PARCO-Mid Country Refinery PROCESS TRAINING MANUAL
HEAT EXCHANGERS & FIN FAN COOLERS
DOC. #: PAR-MCR-PROCESS/ Training Manual-01 Issue # 01 Issue Date: Page 1 of 38
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PARCO-Mid Country Refinery PROCESS TRAINING MANUAL
HEAT EXCHANGERS & FIN FAN COOLERS
Contents 13.1. HEAT TRANSFER 13.2. TYPE OF HEAT TRANSFER 13.2.1. Convection Heat Transfer 13.2.2. Conduction Heat Transfer 13.2.3. Radiation Heat Transfer 13.3. EQUIPMENT FOR HEAT EXCHANGE 13.4. HEAT EXCHANGERS 13.5. MECHANICS OF HEAT TRANSMISSION 13.6. TYPES OF HEAT EXCHANGER 13.7. EXCHANGER OPERATION AND MAINTENANCE 13.8. FIN FAN COOLERS 13.9. MCR EXCHANGERS LIST & DATA
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PARCO-Mid Country Refinery PROCESS TRAINING MANUAL
HEAT EXCHANGERS & FIN FAN COOLERS
Contents 13.1. HEAT TRANSFER 13.2. TYPE OF HEAT TRANSFER 13.2.1. Convection Heat Transfer 13.2.2. Conduction Heat Transfer 13.2.3. Radiation Heat Transfer 13.3. EQUIPMENT FOR HEAT EXCHANGE 13.4. HEAT EXCHANGERS 13.5. MECHANICS OF HEAT TRANSMISSION 13.6. TYPES OF HEAT EXCHANGER 13.7. EXCHANGER OPERATION AND MAINTENANCE 13.8. FIN FAN COOLERS 13.9. MCR EXCHANGERS LIST & DATA
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PARCO-Mid Country Refinery PROCESS TRAINING MANUAL
HEAT EXCHANGERS & FIN FAN COOLERS
13.1.
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HEAT TRANSFER
In the petroleum refining, the proper use of heat is extremely important and successful operation of petroleum processes is largely dependent upon correct heat application. Efficient equipment, designed to take full advantage of processing heat, is in use on all refinery operations. Crude oil is separated into its various products by boiling. Heat is applied to the oil in heaters from which it passes to the distillation columns where the products or fractions are separated and taken off. To supply the heat required, large quantities of fuel must be burned in the heaters and any reduction in the amount of fuel used is a saving in refinery operation costs. Any heat which has been given to the oil and is not used, is a waste to fuel, thus the conversation and full usage of heat is a major part of refinery operation. As the oil entering the plant is usually cold, and products leaving the various columns are hot and need to be cooled before going to storage, we conserve by transferring the heat in the products to the incoming oil. By this means the oil going to the heater is hotter and therefore less fuel is required to bring it up to its required temperature. In the refinery to do this we use equipment called heat exchangers. These devices
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The speed of forced convection is, of course, faster than that of natural convection. Typical example: The heating of air by a radiator in a central heating system. Home water heater. 13.2.2.
Conduction Heat Transfer
Conduction is the transfer of heat from one part of a body to another part of the same body, or from one body to another in contact, without any mixing of each of the components. This heat transfer is the result of transfer of the momentum of atoms and / or molecules. Typical example: The handle of a teaspoon in a cup of hot tea becomes warm after some time. 13.2.3.
Radiation Heat Transfer
Radiation is the transfer of heat from one body to another, not by contact, but by means of electromagnetic waves through space.
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13.3.2. Non-Fired Equipment In this case the heat transfer occurs by means of conduction or convection and no combustion takes place. Examples of this are coolers, condensers and heat exchangers. This lesson covers the second type of heat exchangers, of the non fired type, in detail.
13.4.
HEAT EXCHANGERS
This manual describes the types of heat exchangers in general use in a refinery, together with their operating characteristics and procedures. A heat exchanger is the equipment used to exchange heat between two fluids with different temperature, through a fixed wall, without mixing the two fluids. Heat exchangers are widely used in refineries and chemical plants to: • • • •
Cool or heat a fluid (gas or liquid). To condense a vaporized material. To evaporate a liquid. To recover waste heat.
13.5.
MECHANICS OF HEAT TRANSMISSION
Heat exchange between two materials through a fixed wall utilizes the thermal
PARCO-Mid Country Refinery PROCESS TRAINING MANUAL
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U ∆
A
= tm = =
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Overall heat transfer coefficient of the exchanger, related to thermal conductivities. Average temperature difference between the hot and cold fluids. Total surface area of tubes used for heat transfer.
As can be seen from the equation, the higher the thermal conductivities and the higher the temperature difference (driving force) and surface area of tubes, the greater will be the quantity of heat transferred is given time.
13.6.
TYPES OF HEAT EXCHANGER
The most widely used type of exchanger consists of a bundle of tubes enclosed in a shell, thus called a shell and tube heat exchanger. In a heat exchanger, two fluids flow against the opposite sides of a wall, which separate them. The fluids never come in contact with each other. Heat is passed from the hot fluid to the cold fluid. The temperature of the hot fluid is reduced by transferring heat to the other fluid. The shell and tube exchanger is the most commonly used heat exchanger. Figure 1 shows the arrangement of heat exchanger tubes. It is desirable to place as many tubes as possible in a heat exchanger. These tubes are available in different sizes. Tubes are made of steel, copper, brass or alloys. Tubes are attached to a tube sheet generally made of the same material,
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Figure (2), Tube Sheet and Tubes Special care must be taken to prevent leakage between the tube sheet and the tube. Holes are drilled in the tube sheet. These holes are only slightly larger than the outside diameter of the tubes. Specialized equipment is then used to expand the tube to fit the hole. This expanding and rolling equipment is highly specialized and its use is usually left to specialists. If a leak free joint is not made, the tube fluid and the shell fluid will mix, which is undesirable. Either under rolling or over rolling the tubes can cause leaks. The tubes and tube sheets together are called the tube bundle. The tube bundle is installed as a single unit. The bundle is also removed as a unit for inspection, cleaning and repair.
