105-b_rev.1

Codeware, Inc.

Houston, TX, USA

www.codeware.com

COMPRESS Pressure Vessel Design Calculations

Item: Split Stream DearatorVessel No: V-1234Customer: Magaladon Oil Venture

Contract: C-45490-R56Designer: John Doe

Date: April 1, 2001

You can edit this page by selecting Cover Page settings... in the report menu.

PC ODRŽAVANJE INŽENJERING PETROKEMIJA, d.d., KUTINA

Izradio: Ante Turkalj,d.i.s. 01/2012

PRORAČUN IZMJENJIVAČA E 21 105-B TU.O.401/12

Table Of ContentsDeficiencies Summary1.

Pressure Summary2.

Revision History3.

Settings Summary4.

Thickness Summary5.

Weight Summary6.

Test Report7.

Vacuum Summary8.

Design Conditions Summary9.

Data Inputs Summary10.

Materials and Gaskets Summary11.

Tubesheet Maximum Pressure Report12.

Tubesheet -- TEMA13.

Tubesheet -- ASME14.

Tubes15.

Pass Partition16.

Baffle Summary17.

Seismic Code18.

1/33




Deficiencies Summary

No deficiencies found.

2/33




Pressure Summary

Pressure Summary for Tube side chamber

IdentifierP

Design( kPa)

T

Design(°C)

MAWP( kPa)

MAP( kPa)

MAEP( kPa)

Te

external(°C)

MDMT(°C)

MDMTExemption

Total

Corrosion

Allowance(mm)

ImpactTest

Front Head 3150.0 266.0 3598.66 4138.46 0.00 266.0 -196.0 Note 1 0.00 No

Straight Flange on Front Head 3150.0 266.0 3861.00 4440.15 N/A 266.0 -196.0 Note 2 0.00 No

Tubesheet (see Maximum PressureRating note)

3150.0 266.0 7256.69 17058.90 7256.69 266.0 -17.8 Note 3 0.00 No

Tubes 3150.0 266.0 28076.28 31303.44 14780.53 266.0 -196.0 Note 4 0.00 No

Tube Side Flange (front) 3150.0 266.0 3911.14 4440.09 0.00 266.0 -196.0 Note 2 0.00 No

Tube Side Flange (front) - Flange Hub 3150.0 266.0 3259.33 3700.13 N/A 266.0 -196.0 Note 2 0.00 No

Chamber design MDMT is -17.78°CChamber rated MDMT is -17.78°C @ 3259.33 kPa

Chamber MAWP hot & corroded is 3259.33 kPa @ 266.0°C

Chamber MAP cold & new is 3700.13 kPa @ 20.0°C

Chamber MAEP is 0.00 kPa @ 266.0°CVacuum rings did not govern the external pressure rating.

Pressure Summary for Shell side chamber

IdentifierP

Design( kPa)

T

Design(°C)

MAWP( kPa)

MAP( kPa)

MAEP( kPa)

Te

external(°C)

MDMT(°C)

MDMTExemption

Total

Corrosion

Allowance(mm)

ImpactTest

Tubesheet (see Maximum PressureRating note)

1050.0 266.0 7256.69 17058.90 7256.69 266.0 -17.8 Note 3 0.00 No

Shell 1050.0 150.0 2028.08 2152.89 N/A 150.0 -196.0 Note 2 0.00 No

Straight Flange on Rear Shell Head 1050.0 150.0 1796.87 1796.87 N/A 150.0 -31.3 Note 6 0.00 No

Rear Shell Head 1050.0 150.0 1686.52 1686.52 0.00 150.0 -31.3 Note 5 0.00 No

Tubes 3150.0 266.0 14780.53 14780.53 28076.28 266.0 N/A N/A 0.00 No

Shell Side Flange (front) 1050.0 150.0 3921.76 4452.15 0.00 150.0 -196.0 Note 2 0.00 Yes

Shell Side Flange (front) - Flange Hub 1050.0 150.0 1794.07 1794.07 N/A 150.0 -196.0 Note 2 0.00 Yes

Chamber design MDMT is -17.78°CChamber rated MDMT is -17.78°C @ 1686.52 kPaChamber MAWP was used in the MDMT determination

Chamber MAWP hot & corroded is 1686.52 kPa @ 150.0°C

Chamber MAP cold & new is 1686.52 kPa @ 20.0°C

Chamber MAEP is 0.00 kPa @ 150.0°CVacuum rings did not govern the external pressure rating.

3/33




Notes for Maximum Pressure Rating:

Note# Details

1. The largest tubesheet MAWP/MAP values have been selected from the multiple design conditions to maximize the hydrotest pressure and to comply withUG-20(b). The MAWP/MAP selected for the shell side may not be coincident with the MAWP/MAP selected for the tube side (and vice versa).

2.The chamber MAWP listed above is based on the largest tubesheet MAWP values from the multiple design conditions. The lowest tubesheet MAWP valuesshould be considered when determining the final chamber MAWP. Refer to the Tubesheet Maximum Pressure Report for the lowest tubesheet maximumpressure ratings.

Notes for MDMT Rating:

Note # Exemption Details

1. Straight Flange governs MDMT

2. Rated MDMT per UHA-51(d)(1)(a) = -196 °C

3. Tubesheet Impact testing per UHA-51(a) is required by UHA-51(d)(3)(a).

4. Impact test exempt per UHA-51(d)

5. Straight Flange governs MDMT

6. Material impact test exemption temperature from Fig UCS-66M Curve B = -27.75 °CFig UCS-66.1M MDMT reduction = 3.5 °C, (coincident ratio = 0.9381302) UCS-66 governing thickness = 10 mm

Design notes are available on the Settings Summary page.

4/33




Revision History

No. Date Operator Notes

0 1/30/2012 XPMUser New vessel created Heat Exchanger. [Build 6258]

5/33




Settings Summary

COMPRESS Build 6258

Units: SI

Datum Line Location: 0.00 mm from right seam

Design

ASME Section VIII Division 1, 2007 Edition Metric

Design or Rating: Get Thickness from PressureMinimum thickness: 1.50 mm per UG-16(b)Design for cold shut down only: NoDesign for lethal service (full radiography required): NoDesign nozzles for: Design P, find nozzle MAWP and MAPCorrosion weight loss: 100% of theoretical lossUG-23 Stress Increase: 1.20Skirt/legs stress increase: 1.0Minimum nozzle projection: 152.40 mmJuncture calculations for α > 30 only: YesPreheat P-No 1 Materials > 1.25&#34 and <= 1.50" thick: NoButt welds are tapered per Figure UCS-66.3(a).

