplen - Clearance ) / ( Nribs - 1)
= ( 400.0000 - 25.4 ) / ( 3 - 1 ) = 187.3000 mm.
Baseplate Pressure Area (Ap)

= e * Bpwid / 2
= 187.3000 * 150.0000 / 2 = 14048.3711 sq.mm.
Axial Load (P)

= Ap * Bp
= 14048.4 * 0.01 = 110.5 KG
Area of the Rib and Web (Ar)

= ( Bpwid - Clearance - Webtk ) * Ribtk + e/2 * Webtk
= ( 150.000 - 25.4 - 10.000 ) * 10.000 + 187.3000 /2 * 10.000
= 2082.629 sq.mm.
Compressive Stress (Sc)

= P/Ar
= 110.5 / 2082.6292 = 5.3091 KG/CM2
Check of Outside Ribs:

Inertia of Saddle, Outer Ribs - Longitudinal Direction
Y A AY Ay² Io
Rib 67.3 1223.1 82307.9 892709.8 1929731.2
Web 5.0 936.6 4682.5 1165812.8 15608.3
Values 40.3 2159.6 86990.4 2058522.4 1945339.5
KL/R < Cc ( 7.8111 < 126.0992 ) per AISC E2-1

Sca = (1-(Klr)²/(2*Cc²))*Fy/(5/3+3*(Klr)/(8*Cc)-(Klr³)/(8*Cc³)
Sca = ( 1-( 7.81 )²/(2 * 126.10 ² )) * 2531 /
( 5/3+3*(7.81 )/(8* 126.10 )-( 7.81 ³)/(8*126.10 ³)
Sca = 1494.91 KG/CM2
AISC Unity Check on Outside Ribs ( must be <= 1.0 )

Check = Sc/Sca + (Rm/Z)/Sba
Check = 5.31 / 1494.91 + (3.85 /47485.629 ) / 1687.37
Check = 0.01
Check of Inside Ribs

Inertia of Saddle, Inner Ribs - Axial Direction
Y A AY Ay² Io
Rib 67.3 1146.1 77125.8 1712019.0 1612023.6
Web 5.0 1873.1 9365.0 1047502.9 15608.3
Values 28.6 3019.2 86490.8 2759522.0 1627631.9
KL/R < Cc ( 6.2302 < 126.0992 ) per AISC E2-1

Sca = ( 1-( 6.23 )²/(2 * 126.10 ² )) * 2531 /
( 5/3+3*(6.23 )/(8* 126.10 )-( 6.23 ³)/(8*126.10 ³)
Sca = 1500.11 KG/CM2
AISC Unity Check on Inside Ribs ( must be <= 1.0 )

Check = 7.32 / 1500.11 + ( 5.33 /70419.812 ) / 1687.37
Check = 0.01
Input Data for BasePlate Bolting Calculations:

FOR HEAT EXCHANGER
Total Number of Bolts per BasePlate Nbolts 2

Total Number of Bolts in Tension/Baseplate Nbt 2
Bolt Material Specification SA-307 B
Bolt Allowable Stress Stba 492.15 KG/CM2
Bolt Corrosion Allowance Bca 0.0000 mm.
Distance from Bolts to Edge Edgedis 50.0126 mm.
Nominal Bolt Diameter Bnd 19.0500 mm.
Thread Series Series UNC
BasePlate Allowable Stress S 1167.10 KG/CM2
Area Available in a Single Bolt BltArea 194.8504 sq.mm.
Saddle Load QO QO 319.8 KG
Bolt Area Calculation per Dennis R. Moss
Bolt Area Requirement Due to Longitudinal Load (Bltarearl)

= 0.0 (QO > QL --> No Uplift)
Bolt Area due to Shear Load (Bltarears)

= FL / (Stba * Nbolts)
= 95.95 / (492.15 * 2.00 )
= 9.7502 sq.mm.
Bolt Area due to Transverse Load
Moment on Baseplate Due to Transverse Load (Rmom)

= B * Transverse Force + Sum of X Moments
= 450.00 * 38.99 + 0.00
= 17.54 KG-M
Eccentricity (e):
= Rmom / QO
= 17.54 / 319.82
= 54.86 mm. < Bplen/6 --> No Uplift
Bolt Area due to Transverse Load (Bltareart)

= 0 (No Uplift)
Required of a Single Bolt (Bltarear)

= max[Bltarearl, Bltarears, Bltareart]
= max[0.0000 , 9.7502 , 0.0000 ]
= 9.7502 sq.mm.
Zick Analysis: Stresses for the Right Saddle
Shell Allowable Stress used in Calculation 1406.14 KG/CM2

Shell Compressive Yield used in Calculation 2274.47 KG/CM2
Head Allowable Stress used in Calculation 1406.14 KG/CM2
Saddle Force Q, Operating Case 511.65 KG
Stress Results for Zick Stresses: Actual Allowable

Long. Stress at Top of Saddles 355.06 1195.22 KG/CM2
Long. Stress at Bottom of Saddles -64.44 1038.48 KG/CM2
Long. Stress at Top of Midspan 161.97 1195.22 KG/CM2
Long. Stress at Bottom of Midspan 128.64 1195.22 KG/CM2
Tangential Shear in Shell 16.04 1124.91 KG/CM2

Circ. Stress at Horn of Saddle -106.39 -2047.02 KG/CM2
Circ. Stress at Tip of Wear Plate -94.76 -2047.02 KG/CM2
Circ. Compressive Stress in Shell -20.75 -1137.23 KG/CM2
FOR HEAT EXCHANGER
Intermediate Results: Saddle Reaction Q due to Wind or Seismic
Saddle Reaction Force due to Wind Ft

Fwt = Ftr * ( Ft/Num of Saddles + Z Force Load ) * B / E
Fwt = 3.00 * ( 78.0 /2 + 0 ) * 450.0000 / 345.5441
Fwt = 152.3169 KG
Saddle Reaction Force due to Wind Fl or Friction

Fwl = Max( Fl, Friction Load, Sum of X Forces) * B / Ls
Fwl = Max( 5.65 , 107.80 , 0 ) * 450.0000 / 1600.0001
Fwl = 30.3189 KG
Saddle Reaction Force due to Earthquake Fl or Friction

Fsl = Max( Fl, Friction Force, Sum of X Forces ) * B / Ls
Fsl = Max( 0.00 , 107.80 , 0 ) * 450.0000 / 1600.0001
Fsl = 30.3189 KG
Saddle Reaction Force due to Earthquake Ft

Fst = Ftr * ( Ft/Num of Saddles + Z Force Load ) * B / E
Fst = 3.00 * ( 0 /2 + 0 ) * 450.0000 / 345.5441
Fst = 0.0000 KG
Load Combination Results for Q + Wind or Seismic

Q = Saddle Load + Max( Fwl, Fwt, Fsl, Fst )
Q = 359 + Max( 30 , 152 , 30 , 0 )
Q = 511.6521 KG
Formulas and Substitutions for Zick Analysis Results:
Longitudinal Bending (+-) at Midspan

= ( 3 * Q * L/12 * K.2 / ( pi * R² * ( Ts - Ca )))
= ( 3 * 511 * 3000.00 /12 * -0.3252 ) /
( pi * 191.5000 * 191.5000 * ( 8.0000 - 1.5000 )))
= -16.67 KG/CM2
Longitudinal Bending (+-) at Saddle

= ( 3 * Q * L/12 * K.1 / ( pi * R² * ( Ts - Ca )))
= ( 3 * 511 * 3000.00 /12 * 4.0924 ) /
( pi * 191.5000 * 191.5000 * ( 8.0000 - 1.5000 )))
= 209.75 KG/CM2
Tangential Shear in Shell near Saddle