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Figure (3), Segmental Baffles They help to route the fluid flow outside of the tubes. These baffles alternate between the top and bottom of the shell. The arrows indicate fluid flow direction around the tubes. In this diagram, very few tubes are shown. There are many more tubes in a tube bundle. Figure (4) shows a disc and doughnut baffle arrangement. The disc support tubes but does not attach to the exchanger shell. The doughnut portion of the baffle supports tubes and also attaches to the exchanger shell.
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Figure (5), Fixed tube sheet heat Exchanger A partition forces the fluid to flow through the upper tubes toward the right hand part of the exchanger. A partition on the right hand side of the exchanger causes the fluid to flow back through tubes to the left middle section of the exchanger.
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Since the fluid flows back and forth throughout the exchanger, this exchanger is known as a multi-pass fixed tube heat exchanger. The cooling fluid, usually water, enters the exchanger at the inlet marked “IN” in the lower right hand portion of the exchanger. The baffle aid in circulation of the cooling water. The water leaves the exchangers at the top of the exchanger. Both ends of the tube bundle are rigid and fixed. This allows for very little expansion of the tubes. This heat exchange is only used where the temperature difference between the two fluids is very small. Figure (6) shows a U tube heat exchanger. The tubes in this exchanger are bent in the form of a “U”. This design allows for large amounts of tube expansion but makes it difficult to clean out tubes if they get clogged.
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Legend: 1) 2) 3) 4) 5) 6) 7) 8)
Channel or bonnet Channel nozzle Instrument connection Shell nozzle Shell Baffle Plate Tie rod and spacer Tube
09) Shell Cover 10) Shell nozzle 11) Support saddle 12) Support saddle 13) Shell flange fixed heat end 14) Instrument connection 15) Pass partition plate
Coolin water
Head
A538 Product
U-Tube Type Figure (7) shows a floating head removable tube bundle exchanger. This type of exchanger is standard for oil refinery use. Oil flows through the shell of the exchanger. Oil enters the shell inlet nozzle. It is directed back and forth across the
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Figure (8) shows the details of the tube bundle used in the floating head exchanger. The fixed tube sheet is larger than the floating tube sheet. This allows the floating tube sheet to be slipped into the shell for ease of installation and removal. The fixed tube sheet fits against the exchanger shell. The channel section is then bolted to this tube sheet.
Figure (8), Floating Head Tube Bundle The end remains fixed and unable to move. This is shown in figure (9). The floating head tube cover is removable. This cover allows easy removal of the tube bundle and easy access for cleaning. Figure (10) shows a detail of a tube sheet and floating head cover. Its function is to direct the flow of the cooling water in the exchanger. Gaskets are used to make a leak proof connection between the floating head and the tube sheet. The partially assembled unit is shown in figure (11).
PARCO-Mid Country Refinery PROCESS TRAINING MANUAL
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Floating head - type
Figure (9), Bundle Installation
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Figure (11), Piping around heat exchanger
13.7.
EXCHANGER OPERATION AND MAINTENANCE
Heat exchangers are a necessary part of refinery operation. Heat exchanger
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Both sides should be vented on start up to remove any trapped air. The cooler of the two fluids should be introduced first when starting up a heat exchanger. When shutting down, the hotter fluid should be shut off first. Tubes must be cleaned periodically. If the unit is scheduled for a shutdown, it is good time to take the exchanger apart and thoroughly clean it. Care must be taken in cleaning the tubes to avoid damage. When rotating tube cleaners are used, the inside surface of the tubes may be worn thin or cut. They may also be bent or dented if they are cleaned on the outside. Sand blasting or hydro blasting can wear away the metal if used too long. Pressure tests and leak tests can be used to check the tubes in a bundle. A pressure test consists of filling the exchanger with liquid or air to a pressure higher than atmosphere pressure. A loss of pressure after a period of time will indicate a leak. Leaky tubes may be re-rolled if they are leaking at the tube sheet. If only a few tubes are leaking some where in the middle of the tube, they may be plugged. In this case a tapered metal plug is driven into each end of the tube. The plugging of a few tubes in a tube bundle and putting the exchanger back in service is not uncommon. This may be repeated until the number of tubes plugged interferes with efficient exchanger operation.
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In a cooler the fluid temperature does drop due to the removal of the hot fluids sensible heat. Likewise the same principle applies in a re-boiler another change of phase application.
A – Cooling or Heating – Sensible Heat
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Kettle type reboiler This design is frequently found as heating units at the base of distillation columns. In this type, liquid is vaporized in the shell (space around the tubes) using steam or other hot material passing through the tubes. An overflow baffle makes sure that tubes are always submerged in the liquid. The vapors, given off during the heating, can be returned to the distillation column. Non-evaporated liquid returns as bottom product.
13.8.
FIN FAN COOLERS
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The hot fluid is passed through the tubes and cooled by air passes over the tubes at a high velocity by either a forced or an induced draft. It has the advantages of: • • •
An air piping system is not required, and there is no limit to the air supply volume. There is practically no fouling on the outside surfaces of the tubes. It is economical and easily maintained.
However, it also has the disadvantage where the minimum cooling level is limited by ambient temperature. For this reason air coolers are normally confined to “Low Grade” cooling.
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Extended area fins
During warm periods it is common in refineries to direct a fire water spray on to the fin tubes which increases the fin fan capacity for heat removal due to the cooling effect of the evaporating water.
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13.9.
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MCR EXCHANGERS LIST & DATA EXCHANGERS DATA OF CRUDE DISTILLATION UNIT (U-100)
Sr. No.
Tag No.
