DESIGN OF HEAT EXCHANGER

presented by:Satish yadav kailash srimangale Satish pawar

COMPANY PROFILE
THE COMPANY IS ENGAGED IN :-

ECONOMISERS (GILLED/ FINNED TUBES) TUBE BENDING ON CNC BENDING MACHINE , TURN KEY PROJECTS IN WASTE HEAT RECOVERY WHERE KSB PUMPS, KSB VALVES, CONTROL VALVES, HP & LP HEATERS

CLIENT PROFILE
ATRIA POWER CORPORATION LTD.
PROBLEM STATEMENT:The Solar Steam Generator system is used to recover the heat from Hot Thermic Fluid coming from solar field in the form of superheated steam.

SHELL AND TUBE HEAT EXCHANGER

Shell and Tube heat exchangers are most commonly used in heating or cooling process fluids and gases. Typically found in applications where a need to heat or cool large volumes exist; however small volume applications are also very common. Shell and tube exchangers come in many variations to meet process requirements in almost every industry or application. They deliver reliable heat transfer performance by utilizing a high turbulence and counter flow, making one or more passes. While one (1), two (2) and four (4) pass models are standard

ADVATAGES Less expensive as compared to Plate type coolers Can be used in systems with higher operating temperatures and pressures Pressure drop across a tube cooler is less Tube leaks are easily located and plugged since pressure test is comparatively easy Tubular coolers in refrigeration system can act as receiver also. Using sacrificial anodes protects the whole cooling system against corrosion Tube coolers may be preferred for lubricating oil cooling because of the pressure differential

DISADVANTAGES Heat transfer efficiency is less compared to plate type cooler Cleaning and maintenance is difficult since a tube cooler requires enough clearance at one end to remove the tube nest Capacity of tube cooler cannot be increased. Requires more space in comparison to plate coolers
APPLICATION Industrial Process HVAC Air Processing Compressor Cooling Chemical Petrochemical: Processing & Refining Power & Electrical Generation Metals and Mining Refrigeration Pulp & Paper One of the most common applications is the cooling of Hydraulic Fluid and oil in engines, transmissions and hydraulic power packs. With the right choice of materials they can also be used to cool or heat other mediums, such as swimming pool water or charge air.

DESIGN
HEAT EXCHANGER CONSISTS OF : SHELL Design DISH END Design TUBE Design FLANGE Design NOZZLE Design

SPECIFICATION
Type of Boiler Natural circulation shell and tube heat exchanger. HTF side data Name of HTF fluid - Therminol VP1 HTF flow - 90000 Kg/hr HTF pressure at inlet - 12 Kg/cm HTF inlet temperature - 375C-Superheater, 359C-Evaporator, 258C-Economiser HTF outlet temperature -359C-Superheater, 257C-Evaporator, 228C-Economiser HTF max. pressure drop across the equipments - <4 Kg/cm

 Water/Steam side data Steam flow at super heater Steam pressure at super heater outlet Steam temp. at super heater Feed water flow at Economiser Feed water pressure at Economiser inlet Feed water temp. at Economiser Blow down loss

11700 Kg/hr 35 Kg/cm at 355 C at outlet 12099.6 Kg/hr 39 Kg/cm at 130 C at inlet 400 kg/hr

 Design codes Pressure parts Structural design Non pressure parts Equipments (I) Pvt. Ltd. Inspection Stage wise and final inspection Power Equipments (I) Pvt. Ltd. Final dispatch inspection required by the purchaser

IBR and TEMA R IS 800 As per Esteem Power

IBR and as per Esteem Purchase or third party if

MATERIAL OF CONSTRUCTION
Tubes Tube sheets Shell Baffle plates Saddle support Flanges Pipes Structural Gasketsa Wound SS304For Steam + Water CAF SA 210 Gr. A1 / Equivalent SA 266 Gr. 2/4 / Equivalent SA 516 Gr. 70 SA 516 Gr. 70 IS 2062 Gr. B SA 105 / SA 516 Gr. 70 SA 106 Gr. B IS 2062 Gr. B For Thermic Fluid Spiral

