CALDEROS Y AFINES S.A.

GUAYAQUIL - ECUADOR

HEAT EXCHANGER DESIGN CALCULATIONS

Item: HIGH PRESSURE TRIM COOLER - FLOATING COVER

Tag Number: G-E20
Purchaser: EP PETROECUADOR
Location: ESMERALDAS
Class: E - Heat Exchanger
P.O. Number: OW 365

Document No.: ANNEX 1 - EQ-365-ENG-CLC-400

Date: 15/02/2024
Rev.: A
 Table of Contents
Dished Cover #1..........................................................................................................................................................1/7

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 Dished Cover #1

ASME Section VIII Division 1, 2023 Edition Metric

Component Dished Cover Figure 1-6 Sketch (d)

Internal design pressure, P 6 kgf/cm2 @ 121 °C
External design pressure, Pe 18.6 kgf/cm2 @ 121 °C
Design MDMT 6.7°C
Rated MDMT -34.94°C

Dimensions
Head Flange
Material specification SA-516 70 (II-D Metric p.20, ln. 45) SA-105 (II-D Metric p. 20, ln. 31)
Inside crown radius, L 482.6 mm
Thickness (note 1) 17 mm 67 mm
Inner diameter, B 625.48 mm
Outer diameter, A 739.78 mm
Lever arm, hr 3.18 mm
Head overall depth (note 2) 157.56 mm
Bolt circle, C 698.5 mm
Raised face ID, Rf 654.05 mm
Facing height, trf 4.76 mm
Corrosion allowance inner/bore 3.18 mm 3.18 mm
Corrosion allowance outer/flange 4.8 mm 4.8 mm
Impact tested No No
Normalized No Yes
PWHT No No
Maximize MDMT/No MAWP No No
Bolting Holes Slotted No
Bolting

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 Material SA-193 B7 Bolt <= 64 (II-D Metric p. 418, ln. 32)
Description 24 - 0.75" coarse threaded
Corrosion on root 0 mm
Gasket
Type Jacketed
Description Flexitallic Double Jacketed 123 Carbon Steel / Flexicarb
Factor, m 3.75
Seating Stress, y 534.333 kgf/cm2
Thickness 3.18 mm
Inner Diameter 625.48 mm
Outer Diameter 650.88 mm
Weight (kg)
New 46.21 67.82
Corroded 24.54 62.07
Capacity (liters)
New 18.47 9.79
Corroded 18.3 11.29
Radiography
Head longitudinal seam Seamless No RT
Flange longitudinal seam Seamless No RT
Notes
1 Flange thickness does not include consideration of the flange facing.

2 Depth is from flange face excluding the facing to the outer diameter of the crown radius.

Liquid
Specific gravity Liquid Height Static liquid pressure
Operating Internal 1 0 mm 0 kgf/cm2
Horizontal test 1 625.48 mm 0.0625 kgf/cm2

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 Results Summary
Head Flange
Minimum thickness per UG-16 10.48 mm 12.1 mm
Design thickness due to internal pressure (t) 9.71 mm 66.31 mm
Design thickness due to external pressure (te) 16.68 mm 66.31 mm
Maximum allowable working pressure (MAWP) 31.37 kgf/cm2 14.97 kgf/cm2
Rated MDMT -34.94°C

UCS-66 Material Toughness Requirements Flange

Governing thickness, tg = 17 mm
Exemption temperature from Fig UCS-66M Curve B = -12.94°C
Stress ratio per UCS-66(b)(1)(b) = 0.6078
Reduction in MDMT, TR from Fig UCS-66.1M = 22°C
MDMT = max[ MDMT - TR, -48] = max[ -12.94 - 22 , -48] = -34.94°C
Bolts rated MDMT per Fig UCS-66 note (c) = -48°C = -48°C
Material is exempt from impact testing at the Design MDMT of 6.7°C.

UCS-66 Material Toughness Requirements Head

tr = 5*6*485.78 / (6*1,407.21) = 1.73 mm
Stress ratio = tr*E* / (tn - c) = 1.73*1 / (17 - 7.98) = 0.1912
Stress ratio ≤ 0.35, MDMT per UCS-66(b)(3) = -105°C
Material is exempt from impact testing at the Design MDMT of 6.7°C.