Design Press. (Kg/cm²)
Service
Description S/S
T/S
Design Temp. (°C)
Opr. Press. (Kg/cm²)
Opr. Temp. (°C)
S/S
T/S
S/S
T/S
S/S
T/S
S/S
T/S
Type
1
100-E1 A/B
Crude Circulation Naphtha Exchanger
Crude
Circulating Naphtha
39.00
26.00
120.00
161.00
28.40
8.29
10 / 66
127 / 71
Tubular
2
100-E2 A/B
Kerosene Product Trim Cooler
Kerosene Product
Cooling Water
26.00
15.80
125.00
120.00
14.50
4.50
65 / 40
34.5 / 45
Tubular
3
100-E3
Crude Kerosene Product Exchanger
Kerosene Product
Crude
26.00
39.00
182.00
120.00
15.80
27.10
154 / 102
66 / 78
Tubular
4
100-E4 A/B
Crude Circulation Kerosene Exchanger
Circulating Kerosene
Crude
26.00
39.00
208.00
154.00
7.26
26.40
180 / 108
78 / 126
Tubular
5
100-E5
Diesel Product Trim Cooler
Diesel Product
Cooling Water
26 / FV
15.00
120 / 65
120.00
8.12
4.50
65 / 50
34.5 / 45
Tubular
6
100-E6
Crude Circulation Diesel Exchanger
Circulating Diesel
Crude
26.00
39.00
220.00
157.00
4.07
26.00
181 / 163
118 / 129
Tubular
7
100-E7 A/B
Desalting Water Desalter Brine Exchanger
Desalted Water
Desalted Brine
39.00
40.00
129.00
151.00
33.20
23.20
66 / 101
123 / 86
Tubular
8
100-E8 A/B
Desalter Brine Cooler
Desalted Brine
Cooling Water
27.00
40.00
120.00
123.00
4.50
2.11
34.5 / 45
86 / 41
Tubular
9
100-E9
Desalted Crude Cold Diesel Product Exchanger
Diesel Product
Desalted Crude
26 / FV
39.00
244 / 203
153.00
11.90
20.30
199 / 153
116 / 125
Tubular
10
100-E11 A/B
HVGO
Desalted Crude
26.00
39.00
236.00
179.00
13.70
20.20
208 / 157
120 / 150
Tubular
11
100-E12 A/B
Circulating Diesel
Crude
26.00
39.00
248.00
202.00
5.64
19.00
220 / 176
150 / 174
Tubular
Desalted Crude HVGO Exchanger No.1 Desalted Crude Circulating Diesel Exchanger
SAH/- Heat Exchanger and fin fan cooler-Final
11/07/05
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12
100-E13
Desalted Crude HVGO Exchanger No.2
HVGO
Desalted Crude
26.00
39.00
285.00
213.00
14.50
17.40
225 / 208
174 / 185
Tubular
13
100-E14
Desalted Crude Hot Diesel Product Exchanger
Diesel Product
Desalted Crude
26 / FV
39.00
272 / 244
231.00
11.80
16.50
239 / 203
185 / 193
Tubular
14
100-E15
Flashed Crude HVGO Exchanger No. 3
HVGO
Flashed Crude
24.00
30.00
285.00
247.00
15.40
22.00
284 / 225
191 / 219
Tubular
15
100-E16
Flashed Crude Circulating Diesel Exchanger No. 3
Circulating Diesel
Flashed Crude
26.00
30.00
263.00
233.00
6.48
22.70
231 / 220
191 / 205
Tubular
16
100-E17 A/B
Flashed Crude
22.00
30.00
362.00
249.00
12.90
22.00
268 / 232
205 / 221
Tubular
17
100-E18 A/B
HVGO
Flashed Crude
24.00
30.00
313.00
272.00
16.50
21.00
285 / 265
220 / 231
Tubular
18
100-E19 A/B
Hot Vacuum Bottoms
Flashed Crude
22.00
30.00
390.00
293.00
13.70
19.80
362 / 268
244 / 265
Tubular
19
100-E20 A/B
Crude Column Trim Condenser
Crude Column Vapor
Cooling Water
3.9 / FV
7.00
120 / 61
120.00
0.58
4.50
61 / 41
34.5 / 41
Tubular
20
100-E21 A/B
Demineralized Water Diesel Product Exchanger
Diesel Product
Demineralized Water
26 / FV
27.00
244 / 187
138.00
11.20
12.60
153 / 56
21 / 92
Tubular
21
100-E22
Steam / Air Preheater
Air
MP Steam
6.00
13.00
260.00
300.00
_
_
_
_
_
Flashed Crude/Cold Vacuum Bottoms Exchanger Flashed Crude HVGO Exchanger No.4 Flashed Crude Hot Vacuum Bottoms Exchanger
SAH/- Heat Exchanger and fin fan cooler-Final
Cold Vacuum Bottoms
11/07/05
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AIR COOLED EXCHANGERS DATA OF CRUDE DISTILLATION UNIT (U-100) Sr. No.
Tag No.
Description
1
100-EA1
Kerosene Product Cooler
2
100-EA2
Diesel Product Cooler
3
100-EA4
Crude Column Condenser
SAH/- Heat Exchanger and fin fan cooler-Final
Service T/S
Design Press. (Kg/cm²)
Design Temp. (°C)
Opr. Press. (Kg/cm²)
Opr. Temp. (°C)
Type
Kerosene Product
26.0
182
_
_
Finned
Diesel Product
26 / FV
187 / 118
_
_
Finned
Overhead Vapors
3.5 / FV
143 / 115
_
_
Finned
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EXCHANGERS DATA OF VACUUM DISTILLATION UNIT (U-110) Sr. No.
Tag No.
Service
Description S/S
T/S
Design Press. (Kg/cm²)
Design Temp. (°C)
Opr. Press. (Kg/cm²)
Opr. Temp. (°C)
S/S
T/S
S/S
T/S
S/S
T/S
S/S
T/S
Type
1
110-E1 A/B
LVGO Trim Cooler
LVGO
Cooling Water
17.50
11.70
128.00
120.00
10.40
4.50
65 / 40
34.5 / 45
Tubular
2
110-E2
HVGO Trim Cooler
HVGO
Tempered Water
24.00
16.00
175.00
120.00
10.20
8.61
100 / 85
66 / 85
Tubular
3
110-E3
Steam/Air Preheater
Air
Steam
_
300.00
_
13.00
AIR COOLED EXCHANGERS DATA OF VACUUM DISTILLATION UNIT (U-110) Sr. No.
