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Details of Air chiller

SN

DESCRIPTION

1 Fluid Name
2 Fluid QTY TOTAL
3 VAPOUR(AIR)
4 LIQUID(WATER
5 WATER
6 MOISTURE
7 NONCONDENSABLE
8 TEMP
9 SP GRAVITY
10 VISCOCITY
11 MOL WEIGHT VAPOUR
12 MOL WEIGHT NON CONDENSABLE
13 SPECIFIC HEAT
14 THERMAL CONDUCTIVITY
15 LATENT HEAT
16 INLET PR
17 VELOCITY
18 PR DROP ALLOW/CAL
19 FOULING RESISTANCE
20 HEAT EXCHANGED
21 DESIGN PR
22 TEST PR.
23 DESIGN TEMP.
24 TUBE TYPE
25 TUBE MATERIAL
26 NO TUBES
27 SIZE OF TUBE
28 LENGTH OF TUBE
28 MOC OF BAFFKES
29 BODY OF SHELL
30 NO BAFFLES

UOM

NM3/HR
NM3/HR
KG/HR
KG/HR
KG/HR
KG/HR
DEG C
KG/L
CP

KCAL/KG,DEG C
KCAL/M/HRM2 C
KCAL/KG@DEG C
KG/CM2G
M/SEC
KG/CM2G
HRM2DEGC/KCAL
(KCAL/HR)
KG/CM2G
KG/CM2G
DEG C
PAIN
COPPER
EA
INCH
MM

Shell
inlet

Tube
out let

Comp air 4.5 Kg/cm2


15000
APPROX-15000

45
0.0081AT AVG TEMP
.019AT AVG TEMP

inlet
Chilled water
?
?

17

18
28.92

9
1
1.3
18
18
1
.5AT AVG TEMP

4.5

4.5

0.1
0.0002

.7/0.22
0.0002

7
9
65

7
9
35

1/2"
SS 304
CS IS 1239

out let

12
1
1.2

TF Condenser Design

Design Basis

Description
TF hold up
Initial Temp
Final Temp
Density
Specific Heat
Heat Load

Unit
Ltrs
Deg C
Deg C
kg/Ltr
kcal/kg C
kcal

Value
800
200
50
0.83
0.53
52788

Platten Wt
Initial Temp
Final Temp
Specific Heat
Heat Load

kg
Deg C
Deg C
kcal/kg C
kcal

15000
150
50
0.12
180000

Total Heat Load


Cooling Time
Avg Cooling Rate

kcal
min
kcal/h

232788
20
698364

Cooling water Flow


Inlet Temp
Outlet Temp

m3/h
Deg C
Deg C

150
32
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
Process data
Medium
No of passes
Flow Rate

Unit

Shell Side

Tube Side

Thermic Fluid Cooling Water


1
2

Initial / Inlet Temp

m3/h
kg/h
Deg C

150
124500
200

150
149253
32

Final / Outlet Temp


Average Temp Diff for Tube Expn
Max operating Pressure
Pressure drop Allowed
Design Pressure
Design temp
Fouling factor

Deg C
Deg C
bar a
bar
bar g
Deg C
h m2 Deg C/kcal

50
150
5.0
0.50
7.0
150.0
0.0002

36.7
5
3.0
0.50
5.0
36.7
0.0002

Properties of fluid Temp

Deg C

125

32

Density at working pressure


Specific Heat
Thermal Conductivity
Viscosity
Prandtl No
Heat Exchanger Load

kg/m3
kcal/kg Deg C
kcal/h m Deg C
kgf-s/m2

830.0
0.530
0.108
4.49E-05
7.77
698364
812.1

995.0
1.000
0.528
7.82E-05
5.23
698364

Total Heat Load


LMTD
R Factor
S Factor
Correction factor from graph
Corrected LMTD
Heat Exchanger Geometry

kcal/h
deg C

698364

698364
65.89
32.04
0.03
0.96
63.6

Shell Size
Shell OD
Shell thickness
Shell ID
No of passes
Total No of tubes in shell
No of tubes per pass
Selected Tube size
Tube OD

Thk
Tube ID
C/s area
Tube arrangement
Pitch
Tube length

kcal/h
kW

inch
mm
mm
mm
N0
No
inch
mm
inch
mm
mm
m2
mm
ft / mm

Shell
Tube
14 inch Standard sch
355.6
9.53
337
1
2
200
100
5/8" OD x 16 G
5/8
15.88
0.065
1.65
12.57
0.000124
Triangular
19.8
4
1220