TUBE THICKNESS CALCULATIONS AS PER IBR

AS PER CLAUSE NO 338 PROVE THAT TUBES THK AFTER TOLERENCES IS HIGHER THAN REQUIRMENT AS PER ABOVE CLAUSE. t = ( WP * D/ 2 * f + WP)+c WHERE WP WORKING DESIGN PRESSURE 25 Kg/cm or 2 355.5 psi D OUTSIDE DIA OF TUBE 19.05 mm or 0.75 inch T ACTUAL THICKNESS 3.25 mm or 0.128 inch % - ve MILL TOLERANCE 12.5 t (T- tolerence ) 2.844 mm or 0.112 inch f ALLOWABLE STRESS psi 1356 Kg/cm2 or 19285 psi C CORROSION ALLOWANCE 0.75 mm 0.03 inch Ph HYDROTEST PRESSURE 37.5 Kg/cm2 533.3 psi t = ((266.62514 / 38926.397 ) + 0.029528 ) = 0.036377 inch , 0.92398 mm t = 0.9239769 mm HENCE SELECTED 2.84375 mm THK IS OK

CHECK FOR MAX PRESSURE ALLOWABLE

PROVE THAT CALCULATED PRESSURE IS HIGHER THAN DESIGN PRESSURE. WP = ((2 * f * ( t - c ) )/ (D - t + c)) =(5679.1713 / 16.95625 WP = 334.93085 kg/cm2 334.93085 kg/cm2 is > THAN 25 kg/cm2 HENCE SAFE

SHELL INTERNAL PRESSURE CALCULATIONS AS PER IBR

AS PER CLAUSE NO 270 WP = ((2*f*E*(T - 0.03) )/ (D + T - 0.03 )) WHERE WP WORKING DESIGN PRESSURE f PERMISSIBLE STRESS E EFFICIENCY OF LIGAMENT 1 T THICKNESS OF SHELL PLATE D MAX. INTERNAL DIAMETER Ph HYDROTEST PRESSURE C CORROSION ALLOWANCE R INSIDE RADIUS WP =( 23664.675 / 25.639305 ) WP = 922.98427 psi OR 64.9075 Kg/cm2 WP = 64.907473 kg/cm2 is > THAN 42 kg/cm2

42 Kg/cm2 or 597.2 psi 1387 Kg/cm2 or 19723 psi

16 mm or 0.63 inch 636 mm or 25.04 inch 63 Kg/cm2 or 895.9 psi 0.762 mm or 0.03 inch 318 mm or 12.52 inch

HENCE SAFE

CHECK FOR MIN THK REQUIRED

PROVE THAT CALCULATED THK IS LESS THAN ACTUAL THK t = (((WP*R )/ ((f*E) - (0.5*WP) )) +C) =((7477.2607 / 19424.52) + 0.03) t = 0.4149393 inch or 10.53946 mm t = 10.539458 mm HENCE SELECTED 16 mm THK IS OK

CHANNEL INTERNAL PRESSURE CALCULATIONS AS PER IBR

AS PER CLAUSE NO 270 WP = ((2*f*E*(T - 0.03) ) / (D + T - 0.03 )) WHERE WP WORKING DESIGN PRESSURE f PERMISSIBLE STRESS E EFFICIENCY OF LIGAMENT 1 T THICKNESS OF SHELL PLATE D MAX. INTERNAL DIAMETER Ph HYDROTEST PRESSURE C CORROSION ALLOWANCE R INSIDE RADIUS

25 Kg/cm2 or 355.5 psi 1387 Kg/cm2 or 19723 psi 16 mm or 0.63 inch 636 mm or 25.04 inch 37.5 Kg/cm2 or 533.3 psi 0.762 mm or 0.03 inch 318 mm or 12.52 inch