Hydro/Pneumatic Test

Shop Hydrotest at user defined pressureTest liquid specific gravity: 1.00Maximum stress during test: 90% of yield

Required Marking - UG-116

Shell SideUG-116 (e) Radiography: RT1UG-116 (f) Postweld heat treatment: None

Tube SideUG-116 (e) Radiography: RT1UG-116 (f) Postweld heat treatment: None

Code Cases\Interpretations

Use Code Case 2547: NoApply interpretation VIII-1-83-66: YesApply interpretation VIII-1-86-175: YesApply interpretation VIII-1-83-115: YesApply interpretation VIII-1-01-37: YesDisallow UG-20(f) exemptions: No

6/33




UG-22 Loadings

UG-22 (a) Internal or External Design Pressure : YesUG-22 (b) Weight of the vessel and normal contents under operating or test conditions: NoUG-22 (c) Superimposed static reactions from weight of attached equipment (external loads): NoUG-22 (d)(2) Vessel supports such as lugs, rings, skirts, saddles and legs: NoUG-22 (f) Wind reactions: NoUG-22 (f) Seismic reactions: NoNote: UG-22 (b),(c) and (f) loads only considered when supports are present.

7/33




Thickness Summary

ComponentIdentifier

Material Diameter(mm)

Length(mm)

Nominal t(mm)

Design t(mm)

JointE

Load

Front Head SA-240 304 1524.00 ID 410.40 25.00* 21.88 1.0000 Internal

Straight Flange on Front Head SA-240 304 1524.00 ID 2100.00 25.00 20.33 1.0000 Internal

Tubesheet SA-182 F51 Forgings S31803 1605.00 OD 207.00 207.00 137.41 1.0000 Unknown

Tubes SA-789 Wld. tube <= 25 S32750 19.050 OD 8233.00 1.65 0.38 1.0000 External

Shell SA-240 304 1524.00 ID 8208.00 12.00 6.18 1.0000 Internal

Straight Flange on Rear Shell Head SA-516 70 1524.00 ID 50.00 10.00 5.83 1.0000 Internal

Rear Shell Head SA-516 70 1524.00 ID 396.67 10.00* 6.22 1.0000 Internal

Nominal t: Vessel wall nominal thickness

Design t: Required vessel thickness due to governing loading + corrosion

Joint E: Longitudinal seam joint efficiency

* Head minimum thickness after forming

Load

internal: Circumferential stress due to internal pressure governs

external: External pressure governs

Wind: Combined longitudinal stress of pressure + weight + wind governs

Seismic: Combined longitudinal stress of pressure + weight + seismic governs

8/33




Weight Summary

ComponentWeight ( kg) Contributed by Vessel Elements

MetalNew*

Metal

Corroded*Insulation &

Supports Lining Piping+ Liquid

OperatingLiquid

TestLiquid

Front Head 2,580.57 2,580.57 0.00 0.00 0.00 0.00 4,848.44

Tubesheet 2,286.68 2,286.68 0.00 0.00 0.00 0.00 0.00

Shell 3,815.16 3,815.16 0.00 0.00 0.00 0.00 9,489.91

Tubes 15,497.85 15,497.85 0.00 0.00 0.00 0.00 4,167.00

Rear Shell Head 220.41 220.41 0.00 0.00 0.00 0.00 554.99

TOTAL: 24,400.68 24,400.68 0.00 0.00 0.00 0.00 19,060.34

* Shells with attached nozzles have weight reduced by material cut out for opening.

Component

Weight ( kg) Contributed by Attachments

Body Flanges Nozzles &Flanges Packed

BedsTrays &

SupportsRings &

ClipsVerticalLoads

New Corroded New Corroded

Front Head 1,455.86 1,455.86 0.00 0.00 0.00 0.00 0.00 0.00

Tubesheet 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Shell 1,405.13 1,405.13 0.00 0.00 0.00 725.72 0.00 0.00

Rear Shell Head 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

TOTAL: 2,860.99 2,860.99 0.00 0.00 0.00 725.72 0.00 0.00

Vessel operating weight, Corroded: 27,987 kgVessel operating weight, New: 27,987 kgVessel empty weight, Corroded: 27,987 kgVessel empty weight, New: 27,987 kgVessel test weight, New: 47,048 kg

Vessel center of gravity location - from datum - lift condition

Vessel Lift Weight, New: 27,987 kgCenter of Gravity: 5,481.92 mm

Vessel Capacity

Shell side Capacity** (New): 10,053 litersShell side Capacity** (Corroded): 10,053 litersTube side Capacity** (New): 9,023 litersTube side Capacity** (Corroded): 9,023 liters**The shell and tube capacity does not include volume of nozzle, piping or other attachments.

9/33




Test Report

Shop test pressure determination for Tube side chamber based on user defined pressure

Shop test gauge pressure is 5,650 kPa at 20 °C

The shop test is performed with the vessel in the horizontal position.

IdentifierLocal testpressure

kPa

Test liquidstatic head

kPa

Front Head 5,664.93 14.93

Straight Flange on Front Head 5,664.93 14.93

Tubes 5,664.67 14.67

Tube Side Flange (front) 5,664.93 14.93

Tubesheet 5,664.93 14.93

Notes:(1) The zero degree angular position is assumed to be up, and the test liquid height is assumed to the top-mostflange.

The field test condition has not been investigated for the Tube side chamber.

Shop test pressure determination for Shell side chamber based on user defined pressure

Shop test gauge pressure is 1,770 kPa at 20 °C

The shop test is performed with the vessel in the horizontal position.

IdentifierLocal testpressure

kPa

Test liquidstatic head

kPa

Shell 1,784.93 14.93

Straight Flange on Rear Shell Head 1,784.93 14.93

Rear Shell Head 1,784.93 14.93

Tubes 1,784.67 14.67

Tubesheet 1,784.93 14.93

Shell Side Flange (front) 1,784.93 14.93

Notes:(1) The zero degree angular position is assumed to be up, and the test liquid height is assumed to the top-mostflange.

The field test condition has not been investigated for the Shell side chamber.

The test temperature of 20 °C is warmer than the minimum recommended temperature of -14.25 °C so the brittlefracture provision of UG-99(h) has been met.