No of baffles
Baffle spacing
Bundle cross flow area

as

Equivalent dia
Heat Transfer Area provided
Heat Transfer Calculations
Mass velocity
Actual Velocity
Reynolds No
Re
Prandtl No
Pr
Nusselt No
Nu
Heat Trans coeff
h
Thermal conductivity of tube
Overall heat trans coeff
U
Area required
Area provided
Excess area provided

No
mm

6
174

m2
m
m2

0.012
0.0113

kg/m2 S
m/s

2949
3.55
75643
7.77
341.6
3269
35
1086
10.1
12.2
20

3339
3.4
54760
5.23
275.3
11557

75643

54760
0.05

kcal/h m2 C
kcal/h m C
kcal/h m2 C
m2
m2
% of reqd

Pressure Drop Calculations


Reynold's No
Hydraulic roughness
k mm
Friction factor
f
ft2/in2
Roughness factor
e
Resistance Coeff
shii
Velocity head
p7
Pressure Drop per pass
Psf
Pa
Pressure Drop in HE
Pa
Calculated Bar
Specified Bar
Pressure Drop Design is
Heat Transfer Design is

Approx tube expansion wrt to shell

0.0126
12.2

Safe

0.00144
0.028
2.75
5603
525.0
25122
25122
0.251
0.50
Safe
Safe

mm

15399
30797
0.31
0.50
Safe

-0.2

from fig 29
page 839 of kern

Heat Exchanger Geometry


TEMA Heat Exchange type
BEU
Shell Fluid In
U Tube Type Heat Exchanger

Tube Fluid In

1
2

Tube length

1220

mm

Tube Fluid Out


Shell Size 14 inch Standard sch
Tube Size 5/8" OD x 16 G
Tube OD
Thk
Total No of tubes
No of passes on tube side

15.88
1.65
200
2

No of passes on shell side

mm
mm

Tube Layout for 2 Pas

Total No of baffles
Baffle Pitch

6
174

mm

Heating surface provided

12.2

m2

6type1
90
11.9
10.1
2
6
0
1
Calculate

Shell Fluid out

10 inch sch 10
12 inch sch 10
14 inch sch 10
16 inch sch 10

4.62744119848427E-005

ube Layout for 2 Pass

0 inch sch 10
2 inch sch 10
4 inch sch 10
6 inch sch 10

Pipe OD
273
323.8
355.6
406.4

Pipe Thk
9.27
9.53
9.53
9.53

Pipe ID
254.46
304.74
336.54
387.34

No of Tubes
114
160
200
274

Selecetd after trials

Corrected Log Mean Temperature Differen


http://excelcalculations.blogspot.com
Parameters
Th1 (K)
Th2 (K)
Tc1 (K)
Tc2 (K)
Shell-Side

200
50
32
37
1

Results
Correction 0.964457
LMTD
65.89435
Corrected 63.5523

Intermediate Calculations
P
R
X

0.027863
32.04478
0.027863

re Difference

Heat Exchanger Mechanical Design

Design Code - TEMA


Heat Exchanger Type
C
Selected for moderate requirements of Commercial and General process applications.
TEMA clause RCB 1.12 & C 1.12
Ps
Design Pressure Shell Side
7
Bar g
116.3 psia
RCB 1.21
Pt
Design Pressure Tube Side
5
Bar g
87.2
psia
RCB 1.21
Design Temp Shell Side
Design Temp Tube Side
Average Operating Temp Shell Side
Average Operating Temp Tube Side
Temp Diff for Tube Thermal Expansion

150
Deg C
36.68095 Deg C
125.0 Deg C
34
Deg C
91
Deg C
from ASME section II part D
Shell Material
SA 106 Gr B
Allowable stress
Tube Sheet material SA 516 Gr 70
Allowable stress
Tube Material
SA 213 TP 304
Allowable stress
A ) Corrosion allowance as per clause RCB 1.52
Shell
Tube
Tube Sheet
External Covers
End Flanges