Head Design Thickness per Appendix 1-6(g)(1)(a):

tr = 5*P*L / (6*S) + Corrosion

= 5*6*485.78 / (6*1,407.21) + 7.98
= 9.71 mm

Head Design Thickness per Appendix 1-6(g)(1)(b):

Equivalent outside spherical radius (Ro)

= Outside crown radius
= 499.6 mm

A = 0.125 / (Ro / t)
= 0.125 / (499.6 / 8.7)
= 0.002176

B = 1,068.7192 kgf/cm2

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From Table CS-2
Metric:

Pa = B / (Ro / t)
= 1,068.7183 / (499.6 / 8.7)
= 18.6 kgf/cm2
te = 8.7 + 7.98 = 16.68 mm

Flange Required Thickness per Appendix 1-6(g)(2)

β1 = Sin-1 (B / (2*L + t))
Hr = HD*cot(180*β1 / π)
Mo = Mo,App2 - Hr*hr
F = P*B*(4*L2 - B2)1/2 / (8*S*(A - B))
J = (Mo / (S*B))*(A + B) / (A - B)
Tr = F + (F2 + J)1/2
0.700162
β1 = Sin-1 (631.83 / (2*485.78 + 9.03))
radians
Hr = 18,802.45*cot(180*0.700162 / π) 22,315.74 kgf
Operating Mo = 810.14 - 22,315.74*3.18/1000 739.3 kgf-m

Operating, Hot & Corr F = 6*631.83*(4*485.782 - 631.832)1/2 / (8*1,407.21*(739.78

2.3 mm
- 631.83))
J = (739.3 / (1,407.21*631.83))*(739.78 + 631.83) / (739.78 1,056.4841
- 631.83) *105 mm2
Tr = 2.3 + (2.32 + 1,056.4841)1/2 34.89 mm
Mo = Mg 2,250.4 kgf-m
Gasket
J = (2,250.4 / (1,407.21*631.83))*(739.78 + 631.83) / 3,216.0203
Seating
(739.78 - 631.83) *105 mm2
Tr = 0 + (02 + 3,216.0203)1/2 56.71 mm
0.700162
β1 = Sin-1 (631.83 / (2*485.78 + 9.03))
radians
Hr = 58,287.61*cot(180*0.700162 / π) 69,178.79 kgf
Operating Mo = 189.95 - 69,178.79*3.18/1000 29.7 kgf-m
External Pressure, Hot F = 18.6*631.83*(4*485.782 - 631.832)1/2 /
& Corr 7.14 mm
(8*1,407.21*(739.78 - 631.83))
J = (29.7 / (1,407.21*631.83))*(739.78 + 631.83) / (739.78 -
42.4269 mm2
631.83) *105
Tr = 7.14 + (7.142 + 42.4269)1/2 16.8 mm
Mo = Mg 2,250.4 kgf-m
Gasket
J = (2,250.4 / (1,407.21*631.83))*(739.78 + 631.83) / 3,216.0203
Seating
(739.78 - 631.83) *105 mm2
Tr = 0 + (02 + 3,216.0203)1/2 56.71 mm
Hot & Corr, Zero Mo 2,250.4 kgf-m
Operating
Pressure

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 J = (2,250.4 / (1,407.21*631.83))*(739.78 + 631.83) / 3,216.0203
(739.78 - 631.83) *105 mm2
Tr = 0 + (02 + 3,216.0203)1/2 56.71 mm
Flange Design Thickness = 56.71 + 9.6 = 66.31 mm

Head MAWP per Appendix 1-6(g)(1)(a):

MAWP = 6*S*t / (5*L) - Ps

= 6*1,407.21*9.03 / (5*485.78) - 0
= 31.37 kgf/cm2

Flange MAWP per Appendix 1-6(g)(2)

J = (Mo / (S*B))*(A + B) / (A - B)
= (1,844.2 / (1,407.21*631.83))*(739.78 + 631.83) / (739.78 - 631.83)*105
= 2,635.4387 mm2
MAWP = (T2 - J)*8*S*(A - B) / (2*T*B*(4*L2 - B2)0.5) - Ps
= (57.42 - 2,635.4387)*8*1,407.21*(739.78 - 631.83) / (2*57.4*631.83*(4*485.782 - 631.832)0.5) - 0
= 14.97 kgf/cm2

% Extreme fiber elongation - UCS-79(d)

EFE = (75*t / Rf)*(1 - Rf / Ro)

= (75*17 / 491.1)*(1 - 491.1 / infinity)
= 2.5962%

The extreme fiber elongation does not exceed 5%.