10/33




Vacuum Summary

Component Line of SupportElevation

above Datum(mm)

Length Le(mm)

Front Head - 11500.40 N/A

- 1/3 depth of Front Head 11218.46 N/A

Straight Flange on Front Head Top - 11090.00 2533.47

Straight Flange on Front Head Bottom - 8990.00 2533.47

- Tube Side Flange (front) 8685.00 N/A

Tubesheet - 8685.00 N/A

- Shell Side Flange (front) 8478.00 N/A

Shell Top - 8208.00 8656.89

Shell Bottom - 0.00 8656.89

Straight Flange on Rear Shell Head Top - 0.00 8656.89

Straight Flange on Rear Shell Head Bottom - -50.00 8656.89

- 1/3 depth of Rear Shell Head -178.89 N/A

Rear Shell Head - -446.67 N/A

Note

For main components, the listed value of 'Le' is the largest unsupported length for the component.

11/33




Design Conditions Summary

Design Conditions

Description Condition 1 Condition 2 Tube side hydrotest Shell side hydrotest

Tube Side

Pressure (kPa) 3,150 3,150 5,664.93 0

Design temperature (°C) 266 266 20 20

Et (MPa) 195,233.402 195,233.402 195,300.005 195,300.005

St (MPa) 204.706* 204.706* 496.8* 496.8*

Shell Side

Pressure (kPa) 1,050 1,050 0 1,784.93


Es (MPa) 195,233.402 195,233.402 195,300.005 195,300.005

Ss (MPa) 130 130 207 207

TubesheetDesign temperature (°C) 266 266 20 20

E (MPa) 195,233.402 195,233.402 195,300.005 195,300.005

S (MPa) 161 161 403.2 403.2

*The allowable tensile stress from Section II-D has been divided by 0.85 as the calculated stresses are longitudinal.

12/33




Data Inputs Summary

General Options

Identifier 105-B_rev1

CodesASME VIII-1,2007 Edition

MetricTEMA Eighth Edition (1999)

Description U-tube Class R Double split flow shell SIZE 60-324.1339 TYPE BHU

Shell material: SA-240 304 Perform ASME tube design check

Tube supports\baffle plates present

Maximumtubesheet

totube

supportdistance:

1,341mm

Maximum tube supportseparation: 2,332.34 mm Baffles support all tubes: Yes

Tube Options

Tube material: SA-789 Wld. tube <= 25 S32750 Tube length from outer tubesheet face to bend: L t= 8,233 mm

Tube dimensions, new, mm do= 19.05 tt= 1.65 Inner corrosion: 0 Outer corrosion: 0

Tube to tubesheet joint option Tube to tubesheet joint calculations have not been performed

Channel and Shell Options

Shell dimensionsnew, mm

Material:SA-240 304 Di= 1,524 ts= 12 Inner corrosion: 0 Outer corrosion: 0 MDMT:

-17.78 °C

Front channeldimensions, new, mm

Type: bonnet Torispherical head Inner corrosion: 0 Outer corrosion: 0 MDMT: -17.78 °C

Cylinder SA-240 304 Di= 1,524 tc= 25 L= 2,100

Closure SA-240 304 Di= 1,524 tmin= 25 LSF= 2,100

Tubesheet Options

Tube Layout Shear doesnot govern Tube count: 2270 Tube pitch: 25.4 mm Pattern: 90° (square)

Tubesheet dimensions,mm

(front and rear)

Material:SA-182 F51

ForgingsS31803

T = 207 OD = 1,605 Shell sidecorrosion = 0

Tube sidecorrosion = 0

MDMT = -17.78°C

Tubesheetpass groove depth =

3

Impact testis not

performedNot normalized Produced fine grain

practice PWHT not performed Gasketed shellside Gasketed tube side

13/33




Materials and Gaskets Summary

Materials And Gaskets

Part Quantity Size Material Gasket

Front torispherical head 1 1524.00 ID x 25 mm min thk SA-240 304 -

Front channel cylinder 1 1524.00 ID x 25 thkx 2100.00 mm SA-240 304 -

Tube Side Flange (front) 1 1810.00 OD x 230 mm thk SA-182 F304L > 125 Spiral-wound metal, asbestos filled Stainless,Monel, and nickel-base alloys1605.00 OD x 1570.00 ID mmFront tubesheet 1 1605.00 OD x 207 mm thk SA-182 F51 Forgings S31803

Shell Side Flange (front) 1 1810.00 OD x 230 mm thk SA-182 F304L > 125Spiral-wound metal, asbestos filled Stainless,

Monel, and nickel-base alloys1605.00 OD x 1570.00 ID mm

Front Tubesheet flangebolts 48 48 mm dia. stud x 798.30 mm

long SA-193 B7 -

Tubes 1135 19.05 OD x 1.65 wall mm SA-789 Wld. tube <= 25S32750 -

Shell cylinder 1 1524.00 ID x 12 mm thkx 8208.00 mm SA-240 304 -

Rear torispherical head 1 1524.00 ID x 10 mm min thk SA-516 70 -

Front pass partition - 13 mm thk SA-516 70 -

14/33




Tubesheet Maximum Pressure Report

ASME Tubesheet Maximum Pressure Ratings


Tube Side Pressure (kPa) 7,256.69 7,256.69 17,058.9 0


Shell Side Pressure (kPa) 7,256.69 7,256.69 0 17,058.9


Tubesheet Design temperature (°C) 266 266 20 20

TEMA Tubesheet Maximum Pressure Ratings


Tube Side Pressure (kPa) 8,523.26 8,523.26 11,491.17 0


Shell Side Pressure (kPa) 8,523.26 8,523.26 0 11,491.17


Tubesheet Design temperature (°C) 266 266 20 20

15/33




Tubesheet -- TEMA

TEMA RCB-7.13 Required Effective Tubesheet Thickness, in (mm)

Actual Tubesheet Thickness Used, TNominal = 8.1496 in (207 mm)

TMin effective for bending/shear, corr

= TNominal - Larger (Tube Side Pass Groove Depth, Tube Side Corrosion) - ShellSide Corrosion

= 8.1496 - Larger(0.1181, 0) - 0 = 8.0315 in (204 mm)

TMin effective for bending/shear, new

= TNominal - Larger (Tube Side Pass Groove Depth, Tube Side Corrosion) - ShellSide Corrosion