WP = (23664.675 / 25.639305 ) WP = 922.98427 psi or 64.9075 Kg/cm2 WP = 64.907473 kg/cm2 is > THAN 25 kg/cm2 HENCE SAFE

CHECK FOR MIN THK REQUIRED

PROVE THAT CALCULATED THK IS LESS THAN ACTUAL THK t = ((( WP*R) / ((f*E) - (0.5*WP) )) + C ) =((4450.7504 / 19545.39 ) + 0.03) t = 0.2577136 inch OR 6.545925 mm t = 6.545925 mm HENCE SELECTED 16 mm THK IS OK

SEMIELLIPSOIDAL SHELL CAP INTERNAL PRESSURE CALCULATIONS AS PER IBR

AS PER CLAUSE NO 278 WP = (2*f(T-C) / D*K ) WHERE WP WORKING DESIGN PRESSURE f PERMISSIBLE STRESS T THICKNESS OF DISH END PLATE D OUTSIDE DIAMETER Ph HYDROTEST PRESSURE C CORROSION ALLOWANCE K K FACTOR FROM FIG. 23D WP = (20189.052 / 26.503951 ) WP =761.73743 psi OR 53.568 Kg/cm2 WP = 53.568033 kg/cm2 is > THAN 42 kg/cm2

42 Kg/cm2 or 597.2 psi 1387 Kg/cm2 or 19723 psi 16 mm or 0.63 inch 660 mm or 25.98 inch 63 Kg/cm2 or 895.9 psi 3 mm or 0.118 inch 1.02

HENCE SAFE

CHECK FOR MIN THK REQUIRED

PROVE THAT CALCULATED THK IS LESS THAN ACTUAL THK t = ((WP*D*K / 2*f ) + C ) = ((15829.22 / 39446.28 ) + 0.11811 ) t = 0.5193958 inch or 13.19265 mm t = 13.192653 mm HENCE SELECTED 16 mm THK IS OK

TUBESHEET THICKNESS CALCULATIONS AS PER IBR

AS PER RCB 7.133 TEMA PROVE THAT TUBESHEET THK IS HIGHER THAN REQUIRMENT AS PER ABOVE CLAUSE. TUBESHEET FORMULA FOR SHEAR t = ((0.31*DL*WP ) / (1 - DO/PITCH)*S ) WHERE WP WORKING DESIGN PRESSURE 25 Kg/cm or 2 355.5 psi DL = 4A/C EQUIVALENT DIA OF TUBE CENTER LIMIT PERIMETER 1696 mm or 66.76 inch T ACTUAL THICKNESS 115 mm or 4.528 inch Ph HYDROTEST PRESSURE 37.5 Kg/cm or 2 533.3 psi C PERIMETER OF TUBE LAYOUT MEASURED IN INCREMENT OF ONE TUBE PITCH FRM CENTER TO CENTER OF OUTERMOST TUBES 540 mm or 21.26 inch S CODE ALLOWABLE STRESS psi 1387 Kg/cm or 2 19723 psi A TOTAL AREA ENCLOSED BY PERIMETER C 2E+05 mm2 or 9012 inch2 P PITCH (TUBE CENTER TO CENTER DISTANCE) 30 mm or 1.181 inch Do OUTSIDE DIA OF TUBE 19.05 mm or 0.75 inch t = (7356.8385 / 7198.9461 ) t = 1.0219327 inch or 25.95709 mm t = 25.957091 mm HENCE SELECTED 115 mm THK IS OK AS PER ABOVE CLAUSE SHEAR WIL NOT CONTROL WHEN: P <1.6 (1- Do/PITCH)2 S 0.02 IS < THAN 0.21316 HENCE SAFE

