Details of Air chiller

SN DESCRIPTION UOM

1 Fluid Name2 Fluid QTY TOTAL NM3/HR3 VAPOUR(AIR) NM3/HR4 LIQUID(WATER KG/HR5 WATER KG/HR6 MOISTURE KG/HR7 NONCONDENSABLE KG/HR8 TEMP DEG C9 SP GRAVITY KG/L

10 VISCOCITY CP11 MOL WEIGHT VAPOUR12 MOL WEIGHT NON CONDENSABLE13 SPECIFIC HEAT KCAL/KG,DEG C14 THERMAL CONDUCTIVITY KCAL/M/HRM2 C15 LATENT HEAT KCAL/KG@DEG C16 INLET PR KG/CM2G17 VELOCITY M/SEC18 PR DROP ALLOW/CAL KG/CM2G19 FOULING RESISTANCE HRM2DEGC/KCAL20 HEAT EXCHANGED (KCAL/HR)21 DESIGN PR KG/CM2G22 TEST PR. KG/CM2G23 DESIGN TEMP. DEG C24 TUBE TYPE PAIN25 TUBE MATERIAL COPPER26 NO TUBES EA27 SIZE OF TUBE INCH28 LENGTH OF TUBE MM28 MOC OF BAFFKES 29 BODY OF SHELL 30 NO BAFFLES

Shell Tubeinlet out let inlet out let

Comp air 4.5 Kg/cm2 Chilled water15000 ?

APPROX-15000 ?

45 17 9 120.0081AT AVG TEMP 1 1

.019AT AVG TEMP 1.3 1.218 18

28.92 181 1

.5AT AVG TEMP

4.5 4.5

0.1 .7/0.220.0002 0.0002

7 79 9

65 35

1/2"SS 304

CS IS 1239

TF Condenser Design Design Basis

Description Unit ValueTF hold up Ltrs 800Initial Temp Deg C 200Final Temp Deg C 50Density kg/Ltr 0.83Specific Heat kcal/kg C 0.53Heat Load kcal 52788

Platten Wt kg 15000Initial Temp Deg C 150Final Temp Deg C 50Specific Heat kcal/kg C 0.12Heat Load kcal 180000

Total Heat Load kcal 232788Cooling Time min 20Avg Cooling Rate kcal/h 698364

Cooling water Flow m3/h 150Inlet Temp Deg C 32Outlet Temp Deg C 36.8

Thermic Flow Rate m3/h 150

1. T.F. hold up apprx. in the system = 800- lts.( except condensor).2. T.F. temp. = 200 deg.C.3. Platten temp.= 150 deg.C.4. Platten temp. to be brought down = 50-60 deg.C.5. Cooling water ( from tower ) flow = 150 M3 / ?

Thermic Fluid Condenser for Platten Press

Description Unit Shell Side Tube SideProcess dataMedium Thermic Fluid Cooling WaterNo of passes 1 2Flow Rate

m3/h 150 150kg/h 124500 149253

Initial / Inlet Temp Deg C 200 32

Final / Outlet Temp Deg C 50 36.7Average Temp Diff for Tube Expn Deg C 150 5Max operating Pressure bar a 5.0 3.0Pressure drop Allowed bar 0.50 0.50Design Pressure bar g 7.0 5.0Design temp Deg C 150.0 36.7Fouling factor h m2 Deg C/kcal 0.0002 0.0002

Properties of fluid Temp Deg C 125 32

Density at working pressure kg/m3 830.0 995.0Specific Heat kcal/kg Deg C 0.530 1.000Thermal Conductivity kcal/h m Deg C 0.108 0.528Viscosity kgf-s/m2 4.49E-05 7.82E-05Prandtl No 7.77 5.23

Heat Exchanger Load kcal/h 698364 698364kW 812.1

Total Heat Load kcal/h 698364 698364LMTD deg C 65.89R Factor 32.04S Factor 0.03Correction factor from graph 0.96

Corrected LMTD 63.6Heat Exchanger Geometry

Shell TubeShell Size inch 14 inch Standard sch

Shell OD mm 355.6Shell thickness mm 9.53Shell ID mm 337

No of passes 1 2Total No of tubes in shell N0 200No of tubes per pass No 100Selected Tube size 5/8" OD x 16 G

Tube OD inch 5/8mm 15.88inch 0.065

Thk mm 1.65Tube ID mm 12.57C/s area m2 0.000124Tube arrangement TriangularPitch mm 19.8Tube length ft / mm 4 1220