= 8.1496 - Larger(0.1181, 0) - 0 = 8.0315 in (204 mm)

Equations used

RCB-7.132(bending)

η = 1 - 0.785/(Pitch/Tube OD)2 = 1 - 0.785/(1/0.75)2 =0.5584

F = 1.25

Tbending = (F*G/3)*(P/(η*S))1/2

RCB-7.133(shear)

DL = 4*A/C

Tshear = 0.31*DL*(P/S)/(1 - do/Pitch)

Shear does not control if (P/S) < 1.6*(1 - do/Pitch)2

Condition 1 Corroded

Shell Side

Tbending =(1.25*62.60197/3)*(152.2896/(0.5584*23,351.08)) 1/2

= 2.8189 (71.6 mm)

Shear does not control as (152.2896/23,351.08) <1.6*(1 - 0.75/1)2

Tube Side

Tbending =(1.25*62.60197/3)*(456.8689/(0.5584*23,351.08)) 1/2

= 4.8825 (124.02 mm)


Condition 2 Corroded

Shell Side

Tbending =(1.25*62.60197/3)*(152.2896/(0.5584*23,351.08)) 1/2

= 2.8189 (71.6 mm)


Tube Side

Tbending =(1.25*62.60197/3)*(456.8689/(0.5584*23,351.08)) 1/2

= 4.8825 (124.02 mm)


Tube side hydrotest New Tube Side

Tbending =(1.25*62.60197/3)*(821.6292/(0.5584*58,479.22)) 1/2

= 4.1375 (105.09 mm)


Shell side hydrotest New Shell Side

Tbending =(1.25*62.60197/3)*(258.8826/(0.5584*58,479.22)) 1/2

= 2.3225 (58.99 mm)


16/33




Tubesheet -- ASME

ASME Section VIII, Division 1, 2007 Edition Metric

TubesheetType of heat exchanger: U-Tube

Type of construction: Fig. UHX-12.1 Configuration d:tubesheet gasketed with shell and channel

Simply supported: NoTubesheet material specification: SA-182 F51 Forgings S31803 (II-D Metric p. 126, ln. 37)Tube layout: SquareTubesheet outer diameter, A: 1,605 mmTubesheet thickness, h: 207 mm (tdesign = 137.41 mm)Number of tubes, Nt: 2270Tube pitch, p: 25.4 mmRadius to outer tube center, ro: 726 mmTotal area of untubed lanes, AL: 0.1613 m2

Pass partition groove depth, hg: 3 mmCorrosion allowance shell side , cs: 0 mmCorrosion allowance tube side , ct: 0 mmTubesheet poisson's ratio, ν: 0.3Gasket groove depth shell side: 0 mmGasket groove depth tube side: 0 mm

ShellShell material specification: SA-240 304 (II-D Metric p. 90, ln. 4)Shell inner diameter, Ds: 1,524 mmShell thickness, ts: 12 mmShell inner corrosion allowance: 0 mmShell outer corrosion allowance: 0 mmShell poisson's ratio, νs: 0.31

ChannelChannel material specification: SA-240 304 (II-D Metric p. 90, ln. 4)Channel inner diameter, Dc: 1,524 mmChannel thickness, tc: 25 mmChannel inner corrosion allowance: 0 mmChannel outer corrosion allowance: 0 mmChannel poisson's ratio, νc: 0.3

TubesTube material specification: SA-789 Wld. tube <= 25 S32750 (II-D Metric p. 138, ln. 19)Tube outer diameter, dt: 19.05 mmTube nominal thickness, tt: 1.65 mmTube inner corrosion allowance: 0 mmTube outer corrosion allowance: 0 mmTube expansion depth ratio, ρ: 0.85Tube poisson's ratio, νt: 0.3

FlangeBolt circle diameter, C: 1,710 mmShell side gasket load reaction diameter, Gs: 1,590.09 mmChannel side gasket load reaction diameter, Gc: 1,590.09 mm

Tube SupportsTube supports present: YesSupport all tubes: YesMaximum distance from tubesheet to first support: 1,341 mmMaximum distance between tube supports: 2,332.34 mm

17/33




Summary Tables

Tubesheet DesignThickness Summary

Condition tdesign(mm)

Condition 1 137.4055643

Condition 2 137.4055643

Tube side hydrotest 120.5581797

Shell side hydrotest 68.9891382

Bolt Load Summary

Condition Load CaseShell design bolt load

Ws(N)

Channel design bolt loadWc(N)

Condition 1Load case 1 9,367,086.24 9,367,086.24

Load case 2 7,197,497.02 7,197,497.02

Load case 3 9,367,086.24 9,367,086.24

Condition 2Load case 1 9,367,086.24 9,367,086.24

Load case 2 7,197,497.02 7,197,497.02

Load case 3 9,367,086.24 9,367,086.24

Tube side hydrotest Load case 1 12,151,259.63 12,151,259.63

Shell side hydrotest Load case 2 7,850,525.5 7,850,525.5

Pressures and Temperatures

Condition

Shell side designpressure

Ps(kPa)

Tube side designpressure

Pt(kPa)

Tubesheet designtemp

T(°C)

Shell designtemp

Ts(°C)

Channel designtemp

Tc(°C)

Tube designtemp

Tt(°C)

Condition 1 1,050 3,150 266 150 266 266

Condition 2 1,050 3,150 266 150 266 266

Tube sidehydrotest 0 5,664.93 20 20 20 20

Shell sidehydrotest 1,784.93 0 20 20 20 20

Material Properties

Condition Component MaterialModulus ofElasticity

(MPa)

AllowableStress(MPa)

YieldStress(MPa)

Condition 1

Shell SA-240 304 Es = 185,999.999 Ss = 130 Sy,s =154

Channel SA-240 304 Ec =178,040.002 Sc =120 Sy,c =133

Tubesheet SA-182 F51 Forgings S31803 E =178,040.002 S =161 S =341

Tubes SA-789 Wld. tube <= 25 S32750 Et =178,040.002 St =204.706* Sy,t =401

Condition 2

Shell SA-240 304 Es = 185,999.999 Ss = 130 Sy,s =154


Tubesheet SA-182 F51 Forgings S31803 E =178,040.002 S =161 S =341

18/33





Tube side hydrotest

Shell SA-240 304 Es = 195,300.005 Ss = 207 Sy,s =207


Tubesheet SA-182 F51 Forgings S31803 E =195,300.005 S =403.2 S =448


Shell side hydrotest

Shell SA-240 304 Es = 195,300.005 Ss = 207 Sy,s =207


Tubesheet SA-182 F51 Forgings S31803 E =195,300.005 S =403.2 S =448


*The allowable tensile stress from Section II-D has been divided by 0.85 as the calculated stresses are longitudinal.