Service Tag No.
Design Temp. (°C)
Opr. Press. (Kg/cm²)
Opr. Temp. (°C)
Type
T/S
Design Press. (Kg/cm²)
LVGO
17.50
139.00
_
_
Finned Tube
HVGO Product
24.00
191.00
_
_
Finned Tube
Tempered Water
7.8 / FV
120 / 85
_
_
Finned Tube
Description
1
110-EA1
LVGO Cooler
3
110-EA3
HVGO Product Cooler
4
110-EA4
Tempered Water Cooler
SAH/- Heat Exchanger and fin fan cooler-Final
11/07/05
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EXCHANGERS DATA OF VISBREAKER UNIT (U-130) Sr. No. 1
Tag No.
S/S 130-E1 A/B/C//D
Frac. Btm./ Feed Exchanger Frac. Btm./ MP Steam generator
Design Press. (Kg/cm²)
Service
Description Vac. Residue
Fract. Btm.
Design Temp. (°C)
Opr. Press. (Kg/cm²)
Opr. Temp. (°C)
Type
T/S
S/S
T/S
S/S
T/S
S/S
T/S
S/S
T/S
Frac. Btm.
62.36
41.57
344.00
371.00
50.40
19.28
232 / 315
343 / 289
Tubular
BFW & MP Steam
24.18
16.12 / FV
318.00
224 / 196
16.20
14.18
290 / 224
196 / 196
Tubular
2
130-E3A/B
3
130-E4
Vis. Btm./ LP Steam generator
Vis. Btm.
BFW & LP Steam
24.18
16.12 / FV
289.00
193 / 165
9.75
6.88
224 /193
165 / 165
Tubular
4
130-E5
Vis. Btm./ BFW Preheat Exchanger
Vis. Btm.
BFW
52.00
78.00
221.00
197.00
8.44
59.20
193 / 175
121 / 168
Tubular
5
130-E6
Fract. O/H Trim Condenser
Fract. O/H Vapors
Cooling Water
7.18
7.00
120.00
120.00
4.43
4.50
65 / 49
34.5 / 45
Tubular
6
130-E7
Gas Oil P-A/ MP Steam Generator
Gas Oil P-A & Quench
BFW & MP Steam
16.73
15.94 / FV
289.00
224 / 100
13.29
14.18
260 / 224
196 / 196
Tubular
7
130-E8
Combustion Air Heating Coil
Combustion Air
MP Steam
_
13.00
_
300.00
_
_
_
_
_
AIR COOLED EXCHANGERS DATA OF VISBREAKER UNIT (U-130) Sr. No.
Tag No.
Description
1
130-EA1
Gas Oil Quench Cooler
2
130-EA2
Fract. O/H Condenser
SAH/- Heat Exchanger and fin fan cooler-Final
Service T/S
Design Press. (Kg/cm²)
Design Temp. (°C)
Opr. Press. (Kg/cm²)
Opr. Temp. (°C)
Gas Oil
16.73
252.00
_
_
Fined Tube
Fract. O/H
7.18
180.00
_
_
Fined Tube
11/07/05
Type
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EXCHANGERS DATA OF GAS CONCENTRATION UNIT (U-411) Sr. No.
Tag No.
Design Press. (Kg/cm²)
Service
Description S/S
T/S
S/S
T/S
Design Temp. (°C) S/S
T/S
Opr. Press. (Kg/cm²) S/S
T/S
1
411-E1
Compressor Suction Cooler
Feed Gases
Cooling Water
5.10
7.00
120.00
120.00
3.21
4.50
2
411-E2
Inter Stage Cooler
Feed Gases
Cooling Water
8.90
7.00
120.00
120.00
7.06
4.50
3
411E3A/B
High Pressure Cooler
Gas & Liquid Feed
Cooling Water
17.80
11.90
120.00
120.00
15.70
4.50
4
411-E4
Lean Oil
Cooling Water
22.50
15.00
120.00
120.00
18.60
4.50
5
411-E5
Rich Oil
Lean Oil
14.70
22.00
170.00
263.00
3.73
6.63
6
411-E6
Sponge Abs. Lean Oil Trim Cooler
Lean Oil
Cooling Water
22.00
14.70
173.00
120.00
5.82
4.50
7
411-E7
Stripper Feed Exchanger
Naphtha/LPG mix.
21.00
14.00
120.00
183.00
19.00
11.00
8
411-E8
Stripper Reboiler Exchanger
Naphtha & LPG
19.00
14.00
173.00
220.00
16.70
11.90
9
411-E9
Stripper Reboiler
Naphtha & LPG
MP Steam
19.00
13 / FV
200.00
300 / FV
16.70
10.20
Debutanizer Btm. Cooler
Naphtha
Cooling Water
13.40
9.00
162.00
120.00
7.90
4.50
Debutanizer Reboiler
Naphtha
Cir. Diesel
18.40
20.40
231.00
291.00
11.90
7.40
Debutanizer Net O/H Cooler
LPG
Cooling Water
31.00
21.00
120.00
120.00
23.80
4.50
10 11
12
411E10A/B 411E11 411E12
Primary Absorber Inter Cooler Sponge Abs. Lean Oil/ Rich Oil Exchanger
SAH/- Heat Exchanger and fin fan cooler-Final
Debutanizer Btm. Debutanizer Btm.