6/95 inch
0
inch
0.20 inch
6/95 inch
6/95 inch

1.6 mm
0.0 mm
5 mm
1.6 mm
1.6 mm

RCB 1.42
RCB 1.42

17150
20057
13909

Mpa
Mpa
Mpa

No corrosion allowance for SS tubes


Same as gasket groove when provided

B ) Tube Material and Size as per clause RCB 2.2


Material
SA 213 TP 304
Tube OD
5/ 8 inch
15.9 mm
Thk
0.065 inch
1.65 mm
Thickness provided is more than required as per Table RCB 2.21 so it is acceptable
C ) Tube Pattern as per Clause RCB 2.4
Triangular 30 deg as per Fig RCB 2.4
No 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 mm
Tube OD
15.9 mm
Ratio
1.25
Ratio is as per code requirement
E ) Minimum shell Thickness as per Clause RCB 3.13
Shell ID
13.25 inch
Minimum pipe thickness required

psi
psi
psi

Standard Schedule thickness

Thickness provided

0.38 inch

9.53 mm

Therefore the thickness selected for shell is acceptable


F ) Shell Cover thickness as per Clause RCB 3.2
Thickness required at least equal to shell thickness.
Provided thickness is 8 mm, more than shell thickness so acceptable.
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 mm
6.86 inch
For tube Ods less than 1 1/4 inch dia
max 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
Unsupported tube len

13.25 ich
6.86 inch

Table CB 4.41, baffle plate thickness require


1/ 8 inch
Provide thickness of 4 mm
J ) Maximum unsupported tube length by Table RCB 4.52

3.2 mm

For Tube OD
5/ 8 inch
Material SS 304
So Max unsupported tube length
52 inch
Actual unsupported length
6.9 inch
Since unsupported length is less design is acceptable.

Flow
Inlet nozzle

Fluid state
Fluid Flow Rate
Density
Shell side Inlet Nozzle size
Shell ID
Bundle Height
Clear height for flow
Flow area
Velocity head (rho v2)

Liquid
150.0 m3/h
830.0 kg/m3
150 mm
336.5 mm
260 mm
30.3 mm
0.014 m2

260

K ) Impingement Baffles and Erosion Protection as per RCB 4.6

7052.7 kg/m s2
4730.5 lb/ft s2
Since the value is not less than 1500, impingement baffle is required.

Clear height

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
Tube sheet thickness provided

24
mm
0.94
inch
Tube sheet thickness should be for maximum of the following three condiitons
1. Minimum tube sheet thickness T1 >
3/4 x Tube OD. =
11.9 mm

T =

2. Calculation as per pressure requirement for Bending


T = FG / 3 (P / .s ) 1/2
T inch
S psi
G inch

F
P psi

Clause C-7.11

Clause A.131

where

Effective tube sheet thickness


Allowable stress as per code
20057.18
Shell dia for fixed tube sheet

1-

0.907
(Pitch / Tube OD)2

For Triangular rotated tube pattern

0.420
1
for supported tube sheets like fixed
Larger of Ps or (Pt+PB)
for U tube with tube sheet welded to channel and extended as flange

Ps psi

116.3

Pt psi

87.2
PB is defined as
PB= (6.2M)/(F2G3)

M1 ibf-in
M0 ibf-in

inch

M is larger of M1 or M2 as per A.152

Moment under operating condition defined as M 0 in ASME code


As defined in Clause 2-6 of Mandatory Appendix 2 of ASME section VIII Div 1
is sum of MD, MT and MG

MD

HD.hD

MG

HG.hG

MT

HT.hT

M2 ibf-in

Moment under bolting condition defined as M0 in ASME code

299 psi

As decided in the calculations given below

Therefore T2 =

0.83 inch
21.1 mm
Required thickness is maximum of 2 conditins T1, T2 given above.
T=
21.1
mm
minimum thickness tube sheet required
Provided =
24
mm
Tube sheet thickness provided is acceptable
3.1

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

7 bar g
113.784 psi

Shell side design pressure

1 - N (do / G)2

fs
=
N
do
G
J

Do
ts

0.555
Where
200 No of tubes in the shell
5/ 8 inch
Tube outside dia
13.25 inch
Shell inside dia
Differential expansion factor
As defined in RCB 1.161
= {(1 + (pi(Do - ts)ts. Es)) / (Sj. L)} -1
=
1
for shells without expansion joints
Differential expansion factor
= {Es.ts.(Do-ts)} / {Et. tt. N. (do-tt)}
= 0.554824
13.25 inch
5/16

inch

where
Shell outside dia
Shell wall thickness excluding corrosion allowance

Table D-10Es

1.77E+07 psi

Elastic modulus of shell at temp

Table D-10Et

1.77E+07 psi

Elastic modulus of tube at temp 98.02571 deg F

302 deg F

tt

0.065 inch
0.945 inch
6.86 inch

T
L
Fq

Tube wall thickness


Assumed tube sheet thickness
Tube length between tubesheet faces

0.25 + (F - 0.6) 300.ts.Es


G 3 1/4
KLE
T
6.70605
0r
1 higher of the two
6.70605
0.4.J.[1.5 K (1.5 + f s) ] - [( (1 - J)/ 2). (Dj2/G2 - 1)]
= Ps