= Q * K.4 * (( L-H-2A )/( L+H ))/( R*(Ts-Ca))
= 511 * 1.1707 * (( 3000.00 - 0.00 - 2 * 1000.00 )/
( 3000.00 + 0.00 ))/( 191.5000 * ( 8.0000 - 1.5000 ))
= 16.04 KG/CM2
Circumferential Stress at Tip of the Wear Plate

= -Q/(4*(TS-CA)*(SADWTH+1.56*Sqrt(R*(TS-CA))))-3.0*Q*K13/(2*(TS-CA)²)
= -511 /( 4 * 6.5000 * (140.00 + 1.56*Sqrt(191.5000 *6.5000 )))
-3 * 511 * 0.0466 / ( 2 * 42.2500 )
= -94.76 KG/CM2
Circumferential Stress at Horn of Saddle

= -Q /(4*TEM*(SADWTH+1.56*Sqrt(R*(TS-CA))))-3.0*Q*K.7/(2*TEB)
= -511 /( 4 * 6.5000 * (140.00 + 1.56*Sqrt(191.5000 *6.5000 )))
-3 * 511 * 0.0530 / ( 2 * 42.2500 )
= -106.39 KG/CM2
Circumferential Compression at Bottom of Shell

= (Q*( K.9/( TEM9 * WPDWTH ) ) )
FOR HEAT EXCHANGER
= ( 511 *( 0.7603 /( 12.5000 * 150.000 ) ) )

= -20.75 KG/CM2
Results for Vessel Ribs, Web and Base
Baseplate Length Bplen 400.0000 mm.

Baseplate Thickness Bpthk 10.0000 mm.
Baseplate Width Bpwid 150.0000 mm.
Number of Ribs ( inc. outside ribs ) Nribs 3
Rib Thickness Ribtk 10.0000 mm.
Web Thickness Webtk 10.0000 mm.
Web Location Webloc Side
Moment of Inertia of Saddle - Lateral Direction
Y A AY Ay² Io
Shell 3. 1333. 4331. 14077. 4692.
Wearplate 10. 900. 8550. 81225. 2700.
Web 126. 2275. 287219. 36261240. 9812087.
BasePlate 245. 1500. 367500. 90037184. 12500.
Totals 384. 6008. 667600. 126393728. 9831980.
Value C1 = Sumof(Ay)/Sumof(A) = 111. mm.

Value I = Sumof(Ay² ) + Sumof(Io) - C1*Sumof(Ay) = 62040112. mm**4
Value As = Sumof(A) - Ashell = 4675. sq.mm.
K1 = (1+Cos(beta)-.5*Sin(beta)² )/(pi-beta+Sin(beta)*Cos(beta)) = 0.2035
Fh = ( K1 * Q ) = 104.1323 KG
Tension Stress, St = ( Fh/As ) = 2.2279 KG/CM2

Allowed Stress, Sa = 0.6 * Yield Str = 1518.6301 KG/CM2
Bending Moment, M = Fh * d = 29.4773 KG-M
Bending Stress, Sb = ( M * C1 / I ) = 5.2819 KG/CM2

Allowed Stress, Sa = 2/3 * Yield Str = 1687.3668 KG/CM2
Minimum Thickness of Baseplate :

Baseplate Min., = (3*Q*F/(2*A*SA))½ = 4.1304 mm.
Calc. of Axial Load, Inter. Values and Comp. Stress
Effective Baseplate Length (e)

= ( Bplen - Clearance ) / ( Nribs - 1)
= ( 400.0000 - 25.4 ) / ( 3 - 1 ) = 187.3000 mm.
Baseplate Pressure Area (Ap)

= e * Bpwid / 2
= 187.3000 * 150.0000 / 2 = 14048.3711 sq.mm.
Axial Load (P)

= Ap * Bp
= 14048.4 * 0.01 = 119.8 KG
Area of the Rib and Web (Ar)

= ( Bpwid - Clearance - Webtk ) * Ribtk + e/2 * Webtk
= ( 150.000 - 25.4 - 10.000 ) * 10.000 + 187.3000 /2 * 10.000
= 2082.629 sq.mm.
Compressive Stress (Sc)

= P/Ar
FOR HEAT EXCHANGER
= 119.8 / 2082.6292 = 5.7534 KG/CM2
Check of Outside Ribs:

Inertia of Saddle, Outer Ribs - Longitudinal Direction
Y A AY Ay² Io
Rib 67.3 1223.1 82307.9 892709.8 1929731.2
Web 5.0 936.6 4682.5 1165812.8 15608.3
Values 40.3 2159.6 86990.4 2058522.4 1945339.5
KL/R < Cc ( 7.8111 < 126.0992 ) per AISC E2-1

Sca = ( 1-( 7.81 )²/(2 * 126.10 ² )) * 2531 /
( 5/3+3*(7.81 )/(8* 126.10 )-( 7.81 ³)/(8*126.10 ³)
Sca = 1494.91 KG/CM2
AISC Unity Check on Outside Ribs ( must be <= 1.0 )

Check = 5.75 / 1494.91 + (4.32 /47485.629 ) / 1687.37
Check = 0.01
Check of Inside Ribs

Inertia of Saddle, Inner Ribs - Axial Direction
Y A AY Ay² Io
Rib 67.3 1146.1 77125.8 1712019.0 1612023.6
Web 5.0 1873.1 9365.0 1047502.9 15608.3
Values 28.6 3019.2 86490.8 2759522.0 1627631.9
KL/R < Cc ( 6.2302 < 126.0992 ) per AISC E2-1

Sca = ( 1-( 6.23 )²/(2 * 126.10 ² )) * 2531 /
( 5/3+3*(6.23 )/(8* 126.10 )-( 6.23 ³)/(8*126.10 ³)
Sca = 1500.11 KG/CM2
AISC Unity Check on Inside Ribs ( must be <= 1.0 )

Check = 7.94 / 1500.11 + ( 5.99 /70419.812 ) / 1687.37
Check = 0.01
Input Data for BasePlate Bolting Calculations:
Total Number of Bolts per BasePlate Nbolts 2

Total Number of Bolts in Tension/Baseplate Nbt 2
Bolt Material Specification SA-307 B
Bolt Allowable Stress Stba 492.15 KG/CM2
Bolt Corrosion Allowance Bca 0.0000 mm.
Distance from Bolts to Edge Edgedis 50.0126 mm.
Nominal Bolt Diameter Bnd 19.0500 mm.
Thread Series Series UNC
BasePlate Allowable Stress S 1167.10 KG/CM2
Area Available in a Single Bolt BltArea 194.8504 sq.mm.
Saddle Load QO QO 359.3 KG
Bolt Area Calculation per Dennis R. Moss
Bolt Area Requirement Due to Longitudinal Load (Bltarearl)

= 0.0 (QO > QL --> No Uplift)
Bolt Area due to Shear Load (Bltarears)

= FL / (Stba * Nbolts)
= 107.80 / (492.15 * 2.00 )
FOR HEAT EXCHANGER
= 10.9549 sq.mm.
Bolt Area due to Transverse Load
Moment on Baseplate Due to Transverse Load (Rmom)

= B * Transverse Force + Sum of X Moments
= 450.00 * 38.99 + 0.00
= 17.54 KG-M
Eccentricity (e):
= Rmom / QO
= 17.54 / 359.34
= 48.82 mm. < Bplen/6 --> No Uplift
Bolt Area due to Transverse Load (Bltareart)

= 0 (No Uplift)
Required of a Single Bolt (Bltarear)

= max[Bltarearl, Bltarears, Bltareart]
= max[0.0000 , 10.9549 , 0.0000 ]
= 10.9549 sq.mm.

FOR HEAT EXCHANGER
Nozzle Calcs. T1 NOZL: 1 2:02p Dec 11,2006
INPUT VALUES, Nozzle Description: T1 From : 20
Pressure for Nozzle Reinforcement Calculations P 7.50 KG/CM2

Temperature for Internal Pressure Temp 80.00 C
Shell Material SA-516 70

Shell Allowable Stress at Temperature S 1406.14 KG/CM2
Shell Allowable Stress At Ambient Sa 1406.14 KG/CM2
Inside Diameter of Cylindrical Shell D 380.0000 mm.