11/07/05
Opr. Temp. (°C) S/S
T/S
87 / 41 59 / 39
34.5 / 41 34.5 / 41
59 / 39
34.5 / 41
47 / 39 55 / 142
34.5 / 39 232 / 146
65 / 39 40 / 60 132 / 142 142 / 164 128 / 39.5 186 / 195
34.5 / 39 149 / 128 186 / 149 184 / 184 34.5 / 45 263 / 224
57 / 38
34.5 / 38
Type
Tubular Tubular Tubular Tubular Tubular Tubular Tubular Tubular Tubular Tubular Tubular
Tubular
DOC. #: PAR-MCR-PROCESS/ Training Manual-01 Issue # 01 Issue Date:
PARCO-Mid Country Refinery PROCESS TRAINING MANUAL
HEAT EXCHANGERS & FIN FAN COOLERS
Page 26 of 38
01-07-2005
AIR COOLED EXCHANGERS DATA OF GAS CONCENTRATION UNIT (U-411) Sr. No. 1 2
Tag No. 411EA1 411EA2
Description Sponge Abs. Lean Oil Cooler Debutanizer Condenser
SAH/- Heat Exchanger and fin fan cooler-Final
T/S
Design Press. (Kg/cm²)
Design Temp. (°C)
Opr. Press. (Kg/cm²)
Opr. Temp. (°C)
Lean Oil
22.00
173.00
4.99
_
Debutanizer O/H liquid
13.40
120.00
10.70
_
Service
11/07/05
Type Finned Tube Finned Tube
DOC. #: PAR-MCR-PROCESS/ Training Manual-01 Issue # 01 Issue Date:
PARCO-Mid Country Refinery PROCESS TRAINING MANUAL
HEAT EXCHANGERS & FIN FAN COOLERS
Page 27 of 38
01-07-2005
EXCHANGERS DATA OF DIESEL MAX UNIT (U-284) Sr. No. 1
Tag No.
Service
Description S/S
284E1A1-B1 284-E2
Reactor Effluent/Combined Feed Exchanger Reactor Effluent/Recycle Gas Exchanger Reactor Effluent/Separator Liquid Exchanger
2
284-E3
3
284-E4
Recycle Gas Cooler
4
284-E5
Kerosene Product Trim Cooler
5
284-E6
Kerosene Stripper Reboiler
6
284-E7
7
284-E8
8
284-E9
9
284-E10
Stripper Trim Condenser Diesel Product Trim Cooler Stripper Bottoms/Kerosene Product Exchanger Stripper Bottoms/Diesel Product Exchanger
SAH/- Heat Exchanger and fin fan cooler-Final
T/S
Design Press. (Kg/cm²) S/S T/S
Design Temp. (°C) S/S T/S
Opr. Press. (Kg/cm²) S/S T/S
Opr. Temp. (°C) S/S T/S
Type
H.C (Combined Feed)
H.C (Reactor Eff.)
105 / FV
83 / FV
435 / 177
454 / 177
89.30
75.00
347 / 379
403 / 380
Tubular
H.C (Reactor Eff.)
H2 (Hydrogen)
81 / FV
107 / FV
477 / 177
183 / 177
73.10
93.00
251 / 241
92 / 154
Tubular
54 / FV
80 / FV
191 / 177
269 / 177
9.79
72.30
59 / 163
238 / 177
Tubular
78 / FV
52.00
120 / 177
120.00
70.10
4.50
60 / 41
16.50
11.00
178.00
120.00
6.30
4.50
60 / 41
45.00
67.00
275.00
376.00
2.15
39.70
228 / 243
11.30
7.60
134.00
120.00
7.74
4.50
60 / 41
16.70
11.20
178.00
120.00
7.28
4.50
60 / 50
22.10
16.50
203.00
256.00
16.60
8.53
165 / 175
228 / 193
Tubular
22.10
16.70
225.00
318.00
16.20
12.60
175 / 197
290 / 203
Tubular
H.C (Sep. Liquid) Recycle Gas H2 Kerosene (H.C) Kerosene (Stripper Liq.) V-9 OVHD Gases+Vap. Diesel (H.C) H.C Stripper BTM H.C Stripper BTM
H.C (Reactor Eff.) Cooling Water Cooling Water H.C (V11BTM) Cooling Water Cooling Water Kero Product (H.C) Diesel Product (H.C)
11/07/05
34.5 / 41 34.5 / 41 348 / 321 34.5 / 41 34.5 / 45
Tubular Tubular Tubular Tubular Tubular
DOC. #: PAR-MCR-PROCESS/ Training Manual-01 Issue # 01 Issue Date:
PARCO-Mid Country Refinery PROCESS TRAINING MANUAL
HEAT EXCHANGERS & FIN FAN COOLERS
Page 28 of 38
10
284-E11
Stripper Bottoms/Diesel Pump around Exchanger
11
284-E12
Backwash Cooler
H.C Back Wash Oil
Diesel Pump around (H.C) Tempered Water
12
284-E13
Product Fractionator Bottoms MP Steam Generator
BFW & MP Steam
13
284E18A/B
Lean Amine Cooler
14
284-E50
15
22.10
14.80
259.00
344.00
15.70
5.89
197 / 231
316 / 247
Tubular
9.80
7.80
182.00
120.00
6.16
4.50
154 / 85
66 / 85
Tubular
PF BTM (H.C)
45 / FV
67.10
300 / 194
349.00
11.90
35.00
121 / 194
321 / 213
Tubular
Lean Amine
Cooling Water
27.50
18.40
120.00
120.00
16.10
4.50
61.43
34.5 / 45
Tubular
Distillate Pump around/MP Steam Generator
Distillate Pump around (H.C)
MP Steam Generator
15.30
15.5 / FV
290.00
225 / 195
12.50
14.00
260 / 212
194 / 194
Tubular
284-E52
Distillate Product/LP Steam Generator
BFW & LP Steam
7 / FV
10.50
260 / 156
260.00
4.70
8.33
121 / 156
230 / 169
Tubular
16
284E56A/B
Flash Fractionator Trim Condenser
8.00
7.00
145.00
120.00
5.63
4.50
60 / 41
34.5 / 45
Tubular
17
284-E59
Flash Fractionator Bottoms/MP Steam Generator
BFW & MP Steam
FF BTMs (H.C)
15.5 / FV
12.50
225 / 195
426.00
14.00
9.60
194 / 194
383 / 232
Tubular
18
284-E61
Distillate Product Trim Cooler
H.C Distillate
Cooling Water
10.50
7.00
169.00
120.00
SAH/- Heat Exchanger and fin fan cooler-Final
H.C Stripper BTM
01-07-2005
FF OVHD Vap.