PROVE THAT TUBESHEET THK IS HIGHER THAN REQUIRMENT AS PER ABOVE CLAUSE
AS PER RCB 7.132 TEMA TUBESHEET FORMULA FOR BENDING t = (FG*[W P / *S ]^(1/2) )/ 3 WHERE WP WORKING TUBE SIDE PRESSURE F PARAMETER FOR UNSUPPORTED TUBESHEET T ACTUAL THICKNESS Ph HYDROTEST PRESSURE G PARAMETER FOR FIXED TUBESHEET WHICH IS SAME AS INSIDE SHELL DIA. d TUBE DIAMETER PITCH BETWEEN TUBES S CODE ALLOWABLE STRESS psi 1 - 0.907 FOR TRIANGULAR (P/d)2 PATTERN t = 1.7366325 = 1.7366325 inch or 44.11 mm t = 44.11 mm HENCE SELECTED 115 mm THK IS OK

25 Kg/cm2 or 355.5 psi 1.25 115 mm or 4.528 inch 37.5 Kg/cm or 2 533.3 psi 628 mm or 24.72 inch 19.05 mm or 0.75 inch 30 mm or 1.181 inch 1387 Kg/cm or 2 19723 psi 0.634

NOZZLE INTERNAL PRESSURE CALCULATIONS AS PER IBR

AS PER CLAUSE NO 270 WP = (2*f*E*(T - 0.03))/ (D + T - 0.03 ) CACULATION FOR N1 & N2 WHERE WP WORKING DESIGN PRESSURE 25 Kg/cm2 355.5 psi f PERMISSIBLE STRESS 1203 Kg/cm2 17110 psi E EFFICIENCY OF LIGAMENT 1 T THICKNESS OF NOZZLE (SCH 80) 10.97 mm 0.432 inch D MAX. INTERNAL DIAMETER 146.4 mm 5.762 inch Ph HYDROTEST PRESSURE 37.5 Kg/cm2 533.3 psi C CORROSION ALLOWANCE 0.762 mm 0.03 inch R INSIDE RADIUS 73.18 mm 2.881 inch WP = (13753.077 /6.1640978 ) WP = 2231.1581 psi or 156.903 Kg/cm2 WP = 156.90282 Kg/cm2 is > THAN 25 Kg/cm2 HENCE SAFE CHECK FOR MIN THK REQUIRED PROVE THAT CALCULATED THK IS LESS THAN ACTUAL THK t = (WP*R /((f*E) - (0.5*WP))) + C = (1024.2324 /16932.749) + 0.03 t = 0.0904883 inch or 2.298402 mm t = 2.2984021 mm HENCE SELECTED 10.97 mm THK IS OK

NOZZLE INTERNAL PRESSURE CALCULATIONS (SHELL SIDE) AS PER IBR

AS PER CLAUSE NO 270 WP = (2*f*E*(T - 0.03) )/( D + T - 0.03 ) CACULATION FOR N3,N4 WHERE WP WORKING DESIGN PRESSURE f PERMISSIBLE STRESS E EFFICIENCY OF LIGAMENT 1 T THICKNESS OF NOZZLE (SCH. 80) D MAX. INTERNAL DIAMETER Ph HYDROTEST PRESSURE C CORROSION ALLOWANCE R INSIDE RADIUS WP = (8417.8319 / 2.5680329 ) WP =3277.9299 psi or 230.515 Kg/cm2 WP = 230.52 Kg/cm2 is > THAN 42 Kg/cm2 HENCE SAFE CHEAK FOR MIN THK REQUIRED t = (((WP*R)/ ((f*E) - (0.5*WP) )) + C ) t=( (693.41012 /16811.879 ) + 0.03) t = 0.0712453 inch or 1.80963 mm t = 1.8096297 mm HENCE SELECTED 7.01 mm THK IS OK

42 Kg/cm2 597.2 psi 1203 Kg/cm2 17110 psi 7.01 mm 0.276 inch 58.98 mm 2.322 inch 63 Kg/cm2 895.9 psi 0.762 mm 0.03 inch 29.49 mm 1.161 inch