Shell Actual Thickness T 8.0000 mm.
Shell Corrosion Allowance Cas 1.5000 mm.
Distance from Bottom/Left Tangent 150.0000 mm.
User Entered Minimum Design Metal Temperature 10.00 C
Nozzle Material SA-106 B

Nozzle Allowable Stress at Temperature Sn 1202.25 KG/CM2
Nozzle Allowable Stress At Ambient Sna 1202.25 KG/CM2
Nozzle Diameter Basis (for tr calc only) Inbase ID

Layout Angle 180.00 deg
Nominal Nozzle Diameter Dia 80 mm.
Nozzle Size and Thickness Basis Idbn Nominal

Nominal Thickness of Nozzle Thknom SCH 40
Nozzle Flange Material SA-105

Nozzle Flange Type Slip on
Nozzle Corrosion Allowance Can 1.5000 mm.

Joint Efficiency of Shell Seam at Nozzle Es 1.00
Joint Efficiency of Nozzle Neck En 1.00
Nozzle OutSide Projection Ho 150.0000 mm.

Weld leg size between Nozzle and Pad/Shell Wo 6.0000 mm.
Groove weld depth between Nozzle and Vessel Wgnv 4.0000 mm.
ASME Code Weld Type per UW-16 None
The Nozzle Pressure Design option was Design Pressure + static head
NOZZLE CALCULATION, Description: T1

ASME Code, Section VIII, Division 1, 2004, UG-37 to UG-45
Actual Nozzle Diameter Used in Calculation 77.927 mm.

Actual Nozzle Thickness Used in Calculation 5.486 mm.
Nozzle input data check completed without errors.
Reqd thk per UG-37(a)of Cylindrical Shell, Tr [Int. Press]

= (P*(D/2+CA))/(S*E-0.6*P) per UG-27 (c)(1)
= (7.50*(380.0000/2+1.5000))/(1406*1.00-0.6*7.50)
= 1.0247 mm.
Reqd thk per UG-37(a)of Nozzle Wall, Trn [Int. Press]

= (P*(D/2+CA))/(S*E-0.6*P) per UG-27 (c)(1)
= (7.50*(77.9272/2+1.5000))/(1202*1.00-0.6*7.50)
= 0.2534 mm.
UG-40, Thickness and Diameter Limit Results : [Int. Press]

FOR HEAT EXCHANGER
Effective material diameter limit, Dl 161.8544 mm.

Effective material thickness limit, no pad Tlnp 9.9660 mm.
Note: Taking a UG-36(c)(3)(a) exemption for T1 .

This calculation is valid for nozzles that meet all the requirements of
paragraph UG-36. Please check the Code carefully, especially for nozzles
that are not isolated or do not meet Code spacing requirements. It may
be necessary to force the program to print the areas per UG-37.
UG-45 Minimum Nozzle Neck Thickness Requirement: [Int. Press.]

= Max( Min(Max(Max(UG45B1,UG16B),Max(UG45B2,UG16B)),UG45B4), UG45A )
= Max(Min(Max(Max(2.5247,3.8812),Max(1.5000,3.8812)),6.3006),1.7534)
= 3.8812 < Minimum Nozzle Thickness 4.8006 mm. OK
Minimum Design Metal Temperature (Nozzle Neck), Curve: B

Minimum Temp. w/o impact per UCS-66 -29 C
Minimum Temp. at required thickness -104 C
Nozzle MDMT Thickness Calc. per UCS-66 (a)1(b), MIN(tn,t,te), Curve: B

Minimum Temp. w/o impact per UG-20(f) -29 C
The Drop for this Nozzle is 5.0539 mm.
Weld Size Calculations, Description: T1
Intermediate Calc. for nozzle/shell Welds Tmin 3.9864 mm.
Results Per UW-16.1, Required Thickness Actual Thickness

Nozzle Weld 2.7905 = 0.7 * TMIN 4.2420 = 0.7 * WO , mm.
NOTE : Skipping the nozzle attachment weld strength calculations.

Per UW-15(b)(2) the nozzles exempted by UG-36(c)(3)(a)
(small nozzles) do not require a weld strength check.

FOR HEAT EXCHANGER












= (P*(D/2+CA))/(S*E-0.6*P) per UG-27 (c)(1)
= (7.50*(380.0000/2+1.5000))/(1406*1.00-0.6*7.50)
= 1.0247 mm.

= (P*(D/2+CA))/(S*E-0.6*P) per UG-27 (c)(1)
= (7.50*(77.9272/2+1.5000))/(1202*1.00-0.6*7.50)
= 0.2534 mm.

FOR HEAT EXCHANGER








FOR HEAT EXCHANGER
Nozzle Calcs. S1 NOZL: 3 2:02p Dec 11,2006
INPUT VALUES, Nozzle Description: S1 From : 40









Nozzle Inside Projection H 0.0000 mm.
Weld leg size, Inside Nozzle to Shell Wi 0.0000 mm.
NOZZLE CALCULATION, Description: S1



= (P*(D/2+CA))/(S*E-0.6*P) per UG-27 (c)(1)
= (10.00*(380.0000/2+1.5000))/(1406*1.00-0.6*10.00)
= 1.3677 mm.

= (P*(D/2+CA))/(S*E-0.6*P) per UG-27 (c)(1)
= (10.00*(102.2604/2+1.5000))/(1202*1.00-0.6*10.00)
= 0.4400 mm.
FOR HEAT EXCHANGER

Results of Nozzle Reinforcement Area Calculations:

AREA AVAILABLE, A1 to A5 Design External Mapnc
Area Required Ar 145.769 NA NA sq.mm.
Area in Shell A1 533.532 NA NA sq.mm.
Area in Nozzle Wall A2 78.836 NA NA sq.mm.
Area in Inward Nozzle A3 0.000 NA NA sq.mm.
Area in Welds A4 21.376 NA NA sq.mm.
Area in Pad A5 0.000 NA NA sq.mm.
TOTAL AREA AVAILABLE Atot 633.744 NA NA sq.mm.
The Internal Pressure Case Governs the Analysis.
Nozzle Angle Used in Area Calculations 90.00 Degs.
The area available without a pad is Sufficient.
Reinforcement Area Required for Nozzle [Ar]:

= (Dlr*Tr+2*Thk*Tr*(1-fr1)) UG-37(c)
= (105.2604*1.3677+2*(6.0198-1.5000)*1.3677*(1-0.8550))
= 145.769 sq.mm.
Areas per UG-37.1 but with DL = Diameter Limit, DLR = Corroded ID:
Area Available in Shell [A1]:

= (DL-Dlr)*(ES*(T-Cas)-Tr)-2*(Thk-Can)*(ES*(T-Cas)-Tr)*(1-fr1)
= (210.521-105.260)*(1.00*(8.0000-1.500)-1.368)-2*(6.020-1.500)
*(1.00*(8.0000-1.5000)-1.3677)*(1-0.8550)
= 533.532 sq.mm.
Area Available in Nozzle Wall, no Pad [A2np]:

= ( 2 * min(Tlnp,ho) ) * ( Thk - Can - Trn ) * fr2
= ( 2 * min(11.3 ,150.0 ) ) * ( 6.0 - 1.5 - 0.4 ) * 0.8550 )
= 78.836 sq.mm.
Area Available in Welds, no Pad [A4np]:

= Wo² * fr2 + ( Wi-Can/0.707 )² * fr2
= 5.0000 ² * 0.8550 + ( 0.0000 )² * 0.8550
= 21.376 sq.mm.