Distillate Product (H.C) Cooling Water
11/07/05
Hair pin
DOC. #: PAR-MCR-PROCESS/ Training Manual-01 Issue # 01 Issue Date:
PARCO-Mid Country Refinery PROCESS TRAINING MANUAL
HEAT EXCHANGERS & FIN FAN COOLERS
Page 29 of 38
01-07-2005
AIR COOLED EXCHANGERS DATA OF DIESEL MAX UNIT (U-284) Opr. Press. (Kg/cm²)
Opr. Temp. (°C)
T/S
T/S
241
_
_
Finned Tube
11.3
192
_
_
Finned Tube
PF OVHD Vapors (H/C)
3.5
122
_
_
Finned Tube
Diesel Product (H/C)
16.7
231
_
_
Finned Tube
Kerosene Product (H/C)
11.2
223
_
_
Finned Tube
Kerosene Product (H/C)
16.5
221
_
_
Finned Tube
Product Fractionator Bottoms Cooler
P.F BTM (H/C)
67.1
241
_
_
Finned Tube
284-EA50
Distillate Product Cooler
Distillate (H/C)
10.5
230
_
_
Finned Tube
9
284-EA51
Flash Fractionator Condenser
FF OVHD Vapors (H/C)
8.0
170
_
_
Finned Tube
10
284-EA54
Distillate (H/C)
15.3
240
_
_
Finned Tube
11
284-EA55
FF BTM (H/C)
12.5
260
_
_
Finned Tube
Sr. No.
Tag No.
1
284-EA1
Product Condenser
2
284-EA2
3
Service
Design Press. (Kg/cm²)
Design Temp. (°C)
H/C / Wash Water/Recycle Gas
79.0
Stripper Condenser
Stripper OVHD Vapors/H2S/H2S (H/C)
284-EA3
Product Fractionator Condenser
4
284-EA4
Diesel Product Cooler
5
284-EA5
6
284-EA6
Kerosene Product Cooler
7
284-EA7
8
Description
T/S
Kerosene Pump Around Cooler
Distillate Pump Around Cooler Flash Fractionator Bottoms Cooler
SAH/- Heat Exchanger and fin fan cooler-Final
11/07/05
Type
DOC. #: PAR-MCR-PROCESS/ Training Manual-01 Issue # 01 Issue Date:
PARCO-Mid Country Refinery PROCESS TRAINING MANUAL
HEAT EXCHANGERS & FIN FAN COOLERS
Page 30 of 38
01-07-2005
EXCHANGERS DATA OF NAPHTHA HYDROTREATING UNIT (U-200) Sr. No.
Tag No.
1
200-E1A 200-E2
Service
Description S/S Combined Feed Exchanger Reactor No. 1 Effluent Cooler Products Trim Condenser Stripper Feed / Splitter Bottoms Exchanger Stripper Feed / Bottoms Exchanger Heavy Naphtha Trim Cooler Stripper Trim Condenser
T/S
Design Press. (Kg/cm²)
Design Temp. (°C)
Opr. Press. (Kg/cm²)
Opr. Temp. (°C)
S/S
T/S
S/S
T/S
S/S
T/S
S/S
T/S
Type
Combined Feed
Reactor Eff.
62.00
51.00
181.00
215.00
53.20
45.60
118.00
188.00
Tubular
Combined Feed
Reactor Eff.
60 / FV
52 / FV
357 / 330
406 / 378
50.90
46.90
294.00
378.00
Tubular
Reactor Eff.
CW
48 / FV
32.00
171 / 65
120.00
42.80
4.50
65.00
34.50
Tubular
Stripper Feed
Heavy Naph.
14.00
16.3 / FV
120.00
178 / 151
12.20
11.45
49.00
120.00
Tubular
Stripper Feed
Stripper Bottom
13.50
12.7 / FV
170.00
232 / 185
11.80
10.50
84.00
185.00
Tubular
Heavy Naph.
CW
16.3 / FV
10.90
120 / 65
120.00
9.56
4.50
65.00
34.50
Tubular
Stripper Off gases
CW
13.20
8.80
128.00
120.00
9.74
4.50
65.00
34.50
Tubular
12.70
47.5 / FV
237.00
426 / 252
10.50
41.10
185.00
371.00
Tubular
2
200-E3
3
200-E4
4
200-E5
5
200-E6
6
200-E7
7
200-E8
Stripper Reboiler
Stripper Bottom
HP Steam
8
200-E9
Splitter Trim Condenser
Light Naph.
CW
6.3 / FV
7.00
128 / 63
120.00
1.72
4.50
63.00
34.50
Tubular
9
200-E10
Splitter Reboiler No.1
Splitter Bottom
MP Steam
4.6 / FV
13 / FV
181 / 132
300 / 184
2.63
10.20
127.00
184.00
Tubular
SAH/- Heat Exchanger and fin fan cooler-Final
11/07/05
PARCO-Mid Country Refinery PROCESS TRAINING MANUAL
HEAT EXCHANGERS & FIN FAN COOLERS
DOC. #: PAR-MCR-PROCESS/ Training Manual-01 Issue # 01 Issue Date: Page 31 of 38
01-07-2005
AIR COOLED EXCHANGERS DATA OF NAPHTHA HYDROTREATING UNIT (U-200) Sr. No.
Tag No.
Description
Service T/S
Design Press. (Kg/cm²)
Design Temp. (°C)
Opr. Press. (Kg/cm²)
Opr. Temp. (°C)
T/S
T/S
Type
1
200-EA1
Product Condenser
Reactor Eff.
48.0
201
_
_
Finned
2
200-EA2
Stripper Condenser
Stripper Overhead
13.2
128
_
_
Finned
3
200-EA3
Heavy Naphtha Cooler
Heavy Naph.
16.3
120
_
_
Finned
SAH/- Heat Exchanger and fin fan cooler-Final
11/07/05
PARCO-Mid Country Refinery PROCESS TRAINING MANUAL
HEAT EXCHANGERS & FIN FAN COOLERS
DOC. #: PAR-MCR-PROCESS/ Training Manual-01 Issue # 01 Issue Date: Page 32 of 38
01-07-2005
EXCHANGERS DATA OF PLATFORMING UNIT (U-300) Sr. No.