Calculations for Condition 1 Condition

UHX-12.5.1 Step 1

Do = 2*ro + dt

µ = (p - dt) / p

d* = MAX{[dt - 2*tt*(Et / E)*(St / S)*ρ], [dt - 2*tt]}

p* = p /(1 - 4*MIN(AL, 4*Do*p) /(π*Do2))0.5

µ* = (p* - d*)/p*

hg' = MAX[(hg - ct), 0]

Condition Condition 1

New or corroded Do = 2*726 + 19.05 = 1,471.05

New or corroded µ = (25.4 - 19.05) /25.4 = 0.25

New or corrodedd* = MAX{[19.05 - 2*1.65*(178,040.002 / 178,040.002)*(204.706 / 161)*0.85],

[19.05 - 2*1.65]} = 15.7499998

New or corroded p* = 25.4 /(1 - 4*MIN(0.1613, 4*1,471.05*25.4) /(π*1,471.052))0.5 = 26.6

New or corroded µ* = (26.5963171 - 15.7499998)/26.5963171 = 0.407813

hg' = 3

UHX-12.5.2 Step 2

ρs = Gs / Do

ρc = Gc / Do

MTS = Do2 / 16 *[(ρs -1)*(ρs

2 + 1)*Ps - (ρc - 1)*(ρc2 + 1)*Pt]


New orcorroded

All loadcases ρs = 1,590.09 / 1,471.05 = 1.0809

ρc = 1,590.09 / 1,471.05 = 1.0809

19/33




New orcorroded

All loadcases

New orcorroded

Load case1

MTS = 1,471.052 / 16 *[(1.0809219 -1)*(1.08092192 + 1)*0 - (1.0809219 -1)*(1.08092192 + 1)*3,150] / 1000 = -74,756.55

Load case2

MTS = 1,471.052 / 16 *[(1.0809219 -1)*(1.08092192 + 1)*1,050 - (1.0809219 -1)*(1.08092192 + 1)*0] / 1000 = 24,918.85

Load case3

MTS = 1,471.052 / 16 *[(1.0809219 -1)*(1.08092192 + 1)*1,050 - (1.0809219 -1)*(1.08092192 + 1)*3,150] / 1000 = -49,837.7

UHX-12.5.3 Step 3

E* / E = α0 + α1*µ* + α2*µ*2 + α3*µ*3 + α4*µ*4

ν* = β0 + β1*µ* + β2*µ*2 + β3*µ*3 + β4*µ*4


New or corroded h/p = 207/25.4 = 8.1496

New or corroded - from Fig. UHX-11.4(a) E*/E = 0.4684

New or corroded E* = 0.4683965*178,040.002 = 83,393.321

New or corroded - from Fig. UHX-11.4(b) ν* = 0.3154

UHX-12.5.5 Step 5

K = A / Do

F = ((1 - ν*) / E*)*(E*ln(K))


New or corroded All load cases K = 1,605 / 1,471.05 = 1.0911

New or corroded All load cases F = ((1 - 0.3153799) / 83,393.321)*(178,040.002*ln(1.0911)) = 0.1274

UHX-12.5.6 Step 6

M* = MTS + Wmax*(Gc - Gs) / (2*π*Do)


New or corroded

Load case 1 M* = -74,756.55 + 9,367,086.24*(1,590.09 - 1,590.09) / (2*π*1,471.05) = -74,756.55

Load case 2 M* = 24,918.85 + 7,197,497.02*(1,590.09 - 1,590.09) / (2*π*1,471.05) = 24,918.85

Load case 3 M* = -49,837.7 + 9,367,086.24*(1,590.09 - 1,590.09) / (2*π*1,471.05) = -49,837.7

UHX-12.5.7 Step 7

Mp = (M* - (Do2 / 32)*F*(Ps - Pt)) / (1 + F)

20/33




Mo = Mp + (Do2 / 64)*(3 + ν*)*(Ps - Pt)

M = Max[Abs(Mp),Abs(Mo)]


New orcorroded

Load case1

Mp = (-74,756.55 - (1,471.052 / 32)*0.1274*(0 - 3,149.9999) / 1000) / (1 +0.1274) = -42,242.38

Load case2

Mp = (24,918.85 - (1,471.052 / 32)*0.1274*(1,049.9999 - 0) / 1000) / (1 +0.1274) = 14,080.79

Load case3

Mp = (-49,837.7 - (1,471.052 / 32)*0.1274*(1,049.9999 - 3,149.9999) / 1000) /(1 + 0.1274) = -28,161.59

New orcorroded

Load case1 Mo = -42,242.38 + (1,471.052 / 64)*(3 + 0.3153799)*(0 - 3,149.9999) / 1000 = -395,359.55

Load case2 Mo = 14,080.79 + (1,471.052 / 64)*(3 + 0.3153799)*(1,049.9999 - 0) / 1000 = 131,786.51

Load case3

Mo = -28,161.59 + (1,471.052 / 64)*(3 + 0.3153799)*(1,049.9999 - 3,149.9999)/ 1000 = -263,573.04

New orcorroded

Load case1 M = Max[Abs(-42,242.38),Abs(-395,359.55)] = 395,359.55

Load case2 M = Max[Abs(14,080.79),Abs(131,786.51)] = 131,786.51


UHX-12.5.8 Step 8

σ = 6*M / (µ**(h - hg')2)

Condition Condition 1 Stress(MPa)

Allowable2*S

(MPa)

Over-stressed?

New or corroded

Load case 1 σ = 6*395,359.5 / (0.4078128*(207 - 3)2) = 139.773 322 No

Load case 2 σ = 6*131,786.5 / (0.4078128*(207 - 3)2) = 46.591 322 No

Load case 3 σ = 6*263,573 / (0.4078128*(207 - 3)2) = 93.182 322 No

UHX-12.5.9 Step 9

τ = (1 / (4*µ))*(Do / h)*ABS(Ps - Pt)


Tubesheet Shear Stress Stress(MPa)

Allowable(MPa)

Over-stressed?