No of baffles No 6Baffle spacing mm 174

m2 0.012Equivalent dia m 0.0113 0.0126Heat Transfer Area provided m2 12.2Heat Transfer CalculationsMass velocity kg/m2 S 2949 3339Actual Velocity m/s 3.55 3.4Reynolds No Re 75643 54760Prandtl No Pr 7.77 5.23Nusselt No Nu 341.6 275.3Heat Trans coeff h kcal/h m2 C 3269 11557Thermal conductivity of tube kcal/h m C 35Overall heat trans coeff U kcal/h m2 C 1086Area required m2 10.1Area provided m2 12.2Excess area provided % of reqd 20 Safe

Pressure Drop CalculationsReynold's No 75643 54760

mm 0.05Friction factor f ft2/in2 0.00144 from fig 29

0.028 page 839 of kern2.755603

Pressure Drop per pass Psf 525.0Pa 25122 15399

Pressure Drop in HE Pa 25122 30797Calculated Bar 0.251 0.31

Specified Bar 0.50 0.50Pressure Drop Design is Safe SafeHeat Transfer Design is Safe

Approx tube expansion wrt to shell mm -0.2

Bundle cross flow area as

Hydraulic roughness k

Roughness factor eResistance Coeff shiiVelocity head p7

\

Heat Exchanger Geometry

TEMA Heat Exchange type BEUShell Fluid In

Tube Fluid In U Tube Type Heat Exchanger

Tube length 1220 mm

Tube Fluid OutShell Size 14 inch Standard sch Shell Fluid out

Tube Size 5/8" OD x 16 G

Tube OD 15.88 mmThk 1.65 mm

Total No of tubes 200No of passes on tube side 2 Tube Layout for 2 Pass

No of passes on shell side 110 inch sch 10

Total No of baffles 6 12 inch sch 10Baffle Pitch 174 mm 14 inch sch 10

16 inch sch 10Heating surface provided 12.2 m2

1I

2

10.111.9906type162101 Calculate

4.62744119848427E-005

Tube Layout for 2 Pass

Pipe OD Pipe Thk Pipe ID No of Tubes10 inch sch 10 273 9.27 254.46 11412 inch sch 10 323.8 9.53 304.74 16014 inch sch 10 355.6 9.53 336.54 200 Selecetd after trials16 inch sch 10 406.4 9.53 387.34 274

Corrected Log Mean Temperature Difference

ParametersTh1 (K) 200Th2 (K) 50Tc1 (K) 32Tc2 (K) 37Shell-Side 1

ResultsCorrection 0.964457LMTD 65.89435Corrected 63.5523

Intermediate CalculationsP 0.027863R 32.04478X 0.027863

http://excelcalculations.blogspot.com

Corrected Log Mean Temperature Difference

Heat Exchanger Mechanical Design

Heat Exchanger Type CSelected for moderate requirements of Commercial and General process applications.

TEMA clause RCB 1.12 & C 1.12Design Pressure Shell Side 7 Bar g 116.3 psia RCB 1.21Design Pressure Tube Side 5 Bar g 87.2 psia RCB 1.21

Design Temp Shell Side 150 Deg C RCB 1.42Design Temp Tube Side 36.68095 Deg C RCB 1.42Average Operating Temp Shell Side 125.0 Deg CAverage Operating Temp Tube Side 34 Deg CTemp Diff for Tube Thermal Expansion 91 Deg C

from ASME section II part D Shell Material SA 106 Gr B Allowable stress 17150 psi MpaTube Sheet material SA 516 Gr 70 Allowable stress 20057 psi MpaTube Material SA 213 TP 304 Allowable stress 13909 psi MpaA ) Corrosion allowance as per clause RCB 1.52

Shell 6/95 inch 1.6 mmTube 0 inch 0.0 mm No corrosion allowance for SS tubesTube Sheet 0.20 inch 5 mm Same as gasket groove when providedExternal Covers 6/95 inch 1.6 mmEnd Flanges 6/95 inch 1.6 mm

B ) Tube Material and Size as per clause RCB 2.2

Material SA 213 TP 304Tube OD 5/ 8 inch 15.9 mmThk 0.065 inch 1.65 mmThickness provided is more than required as per Table RCB 2.21 so it is acceptableC ) Tube Pattern as per Clause RCB 2.4

Triangular 30 deg as per Fig RCB 2.4No shell side cleaning is reqd this pitch with p/d is acceptable.

D ) Tube Pitch as per Clause C 2.5

Minimum centre to centre distance required should be 1.25 times tube OD.

Pitch provided 19.84 mmTube OD 15.9 mmRatio 1.25Ratio is as per code requirement

E ) Minimum shell Thickness as per Clause RCB 3.13

Shell ID 13.25 inchMinimum pipe thickness required Standard Schedule thickness

Design Code - TEMA

PsPt

Thickness provided 0.38 inch 9.53 mm

Therefore the thickness selected for shell is acceptableF ) Shell Cover thickness as per Clause RCB 3.2

Thickness required at least equal to shell thickness.