Tag No.
S/S
1
300-E1
2
300E2A/B
3
300-E3
4
300-E4A
5
300-E5A
6
300-E6A
7
300-E7A
8
300E8A/B/C
9
300-E9
10
300-E10
11
300-E11
12
300-E16
Combined Feed Exchanger Product Trim Condenser Reactor Purge Exchanger Net Gas Trim Cooler Recontact Cooler No.1 Re-contact Cooler No.2 Re-contact Cooler No.3 Debutanizer Feed/Bottoms Exchanger Debutanizer Reboiler Debutanizer Condenser Debutanizer Bottoms Cooler Splitter Bypass Cooler
SAH/- Heat Exchanger and fin fan cooler-Final
Design Press. (Kg/cm²)
Service
Description
Reactor Effluent Recycle Gas Net Gas Recont. Liq. Net Gas Recont. Liq. Net Gas Recont. Liq. Net Gas Recontact Separator Liq. Debut. Bottom/Liq. Debut. OHVD Reformats
LPG
T/S
Cooling Water Reactor Effluent Cooling Water Cooling Water Cooling Water Cooling Water
Design Temp. (°C)
Opr. Press. (Kg/cm²)
Opr. Temp. (°C)
Type
S/S
T/S
S/S
T/S
S/S
T/S
S/S
T/S
4.7 / FV
7.00
120 / 65
120.00
2.74
4.50
65 / 41
34.5 / 41
Tubular
5.60
7.50
549.00
549.00
3.44
3.89
_
_
Hair Pin
4.90
4.50
120 / 62
120.00
4.90
4.50
62 / 41
11.90
120 / 52
120.00
15.90
4.50
52 / 41
30.30
120 / 55
120.00
41.50
4.50
55 / 41
71.00
120 / 56
120.00
96.70
4.50
56 / 41
17.8 / FV 45.4 / FV 106.5 / FV
34.5 41 34.5 41 34.5 41 34.5 41
/ / / /
Debutanizer Bottom Liq.
14.40
13.00
183.00
225.00
12.60
10.90
41 / 155
197 / 69
HP Steam
12.8 / FV
47.5 / FV
235 / 207
426 / 252
11.00
41.10
195 / 207
12.30
8.20
120.00
120.00
10.50
4.50
61 / 42
13.00
8.70
120.00
120.00
9.10
4.50
69 / 41
371 / 252 34.5 / 42 34.5 / 41
26.50
17.70
120.00
120.00
20.30
4.50
41 / 38
Cooling Water Cooling Water Cooling Water
11/07/05
34.5 / 37
Tubular Tubular Tubular Tubular Tubular Tubular Tubular Tubular
Tubular
PARCO-Mid Country Refinery PROCESS TRAINING MANUAL
HEAT EXCHANGERS & FIN FAN COOLERS
DOC. #: PAR-MCR-PROCESS/ Training Manual-01 Issue # 01 Issue Date: Page 33 of 38
01-07-2005
EXCHANGERS DATA FOR PLAT EXCHANGER (U-300) Sr. No. 1
Service Tag No.
Description Cold Side
Hot Side
Naphtha+H2
5.60
Hot Side 300-E1
Combined Feed Exchanger
Reactor Effluent
Design Press. (Kg/cm²)
Design Temp. (°C)
Opr. Press. (Kg/cm²)
Opr. Temp. (°C)
Type
Cold Side
Hot Side
Cold Side
Hot Side
Cold Side
Hot Side
Cold Side
7.40
549.00
5.10
3.47
5.18
_
_
Plate
Opr. Press. (Kg/cm²)
Opr. Temp. (°C)
Type
T/S
T/S
AIR COOLED EXCHANGERS DATA OF PLATFORMING UNIT (U-300) Sr. No.
Tag No.
1
300-EA1
Product Condenser
2
300-EA2
Net Gas Cooler
3
300-EA3
4
300-EA4
5
300-EA5
Description
Service
Design Press. (Kg/cm²)
Design Temp. (°C)
Reactor Effluent
5.0
120
_
_
Finned
Net Gas
7.4
120
_
_
Finned
Net Gas
18.0
145
_
_
Finned
Net Gas
45.6
141
_
_
Finned
Net Gas
106.7
142
_
_
Finned
T/S
First Stage Discharge Cooler Second Stage Discharge Cooler Third Stage Discharge Cooler
SAH/- Heat Exchanger and fin fan cooler-Final
11/07/05
PARCO-Mid Country Refinery PROCESS TRAINING MANUAL
HEAT EXCHANGERS & FIN FAN COOLERS
DOC. #: PAR-MCR-PROCESS/ Training Manual-01 Issue # 01 Issue Date: Page 34 of 38
01-07-2005
EXCHANGERS DATA OF CCR UNIT (U-312) Sr. No.
Design Press. (Kg/cm²)
Service Tag No.
Description S/S
T/S
Design Temp. (°C)
Opr. Press. (Kg/cm²)
Opr. Temp. (°C)
S/S
T/S
S/S
T/S
S/S
T/S
S/S
T/S
Type
1
312-E1
Reduction Gas Exchanger
Reduction Gas
Reduction Gas
13.80
13.80
4.20
234.00
6.30
12.00
_
_
Hair Pin
2
312-E2
Booster Gas Heater
MP Steam
Booster Gas
13.00
13.80
300.00
205.00
10.20
12.00
_
_
Hair Pin
3
312-E3
Caustic Cooler
Caustic
Cooling Water
12.30
8.20
120.00
120.00
6.80
4.50
43.00
34.50
Tubular
SAH/- Heat Exchanger and fin fan cooler-Final
11/07/05
DOC. #: PAR-MCR-PROCESS/ Training Manual-01 Issue # 01 Issue Date:
PARCO-Mid Country Refinery PROCESS TRAINING MANUAL
HEAT EXCHANGERS & FIN FAN COOLERS
Page 35 of 38
01-07-2005
EXCHANGERS DATA OF LPG MEROX UNIT (U-802) Sr. No.
Tag No.