New or corroded

Load case 1 τ = (1 / (4*0.25))*(1,471.05 / 207)*ABS(0 - 3,150) / 1000 = 22.386 128.8 No

Load case 2 τ = (1 / (4*0.25))*(1,471.05 / 207)*ABS(1,050 - 0) / 1000 = 7.462 128.8 No

Load case 3 τ = (1 / (4*0.25))*(1,471.05 / 207)*ABS(1,050 - 3,150) / 1000 = 14.924 128.8 No

Calculations for Condition 2 Condition

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UHX-12.5.1 Step 1

Do = 2*ro + dt

µ = (p - dt) / p


p* = p /(1 - 4*MIN(AL, 4*Do*p) /(π*Do2))0.5

µ* = (p* - d*)/p*

hg' = MAX[(hg - ct), 0]


New or corroded Do = 2*726 + 19.05 = 1,471.05

New or corroded µ = (25.4 - 19.05) /25.4 = 0.25

New or corrodedd* = MAX{[19.05 - 2*1.65*(178,040.002 / 178,040.002)*(204.706 / 161)*0.85],

[19.05 - 2*1.65]} = 15.7499998

New or corroded p* = 25.4 /(1 - 4*MIN(0.1613, 4*1,471.05*25.4) /(π*1,471.052))0.5 = 26.6

New or corroded µ* = (26.5963171 - 15.7499998)/26.5963171 = 0.407813

hg' = 3

UHX-12.5.2 Step 2

ρs = Gs / Do

ρc = Gc / Do

MTS = Do2 / 16 *[(ρs -1)*(ρs

2 + 1)*Ps - (ρc - 1)*(ρc2 + 1)*Pt]


New orcorroded

All loadcases ρs = 1,590.09 / 1,471.05 = 1.0809

New orcorroded

All loadcases ρc = 1,590.09 / 1,471.05 = 1.0809

New orcorroded

Load case1

MTS = 1,471.052 / 16 *[(1.0809219 -1)*(1.08092192 + 1)*0 - (1.0809219 -1)*(1.08092192 + 1)*3,150] / 1000 = -74,756.55

Load case2

MTS = 1,471.052 / 16 *[(1.0809219 -1)*(1.08092192 + 1)*1,050 - (1.0809219 -1)*(1.08092192 + 1)*0] / 1000 = 24,918.85

Load case3

MTS = 1,471.052 / 16 *[(1.0809219 -1)*(1.08092192 + 1)*1,050 - (1.0809219 -1)*(1.08092192 + 1)*3,150] / 1000 = -49,837.7

UHX-12.5.3 Step 3

E* / E = α0 + α1*µ* + α2*µ*2 + α3*µ*3 + α4*µ*4

ν* = β0 + β1*µ* + β2*µ*2 + β3*µ*3 + β4*µ*4

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New or corroded h/p = 207/25.4 = 8.1496

New or corroded - from Fig. UHX-11.4(a) E*/E = 0.4684

New or corroded E* = 0.4683965*178,040.002 = 83,393.321

New or corroded - from Fig. UHX-11.4(b) ν* = 0.3154

UHX-12.5.5 Step 5

K = A / Do

F = ((1 - ν*) / E*)*(E*ln(K))


New or corroded All load cases K = 1,605 / 1,471.05 = 1.0911

New or corroded All load cases F = ((1 - 0.3153799) / 83,393.321)*(178,040.002*ln(1.0911)) = 0.1274

UHX-12.5.6 Step 6



New or corroded

Load case 1 M* = -74,756.55 + 9,367,086.24*(1,590.09 - 1,590.09) / (2*π*1,471.05) = -74,756.55

Load case 2 M* = 24,918.85 + 7,197,497.02*(1,590.09 - 1,590.09) / (2*π*1,471.05) = 24,918.85

Load case 3 M* = -49,837.7 + 9,367,086.24*(1,590.09 - 1,590.09) / (2*π*1,471.05) = -49,837.7

UHX-12.5.7 Step 7

Mp = (M* - (Do2 / 32)*F*(Ps - Pt)) / (1 + F)

Mo = Mp + (Do2 / 64)*(3 + ν*)*(Ps - Pt)



New orcorroded

Load case1

Mp = (-74,756.55 - (1,471.052 / 32)*0.1274*(0 - 3,149.9999) / 1000) / (1 +0.1274) = -42,242.38

Load case2

Mp = (24,918.85 - (1,471.052 / 32)*0.1274*(1,049.9999 - 0) / 1000) / (1 +0.1274) = 14,080.79

Load case3

Mp = (-49,837.7 - (1,471.052 / 32)*0.1274*(1,049.9999 - 3,149.9999) / 1000) /(1 + 0.1274) = -28,161.59

New orcorroded

Load case1 Mo = -42,242.38 + (1,471.052 / 64)*(3 + 0.3153799)*(0 - 3,149.9999) / 1000 = -395,359.55

Load case2 Mo = 14,080.79 + (1,471.052 / 64)*(3 + 0.3153799)*(1,049.9999 - 0) / 1000 = 131,786.51

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Load case3

Mo = -28,161.59 + (1,471.052 / 64)*(3 + 0.3153799)*(1,049.9999 - 3,149.9999)/ 1000 = -263,573.04

New orcorroded


Load case2 M = Max[Abs(14,080.79),Abs(131,786.51)] = 131,786.51


UHX-12.5.8 Step 8

σ = 6*M / (µ**(h - hg')2)

Condition Condition 2 Stress(MPa)

Allowable2*S

(MPa)

Over-stressed?

New or corroded

Load case 1 σ = 6*395,359.5 / (0.4078128*(207 - 3)2) = 139.773 322 No

Load case 2 σ = 6*131,786.5 / (0.4078128*(207 - 3)2) = 46.591 322 No

Load case 3 σ = 6*263,573 / (0.4078128*(207 - 3)2) = 93.182 322 No

UHX-12.5.9 Step 9



Allowable(MPa)

Over-stressed?