G ) Transverse Baffles as per Clause RCB 4.1

25% segmental horizontal cut baffles are provided.This arrangement meets the code requirement as per Fig RCB 4.1

H ) Tube Holes size in Baffles as per clause RCB 4.2

Baffle pitch 174.2 mm6.86 inch

For tube Ods less than 1 1/4 inch diamax Tube hole size = Tube OD + 1/64" = 16.27 mm

Provide Tube Hole as mentioned here.I ) Thickness of Baffles as per clause RCB 4.4

Shell ID 13.25 ichUnsupported tube len 6.86 inch

Table CB 4.41, baffle plate thickness require 1/ 8 inch 3.2 mmProvide thickness of 4 mmJ ) Maximum unsupported tube length by Table RCB 4.52

For Tube OD 5/ 8 inchMaterial SS 304So Max unsupported tube length 52 inch FlowActual unsupported length 6.9 inch Inlet nozzleSince unsupported length is less design is acceptable.

K ) Impingement Baffles and Erosion Protection as per RCB 4.6 Clear height

Fluid state LiquidFluid Flow Rate 150.0 m3/hDensity 830.0 kg/m3

260

Shell side Inlet Nozzle size 150 mmShell ID 336.5 mmBundle Height 260 mmClear height for flow 30.3 mmFlow area 0.014 m2

7052.74730.5

Since the value is not less than 1500, impingement baffle is required.

Provided thickness is 8 mm, more than shell thickness so acceptable.

Velocity head (rho v2) kg/m s2

lb/ft s2

L ) Required effective Tube Sheet Thickness as per Clause RCB 7.1

Consider Blind Flange Dimension of class 150 flange for tube sheet as per ANSI B 16.5.

21 inch

1.38 inch

18.75 inchTube sheet thickness provided T = 24 mm

0.94 inchTube sheet thickness should be for maximum of the following three condiitons

3/4 x Tube OD. = 11.9 mm Clause C-7.11

Clause A.131

where

T inch Effective tube sheet thicknessS psi Allowable stress as per code

20057.18G inch Shell dia for fixed tube sheet

1 - 0.907 For Triangular rotated tube pattern

0.420F 1 for supported tube sheets like fixed

P psifor U tube with tube sheet welded to channel and extended as flange

psi 116.3psi 87.2

ibf-inibf-in As defined in Clause 2-6 of Mandatory Appendix 2 of ASME section VIII Div 1

1. Minimum tube sheet thickness T1 >

2. Calculation as per pressure requirement for Bending

T = FG / 3 (P / .s ) 1/2

(Pitch / Tube OD)2

Larger of Ps or (Pt+PB)

PsPt

PB is defined as PB= (6.2M)/(F2G3) M is larger of M1 or M2 as per A.152

M1 Moment under operating condition defined as M0 in ASME codeM0

is sum of MD, MT and MGMD HD.hDMG HG.hGMT HT.hT

ibf-in

= 299 psi As decided in the calculations given below

Therefore T2 = 0.83 inch21.1 mm

Required thickness is maximum of 2 conditins T1, T2 given above.T = 21.1 mm minimum thickness tube sheet required

Provided = 24 mmTube sheet thickness provided is acceptable

3.1 Design Pressure calculation as per clause RCB 7.163 - Shell side Pressure

Ps 7 bar g Shell side design pressure113.784 psi

fs= 0.555 Where

N 200 No of tubes in the shelldo 5/ 8 inch Tube outside diaG 13.25 inch Shell inside diaJ Differential expansion factor As defined in RCB 1.161

== 1 for shells without expansion joints

K Differential expansion factor== 0.554824 where

Do 13.25 inch Shell outside dia 5/16 inch Shell wall thickness excluding corrosion allowance

Table D-10 1.77E+07 psi Elastic modulus of shell at temp 302 deg FTable D-10 1.77E+07 psi Elastic modulus of tube at temp 98.02571 deg F

M2 Moment under bolting condition defined as M0 in ASME code

1 - N (do / G)2

{(1 + (pi(Do - ts)ts. Es)) / (Sj. L)} -1

{Es.ts.(Do-ts)} / {Et. tt. N. (do-tt)}

tsEsEt

0.065 inch Tube wall thicknessT 0.945 inch Assumed tube sheet thicknessL 6.86 inch Tube length between tubesheet faces

KLE T6.70605 0r 1 higher of the two6.70605

Ps' = Ps1 + J K Fq

Dj = G when no expansion joint is provided25.5 psi

Alpha 8.5E-06 inch / Deg F Coeff.of thermal expansion for tube from Table D-11Temp Diff 163.2 Deg F For thermal expansion

9.5E-03Pd

(Do - 3 ts) . (1 + J.K.Fq)413.54 psi

156.5 psiSame as shell side pressure when tube pressure is not acting.