Design Press. (Kg/cm²)
Service
Description
1
802-E1
Caustic Heater
2
802-E2
Lean Amine Trim Cooler
Design Temp. (°C)
Opr. Press. (Kg/cm²)
Hot Side
T/S
S/S
T/S
S/S
T/S
Caustic
Steam
20.6
30.9
260
120
27.50
18.40
120.00
120.00
Lean Amine
Cooling Water
S/S
15.10
T/S
Opr. Temp. (°C) S/S
Type
T/S
4.2
Hair Pin
3.80
Hair Pin
EXCHANGERS DATA OF AMINE TREATING UNIT (U-810) Sr. No.
Tag No.
Description S/S
1
810E2A/B
2
810-E3
3
810-E6 A/B/C
4
810-E7
5
810-E8
Amine Regenerator Reboiler Rich-Lean Amine Exchanger Sour Water Stripper Feed/Bottoms Exchanger Sour Water Stripper Reboiler Stripped Water Cooler
SAH/- Heat Exchanger and fin fan cooler-Final
Design Press. (Kg/cm²)
Service
Amine
T/S Steam
Design Temp. (°C)
Opr. Press. (Kg/cm²)
Opr. Temp. (°C)
Type
S/S
T/S
S/S
T/S
S/S
T/S
S/S
T/S
6 / FV
6/ FV
160 / 131
260 / 145
1.70
3.20
131 / 131
145 / 145
Tubular
Lean Amine
Rich Amine
7.60
11.30
160 /132
120.00
1.70
6.20
132 /101
56 /88
Tubular
Stripped Water
Sour Water
7.4 /FV
11.10
159 /130
136.00
1.80
7.80
130 /160
38 /107
Tubular
Sour Water
LP Steam
6 /FV
6 /FV
160 /146
260 / 146
1.80
3.20
130 / 130
145 / 145
Tubular
Stripped Water
Cooling Water
12.90
8.60
120.00
120.00
3.70
3.80
60 / 43
35 / 43
Tubular
11/07/05
PARCO-Mid Country Refinery PROCESS TRAINING MANUAL
HEAT EXCHANGERS & FIN FAN COOLERS 6
810-E9
Lean Amine Trim Cooler
Lean Amine
Cooling Water
DOC. #: PAR-MCR-PROCESS/ Training Manual-01 Issue # 01 Issue Date: Page 36 of 38
27.50
18.40
01-07-2005
120.00
120.00
13.50
3.80
61 / 50
35 / 45
Tubular
AIR COOLED EXCHANGERS DATA OF AMINE TREATING UNIT (U-810) Sr. No.
Tag No.
1
810-EA1
2
810-EA2
3
810-EA3
Description
Service
Circulating Sour Water Cooler
SAH/- Heat Exchanger and fin fan cooler-Final
Opr. Temp. (°C)
T/S
T/S
160
_
_
Finned
27.5
129
_
_
Finned
13.1
130
_
_
Finned
Design Temp. (°C)
Amine Regenerator Overhead
6.0
Lean Amine Circulating Sour Water
T/S Amine Regenerator Condenser Lean Amine Cooler
Opr. Press. (Kg/cm²)
Design Press. (Kg/cm²)
11/07/05
Type
PARCO-Mid Country Refinery PROCESS TRAINING MANUAL
HEAT EXCHANGERS & FIN FAN COOLERS
DOC. #: PAR-MCR-PROCESS/ Training Manual-01 Issue # 01 Issue Date: Page 37 of 38
01-07-2005
EXCHANGERS DATA OF SULFUR RECOVERY UNIT (U-820) Sr. No .
Tag No.
1
820-E2
2
820-E3
3
820-E4
4
820-E5
5
820-E6
6 7 8
820E51 820E55 820E56
No. 1 Condenser No.2 Condenser No.3 Condenser No.1 Reheater No. 2 Reheater SCOT Waste Heat Boiler Regenerator Reboiler Regenerator Ovhd. Condenser
Design Press. (Kg/cm²)
Service
Description S/S
T/S
S/S
T/S
BFW & Steam
WHB effluent
6 / FV
3.50
BFW & Steam
WHB effluent
6 / FV
3.50
BFW & Steam
WHB effluent
6 / FV
3.50
Reaction Gas
HP Steam
3.50
Reaction Gas
HP Steam
3.50
BFW & Steam
WHB effluent
MDEA (Amine) Amine & Water
49.7 / FV 49.7 / FV
6 / FV
3.50
LP Steam
4.5 / FV
6 / FV
Cooling Water
3.5 / FV
7.00
Design Temp. (°C) S/S
Opr. Press. (Kg/cm²)
T/S
S/S
T/S
320 / 185
4.00
0.58
343.00
4.00
0.45
343.00
4.00
0.34
275.00
426 / 258
0.54
44.20
275.00
426 / 258
0.42
44.20
343.00
4.00
0.23
260 / 145
1.52
3.20
120.00
1.24
3.80
260 / 152 260 / 152 260 / 152
260 / 152 157 / 132 149 / 149
Opr. Temp. (°C) S/S 115 / 152 115 / 152 115 / 152 185 / 230 170 / 210 115 / 152 132 / 132 120 / 61
Type
T/S 320 / 185
Tubular
300 / 170
Tubular
227 / 160
Tubular
258 / 258
Tubular
258 / 258
Tubular
310 / 170
Tubular
145 / 145
Tubular
34.5 / 45
Tubular
PLATE AND FRAME HEAT EXCHANGER OF SULFUR RECOVERY UNIT (U-820) Sr. No .
Tag No.
1
820E52
Service Description
Circulation Water Cooler
SAH/- Heat Exchanger and fin fan cooler-Final
Hot Side
Cold Side
Sour Water
Cooling Water
Design Press. (Kg/cm²) Hot Side 11.30
Cold Side 7.00
Design Temp. (°C) Hot Side
Cold Side
120.00
11/07/05
120.00
Opr. Press. (Kg/cm²) Hot Side 5.30
Cold Side 3.80
Opr. Temp. (°C) Hot Side 78 / 41
Type
Cold Side 34.5 / 45
PLT/FR