NOZZLE INTERNAL PRESSURE CALCULATIONS (SHELL SIDE) AS PER IBR

AS PER CLAUSE NO 270 WP = (2*f*E*(T - 0.03))/ (D + T - 0.03 ) CACULATION FOR N5 & N6 WHERE WP WORKING DESIGN PRESSURE f PERMISSIBLE STRESS E EFFICIENCY OF LIGAMENT 1 T THICKNESS OF NOZZLE (SCH. 80) D MAX. INTERNAL DIAMETER Ph HYDROTEST PRESSURE C CORROSION ALLOWANCE R INSIDE RADIUS WP = (6437.3242 / 2.1259067) WP= 3028.0371 psi or 212.942 Kg/cm2 WP = 212.94 Kg/cm2 is > THAN 42 Kg/cm2 HENCE SAFE CHEAK FOR MIN THK REQUIRED t = ((WP*R /(f*E) - (0.5*WP)) + C ) = ((578.66474 /16811.879 ) + 0.03 ) t = 0.06442 inch or 1.636268 mm t = 1.6362682 mm HENCE SELECTED 5.54 mm THK IS OK

42 Kg/cm or 2 597.2 psi 1203 Kg/cm or 2 17110 psi 5.54 mm or 0.218 inch 49.22 mm or 1.938 inch 63 Kg/cm2 or 895.9 psi 0.762 mm or 0.03 inch 24.61 mm or 0.969 inch

NOZZLE INTERNAL PRESSURE CALCULATIONS (CHANNEL SIDE) AS PER IBR

AS PER CLAUSE NO 270 WP = (2*f*E*(T - 0.03))/ (D + T - 0.03 ) CACULATION FOR N7 & N8 WHERE WP WORKING DESIGN PRESSURE 25 Kg/cm or 2 355.5 psi f PERMISSIBLE STRESS 1203 Kg/cm or 2 17110 psi E EFFICIENCY OF LIGAMENT 1 T THICKNESS OF NOZZLE (SCH. 80) 5.54 mm or 0.218 inch D MAX. INTERNAL DIAMETER 49.22 mm or 1.938 inch Ph HYDROTEST PRESSURE 37.5 Kg/cm or 2 533.3 psi C CORROSION ALLOWANCE 0.762 mm or 0.03 inch R INSIDE RADIUS 24.61 mm or 0.969 inch WP = (6437.3242 /2.1259067 ) WP =3028.0371 psi or 212.942 Kg/cm2 WP = 212.94 Kg/cm2 is > THAN 25 Kg/cm2 HENCE SAFE CHEAK FOR MIN THK REQUIRED t = ( (WP*R /(f*E) - (0.5*WP)) + C) =(344.4433 /16932.749 ) + 0.03 t = 0.0503419 inch or 1.278683 mm t = 1.2786832 mm HENCE SELECTED 5.54 mm THK IS OK

FLANGE SELECTION AS PER IBR

FROM ANSI B16.5 (PIPE FLANGE & FLANGE FITTING) FOR NOZZLE N1 & N2 OF MATERIAL SA 105 (MAT. GROUP 1.1) TYPE CLASS 300 I S SELECTED UNDER TYPE CLASS 300 FOR MAT. GROUP 1.1 ALLOWABLE WORKING PRESSURE IS 505 psig AT DESIGN TEMPERATURE 750F WHICH IS GREATER THAN WORKING PRESSURE 355.57 psig HENCE SAFE FOR NOZZLE N3 & N4 OF MATERIAL SA 105 (MAT. GROUP 1.1) TYPE CLASS 600 IS SELECTED. UNDER TYPE CLASS 600 FOR MAT. GROUP 1.1 ALLOWABLE WORKING PRESSURE IS 1095 psig AT DESIGN TEMPERATURE 600F WHICH IS GREATER THAN WORKING PRESSURE 597.36 psig HENCE SAFE