Flange calculations for Internal Pressure + Weight Only

Gasket details from facing sketch Confined gasket 1(a), Column II

Gasket width N = 12.7 mm

b0 = N/2 = 6.35 mm

Effective gasket seating width, b = 2.5*b01/2 = 6.3 mm

G = OD of contact face - 2*b = 650.88 - 2*6.3 = 638.28 mm

hG = (C - G)/2 = (698.5 - 638.28)/2 = 30.11 mm

hD = (C - B)/2 = (698.5 - 631.83)/2 = 33.34 mm

hT = (hD + hG)/2 = (33.34 + 30.11)/2 = 31.72 mm

Hp = 2*b*3.14*G*m*P
= 0.01*2*6.3*3.14*638.28*3.75*6
= 5,681.15 kgf

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H = 0.785*G2*P
= 0.01*0.785*638.282*6
= 19,188.4 kgf

HD = 0.785*B2*P
= 0.01*0.785*631.832*6
= 18,802.45 kgf

HT = H - HD
= 19,188.4 - 18,802.45
= 385.95 kgf

Wm1 = H + Hp
= 19,188.4 + 5,681.15
= 24,869.55 kgf

Wm2 = 3.14*b*G*y
= 0.01*3.14*6.3*638.28*534.3329
= 67,458.38 kgf

Required bolt area, Am = greater of Am1, Am2 = 38.4617 cm2

Am1 = Wm1/Sb = 24,869.55/1,753.912 = 14.1795 cm2

Am2 = Wm2/Sa = 67,458.38/1,753.912 = 38.4617 cm2

Total area for 24 - 0.75" coarse threaded bolts, corroded, Ab = 46.7612 cm2

W = (Am + Ab)*Sa/2
= (38.4617 + 46.7612)*1,753.912/2
= 74,736.7 kgf

MD = HD*hD = 18,802.45*0.0333 = 626.8 kgf-m

MT = HT*hT = 385.95*0.0317 = 12.2 kgf-m

HG = Wm1 - H = 24,869.55 - 19,188.4 = 5,681.15 kgf

MG = HG*hG = 5,681.15*0.0301 = 171.1 kgf-m

Mo = MD + MT + MG = 626.8 + 12.2 + 171.1 = 810.1 kgf-m

Mg = W*hG = 74,736.7*0.0301 = 2,250.4 kgf-m

Flange calculations for External Pressure + Weight Only per VIII-1, Appendix 2-11

Gasket details from facing sketch Confined gasket 1(a), Column II

Gasket width N = 12.7 mm

b0 = N/2 = 6.35 mm

Effective gasket seating width, b = 2.5*b01/2 = 6.3 mm

G = OD of contact face - 2*b = 650.88 - 2*6.3 = 638.28 mm

hG = (C - G)/2 = (698.5 - 638.28)/2 = 30.11 mm

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hD = (C - B)/2 = (698.5 - 631.83)/2 = 33.34 mm

hT = (hD + hG)/2 = (33.34 + 30.11)/2 = 31.72 mm

Hp = 2*b*3.14*G*m*P
= 0.01*2*6.3*3.14*638.28*3.75*18.6
= 17,611.58 kgf

H = 0.785*G2*P
= 0.01*0.785*638.282*18.6
= 59,484.04 kgf

HD = 0.785*B2*P
= 0.01*0.785*631.832*18.6
= 58,287.61 kgf

HT = H - HD
= 59,484.04 - 58,287.61
= 1,196.43 kgf

Wm1 = H + Hp
= 59,484.04 + 17,611.58
= 77,095.62 kgf

Wm2 = 3.14*b*G*y
= 0.01*3.14*6.3*638.28*534.3329
= 67,458.38 kgf

Required bolt area, Am = greater of Am1, Am2 = 38.4617 cm2

Am1 = 0.785*G2*(Pm - Pr)/Sb = 0/1,753.912 = 0 cm2

Am2 = Wm2/Sa = 67,458.38/1,753.912 = 38.4617 cm2

Total area for 24 - 0.75" coarse threaded bolts, corroded, Ab = 46.7612 cm2

W = (Am2 + Ab)*Sa/2
= (38.4617 + 46.7612)*1,753.912/2
= 74,736.7 kgf

Mo = HD*(hD - hG) + HT*(hT - hG)

= 58,287.61*(0.0333 - 0.0301) + 1,196.43*(0.0317 - 0.0301)
= 190 kgf-m

Mg = W*hG = 74,736.7*0.0301 = 2,250.4 kgf-m

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