M.A.W.P. Results for this Nozzle Geometry (Based on Areas)

Approximate M.A.W.P. for given geometry AMAP 26.460 KG/CM2



FOR HEAT EXCHANGER
Weld Size Calculations, Description: S1

Weld Strength and Weld Loads per UG-41.1, Sketch (a) or (b)
Weld Load [W]:
= (Ar-A1+2*(Thk-can)*Ffr1*(E1(T-Cas)-Tr))*S
= (145.7686 - 533.5318 + 2 * ( 6.0198 - 1.5000 ) * 0.8550 *
(1.00 * ( 8.0000 - 1.5000 ) - 1.3677 ) ) * 1406
= 0.00 KG
Weld Load [W1]:

= (A2+A5+A4-(Wi-Can/.707)²*Ffr2)*S
= ( 78.8361 + 0.0000 + 21.3763 - 0.0000 * 0.86 ) * 1406
= 1408.75 KG
Weld Load [W2]:

= ((A2+A6)+A3+A4+(2*(Thk-Can)*(T-Ca)*Fr1))*S
= ( 78.8361 + 0.0000 + 21.3763 + 50.2407 ) * 1406
= 2115.02 KG
Weld Load [W3]:

= ((A2+A6)+A3+A4+A5+(2*(Thk-Can)*(T-Ca)*Fr1))*S
= ( 78.8361 + 0.0000 + 21.3763 + 0.0000 + 50.2407 ) * 1406
= 2115.02 KG
Strength of Connection Elements for Failure Path Analysis
Shear, Outward Nozzle Weld [Sonw]:

= (pi/2) * Dlo * Wo * 0.49 * Snw
= ( 3.1416 / 2.0 ) * 114.3000 * 5.0000 * 0.49 * 1202
= 5287. KG
Shear, Nozzle Wall [Snw]:

= (pi *( Dlr + Dlo )/4 ) * ( Thk - Can ) * 0.7 * Sn
= (3.1416 * 54.8901 ) * ( 6.0198 - 1.5000 ) * 0.7 * 1202
= 6558. KG
Tension, Nozzle Groove Weld [Tngw]:

= (PI/2) * Dlo * (Wgnvi-Cas) * 0.74 * Sng
= ( 3.1416 / 2.0 ) * 114.3000 * ( 5.0000 - 1.5000 ) * 0.74 * 1202
= 5589. KG
Strength of Failure Paths:
PATH11 = ( SONW + SNW ) = ( 5287 + 6557 ) = 11845 KG

PATH22 = ( Sonw + Tpgw + Tngw + Sinw )
= ( 5287 + 0 + 5589 + 0 ) = 10876 KG
PATH33 = ( Sonw + Tngw + Sinw )
= ( 5287 + 5589 + 0 ) = 10876 KG
Summary of Failure Path Calculations:

Path 1-1 = 11845 KG , must exceed W = 0 KG or W1 = 1408 KG

FOR HEAT EXCHANGER
INPUT VALUES, Nozzle Description: S2 From : 40









Nozzle Inside Projection H 0.0000 mm.
Weld leg size, Inside Nozzle to Shell Wi 0.0000 mm.
NOZZLE CALCULATION, Description: S2



= (P*(D/2+CA))/(S*E-0.6*P) per UG-27 (c)(1)
= (10.00*(380.0000/2+1.5000))/(1406*1.00-0.6*10.00)
= 1.3677 mm.

= (P*(D/2+CA))/(S*E-0.6*P) per UG-27 (c)(1)
= (10.00*(102.2604/2+1.5000))/(1202*1.00-0.6*10.00)
= 0.4400 mm.
FOR HEAT EXCHANGER

Results of Nozzle Reinforcement Area Calculations:

AREA AVAILABLE, A1 to A5 Design External Mapnc
Area Required Ar 145.769 NA NA sq.mm.
Area in Shell A1 533.532 NA NA sq.mm.
Area in Nozzle Wall A2 78.836 NA NA sq.mm.
Area in Inward Nozzle A3 0.000 NA NA sq.mm.
Area in Welds A4 21.376 NA NA sq.mm.
Area in Pad A5 0.000 NA NA sq.mm.
TOTAL AREA AVAILABLE Atot 633.744 NA NA sq.mm.
The Internal Pressure Case Governs the Analysis.
Nozzle Angle Used in Area Calculations 90.00 Degs.
The area available without a pad is Sufficient.
Reinforcement Area Required for Nozzle [Ar]:

= (Dlr*Tr+2*Thk*Tr*(1-fr1)) UG-37(c)
= (105.2604*1.3677+2*(6.0198-1.5000)*1.3677*(1-0.8550))
= 145.769 sq.mm.
Areas per UG-37.1 but with DL = Diameter Limit, DLR = Corroded ID:
Area Available in Shell [A1]:

= (DL-Dlr)*(ES*(T-Cas)-Tr)-2*(Thk-Can)*(ES*(T-Cas)-Tr)*(1-fr1)
= (210.521-105.260)*(1.00*(8.0000-1.500)-1.368)-2*(6.020-1.500)
*(1.00*(8.0000-1.5000)-1.3677)*(1-0.8550)
= 533.532 sq.mm.
Area Available in Nozzle Wall, no Pad [A2np]:

= ( 2 * min(Tlnp,ho) ) * ( Thk - Can - Trn ) * fr2
= ( 2 * min(11.3 ,150.0 ) ) * ( 6.0 - 1.5 - 0.4 ) * 0.8550 )
= 78.836 sq.mm.
Area Available in Welds, no Pad [A4np]:

= Wo² * fr2 + ( Wi-Can/0.707 )² * fr2
= 5.0000 ² * 0.8550 + ( 0.0000 )² * 0.8550
= 21.376 sq.mm.

M.A.W.P. Results for this Nozzle Geometry (Based on Areas)

Approximate M.A.W.P. for given geometry AMAP 26.460 KG/CM2



FOR HEAT EXCHANGER
Weld Size Calculations, Description: S2

Weld Strength and Weld Loads per UG-41.1, Sketch (a) or (b)
Weld Load [W]:
= (Ar-A1+2*(Thk-can)*Ffr1*(E1(T-Cas)-Tr))*S
= (145.7686 - 533.5318 + 2 * ( 6.0198 - 1.5000 ) * 0.8550 *
(1.00 * ( 8.0000 - 1.5000 ) - 1.3677 ) ) * 1406
= 0.00 KG
Weld Load [W1]:

= (A2+A5+A4-(Wi-Can/.707)²*Ffr2)*S
= ( 78.8361 + 0.0000 + 21.3763 - 0.0000 * 0.86 ) * 1406
= 1408.75 KG
Weld Load [W2]:

= ((A2+A6)+A3+A4+(2*(Thk-Can)*(T-Ca)*Fr1))*S
= ( 78.8361 + 0.0000 + 21.3763 + 50.2407 ) * 1406
= 2115.02 KG
Weld Load [W3]:

= ((A2+A6)+A3+A4+A5+(2*(Thk-Can)*(T-Ca)*Fr1))*S
= ( 78.8361 + 0.0000 + 21.3763 + 0.0000 + 50.2407 ) * 1406
= 2115.02 KG
Strength of Connection Elements for Failure Path Analysis
Shear, Outward Nozzle Weld [Sonw]:

= (pi/2) * Dlo * Wo * 0.49 * Snw
= ( 3.1416 / 2.0 ) * 114.3000 * 5.0000 * 0.49 * 1202
= 5287. KG
Shear, Nozzle Wall [Snw]:

= (pi *( Dlr + Dlo )/4 ) * ( Thk - Can ) * 0.7 * Sn
= (3.1416 * 54.8901 ) * ( 6.0198 - 1.5000 ) * 0.7 * 1202
= 6558. KG
Tension, Nozzle Groove Weld [Tngw]:

= (PI/2) * Dlo * (Wgnvi-Cas) * 0.74 * Sng
= ( 3.1416 / 2.0 ) * 114.3000 * ( 5.0000 - 1.5000 ) * 0.74 * 1202
= 5589. KG
Strength of Failure Paths:
PATH11 = ( SONW + SNW ) = ( 5287 + 6557 ) = 11845 KG

PATH22 = ( Sonw + Tpgw + Tngw + Sinw )
= ( 5287 + 0 + 5589 + 0 ) = 10876 KG
PATH33 = ( Sonw + Tngw + Sinw )
= ( 5287 + 5589 + 0 ) = 10876 KG
Summary of Failure Path Calculations:


FOR HEAT EXCHANGER







Nozzle Flange Type Weld Neck Flange





= (P*(D/2+CA))/(S*E-0.6*P) per UG-27 (c)(1)
= (7.50*(380.0000/2+1.5000))/(1406*1.00-0.6*7.50)
= 1.0247 mm.