New or corroded

Load case 1 τ = (1 / (4*0.25))*(1,471.05 / 207)*ABS(0 - 3,150) / 1000 = 22.386 128.8 No

Load case 2 τ = (1 / (4*0.25))*(1,471.05 / 207)*ABS(1,050 - 0) / 1000 = 7.462 128.8 No

Load case 3 τ = (1 / (4*0.25))*(1,471.05 / 207)*ABS(1,050 - 3,150) / 1000 = 14.924 128.8 No

Calculations for Tube side hydrotest Condition

UHX-12.5.1 Step 1

Do = 2*ro + dt

µ = (p - dt) / p


p* = p /(1 - 4*MIN(AL, 4*Do*p) /(π*Do2))0.5

µ* = (p* - d*)/p*

hg' = MAX[(hg - ct), 0]

Condition Tube side hydrotest

New Do = 2*726 + 19.05 = 1,471.05

New µ = (25.4 - 19.05) /25.4 = 0.25

24/33




Newd* = MAX{[19.05 - 2*1.65*(195,300.005 / 195,300.005)*(496.8 / 537.6)*0.85],

[19.05 - 2*1.65]} = 16.4578796

New p* = 25.4 /(1 - 4*MIN(0.1613, 4*1,471.05*25.4) /(π*1,471.052))0.5 = 26.6

New µ* = (26.5963171 - 16.4578796)/26.5963171 = 0.381197

hg' = 3

UHX-12.5.2 Step 2

ρs = Gs / Do

ρc = Gc / Do

MTS = Do2 / 16 *[(ρs -1)*(ρs

2 + 1)*Ps - (ρc - 1)*(ρc2 + 1)*Pt]


New All loadcases ρs = 1,590.09 / 1,471.05 = 1.0809

New All loadcases ρc = 1,590.09 / 1,471.05 = 1.0809

New Load case 1MTS = 1,471.052 / 16 *[(1.0809219 -1)*(1.08092192 + 1)*0 - (1.0809219 -

1)*(1.08092192 + 1)*5,664.93] / 1000 = -134,441.55

UHX-12.5.3 Step 3

E* / E = α0 + α1*µ* + α2*µ*2 + α3*µ*3 + α4*µ*4

ν* = β0 + β1*µ* + β2*µ*2 + β3*µ*3 + β4*µ*4


New h/p = 207/25.4 = 8.1496

New - from Fig. UHX-11.4(a) E*/E = 0.4362

New E* = 0.4361677*195,300.005 = 85,183.558

New - from Fig. UHX-11.4(b) ν* = 0.3184

UHX-12.5.5 Step 5

K = A / Do

F = ((1 - ν*) / E*)*(E*ln(K))


New All load cases K = 1,605 / 1,471.05 = 1.0911

New All load cases F = ((1 - 0.3184018) / 85,183.558)*(195,300.005*ln(1.0911)) = 0.1362

25/33




UHX-12.5.6 Step 6



New Load case 1 M* = -134,441.55 + 12,151,259.63*(1,590.09 - 1,590.09) / (2*π*1,471.05) = -134,441.55

UHX-12.5.7 Step 7

Mp = (M* - (Do2 / 32)*F*(Ps - Pt)) / (1 + F)

Mo = Mp + (Do2 / 64)*(3 + ν*)*(Ps - Pt)



New Load case 1 Mp = (-134,441.55 - (1,471.052 / 32)*0.1362*(0 - 5,664.9332) / 1000) / (1 + 0.1362) = -72,409.52

New Load case 1 Mo = -72,409.52 + (1,471.052 / 64)*(3 + 0.3184018)*(0 - 5,664.9332) / 1000 = -708,031.31

New Load case 1 M = Max[Abs(-72,409.52),Abs(-708,031.31)] = 708,031.31

UHX-12.5.8 Step 8

σ = 6*M / (µ**(h - hg')2)

Condition Tube side hydrotest Stress(MPa)

Allowable(MPa)

Over-stressed?

New Load case 1 σ = 6*708,031.3 / (0.3811971*(207 - 3)2) = 267.79 806.4 No

UHX-12.5.9 Step 9



Allowable(MPa)

Over-stressed?

New Load case 1 τ = (1 / (4*0.25))*(1,471.05 / 207)*ABS(0 - 5,664.93) / 1000 = 40.258 322.56 No

Calculations for Shell side hydrotest Condition

UHX-12.5.1 Step 1

Do = 2*ro + dt

µ = (p - dt) / p


p* = p /(1 - 4*MIN(AL, 4*Do*p) /(π*Do2))0.5

µ* = (p* - d*)/p*

hg' = MAX[(hg - ct), 0]

26/33




Condition Shell side hydrotest

New Do = 2*726 + 19.05 = 1,471.05

New µ = (25.4 - 19.05) /25.4 = 0.25

Newd* = MAX{[19.05 - 2*1.65*(195,300.005 / 195,300.005)*(496.8 / 537.6)*0.85],

[19.05 - 2*1.65]} = 16.4578796

New p* = 25.4 /(1 - 4*MIN(0.1613, 4*1,471.05*25.4) /(π*1,471.052))0.5 = 26.6

New µ* = (26.5963171 - 16.4578796)/26.5963171 = 0.381197

hg' = 3

UHX-12.5.2 Step 2

ρs = Gs / Do

ρc = Gc / Do

MTS = Do2 / 16 *[(ρs -1)*(ρs

2 + 1)*Ps - (ρc - 1)*(ρc2 + 1)*Pt]


New All loadcases ρs = 1,590.09 / 1,471.05 = 1.0809

New All loadcases ρc = 1,590.09 / 1,471.05 = 1.0809

New Load case 2MTS = 1,471.052 / 16 *[(1.0809219 -1)*(1.08092192 + 1)*1,784.93 - (1.0809219 -

1)*(1.08092192 + 1)*0] / 1000 = 42,360.45

UHX-12.5.3 Step 3

E* / E = α0 + α1*µ* + α2*µ*2 + α3*µ*3 + α4*µ*4

ν* = β0 + β1*µ* + β2*µ*2 + β3*µ*3 + β4*µ*4


New h/p = 207/25.4 = 8.1496

New - from Fig. UHX-11.4(a) E*/E = 0.4362

New E* = 0.4361677*195,300.005 = 85,183.558

New - from Fig. UHX-11.4(b) ν* = 0.3184

UHX-12.5.5 Step 5

K = A / Do

F = ((1 - ν*) / E*)*(E*ln(K))


27/33




New All load cases K = 1,605 / 1,471.05 = 1.0911

New All load cases F = ((1 - 0.3184018) / 85,183.558)*(195,300.005*ln(1.0911)) = 0.1362