Ps'

1 + J K Fq
Dj = G when no expansion joint is provided
25.5 psi
Alpha
Temp Diff
DL

8.5E-06 inch / Deg F


Coeff.of thermal expansion for tube from Table D-11
163.2 Deg F
For thermal expansion
=

Pd

9.5E-03
4 J . Es. Ts. (DL/Lt)
(Do - 3 ts) . (1 + J.K.Fq)
413.54 psi

PBS

156.5 psi
Same as shell side pressure when tube pressure is not acting.

Shell side design pressure is maximum of the following conditions


P
P

=
=

P
P
P
P

-194.0
25.5

psi
psi

( Ps' - Pd ) /2
Ps'
PBS

156.5

psi

( Ps' - Pd - PBS ) / 2

-272.3

psi

( PBS - Pd ) / 2

-128.5

psi

( Ps' - PBS )

-131.0

psi

Therefore P3.1 =
3.2

156.5

psi

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

85.3 psi
=

Pt

=
ft

Design pressure for tubes

1 + 0.4 J K (1.5 + ft)


1 + J K Fq
26.99
psi

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


Where
N
do
tt
G
J
K
Fq

0.72

200 No of tubes in the shell


5/ 8
inch Tube outside dia
0.065
13.24961
1
0.55
6.71

inch
inch

Tube thickness
Shell inside dia
Calculated as above
Calculated as above
Calculated as above

Pd

So

413.54

Calculated as above

PBt

=
psi
156.5
Tube side design pressure is maximum of the following conditions
Pt' + PBt + Pd
P
=
298.5
psi
2
Pt' + PBt

P
=
Therefore P3.2 =
3.3

psi

298.5

91.7

psi
psi

Design Pressure calculation as per clause RCB 7.165 - Differential Design pressure
Pt'
26.99
psi
Calculated as above
Ps'
25.5
PBt
156.5
Pd
PBs

413.54

156.5
Differential design pressure is maximum of the following conditions
Pt' - Ps' + PBt
P
=
158.0
psi

Therefore P3.3 =

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

-127.8

psi

PBs

156.5
psi

psi

158.0

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


P =
298.5
psi
M ) Check for Tube Sheet thickness for Shear
T=

0.31 DL

Clause RCB .133

(1-do/Pitch)
S
P
298.5 psi
S
20057.18 psi
do
5/ 8 inch
Pitch
0.78125 inch
P/S
0.014883
1.6 (1 - do/Pitch)2 =
0.064
since P/S less than 1.6 (1 - do/Pitch)2 Shear will not control
N ) Shell Longitudinal Stresses as per RCB - 7.22
Ss
=
Cs (Do - ts) Ps
4 ts
Where

3092.5 psi
Cs
1
Do
13.24961 inch
ts
5/16 inch
Ps
298.5 psi
Shell thickness provided is safe

O ) Tube Longitudinal Stresses as per RCB - 7.23


Ct Fq Pt G2
St
=

4 N tt (do- tt)
3450.0 psi
Where
Ct
Fq
Pt
do
tt

1 Maximum value as per clause


6.71
85.3 psi
5/ 8 inch

0.065 inch
N
200
G
13.24961 inch
Tube thickness provided is safe
P ) Tube to Tube Sheet Joint Loads - Periphery of Bundle as per RCB - 7.25
Wl
= Fq Pt G2
=
394.5 lbs
4N
Fq
6.71
Pt
85.3 psi
do
5/ 8 inch
N
200
G
13.24961 inch
This load is taken by the soldered joint.
Joint thickness
tj
1 mm
Where

Shear Stress area at the joint asdo


= tj
0.077 inch2
Calculated stress on the joint
5103.6 psi
Sealing Material
Cupro Nickel
Allowable 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
Shell ID
G
Total force on tube shFs
No of tubes
N
Load per joint
Shear stress area
Shear Stress calculated
Allowable shear stress

Ps

7 Bar g
99.6 psi g
13.25 inch
13727.3 lbs
200
68.64 lbs
0.077 inch2
887.9 psi
11200.0 psi

As calculated above

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.

DESIGN CALCULATIONS
INCOMPLETE

118
138
95.7