= (P*(D/2+CA))/(S*E-0.6*P) per UG-27 (c)(1)
= (7.50*(24.3078/2+0.0000))/(1202*1.00-0.6*7.50)
= 0.0761 mm.

FOR HEAT EXCHANGER








FOR HEAT EXCHANGER







Nozzle Flange Type Weld Neck Flange





= (P*(D/2+CA))/(S*E-0.6*P) per UG-27 (c)(1)
= (7.50*(380.0000/2+1.5000))/(1406*1.00-0.6*7.50)
= 1.0247 mm.

= (P*(D/2+CA))/(S*E-0.6*P) per UG-27 (c)(1)
= (7.50*(24.3078/2+0.0000))/(1202*1.00-0.6*7.50)
= 0.0761 mm.

FOR HEAT EXCHANGER








FOR HEAT EXCHANGER
Nozzle Schedule STEP: 18 2:02p Dec 11,2006
Nozzle Schedule:
Nom. Flange Noz. Wall Re-Pad

Description Size Schd Type O/Dia Thk ODia Thick
------------------------------------------------------------------------------
T3 25 80 WNF 33.401 4.547 - -
T4 25 80 WNF 33.401 4.547 - -
T1 80 40 SlipOn 88.900 5.486 - -
T2 80 40 SlipOn 88.900 5.486 - -
S1 100 40 SlipOn 114.300 6.020 - -
S2 100 40 SlipOn 114.300 6.020 - -
Please Note: In the case of Oblique Nozzles, the Outside Diameter must
be increased. The Re-Pad WIDTH around the nozzle is calculated as follows:
Width of Pad = (Pad Outside Dia. (per above) - Nozzle Outside Dia.)/2
Nozzle Material and Weld Fillet Leg Size Details:

Noz Shl/Pad Pad/Shl Inside
Nozzle Material Weld Weld Weld
------------------------------------------------------------------------------
T3 SA-106 B 5.000 - -
T4 SA-106 B 5.000 - -
T1 SA-106 B 6.000 - -
T2 SA-106 B 6.000 - -
S1 SA-106 B 5.000 - -
S2 SA-106 B 5.000 - -
Nozzle Miscellaneous Data:
Elevation/Distance Layout Projection Installed In

Nozzle From Datum Angle Outside Inside Component
mm. deg. mm. mm.
----------------------------------------------------------------------------
T3 3410.000 0.00 150.0 0.0 Node: 60
T4 3410.000 180.00 150.0 0.0 Node: 60
T1 150.000 180.00 150.0 0.0 Node: 20
T2 150.000 0.00 150.0 0.0 Node: 20
S1 3080.000 0.00 150.0 0.0 Node: 40
S2 405.000 180.00 150.0 0.0 Node: 40

FOR HEAT EXCHANGER
Nozzle Summary STEP: 19 2:02p Dec 11,2006
Nozzle Calculation Summary
Description Internal Ext MAPNC UG45 [tr] Weld Areas

KG/CM2 KG/CM2 Path
---------------------------------------------------------------------------
T1 ... ... OK 3.88 OK NoCalc[*]
T2 ... ... OK 3.88 OK NoCalc[*]
S1 26.46 ... ... OK 3.88 OK Passed
S2 26.46 ... ... OK 3.88 OK Passed
T3 ... ... OK 2.96 OK NoCalc[*]
T4 ... ... OK 2.96 OK NoCalc[*]
---------------------------------------------------------------------------
Min. - Nozzles 26.46 S2
Min. Shell&Flgs 13.22
Computed Vessel M.A.W.P. 13.22 KG/CM2
[*] - This was a small opening and the areas were not computed.
Check the Spatial Relationship between the Nozzles
From Node Nozzle Description X Coordinate, Layout Angle, Dia. Limit

20 T1 150.000 180.000 161.854
20 T2 150.000 0.000 161.854
40 S1 3080.000 0.000 210.521
40 S2 405.000 180.000 210.521
60 T3 3410.000 0.000 48.616
60 T4 3410.000 180.000 48.616
The nozzle spacing is computed by the following:

= Sqrt( ll² + lc² ) where
ll - Arc length along the inside vessel surface in the long. direction.
lc - Arc length along the inside vessel surface in the circ. direction
If any interferences/violations are found, they will be noted below.
No interference violations have been detected !

FOR HEAT EXCHANGER
Tubesheet Analysis: TUBESHEET Case: 1 2:02p Dec 11,2006
Input Echo, TubeSheet Item 1, Description: TUBESHEET
Tubesheet Design Code TEMA

Shell Desc. From Node 40 to 50
Shell Design Pressure PS 10.00 KG/CM2
Shell Temperature for Internal Pressure TEMPS 210.00 C
Shell Material UNS Number K02700
Shell Allowable Stress at Temperature SOS 1406.14 KG/CM2
Shell Allowable Stress at Ambient SAS 1406.14 KG/CM2
Shell Thickness TS 8.0000 mm.
Shell Corrosion Allowance CAS 1.5000 mm.
Inside Diameter of Shell DS 380.0000 mm.
Mean Metal Temperature for Shell ACTUAL1 76.80 C
Channel Desc. From Node 20 to 30

Channel Design Pressure PC 7.50 KG/CM2
Channel Temperature for Internal Pressure TEMPC 80.00 C
Channel Material SA-516 70
Channel Material UNS Number K02700
Channel Allowable Stress at Temperature SOC 1406.14 KG/CM2
Channel Allowable Stress at Ambient SAC 1406.14 KG/CM2
Channel Thickness TC 8.0000 mm.
Channel Corrosion Allowance CAC 1.5000 mm.
Inside Diameter of Channel DC 380.0000 mm.
Mean Metal Temperature for Tubes ACTUAL2 42.20 C
Tube Design Temperature Tubtmp 80.00 C

Tube Material SA-179
Tube Material UNS Number K01200
Tube Allowable Stress at Temperature SOT 942.11 KG/CM2
Tube Allowable Stress At Ambient SAT 942.11 KG/CM2
Tube Yield Stress At Operating Temperature SYT 1693.57 KG/CM2
Tube Wall Thickness TT 1.6500 mm.
Tube Corrosion Allowance Catt 0.0000 mm.
Number of Tubes Holes NTUBS 132
Tube Layout Pattern Triangular
Tube Outside Diameter do 19.0500 mm.
Tube Pitch (Center to Center Spacing) PTube 25.0000 mm.
Fillet Weld Leg af 2.0000 mm.

Groove Weld Leg ag 0.0000 mm.
Design Strength of Weld Fd 0.0000 KG
Tube-Tubesheet Joint Weld Type Seal Weld
Is Tube-Tubesheet Joint Tested No
Tube-Tubesheet Joint Classification f
Tube Joint Reliability Factor FASME 0.7500
Straight Tube Length, bet. inner tubsht faces RL 2934.0000 mm.