UHX-12.5.6 Step 6



New Load case 2 M* = 42,360.45 + 7,850,525.5*(1,590.09 - 1,590.09) / (2*π*1,471.05) = 42,360.45

UHX-12.5.7 Step 7

Mp = (M* - (Do2 / 32)*F*(Ps - Pt)) / (1 + F)

Mo = Mp + (Do2 / 64)*(3 + ν*)*(Ps - Pt)



New Load case 2 Mp = (42,360.45 - (1,471.052 / 32)*0.1362*(1,784.9328 - 0) / 1000) / (1 + 0.1362) = 22,815.12

New Load case 2 Mo = 22,815.12 + (1,471.052 / 64)*(3 + 0.3184018)*(1,784.9328 - 0) / 1000 = 223,089.71

New Load case 2 M = Max[Abs(22,815.12),Abs(223,089.71)] = 223,089.71

UHX-12.5.8 Step 8

σ = 6*M / (µ**(h - hg')2)

Condition Shell side hydrotest Stress(MPa)

Allowable(MPa)

Over-stressed?

New Load case 2 σ = 6*223,089.7 / (0.3811971*(207 - 3)2) = 84.376 806.4 No

UHX-12.5.9 Step 9



Allowable(MPa)

Over-stressed?

New Load case 2 τ = (1 / (4*0.25))*(1,471.05 / 207)*ABS(1,784.93 - 0) / 1000 = 12.685 322.56 No

28/33




Tubes

ASME Section VIII Division 1, 2007 Edition Metric

Component: TubesMaterial specification: SA-789 Wld. tube <= 25 S32750 (II-D Metric p. 138, ln. 19)Impact test exempt per UHA-51(d)

Internal design pressure: P = 3150 kPa @ 266°CExternal design pressure: Pe = 1050 kPa @ 266°C

Static liquid head:

Pth =14.6734 kPa (SG=1.0000, Hs=1497.53 mm, Horizontal test head)

Corrosion allowance: Inner C = 0.00 mm Outer C = 0.00 mm

Design MDMT = -17.78°C No impact test performedRated MDMT = -196.00°C Material is not normalized

Material is not produced to Fine Grain PracticePWHT is not performed

Estimated weight: New = 6.8272 kg corr = 6.8272 kgCapacity: New = 1.8372 liters corr = 1.8372 litersOD = 19.05 mmLength Lc = 8233.00 mmt = 1.65 mm

Design thickness, (at 266.00°C) Appendix 1-1

t = P*Ro/(S*E + 0.40*P) + Corrosion= 3150.00*9.52/(174000*1.00 + 0.40*3150.00) + 0.00= 0.1727 mm

Maximum allowable working pressure, (at 266.00°C) Appendix 1-1

P = S*E*t/(Ro - 0.40*t) - Ps= 174000*1.00*1.4438 / (9.52 - 0.40*1.4438) - 0.0000= 28076.2773 kPa

Maximum allowable pressure, (at 20.00°C) Appendix 1-1

P = S*E*t/(Ro - 0.40*t)= 194000*1.00*1.4438 / (9.52 - 0.40*1.4438)= 31303.4355 kPa

External Pressure, (Corroded & at 266.00°C) UG-28(c)

L/Do = 8233.0000/19.0500 = 50.0000Do/t = 19.0500/0.380533 = 50.0614

From table G: A = 0.000439From table HA-5 Metric: B = 39.4251 MPa

Pa = 4*B/(3*(Do/t))= 4*39.4251/(3*(19.0500/0.380533))

29/33




= 1050.0466 kPa

Design thickness for external pressure Pa = 1050.0466 kPa

= t + Corrosion = 0.380533 + 0.00 = 0.38 mm

Maximum Allowable External Pressure, (Corroded & at 266.00°C) UG-28(c)

L/Do = 8233.0000/19.05 = 50.0000Do/t = 19.05/1.4438 = 13.1948

From table G: A = 0.007138From table HA-5 Metric: B = 146.2697 MPa

Pa = 4*B/(3*(Do/t))= 4*146.2697/(3*(19.05/1.4438))= 14780.5322 kPa

30/33




TEMA RCB-9.132 Pass Partition Plate Calculations

Minimum Front Pass Partition Plate Thickness

Front tube side pressure drop: q = 0 psi (0 kPa)Front pass plate material: SA-516 70 (II-D Metric p. 18, ln. 22)Front pass plate allowable stress: S = 19,870.1699psi (137 MPa)Front pass plate dimension: a = 180.7775 in (4,591.75 mm)Front pass plate dimension: b = 59.9409 in (1,522.5 mm)Front pass plate thickness, new: T = 0.5118 in (13 mm)Front pass plate corrosion allowance: C = 0 in (0 mm)Front pass plate fillet weld leg size, new 0 in (0 mm)

From TABLE RCB-9.131

t = 0.5

From TABLE RCB-9.132, long sides fixed, a/b = 3.0159, B = 0.5

t = b*(q*B/(1.5*S))1/2 + C= 59.94094*(0*0.5/(1.5*19,870.17))1/2 + 0= 0 in (0 mm)

The pass partition plate thickness of 13 mm is adequate.

Pass partition minimum weld size = 0.75*t + C/0.7= 0 in (0 mm)

The pass partition fillet weld size of 0 mm is adequate.

31/33




Baffle Summary Report

Baffle Name Distance fromFront Tubesheet (mm) Cut Direction Cut Distance

from Center (mm) Baffle Weight (kg)

Baffle #1 347.66 Downwards 762.00 145.14

Baffle #2 2680.00 Upwards 762.00 145.14


Baffle #4 5350.00 Upwards 762.00 145.14


Baffle Material: SA-204Gr.304LBaffle Type: Single SegmentalBaffle Orientation: HorizontalBaffle Shell Clearance: 4.00 mm (7.94 mm TEMA (Max))Baffle Thickness: 16.00 mm (15.88 mm TEMA)Baffle Diameter: 1516.00 mmBaffle Count: 5Maximum Tubesheet to Baffle Distance: 1341.00 mmMaximum Baffle to Baffle Distance: 2332.34 mmDistance from Shell Side Tubesheet Face to Bend: 8026.00 mmBaffle Group Weight: 725.72 kgBaffle Material Density (assumed): 7833.41 kg/m³* Each baffle supports every tube

32/33




Seismic Code

Seismic calculations were not performed because:Vessel is horizontal.

33/33




105-b_rev.1

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