Shell side design pressure is maximum of the following conditions

P = ( Ps' - Pd ) /2 -194.0 psiP = Ps' 25.5 psiP = 156.5 psiP = -272.3 psiP = -128.5 psiP = -131.0 psi

156.5 psi

3.2 Design Pressure calculation as per clause RCB 7.164 - Tube side pressure

Pt 85.3 psi Design pressure for tubes

Pt' = Pt 1 + J K Fq

= 26.99 psi

= 0.72WhereN 200 No of tubes in the shelldo 5/ 8 inch Tube outside dia

0.065 inch Tube thicknessG 13.24961 inch Shell inside diaJ 1 Calculated as aboveK 0.55 Calculated as above

6.71 Calculated as above

tt

Fq 0.25 + (F - 0.6) 300.ts.Es G 3 1/4

0.4.J.[1.5 K (1.5 + fs) ] - [( (1 - J)/ 2). (Dj2/G2 - 1)]

DL = 4 J . Es. Ts. (DL/Lt)

PBS

PBS( Ps' - Pd - PBS ) / 2( PBS - Pd ) / 2( Ps' - PBS )

Therefore P3.1 =

1 + 0.4 J K (1.5 + ft)

ft = 1 - N (do - 2tt / G)2

tt

Fq

Pd 413.54 psi Calculated as above

So = psi 156.5Tube side design pressure is maximum of the following conditionsP = 298.5 psi

2P = 91.7 psi

298.5 psi

3.3 Design Pressure calculation as per clause RCB 7.165 - Differential Design pressurePt' 26.99 psi Calculated as abovePs' 25.5

156.5Pd 413.54

156.5Differential design pressure is maximum of the following conditionsP = 158.0 psi

-127.8 psi156.5 psi

158.0 psi

P = 298.5 psiM ) Check for Tube Sheet thickness for Shear Clause RCB .133

T = (1-do/Pitch) S

P 298.5 psiS 20057.18 psido 5/ 8 inchPitch 0.78125 inchP/S 0.0148831.6 (1 - do/Pitch)2 = 0.064

since P/S less than 1.6 (1 - do/Pitch)2 Shear will not controlN ) Shell Longitudinal Stresses as per RCB - 7.22

3092.5 psiWhere Cs 1

Do 13.24961 inchts 5/16 inchPs 298.5 psiShell thickness provided is safe

O ) Tube Longitudinal Stresses as per RCB - 7.23St =

PBt

Pt' + PBt + Pd

Pt' + PBt Therefore P3.2 =

PBt

PBs

Pt' - Ps' + PBt

(Pt' - Ps' + PBt - Pd ) / 2PBs

Therefore P3.3 =

Thus P is maximum of P3.1, P3.2 and P3.3

0.31 DL P

Ss = Cs (Do - ts) Ps 4 ts

Ct Fq Pt G2

3450.0 psiWhere

1 Maximum value as per clauseFq 6.71Pt 85.3 psido 5/ 8 inch

0.065 inchN 200G 13.24961 inchTube thickness provided is safe

P ) Tube to Tube Sheet Joint Loads - Periphery of Bundle as per RCB - 7.25= 394.5 lbs

4 NWhere Fq 6.71

Pt 85.3 psido 5/ 8 inchN 200G 13.24961 inch

This load is taken by the soldered joint.1 mm

0.077Calculated stress on the joint

5103.6 psiSealing Material Cupro NickelAllowable stress for this material

fs 11200 psi

Since actual stress is less than allowable, joint is safe.

Q ) Tube to Tube Sheet Joint Loads - Due to shell side pressure

Shell Side Design Pressure Ps 7 Bar g99.6 psi g

Shell ID G 13.25 inchTotal force on tube shFs 13727.3 lbsNo of tubes N 200Load per joint 68.64 lbsShear stress area 0.077 inch2 As calculated aboveShear Stress calculated 887.9 psiAllowable shear stress 11200.0 psi

Since actual stress is less than allowable, soldered joint is safe.

Thus the design of heat exchanger is safe as it satisfies all strength calculations as per TEMA.

4 N tt (do- tt)

Ct

tt

W l = Fq Pt G2

Joint thickness tjShear Stress area at the joint as =do tj

inch2

11813895.7

DESIGN CALCULATIONS INCOMPLETE

DESIGN CALCULATIONS INCOMPLETE

Enquiry SheetDesign BasisThermal DesignLMTDTEMA Calculations