Unsupported Tube Length for max. (k*SL) SL 337.0000 mm.
Tube end condition corres. to span (SL) k 0.8000
Length of Expanded Portion of Tube l 22.0000 mm.
TUBESHEET TYPE: Fixed Tubesheet Exchanger

Tubesheet Design Metal Temperature TEMPTS 210.00 C
Tubesheet Material (Not Normalized) SA-266 2
Tubesheet Material UNS Number K03506
Tubesheet Allowable Stress at Temperature SOTS 1403.34 KG/CM2
Tubesheet Allowable Stress at Ambient SATS 1406.14 KG/CM2
Thickness of Tubesheet TTS 25.0000 mm.
FOR HEAT EXCHANGER
Tubesheet Corr. Allowance (Shell side) CATS 1.5000 mm.

Tubesheet Corr. Allowance (Channel side) CATC 1.5000 mm.
Depth of Groove in Tube Sheet GROOVE 5.0000 mm.
TEMA Tubesheet class C
Additional Data for Fixed Tubesheet Exchangers

Mean Metal Temperature for Tubesheet ACTUAL3 76.80 C
Run Multiple Load Cases for Fixed Tubesheets No
Is this a Kettle-type configuration No
Additional Data for Tubesheets Extended as Flanges:

Outside Diameter of Flanged Portion DF 510.0000 mm.
Diameter of Bolt Circle DB 450.0000 mm.
Thickness of Extended Portion of Tubesheet TF 15.0000 mm.
Nominal Bolt Diameter DBOLT 20.0000 mm.
Type of Thread Series TEMA Metric Thread
Number of Bolts NUMBER 16
Bolt Allowable Stress At Temperature SBO 1757.68 KG/CM2
Bolt Allowable Stress At Ambient SBA 1757.68 KG/CM2
Weld between Flange and Shell/Channel WLDH 0.0000 mm.
Additional Data for Gasketed Tubesheets:

Flange Face Outside Diameter FOD 440.0000 mm.
Flange Face Inside Diameter FID 394.0000 mm.
Flange Facing Sketch Code Sketch 1a
Gasket Outside Diameter GOD 436.0000 mm.
Gasket Inside Diameter GID 394.0000 mm.
Column for Gasket Seating Code Column II
Gasket Thickness GTHICK 3.0000 mm.
Full face Gasket Flange Option Check
Tubesheet Gasket on which Side SIDE CHANNEL
Intermediate Calculations For Tubesheets Extended As Flanges:

ASME Code, Section VIII, Div. 1, Ed-2004 App. 2
Gasket Contact Width, N = (GODC-GIDC) / 2 21.000 mm.

Gasket Reaction Diameter, G = GODC-2.0*BE 419.669 mm.
Basic Flange and Bolt loads:

Hydrostatic End Load due to Pressure:
H = 0.785 * G * G * PEQ
H = 0.7854 * 419.6690 *419.6690 *7.5000
H = 10372. KG
Contact Load on Gasket Surfaces:

HP = 2 * BE * PI * G * M * P
HP = 2 * 8.1655 * 3.1416 * 419.6690 * 2.0000 * 7.50
HP = 3229. KG
Hydrostatic End Load at Flange ID:

HD = 0.785 * Bcor * Bcor * P
HD = 0.785 * 383.0000 * 383.0000 *7.5000
HD = 8639. KG
Pressure Force on Flange Face:

HT = H - HD
HT = 10372 - 8638
FOR HEAT EXCHANGER
HT = 1733. KG
Operating Bolt Load:

WM1 = H + HP + HPP (cannot be < 0)
WM1 = ( 10372 + 3229 + 0 )
WM1 = 13601. KG
Gasket Seating Bolt Load:

WM2 = Y * BE * PI * G + Ypart * BEpart * GLPG + HPGY
WM2 = 112.60*8.1655*3.141*419.669+0.00*0.0000*0.00+0.00
WM2 = 12120. KG
Required Bolt Area:

AM = Maximum of WM1/SBO, WM2/SBA
AM = Maximum of 13601 / 1757 , 12119 / 1757
AM = 774.032 sq.mm.

Bolt spacing correction factor 1.075
-----------------------------------------------------------------------------
-----------------------------------------------------------------------------
Bolt Area, sq.mm. 774.032 3473.031
-----------------------------------------------------------------------------
Flange Design Bolt Load, Gasket Seating:

W = SBA * ( AM + AB ) / 2.0
W = 1757.68 * ( 774.0323 + 3473.0312 ) / 2.0
W = 37314.85 KG
Gasket Seating Force:

HG = WM1 - H
HG = 13601 - 10372
HG = 3229.02 KG
Distance to Hub Large End:

R = (C - BCOR) / 2 - G1COR
R = (450.000 - 383.000 ) / 2 - 6.500
R = 27.0000 mm.
Distance to Gasket Load Reaction:

DHG = (C - G ) / 2.0
DHG = ( 450.0000 - 419.6690 ) / 2.0
DHG = 15.1655 mm.
Distance to Face Pressure Reaction:

DHT = ( R + G1COR + DHG ) / 2.0
DHT = ( 27.0000 + 6.5000 + 15.1655 ) / 2.0
DHT = 24.3327 mm.
Distance to End Pressure Reaction:

DHD = R + ( G1COR / 2.0 )
DHD = 27.0000 + ( 6.5000 / 2.0 )
DHD = 30.2500 mm.
SUMMARY OF MOMENTS FOR INTERNAL PRESSURE:

FOR HEAT EXCHANGER
LOADING Force Distance Bolt Corr Moment


TUBESHEET ANALYSIS, TUBESHEET NUMBER 1,Description:TUBESHEET

TEMA Standards, Eighth Edition, 1999, RCB-7 Tubesheets
TEMA C-7.131 Minimum Tubesheet Thickness for C-type:

TMIN = 3/4 * do
TMIN = 3/4 * 19.050
TMIN = 14.2875 mm.
Min. Thickness + CATS + CATC
TREQMIN = 17.2875 mm.
Shellside Fixity Factor, F, per RCB 7.132 FS 1.0000

Shellside Effective Diameter, per RCB 7.132 GS 383.0000 mm.
Tubeside Fixity Factor, F, per RCB 7.132 FC 1.0000
Tubeside Effective Diameter, per RCB 7.132 GC 383.0000 mm.
TEMA Eta factor used in calculation ETA 0.4734
Material Properties for Thermal Expansion Analysis:

Shell - C-Mn-Si, 1-1/4Cr-1/2Mo & 3Cr-1M
Th. Exp. Coeff. Metal Temp. 76.8 C 0.0000104082 /C
Elastic Mod. at Metal Temp. 76.8 C 0.2014E+07 KG/CM2
Tubes - Plain Carbon Stl & C-Mn Stl.

TubeSheet - C-SI, C-1/2Mo & Cr-1/2Mo

Note: Iterating to compute the required Tubesheet thk.
TEMA RCB-7.132 Required Thickness for Shellside Pressure :

TRS = FS * GS * SQRT ( PSU / ( ETA * SOTS ) ) / 3.0
TRS = 1.0000 * 383.0000 * SQRT( 8.88 / ( 0.4734 * 1403 ) ) / 3.0
TRS = 14.7631 mm.
TEMA RCB-7.132 Required Thickness for Tubeside Pressure :
TRC = FC * GC * SQRT ( PTU / ( ETA * SOTS ) ) / 3.0
TRC = 1.0000 * 383.0000 * SQRT( 9.05 / ( 0.4734 * 1403 ) ) / 3.0
TRC = 14.9038 mm.
TEMA RCB-7.132 Required Thickness for Bending + CATS + MAX( CATC,GROOVE):
TREQ = 21.4038 mm.
Note: Recomputing the Equivalent pressures at given Tubesheet thk.
TEMA RCB-7.161 J Factor for Thermal Expansion = 1.0 (No Expansion Jt.)
TEMA RCB-7.161 K Factor for Thermal Expansion 0.6609

TEMA RCB-7.161 Fq Factor for Thermal Expansion 4.1377
TEMA RCB-7.161 Differential Expansion / Length 0.33E-03
TEMA RCB-7.161 Equivalent Differential Thermal Expansion Pressure:

PD = 4 * J * ES * TS * DLL /
FOR HEAT EXCHANGER
( DOS - 3.0*TS ) * ( 1.0 + J * RK * FQ )

PD = 4 * 1.0000 * .20142E+07 * 6.5000 * 0.0003 /
( 396.0000 - 3.0 * 6.5000 ) * ( 1.0 + 1.0000 * 0.6609 * 4.1377 )
PD = 12.380 KG/CM2
RCB 7.162 Equivalent Shellside Bolting Pressure:

PBS = 6.2 * RMA / ( F2 * G3 )
PBS = 6.2 * 608 / ( 1.0000 2 * 383.0000 3 )
PBS = 6.71 KG/CM2
RCB 7.162 Equivalent Tubeside Bolting Pressure:
PBT = 6.2 * RMO / ( F2 * G3 )
PBT = 6.2 * 378 / ( 1.0000 ^2 * 383.0000 ^3 )
PBT = 4.18 KG/CM2
TEMA RCB 7.163 Effective Shellside Design Pressure:

TEMA RCB-7.163 FFs Factor for Shellside Design 0.6734
PSP1 = 0.4 * J * ( 1.5 + K * (1.5 + FFS ) )
= 0.4 * 1.0000 * ( 1.5 + 0.6609 * (1.5 + 0.6734 ) )
PSP2 = ( ( 0.5 - J / 2.0 ) * ( DJ2 / G2 - 1.0 )
= ( ( 0.5 - 1.0000 / 2.0 ) * ( 383.0000 2 /383.0000 2
- 1.0 )
PSP3 = 1.0 + J * K * FQ
= 1.0 + 1.0000 * 0.6609 * 4.1377
PSP = PS * ( ( PSP1 - PSP2 ) / PSP3 )
= 10.00 * ( ( 1.1745 - 0.0000 ) / 3.7345 )
PSP = 3.145 KG/CM2
TEMA RCB-7.163 Effective Shell Side Design Pressure:

PSU = Max (absolute) of PSP : 3.15
or PBS : 6.71
or ( PSP - PD ) / 2 : ( 3.15 - 12.38 ) / 2.0
or ( PSP - PD - PBS ) / 2 : ( 3.15 -12.38 -6.71 ) / 2.0
or ( PBS + PD ) / 2 : ( 6.71 + 12.38 ) / 2.0
or ( PSP - PBS ) : ( 3.15 - 6.71 )
PSU = : 9.547 KG/CM2
TEMA RCB 7.163 Shellside Shear Design Pressure, PBS=0:
PSS = : 6.190 KG/CM2
TEMA RCB 7.164 Effective Tubeside Design Pressure:

TEMA RCB-7.164, FFt Factor for Tubeside Design 0.7768
PTP1 = 1.0 + 0.4 * J * K * ( 1.5 + FFT )
= 1.0 + 0.4 * 1.0000 * 0.6609 * ( 1.5 + 0.7768 )
PTP2 = 1.0 + J * K * FQ
= 1.0 + 1.0000 * 0.6609 * 4.1377
PTP = PT * PTP1 / PTP2
= 7.50 * 1.6019 / 3.7345
PTP = 3.217 KG/CM2
TEMA RCB-7.164 Effective Tube Side Design Pressure:

PTU = Max (absolute) of :
( PTP + PBT + PD ) / 2 : ( 3.22 +4.18 +12.38 ) / 2.0
or ( PTP + PBT ) : ( 3.22 + 4.18 )
PTU = : 9.889 KG/CM2
TEMA RCB 7.164 Tubeside Shear Design Pressure (PBT=0):
PTS = : 7.799 KG/CM2
No Shear Calculation, since Pressure is less than 127.1850 KG/CM2
TEMA RCB-7.134 Required Thickness for Tubesheet Flanged Extension :

TFREQ = .98* SQRT((RM*(R^2 - 1 + 3.71* R^2 * LN(R)))
/ ( SOTS * ( DF - G ) * ( 1.0 + 1.86 * R^2 )))
TFREQ = .98* SQRT((608 *(1.33 ^2 - 1 + 3.71* 1.33 ^2*LN(1.33 )))
/ ( 1403 * ( 510.00 -383.00 ) * ( 1.0 + 1.86 * 1.33 ^2 )))
FOR HEAT EXCHANGER
TFREQ = 14.2356 mm.
TEMA RCB-7.22 Shell Longitudinal Stress :

Max. Effective Pressure for Longitudinal Stress, 7.428 KG/CM2
Min. Effective Pressure for Longitudinal Stress, -12.380 KG/CM2
TEMA RCB-7.22 Maximum Shell Longitudinal Stress :

STSMAX = PSSMAX * CS * ( DOS - TS )/( 4 * TS )
STSMAX = 7.43 * 1.00 * ( 396.0000 - 6.5000 ) / ( 4 * 6.5000 )
STSMAX = 111. KG/CM2
TEMA RCB-7.22 Allowable Shell Longitudinal Stress :
STSALL = 1406. KG/CM2
TEMA RCB-7.22 Minimum Shell Longitudinal Stress :

STSMIN = PSSMIN * CS * ( DOS - TS )/( 4 * TS )
STSMIN = -12.38 * 1.00 * ( 396.0000 - 6.5000 ) / ( 4 * 6.5000 )
STSMIN = -185. KG/CM2
TEMA RCB-7.22 Allowable Shell Compressive Stress :

External Pressure Chart CS-2 at 210.00 C
Geometry Factor, A = 0.125/(Ro/t) A 0.0041035
Materials Factor, B, Function(A, Chart) B 1039. KG/CM2
STSCOM = -1039. KG/CM2
TEMA RCB-7.23 Tube Longitudinal Stress Results :

Max. Effective Pressure for Longitudinal Stress, 14.189 KG/CM2
Min. Effective Pressure for Longitudinal Stress, -1.518 KG/CM2
TEMA RCB-7.23 Maximum Tube Long. Stress (Tension):

STTMAX = PTTMAX*CT*FQ*G*G /(4*NTUBS*TT*(do-TT))
STTMAX = 14.19 *0.50 *4.14 *383.0000 *383.0000
/ ( 4*132 *1.6500 *(19.0500 -1.6500 ) )
STTMAX = 284.07 KG/CM2
TEMA RCB-7.23 Allowable Tube Long. Stress (Tension):

STTALL = 942.11 KG/CM2
TEMA RCB-7.23 Minimum Tube Comp. Longitudinal Stress :

STTMIN = PTTMIN*CT*FQ*G*G/(4*NTUBS*TT*(do-TT))
STTMIN = -1.52 *1.00 *4.14 *383.0000 *383.0000
/ ( 4*132 *1.6500 *(19.0500 -1.6500 ) )
STTMIN = -60.76 KG/CM2
TEMA RCB-7.24 Allowable Tube Compressive Stress :

STTCOM = -SYT*(1-RKLR/(2*CC))/FSAF
STTCOM = -1693 * ( 1.0 -43.6286 / ( 2.0 *154.0508 ) ) / 1.25
STTCOM = -942.11 KG/CM2
TEMA RCB-7.25 Tube-To-Tubesheet Joint Load :

Effective Pressure for Tube-to-Tubesheet Load : 1.809 KG/CM2
TEMA RCB-7.25 Actual Tube-To-Tubesheet Load :

WJ = PI * FQ * PTLOAD * G * G / ( 4.0 * NTUBS )
WJ = 3.14 * 4.14 * 1.809 * 383.00 * 383.00 / ( 4.0 * 132 )
WJ = 65.32 KG
Allowable Tube-To-Tubesheet Load per ASME App. A [Lmax]:

= (PI/4)*(DT²-(DT-2*TT)²)*SOT*fr*fe*fy
= .785*(19.0500²-(19.0500-2*1.6500)²)*942*0.75*1.00*1.00
= 637.18 KG
Summary of Tubesheet Results:

FOR HEAT EXCHANGER
------------------------------------------------------------------------
Condition Req Thk Actual Thk Actual Allow Result
(+CA) (mm.) Stress (KG/CM2)
------------------------------------------------------------------------
Bending 21.404 25.000 1492.41 2105.01 Ok
Bolted Exten. 14.236 15.000 ------ ------ Ok
Tube Fillet Leg 0.000 2.000 ------ ------ Ok
------------------------------------------------------------------------
Longitudinal stresses:
--------------------------------------------------------------------
Compressive Tensile
Condition Actual Allow Actual Allow Result
--------------------------------------------------------------------
Shell -185.468 1038.521 111.279 1406.140 Ok
Long Tubes -60.763 942.114 284.070 942.114 Ok
Tube Load 65.318 637.175 Ok
--------------------------------------------------------------------
Equivalent Differential Ther. Expansion Pressure 12.3804 KG/CM2
Shellside Prime Pressure 3.1451 KG/CM2
Tubeside Prime Pressure 3.2170 KG/CM2

FOR HEAT EXCHANGER
Vessel Design Summary STEP: 20 2:02p Dec 11,2006
Design Code: ASME Code Section VIII Division 1, 2004
Diameter Spec : 380.000 mm.

Vessel Design Length, Tangent to Tangent 3560.00 mm.
Distance of Base above Grade 0.00 mm.

Specified Datum Line Distance 0.00 mm.
Shell/Head Matl SA-516 70

Stiff Ring Matl SA-516 70
Vessel Design Temperature 80.00 C

Vessel Design Pressure 7.50 KG/CM2
Maximum Allowable Working Pressure 13.22 KG/CM2

External Max. Allowable Working Pressure 12.72 KG/CM2
Hydrostatic Test Pressure 0.00 KG/CM2
Computed Vessel MDMT per UCS 66 -29 C

Computed Vessel MDMT per UCS 66.1 -36 C
Computed Vessel MDMT per UG-20F -29 C
Specified Minimum Design Metal Temperature 10
Wind Design Code ASCE-93

Earthquake Design Code No Seismic
Element Pressures and MAWP: KG/CM2
Element Desc Internal External M.A.W.P Corr. All.

Ellipse 7.500 0.000 32.965 1.5000
Cylinder 7.500 0.000 39.759 1.5000
Body Flg 7.500 0.000 14.708 0.0000
Cylinder 10.000 0.000 39.759 1.5000
Body Flg 7.500 0.000 14.708 0.0000
Cylinder 7.500 0.000 39.759 1.5000
Ellipse 7.500 0.000 44.265 0.0000
Stiffener Ring Specifications:

Elevation mm. Selected Type User Description
630.00 Bar 54 x 4 LR
1430.00 Bar 54 x 4 RR
Element "To" Elev Length Actual Thk R e q d T h k J.E.

Type mm. mm. mm. Int. Ext. L C
Ellipse 50.0 50.0 6.0 3.9 ------- 1.00 1.00
Cylinder 250.0 200.0 8.0 3.9 ------- 0.85 0.85
Body Flg 280.0 30.0 30.0 28.0 ------- 1.00 1.00
Cylinder 3280.0 3000.0 8.0 3.9 ------- 0.85 0.85
Body Flg 3310.0 30.0 30.0 28.0 ------- 1.00 1.00
Cylinder 3510.0 200.0 8.0 3.9 ------- 0.85 0.85
Ellipse 3560.0 50.0 6.0 2.4 ------- 1.00 1.00
Saddle Parameters:
Saddle Width 140.000 mm.
Saddle Bearing Angle 120.000 deg.
Centerline Dimension 450.000 mm.
Wear Pad Width 150.000 mm.
Wear Pad Thickness 6.000 mm.
Wear Pad Bearing Angle 130.000 deg.
Distance from Saddle to Tangent 1000.000 mm.
FOR HEAT EXCHANGER
Vessel Design Summary STEP: 20 2:02p Dec 11,2006
Baseplate Length 400.000 mm.

Baseplate Thickness 10.000 mm.
Baseplate Width 150.000 mm.
Number of Ribs (including outside ribs) 3
Rib Thickness 10.000 mm.
Web Thickness 10.000 mm.
Height of Center Web 250.000 mm.
Weights:
Fabricated - Bare W/O Removable Internals 786.9 KG
Shop Test - Fabricated + Water ( Full ) 1205.2 KG
Shipping - Fab. + Rem. Intls.+ Shipping App. 786.9 KG
Erected - Fab. + Rem. Intls.+ Insul. (etc) 786.9 KG
Empty - Fab. + Intls. + Details + Wghts. 786.9 KG
Operating - Empty + Operating Liquid (No CA) 786.9 KG
Field Test - Empty Weight + Water (Full) 1205.2 KG

FOR HEAT EXCHANGER
Summary of Known Problems/Failures STEP: 21 2:02p Dec 11,2006
Listed below are the known problem areas for the current design. If
one or more of the design flags are turned on, please re-run the analysis.
Some of these issues may be resolved when using updated input values.
** Warning: An ANSI Flange is limiting the MAWP and this may affect the
pressure used in the Nozzle Reinforcement Calculations.
Please review all reports carefully!

Design Cal - Feed Preheater

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Design Cal - Feed Preheater

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Table of Contents

MECHANICAL DESIGN CALCULATIONS

In Accordance with ASME Section VIII Div. 1

ASME Code Version : 2004

Analysis Performed by : USER

Job File : D:\PVELITE JOB FILES\AIROX-HE\FEED PREHEATER.PVI

Date of Analysis : Dec 11,2006

PVElite 2005, January 2005

DESIGNED BY : AIROX NIGEN EQUIPMENT PVT. LTD

Class From To : Basic Element Checks.

Class From To: Check of Additional Element Data

There were no geometry errors or warnings.

PVElite 2005 ©1993-2005 by COADE Engineering Software

PVElite Vessel Analysis Program: Input Data

MECHANICAL DESIGN CALCULATIONS

Design Internal Pressure (for Hydrotest) 7.5000 KG/CM2

Load Case 1 IP+OW

Wind Design Code ASCE-7 93

Seismic Design Code No Seismic

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

Material Database Year Current w/Addenda or Code Year

Complete Listing of Vessel Elements and Details:

Element From Node 10

Element Thickness 6.0000 mm.

Element From Node 20

Element From Node 20

Element From Node 20

Element From Node 30

Element From Node 40

Element From Node 40

Element From Node 40

Width of Saddle 140.00 mm.

Element From Node 40

Element From Node 40

Element From Node 40

Element From Node 40

Element From Node 50

Design Internal Pressure 7.5000 KG/CM2

Element From Node 60

Element From Node 60

Element From Node 60

Element From Node 70

Element Thickness 6.0000 mm.

PVElite 2005 ©1993-2005 by COADE Engineering Software

PVElite 2005 ©1993-2005 by COADE Engineering Software

Flange Input Data Values Description: FLANGE :

Description of Flange Geometry (Type) Loose Ring

Flange Material SA-516 70

Bolt Material SA-193 B7

Length of Weld Leg at Back of Ring WLEG 0.0000 mm.

Diameter of Bolt Circle C 450.0000 mm.

Flange Face Outside Diameter Fod 440.0000 mm.

Gasket Outside Diameter God 436.0000 mm.

Column for Gasket Seating 2, Code Column II

ASME Code, Section VIII, Division 1, 2004

Code R Dimension, R = (C-B)/2 - G1 28.000 mm.

Gasket Contact Width, N = (GOD-GID) / 2.0 21.000 mm.

Basic Flange and Bolt Loads:

Hydrostatic End Load due to Pressure [H]:

Bolting Information for TEMA Metric Thread Series:

Flange Design Bolt Load, Gasket Seating [W]:

Moment Arm Calculations:

Summary of Moments for Internal Pressure: