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Cairo Oil Refining Co.

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Subsidery of Egyotian Gen. Petroleum Corp. sII 2,InI 2q,I 2aqI oIm aJ
P.O. Box : Heliopolis 11757 Cairo A.R.E. 2q,I , qIqIy : .,.
Tel. : 202 - 2529821 (5 Lines) (a ) - : sqIs
Fax : 202 - 2529826 - : mIs
E-mail : corc2000@excite.com corc2000@excite.com : asmI q
Shell & Tube Heat Exchanger
DESIGN CALCULATIONS
Code : ASME Section VIII, Division 1, Edition 2001, Addenda 2002
& TEMA Class R, 7th. Edition 1988.
Code Stamp : U
Client : Amerya Petroleum Refining Co. (APRC)
Project : Design & Fabrication of Residue Cooler
Location : Alexandria, EGYPT
Item No. : E-323 A E-323 B E-514 C E-514 C
Serial No. : 7443-33-U-2008, 7443-33-U-2009, 7443-33-U-2010 & 7443-33-U-2011
Title : Heat Exchanger
Service : Residue Cooler
Type : AES
Job No. : 7443-33
Dwg. No. : 7443-33-1A Rev. : 1
Cooler capacity 1.910848 M
3
Weight of exchanger, empty (erection), W 4152.911 Kg
Weight of contents, Wc 764 Kg
Total weight of vessel and contents, Wt 4917 Kg
MAWP : Shell Side 284.776 PSIG 20.04826 Kg/CM
2
G
Tube Side Tube Side 71.7082 PSIG 5.04826 Kg/CM
2
G
Design Temp. : Shell Side 302
o
F 150
o
C
Tube Side 140
o
F 60
o
C
MDMT : Shell Side 29
o
F -2
o
C
Tube Side Tube Side 29
o
F -2
o
C
No. of saddles 2 Saddles
No. of anchor bolts per saddle 4 Bolts
Anchor bolts size 28 MM Dia.
By
Eng. Abdel Halim Galala
Design General Manager
Design Sector q,sI IJ
Page : 1 of 136 Sheet 1 of 2 Date : 11.4.2004
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 2 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 2
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
A. Title (cont.)
DESIGN CALCULATIONS
Code : ASME Section VIII, Division 1, Edition 2001, Addenda 2002
& TEMA Class R, 7th. Edition 1988.
Client : Amerya Petroleum Refining Co.
Project : Design & Fabrication of Residue Cooler
Location : Alexandria, EGYPT
Item No. : E-323 A E-323 B E-514 C E-514 C
Serial No. : 7443-33-U-2008, 7443-33-U-2009, 7443-33-U-2010 & 7443-33-U-2011
Title : Heat Exchanger
Service : Residue Cooler
Type : AES
Job No. : 7443-33
Dwg. No. : 7443-33-1A Rev. : 1
Notes.
1. The calculated thicknesses are the min. required, where the actual thicknesses shown
on drawings shall be equal or may be greater.
2. The greater thicknesses at drawings are taken into consideration while calaculating the
MDMT and additional stresses due to incresed weight of vessel.
3
2
1 Issued for approval 11.4.2004 11.4.2004 11.4.2004
A. Halim A.H. Galala A.H.G
0 Issued for comments 4.7.2003 4.7.2003 4.7.2003
Designed by Reviewed by Approved by
Rev. Description Date Date Date
Revision Table
Dwg. No. : 7443-33-1A Rev. : 1
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 3 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 1
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
B. Copyright.
Copyright 2002 by
CORC
A.H.Galala, the Design Manager, on behalf of
Cairo Oil Refining Co. (CORC)
All rights reserved.
1st. date of issue - J uly, 4th., 2003
No part of this document may be reproduced in any form, in
an electronic retrieveal system or any otherwise without the
prior written permission of the CORC/Designer.
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 4 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 1
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
C. Revision Description.
This page is a record of all revisions of the document, and the
following revision(s) has (have) been made to this document.
Sheet
Rev. Date No. Revision Description
0 4.7.2003 all Issued for comments
1 11.4.2004 all Issued for approval
2 16.1.2005 7 UG-22 : Abnormal pressures
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 5 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 2
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
D. Table of Contents.
Description Page
A. Title. Page : 1 of 136
B. Copyright. Page : 3 of 136
C. Revisions Description. Page : 4 of 136
D. Table of Contents. Page : 5 of 136
E. Applicable Loading Considered in Design. Page : 7 of 136
F. Impact Test Requirements. Page : 8 of 136
G. Standarad ASME B16.5 Flange Rating Class. Page : 8 of 136
H. Cylindrical Main Shell Thickness
1. Under Internal Pressureal (Pipe 20" NPS) Page : 9 of 136
2. Check of Main Shell Thickness for External Pressure (FV). Page : 10 of 136
I. Cylindrical Stationary Head-Channel.
1. Under Internal Pressure Page : 12 of 136
2. Check of Channel Thickness for External Pressure (Full Vacuum) Page : 13 of 136
J. Main Ellipsoidal Head Thickness
Under Internal Pressure. Page : 14 of 136
K. Max. Internal Working Pressure, MWP at New (cold) & Operating (corroded)
1. For Shell-Side : Page : 15 of 136
2. For Tube-Side : Page : 15 of 136
3. For Tubes : (Item 38) Page : 17 of 136
L. Check for External Pressure (Convex Side), (Tube Side Full Vacuum)
1. Ellipsoidal Head (Stationary Head-Bonnet NA) Page : 18 of 136
2. Channel Page : 19 of 136
3. Tubes Page : 20 of 136
M. Nozzle Neck Thicknesses & Nozzle Openings Compensation :
M1 S1 & S2 6" NPS 300# WNRF Sch. 80 10.9728 Page : 21 of 136
M2 T1 & T2 6" NPS 150# WNRF Sch. 80 10.9728 Page : 26 of 136
N. Main Shell Flange (item no. 4). E514FLG 5 Page : 36 of 136
N1. Main Shell Flanges (item no. 3). E514FLG 6 Page : 46 of 136
N2. Main Shell Flanges (item no. 12). E514FLG 7 Page : 56 of 136
O. Main Channel Flanges (items no. 18). E514FLG 9 Page : 66 of 136
P. Channel Cover (blind flange) (item no. 22). E514FLG 14 Page : 76 of 136
Q. Stationary Tubesheet (item no. 36). TUBSH514 4 Page : 82 of 136
Q1. Floating Tubesheet (item no. 37). TUBSH514 6 Page : 84 of 136
Q2. TEMA Pass Partition Plate Thickness Calculation (item nTUBSH514 7 Page : 86 of 136
Q3. Floating Head, Flange & Backing Ring (items no. 29, 30 E514FLG 15 Page : 87 of 136
File Sheet
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 6 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 2
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
D. Table of Contents (cont.)
Description Page
R. Design of Saddle Supports. Page : 99 of 136
S. Lowest MDMT Without Impact Test. Page : 106 of 136
T. Radiography. Page : 116 of 136
U. Hydrostatic Test Pressure. [UG-99(b)] [ Refer to Page : 116 of 136
V. Post Weld Heat Treatment (PWHT). Page : 116 of 136
W. Calculation of Exchanger Weight. Page : 117 of 136
X. Stresses in Vessel on Two Saddle Supports Using ZICK's Method. Page : 121 of 136
Y. Check for the Anchor Bolts Due to Seismic and Wind Loading. Page : 129 of 136
Check for the Existing Anchor Bolts Due to Seismic and Wind Loading. Page : 130 of 136
Z. Check for Bundle Pulling. Page : 131 of 136
Z1. Lifting Lugs Thickness Calculations. Page : 133 of 136
Z2. References. Page : 135 of 136
Z3. Notes. Page : 136 of 136
Figures Index.
Figure (1) Page : 36 of 136
Figure (2) Page : 46 of 136
Figure (3) Page : 56 of 136
Figure (4) Page : 66 of 136
Figure (5) Page : 76 of 136
Figure (6) Page : 87 of 136
Figure (7) Page : 91 of 136
Figure (8) Page : 100 of 136
Figure (9) Page : 100 of 136
Figure (10) Page : 104 of 136
Figure (11) Page : 122 of 136
Figure (12) Page : 123 of 136
Figure (13) Page : 124 of 136
Figure (14) Page : 124 of 136
Figure (15) Page : 128 of 136
Figure (16) Page : 129 of 136
Figure (17) Page : 129 of 136
Figure (18) Page : 131 of 136
Figure (19) Page : 131 of 136
Figure (20) Page : 132 of 136
Figure (21) Page : 133 of 136
Figure (22) Page : 134 of 136
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 7 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 1
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 2
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
E. Applicable Loading Considered in Design. [UG-22 & UG-98]
I. By considering UG-22 :
1. The loadings to be considered in design of exchanger shall include the following :
a. Internal & external design pressure (see item II below).
b. Weight of the vessel and contents under test conditions.
c. Attachment of vessel supports such as lifting lugs and saddles.
2. No expected effect for superimposed static reactions such as piping.
There is no attached equipment such as motors, machinery, other vessels,
and lining. and insulation.
3. The effect of the following loadings is considered negligible and/or not applicable :
a. Cyclic and dynamic reactions due to pressure for thermal variations.
b. Snow reactions.
c. Impact reactions due to fluid chock.
d. Temperature gradients and differential thermal expansion.
e. Abnormal pressures, such as those caused by deflagration.
II. By considering UG-21 & UG-98 :
The max. allowable working pressure for a vessel part is the max.internal
pressure at the highest point of vessel (i.e. including the static head theron).
Since the exchanger is intended to be erected horizontaly, the static head
equals almost the ID of the exchanger (dimension units of water).
Max. Operating Pressure, Shell side 241.5 PSIG 17 Kg/cm
2
G
Tube side 42.6 PSIG 3 Kg/cm
2
G
Internal design pressure, P (MAWP) Shell side 284.0909 PSIG 20 Kg/cm
2
G
Tube side 71.02273 PSIG 5 Kg/cm
2
G
External design pressure, Pex (Tube side) 15 PSIG 1.056 Kg/cm
2
G
Exchanger shell ID (fabricated from Pipe 24" NPS, Sch. 30), ID 19 INCH 482.6 MM
Water sp. gr. 1
Fluid sp. gr. 0.8
Max. hydrostatic head at internal bottom of vessel* 0.685511 PSIG 0.04826 Kg/cm
2
G
Max. internal pressure : Shell side 284.7764 PSIG 20.0483 Kg/cm
2
G
Tube side 71.70824 PSIG 5.04826 Kg/cm
2
G
* p
water
0.036127
lb/INCH
3
1000
Kg/M
3
Max. internal working pressure MAWP for calculation : Shell side 286 PSIG 20.0483 Kg/cm
2
G
Tube side 73 PSIG 5.04826 Kg/cm
2
G
External design pressure, Pe (at tube side) 15 PSIG 1.056 Kg/cm
2
G
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 8 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 1
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
F. Impact Test Requirements. [UG-22 & UG-98]
Impact test is not mandatory for the following pressure vessels materials at the specified MDMT :
I. Pressure Parts.
a. Main Exchanger Components : P-No. Group No. Curve
a. Shell, Main Shell : ASME SA 106 Grade B 1 1 B
Shell Cover Course
Channel : ASME SA516 Grade 70 1 1 D
b. Faormed Heads (cap) : ASME SA234 WPB 1 1 B
Floating Head (Spherical Sector) :
c. Nozzle Necks : ASMESA 106 Grade B 1 1 B
d. Standard Flanges : ASME SA105 1 2 B
Non Standard Shell Flanges : ASME SA266 Class 2 1 2 B
Non Standard Channel Flanges : ASME SA266 Class 2 1 2
Channel Cover (blind flange) : ASME SA266 Class 2 1 2
Floating Head Flange : ASME SA266 Class 2 1 2
Backing Ring Flange : ASME SA266 Class 2 1 2
e. Stationary Tubesheet : ASME SB171 C63000 1 1 B
Floatng Tubesheet : ASME SB171 C63000 1 1 B
f. Tubes : ASME SB111 C68700 1 2 B
g. Fittings : Half Couplings : ASME SA105
90 0 Elbows : ASME SA234 WPB
b. Stud Bolts & Nuts :
i. Stud Bolts : ASME SA193 Grade B7 UNS No. G41400 [Size <2-1/2"]
j. Nuts : ASME SA194 Grade 2H
II. Non-Pressure Parts.
a. Saddle plate : ASME SA106 Grade B 1 1 B
b. Lifting lugs & Pads : ASME SA 516 Grade 70 1 2 D
Thickness of exchanger components :
- Shell & Heads ASME SA106 Grade B 0.5 INCH 12.7 MM
- Max. Nozzle Necks Thk. ASME SA106 Grade B 0.432 INCH 10.9728 MM
Min. Design Metal Temperature, MDMT 28
o
F -2
o
C
Where the MDMT is in accordance with UG-20(f), UCS-66
and FIG. UCS-66, no impact test is required. Please refer to : Page : 106 of 136
Impct Test is not required as per ASME Code for MDMT of 28
o
F -2
o
C
but is required as a client request.
G. Standard ASME Flange Rating Class.
1. Standard ASME B16.5 welded neck flanges shall be used.
2. For standard flange, Carbon Steel material in accordance with ASME SA105,
P-No. 1, Group No. 2 :
a. Shell side flanges, S1 & S2, 6" NPS : MAWP 186 PSIG & Design temp. 302
o
F : Raing 300#
b. Tube side flanges, T1 & T2, 6" NPS : MAWP 72 PSIG & Design temp. 140
o
F : Raing 150#
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 9 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 3
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
H. Cylindrical Main Shell Thickness [UG-27(C)]
1. Under Internal Pressureal (Pipe 20" NPS)
Shell material, Killed carbon steel ASME SA 106 Grade B
Operating Temperature : Shell Side 230
o
F 110
o
C
Tube Side 104
o
F 40
o
C
Design Temperature : Shell Side 302
o
F 150
o
C
Tube Side 140
o
F 60
o
C
Min. Design Metal Temperature, MDMT 28
o
F -2
o
C
Operating Pressure: Shell Side 241.477 PSIG 17 Kg/CM
2
G
Tube Side 42.6136 PSIG 3 Kg/CM
2
G
Internal Design Pressure: Shell Side 284.091 PSIG 20 Kg/CM
2
G
Tube Side 71.0227 PSIG 5 Kg/CM
2
G
Shell Inside Diameter, D (by using pipe 20" NPS, Sch.30) 19 INCH 482.6 MM
Shell Inside Radius, R 9.5 INCH 241.3 MM
Stationary Shell Inside Diameter, Ds 19 INCH 482.6 MM
Static Head = Inside Diameter (D) 0.4826 M
Static Head Pressure: Shell & Tube Side 0.68551 PSIG 0.04826 Kg/CM
2
G
Floating Head Side 0.68551 PSIG 0.04826 Kg/CM
2
G
Internal Design Pressure, P (MAWP): Shell Side 284.776 PSIG 20.04826 Kg/CM
2
G
Tube Side 71.7082 PSIG 5.04826 Kg/CM
2
G
Max. Allowable Stress @ Design Temp., S 17100 PSIG 1203.84 Kg/CM
2
G
Max. Allowable Stress @ Test Temp., St 17100 PSIG 1203.84 Kg/CM
2
G
[ Table 1A , SubPart 1 , ASME Sec. II , Part D]
Hydrostatic Test Pressure, Ph =1.3*MAWP(St/S) [UG-99(b)]
370.2093347 PSIG 26.062738
Kg/CM
2
G
Ph =1.5*MAWP(St/S) [shell side] [Owner request]
427.164617 PSIG 30.07239
Kg/CM
2
G
Corrosion Allowance, C [UG-25] 0.19685 INCH 5 MM
J oint Efficiency, E [Table UW-12] 0.85
[Spot Radiography], [Table UCS-57]
Value of 0.385 SE [UG-27C(1)] 5595.98 PSIG 393.9567 Kg/CM
2
G
Since P does not exceed 0.385 SE , Use Thin Wall Equation:
[1] Min. Wall Thickness for Longitudinal J oints,
t
1
=PR/(SE - 0.6 P) [UG-27C(1)] 0.18834 INCH 4.783898 MM
[2] Min. Wall Thickness for Circumferential J oints,
t
2
=PR/(2SE +0.4 P) [UG-27C(2)] 0.0927 INCH 2.354604 MM
The Min. Thickness shall be the Greater of t
1
or t
2
0.18834 INCH 4.783898 MM
By Adding Corrosion Allowance to Wall Tickness, t 0.38519 INCH 9.783898 MM
Use 20" Pipe with thickness of Construction, t (Sch. 30, 12.7 MM) 0.5 INCH 12.7 MM
20" Pipe wall thickness without tolerance 12.5% 0.4375 INCH 11.1125 MM
20" Pipe wall thickness without corrosion allowance 0.24065 INCH 6.1125 MM
Min. Pipe Shell Thickness according to TEMA Table R-3.13 0.375 INCH 9.525 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 10 of 136 S
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 3
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
2. Check of Main Shell Thickness for External Pressure (FV).
a. Check of Shell Thickness (NA)
For external pressure on cylinder, use UG-28 and Subpart 3.
Determine the effective length of shell without stiffening rings, L
Height of shell flange-stationary head end (flange 7), L7 3.70079 INCH 94 MM
Height of shell flange-rear head end (flange 6), L6 3.74016 INCH 95 MM
Total shell length (flange-to-flange), L' 228.346 INCH 5800 MM
Effective shell length without stiffening, L =L' - (L6 +L7) 228.346 INCH 5800 MM
In case of shell with heads, L =1/3 each head depth +straight 234.68 INCH 5960.867 MM
Assume t for internal pressure (corroded) 0.24065 INCH 6.1125 MM
Do =ID +2 t 19.4813 INCH 494.825 MM
L / Do 12.0464 For L/Do >50, use it =50
Do / t 80.953
a. Enter Fig. G with L / Do and read across to sloping line of Do/t
Read factor A 0.00038
b. Enter Fig. CS-2 with A (to find factor B), 5600 PSIG 394.24 Kg/CM
2
G
Follow step (6) of UG-28(c), P
A
=4B / 3 (Do / t) 92.2346 PSIG 6.493318
Kg/CM
2
G
Change t untill P
A
>15 PSI (full vacuum) 15 PSIG 1.056
Kg/CM
2
G
OK
For A falling to the left of the applicable material/temp. line,
Pa can be calculated from formula, Pa =2 A E / 3(Do/t) 86.4329 PSIG 6.084877 Kg/CM
2
G
E =Modulus of elasticity at design temp. 2.8E+07 PSIG 1970355 Kg/CM
2
G
at amp. temp. 2.9E+07 PSIG 2055680 Kg/CM
2
G
The uncorroded shell wall thickness must not lrss than
Use the uncorroded shell wall thickness
Use Thickness of Construction, t (Adopted thickness)
Corroded Thickness =Adopted thickness +Corrosion allowance
Insulation Yes
Post Weld Heat Treatment, PWHT N.A.
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 11 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 3 of 3
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
A. CYLINDRICAL SHELL THICKNESSES [UG-27(C)]
a.2. Floating Shell
Shell material, Killed carbon steel (Pipe 26" Sch. 20) ASME SA 516 Grade 70
Operating Temperature : Shell Side 230
o
F 110
o
C
Tube Side 104
o
F 40
o
C
Design Temperature : Shell Side 302
o
F 150
o
C
Tube Side 140
o
F 60
o
C
Min. Design Metal Temperature, MDMT 28.4
o
F -2
o
C
Operating Pressure: Shell Side 241.477 PSIG 17 Kg/CM
2
G
Tube Side 42.6136 PSIG 3 Kg/CM
2
G
Internal Design Pressure: Shell Side 284.091 PSIG 20 Kg/CM
2
G
Tube Side 71.0227 INCH 5 MM
Shell Inside Diameter, D 24.9843 INCH 634.6 MM
Shell Inside Radius, R 12.4921 INCH 317.3 MM
Stationary Shell Inside Diameter, Ds 19 INCH 482.6 MM
Static Head = Inside Diameter (D) 0.6346 M
Static Head Pressure: Shell & Tube Side 0.90142 PSIG 0.06346 Kg/CM
2
G
Floating Head Side 0.0009 PSIG 6.35E-05 Kg/CM
2
G
Internal Design Pressure, P (MAWP): Shell Side 284.092 PSIG 20.00006 Kg/CM
2
G
Tube Side 71.9241 PSIG 5.06346 Kg/CM
2
G
Max. Allowable Stress @ Design Temp., S 17100 PSIG 1203.84 Kg/CM
2
G
Max. Allowable Stress @ Test Temp., St 17100 PSIG 1203.84 Kg/CM
2
G
[ TABLE 1A , SUBPART 1 , ASME SEC. II , PART D]
Hydrostatic Test Pressure, P
h
=1.3*MAWP(St/S) 369.319 PSIG 26.00008
Kg/CM
2
G
[ UG-99(b) ]
Corrosion Allowance, C [UG-25] 0.19685 INCH 5 MM
J oint Efficiency, E [TABLE UW-12] 0.85
[Full Radiography], [Table UCS-57]
Value of 0.385 SE [UG-27C(1)] 5595.98 PSIG 393.9567 Kg/CM
2
G
Since P does not exceed 0.385 SE , Use Thin Wall Equation:
[1] Min. Wall Thickness for Longitudinal J oints,
t
1
=PR/(SE-0.6P) [UG-27C(1)] 0.24706 INCH 6.275335 MM
[2] Min. Wall Thickness for Circumferential J oints,
t
2
=PR/(2SE+0.4P) [UG-27C(2)] 0.12161 INCH 3.088797 MM
The Min. Thickness shall be the Greater of t
1
or t
2
0.24706 INCH 6.275335 MM
By Adding Corrosion Allowance to Wall Tickness, t 0.44391 INCH 11.27533 MM
Use Plate with thickness of Construction, t 0.5 INCH 12.7 MM
Min. Plate Shell Thickness according to TEMA Table R-3.13 0.4375 INCH 11.1125 MM
Insulation Yes
Post Weld Heat Treatment, PWHT N.A.
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 12 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 2
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
I. Cylindrical Stationary Head-Channel. [UG-27(C)]
1. Under Internal Pressure
Shell material, Killed carbon steel ASME SA 106 Grade B
Operating Temperature : Shell Side 230
o
F 110
o
C
Tube Side 104
o
F 40
o
C
Design Temperature : Shell Side 302
o
F 150
o
C
Tube Side 140
o
F 60
o
C
Min. Design Metal Temperature, MDMT 28.4
o
F -2
o
C
Operating Pressure: Shell Side 241.477 PSIG 17 Kg/CM
2
G
Tube Side 42.6136 PSIG 3 Kg/CM
2
G
Internal Design Pressure: Shell Side 284.091 PSIG 20 Kg/CM
2
G
Tube Side 71.0227 PSIG 5 Kg/CM
2
G
Shell Inside Diameter, D 19 INCH 482.6 MM
Shell Inside Radius, R 9.5 INCH 241.3 MM
Stationary Shell Inside Diameter, Ds 19.0157 INCH 483 MM
Static Head = Inside Diameter (D) 0.4826 M
Static Head Pressure: Shell & Tube Side 0.68551 PSIG 0.04826 Kg/CM
2
G
Floating Head Side 0.68608 PSIG 0.0483 Kg/CM
2
G
Internal Design Pressure, P (MAWP): Shell Side 284.776 PSIG 20.04826 Kg/CM
2
G
Tube Side 71.7082 PSIG 5.04826 Kg/CM
2
G
Max. Allowable Stress @ Design Temp., S 17100 PSIG 1203.84 Kg/CM
2
G
Max. Allowable Stress @ Test Temp., St 17100 PSIG 1203.84 Kg/CM
2
G
[ TABLE 1A , SUBPART 1 , ASME SEC. II , PART D]
Hydrostatic Test Pressure, Ph =1.3*MAWP(St/S) [UG-99(b)]
370.2093347 PSIG 26.062738
Kg/CM
2
G
Ph =1.5*MAWP(St/S) [tubel side] [Owner request]
427.164617 PSIG 30.07239
Kg/CM
2
G
Corrosion Allowance, C [UG-25] 0.19685 INCH 5 MM
J oint Efficiency, E [TABLE UW-12] 0.85
[Full Radiography], [Table UCS-57]
Value of 0.385 SE [UG-27C(1)] 5595.98 PSIG 393.9567 Kg/CM
2
G
Since P does not exceed 0.385 SE , Use Thin Wall Equation:
[1] Min. Wall Thickness for Longitudinal J oints,
t
1
=PR/(SE-0.6P) [UG-27C(1)] 0.04743 INCH 1.204611 MM
[2] Min. Wall Thickness for Circumferential J oints,
t
2
=PR/(2SE+0.4P) [UG-27C(2)] 0.0927 INCH 2.354604 MM
The Min. Thickness shall be the Greater of t
1
or t
2
0.0927 INCH 2.354604 MM
By Adding Corrosion Allowance to Wall Tickness, t 0.28955 INCH 7.354604 MM
Use plate thickness, Use 20" Pipe with thickness of Construction, t (Sch. 30, 12.7 MM) 0.51181 INCH 13 MM
20" Pipe wall thickness without tolerance12.5%
0.511811024 INCH 13 MM
Plate Thickness less corrosion allowance 20" Pipe wall thickness without corrosion allowance 0.51181 INCH 13 MM
Min. Plate thickness Min. Pipe Shell Thickness according to TEMA Table R-3.13 0.375 INCH 9.525 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 13 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 2
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
I. Cylindrical Stationary Head-Channel. [UG-27(C)]
2. Check of Channel Thickness for External Pressure (Full Vacuum)
For external pressure on cylinder, use UG-28 and Subpart 3.
Determine the effective length of shell without stiffening rings, L
Height of shell flange-stationary head end (flange 5), L7 4.72441 INCH 120 MM
Height of shell flange-rear head end (flange 6), L6 5.11811 INCH 130 MM
Total shell length (flange-to-flange), L' 23.622 INCH 600 MM
Effective shell length without stiffening, L =L' - (L6 +L7) 23.622 INCH 600 MM
In case of shell with heads, L =1/3 each head depth +straight 29.96062992 INCH 761 MM
Assume t for internal pressure (corroded) 0.51181 INCH 13 MM
Do =ID +2 t 20.0236 INCH 508.6 MM
L / Do 1.49626 For L/Do >50, use it =50
Do / t 39.1231
a. Enter Fig. G with L / Do and read across to sloping line of Do/t
Read factor A 0.00038
b. Enter Fig. CS-2 with A (to find factor B), which is off to the left side and can4750 PSIG 334.4 Kg/CM
2
G
Follow step (6) of UG-28(c), P
A
=4B / 3 (Do / t) 161.882 PSIG 11.39651
Kg/CM
2
G
Change t untill P
A
>15 PSI (full vacuum) 15 PSIG 1.056
Kg/CM
2
G
OK
For A falling to the left of the applicable material/temp. line,
Pa can be calculated from formula, Pa =2 A E / 3(Do/t) 201.032 PSIG 14.15267 Kg/CM
2
G
E =Modulus of elasticity at design temp. 3.1E+07 PSIG 2214784 Kg/CM
2
G
at amp. temp. 2.9E+07 PSIG 2055680 Kg/CM
2
G
The uncorroded shell wall thickness must not lrss than
Use the uncorroded shell wall thickness
Use Thickness of Construction, t (Adopted thickness)
Corroded Thickness =Adopted thickness +Corrosion allowance
Insulation Yes
Post Weld Heat Treatment, PWHT N.A.
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 14 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 1
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
J. Main Ellipsoidal Head Thickness [UG-32(d)]
Under Internal Pressure. [Semi-ellipsoidal form 2:1 ]
Head Material, Carbon Steel ASME SA 234 WPB
Design Temperature (shell side) 302
o
F 150
o
C
MIN. Design Metal Temperature, MDMT 28
o
F -2
o
C
Operating Pressure (shell side) 156.25 PSIG 11 Kg/CM
2
G
Internal Design Pressure (shell side) 284.091 PSIG 20 Kg/CM
2
G
Internal Design Pressure, P (MAWP) 284.992 PSIG 20.06346 Kg/CM
2
G
Head Skirt Inside Diameter, Di 24.9843 INCH 634.6 MM
Head Inside Radius, L ( ri ) 12.4921 INCH 317.3 MM
Static Head 0.90142 PSIG 0.06346 Kg/CM
2
G
Max. Allowable Stress @ Design Temp., S 17100 PSIG 1203.84 Kg/CM
2
G
Max. Allowable Stress @ Test Temp., St 17100 PSIG 1203.84 Kg/CM
2
G
[TABLE 1A , SUBPART 1 , ASME SEC. II , PART D]
Corrosion Allowance, C [UG-25] 0.19685 INCH 5 MM
J oint Efficiency, E (Spot Radiography) [Table UW-12] 0.85
Assume Outside Diameter of Head, D
O
25.4751 INCH 647.0672 MM
Outside Radius of Head, R
O
12.7375 INCH 323.5336 MM
Value of 0.665 SE 9665.78 PSIG 680.4706 Kg/CM
2
G
Since the value of 0.66SE > P, Use Thin Wall Equation for
Calculating the Min. required Thickness of Head, t:
t1

=PD /(2SE-0.2P) [UG-32(d)] (1) 0.24542 INCH 6.233623 MM
Compare to Thickness of Seamless Spherical Shell :
Ps =0.665 SE 9665.78 PSIG 680.4706 Kg/CM
2
G
Since P <Ps, Calculate Thickness for thin Wall Spherical Shell:
t2 =PR/(2SE-0.2P) [UG-27(d)] (2) 0.12271 INCH 3.116812 MM
Head Thickness due to Internal Pressure: t =MAX ( t
1
, t
2
) 0.24542 INCH 6.233623 MM
By adding Corrosion Allowance to Wall Thickness, 0.44227 INCH 11.23362 MM
Use 26" Cap with thickness of Construction, t (Thk. 14.27 MM) 0.56181 INCH 14.27 MM
[ t Represents the Min. Thickness after Forming ]
Head required thickness, tr =P K
1
D / (2SE - 0.2P) 0.22088 INCH 5.610261 MM
NB. The required head thickness for reinforcement calculation are to be determined by the
hemispherical head formula using an equivalent radius of K
1
D where,
Spherical Radius Factor, K1 (for ellipsoidal head 2:1) 0.9 [Table UG-37]
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 15 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 3
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
K. Max. Internal Working Pressure, MWP at New (cold) & Operating (corroded)
[MWP is differ from MAP or MAWP]
1. For Shell-Side : 302
o
F 150
o
C
Main shell (Item 1) :
MWP, New & cold (12.7 MM-12.5%) P =SE t /(R +0.6 t) [UG-27(c)(1)] 608.569 PSIG 42.843 Kg/CM
2
G
MWP, Operating & corroded (9.286 MM) P =SE t /(R +0.6 t) 455.517 PSIG 32.068 Kg/CM
2
G
Head (cap) (Item 13) :
MWP, New & cold (12.7-12.5% MM) P =2SE t /(D +0.2 t) [UG-32(d)(1)] 621.582 PSIG 43.75937 Kg/CM
2
G
MWP, Operating & corroded (9.286 MM), P =2SE t /(D +0.2 t) 462.789 PSIG 32.58034 Kg/CM
2
G
Nozzle Neck 6" NPS, Sch. 80 for N3 & N4 (item 6) :
MWP, New & cold (7.489 MM-12.5%) neck 740 PSIG 52.096 Kg/CM
2
G
MWP, Operating & corroded (4.289 MM) neck N3 & N4 664.4 PSIG 46.774 Kg/CM
2
G
Standard Flange 6" NPS, ANSI 300#, Sch. 80 for N3 & N4 (items 5) :
MWP, New & cold [TEMA Table D-6.1] 740 PSIG 52.096 Kg/CM
2
G
MWP, Operating & corroded [TEMA Table D-6.1] 655 PSIG 46.112 Kg/CM
2
G
Non Standard Flange (Item 4) : MWP, New & cold 425.258 PSIG 29.938 Kg/CM
2
G
MWP, Operating & corroded 335.398 PSIG 23.612 Kg/CM
2
G
Non Standard Flange (Item 3) : MWP, New & cold 425.258 PSIG 29.938 Kg/CM
2
G
MWP, Operating & corroded 335.398 PSIG 23.612 Kg/CM
2
G
Non Standard Flange (Item 12) : MWP, New & cold 425.258 PSIG 29.938 Kg/CM
2
G
MWP, Operating & corroded 335.398 PSIG 23.612 Kg/CM
2
G
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 16 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 3
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 2
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
K. Max. Internal Working Pressure, MWP at New (cold) & Operating (corroded) (cont.)
[MWP is differ from MAP or MAWP]
2. For Tube-Side : 608
o
F 320
o
C
Channel (Item 17) :
MWP, New & cold (13 MM-12.5%.) P =SE t /(R +0.6 t) [UG-27(c)(1)] 608.569 PSIG 42.843 Kg/CM
2
G
MWP, Operating & corroded (8 MM) P =SE t /(R +0.6 t) 455.537 PSIG 32.07 Kg/CM
2
G
Nozzle Neck 6" NPS, Sch. 80 for N1& N2 (item 20) :
MWP, New & cold (7.489 MM-12.5%) neck 285 PSIG 20.064 Kg/CM
2
G
MWP, Operating & corroded (4.289 MM) neck 275 PSIG 19.36 Kg/CM
2
G
Standard Flange 6" NPS, ANSI 150#, Sch. 80 for N1& N2 (item 19) :
MWP, New & cold [TEMA Table D-6.1] 285 PSIG 20.064 Kg/CM
2
G
MWP, Operating & corroded [TEMA Table D-6.1] 260 PSIG 18.304 Kg/CM
2
G
Non Standard Flanges (Item 18) : MWP, New & cold 425.258 PSIG 29.938 Kg/CM
2
G
MWP, Operating & corroded 335.368 PSIG 23.61 Kg/CM
2
G
Blind Flange (Item 22) : [see page 47 of 80]MWP, New & cold 289.381 PSIG 20.372 Kg/CM
2
G
MWP, Operating & corroded 263.006 PSIG 18.516 Kg/CM
2
G
Stationary Tubesheet (Item 36) : [see page 49 of 80]MWP, New & cold 431.681 PSIG 30.39 Kg/CM
2
G
MWP, Operating & corroded 384.282 PSIG 27.053 Kg/CM
2
G
Floating Tubesheet (Item 37) : [see page 49 of 80]MWP, New & cold 431.681 PSIG 30.39 Kg/CM
2
G
MWP, Operating & corroded 384.282 PSIG 27.053 Kg/CM
2
G
Floating Head Spherical Sector (Item 30) : [see page 49 of 80]MWP, New & c431.681 PSIG 30.39 Kg/CM
2
G
MWP, Operating & corroded 384.282 PSIG 27.053 Kg/CM
2
G
Floating Head Elange (Item 29) : [see page 49 of 80]MWP, New & cold 431.681 PSIG 30.39 Kg/CM
2
G
MWP, Operating & corroded 384.282 PSIG 27.053 Kg/CM
2
G
Floating Head Backing Ring (Item 31) : [see page 49 of 80]MWP, New & cold 431.681 PSIG 30.39 Kg/CM
2
G
MWP, Operating & corroded 384.282 PSIG 27.053 Kg/CM
2
G
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 17 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 3 of 3
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
K. Max. Internal Working Pressure, MWP at New (cold) & Operating (corroded) (cont.)
3. For Tubes : (Item 38)
Tube Material ASME SB111 UNS No. C68700-061
P-Number
Group Number
Max. Temp. Limit 450
o
F 232.2222
o
C
Design Temperature : Shell Side 302
o
F 150
o
C
Tube Side 140
o
F 60
o
C
Test Pressure Temp. (ambient temp.) 104
o
F 40
o
C
Max. Allowable Stress @ Design Temp.302
o
F (150
o
C), S 11492 PSIG 809.0368 Kg/CM
2
G
Max. Allowable Stress @ Test Temp. 104
o
F (40
o
C), St 11992 PSIG 844.2368 Kg/CM
2
G
[Table 1A, SubPart 1, ASME Sec. II, Part D]
No of tubes, n 146
Tube OD 1 INCH 25.4 MM
Tube length, L 236.22 INCH 6000 MM
Tube pitch, p 1.45472 INCH 36.95 MM
Tube BWG [TEMA Table D-7] 13
Tube wall thickness, t
t
[TEMA Table D-7] 0.09843 INCH 2.500122 MM
Tube pattern (Triangle, equal angles 60
o
) (square rotated) 30
o
MWP (internal), New & cold [TEMA Table D-9] 4132.3 PSIG 290.9139 Kg/CM
2
G
MWP (internal), Operating & corroded [TEMA Table D-9] 3963.55 PSIG 279.0339 Kg/CM
2
G
Design pressure (tube-side), P 71.0227 PSI 5 Kg/CM
2
G
Design temperature (tube-side) 140
o
F 60
o
C
Max. Allowable Stress @ Design Temp.302
o
F (150
o
C), S 11492 PSIG 809.0368 Kg/CM
2
G
Corrosion Allowance, C [UG-25] 0 INCH 0 MM
J oint Efficiency, E [TABLE UW-12] 1
Tube required thickness, trn =PRn /(SnEn - 0.6 P) [UG-27] 0.0062 INCH 0.157561 MM
Max. Internal Working pressure MWP for whole Exchanger :
Shell side : MWP, New & cold 425.258 PSIG 29.938 Kg/CM
2
G
MWP, Operating & corroded 335.398 PSIG 23.612 Kg/CM
2
G
Tube side : MWP, New & cold 285 PSIG 20.064 Kg/CM
2
G
MWP, Operating & corroded 260 PSIG 18.304
Kg/CM
2
G
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 18 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 3
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
L. Check for External Pressure (Convex Side), (Tube Side Full Vacuum)
1. Ellipsoidal Head (Stationary Head-Bonnet NA)
[UG-33(d)]
Assumed corroded thickness of head, t 0.43583 INCH 11.07 MM
Outside diameter of the head skirt, Do 23.7638 INCH 603.6 MM
The equivalent outside spherical, Ro =Ko Do [UG-33(b)] 20.2171 INCH 513.5147 MM
Outside height of the ellipsoidal head (measured from head-bend line), ho 6.28484 INCH 159.635 MM
Ratio of the major to the minor axis of ellipsoidal head, Do/2ho 1.89056
Factor depending on the ellipsoidal head proportions Do/2ho, Ko 0.85075
(use interpolation) [See Table UG-33.1]
The required thickness of an ellipsoidal head having pressure on the
convex side, either seamless or of built-up construction with butt joints,
shall not be less than that determined by the following procedure :
Step 1. Assume a value for t and calculate the value of factor A
using the following formula : A =0.125 / (Ro / t) 0.00269
Step 2. Using the value of A calculate in Step 1, follow the same
procedure as that given for sphericalshells in UG-28(d),
Step 2 through 6 :
a. Enter Fig. CS-2 with A (to find factor B), which is under the curve, B 9900 PSIG 696.96 Kg/CM
2
G
Follow step (4) of UG-28(d), and calculate the value of max. allowable
external working pressure, P
A
=B / (Ro / t) 213.417 PSIG 15.02459
Kg/CM
2
G
Change t untill P
A
>15 PSI (full vacuum) 15 PSIG 1.056
Kg/CM
2
G
OK
Notes.
1. For value of A falling to the left of the material-temp. line, the value
of Pa can be calculated in accordance with Step 5 of UG-28(d), as
follows : Pa =0.0625 E / (Ro /t)
2
E =Modulus of elasticity at design temp. 2.6E+07 PSIG 1823360 Kg/CM
2
G
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 19 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 3
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
L. Check of External Pressure (Convex Side), (Tube Side Full Vacuum) (cont.)
2. Channel
Channel Material ASME SA106 Grade B
Design Temperature 140
o
F 60
o
C
Corrosion allowance 0.19685 INCH 5 MM
Channel Diameter, 20" NPS 20 INCH 508 MM
Channel Thickness (20" Sch. 30) 0.562 INCH 14.2748 MM
Channel Thickness (20" Sch. 30) - 12.5% 0.49175 INCH 12.49045 MM
For external pressure on cylinder, use UG-28 and Subpart 3.
Determine the effective length of shell without stiffening rings, L : 23.622 INCH 600 MM
Assume t for internal pressure (at corroded condition) 0.2949 INCH 7.49045 MM
Do =ID +2 t 20 INCH 508 MM
L / Do 1.1811
Do / t 67.8197 > 10 UG-28(c)(1)
Since Do/t >10, use UG-28(c)(1)
a. Enter Fig. G with L / Do and read across to sloping line of Do/t
Read factor A 0.00035
b. Enter Fig. CS-2 with A (to find factor B), which falls under the curve. 11500 PSIG 809.6 Kg/CM
2
G
Follow step (6) of UG-28(c)(1), and calculate the value of max. allowable
external working pressure, P
A
=4B / 3 (Do / t) 226.09 PSIG 15.91672
Kg/CM
2
G
Change t untill P
A
>15 PSI (full vacuum) 15 PSIG 1.056
Kg/CM
2
G
OK
E =Modulus of elasticity at design temp. 3.3E+07 PSIG 2323200 Kg/CM
2
G
at amp. temp. 2.9E+07 PSIG 2055680 Kg/CM
2
G
Notes 1. For value of A falling to the left of the material-temp. line, the value
of Pa can be calculated as follows : Pa =2 A E / 3 (Do /t)
2. For L/Do >50, use L/Do =50
For L/Do <0.05, use L/Do =0.05
3. For Do/t >10, use UG-28(c)(1)
For Do/t <10, use UG-28(c)(2)
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 20 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 3 of 3
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
L. Check of External Pressure (Convex Side), (Tube Side Full Vacuum) (cont.)
3. Tubes
Tube Material ASME SB111 UNS No. C68700-061
Design Temperature 140
o
F 60
o
C
Corrosion allowance 0 INCH 0 MM
Tube OD 1 INCH 25.4 MM
Tube BWG 13
Tube Wall Thickness 0.09843 INCH 2.500122 MM
For external pressure on cylinder, use UG-28 and Subpart 3.
Determine the effective length of tube without stiffening rings, L : 236.22 INCH 6000 MM
Assume t for internal pressure (at corroded condition) 0.09843 INCH 2.500122 MM
Do 1 INCH 25.4 MM
L / Do 236.22 > 50
Use L / Do 50
Do / t 10.1595 > 10 UG-28(c)(1)
Since Do/t >10, use UG-28(c)(1)
Step 1. Enter Fig. G in Subpart 3 of Sec. II, Part D with L / Do and read
across to sloping line of Do/t Read factor A 0.012
Step 2. Enter Fig. NFC-2 with A (to find factor B), which falls under the curve. 6150 PSIG 432.96 Kg/CM
2
G
Follow step (2) of UG-28(c)(1), and calculate the value of max. allowable
external working pressure.
Step 3. Calculate a value of Pa =4 B / 3 (Do/t) 807.126 PSIG 56.82167 Kg/CM
2
G
Step 4. Compare the calculated value of Pa with Pe 807.126 PSIG 56.82167 Kg/CM
2
G
Change t untill P
a
>15 PSI (full vacuum) 15 PSIG 1.056
Kg/CM
2
G
OK
Change t untill P
a
>186 PSI (full vacuum with respect to shell-side) 186 PSIG 13.0944
Kg/CM
2
G
OK
Change t untill P
a
>30.7Kg/cm2 (436 PSI) (hydrostatic test of tube sid436 PSIG 30.6944
Kg/CM
2
G
OK
Notes 1. For value of A falling to the left of the material-temp. line, the value
of Pa can be calculated as follows : Pa =2 A E / 3 (Do /t)
2. For L/Do >50, use L/Do =50
For L/Do <0.05, use L/Do =0.05
3. For Do/t >10, use UG-28(c)(1)
For Do/t <10, use UG-28(c)(2) :
- for Do/t <4, A =1.1 / (Do/t)
2
- for A >0.10, use a value of 0.10
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 21 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 5
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
M1. Nozzle Mark : N3 & N4 6" 300# WNRF (Located at Shell) with Reinforcement
Nozzle Neck Thickness Calculation [UG-27(c) & Appendix 1-1]
Nozzle Size, NPS 6 INCH 150 DN
Nozzle Material ASME SA 106 Grade B
Design Pressure, P 284.776 PSIG 20.04826 Kg/CM
2
G
Design Temperature 302
o
F 150
o
C
For nominated Design Pressure & Temperature, Flange Rating 300#
[ASME B16.5-1996]
Max. Allowable Stress of Nozzle Material @ Design Temp.(150
o
C), Sn 17100 PSIG 1203.84 Kg/CM
2
G
Max. Allowable Stress of Nozzle Materiall @ Test Temp.(40
o
C), Snt 17100 PSIG 1203.84 Kg/CM
2
G
[Table 1A, SubPart 1, ASME Sec. II, Part D]
Outside Radius of Nozzle, Ron 3.3125 INCH 84.1375 MM
J oint Efficiency of Nozzle, En (Seamless Pipe) 1
Nozzle Corrosion Allowance, Can 0.19685 INCH 5 MM
Nozzle Thickness Calculation :
Longitudinal Stress, t =PRon /(Sn*En +0.4 P) [Appendix 1.1] 0.0548 INCH 1.391917 MM
By adding Corrosion Allowance, t [UG-25] 0.25165 INCH 6.391917 MM
By adding Pipe Tolerance 12.5% to the Thickness of Nozzle, t 0.28311 INCH 7.190907 MM
Use Nozzle 6" NPS with Selected Neck Sch. 80, 0.432 INCH 10.9728 MM
with Thickness 0.432" ( 10.97 MM ). [Table 2 of ASME B 36.10M-1985-(R-1994)]
Nozzle Neck Maximum Working Pressure, MWP (New & Operating)
Nozzle wall thickness less tolerance 12.5% 0.378 INCH 9.6012 MM
Nozzle wall thickness less tolerance 12.5% - Corrosion allowance 0.18115 INCH 4.6012 MM
MWP, New & cold (10.97 MM) P =Snt E t /(Ron - 0.4 t) [App. 1.1] 2044.67 PSIG 143.944 Kg/CM
2
G
MWP, Operating & corroded (4.6 MM) P =Sn E t /(Ron - 0.4 t) 956.056 PSIG 67.306 Kg/CM
2
G
Nozzle Flange Maximum Working Pressure, MWP (New & Operating)
MWP, New & cold , 300# @ 100
o
F [ASME B.165, Table 2] 740 PSIG 52.096 Kg/CM
2
G
MWP, Operating & corroded, 300# @ 302
o
F [ASME B16.5, Table 2] 664.4 PSIG 46.774 Kg/CM
2
G
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 22 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 5
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
M1. Nozzle Mark : N3 & N4 6" 300# WNRF (Located at Shell) (cont.)
Nozzle Opening Calculation With Reinforcing [UG-27(c) & Appendix 1-1]
Nozzle Pipe Size, NPS 6 INCH 150 DN
Nozzle Pipe Sch. 80
Design Pressure, P 185.483 PSIG 13.058 Kg/CM
2
G
Design Temparture 302
o
F 150
o
C
Shell Material ASME SA106 Grade B
Nozzle Material ASME SA 106 Grade B
Reinforcing Pad Material ASME SA 106 Grade B
Allowable Stress of Shell Material, Sv 17100 PSIG 1203.84 Kg/CM
2
G
Allowable Stress of Nozzle Material, Sn 17100 PSIG 1203.84 Kg/CM
2
G
Allowable Stress of Pad Material, Sp 17100 PSIG 1203.84 Kg/CM
2
G
Shell Thickness 0.5 INCH 12.7 MM
Shell Corrosion Allowance, Cas 0.19685 INCH 5 MM
Shell Thickness less Pipe Tolerance 12.5% (12.5%NA) 0.4375 INCH 11.1125 MM
Shell Thickness less Corrosion Allowance & 12.5%, t (12.5%NA) 0.24065 INCH 6.1125 MM
Nozzle Wall Nominal Thickness 0.432 INCH 10.9728 MM
Nozzle Wall Thickness less Pipe Tolerance 12.5% 0.378 INCH 9.6012 MM
Nozzle Corrosion Allowance, Can 0.19685 INCH 5 MM
Nozzle Wall Thick. less Corr. Allowance & 12.5% , tn 0.18115 INCH 4.6012 MM
Nozzle Wall Thick.of Internal Projection (less Corr. Allowance & 12.5%), ti 0.18115 INCH 4.6012 MM
Reinforced Pad Thickness, te 0.5 INCH 12.7 MM
J oint Efficiency of Shell, E 1
J oint Efficiency of Nozzle, En 1
Correction Factor, F [UG-37(a)] 1
E1 [Nozzle in solid plate] 1
Shell Outside Diameter, OD 20 INCH 508 MM
Shell Inside Diameter in Corroded Condition, 2R =OD - 2 t 19.5187 INCH 495.775 MM
Shell Inside Radius in Corroded Condition, R 9.75935 INCH 247.8875 MM
Nozzle Outside Diameter, OD 6.625 INCH 168.275 MM
Nozzle Inside Diameter, ID 5.761 INCH 146.3294 MM
Nozzle Projection beyond Inner Vessel Wall, h =min. (h1,h2) 0 INCH 0 MM
h1 =2.5 t 0.60162 INCH 15.28125 MM
h2 =2.5 ti 0.45287 INCH 11.503 MM
Nozzle ID Without Corrosion Allowance & 12.5% , d =OD - 2*tn 6.2627 INCH 159.0726 MM
Finished Radius of Circular Opening, Rn 3.13135 INCH 79.5363 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 23 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 3 of 5
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
M1. Nozzle Mark : N3 & N4 6" 300# WNRF (Located at Shell) (cont.)
Nozzle Opening Calculation With Reinforcing (cont.)
[UG-27(c) & Appendix 1-1]
* Outside Diameter of Reinforced Pad (if used) [UG-40(b)&FIG.UG-37.1]
Dp1 =2 d 12.5254 INCH 318.1452 MM
Dp2 =2 (Rn +nozzle wall thk. , tn +vessel wall thk. , t ) 7.1063 INCH 180.5 MM
OD of Reinf. Pad, Dp =the greater of Dp1 or Dp2 12.5254 INCH 318.1452 MM
Calculating Siz of Fillet Welds : [UW-16(c)(2)&Fig.UW-16.1]
* For Outward Nozzle Weld [UW-16(c)(2)&Fig.UW-16.1Sketch (c)]
Calculation of tmin. :
tmin.1 =0.75 inch 0.75 INCH 19.05 MM
tmin.2 (nozzle wall nominal thickness) 0.432 INCH 10.9728 MM
tmin.3 (shell wall thickness) 0.56181 INCH 14.27 MM
tmin. =lesser of tmin.1, tmin. & tmin.3 0.432 INCH 10.9728 MM
Calculation of tc : tc1 =0.25 inch 0.25 INCH 6.35 MM
tc2 =0.7 t min. 0.3024 INCH 7.68096 MM
tc =lesser of tc1 & tc2 0.25 INCH 6.35 MM
By Considering Equal Legs Fillet Welds :
Leg of Outward Nozzle Weld =SQRT2 * tc 0.35355 INCH 8.980256 MM
Use Leg with Dimension E in Dwg. No. 7443-33-1A 0.35433 INCH 9 MM
* For Outer Reinforcing Pad Weld [Fig.UW-16 Sketch (c)]
tmin.1 =0.75 inch 0.75 INCH 19.05 MM
tmin.2 ( te =thk. of reinforcing element) 0.5 INCH 12.7 MM
tmin.3 ( shell wall thickness) 0.5 INCH 12.7 MM
tmin. =lesser of tmin.1, tmin. 2 & tmin.3 0.5 INCH 12.7 MM
1/2 tmin. 0.25 INCH 6.35 MM
By Considering Equal Legs Fillet Welds :
Leg of Outer Pad Weld =SQRT(2)*(tmin./2) 0.35355 INCH 9 MM
Use Leg with Dimension Din Dwg. No. 7443-33-1A 0.35433 INCH 9 MM
* Wall Thickness Required : [UG-27(c)(1)]
Shell tr =PR / (SE - 0.6 P) 0.1255 INCH 3.187732 MM
Nozzle trn =PRn /(SnEn - 0.6 P) 0.03419 INCH 0.868379 MM
* Strength Reduction Factors : Sp / Sv 1
fr1 =Sn / Sv 1
fr2 = Sn / Sv 1
fr3 =lesser of Sn/Sv or Sp/Sv 1
fr4 =Sp / Sv 1
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 24 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 4 of 5
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
M1. Nozzle Mark : N3 & N4 6" 300# WNRF (Located at Shell) (cont.)
Min. Nozzle Neck Wall Thickness Check Per UG-45
A. Wall Thickness per UG-45(a) : trna =trn +C.A. 0.23104 INCH 5.868379 MM

B. Wall Thickness per UG-45(b) : trnb =Min. (trnb1, trnb2, trnb3, trnb0.245 INCH 6.223 MM
Wall Thickness per UG-45(b)(1), trnb1 =Min. (trnb11, trnb12) 0.2906 INCH 7.38125 MM
trnb11 =tr +C.A. (tr for shell or head at E=1) 0.32235 INCH 8.187732 MM
trnb12 =Min Wall Thickness per UG-16(b), see below 0.2906 INCH 7.38125 MM
Wall Thickness per UG-45(b)(2), trnb2 (apply to external pressure only), NA INCH #VALUE! MM
Wall Thickness per UG-45(b)(3), trnb3 (apply to internal & external pressure)
=Max. (trnb1, trnb2) NA INCH #VALUE! MM
Wall Thickness per UG-45(b)(4), trnb4
=Min. thickness of std. wall pipe - 12.5% Max. (including CA) 0.245 INCH 6.223 MM
(Under tolerance12.5% in accordance with ASME B36.10M)
Nominal thickness of std. pipe wall thickness, NPS 6", Sch. Std. 0.28 INCH 7.112 MM
Wall Thickness per UG-16(b), trnb12
I - Min. Wall Thickness 1/16" +C.A. 0.25935 INCH 6.5875 MM
II - Min. Wall Thickness of Unfired Steam Boilers =1/4" +C.A. 0.44685 INCH 11.35 MM
III - Min. Wall Thickness of Shell/Head in Compressed Air
Service, Steam Service, and Water Service =3/32" +C.A. 0.2906 INCH 7.38125 MM
Selected Vessel Service in our case is : Case III (compressed air)
So, the Min. Wall Thickness per UG-16(b), trnb12 0.2906 INCH 7.38125 MM
The min. nozzle wall thk. =Max. thk. determined by UG-45(a), or by UG-45(b)0.245 INCH 6.223 MM
The min. nozzle thk. provided =t (1-0.125) 0.378 INCH 9.6012 MM
So, the thickness provided meets the rules of UG-45. OK
Since there is no superimposed loads, the vessel doesn't require
a calculationon shear stresses caused by UG-22(c).
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 25 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 5 of 5
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
M1. Nozzle Mark : N3 & N4 6" 300# WNRF (Located at Shell) (cont.)
Nozzle Opening Calculation With Reinforcing (cont.) [UG-27]
Area of Reinforcement (witht Reinforcing element) :
Required Area, A =d tr F +2 tn tr F(1-fr1) 0.78598 INCH
2
507.0808 MM
2
Area Available in Shell, A1:
A11 =d (E1 t - F tr) - 2tn (E1 t - F tr)(1-fr1) 0.72114 INCH
2
465.2505 MM
2
A12 =2 (t +tn)(E1 t - F tr) - 2tn (E1 t - F tr)(1-f r1) 0.09714 INCH
2
62.67018 MM
2
A1 =The Greater of A11 or A12 0.72114 INCH
2
465.2505 MM
2
Area Available in Nozzle Projecting Outward, A2 :
A21 =5 (tn - trn) fr2 t 0.17683 INCH
2
114.0844 MM
2
A22 =2 (tn - trn)(2.5tn+te) fr2 0.28007 INCH
2
180.691 MM
2
A2 =The Lesser of A21 or A22 0.17683 INCH
2
114.0844 MM
2
Area Available in Inward Nozzle, A3 : (Not applicable)
A31 =5 t ti fr2 0.21797 INCH
2
140.6242 MM
2
A32 =5 ti ti fr2 0.16408 INCH
2
105.8552 MM
2
A33 =2 h ti fr2 0 INCH
2
0 MM
2
A3 =The Greater of A31, A32 or A33 0 INCH
2
0 MM
2
Area Available in Outward Nozzle Weld, A41:
A41 =(LEG)
2
fr2 0.12555 INCH
2
81 MM
2
Area Available in Outer Reinforcing Pad Weld, A42:
A42 =(LEG)
2
fr4 0.12555 INCH
2
81 MM
2
Area Available in Inward Nozzle Weld, A43 :
A43 =(LEG)
2
fr2 0 INCH
2
0 MM
2
Area Available in Reinforcing Pad, A5 :
A5 =(Dp - d - 2tn) te fr4 2.9502 INCH
2
1903.352 MM
2
Total Area Available, AT :
AT =A1 +A2 + A41 +A42 +A43 +A5 4.09927 INCH
2
2644.686 MM
2
AT is greater than A, therefore opening is adequately reinforced.
NOTE. No need for Strength Path Calculations.
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 26 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 5
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
M2. Nozzle Mark : N1 & N2 6" 150# WNRF (Located at Channel) with reinforcement
Nozzle Neck Thickness Calculation [UG-45, UG-27 & APPENDIX 1-1]
Nozzle Size, NPS 6 INCH 150 DN
Nozzle Material ASME SA 106 Grade B
Design Pressure, P 71.708 PSIG 5.04826 Kg/CM
2
G
Design Temperature 140
o
F 60
o
C
For nominated Design Pressure & Temperature, Flange Rating 150#
[ASME B16.5-1996]
Max. Allowable Stress of Nozzle Material @ Design Temp.(60
o
C), Sn 17100 PSIG 1203.84 Kg/CM
2
G
Max. Allowable Stress of Nozzle Materiall @ Test Temp.(40
o
C), Snt 17100 PSIG 1203.84 Kg/CM
2
G
[Table 1A, SubPart 1, ASME Sec. II, Part D]
Outside Radius of Nozzle, Ron 3.3125 INCH 84.1375 MM
J oint Efficiency of Nozzle, En (Seamless Pipe) 1
Nozzle Corrosion Allowance, Can 0.19685 INCH 5 MM
Nozzle Thickness Calculation :
Longitudinal Stress, t =PRon /(Sn*En +0.4 P) [APPENDIX 1.1] 0.01387 INCH 0.352236 MM
By adding Corrosion Allowance, t [UG-25] 0.21072 INCH 5.352236 MM
By adding Pipe Tolerance 12.5% to the Thickness of Nozzle, t 0.23706 INCH 6.021265 MM
Use Nozzle 6" NPS with Selected Neck Sch. 80, 0.432 INCH 10.9728 MM
with Thickness 0.432" ( 10.97 MM ). [Table 2 of ASME B 36.10M-1985-(R-1994)]
Nozzle Neck Maximum Working Pressure, MWP (New & Operating)
Nozzle wall thickness less tolerance 12.5% 0.378 INCH 9.6012 MM
Nozzle wall thickness less tolerance 12.5% - Corrosion allowance 0.18115 INCH 4.6012 MM
MWP, New & cold (10.97 MM) P =Snt E t /(Ron - 0.4 t) [App. 1.1] 2044.67 PSIG 143.944 Kg/CM
2
G
MWP, Operating & corroded (4.6 MM) P =Sn E t /(Ron - 0.4 t) 956.056 PSIG 67.306 Kg/CM
2
G
Nozzle Flange Maximum Working Pressure, MWP (New & Operating)
MWP, New & cold , 150# @ 100
o
F [ASME B.165, Table 2] 285 PSIG 20.064 Kg/CM
2
G
MWP, Operating & corroded, 150# @ 140
o
F [ASME B16.5, Table 2] 275 PSIG 19.36 Kg/CM
2
G
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 27 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 5
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
M2. Nozzle Mark : N1 & N2 6" 150# WNRF (located at channel) (cont.)
Nozzle Opening Calculation With Reinforcing [UG-27(c) & Appendix 1-1]
Nozzle Pipe Size, NPS 6 INCH 150 DN
Nozzle Pipe Sch. 80
Design Pressure, P 71.708 PSIG 5.048243 Kg/CM
2
G
Design Temparture 140
o
F 60
o
C
Shell Material ASME SA106 Grade B
Nozzle Material ASME SA 106 Grade B
Reinforcing Pad Material ASME SA106 Grade B
Allowable Stress of Shell Material, Sv 17100 PSIG 1203.84 Kg/CM
2
G
Allowable Stress of Nozzle Material, Sn 17100 PSIG 1203.84 Kg/CM
2
G
Allowable Stress of Pad Material, Sp 17100 PSIG 1203.84 Kg/CM
2
G
Shell Thickness 0.5 INCH 12.7 MM
Shell Corrosion Allowance, Cas 0.19685 INCH 5 MM
Shell Thickness less Pipe Tolerance 12.5% (12.5%NA) 0.4375 INCH 11.1125 MM
Shell Thickness less Corrosion Allowance & 12.5%, t (12.5%NA) 0.24065 INCH 6.1125 MM
Nozzle Wall Nominal Thickness 0.432 INCH 10.9728 MM
Nozzle Wall Thickness less Pipe Tolerance 12.5% 0.378 INCH 9.6012 MM
Nozzle Corrosion Allowance, Can 0.19685 INCH 5 MM
Nozzle Wall Thick. less Corr. Allowance & 12.5% , tn 0.18115 INCH 4.6012 MM
Nozzle Wall Thick.of Internal Projection (less Corr. Allowance & 12.5%), ti 0.18115 INCH 4.6012 MM
Reinforced Pad Thickness, te 0.5 INCH 12.7 MM
J oint Efficiency of Shell, E 1
J oint Efficiency of Nozzle, En 1
Correction Factor, F [UG-37(a)] 1
E1 [Nozzle in solid plate] 1
Shell Outside Diameter, OD 20 INCH 508 MM
Shell Inside Diameter in Corroded Condition, 2R =OD - 2 t 19.5187 INCH 495.775 MM
Shell Inside Radius in Corroded Condition, R 9.75935 INCH 247.8875 MM
Nozzle Outside Diameter, OD 6.625 INCH 168.275 MM
Nozzle Inside Diameter, ID 5.761 INCH 146.3294 MM
Nozzle Projection beyond Inner Vessel Wall, h =min. (h1,h2) 0 INCH 0 MM
h1 =2.5 t 0.60162 INCH 15.28125 MM
h2 =2.5 ti 0.45287 INCH 11.503 MM
Nozzle ID Without Corrosion Allowance & 12.5% , d =OD - 2*tn 6.2627 INCH 159.0726 MM
Finished Radius of Circular Opening, Rn 3.13135 INCH 79.5363 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 28 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 3 of 5
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
M2. Nozzle Mark : N1 & N2 6" 150# WNRF (located at channel) (cont.)
Nozzle Opening Calculation With Reinforcing (cont.) [UG-27(c) & Appendix 1-1]
* Outside Diameter of Reinforced Pad [UG-40(b) & Fig.UG-37.1]
Dp1 =2 d 12.5254 INCH 318.1452 MM
Dp2 =2 (Rn +nozzle wall thk. , tn +vessel wall thk. , t ) 7.1063 INCH 180.5 MM
OD of Reinf. Pad, Dp =the greater of Dp1 or Dp2 12.5254 INCH 318.1452 MM
Calculating Size of Fillet Welds : [UW-16(c)(2) & Fig.UW-16.1]
* For Outward Nozzle Weld [UW-16(c)(2)&Fig.UW-16.1 Sketch (c)]
Calculation of tmin. :
tmin.1 =0.75 inch 0.75 INCH 19.05 MM
tmin.2 (nozzle wall nominal thickness) 0.432 INCH 10.9728 MM
tmin.3 (shell wall thickness) 0.5 INCH 12.7 MM
tmin. =lesser of tmin.1, tmin. & tmin.3 0.432 INCH 10.9728 MM
Calculation of tc : tc1 =0.25 inch 0.25 INCH 6.35 MM
tc2 =0.7 t min. 0.3024 INCH 7.68096 MM
tc =lesser of tc1 & tc2 0.25 INCH 6.35 MM
By Considering Equal Legs Fillet Welds :
Leg of Outward Nozzle Weld =SQRT2 * tc 0.35355 INCH 8.980256 MM
Use Leg with Dimension E in Dwg. No. 7443-33-1A 0.35433 INCH 9 MM
* For Outer Reinforcing Pad Weld [Fig.UW-16 Sketch (c)]
tmin.1 =0.75 inch 0.75 INCH 19.05 MM
tmin.2 ( te =thk. of reinforcing element) 0.5 INCH 12.7 MM
tmin.3 ( shell wall thickness) 0.5 INCH 12.7 MM
tmin. =lesser of tmin.1, tmin. 2 & tmin.3 0.5 INCH 12.7 MM
1/2 t min. 0.25 INCH 6.35 MM
By Considering Equal Legs Fillet Welds :
Leg of Outer Pad Weld =SQRT(2)*(tmin./2) 0.35355 INCH 9 MM
Use Leg with Dimension Din Dwg. No. 7443-33-1A 0.35433 INCH 9 MM
* Wall Thickness Required : [UG-27(c)(1)]
Shell tr =PR / (SE - 0.6 P) 0.04829 INCH 1.226577 MM
Nozzle trn =PRn /(SnEn - 0.6 P) 0.03419 INCH 0.868379 MM
* Strength Reduction Factors : Sp / Sv 1
fr1 =Sn / Sv 1
fr2 = Sn / Sv 1
fr3 =lesser of Sn/Sv or Sp/Sv 1
fr4 =Sp / Sv 1
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 29 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 4 of 5
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
M2. Nozzle Mark : N1 & N2 6" 150# WNRF (located at channel) (cont.)
Min. Nozzle Neck Wall Thickness Check Per UG-45
A. Wall Thickness per UG-45(a) : trna =trn +C.A. 0.23104 INCH 5.868379 MM

B. Wall Thickness per UG-45(b) : trnb =Min. (trnb1, trnb2, trnb3, trnb0.245 INCH 6.223 MM
Wall Thickness per UG-45(b)(1), trnb1 =Min. (trnb11, trnb12) 0.24514 INCH 6.226577 MM
trnb11 =tr +C.A. (tr for shell or head at E=1) 0.24514 INCH 6.226577 MM
trnb12 =Min Wall Thickness per UG-16(b), see below 0.2906 INCH 7.38125 MM
Wall Thickness per UG-45(b)(2), trnb2 (apply to external pressure only), NA INCH #VALUE! MM
Wall Thickness per UG-45(b)(3), trnb3 (apply to internal & external pressure)
=Max. (trnb1, trnb2) NA INCH #VALUE! MM
Wall Thickness per UG-45(b)(4), trnb4
=Min. thickness of std. wall pipe - 12.5% Max. (including CA) 0.245 INCH 6.223 MM
(Under tolerance12.5% in accordance with ASME B36.10M)
Nominal thickness of std. pipe wall thickness, NPS 6", Sch. Std0.28 INCH 7.112 MM
Wall Thickness per UG-16(b), trnb12
I - Min. Wall Thickness 1/16" +C.A. 0.25935 INCH 6.5875 MM
II - Min. Wall Thickness of Unfired Steam Boilers =1/4" +C.A. 0.44685 INCH 11.35 MM
III - Min. Wall Thickness of Shell/Head in Compressed Air
Service, Steam Service, and Water Service =3/32" +C.A. 0.2906 INCH 7.38125 MM
Selected Vessel Service in our case is : Case III (compressed air)
So, the Min. Wall Thickness per UG-16(b), trnb12 0.2906 INCH 7.38125 MM
The min. nozzle wall thk. =Max. thk. determined by UG-45(a), or by UG-45(b)0.245 INCH 6.223 MM
The min. nozzle thk. provided =t (1-0.125) 0.378 INCH 9.6012 MM
So, the thickness provided meets the rules of UG-45. OK
Since there is no superimposed loads, the vessel doesn't require
a calculationon shear stresses caused by UG-22(c).
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 30 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 5 of 5
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
M2. Nozzle Mark : N1 & N2 6" 150# WNRF (located at channel) (cont.)
Nozzle Opening Calculation With Reinforcing (cont.) [UG-37]
Area of Reinforcement (with reinforcing Element) :
Required Area, A =d tr F +2 tn tr F(1-fr1) 0.30243 INCH
2
195.1147 MM
2
Area Available in Shell, A1:
A11 =d (E1 t - F tr) - 2tn (E1 t - F tr)(1-fr1) 1.20469 INCH
2
777.2165 MM
2
A12 =2 (t +tn)(E1 t - F tr) - 2tn (E1 t - F tr)(1-f r1) 0.16227 INCH
2
104.6926 MM
2
A1 =The Greater of A11 or A12 1.20469 INCH
2
777.2165 MM
2
Area Available in Nozzle Projecting Outward, A2 :
A21 =5 (tn - trn) fr2 t 0.17683 INCH
2
114.0844 MM
2
A22 =2 (tn - trn)(2.5tn+te) fr2 0.28007 INCH
2
180.691 MM
2
A2 =The Lesser of A21 or A22 0.17683 INCH
2
114.0844 MM
2
Area Available in Inward Nozzle, A3 :
A31 =5 t ti fr2 0.21797 INCH
2
140.6242 MM
2
A32 =5 ti ti fr2 0.16408 INCH
2
105.8552 MM
2
A33 =2 h ti fr2 0 INCH
2
0 MM
2
A3 =The Greater of A31, A32 or A33 0 INCH
2
0 MM
2
Area Available in Outward Nozzle Weld, A41:
A41 =(LEG)
2
fr2 0.12555 INCH
2
81 MM
2
Area Available in Outer Reinforcing Pad Weld, A42:
A42 =(LEG)
2
fr4 0.12555 INCH
2
81 MM
2
Area Available in Inward Nozzle Weld, A43 :
A43 =(LEG)
2
fr2 0 INCH
2
0 MM
2
Area Available in Reinforcing Pad, A5 :
A5 =(Dp - d - 2tn) te fr4 2.9502 INCH
2
1903.352 MM
2
Total Area Available, AT :
AT =A1 +A2 + A41 +A42 +A43 +A5 4.58282 INCH
2
2956.652 MM
2
AT is greater than A, therefore opening is adequately reinforced.
NOTE. No need for Strength Path Calculations.
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 31 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 5
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
M4a. Nozzle Mark : N1 & N2 6" 150# WNRF (Located at Shell ) without reinforcement
Nozzle Neck Thickness Calculation [UG-45 , UG-27 & APPENDIX 1-1]
Nozzle Size, NPS 6 INCH 150 DN
Nozzle Material ASME SA 106 Grade B
Design Pressure, P 71.708 PSIG 5.04826 Kg/CM
2
G
Design Temperature 140
o
F 60
o
C
For nominated Design Pressure & Temperature, Flange Rating 150#
[ANSI/ASME B16.5-1996]
Allowable Stress of Nozzle Material @ Design Temp. (60
o
C), Sn 17100 PSIG 1203.84 Kg/CM
2
G
Max. Allowable Stress of Nozzle Materiall @ Test Temp.(40
o
C), Snt 17100 PSIG 1203.84 Kg/CM
2
G
[Table 1A, SubPart 1, ASME Sec. II, Part D]
Outside Radius of Nozzle, Ron 3.3125 INCH 84.1375 MM
J oint Efficiency of Nozzle, En (Seamless Pipe) 1
Nozzle Corrosion Allowance, Can 0.19685 INCH 5 MM
Nozzle Thickness Calculation :
Longitudinal Stress, t =PRon /(Sn*En +0.4 P) [APPENDIX 1.1] 0.01387 INCH 0.352236 MM
By adding Corrosion Allowance, t [UG-25] 0.21072 INCH 5.352236 MM
By adding Pipe Tolerance 12.5% to the Thickness of Nozzle, t 0.23706 INCH 6.021265 MM
Use Nozzle 6" NPS with Selected Neck Sch. 80, 0.432 INCH 10.9728 MM
with Thickness 0.432" ( 10.97 MM ). [Table 2 of ANSI B 36.10M-1985-(R-1994)]
Nozzle Neck Maximum Working Pressure, MWP (New & Operating)
Nozzle wall thickness less tolerance 12.5% 0.378 INCH 9.6012 MM
Nozzle wall thickness less tolerance 12.5% - Corrosion allowance 0.18115 INCH 4.6012 MM
MWP, New & cold (10.97 MM) P =Snt E t /(Ron - 0.4 t) [App. 1.1] 2044.67 PSIG 143.944 Kg/CM
2
G
MWP, Operating & corroded (4.6 MM) P =Sn E t /(Ron - 0.4 t) 956.056 PSIG 67.306 Kg/CM
2
G
Nozzle Flange Maximum Working Pressure, MWP (New & Operating)
MWP, New & cold , 150# @ 100
o
F [ASME B.165, Table 2] 285 PSIG 20.064 Kg/CM
2
G
MWP, Operating & corroded, 150# @ 140
o
F [ASME B16.5, Table 2] 275 PSIG 19.36 Kg/CM
2
G
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 32 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 5
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Date : 11.4.2004
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Client : APRC
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
M4. Nozzle Mark : N1 & N2 6" 150#WNRF (Located at Channel) without reinforcement (cont.)
Nozzle Opening Calculation Without Reinforcing [UG-27(c) & Appendix 1-1]
Nozzle Pipe Size, NPS 6 INCH 150 DN
Nozzle Pipe Sch. 80
Design Pressure, P 71.708 PSIG 5.048243 Kg/CM
2
G
Design Temparture 140
o
F 60
o
C
Shell Material ASME SA106 Grade B
Nozzle Material ASME SA 106 Grade B
Reinforcing Pad Material N.A.
Allowable Stress of Shell Material, Sv 17100 PSIG 1203.84 Kg/CM
2
G
Allowable Stress of Nozzle Material, Sn 17100 PSIG 1203.84 Kg/CM
2
G
Allowable Stress of Pad Material, Sp 0 PSIG 0 Kg/CM
2
G
Shell Thickness 0.5 INCH 12.7 MM
Shell Corrosion Allowance, Cas 0.19685 INCH 5 MM
Shell Thickness less Pipe Tolerance 12.5% (12.5% NA) 0.4375 INCH 11.1125 MM
Shell Thickness less Corrosion Allowance & 12.5%, t (12.5% NA) 0.24065 INCH 6.1125 MM
Nozzle Wall Nominal Thickness 0.432 INCH 10.9728 MM
Nozzle Wall Thickness less Pipe Tolerance 12.5% 0.378 INCH 9.6012 MM
Nozzle Corrosion Allowance, Can 0.19685 INCH 5 MM
Nozzle Wall Thick. less Corr. Allowance & 12.5% , tn 0.18115 INCH 4.6012 MM
Nozzle Wall Thick.of Internal Projection (less Corr. Allowance & 12.5%), ti 0.18115 INCH 4.6012 MM
Reinforced Pad Thickness, te 0 INCH 0 MM
J oint Efficiency of Shell, E 1
J oint Efficiency of Nozzle, En 1
Correction Factor, F [UG-37(a)] 1
E1 [Nozzle in solid plate] 1
Shell Outside Diameter, OD 20 INCH 508 MM
Shell Inside Diameter in Corroded Condition, 2R =OD - 2 t 19.5187 INCH 495.775 MM
Shell Inside Radius in Corroded Condition, R 9.75935 INCH 247.8875 MM
Nozzle Outside Diameter, OD 6.625 INCH 168.275 MM
Nozzle Inside Diameter, ID 5.761 INCH 146.3294 MM
Nozzle Projection beyond Inner Vessel Wall, h =min. (h1,h2) 0 INCH 0 MM
h1 =2.5 t 0.60162 INCH 15.28125 MM
h2 =2.5 ti 0.45287 INCH 11.503 MM
Nozzle ID Without Corrosion Allowance & 12.5% , d =OD - 2*tn 6.2627 INCH 159.0726 MM
Finished Radius of Circular Opening, Rn 3.13135 INCH 79.5363 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 33 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 3 of 5
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
M4. Nozzle Mark : N1 & N2 6" 150# WNRF (Located at Channel) without reinforcement (cont.)
Nozzle Opening Calculation With Reinforcing (cont.) [UG-27(c) & Appendix 1-1]
* Outside Diameter of Reinforced Pad (if used) [UG-40(b)&FIG.UG-37.1]
Dp1 =2 d 12.5254 INCH 318.1452 MM
Dp2 =2 (Rn +nozzle wall thk. , tn +vessel wall thk. , t ) 7.1063 INCH 180.5 MM
OD of Reinf. Pad, Dp =the greater of Dp1 or Dp2 0 INCH 0 MM
Calculating Size of Fillet Welds : [UW-16(c)(2)&FIG.UW-16.1]
* For Outward Nozzle Weld [UW-16(c)(2)&FIG.UW-16.1SKETCH (c)]
Calculation of tmin. :
tmin.1 =0.75 inch 0.75 INCH 19.05 MM
tmin.2 (nozzle wall nominal thickness) 0.432 INCH 10.9728 MM
tmin.3 (shell wall thickness) 0.5 INCH 12.7 MM
tmin. =lesser of tmin.1, tmin. & tmin.3 0.432 INCH 10.9728 MM
Calculation of tc : tc1 =0.25 inch 0.25 INCH 6.35 MM
tc2 =0.7 t min. 0.3024 INCH 7.68096 MM
tc =lesser of tc1 & tc2 0.25 INCH 6.35 MM
By Considering Equal Legs Fillet Welds :
Leg of Outward Nozzle Weld =SQRT2 * tc 0.35355 INCH 8.980256 MM
Use Leg with Dimension E in Dwg. No. 7443-33-1A 0.35433 INCH 9 MM
* For Outer Reinforcing Pad Weld (NA) [FIG.UW-16 SKETCH (c)]
tmin.1 =0.75 inch 0.75 INCH 19.05 MM
tmin.2 ( te =thk. of reinforcing element) 0 INCH 0 MM
tmin.3 ( shell wall thickness) 0.5 INCH 12.7 MM
tmin. =lesser of tmin.1, tmin. 2 & tmin.3 0 INCH 0 MM
1/2 t min. 0 INCH 0 MM
By Considering Equal Legs Fillet Welds :
Leg of Outer Pad Weld =SQRT(2)*(tmin./2) 0 INCH 0 MM
Use Leg with Dimension Din Dwg. No. 7443-33-1A 0 INCH 0 MM
* Wall Thickness Required : [UG-27(c)(1)]
Shell tr =PR / (SE - 0.6 P) 0.04829 INCH 1.226577 MM
Nozzle trn =PRn /(SnEn - 0.6 P) 0.01316 INCH 0.334373 MM
* Strength Reduction Factors : Sp / Sv 0
fr1 =Sn / Sv 1
fr2 = Sn / Sv 1
fr3 =lesser of Sn/Sv or Sp/Sv 1
fr4 =Sp / Sv 0
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 34 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 4 of 5
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
M4. Nozzle Mark : N1 & N2 6" 150# WNRF (Located at Channel) without reinforcement (cont.)
MIN. NOZZLE NECK WALL THICKNESS CHECK PER UG-45
A. Wall Thickness per UG-45(a) : trna =trn +C.A. 0.21001 INCH 5.334373 MM

B. Wall Thickness per UG-45(b) : trnb =Min. (trnb1, trnb2, trnb3, trnb0.245 INCH 6.223 MM
Wall Thickness per UG-45(b)(1), trnb1 =Min. (trnb11, trnb12) 0.24514 INCH 6.226577 MM
trnb11 =tr +C.A. (tr for shell or head at E=1) 0.24514 INCH 6.226577 MM
trnb12 =Min Wall Thickness per UG-16(b), see below 0.2906 INCH 7.38125 MM
Wall Thickness per UG-45(b)(2), trnb2 (apply to external pressure only), NA INCH #VALUE! MM
Wall Thickness per UG-45(b)(3), trnb3 (apply to internal & external pressure)
=Max. (trnb1, trnb2) NA INCH #VALUE! MM
Wall Thickness per UG-45(b)(4), trnb4
=Min. thickness of std. wall pipe - 12.5% Max. (icluding CA) 0.245 INCH 6.223 MM
(Under tolerance12.5% in accordance with ASME B36.10M)
Nominal thickness of std. pipe wall thickness, NPS 6", Sch. Std. 0.28 INCH 7.112 MM
Wall Thickness per UG-16(b), trnb12
I - Min. Wall Thickness 1/16" +C.A. 0.25935 INCH 6.5875 MM
II - Min. Wall Thickness of Unfired Steam Boilers =1/4" +C.A. 0.44685 INCH 11.35 MM
III - Min. Wall Thickness of Shell/Head in Compressed Air
Service, Steam Service, and Water Service =3/32" +C.A. 0.2906 INCH 7.38125 MM
Selected Vessel Service in our case is : Case III (compressed air)
So, the Min. Wall Thickness per UG-16(b), trnb12 0.2906 INCH 7.38125 MM
The min. nozzle wall thk. =Max. thk. determined by UG-45(a), or by UG-45(b)0.245 INCH 6.223 MM
The min. nozzle thk. provided =t (1-0.125) 0.378 INCH 9.6012 MM
So, the thickness provided meets the rules of UG-45. OK
Since there is no superimposed loads, the vessel doesn't require
a calculationon shear stresses caused by UG-22(c).
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 35 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 5 of 5
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
M4. Nozzle Mark : N1 & N2 6" 150# WNRF (Located at Channel) without reinforcement (cont.)
Nozzle Opening Calculation Without Reinforcing [UG-37]
Area of Reinforcement (without reinforcing Element) :
Required Area, A =d tr F +2 tn tr F(1-fr1) 0.30243 INCH
2
195.1147 MM
2
Area Available in Shell, A1:
A11 =d (E1 t - F tr) - 2tn (E1 t - F tr)(1-fr1) 1.20469 INCH
2
777.2165 MM
2
A12 =2 (t +tn)(E1 t - F tr) - 2tn (E1 t - F tr)(1-f r1) 0.16227 INCH
2
104.6926 MM
2
A1 =The Greater of A11 or A12 1.20469 INCH
2
777.2165 MM
2
Area Available in Nozzle Projecting Outward, A2 :
A21 =5 (tn - trn) fr2 t 0.20213 INCH
2
130.4049 MM
2
A22 =5 (tn - trn) fr2 tn 0.15215 INCH
2
98.16263 MM
2
A2 =The Lesser of A21 or A22 0.15215 INCH
2
98.16263 MM
2
Area Available in Inward Nozzle, A3 : (Not applicable)
A31 =5 t ti fr2 0.21797 INCH
2
140.6242 MM
2
A32 =5 ti ti fr2 0.16408 INCH
2
105.8552 MM
2
A33 =2 h ti fr2 0 INCH
2
0 MM
2
A3 =The Greater of A31, A32 or A33 0 INCH
2
0 MM
2
Area Available in Outward Nozzle Weld, A41:
A41 =(LEG)
2
fr2 0.12555 INCH
2
81 MM
2
Area Available in Outer Reinforcing Pad Weld, A42:
A42 =(LEG)
2
fr4 0 INCH
2
0 MM
2
Area Available in Inward Nozzle Weld, A43 :
A43 =(LEG)
2
fr2 0 INCH
2
0 MM
2
Area Available in Reinforcing Pad, A5 : (Not applicable)
A5 =(Dp - d - 2tn) te fr4 0 INCH
2
0 MM
2
Total Area Available, AT :
AT =A1 +A2 + A41 +A42 + A43 1.48239 INCH
2
956.3792 MM
2
AT is greater than A, therefore opening is adequately reinforced.
NOTE. No need for Strength Path Calculations.
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 36 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 5 Client : APRC
Exchanger : Residue Cooler, Type : AES Item : E-323A/B & E-514C/D
N. Integral Type (WN) Main Shell Flange Thickness (item no. 4) [Appendix 2] [FIG. 2-4, Sketch (6a)]
Flange Material, [Attached by Bolts] ASME SA266 ClassSubjected to internal press.
Design Temperature (shell side) 302
o
F 150
o
C
Min. Design Metal Temperature, MDMT 53.6
o
F 12
o
C
Bolt-up and Gasket Seating Temperature 86
o
F 30
o
C
Assume no corrosion, C [UG-25] 0.19685 INCH 5 MM
Operating Pressure (shell side) 241.477 PSIG 17 Kg/CM
2
G
Internal Design Pressure, P (MAWP) 284.776 PSIG 20.0483 Kg/CM
2
G
Allowable Stress of Bolt Material (ASME SA193 Gr. B7), S
B
:
* at design temp.(operating condition), Sb 25000 PSIG 1760 Kg/CM
2
G
* or at atmospheric temp./bolt-up temp. (gasket seating), Sa 25000 PSIG 1760 Kg/CM
2
G
Allowable Stress of Flange Material (ASME SA266 Class 2) :
* at design temp.(operating condition), Sf
H
20000 PSIG 1408
Kg/CM
2
G
* or at atmospheric temp./bolt-up temp. (gasket seating), Sf
C
20000 PSIG 1408
Kg/CM
2
G
Allowable Stress of Nozzle neck, Vessel or Pipe wall Material (ASME SA106 Gr. B) :
* at design temp.(operating condition), Sn
H
17100 PSIG 1203.84
Kg/CM
2
G
* or at atmospheric temp./bolt-up temp.(gasket seating), Sn
C
17100 PSIG 1203.84
Kg/CM
2
G
[Table 1A , SubPart 1 , ASME Sec. II , Part D]
FIG. 2-4, Sketch (6a)
Figure (1)
No. of bolts 28
Nominal bolt dia., d
B
1 INCH 25.4 MM
Bolt Hole, d 1.10236 INCH 28 MM
Flange outside diameter, A 26.9685 INCH 685 MM
Flange inside diameter, B 19 INCH 482.6 MM
Bolt circut diameter (B.C.D.), C =B +2(g1 +h1+R) [Appendix 2-3] 24.5276 INCH 623 MM
Hup thickness at small end, g
o
=Shell Thickness t 0.5 INCH 12.7 MM
Hup thickness at back of flange, g
1
(assume g1 =2 go) 1 INCH 25.4 MM
R must not less than 1.5 the bolt hole (see TEMA Table D-5) 1.5 INCH 38 MM
Hup length, h (must greater than 1.5 go) [FIG. 2-4, Sketch 6] 1.5748 INCH 40 MM
Use max. slope 1:3, h =3.5 g0 1.73228 INCH 44 MM
Slope angle, Y =arc Tan [(g1-go)/h] 16.1001 Degree
Fillet radius, r =0.25 g1 [but not less than 3/16"(4.7625 MM)] [FIG. 2-4, Sketch 6, Note a] 0.25 INCH 6.35 MM
Use r 0.23622 INCH 6 MM
h1 =r * Tan (45-Y/2) 0.17768 INCH 5 MM
E =(A-C)/2 (Check D292) 1.22047 INCH 31 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 37 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 5 Client : APRC
Exchanger : Residue Cooler, Type : AES Item : E-323A/B & E-514C/D
N. Integral Type (W.N.) Main Shell Flange Thickness, item no. 4 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
[Attached by Bolts] Subjected to internal pressure
Nominal shell (pipe) size 20"
Pipe Schedule 30
No. of bolts 28
Nominal bolt dia., d
B
1 INCH 25.4 MM
Bolt diameter at root of thread 0.88189 INCH 22.4 MM
Actual cross-sectional area of each bolt, [TEMA Table D-5] 0.551 INCH
2
355.483 MM
2
Total actual cross-sectional area of bolts, Ab 15.428 INCH
2
9953.53 MM
2
Flange outside diameter, A 26.9685 INCH 685 MM
Flange inside diameter, B 19 INCH 482.6 MM
Bolt circut diameter (B.C.D.), C 24.5276 INCH 623 MM
Gasket Details: - Flat metal, jacketed asbestos filled, iron or soft steel
- Outside diameter =(B.C.D - d) - 2*13 22.0472 INCH 560 MM
- Inside diameter =O.D - 2N 20.8661 INCH 530 MM
- Width, N 0.59055 INCH 15 MM
Gasket Dimensions:
Basic gasket seating width, b
O
=N/2 [Table 2-5.2] 0.29528 INCH 7.5 MM
Since bo >1/4 inch (6.35 MM), [Table 2-5.2]
Effective gasket seating width, b =0.5*SQRT(b
O
)

[Table 2-5.2] 0.2717 INCH 6.90109 MM
Gasket Factor, m [Table 2-5.1] 3.75
Min. Seating Stress, y [Table 2-5.1] 7600 PSIG 535.04 Kg/CM
2
G
Facing Sketch [Table 2-5.1] (1a); Column II
Diameter at location of gasket load reaction, G
When bo is larger than 1/4", G =O.D.of gasket contact face - 2 b 21.5039 INCH 546.198 MM
[Appendix 2-3]
N.B. When b <1/4", the effective gasket seating width, b =bo [Table 2-5.2]
N.B. When b >1/4", the effective gasket seating width, b =0.5*SQRT(b
O
) [Table 2-5.2]
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 38 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 3 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 5 Client : APRC
Exchanger : Residue Cooler, Type : AES Item : E-323A/B & E-514C/D
N. Integral Type (W.N.) Main Shell Flange Thickness, item no. 4 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
[Attached by Bolts] Subjected to internal pressure
1. Bolt loading and size of bolts: [Appendix 2-5(c)]
(a) Total hydrostatic end force, H =0.785 G
2
P [Appendix 2-3] 103373 lb 46889.2 Kg
(b) Total joint-contact surface compression load, Hp =2b*3.14GmP 39182.8 lb 17773 Kg
[Appendix 2-3]
(c) Min. required bolt load for operating conditions, Wm1 =H +Hp 142556 lb 64662.2 Kg
Min. required bolt load for gasket seating, Wm2 =3.14 b G y 139426 lb 63242.6 Kg
Allowable Bolt Stress at atmospheric temp., Sa 25000 PSIG 1760 Kg/CM
2
G
Allowable Bolt Stress at design temp., Sb 25000 PSIG 1760 Kg/CM
2
G
[Table 1A, SubPart 1, ASME Sec. II, Part D]
(d) Total cross-sectional area of bolts at root of thread required for:
- operating conditions, Am1 =Wm1 / Sb 5.70222 INCH
2
3678.84 MM
2
- Gasket seating, Am2 =Wm2 / Sa 5.57703 INCH
2
3598.08 MM
2
[Appendix 2-3]
Total required cross-sectional of bolts, Am =the greater of Am1 & Am2 5.70222 INCH
2
3678.84 MM
2
Actual bolt area Ab 15.428 INCH
2
9953.53 MM
2
Since area Ab >area Am, the bolts are adequately enough. OK
(e) Flange design bolt load, W :
- For operating conditions, Wo =Wm1 [Appendix 2-5(d)] 142556 lb 64662.2 Kg
- For gasket seating, Wa =0.5(Am +Ab) * Sa [Appendix 2-5(d)] 264128 lb 119806 Kg
2. Total flange moment for design condition: [Appendix 2-5(c)]
Flange Loads:
Hydrostatic end force on area inside flange, H
D
=0.785 B
2
P 80701.4 lb 36605.6 Kg
Gasket load (flange design bolt load - total hydrostatic end force), H
G
Gasket seating force H
G
=Wm1 - H 39182.8 lb 17773 Kg
Difference bet. total hydrostatic end force and the hydrostatic end force on area inside of flange, HT
H
T
=H - H
D
22671.4 lb 10283.6 Kg
Lever arms:
h
D
=R' +0.5 g1 [Table 2-6] 2.17768 INCH 55.3131 MM
h
G
=(C - G) / 2 [Table 2-6] 1.51185 INCH 38.4011 MM
h
T
=(R' +g1 + h
G
) / 2 [Table 2-6] 2.09477 INCH 53.2071 MM
Where R' =R +h1 1.67768 INCH 42.6131 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 39 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 4 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 5 Client : APRC
Exchanger : Residue Cooler, Type : AES Item : E-323A/B & E-514C/D
N. Integral Type (W.N.) Main Shell Flange Thickness, item no. 4 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
[Attached by Bolts] Subjected to internal presure
Flange Moments:
Component of moment due to H
D
, M
D
=H
D
h
D
[Appendix 2-3] 175742 lb-in 2024.77 Kg-M
Component of moment due to H
G
, M
G
=H
G
h
G
[Appendix 2-3] 59238.6 lb-in 682.503 Kg-M
Component of moment due to H
T
, M
T
=H
T
h
T
[Appendix 2-3] 47491.3 lb-in 547.16 Kg-M
Total moment acting upon the flange, Mo:

[Appendix 2-6]
- For operating condition M
O1
=M
D
+M
G
+M
T
282472 lb-in 3254.43 Kg-M
23539.3 lb-ft
3. Total flange moment for bolt-up condition (Gasket condition):
[Appendix 2-6]
Flange Load: H
G
=W
A
=0.5 (Am +Ab) * Sa 264128 lb 119806 Kg
Lever Arm., h
G
=(C - G) / 2 1.51185 INCH 38.4011 MM
Flange Moment for gasket condition, M
O2
=H
G
h
G
=W
A
(C - G) / 2 (5) 399323 lb-in 4600.7 Kg-M
M
o2
* (Sf
H
/ Sf
C
) 399323 lb-in 4600.7 Kg-M
4. M
O
= The greater of M
O1
or M
O2
(Sf
H
/Sf
C
) 399323 lb-in 4600.7 Kg-M
33276.9 lb-ft
5. Shape constants for flange:
1.41939
From Appendix 2, FIG. 2-7.1:
1.74578
2.97106
5.71057
6.27534
g1/go 2
ho =SQRT(B go) 3.08221
h/ho 0.56203
From Appendix 2, FIG. 2-7.2: F 0.81225
From Appendix 2, FIG. 2-7.3: V 0.21166
From Appendix 2, FIG. 2-7.6: f 1.02557
d =(U/V) ho go
2
(for integral type flanges) [APPENDIX 2-3] 22.8457 INCH
3
374374 MM
3
e =F / ho (for integral type flanges) [APPENDIX 2-3] 0.26353 INCH
-1
0.01038 MM
-1
K
B
A
=
T
K Log k
k k
=
+
+
2
10
2
1 855246 1
104720 19448 1
( . )
( . . )( )
Z
K
K
=
+

2
1
2
1
Y
K
K Log K
K
=

1
2
10
2
1
066845 571690
1
. .
U
K Log K
K K
=
+

2
2
1 855246
10
1
136136 1 1
( . )
. ( )( )
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 40 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 5 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 5 Client : APRC
Exchanger : Residue Cooler, Type : AES Item : E-323A/B & E-514C/D
N. Integral Type (W.N.) Main Shell Flange Thickness, item no. 4 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
[Attached by Bolts] Subjected to internal pressure
6. Calculation of flange actual stresses
Assume t 1.45669 INCH 37 MM
[Appendix 2-3] 0.928
Where t =flange thickness
factor e =F/ ho (for integral type flanges) [Appendix 2-3] 0.26353 INCH
-1
0.01038 MM
-1
e =FL/ ho (for loose type flanges) [Appendix 2-3] NA
F = factor for integral type flanges [Fig. 2-7.2] 0.81225
T = factor involving K [Fig. 2-7.1] 1.74578
d =(U/V) ho go
2
[Appendix 2-3] 22.8457 INCH
3
374374 MM
3
For integral type flange, actual stresses (calculated) : [Fig. 2-4, Sketch (6a)]
1. a. Longitudinal hub stress, operating S
H
=f Mo / L g
1
2
B (6) [Appendix 2-7(a)] 23226.7 PSIG 1635.16
Kg/CM
2
G
b. Longitudinal hub stress, seating S
H
=f Mo2 / L g
1
2
B (6) [Appendix 2-7(a)]
23226.7 PSIG 1635.16
Kg/CM
2
G
2. a. Radial flange stress, operating S
R
=(1.33 t e +1) Mo / L t
2
B (7) [Appendix 2-7(a16135.7 PSIG 1135.96
Kg/CM
2
G
b. Radial flange stress, seating S
R
=(1.33 t e +1) Mo2 / L t
2
B (7) [Appendix 2-7(a16135.7 PSIG 1135.96
Kg/CM
2
G
3. a. Tangential flange stress, operating S
T
=(Y Mo / t
2
B) - Z S
R
(8) [Appendix 2-7(a)]8620.34 PSIG 606.872
Kg/CM
2
G
b. Tangential flange stress, seating S
T
=(Y Mo2 / t
2
B) - Z S
R
(8) [Appendix 2-7(a)8620.34 PSIG 606.872
Kg/CM
2
G
4. a. Flange stress, operating 0.5 (S
H
+S
R
) [Appendix 2-8(a)(4)] 19681.2 PSIG 1385.56
Kg/CM
2
G
b. Flange stress, seating 0.5 (S
H
+S
R
) [Appendix 2-8(a)(4)] 19681.2 PSIG 1385.56
Kg/CM
2
G
5. a. Flange stress, operating 0.5 (S
H
+S
T
) [Appendix 2-8(a)(4)] 15923.5 PSIG 1121.02
Kg/CM
2
G
b. Flange stress, seating 0.5 (S
H
+S
T
) [Appendix 2-8(a)(4)] 15923.5 PSIG 1121.02
Kg/CM
2
G
6. a. Bolt stress, operating =Wm1 / Ab 9240.05 PSIG 650.5 Kg/CM
2
G
b. Bolt stress, seating =Wm2 / Ab 9037.19 PSIG 636.219 Kg/CM
2
G
7. a. Shear stress carried by the fillet weld 0 PSIG 0 Kg/CM
2
G
7. Actual Stresses (Calculated) Compared with Allowable Stresses [APPENDIX 2-8]
7.a. For Operating Condition :
Allowable design stress of flange at operating condiotion, Sf 20000 PSIG 1408 Kg/CM
2
G
Allowable design stress of nozzle/vessel at operating condition, Sn 17100 PSIG 1203.84 Kg/CM
2
G
Assume flange thickness (without C.A), toperating 1.45669 INCH 37 MM
Allowable stresses Actual stresses
(Calculated )
PSIG
Kg/CM
2
PSIG
Kg/CM
2
Longitudinal Hub Stress S
H1
=1.5 Sf [Appendix 2-8(a)(1)(b)] 30000
Longitudinal Hub Stress S
H2
=2 Sn [Appendix 2-8(a)(1)(b)] 34200
The calculated (actual) hub stress S
H
< S
H
(min.) allowable 30000 > 23226.7
Radial Flange Stress S
R
=Sf [Appendix 2-8(a)(2)] 20000 > 16135.7
The calculated (actual) radial stress S
R
< S
R
allowable
Factor L
t
T
t
d
e
=
+
+
1 3 ^
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 41 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 6 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 5 Client : APRC
Exchanger : Residue Cooler, Type : AES Item : E-323A/B & E-514C/D
N. Integral Type (W.N.) Main Shell Flange Thickness, item no. 4 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
Subjected to internal pressure
Tangential Flange Stress S
T
=Sf [Appendix 2-8(a)(3)] 20000 > 8620.34
The calculated (actual) tangential stress S
T
< S
T
allowable
0.5(S
H
+S
R
)

=Sf 20000 > 19681.2
The calculated (actual) stress < Allowable stress
0.5(S
H
+S
T
)

=Sf 20000 > 15923.5
The calculated (actual) stress < Allowable stress
Bolt stress

=Wm1 / Ab 25000 > 9240.05
The calculated (actual) stress < Allowable stress
7.b. For Gasket Seating :
Allowable design stress of flange at gasket seating, Sf 20000 PSIG 1408 Kg/CM
2
G
Allowable design stress of nozzle/vessel at gasket seating, Sn 17100 PSIG 1203.84 Kg/CM
2
G
Assume flange thickness (without C.A), tgasket 1.45669 INCH 37 MM
Allowable stresses Actual stresses
(Calculated )
PSIG
Kg/CM
2
PSIG
Kg/CM
2
Longitudinal Hub Stress S
H1
=1.5 Sf [Appendix 2-8(a)(1)(b)] 30000
Longitudinal Hub Stress S
H2
=2 Sn [Appendix 2-8(a)(1)(b)] 34200
The calculated (actual) hub stress S
H
< S
H
(min.) allowable 30000 > 23226.7
Radial Flange Stress S
R
=Sf [Appendix 2-8(a)(2)] 20000 > 16135.7
The calculated (actual) radial stress S
R
< S
R
allowable
Tangential Flange Stress S
T
=Sf [Appendix 2-8(a)(3)] 20000 > 8620.34
The calculated (actual) tangential stress S
T
< S
T
allowable
0.5(S
H
+S
R
)

=Sf 20000 > 19681.2
The calculated (actual) stress < Allowable stress
0.5(S
H
+S
T
)

=Sf 20000 > 15923.5
The calculated (actual) stress < Allowable stress
Bolt stress

=Wm2 / Ab 25000 > 9037.19
The calculated (actual) stress < Allowable stress
The min. flange thickness, t =Max. (t
operating
, t
gasket
)
1.45669 INCH 37 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 42 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 7 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 5 Client : APRC
Exchanger : Residue Cooler, Type : AES Item : E-323A/B & E-514C/D
N. Integral Type (W.N.) Main Shell Flange Thickness, item no. 4 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
Subjected to internal pressure
Since all actual stresses are less than the allowable stresses, the
selection of t =4.5 inch, is adequate. If an optimum min. thickness
of flange is desired, calculations must be operated with a smaller
value of t until one of the actual stresses or stress combination is
approximately equal to the allowable stress even though other
actual stresses are less than the allowable stress for that actual stress.
Flange thickness with C.A & RF =t +2*corrosion all. +raised face 2.04724 INCH 52 MM
Use flange thickness for construction 2.16535 INCH 55 MM
BOLT SUMMARY
Factor K =A/B 1.41939
Gasket width, N 0.59055 INCH 15 MM
Total required cross-sectional area of bolts 5.70222 INCH
2
3678.84 MM
2
Actual bolt cross-sectional area, Ab 15.428 INCH
2
9953.53 MM
2
Nominal bolt dia., d
B
1 INCH 25.4 MM
1. Actual Edge distance, E from drawing =1/2 (A - C) 1.22047 INCH 31 MM
Min. Edge distance, E (for bolt size 0.75") 0.8125 INCH 20.6375 MM
Min. Edge distance, E (for bolt size 7/8") 0.9375 INCH 23.8125 MM
Min. Edge distance, E (for bolt size 1") 1.0625 INCH 26.9875 MM
Min. Edge distance, E (for bolt size 1-1/8") [TEMA Table D-5] 1.125 INCH 28.575 MM
Min. Edge distance, E (for bolt size 1-1/4") 1.25 INCH 31.75 MM
2. Actual Bolt spacing, B from drawing 2.74622 INCH 69.7539 MM
Min. Bolt spacing, B (for bolt size 0.75") 1.75 INCH 44.45 MM
Min. Bolt spacing, B (for bolt size 7/8") 2.0625 INCH 52.3875 MM
Min. Bolt spacing, B (for bolt size 1") 2.25 INCH 57.15 MM
Min. Bolt spacing, B (for bolt size 1-1/8") [TEMA Table D-5] 2.5 INCH 63.5 MM
Min. Bolt spacing, B (for bolt size 1-1/4") 2.8125 INCH 71.4375 MM
Max. Recommended bolt spacing, Bmax =2 d
B
+6 t / (m +0.5) [TEMA RCB-11.224.05651 INCH 103.035 MM
3. Actual Radial distance, Rh from drawing =(C-B)/2-(g1+h1) 1.56693 INCH 39.8 MM
Min. Radial distance, Rh (for bolt size 0.75") 1.125 INCH 28.575 MM
Min. Radial distance, Rh (for bolt size 7/8") 1.25 INCH 31.75 MM
Min. Radial distance, Rh (for bolt size 1") 1.375 INCH 34.925 MM
Min. Radial distance, Rh (for bolt size 1-1/8") [TEMA Table D-5] 1.5 INCH 38.1 MM
Min. Radial distance, Rh (for bolt size 1-1/4") 1.75 INCH 44.45 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 43 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 8 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 5 Client : APRC
Exchanger : Residue Cooler, Type : AES Item : E-323A/B & E-514C/D
N. Integral Type (W.N.) Main Shell Flange Thickness, item no. 4 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
FLANGE FACTORS Subjected to internal pressure
(a) For Integral Flanges
Factor F per Fig. 2-7.2 is then solved by 0.81225
Factor V per Fig. 2-7.3 is then solved by 0.21166
Factor f per Fig. 2-7.6 is then solved by f =C
36
/ (1 +A) 1.02557
h/SQRT(BG
o 0.562026971
The values used in the above equations are solved using Eqs. (1) through (45) below based on the values g
1
, g
0
, h and ho
as defined by 2-3. When g
1
=g
o
, F =0.908920, V =0.550103, and f =1; thus Eqs. (1) through (45) need not be solved.
(b) For Loose Hub Flanges
Factor F
L
per Fig. 2-7.4 is solved by
1.435
Factor V
L
per Fig. 2-7.5 is solved by 0.66229
Factor f per Fig. 2-7.6 is set equal to 1. f =1 1
The values used in the above equations are solved using Eqs. (1) through (5), (7), (9), (10), (12),
(14), (16), (18), (20), (23), and (26) below based on the values of g
1
, g
0
, h, and h
o
as defined by 2-3.
g
o
0.5 INCH 12.7 MM
g
1
1 INCH 25.4 MM
h 1.73228 INCH 44 MM
h
o
=SQRT(B go), Effective hub length 3.08221 INCH 78.2881 MM
B 19 INCH 482.6 MM
(1) A =(g1/go) - 1 1
(2) C =43.68(h/ho)
4
4.35824
(3) C
1
=1/3 +A/12 0.41667
(4) C
2
=5/42 +17 A / 336 0.16964
(5) C
3
=1/210 +A/360 0.00754
(6) C
4
=11/360 +59 A/5040 +(1+3 A)/C 0.96006
(7) C
5
=1/90 +5 A/1008 - (1+A)
3
/C -1.81953
F
E
C A
C
=
+
6
1 4
3
2 73
1
[
.
]
( )
/
V
E
C
A
=
+
4
1 4 3
273
1 [
.
] ( )
/
F
C
A
C
A
C
A A
C A
C
L
=
+

+ +

+ +

+
18 21 24
1 4 3
1
2 6
1
4
11
84
1
70 105
1
40 72
2 73
1
.
( )
/
V
C C
C
C
A
L
=

+
1
4 5
3
2
273
1
24 21
18
1 4
3
.
( )
/
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 44 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 9 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 5 Client : APRC
Exchanger : Residue Cooler, Type : AES Item : E-323A/B & E-514C/D
N. Integral Type (W.N.) Main Shell Flange Thickness, item no. 4 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
FLANGE FACTORS (CONT.) Subjected to internal pressure
(8) C
6
=1/120 +17 A/5040 +1 /C 0.24116
(9) C
7
=215/2772 +51 A/1232 +(60/7 +225 A/14 +75A
2
/7 +5 A
3
/2)/C 8.80529
(10) C
8
=31/6930 +128 A/45045 +(6/7 +15 A/7 +12A
2
/7 +5 A
3
/11)/C 1.19331
(11) C
9
=533/30240 +653 A/73920 +(1/2 +33 A/14 +39 A
2
/28 +25 A
3
/84)/C 1.06991
(12) C
10
=29/3780 +3 A/704 - (1/2 +33 A/14 +81 A
2
/28 +13 A
3
/12)/C -1.55598
(13) C
11
=31/6048 +1763 A/665280 +(1/2 +6 A/7 +15 A
2
/28 +5 A
3
/42)/C 0.46941
(14) C
12
=1/2925 +71 A/300300 +(8/35 +18 A /35 +156 A
2
/385 +6 A
3
/55)/C 0.28903
(15) C
13
=761/831600 +937 A/1663200 +(1/35 +6 A /35 +11 A
2
/70 +3 A
3
/70)/0.09326
(16) C
14
=197/415800 +103 A/332640 - (1/35 +6 A /35 +17 A
2
/70 + A
3
/10)/C -0.12378
(17) C
15
=233/831600 +97 A/554400 +(1/35 +3 A /35 + A
2
/14 + 2 A
3
/105)/C 0.04744
(18) C
16
=C
1
C
7
C
12
+C
2
C
8
C
3
+C
3
C
8
C
2
- (C
3
2
C
7
+C
8
2
C
1
+ C
2
2
C
12
) 0.46133
(19) C
17
=[C
4
C
7
C
12
+C
2
C
8
C
13
+C
3
C
8
C
9
- (C
13
C
7
C
3
+C
8
2
C
4
+ C
12
C
2
C
9
)] / C
16
2.2676
(20) C
18
=[C
5
C
7
C
12
+C
2
C
8
C
14
+C
3
C
8
C
10
- (C
14
C
7
C
3
+C
8
2
C
5
+ C
12
C
2
C
10
)] / C
16
-4.32293
(21) C
19
=[C
6
C
7
C
12
+C
2
C
8
C
15
+C
3
C
8
C
11
- (C
15
C
7
C
3
+C
8
2
C
6
+ C
12
C
2
C
11
)] / C
16
0.55926
(22) C
20
=[C
1
C
9
C
12
+C
4
C
8
C
3
+C
3
C
13
C
2
- (C
3
2
C
9
+C
13
C
8
C
1
+C
12
C
4
C
2
)] / C
16
0.0956
(23) C
21
=[C
1
C
10
C
12
+C
5
C
8
C
3
+C
3
C
14
C
2
- (C
3
2
C
10
+C
14
C
8
C
1
+C
12
C
5
C
2
)] / C
16
-0.11503
(24) C
22
=[C
1
C
11
C
12
+C
6
C
8
C
3
+C
3
C
15
C
2
- (C
3
2
C
11
+C
15
C
8
C
1
+C
12
C
6
C
2
)] / C
16
0.05056
(25) C
23
=[C
1
C
7
C
13
+C
2
C
9
C
3
+C
4
C
8
C
2
- (C
3
C
7
C
4
+C
8
C
9
C
1
+C
2
2
C
13
)] / C
16
-0.13119
(26) C
24
=[C
1
C
7
C
14
+C
2
C
10
C
3
+C
5
C
8
C
2
- (C
3
C
7
C
5
+C
8
C
10
C
1
+C
2
2
C
14
)] / C
16
0.15946
(27) C
25
=[C
1
C
7
C
15
+C
2
C
11
C
3
+C
6
C
8
C
2
- (C
3
C
7
C
6
+C
8
C
11
C
1
+C
2
2
C
15
)] / C
16
-0.05919
(28) C
26
=- (C/4)
1/4
-1.02168
(29) C
27
=C
20
-

C
17
- 5/12 +C
17
C
26
-4.90543
(30) C
28
=C
22
-

C
19
- 1/12 +C
19
C
26
-1.16343
(31) C
29
=- (C/4)
1/2
-1.04382
(32) C
30
=- (C/4)
3/4
-1.06644
(33) C
31
=3 A/2 - C
17
C
30
3.91827
(34) C
32
=1/2 - C
19
C
30
1.09642
(35) C
33
=0.5 C
26
C
32
+C
28
C
31
C
29
- (0.5 C
30
C
28
+C
32
C
27
C
29
) -2.03619
(36) C
34
=1/12 +C
18
- C
21 -
C
18
C
26
-8.54118
(37) C
35
=- C
18
(C/4)
3/4
4.61016
(38) C
36
=(C
28
C
35
C
29
- C
32
C
34
C
29
)/C
33
2.05114
(39) C
37
=[0.5 C
26
C
35
+C
34
C
31
C
29
- (0.5 C
30
C
34
+C
35
C
27
C
29
)] / C
33
-2.16975
(40) E
1
=C
17
C
36
+C
18
+C
19
C
37
-0.88522
(41) E
2
=C
20
C
36
+C
21
+C
22
C
37
-0.02864
(42) E
3
=C
23
C
36
+C
24
+C
25
C
37
0.01881
(43) E
4
=1/4 +C
37
/12

+C
36
/4 -

E
3
/5

-

3E
2
/2 -

E
1
1.50639
(44) E
5
=E
1
(1/2 +A/6) +E
2
(1/4

+11A/84) +E
3
(1/70 +A/105) -0.60061
(45) E
6
=E
5
- C
36
(7/120 +A/36 +3A/C) -

1/40

- A/72 - C
37
(1/60 +A/120 +1/C) -1.67593
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 45 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 10 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 5 Client : APRC
Exchanger : Residue Cooler, Type : AES Item : E-323A/B & E-514C/D
N. Integral Type (W.N.) Main Shell Flange Thickness, item no. 4 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
Subjected to internal pressure
APPENDIX 2-3
When B <20 g1, it will be optional for the designer to substitute B1 in the
formula stress S
H
=f * Mo /( L * g
1
2
* B).
20 * g1 20 INCH 508 MM
B 19 INCH 482.6 MM
B1 =B +g1 for loose & integral type flanges have f <1 ( the min. f permitted is 1) 20 INCH 508 MM
B1 =B +go for integral type flanges when f =>1 19.5 INCH 495.3 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 46 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 6 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
N1. Integral Type (WN) Main Shell Flange Thickness (item no. 3) [Appendix 2] [FIG. 2-4, Sketch (6a)]
Flange Material, [Attached by Bolts] ASME SA266 ClassSubjected to internal press.
Design Temperature (shell side) 302
o
F 150
o
C
Min. Design Metal Temperature, MDMT 53.6
o
F 12
o
C
Bolt-up and Gasket Seating Temperature 86
o
F 30
o
C
Assume no corrosion, C [UG-25] 0.19685 INCH 5 MM
Operating Pressure (shell side) 241.477 PSIG 17 Kg/CM
2
G
Internal Design Pressure, P (MAWP) 284.776 PSIG 20.0483 Kg/CM
2
G
Allowable Stress of Bolt Material (ASME SA193 Gr. B7), S
B
:
* at design temp.(operating condition), Sb 25000 PSIG 1760 Kg/CM
2
G
* or at atmospheric temp./bolt-up temp. (gasket seating), Sa 25000 PSIG 1760 Kg/CM
2
G
Allowable Stress of Flange Material (ASME SA266 Class 2) :
* at design temp.(operating condition), Sf
H
20000 PSIG 1408
Kg/CM
2
G
* or at atmospheric temp./bolt-up temp. (gasket seating), Sf
C
20000 PSIG 1408
Kg/CM
2
G
Allowable Stress of Nozzle neck, Vessel or Pipe wall Material (ASME SA106 Gr. B) :
* at design temp.(operating condition), Sn
H
17100 PSIG 1203.84
Kg/CM
2
G
* or at atmospheric temp./bolt-up temp.(gasket seating), Sn
C
17100 PSIG 1203.84
Kg/CM
2
G
[Table 1A , SubPart 1 , ASME Sec. II , Part D]
FIG. 2-4, Sketch (6a)
Figure (2)
No. of bolts 32
Nominal bolt dia., d
B
1 INCH 25.4 MM
Bolt Hole, d 1.10236 INCH 28 MM
Flange outside diameter, A 33.0709 INCH 840 MM
Flange inside diameter, B 19 INCH 482.6 MM
Bolt circut diameter (B.C.D.), C =B +2(g1 +h1+R) [Appendix 2-3] 30.6299 INCH 778 MM
Hup thickness at small end, g
o
=Shell Thickness t 0.5 INCH 12.7 MM
Hup thickness at back of flange, g
1
(assume g1 =2 go) 1 INCH 25.4 MM
R must not less than 1.5 the bolt hole (see TEMA Table D-5) 1.5 INCH 38 MM
Hup length, h (must greater than 1.5 go) [FIG. 2-4, Sketch 6] 1.5748 INCH 40 MM
Use max. slope 1:3, h =3.5 g0 1.73228 INCH 44 MM
Slope angle, Y =arc Tan [(g1-go)/h] 16.1001 Degree
Fillet radius, r =0.25 g1 [but not less than 3/16"(4.7625 MM)] [FIG. 2-4, Sketch 6, Note a] 0.25 INCH 6.35 MM
Use r 0.23622 INCH 6 MM
h1 =r * Tan (45-Y/2) 0.17768 INCH 5 MM
E =(A-C)/2 (Check D292) 1.22047 INCH 31 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 47 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 6 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
N1. Integral Type (W.N.) Main Shell Flange Thickness, item no. 3 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
[Attached by Bolts] Subjected to internal pressure
Nominal shell (pipe) size 20"
Pipe Schedule 30
No. of bolts 32
Nominal bolt dia., d
B
1 INCH 25.4 MM
Bolt diameter at root of thread 0.88189 INCH 22.4 MM
Actual cross-sectional area of each bolt, [TEMA Table D-5] 0.551 INCH
2
355.483 MM
2
Total actual cross-sectional area of bolts, Ab 17.632 INCH
2
11375.5 MM
2
Flange outside diameter, A 33.0709 INCH 840 MM
Flange inside diameter, B 19 INCH 482.6 MM
Bolt circut diameter (B.C.D.), C 30.6299 INCH 778 MM
Gasket Details: - Flat metal, jacketed asbestos filled, iron or soft steel
- Outside diameter =(B.C.D - d) - 2*13 27.9528 INCH 710 MM
- Inside diameter =O.D - 2N 26.7717 INCH 680 MM
- Width, N 0.59055 INCH 15 MM
Gasket Dimensions:
Basic gasket seating width, b
O
=N/2 [Table 2-5.2] 0.29528 INCH 7.5 MM
Since bo >1/4 inch (6.35 MM), [Table 2-5.2]
Effective gasket seating width, b =0.5*SQRT(b
O
)

[Table 2-5.2] 0.2717 INCH 6.90109 MM
Gasket Factor, m [Table 2-5.1] 3.75
Min. Seating Stress, y [Table 2-5.1] 7600 PSIG 535.04 Kg/CM
2
G
Facing Sketch [Table 2-5.1] (1a); Column II
Diameter at location of gasket load reaction, G
When bo is larger than 1/4", G =O.D.of gasket contact face - 2 b 27.4094 INCH 696.198 MM
[Appendix 2-3]
N.B. When b <1/4", the effective gasket seating width, b =bo [Table 2-5.2]
N.B. When b >1/4", the effective gasket seating width, b =0.5*SQRT(b
O
) [Table 2-5.2]
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 48 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 3 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 6 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
N1. Integral Type (W.N.) Main Shell Flange Thickness, item no. 3 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
[Attached by Bolts] Subjected to internal pressure
1. Bolt loading and size of bolts: [Appendix 2-5(c)]
(a) Total hydrostatic end force, H =0.785 G
2
P [Appendix 2-3] 167947 lb 76179.4 Kg
(b) Total joint-contact surface compression load, Hp =2b*3.14GmP 49943.3 lb 22653.9 Kg
[Appendix 2-3]
(c) Min. required bolt load for operating conditions, Wm1 =H +Hp 217890 lb 98833.4 Kg
Min. required bolt load for gasket seating, Wm2 =3.14 b G y 177716 lb 80610.6 Kg
Allowable Bolt Stress at atmospheric temp., Sa 25000 PSIG 1760 Kg/CM
2
G
Allowable Bolt Stress at design temp., Sb 25000 PSIG 1760 Kg/CM
2
G
[Table 1A , SubPart 1 , ASME Sec. II , Part D]
(d) Total cross-sectional area of bolts at root of thread required for:
- operating conditions, Am1 =Wm1 / Sb 8.7156 INCH
2
5622.96 MM
2
- Gasket seating, Am2 =Wm2 / Sa 7.10863 INCH
2
4586.2 MM
2
[Appendix 2-3]
Total required cross-sectional of bolts, Am =the greater of Am1 & Am2 8.7156 INCH
2
5622.96 MM
2
Actual bolt area Ab 17.632 INCH
2
11375.5 MM
2
Since area Ab >area Am, the bolts are adequately enough. OK
(e) Flange design bolt load, W :
- For operating conditions, Wo =Wm1 [Appendix 2-5(d)] 217890 lb 98833.4 Kg
- For gasket seating, Wa =0.5(Am +Ab) * Sa [Appendix 2-5(d)] 329345 lb 149389 Kg
2. Total flange moment for design condition: [Appendix 2-5(c)]
Flange Loads:
Hydrostatic end force on area inside flange, H
D
=0.785 B
2
P 80701.4 lb 36605.6 Kg
Gasket load (flange design bolt load - total hydrostatic end force), H
G
Gasket seating force H
G
=Wm1 - H 49943.3 lb 22653.9 Kg
Difference bet. total hydrostatic end force and the hydrostatic end force on area inside of flange, HT
H
T
=H - H
D
87245.4 lb 39573.9 Kg
Lever arms:
h
D
=R' +0.5 g1 [Table 2-6] 2.17768 INCH 55.3131 MM
h
G
=(C - G) / 2 [Table 2-6] 1.61028 INCH 40.9011 MM
h
T
=(R' +g1 + h
G
) / 2 [Table 2-6] 2.14398 INCH 54.4571 MM
Where R' =R +h1 1.67768 INCH 42.6131 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 49 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 4 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 6 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
N1. Integral Type (W.N.) Main Shell Flange Thickness, item no. 3 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
[Attached by Bolts] Subjected to internal presure
Flange Moments:
Component of moment due to H
D
, M
D
=H
D
h
D
[Appendix 2-3] 175742 lb-in 2024.77 Kg-M
Component of moment due to H
G
, M
G
=H
G
h
G
[Appendix 2-3] 80422.7 lb-in 926.571 Kg-M
Component of moment due to H
T
, M
T
=H
T
h
T
[Appendix 2-3] 187052 lb-in 2155.08 Kg-M
Total moment acting upon the flange, Mo:

[Appendix 2-6]
- For operating condition M
O1
=M
D
+M
G
+M
T
443217 lb-in 5106.42 Kg-M
36934.7 lb-ft
3. Total flange moment for bolt-up condition (Gasket condition):
[Appendix 2-6]
Flange Load: H
G
=W
A
=0.5 (Am +Ab) * Sa 329345 lb 149389 Kg
Lever Arm., h
G
=(C - G) / 2 1.61028 INCH 40.9011 MM
Flange Moment for gasket condition, M
O2
=H
G
h
G
=W
A
(C - G) / 2 (5) 530337 lb-in 6110.16 Kg-M
M
o2
* (Sf
H
/ Sf
C
) 530337 lb-in 6110.16 Kg-M
4. M
O
= The greater of M
O1
or M
O2
(Sf
H
/Sf
C
) 530337 lb-in 6110.16 Kg-M
44194.8 lb-ft
5. Shape constants for flange:
1.74057
From Appendix 2, FIG. 2-7.1:
1.60851
1.98542
3.67613
4.03969
g1/go 2
ho =SQRT(B go) 3.08221
h/ho 0.56203
From Appendix 2, FIG. 2-7.2: F 0.81225
From Appendix 2, FIG. 2-7.3: V 0.21166
From Appendix 2, FIG. 2-7.6: f 1.02557
d =(U/V) ho go
2
(for integral type flanges) [APPENDIX 2-3] 14.7067 INCH
3
241000 MM
3
e =F / ho (for integral type flanges) [APPENDIX 2-3] 0.26353 INCH
-1
0.01038 MM
-1
K
B
A
=
T
K Log k
k k
=
+
+
2
10
2
1 855246 1
104720 19448 1
( . )
( . . )( )
Z
K
K
=
+

2
1
2
1
Y
K
K Log K
K
=

1
2
10
2
1
066845 571690
1
. .
U
K Log K
K K
=
+

2
2
1 855246
10
1
136136 1 1
( . )
. ( )( )
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 50 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 5 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 6 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
N1. Integral Type (W.N.) Main Shell Flange Thickness, item no. 3 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
[Attached by Bolts] Subjected to internal pressure
6. Calculation of flange actual stresses
Assume t 1.59449 INCH 40.5 MM
[Appendix 2-3] 1.15857
Where t =flange thickness
factor e =F/ ho (for integral type flanges) [Appendix 2-3] 0.26353 INCH
-1
0.01038 MM
-1
e =FL/ ho (for loose type flanges) [Appendix 2-3] NA
F = factor for integral type flanges [Fig. 2-7.2] 0.81225
T = factor involving K [Fig. 2-7.1] 1.60851
d =(U/V) ho go
2
[Appendix 2-3] 14.7067 INCH
3
241000 MM
3
For integral type flange, actual stresses (calculated) : [Fig. 2-4, Sketch (6a)]
1. a. Longitudinal hub stress, operating S
H
=f Mo / L g
1
2
B (6) [Appendix 2-7(a)] 24708.2 PSIG 1739.46
Kg/CM
2
G
b. Longitudinal hub stress, seating S
H
=f Mo2 / L g
1
2
B (6) [Appendix 2-7(a)]
24708.2 PSIG 1739.46
Kg/CM
2
G
2. a. Radial flange stress, operating S
R
=(1.33 t e +1) Mo / L t
2
B (7) [Appendix 2-7(a14785.2 PSIG 1040.88
Kg/CM
2
G
b. Radial flange stress, seating S
R
=(1.33 t e +1) Mo2 / L t
2
B (7) [Appendix 2-7(a14785.2 PSIG 1040.88
Kg/CM
2
G
3. a. Tangential flange stress, operating S
T
=(Y Mo / t
2
B) - Z S
R
(8) [Appendix 2-7(a)]11004.8 PSIG 774.737
Kg/CM
2
G
b. Tangential flange stress, seating S
T
=(Y Mo2 / t
2
B) - Z S
R
(8) [Appendix 2-7(a)11004.8 PSIG 774.737
Kg/CM
2
G
4. a. Flange stress, operating 0.5 (S
H
+S
R
) [Appendix 2-8(a)(4)] 19746.7 PSIG 1390.17
Kg/CM
2
G
b. Flange stress, seating 0.5 (S
H
+S
R
) [Appendix 2-8(a)(4)] 19746.7 PSIG 1390.17
Kg/CM
2
G
5. a. Flange stress, operating 0.5 (S
H
+S
T
) [Appendix 2-8(a)(4)] 17856.5 PSIG 1257.1
Kg/CM
2
G
b. Flange stress, seating 0.5 (S
H
+S
T
) [Appendix 2-8(a)(4)] 17856.5 PSIG 1257.1
Kg/CM
2
G
6. a. Bolt stress, operating =Wm1 / Ab 12357.6 PSIG 869.979 Kg/CM
2
G
b. Bolt stress, seating =Wm2 / Ab 10079.2 PSIG 709.573 Kg/CM
2
G
7. a. Shear stress carried by the fillet weld 0 PSIG 0 Kg/CM
2
G
7. Actual Stresses (Calculated) Compared with Allowable Stresses [APPENDIX 2-8]
7.a. For Operating Condition :
Allowable design stress of flange at operating condiotion, Sf 20000 PSIG 1408 Kg/CM
2
G
Allowable design stress of nozzle/vessel at operating condition, Sn 17100 PSIG 1203.84 Kg/CM
2
G
Assume flange thickness (without C.A), toperating 1.59449 INCH 40.5 MM
Allowable stresses Actual stresses
(Calculated )
PSIG
Kg/CM
2
PSIG
Kg/CM
2
Longitudinal Hub Stress S
H1
=1.5 Sf [Appendix 2-8(a)(1)(b)] 30000
Longitudinal Hub Stress S
H2
=2 Sn [Appendix 2-8(a)(1)(b)] 34200
The calculated (actual) hub stress S
H
< S
H
(min.) allowable 30000 > 24708.2
Radial Flange Stress S
R
=Sf [Appendix 2-8(a)(2)] 20000 > 14785.2
The calculated (actual) radial stress S
R
< S
R
allowable
Factor L
t
T
t
d
e
=
+
+
1 3 ^
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 51 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 6 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 6 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
N1. Integral Type (W.N.) Main Shell Flange Thickness, item no. 3 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
Subjected to internal pressure
Tangential Flange Stress S
T
=Sf [Appendix 2-8(a)(3)] 20000 > 11004.8
The calculated (actual) tangential stress S
T
< S
T
allowable
0.5(S
H
+S
R
)

=Sf 20000 > 19746.7
The calculated (actual) stress < Allowable stress
0.5(S
H
+S
T
)

=Sf 20000 > 17856.5
The calculated (actual) stress < Allowable stress
Bolt stress

=Wm1 / Ab 25000 > 12357.6
The calculated (actual) stress < Allowable stress
7.b. For Gasket Seating :
Allowable design stress of flange at gasket seating, Sf 20000 PSIG 1408 Kg/CM
2
G
Allowable design stress of nozzle/vessel at gasket seating, Sn 17100 PSIG 1203.84 Kg/CM
2
G
Assume flange thickness (without C.A), tgasket 1.59449 INCH 40.5 MM
Allowable stresses Actual stresses
(Calculated )
PSIG
Kg/CM
2
PSIG
Kg/CM
2
Longitudinal Hub Stress S
H1
=1.5 Sf [Appendix 2-8(a)(1)(b)] 30000
Longitudinal Hub Stress S
H2
=2 Sn [Appendix 2-8(a)(1)(b)] 34200
The calculated (actual) hub stress S
H
< S
H
(min.) allowable 30000 > 24708.2
Radial Flange Stress S
R
=Sf [Appendix 2-8(a)(2)] 20000 > 14785.2
The calculated (actual) radial stress S
R
< S
R
allowable
Tangential Flange Stress S
T
=Sf [Appendix 2-8(a)(3)] 20000 > 11004.8
The calculated (actual) tangential stress S
T
< S
T
allowable
0.5(S
H
+S
R
)

=Sf 20000 > 19746.7
The calculated (actual) stress < Allowable stress
0.5(S
H
+S
T
)

=Sf 20000 > 17856.5
The calculated (actual) stress < Allowable stress
Bolt stress

=Wm2 / Ab 25000 > 10079.2
The calculated (actual) stress < Allowable stress
The min. flange thickness, t =Max. (t
operating
, t
gasket
)
1.59449 INCH 40.5 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 52 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 7 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 6 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
N1. Integral Type (W.N.) Main Shell Flange Thickness, item no. 3 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
Subjected to internal pressure
Since all actual stresses are less than the allowable stresses, the
selection of t =4.5 inch, is adequate. If an optimum min. thickness
of flange is desired, calculations must be operated with a smaller
value of t until one of the actual stresses or stress combination is
approximately equal to the allowable stress even though other
actual stresses are less than the allowable stress for that actual stress.
Flange thickness with C.A & RF =t +2*corrosion all. +raised face 1.98819 INCH 50.5 MM
Use flange thickness for construction 2.04724 INCH 52 MM
BOLT SUMMARY
Factor K =A/B 1.74057
Gasket width, N 0.59055 INCH 15 MM
Total required cross-sectional area of bolts 8.7156 INCH
2
5622.96 MM
2
Actual bolt cross-sectional area, Ab 17.632 INCH
2
11375.5 MM
2
Nominal bolt dia., d
B
1 INCH 25.4 MM
1. Actual Edge distance, E from drawing =1/2 (A - C) 1.22047 INCH 31 MM
Min. Edge distance, E (for bolt size 0.75") 0.8125 INCH 20.6375 MM
Min. Edge distance, E (for bolt size 7/8") 0.9375 INCH 23.8125 MM
Min. Edge distance, E (for bolt size 1") 1.0625 INCH 26.9875 MM
Min. Edge distance, E (for bolt size 1-1/8") [TEMA Table D-5] 1.125 INCH 28.575 MM
Min. Edge distance, E (for bolt size 1-1/4") 1.25 INCH 31.75 MM
2. Actual Bolt spacing, B from drawing 3.00226 INCH 76.2573 MM
Min. Bolt spacing, B (for bolt size 0.75") 1.75 INCH 44.45 MM
Min. Bolt spacing, B (for bolt size 7/8") 2.0625 INCH 52.3875 MM
Min. Bolt spacing, B (for bolt size 1") 2.25 INCH 57.15 MM
Min. Bolt spacing, B (for bolt size 1-1/8") [TEMA Table D-5] 2.5 INCH 63.5 MM
Min. Bolt spacing, B (for bolt size 1-1/4") 2.8125 INCH 71.4375 MM
Max. Recommended bolt spacing, Bmax =2 d
B
+6 t / (m +0.5) [TEMA RCB-11.224.25104 INCH 107.976 MM
3. Actual Radial distance, Rh from drawing =(C-B)/2-(g1+h1) 4.61811 INCH 117.3 MM
Min. Radial distance, Rh (for bolt size 0.75") 1.125 INCH 28.575 MM
Min. Radial distance, Rh (for bolt size 7/8") 1.25 INCH 31.75 MM
Min. Radial distance, Rh (for bolt size 1") 1.375 INCH 34.925 MM
Min. Radial distance, Rh (for bolt size 1-1/8") [TEMA Table D-5] 1.5 INCH 38.1 MM
Min. Radial distance, Rh (for bolt size 1-1/4") 1.75 INCH 44.45 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 53 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 8 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 6 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
N1. Integral Type (W.N.) Main Shell Flange Thickness, item no. 3 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
FLANGE FACTORS Subjected to internal pressure
(a) For Integral Flanges
Factor F per Fig. 2-7.2 is then solved by 0.81225
Factor V per Fig. 2-7.3 is then solved by 0.21166
Factor f per Fig. 2-7.6 is then solved by f =C
36
/ (1 +A) 1.02557
h/SQRT(BG
o 0.562026971
The values used in the above equations are solved using Eqs. (1) through (45) below based on the values g
1
, g
0
, h and ho
as defined by 2-3. When g
1
=g
o
, F =0.908920, V =0.550103, and f =1; thus Eqs. (1) through (45) need not be solved.
(b) For Loose Hub Flanges
Factor F
L
per Fig. 2-7.4 is solved by
1.435
Factor V
L
per Fig. 2-7.5 is solved by 0.66229
Factor f per Fig. 2-7.6 is set equal to 1. f =1 1
The values used in the above equations are solved using Eqs. (1) through (5), (7), (9), (10), (12),
(14), (16), (18), (20), (23), and (26) below based on the values of g
1
, g
0
, h, and h
o
as defined by 2-3.
g
o
0.5 INCH 12.7 MM
g
1
1 INCH 25.4 MM
h 1.73228 INCH 44 MM
h
o
=SQRT(B go), Effective hub length 3.08221 INCH 78.2881 MM
B 19 INCH 482.6 MM
(1) A =(g1/go) - 1 1
(2) C =43.68(h/ho)
4
4.35824
(3) C
1
=1/3 +A/12 0.41667
(4) C
2
=5/42 +17 A / 336 0.16964
(5) C
3
=1/210 +A/360 0.00754
(6) C
4
=11/360 +59 A/5040 +(1+3 A)/C 0.96006
(7) C
5
=1/90 +5 A/1008 - (1+A)
3
/C -1.81953
F
E
C A
C
=
+
6
1 4
3
2 73
1
[
.
]
( )
/
V
E
C
A
=
+
4
1 4 3
273
1 [
.
] ( )
/
F
C
A
C
A
C
A A
C A
C
L
=
+

+ +

+ +

+
18 21 24
1 4 3
1
2 6
1
4
11
84
1
70 105
1
40 72
2 73
1
.
( )
/
V
C C
C
C
A
L
=

+
1
4 5
3
2
273
1
24 21
18
1 4
3
.
( )
/
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 54 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 9 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 6 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
N1. Integral Type (W.N.) Main Shell Flange Thickness, item no. 3 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
FLANGE FACTORS (CONT.) Subjected to internal pressure
(8) C
6
=1/120 +17 A/5040 +1 /C 0.24116
(9) C
7
=215/2772 +51 A/1232 +(60/7 +225 A/14 +75A
2
/7 +5 A
3
/2)/C 8.80529
(10) C
8
=31/6930 +128 A/45045 +(6/7 +15 A/7 +12A
2
/7 +5 A
3
/11)/C 1.19331
(11) C
9
=533/30240 +653 A/73920 +(1/2 +33 A/14 +39 A
2
/28 +25 A
3
/84)/C 1.06991
(12) C
10
=29/3780 +3 A/704 - (1/2 +33 A/14 +81 A
2
/28 +13 A
3
/12)/C -1.55598
(13) C
11
=31/6048 +1763 A/665280 +(1/2 +6 A/7 +15 A
2
/28 +5 A
3
/42)/C 0.46941
(14) C
12
=1/2925 +71 A/300300 +(8/35 +18 A /35 +156 A
2
/385 +6 A
3
/55)/C 0.28903
(15) C
13
=761/831600 +937 A/1663200 +(1/35 +6 A /35 +11 A
2
/70 +3 A
3
/70)/0.09326
(16) C
14
=197/415800 +103 A/332640 - (1/35 +6 A /35 +17 A
2
/70 + A
3
/10)/C -0.12378
(17) C
15
=233/831600 +97 A/554400 +(1/35 +3 A /35 + A
2
/14 + 2 A
3
/105)/C 0.04744
(18) C
16
=C
1
C
7
C
12
+C
2
C
8
C
3
+C
3
C
8
C
2
- (C
3
2
C
7
+C
8
2
C
1
+ C
2
2
C
12
) 0.46133
(19) C
17
=[C
4
C
7
C
12
+C
2
C
8
C
13
+C
3
C
8
C
9
- (C
13
C
7
C
3
+C
8
2
C
4
+ C
12
C
2
C
9
)] / C
16
2.2676
(20) C
18
=[C
5
C
7
C
12
+C
2
C
8
C
14
+C
3
C
8
C
10
- (C
14
C
7
C
3
+C
8
2
C
5
+ C
12
C
2
C
10
)] / C
16
-4.32293
(21) C
19
=[C
6
C
7
C
12
+C
2
C
8
C
15
+C
3
C
8
C
11
- (C
15
C
7
C
3
+C
8
2
C
6
+ C
12
C
2
C
11
)] / C
16
0.55926
(22) C
20
=[C
1
C
9
C
12
+C
4
C
8
C
3
+C
3
C
13
C
2
- (C
3
2
C
9
+C
13
C
8
C
1
+C
12
C
4
C
2
)] / C
16
0.0956
(23) C
21
=[C
1
C
10
C
12
+C
5
C
8
C
3
+C
3
C
14
C
2
- (C
3
2
C
10
+C
14
C
8
C
1
+C
12
C
5
C
2
)] / C
16
-0.11503
(24) C
22
=[C
1
C
11
C
12
+C
6
C
8
C
3
+C
3
C
15
C
2
- (C
3
2
C
11
+C
15
C
8
C
1
+C
12
C
6
C
2
)] / C
16
0.05056
(25) C
23
=[C
1
C
7
C
13
+C
2
C
9
C
3
+C
4
C
8
C
2
- (C
3
C
7
C
4
+C
8
C
9
C
1
+C
2
2
C
13
)] / C
16
-0.13119
(26) C
24
=[C
1
C
7
C
14
+C
2
C
10
C
3
+C
5
C
8
C
2
- (C
3
C
7
C
5
+C
8
C
10
C
1
+C
2
2
C
14
)] / C
16
0.15946
(27) C
25
=[C
1
C
7
C
15
+C
2
C
11
C
3
+C
6
C
8
C
2
- (C
3
C
7
C
6
+C
8
C
11
C
1
+C
2
2
C
15
)] / C
16
-0.05919
(28) C
26
=- (C/4)
1/4
-1.02168
(29) C
27
=C
20
-

C
17
- 5/12 +C
17
C
26
-4.90543
(30) C
28
=C
22
-

C
19
- 1/12 +C
19
C
26
-1.16343
(31) C
29
=- (C/4)
1/2
-1.04382
(32) C
30
=- (C/4)
3/4
-1.06644
(33) C
31
=3 A/2 - C
17
C
30
3.91827
(34) C
32
=1/2 - C
19
C
30
1.09642
(35) C
33
=0.5 C
26
C
32
+C
28
C
31
C
29
- (0.5 C
30
C
28
+C
32
C
27
C
29
) -2.03619
(36) C
34
=1/12 +C
18
- C
21 -
C
18
C
26
-8.54118
(37) C
35
=- C
18
(C/4)
3/4
4.61016
(38) C
36
=(C
28
C
35
C
29
- C
32
C
34
C
29
)/C
33
2.05114
(39) C
37
=[0.5 C
26
C
35
+C
34
C
31
C
29
- (0.5 C
30
C
34
+C
35
C
27
C
29
)] / C
33
-2.16975
(40) E
1
=C
17
C
36
+C
18
+C
19
C
37
-0.88522
(41) E
2
=C
20
C
36
+C
21
+C
22
C
37
-0.02864
(42) E
3
=C
23
C
36
+C
24
+C
25
C
37
0.01881
(43) E
4
=1/4 +C
37
/12

+C
36
/4 -

E
3
/5

-

3E
2
/2 -

E
1
1.50639
(44) E
5
=E
1
(1/2 +A/6) +E
2
(1/4

+11A/84) +E
3
(1/70 +A/105) -0.60061
(45) E
6
=E
5
- C
36
(7/120 +A/36 +3A/C) -

1/40

- A/72 - C
37
(1/60 +A/120 +1/C) -1.67593
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 55 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 10 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 6 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
N1. Integral Type (W.N.) Main Shell Flange Thickness, item no. 3 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
Subjected to internal pressure
APPENDIX 2-3
When B <20 g1, it will be optional for the designer to substitute B1 in the
formula stress S
H
=f * Mo /( L * g
1
2
* B).
20 * g1 20 INCH 508 MM
B 19 INCH 482.6 MM
B1 =B +g1 for loose & integral type flanges have f <1 ( the min. f permitted is 1) 20 INCH 508 MM
B1 =B +go for integral type flanges when f =>1 19.5 INCH 495.3 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 56 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 7 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
N2. Integral Type (WN) Main Shell Flange Thickness (item no. 12) [Appendix 2] [FIG. 2-4, Sketch (6a)]
Flange Material, [Attached by Bolts] ASME SA266 Class2 Subjected to internal press.
Design Temperature (shell side) 302
o
F 150
o
C
Min. Design Metal Temperature, MDMT 53.6
o
F 12
o
C
Bolt-up and Gasket Seating Temperature 86
o
F 30
o
C
Assume no corrosion, C [UG-25] 0.19685 INCH 5 MM
Operating Pressure (shell side) 241.4773 PSIG 17 Kg/CM
2
G
Internal Design Pressure, P (MAWP) 284.7764 PSIG 20.04826 Kg/CM
2
G
Allowable Stress of Bolt Material (ASME SA193 Gr. B7), S
B
:
* at design temp.(operating condition), Sb 25000 PSIG 1760 Kg/CM
2
G
* or at atmospheric temp./bolt-up temp. (gasket seating), Sa 25000 PSIG 1760 Kg/CM
2
G
Allowable Stress of Flange Material (ASME SA266 Class 2) :
* at design temp.(operating condition), Sf
H
20000 PSIG 1408
Kg/CM
2
G
* or at atmospheric temp./bolt-up temp. (gasket seating), Sf
C
20000 PSIG 1408
Kg/CM
2
G
Allowable Stress of Nozzle neck, Vessel or Pipe wall Material (ASME SA106 Gr. B) :
* at design temp.(operating condition), Sn
H
17100 PSIG 1203.84
Kg/CM
2
G
* or at atmospheric temp./bolt-up temp.(gasket seating), Sn
C
17100 PSIG 1203.84
Kg/CM
2
G
[Table 1A , SubPart 1 , ASME Sec. II , Part D]
FIG. 2-4, Sketch (6a)
Figure (3)
No. of bolts 32
Nominal bolt dia., d
B
1 INCH 25.4 MM
Bolt Hole, d 1.102362 INCH 28 MM
Flange outside diameter, A 33.07087 INCH 840 MM
Flange inside diameter, B 25.01811 INCH 635.46 MM
Bolt circut diameter (B.C.D.), C =B +2(g1 +h1+R) [Appendix 2-3] 30.53622 INCH 775.62 MM
Hup thickness at small end, g
o
=Shell Thickness t 0.5 INCH 12.7 MM
Hup thickness at back of flange, g
1
(assume g1 =2 go) 1 INCH 25.4 MM
R must not less than 1.5 the bolt hole (see TEMA Table D-5) 1.5 INCH 38 MM
Hup length, h (must greater than 1.5 go) [FIG. 2-4, Sketch 6] 1.574803 INCH 40 MM
Use max. slope 1:3, h =3.5 g0 1.732283 INCH 44 MM
Slope angle, Y =arc Tan [(g1-go)/h] 16.10006 Degree
Fillet radius, r =0.25 g1 [but not less than 3/16"(4.7625 MM)] [FIG. 2-4, Sketch 6, Note a]0.25 INCH 6.35 MM
Use r 0.23622 INCH 6 MM
h1 =r * Tan (45-Y/2) 0.177682 INCH 5 MM
E =(A-C)/2 (Check D292) 1.267323 INCH 32.19 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 57 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 7 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
N2. Integral Type (W.N.) Main Shell Flange Thickness, item no. 12 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
[Attached by Bolts] Subjected to internal pressure
Nominal shell (pipe) size 26"
Pipe Schedule
No. of bolts 32
Nominal bolt dia., d
B
1 INCH 25.4 MM
Bolt diameter at root of thread 0.88189 INCH 22.4 MM
Actual cross-sectional area of each bolt, [TEMA Table D-5] 0.551 INCH
2
355.4832 MM
2
Total actual cross-sectional area of bolts, Ab 17.632 INCH
2
11375.46 MM
2
Flange outside diameter, A 33.07087 INCH 840 MM
Flange inside diameter, B 25.01811 INCH 635.46 MM
Bolt circut diameter (B.C.D.), C 30.53622 INCH 775.62 MM
Gasket Details: - Flat metal, jacketed asbestos filled, iron or soft steel
- Outside diameter =(B.C.D - d) - 2*13 27.95276 INCH 710 MM
- Inside diameter =O.D - 2N 26.77165 INCH 680 MM
- Width, N 0.590551 INCH 15 MM
Gasket Dimensions:
Basic gasket seating width, b
O
=N/2 [Table 2-5.2] 0.295276 INCH 7.5 MM
Since bo >1/4 inch (6.35 MM), [Table 2-5.2]
Effective gasket seating width, b =0.5*SQRT(b
O
)

[Table 2-5.2] 0.271696 INCH 6.901087 MM
Gasket Factor, m [Table 2-5.1] 3.75
Min. Seating Stress, y [Table 2-5.1] 7600 PSIG 535.04 Kg/CM
2
G
Facing Sketch [Table 2-5.1] (1a); Column II
Diameter at location of gasket load reaction, G
When bo is larger than 1/4", G =O.D.of gasket contact face - 2 b 27.40936 INCH 696.1978 MM
[Appendix 2-3]
N.B. When b <1/4", the effective gasket seating width, b =bo [Table 2-5.2]
N.B. When b >1/4", the effective gasket seating width, b =0.5*SQRT(b
O
) [Table 2-5.2]
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 58 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 3 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 7 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
N2. Integral Type (W.N.) Main Shell Flange Thickness, item no. 12 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
[Attached by Bolts] Subjected to internal pressure
1. Bolt loading and size of bolts: [Appendix 2-5(c)]
(a) Total hydrostatic end force, H =0.785 G
2
P [Appendix 2-3] 167946.7 lb 76179.45 Kg
(b) Total joint-contact surface compression load, Hp =2b*3.14GmP 49943.35 lb 22653.95 Kg
[Appendix 2-3]
(c) Min. required bolt load for operating conditions, Wm1 =H +Hp 217890.1 lb 98833.4 Kg
Min. required bolt load for gasket seating, Wm2 =3.14 b G y 177715.8 lb 80610.61 Kg
Allowable Bolt Stress at atmospheric temp., Sa 25000 PSIG 1760 Kg/CM
2
G
Allowable Bolt Stress at design temp., Sb 25000 PSIG 1760 Kg/CM
2
G
[Table 1A , SubPart 1 , ASME Sec. II , Part D]
(d) Total cross-sectional area of bolts at root of thread required for:
- operating conditions, Am1 =Wm1 / Sb 8.715603 INCH
2
5622.959 MM
2
- Gasket seating, Am2 =Wm2 / Sa 7.108631 INCH
2
4586.204 MM
2
[Appendix 2-3]
Total required cross-sectional of bolts, Am =the greater of Am1 & Am2 8.715603 INCH
2
5622.959 MM
2
Actual bolt area Ab 17.632 INCH
2
11375.46 MM
2
Since area Ab >area Am, the bolts are adequately enough. OK
(e) Flange design bolt load, W :
- For operating conditions, Wo =Wm1 [Appendix 2-5(d)] 217890.1 lb 98833.4 Kg
- For gasket seating, Wa =0.5(Am +Ab) * Sa [Appendix 2-5(d)] 329345 lb 149388.6 Kg
2. Total flange moment for design condition: [Appendix 2-5(c)]
Flange Loads:
Hydrostatic end force on area inside flange, H
D
=0.785 B
2
P 139920.9 lb 63467.14 Kg
Gasket load (flange design bolt load - total hydrostatic end force), H
G
Gasket seating force H
G
=Wm1 - H 49943.35 lb 22653.95 Kg
Difference bet. total hydrostatic end force and the hydrostatic end force on area inside of flange, HT
H
T
=H - H
D
28025.81 lb 12712.31 Kg
Lever arms:
h
D
=R' +0.5 g1 [Table 2-6] 2.177682 INCH 55.31312 MM
h
G
=(C - G) / 2 [Table 2-6] 1.563429 INCH 39.71109 MM
h
T
=(R' +g1 + h
G
) / 2 [Table 2-6] 2.120555 INCH 53.8621 MM
Where R' =R +h1 1.677682 INCH 42.61312 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 59 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 4 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 7 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
N2. Integral Type (W.N.) Main Shell Flange Thickness, item no. 12 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
[Attached by Bolts] Subjected to internal presure
Flange Moments:
Component of moment due to H
D
, M
D
=H
D
h
D
[Appendix 2-3] 304703.2 lb-in 3510.565 Kg-M
Component of moment due to H
G
, M
G
=H
G
h
G
[Appendix 2-3] 78082.86 lb-in 899.6129 Kg-M
Component of moment due to H
T
, M
T
=H
T
h
T
[Appendix 2-3] 59430.27 lb-in 684.7116 Kg-M
Total moment acting upon the flange, Mo:

[Appendix 2-6]
- For operating condition M
O1
=M
D
+M
G
+M
T
442216.4 lb-in 5094.89 Kg-M
36851.36 lb-ft
3. Total flange moment for bolt-up condition (Gasket condition):
[Appendix 2-6]
Flange Load: H
G
=W
A
=0.5 (Am +Ab) * Sa 329345 lb 149388.6 Kg
Lever Arm., h
G
=(C - G) / 2 1.563429 INCH 39.71109 MM
Flange Moment for gasket condition, M
O2
=H
G
h
G
=W
A
(C - G) / 2 (5) 514907.5 lb-in 5932.383 Kg-M
M
o2
* (Sf
H
/ Sf
C
) 514907.5 lb-in 5932.383 Kg-M
4. M
O
= The greater of M
O1
or M
O2
(Sf
H
/Sf
C
) 514907.5 lb-in 5932.383 Kg-M
42908.96 lb-ft
5. Shape constants for flange:
1.321877
From Appendix 2, FIG. 2-7.1:
1.78802
3.67609
7.109344
7.812448
g1/go 2
ho =SQRT(B go) 3.536814
h/ho 0.489786
From Appendix 2, FIG. 2-7.2: F 0.82792
From Appendix 2, FIG. 2-7.3: V 0.230119
From Appendix 2, FIG. 2-7.6: f 1.261692
d =(U/V) ho go
2
(for integral type flanges) [APPENDIX 2-3] 30.01842 INCH
3
491913.7 MM
3
e =F / ho (for integral type flanges) [APPENDIX 2-3] 0.234086 INCH
-1
0.009216 MM
-1
K
B
A
=
T
K Log k
k k
=
+
+
2
10
2
1 855246 1
104720 19448 1
( . )
( . . )( )
Z
K
K
=
+

2
1
2
1
Y
K
K Log K
K
=

1
2
10
2
1
066845 571690
1
. .
U
K Log K
K K
=
+

2
2
1 855246
10
1
136136 1 1
( . )
. ( )( )
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 60 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 5 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 7 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
N2. Integral Type (W.N.) Main Shell Flange Thickness, item no. 12 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
[Attached by Bolts] Subjected to internal pressure
6. Calculation of flange actual stresses
Assume t 1.692913 INCH 43 MM
[Appendix 2-3] 0.942541
Where t =flange thickness
factor e =F/ ho (for integral type flanges) [Appendix 2-3] 0.234086 INCH
-1
0.009216 MM
-1
e =FL/ ho (for loose type flanges) [Appendix 2-3] NA
F = factor for integral type flanges [Fig. 2-7.2] 0.82792
T = factor involving K [Fig. 2-7.1] 1.78802
d =(U/V) ho go
2
[Appendix 2-3] 30.01842 INCH
3
491913.7 MM
3
For integral type flange, actual stresses (calculated) : [Fig. 2-4, Sketch (6a)]
1. a. Longitudinal hub stress, operating S
H
=f Mo / L g
1
2
B (6) [Appendix 2-7(a)27550.39 PSIG 1939.547
Kg/CM
2
G
b. Longitudinal hub stress, seating S
H
=f Mo2 / L g
1
2
B (6) [Appendix 2-7(a)]
27550.39 PSIG 1939.547
Kg/CM
2
G
2. a. Radial flange stress, operating S
R
=(1.33 t e +1) Mo / L t
2
B (7) [Appendix 2- 11644.84 PSIG 819.7971
Kg/CM
2
G
b. Radial flange stress, seating S
R
=(1.33 t e +1) Mo2 / L t
2
B (7) [Appendix 2 11644.84 PSIG 819.7971
Kg/CM
2
G
3. a. Tangential flange stress, operating S
T
=(Y Mo / t
2
B) - Z S
R
(8) [Appendix 2-78247.083 PSIG 580.5946
Kg/CM
2
G
b. Tangential flange stress, seating S
T
=(Y Mo2 / t
2
B) - Z S
R
(8) [Appendix 2- 8247.083 PSIG 580.5946
Kg/CM
2
G
4. a. Flange stress, operating 0.5 (S
H
+S
R
) [Appendix 2-8(a)(4)] 19597.61 PSIG 1379.672
Kg/CM
2
G
b. Flange stress, seating 0.5 (S
H
+S
R
) [Appendix 2-8(a)(4)] 19597.61 PSIG 1379.672
Kg/CM
2
G
5. a. Flange stress, operating 0.5 (S
H
+S
T
) [Appendix 2-8(a)(4)] 17898.73 PSIG 1260.071
Kg/CM
2
G
b. Flange stress, seating 0.5 (S
H
+S
T
) [Appendix 2-8(a)(4)] 17898.73 PSIG 1260.071
Kg/CM
2
G
6. a. Bolt stress, operating =Wm1 / Ab 12357.65 PSIG 869.9786 Kg/CM
2
G
b. Bolt stress, seating =Wm2 / Ab 10079.16 PSIG 709.573 Kg/CM
2
G
7. a. Shear stress carried by the fillet weld 0 PSIG 0 Kg/CM
2
G
7. Actual Stresses (Calculated) Compared with Allowable Stresses [APPENDIX 2-8]
7.a. For Operating Condition :
Allowable design stress of flange at operating condiotion, Sf 20000 PSIG 1408 Kg/CM
2
G
Allowable design stress of nozzle/vessel at operating condition, Sn 17100 PSIG 1203.84 Kg/CM
2
G
Assume flange thickness (without C.A), toperating 1.692913 INCH 43 MM
Allowable stresses Actual stresses
(Calculated )
PSIG
Kg/CM
2
PSIG
Kg/CM
2
Longitudinal Hub Stress S
H1
=1.5 Sf [Appendix 2-8(a)(1)(b)] 30000
Longitudinal Hub Stress S
H2
=2 Sn [Appendix 2-8(a)(1)(b)] 34200
The calculated (actual) hub stress S
H
< S
H
(min.) allowable 30000 > 27550.39
Radial Flange Stress S
R
=Sf [Appendix 2-8(a)(2)] 20000 > 11644.84
The calculated (actual) radial stress S
R
< S
R
allowable
Factor L
t
T
t
d
e
=
+
+
1 3 ^
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 61 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 6 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 7 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
N2. Integral Type (W.N.) Main Shell Flange Thickness, item no. 12 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
Subjected to internal pressure
Tangential Flange Stress S
T
=Sf [Appendix 2-8(a)(3)] 20000 > 8247.083
The calculated (actual) tangential stress S
T
< S
T
allowable
0.5(S
H
+S
R
)

=Sf 20000 > 19597.61
The calculated (actual) stress < Allowable stress
0.5(S
H
+S
T
)

=Sf 20000 > 17898.73
The calculated (actual) stress < Allowable stress
Bolt stress

=Wm1 / Ab 25000 > 12357.65
The calculated (actual) stress < Allowable stress
7.b. For Gasket Seating :
Allowable design stress of flange at gasket seating, Sf 20000 PSIG 1408 Kg/CM
2
G
Allowable design stress of nozzle/vessel at gasket seating, Sn 17100 PSIG 1203.84 Kg/CM
2
G
Assume flange thickness (without C.A), tgasket 1.692913 INCH 43 MM
Allowable stresses Actual stresses
(Calculated )
PSIG
Kg/CM
2
PSIG
Kg/CM
2
Longitudinal Hub Stress S
H1
=1.5 Sf [Appendix 2-8(a)(1)(b)] 30000
Longitudinal Hub Stress S
H2
=2 Sn [Appendix 2-8(a)(1)(b)] 34200
The calculated (actual) hub stress S
H
< S
H
(min.) allowable 30000 > 27550.39
Radial Flange Stress S
R
=Sf [Appendix 2-8(a)(2)] 20000 > 11644.84
The calculated (actual) radial stress S
R
< S
R
allowable
Tangential Flange Stress S
T
=Sf [Appendix 2-8(a)(3)] 20000 > 8247.083
The calculated (actual) tangential stress S
T
< S
T
allowable
0.5(S
H
+S
R
)

=Sf 20000 > 19597.61
The calculated (actual) stress < Allowable stress
0.5(S
H
+S
T
)

=Sf 20000 > 17898.73
The calculated (actual) stress < Allowable stress
Bolt stress

=Wm2 / Ab 25000 > 10079.16
The calculated (actual) stress < Allowable stress
The min. flange thickness, t =Max. (t
operating
, t
gasket
)
1.692913 INCH 43 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 62 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 7 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 7 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
N2. Integral Type (W.N.) Main Shell Flange Thickness, item no. 12 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
Subjected to internal pressure
Since all actual stresses are less than the allowable stresses, the
selection of t =4.5 inch, is adequate. If an optimum min. thickness
of flange is desired, calculations must be operated with a smaller
value of t until one of the actual stresses or stress combination is
approximately equal to the allowable stress even though other
actual stresses are less than the allowable stress for that actual stress.
Flange thickness with C.A & RF =t +2*corrosion all. +raised face 2.086614 INCH 53 MM
Use flange thickness for construction 2.125984 INCH 54 MM
BOLT SUMMARY
Factor K =A/B 1.321877
Gasket width, N 0.590551 INCH 15 MM
Total required cross-sectional area of bolts 8.715603 INCH
2
5622.959 MM
2
Actual bolt cross-sectional area, Ab 17.632 INCH
2
11375.46 MM
2
Nominal bolt dia., d
B
1 INCH 25.4 MM
1. Actual Edge distance, E from drawing =1/2 (A - C) 1.267323 INCH 32.19 MM
Min. Edge distance, E (for bolt size 0.75") 0.8125 INCH 20.6375 MM
Min. Edge distance, E (for bolt size 7/8") 0.9375 INCH 23.8125 MM
Min. Edge distance, E (for bolt size 1") 1.0625 INCH 26.9875 MM
Min. Edge distance, E (for bolt size 1-1/8") [TEMA Table D-5] 1.125 INCH 28.575 MM
Min. Edge distance, E (for bolt size 1-1/4") 1.25 INCH 31.75 MM
2. Actual Bolt spacing, B from drawing 2.993073 INCH 76.02405 MM
Min. Bolt spacing, B (for bolt size 0.75") 1.75 INCH 44.45 MM
Min. Bolt spacing, B (for bolt size 7/8") 2.0625 INCH 52.3875 MM
Min. Bolt spacing, B (for bolt size 1") 2.25 INCH 57.15 MM
Min. Bolt spacing, B (for bolt size 1-1/8") [TEMA Table D-5] 2.5 INCH 63.5 MM
Min. Bolt spacing, B (for bolt size 1-1/4") 2.8125 INCH 71.4375 MM
Max. Recommended bolt spacing, Bmax =2 d
B
+6 t / (m +0.5) [TEMA RCB-114.389995 INCH 111.5059 MM
3. Actual Radial distance, Rh from drawing =(C-B)/2-(g1+h1) 1.562205 INCH 39.68 MM
Min. Radial distance, Rh (for bolt size 0.75") 1.125 INCH 28.575 MM
Min. Radial distance, Rh (for bolt size 7/8") 1.25 INCH 31.75 MM
Min. Radial distance, Rh (for bolt size 1") 1.375 INCH 34.925 MM
Min. Radial distance, Rh (for bolt size 1-1/8") [TEMA Table D-5] 1.5 INCH 38.1 MM
Min. Radial distance, Rh (for bolt size 1-1/4") 1.75 INCH 44.45 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 63 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 8 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 7 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
N2. Integral Type (W.N.) Main Shell Flange Thickness, item no. 12 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
FLANGE FACTORS Subjected to internal pressure
(a) For Integral Flanges
Factor F per Fig. 2-7.2 is then solved by 0.82792
Factor V per Fig. 2-7.3 is then solved by 0.230119
Factor f per Fig. 2-7.6 is then solved by f =C
36
/ (1 +A) 1.261692
h/SQRT(BG
o
)
0.48978638
The values used in the above equations are solved using Eqs. (1) through (45) below based on the values g
1
, g
0
, h and ho
as defined by 2-3. When g
1
=g
o
, F =0.908920, V =0.550103, and f =1; thus Eqs. (1) through (45) need not be solved.
(b) For Loose Hub Flanges
Factor F
L
per Fig. 2-7.4 is solved by
1.641051
Factor V
L
per Fig. 2-7.5 is solved by 0.973065
Factor f per Fig. 2-7.6 is set equal to 1. f =1 1
The values used in the above equations are solved using Eqs. (1) through (5), (7), (9), (10), (12),
(14), (16), (18), (20), (23), and (26) below based on the values of g
1
, g
0
, h, and h
o
as defined by 2-3.
g
o
0.5 INCH 12.7 MM
g
1
1 INCH 25.4 MM
h 1.732283 INCH 44 MM
h
o
=SQRT(B go), Effective hub length 3.536814 INCH 89.83508 MM
B 25.01811 INCH 635.46 MM
(1) A =(g1/go) - 1 1
(2) C =43.68(h/ho)
4
2.513677
(3) C
1
=1/3 +A/12 0.416667
(4) C
2
=5/42 +17 A / 336 0.169643
(5) C
3
=1/210 +A/360 0.00754
(6) C
4
=11/360 +59 A/5040 +(1+3 A)/C 1.633556
(7) C
5
=1/90 +5 A/1008 - (1+A)
3
/C -3.166517
F
E
C A
C
=
+
6
1 4
3
2 73
1
[
.
]
( )
/
V
E
C
A
=
+
4
1 4 3
273
1 [
.
] ( )
/
F
C
A
C
A
C
A A
C A
C
L
=
+

+ +

+ +

+
18 21 24
1 4 3
1
2 6
1
4
11
84
1
70 105
1
40 72
2 73
1
.
( )
/
V
C C
C
C
A
L
=

+
1
4 5
3
2
273
1
24 21
18
1 4
3
.
( )
/
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 64 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 9 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 7 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
N2. Integral Type (W.N.) Main Shell Flange Thickness, item no. 12 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
FLANGE FACTORS (CONT.) Subjected to internal pressure
(8) C
6
=1/120 +17 A/5040 +1 /C 0.40953
(9) C
7
=215/2772 +51 A/1232 +(60/7 +225 A/14 +75A
2
/7 +5 A
3
/2)/C 15.17942
(10) C
8
=31/6930 +128 A/45045 +(6/7 +15 A/7 +12A
2
/7 +5 A
3
/11)/C 2.063598
(11) C
9
=533/30240 +653 A/73920 +(1/2 +33 A/14 +39 A
2
/28 +25 A
3
/84)/C1.83561
(12) C
10
=29/3780 +3 A/704 - (1/2 +33 A/14 +81 A
2
/28 +13 A
3
/12)/C -2.706528
(13) C
11
=31/6048 +1763 A/665280 +(1/2 +6 A/7 +15 A
2
/28 +5 A
3
/42)/C 0.808159
(14) C
12
=1/2925 +71 A/300300 +(8/35 +18 A /35 +156 A
2
/385 +6 A
3
/55)/C0.500699
(15) C
13
=761/831600 +937 A/1663200 +(1/35 +6 A /35 +11 A
2
/70 +3 A
3
/70.160608
(16) C
14
=197/415800 +103 A/332640 - (1/35 +6 A /35 +17 A
2
/70 + A
3
/10)/-0.215178
(17) C
15
=233/831600 +97 A/554400 +(1/35 +3 A /35 + A
2
/14 + 2 A
3
/105)/0.081914
(18) C
16
=C
1
C
7
C
12
+C
2
C
8
C
3
+C
3
C
8
C
2
- (C
3
2
C
7
+C
8
2
C
1
+ C
2
2
C
12
) 1.382461
(19) C
17
=[C
4
C
7
C
12
+C
2
C
8
C
13
+C
3
C
8
C
9
- (C
13
C
7
C
3
+C
8
2
C
4
+ C
12
C
2
C
9
)] / C
16
3.884126
(20) C
18
=[C
5
C
7
C
12
+C
2
C
8
C
14
+C
3
C
8
C
10
- (C
14
C
7
C
3
+C
8
2
C
5
+ C
12
C
2
C
10
)] / C-7.555421
(21) C
19
=[C
6
C
7
C
12
+C
2
C
8
C
15
+C
3
C
8
C
11
- (C
15
C
7
C
3
+C
8
2
C
6
+ C
12
C
2
C
11
)] / C0.963379
(22) C
20
=[C
1
C
9
C
12
+C
4
C
8
C
3
+C
3
C
13
C
2
- (C
3
2
C
9
+C
13
C
8
C
1
+C
12
C
4
C
2
)] / C
16
0.095208
(23) C
21
=[C
1
C
10
C
12
+C
5
C
8
C
3
+C
3
C
14
C
2
- (C
3
2
C
10
+C
14
C
8
C
1
+C
12
C
5
C
2
)] / C
1
-0.115776
(24) C
22
=[C
1
C
11
C
12
+C
6
C
8
C
3
+C
3
C
15
C
2
- (C
3
2
C
11
+C
15
C
8
C
1
+C
12
C
6
C
2
)] / C
1
0.0505
(25) C
23
=[C
1
C
7
C
13
+C
2
C
9
C
3
+C
4
C
8
C
2
- (C
3
C
7
C
4
+C
8
C
9
C
1
+C
2
2
C
13
)] / C
16
-0.130112
(26) C
24
=[C
1
C
7
C
14
+C
2
C
10
C
3
+C
5
C
8
C
2
- (C
3
C
7
C
5
+C
8
C
10
C
1
+C
2
2
C
14
)] / C
16
0.161181
(27) C
25
=[C
1
C
7
C
15
+C
2
C
11
C
3
+C
6
C
8
C
2
- (C
3
C
7
C
6
+C
8
C
11
C
1
+C
2
2
C
15
)] / C
16
-0.05904
(28) C
26
=- (C/4)
1/4
-0.890353
(29) C
27
=C
20
-

C
17
- 5/12 +C
17
C
26
-7.66383
(30) C
28
=C
22
-

C
19
- 1/12 +C
19
C
26
-1.853961
(31) C
29
=- (C/4)
1/2
-0.792729
(32) C
30
=- (C/4)
3/4
-0.705809
(33) C
31
=3 A/2 - C
17
C
30
4.241451
(34) C
32
=1/2 - C
19
C
30
1.179962
(35) C
33
=0.5 C
26
C
32
+C
28
C
31
C
29
- (0.5 C
30
C
28
+C
32
C
27
C
29
) -2.114621
(36) C
34
=1/12 +C
18
- C
21 -
C
18
C
26
-14.0833
(37) C
35
=- C
18
(C/4)
3/4
5.332683
(38) C
36
=(C
28
C
35
C
29
- C
32
C
34
C
29
)/C
33
2.523383
(39) C
37
=[0.5 C
26
C
35
+C
34
C
31
C
29
- (0.5 C
30
C
34
+C
35
C
27
C
29
)] / C
33
-3.599076
(40) E
1
=C
17
C
36
+C
18
+C
19
C
37
-1.221557
(41) E
2
=C
20
C
36
+C
21
+C
22
C
37
-0.057285
(42) E
3
=C
23
C
36
+C
24
+C
25
C
37
0.045348
(43) E
4
=1/4 +C
37
/12

+C
36
/4 -

E
3
/5

-

3E
2
/2 -

E
1
1.879338
(44) E
5
=E
1
(1/2 +A/6) +E
2
(1/4

+11A/84) +E
3
(1/70 +A/105) -0.835114
(45) E
6
=E
5
- C
36
(7/120 +A/36 +3A/C) -

1/40

- A/72 - C
37
(1/60 +A/120 +1/C) -2.581105
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 65 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 10 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 7 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
N2. Integral Type (W.N.) Main Shell Flange Thickness, item no. 12 (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
Subjected to internal pressure
APPENDIX 2-3
When B <20 g1, it will be optional for the designer to substitute B1 in the
formula stress S
H
=f * Mo /( L * g
1
2
* B).
20 * g1 20 INCH 508 MM
B 25.01811 INCH 635.46 MM
B1 =B +g1 for loose & integral type flanges have f <1 ( the min. f permitted is 1) 26.01811 INCH 660.86 MM
B1 =B +go for integral type flanges when f =>1 25.51811 INCH 648.16 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 66 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 9 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
O. Integral Type (WN) Main Channel Flanges Thickness (items no. 18) [Appendix 2] [FIG. 2-4, Sketch (6a)]
Flange Material, [Attached by Bolts] ASME SA266 Class2+SB171 C63000
Design Temperature (tube side) 140
o
F 60
o
C
Min. Design Metal Temperature, MDMT 53.6
o
F 12
o
C
Bolt-up and Gasket Seating Temperature 86
o
F 30
o
C
Assume no corrosion, C [UG-25] 0.19685 INCH 5 MM
Operating Pressure (tube side) 42.61364 PSIG 3 Kg/CM
2
G
Internal Design Pressure, P (MAWP) 71.70824 PSIG 5.04826 Kg/CM
2
G
Allowable Stress of Bolt Material (ASME SA193 Gr. B7), S
B
:
* at design temp.(operating condition), Sb 25000 PSIG 1760 Kg/CM
2
G
* or at atmospheric temp./bolt-up temp. (gasket seating), Sa 25000 PSIG 1760 Kg/CM
2
G
Allowable Stress of Flange Material (ASME SA266 Class 2) :
* at design temp.(operating condition), Sf
H
20000 PSIG 1408
Kg/CM
2
G
* or at atmospheric temp./bolt-up temp. (gasket seating), Sf
C
20000 PSIG 1408
Kg/CM
2
G
Allowable Stress of Nozzle neck, Vessel or Pipe wall Material (ASME SA106 Gr. B) :
* at design temp.(operating condition), Sn
H
17100 PSIG 1203.84
Kg/CM
2
G
* or at atmospheric temp./bolt-up temp.(gasket seating), Sn
C
17100 PSIG 1203.84
Kg/CM
2
G
[Table 1A , SubPart 1 , ASME Sec. II , Part D]
FIG. 2-4, Sketch (6a)
Figure (4)
No. of bolts 28
Nominal bolt dia., d
B
1 INCH 25.4 MM
Bolt Hole, d 1.102362 INCH 28 MM
Flange outside diameter, A 26.9685 INCH 685 MM
Flange inside diameter, B 19 INCH 482.6 MM
Bolt circut diameter (B.C.D.), C =B +2(g1 +h1+R) [Appendix 2-3] 24.52756 INCH 623 MM
Hup thickness at small end, g
o
=Shell Thickness t 0.5 INCH 12.7 MM
Hup thickness at back of flange, g
1
(assume g1 =2 go) 1 INCH 25.4 MM
R must not less than 1.5 the bolt hole (see TEMA Table D-5) 1.5 INCH 38 MM
Hup length, h (must greater than 1.5 go) [FIG. 2-4, Sketch 6] 1.574803 INCH 40 MM
Use max. slope 1:3, h =3.5 g0 1.732283 INCH 44 MM
Slope angle, Y =arc Tan [(g1-go)/h] 16.10006 Degree
Fillet radius, r =0.25 g1 [but not less than 3/16"(4.7625 MM)] [FIG. 2-4, Sketch 6, Note a0.25 INCH 6.35 MM
Use r 0.23622 INCH 6 MM
h1 =r * Tan (45-Y/2) 0.177682 INCH 5 MM
E =(A-C)/2 (Check D292) 1.220472 INCH 31 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 67 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 9 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
O. Integral Type (WN) Main Channel Flanges Thickness (item no. 18) (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
[Attached by Bolts] Subjected to internal pressure
Nominal shell size 20"
Pipe Schedule 30
No. of bolts 28
Nominal bolt dia., d
B
1 INCH 25.4 MM
Bolt diameter at root of thread 0.88189 INCH 22.4 MM
Actual cross-sectional area of each bolt, [TEMA Table D-5] 0.551 INCH
2
355.4832 MM
2
Total actual cross-sectional area of bolts, Ab 15.428 INCH
2
9953.528 MM
2
Flange outside diameter, A 26.9685 INCH 685 MM
Flange inside diameter, B 19 INCH 482.6 MM
Bolt circut diameter (B.C.D.), C 24.52756 INCH 623 MM
Gasket Details: - Flat metal, jacketed asbestos filled, soft copp[er or brass
- Outside diameter =(B.C.D - d) - 2*13 22.04724 INCH 560 MM
- Inside diameter =O.D - 2N 20.86614 INCH 530 MM
- Width, N 0.590551 INCH 15 MM
Gasket Dimensions:
Basic gasket seating width, b
O
=N/2 [Table 2-5.2] 0.295276 INCH 7.5 MM
Since bo >1/4 inch (6.35 MM), [Table 2-5.2]
Effective gasket seating width, b =0.5*SQRT(b
O
)

[Table 2-5.2] 0.271696 INCH 6.901087 MM
Gasket Factor, m [Table 2-5.1] 3.5
Min. Seating Stress, y [Table 2-5.1] 6500 PSIG 457.6 Kg/CM
2
G
Facing Sketch [Table 2-5.1] (1a); Column II
Diameter at location of gasket load reaction, G
When bo is larger than 1/4", G =O.D.of gasket contact face - 2 b 21.50385 INCH 546.1978 MM
[Appendix 2-3]
N.B. When b <1/4", the effective gasket seating width, b =bo [Table 2-5.2]
N.B. When b >1/4", the effective gasket seating width, b =0.5*SQRT(b
O
) [Table 2-5.2]
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 68 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 3 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 9 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
O. Integral Type (WN) Main Channel Flanges Thickness (item no. 18) (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
[Attached by Bolts] Subjected to internal pressure
1. Bolt loading and size of bolts: [Appendix 2-5(c)]
(a) Total hydrostatic end force, H =0.785 G
2
P [Appendix 2-3] 26029.82 lb 11806.94 Kg
(b) Total joint-contact surface compression load, Hp =2b*3.14GmP 9208.667 lb 4176.986 Kg
[Appendix 2-3]
(c) Min. required bolt load for operating conditions, Wm1 =H +Hp 35238.49 lb 15983.93 Kg
Min. required bolt load for gasket seating, Wm2 =3.14 b G y 119245.8 lb 54089.04 Kg
Allowable Bolt Stress at atmospheric temp., Sa 25000 PSIG 1760 Kg/CM
2
G
Allowable Bolt Stress at design temp., Sb 25000 PSIG 1760 Kg/CM
2
G
[Table 1A , SubPart 1 , ASME Sec. II , Part D]
(d) Total cross-sectional area of bolts at root of thread required for:
- operating conditions, Am1 =Wm1 / Sb 1.40954 INCH
2
909.3785 MM
2
- Gasket seating, Am2 =Wm2 / Sa 4.769831 INCH
2
3077.304 MM
2
[Appendix 2-3]
Total required cross-sectional of bolts, Am =the greater of Am1 & Am2 4.769831 INCH
2
3077.304 MM
2
Actual bolt area Ab 15.428 INCH
2
9953.528 MM
2
Since area Ab >area Am, the bolts are adequately enough. OK
(e) Flange design bolt load, W :
- For operating conditions, Wo =Wm1 [Appendix 2-5(d)] 35238.49 lb 15983.93 Kg
- For gasket seating, Wa =0.5(Am +Ab) * Sa [Appendix 2-5(d)] 252472.9 lb 114519.9 Kg
2. Total flange moment for design condition: [Appendix 2-5(c)]
Flange Loads:
Hydrostatic end force on area inside flange, H
D
=0.785 B
2
P 20321.04 lb 9217.479 Kg
Gasket load (flange design bolt load - total hydrostatic end force), H
G
Gasket seating force H
G
=Wm1 - H 9208.667 lb 4176.986 Kg
Difference bet. total hydrostatic end force and the hydrostatic end force on area inside of flange, HT
H
T
=H - H
D
5708.784 lb 2589.464 Kg
Lever arms:
h
D
=R' +0.5 g1 [Table 2-6] 2.177682 INCH 55.31312 MM
h
G
=(C - G) / 2 [Table 2-6] 1.511854 INCH 38.40109 MM
h
T
=(R' +g1 + h
G
) / 2 [Table 2-6] 2.094768 INCH 53.2071 MM
Where R' =R +h1 1.677682 INCH 42.61312 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 69 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 4 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 9 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
O. Integral Type (WN) Main Channel Flanges Thickness (item no. 18) (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
[Attached by Bolts] Subjected to internal presure
Flange Moments:
Component of moment due to H
D
, M
D
=H
D
h
D
[Appendix 2-3] 44252.75 lb-in 509.8475 Kg-M
Component of moment due to H
G
, M
G
=H
G
h
G
[Appendix 2-3] 13922.16 lb-in 160.4008 Kg-M
Component of moment due to H
T
, M
T
=H
T
h
T
[Appendix 2-3] 11958.58 lb-in 137.7779 Kg-M
Total moment acting upon the flange, Mo:

[Appendix 2-6]
- For operating condition M
O1
=M
D
+M
G
+M
T
70133.49 lb-in 808.0261 Kg-M
5844.457 lb-ft
3. Total flange moment for bolt-up condition (Gasket condition):
[Appendix 2-6]
Flange Load: H
G
=W
A
=0.5 (Am +Ab) * Sa 252472.9 lb 114519.9 Kg
Lever Arm., h
G
=(C - G) / 2 1.511854 INCH 38.40109 MM
Flange Moment for gasket condition, M
O2
=H
G
h
G
=W
A
(C - G) / 2 (5) 381702.1 lb-in 4397.689 Kg-M
M
o2
* (Sf
H
/ Sf
C
) 381702.1 lb-in 4397.689 Kg-M
4. M
O
= The greater of M
O1
or M
O2
(Sf
H
/Sf
C
) 381702.1 lb-in 4397.689 Kg-M
31808.51 lb-ft
5. Shape constants for flange:
1.419395
From Appendix 2, FIG. 2-7.1:
1.745783
2.971061
5.710574
6.275343
g1/go 2
ho =SQRT(B go) 3.082207
h/ho 0.562027
From Appendix 2, FIG. 2-7.2: F 0.812252
From Appendix 2, FIG. 2-7.3: V 0.211658
From Appendix 2, FIG. 2-7.6: f 1.02557
d =(U/V) ho go
2
(for integral type flanges) [APPENDIX 2-3] 22.84569 INCH
3
374373.9 MM
3
e =F / ho (for integral type flanges) [APPENDIX 2-3] 0.263529 INCH
-1
0.010375 MM
-1
T
K Log k
k k
=
+
+
2
10
2
1 855246 1
104720 19448 1
( . )
( . . )( )
Z
K
K
=
+

2
1
2
1
Y
K
K Log K
K
=

1
2
10
2
1
066845 571690
1
. .
U
K Log K
K K
=
+

2
2
1 855246
10
1
136136 1 1
( . )
. ( )( )
K
B
A
=
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 70 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 5 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 9 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
O. Integral Type (WN) Main Channel Flanges Thickness (item no. 18) (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
[Attached by Bolts] Subjected to internal pressure
6. Calculation of flange actual stresses
Assume t 1.397638 INCH 35.5 MM
[Appendix 2-3] 0.903288
Where t =flange thickness
factor e =F/ ho (for integral type flanges) [Appendix 2-3] 0.263529 INCH
-1
0.010375 MM
-1
e =FL/ ho (for loose type flanges) [Appendix 2-3] NA
F = factor for integral type flanges [Fig. 2-7.2] 0.812252
T = factor involving K [Fig. 2-7.1] 1.745783
d =(U/V) ho go
2
[Appendix 2-3] 22.84569 INCH
3
374373.9 MM
3
For integral type flange, actual stresses (calculated) : [Fig. 2-4, Sketch (6a)]
1. a. Longitudinal hub stress, operating S
H
=f Mo / L g
1
2
B (6) [Appendix 2-7(a)22809.2 PSIG 1605.768
Kg/CM
2
G
b. Longitudinal hub stress, seating S
H
=f Mo2 / L g
1
2
B (6) [Appendix 2-7(a)
22809.2 PSIG 1605.768
Kg/CM
2
G
2. a. Radial flange stress, operating S
R
=(1.33 t e +1) Mo / L t
2
B (7) [Appendix 2 16976.81 PSIG 1195.167
Kg/CM
2
G
b. Radial flange stress, seating S
R
=(1.33 t e +1) Mo2 / L t
2
B (7) [Appendix 216976.81 PSIG 1195.167
Kg/CM
2
G
3. a. Tangential flange stress, operating S
T
=(Y Mo / t
2
B) - Z S
R
(8) [Appendix 2-78291.077 PSIG 583.6918
Kg/CM
2
G
b. Tangential flange stress, seating S
T
=(Y Mo2 / t
2
B) - Z S
R
(8) [Appendix 2-8291.077 PSIG 583.6918
Kg/CM
2
G
4. a. Flange stress, operating 0.5 (S
H
+S
R
) [Appendix 2-8(a)(4)] 19893 PSIG 1400.467
Kg/CM
2
G
b. Flange stress, seating 0.5 (S
H
+S
R
) [Appendix 2-8(a)(4)] 19893 PSIG 1400.467
Kg/CM
2
G
5. a. Flange stress, operating 0.5 (S
H
+S
T
) [Appendix 2-8(a)(4)] 15550.14 PSIG 1094.73
Kg/CM
2
G
b. Flange stress, seating 0.5 (S
H
+S
T
) [Appendix 2-8(a)(4)] 15550.14 PSIG 1094.73
Kg/CM
2
G
6. a. Bolt stress, operating =Wm1 / Ab 2284.061 PSIG 160.7979 Kg/CM
2
G
b. Bolt stress, seating =Wm2 / Ab 7729.18 PSIG 544.1343 Kg/CM
2
G
7. a. Shear stress carried by the fillet weld 0 PSIG 0 Kg/CM
2
G
7. Actual Stresses (Calculated) Compared with Allowable Stresses [APPENDIX 2-8]
7.a. For Operating Condition :
Allowable design stress of flange at operating condiotion, Sf 20000 PSIG 1408 Kg/CM
2
G
Allowable design stress of nozzle/vessel at operating condition, Sn 17100 PSIG 1203.84 Kg/CM
2
G
Assume flange thickness (without C.A), toperating 1.397638 INCH 35.5 MM
Allowable stresses Actual stresses
(Calculated )
PSIG
Kg/CM
2
PSIG
Kg/CM
2
Longitudinal Hub Stress S
H1
=1.5 Sf [Appendix 2-8(a)(1)(b)] 30000
Longitudinal Hub Stress S
H2
=2 Sn [Appendix 2-8(a)(1)(b)] 34200
The calculated (actual) hub stress S
H
< S
H
(min.) allowable 30000 > 22809.2
Radial Flange Stress S
R
=Sf [Appendix 2-8(a)(2)] 20000 > 16976.81
The calculated (actual) radial stress S
R
< S
R
allowable
Factor L
t
T
t
d
e
=
+
+
1 3 ^
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 71 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 6 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 9 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
O. Integral Type (WN) Main Channel Flanges Thickness (item no. 18) (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
Subjected to internal pressure
Tangential Flange Stress S
T
=Sf [Appendix 2-8(a)(3)] 20000 > 8291.077
The calculated (actual) tangential stress S
T
< S
T
allowable
0.5(S
H
+S
R
)

=Sf 20000 > 19893
The calculated (actual) stress < Allowable stress
0.5(S
H
+S
T
)

=Sf 20000 > 15550.14
The calculated (actual) stress < Allowable stress
Bolt stress

=Wm1 / Ab 25000 > 2284.061
The calculated (actual) stress < Allowable stress
7.b. For Gasket Seating :
Allowable design stress of flange at gasket seating, Sf 20000 PSIG 1408 Kg/CM
2
G
Allowable design stress of nozzle/vessel at gasket seating, Sn 17100 PSIG 1203.84 Kg/CM
2
G
Assume flange thickness (without C.A), tgasket 1.397638 INCH 35.5 MM
Allowable stresses Actual stresses
(Calculated )
PSIG
Kg/CM
2
PSIG
Kg/CM
2
Longitudinal Hub Stress S
H1
=1.5 Sf [Appendix 2-8(a)(1)(b)] 30000
Longitudinal Hub Stress S
H2
=2 Sn [Appendix 2-8(a)(1)(b)] 34200
The calculated (actual) hub stress S
H
< S
H
(min.) allowable 30000 > 22809.2
Radial Flange Stress S
R
=Sf [Appendix 2-8(a)(2)] 20000 > 16976.81
The calculated (actual) radial stress S
R
< S
R
allowable
Tangential Flange Stress S
T
=Sf [Appendix 2-8(a)(3)] 20000 > 8291.077
The calculated (actual) tangential stress S
T
< S
T
allowable
0.5(S
H
+S
R
)

=Sf 20000 > 19893
The calculated (actual) stress < Allowable stress
0.5(S
H
+S
T
)

=Sf 20000 > 15550.14
The calculated (actual) stress < Allowable stress
Bolt stress

=Wm2 / Ab 25000 > 7729.18
The calculated (actual) stress < Allowable stress
The min. flange thickness, t =Max. (t
operating
, t
gasket
)
1.397638 INCH 35.5 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 72 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 7 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 9 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
O. Integral Type (WN) Main Channel Flanges Thickness (item no. 18) (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
Subjected to internal pressure
Since all actual stresses are less than the allowable stresses, the
selection of t =4.5 inch, is adequate. If an optimum min. thickness
of flange is desired, calculations must be operated with a smaller
value of t until one of the actual stresses or stress combination is
approximately equal to the allowable stress even though other
actual stresses are less than the allowable stress for that actual stress.
Flange thickness with C.A & RF =t +2*corrosion all. +raised face 1.791339 INCH 45.5 MM
Use flange thickness for construction 1.850394 INCH 47 MM
BOLT SUMMARY
Factor K =A/B 1.419395
Gasket width, N 0.590551 INCH 15 MM
Total required cross-sectional area of bolts 4.769831 INCH
2
3077.304 MM
2
Actual bolt cross-sectional area, Ab 15.428 INCH
2
9953.528 MM
2
Nominal bolt dia., d
B
1 INCH 25.4 MM
1. Actual Edge distance, E from drawing =1/2 (A - C) 1.220472 INCH 31 MM
Min. Edge distance, E (for bolt size 0.75") 0.8125 INCH 20.6375 MM
Min. Edge distance, E (for bolt size 7/8") 0.9375 INCH 23.8125 MM
Min. Edge distance, E (for bolt size 1") 1.0625 INCH 26.9875 MM
Min. Edge distance, E (for bolt size 1-1/8") [TEMA Table D-5] 1.125 INCH 28.575 MM
Min. Edge distance, E (for bolt size 1-1/4") 1.25 INCH 31.75 MM
2. Actual Bolt spacing, B from drawing 2.746215 INCH 69.75387 MM
Min. Bolt spacing, B (for bolt size 0.75") 1.75 INCH 44.45 MM
Min. Bolt spacing, B (for bolt size 7/8") 2.0625 INCH 52.3875 MM
Min. Bolt spacing, B (for bolt size 1") 2.25 INCH 57.15 MM
Min. Bolt spacing, B (for bolt size 1-1/8") [TEMA Table D-5] 2.5 INCH 63.5 MM
Min. Bolt spacing, B (for bolt size 1-1/4") 2.8125 INCH 71.4375 MM
Max. Recommended bolt spacing, Bmax =2 d
B
+6 t / (m +0.5) [TEMA RCB-14.096457 INCH 104.05 MM
3. Actual Radial distance, Rh from drawing =(C-B)/2-(g1+h1) 1.566929 INCH 39.8 MM
Min. Radial distance, Rh (for bolt size 0.75") 1.125 INCH 28.575 MM
Min. Radial distance, Rh (for bolt size 7/8") 1.25 INCH 31.75 MM
Min. Radial distance, Rh (for bolt size 1") 1.375 INCH 34.925 MM
Min. Radial distance, Rh (for bolt size 1-1/8") [TEMA Table D-5] 1.5 INCH 38.1 MM
Min. Radial distance, Rh (for bolt size 1-1/4") 1.75 INCH 44.45 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 73 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 8 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 9 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
O. Integral Type (WN) Main Channel Flanges Thickness (item no. 18) (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
FLANGE FACTORS Subjected to internal pressure
(a) For Integral Flanges
Factor F per Fig. 2-7.2 is then solved by 0.812252
Factor V per Fig. 2-7.3 is then solved by 0.211658
Factor f per Fig. 2-7.6 is then solved by f =C
36
/ (1 +A) 1.02557
h/SQRT(BG
o
)
0.56202697
The values used in the above equations are solved using Eqs. (1) through (45) below based on the values g
1
, g
0
, h and ho
as defined by 2-3. When g
1
=g
o
, F =0.908920, V =0.550103, and f =1; thus Eqs. (1) through (45) need not be solved.
(b) For Loose Hub Flanges
Factor F
L
per Fig. 2-7.4 is solved by
1.435003
Factor V
L
per Fig. 2-7.5 is solved by 0.66229
Factor f per Fig. 2-7.6 is set equal to 1. f =1 1
The values used in the above equations are solved using Eqs. (1) through (5), (7), (9), (10), (12),
(14), (16), (18), (20), (23), and (26) below based on the values of g
1
, g
0
, h, and h
o
as defined by 2-3.
g
o
0.5 INCH 12.7 MM
g
1
1 INCH 25.4 MM
h 1.732283 INCH 44 MM
h
o
=SQRT(B go), Effective hub length 3.082207 INCH 78.28806 MM
B 19 INCH 482.6 MM
(1) A =(g1/go) - 1 1
(2) C =43.68(h/ho)
4
4.358241
(3) C
1
=1/3 +A/12 0.416667
(4) C
2
=5/42 +17 A / 336 0.169643
(5) C
3
=1/210 +A/360 0.00754
(6) C
4
=11/360 +59 A/5040 +(1+3 A)/C 0.960063
(7) C
5
=1/90 +5 A/1008 - (1+A)
3
/C -1.819531
F
C
A
C
A
C
A A
C A
C
L
=
+

+ +

+ +

+
18 21 24
1 4 3
1
2 6
1
4
11
84
1
70 105
1
40 72
2 73
1
.
( )
/
V
C C
C
C
A
L
=

+
1
4 5
3
2
273
1
24 21
18
1 4
3
.
( )
/
F
E
C A
C
=
+
6
1 4
3
2 73
1
[
.
]
( )
/
V
E
C
A
=
+
4
1 4 3
273
1 [
.
] ( )
/
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 74 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 9 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 9 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
O. Integral Type (WN) Main Channel Flanges Thickness (item no. 18) (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
FLANGE FACTORS (CONT.) Subjected to internal pressure
(8) C
6
=1/120 +17 A/5040 +1 /C 0.241157
(9) C
7
=215/2772 +51 A/1232 +(60/7 +225 A/14 +75A
2
/7 +5 A
3
/2)/C 8.805292
(10) C
8
=31/6930 +128 A/45045 +(6/7 +15 A/7 +12A
2
/7 +5 A
3
/11)/C 1.193305
(11) C
9
=533/30240 +653 A/73920 +(1/2 +33 A/14 +39 A
2
/28 +25 A
3
/84)/C1.069912
(12) C
10
=29/3780 +3 A/704 - (1/2 +33 A/14 +81 A
2
/28 +13 A
3
/12)/C -1.555977
(13) C
11
=31/6048 +1763 A/665280 +(1/2 +6 A/7 +15 A
2
/28 +5 A
3
/42)/C 0.469408
(14) C
12
=1/2925 +71 A/300300 +(8/35 +18 A /35 +156 A
2
/385 +6 A
3
/55)/0.28903
(15) C
13
=761/831600 +937 A/1663200 +(1/35 +6 A /35 +11 A
2
/70 +3 A
3
/ 0.093259
(16) C
14
=197/415800 +103 A/332640 - (1/35 +6 A /35 +17 A
2
/70 + A
3
/10)-0.123775
(17) C
15
=233/831600 +97 A/554400 +(1/35 +3 A /35 + A
2
/14 + 2 A
3
/105)0.047438
(18) C
16
=C
1
C
7
C
12
+C
2
C
8
C
3
+C
3
C
8
C
2
- (C
3
2
C
7
+C
8
2
C
1
+ C
2
2
C
12
) 0.461325
(19) C
17
=[C
4
C
7
C
12
+C
2
C
8
C
13
+C
3
C
8
C
9
- (C
13
C
7
C
3
+C
8
2
C
4
+ C
12
C
2
C
9
)] / C
16
2.267604
(20) C
18
=[C
5
C
7
C
12
+C
2
C
8
C
14
+C
3
C
8
C
10
- (C
14
C
7
C
3
+C
8
2
C
5
+ C
12
C
2
C
10
)] / C-4.322926
(21) C
19
=[C
6
C
7
C
12
+C
2
C
8
C
15
+C
3
C
8
C
11
- (C
15
C
7
C
3
+C
8
2
C
6
+ C
12
C
2
C
11
)] / C0.559263
(22) C
20
=[C
1
C
9
C
12
+C
4
C
8
C
3
+C
3
C
13
C
2
- (C
3
2
C
9
+C
13
C
8
C
1
+C
12
C
4
C
2
)] / C
16
0.095599
(23) C
21
=[C
1
C
10
C
12
+C
5
C
8
C
3
+C
3
C
14
C
2
- (C
3
2
C
10
+C
14
C
8
C
1
+C
12
C
5
C
2
)] / C -0.115034
(24) C
22
=[C
1
C
11
C
12
+C
6
C
8
C
3
+C
3
C
15
C
2
- (C
3
2
C
11
+C
15
C
8
C
1
+C
12
C
6
C
2
)] / C 0.050557
(25) C
23
=[C
1
C
7
C
13
+C
2
C
9
C
3
+C
4
C
8
C
2
- (C
3
C
7
C
4
+C
8
C
9
C
1
+C
2
2
C
13
)] / C
16
-0.131187
(26) C
24
=[C
1
C
7
C
14
+C
2
C
10
C
3
+C
5
C
8
C
2
- (C
3
C
7
C
5
+C
8
C
10
C
1
+C
2
2
C
14
)] / C
16
0.159461
(27) C
25
=[C
1
C
7
C
15
+C
2
C
11
C
3
+C
6
C
8
C
2
- (C
3
C
7
C
6
+C
8
C
11
C
1
+C
2
2
C
15
)] / C
16
-0.059193
(28) C
26
=- (C/4)
1/4
-1.021675
(29) C
27
=C
20
-

C
17
- 5/12 +C
17
C
26
-4.905425
(30) C
28
=C
22
-

C
19
- 1/12 +C
19
C
26
-1.163425
(31) C
29
=- (C/4)
1/2
-1.04382
(32) C
30
=- (C/4)
3/4
-1.066445
(33) C
31
=3 A/2 - C
17
C
30
3.918274
(34) C
32
=1/2 - C
19
C
30
1.096424
(35) C
33
=0.5 C
26
C
32
+C
28
C
31
C
29
- (0.5 C
30
C
28
+C
32
C
27
C
29
) -2.036188
(36) C
34
=1/12 +C
18
- C
21 -
C
18
C
26
-8.541184
(37) C
35
=- C
18
(C/4)
3/4
4.610162
(38) C
36
=(C
28
C
35
C
29
- C
32
C
34
C
29
)/C
33
2.051141
(39) C
37
=[0.5 C
26
C
35
+C
34
C
31
C
29
- (0.5 C
30
C
34
+C
35
C
27
C
29
)] / C
33
-2.169755
(40) E
1
=C
17
C
36
+C
18
+C
19
C
37
-0.885216
(41) E
2
=C
20
C
36
+C
21
+C
22
C
37
-0.028644
(42) E
3
=C
23
C
36
+C
24
+C
25
C
37
0.018814
(43) E
4
=1/4 +C
37
/12

+C
36
/4 -

E
3
/5

-

3E
2
/2 -

E
1
1.506391
(44) E
5
=E
1
(1/2 +A/6) +E
2
(1/4

+11A/84) +E
3
(1/70 +A/105) -0.600608
(45) E
6
=E
5
- C
36
(7/120 +A/36 +3A/C) -

1/40

- A/72 - C
37
(1/60 +A/120 +1/C) -1.675933
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 75 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 10 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 9 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
O. Integral Type (WN) Main Channel Flanges Thickness (item no. 18) (cont.) [Appendix 2] [FIG. 2-4, Sketch (6a)]
Subjected to internal pressure
APPENDIX 2-3
When B <20 g1, it will be optional for the designer to substitute B1 in the
formula stress S
H
=f * Mo /( L * g
1
2
* B).
20 * g1 20 INCH 508 MM
B 19 INCH 482.6 MM
B1 =B +g1 for loose & integral type flanges have f <1 ( the min. f permitted is 1) 20 INCH 508 MM
B1 =B +go for integral type flanges when f =>1 19.5 INCH 495.3 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 76 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 6
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 14 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
P. Flat Unstayed Circular Blind Flange(Channel Cover) Thickness (item no. 22) [UG-34 & Fig. UG-34 Sketch (j)]
[Attached by Bolts] Subjected to internal pressure
Blind Cover Material, Clad Metal : SB171 UNS No. C63000 ASME SA266 Class 2
Stud bolt material SA 193 Grade B7
Design Temperature 140
o
F 60
o
C
Min. Design Metal Temperature, MDMT 53.6
o
F 12
o
C
Bolt-up and Gasket Seating Temperature 86
o
F 30
o
C
Assume corrosion allowance, C [UG-25] 0.19685 INCH 5 MM
Operating Pressure (tube side) 56.8182 PSIG 4 Kg/CM
2
G
Internal Design Pressure, P (MAWP) 71.7082 PSIG 5.04826 Kg/CM
2
G
Allowable Stress of Bolt Material, S
B
:
* at design temp.(operating condition), Sb 25000 PSIG 1760 Kg/CM
2
G
* or at atmospheric temp./bolt-up temp. (gasket seating), Sa 25000 PSIG 1760 Kg/CM
2
G
Allowable Stress of Flange Material :
* at design temp.(operating condition), Sf
H
20000 PSIG 1408
Kg/CM
2
G
* or at atmospheric temp./bolt-up temp. (gasket seating), Sf
C
20000 PSIG 1408
Kg/CM
2
G
[Table 1A , SubPart 1 , ASME Sec. II , Part D]
J oint efficiency, E 1
Bolt Hole, 1.10236 INCH 28 MM
Flange outside diameter, A 26.9685 INCH 685 MM
Bolt circut diameter (B.C.D.), 24.5276 INCH 623 MM
Fig. UG-34, Sketch (j)
Figure (5)
No. of bolts 28
Nominal bolt dia., d
B
1 INCH 25.4 MM
Actual cross-sectional area of each bolt, [TEMA Table D-5] 0.551 INCH
2
355.4832 MM
2
Total actual cross-sectional area of bolts, Ab 15.428 INCH
2
9953.528 MM
2
Flange face outer diameter 22.1654 INCH 563 MM
Flange face inner diameter 19 INCH 482.6 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 77 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 6
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 14 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
P. Flat Unstayed Circular Blind Flange (Channel Cover) Thickness (item no. 22) (cont.)
[Attached by Bolts] [UG-34 & Fig. UG-34 Sketch (j)]
Gasket Details: - Flat metal, jacketed asbestos filled, soft copp[er or brass 0.125 INCH 3.175 MM
- Outside diameter 22.0472 INCH 560 MM
- Inside diameter =O.D - 2N 20.8661 INCH 530 MM
- Width, N 0.59055 INCH 15 MM
Gasket Dimensions:
Basic gasket seating width, b
O
=N/2 [Table 2-5.2] 0.29528 INCH 7.5 MM
Since bo >1/4 ", Effective gasket seating width, b =0.5 SQRT(b
O
)

[Table 0.2717 INCH 6.901087 MM
Gasket Factor, m [Table 2-5.1] 3.5
Min. Seating Stress, y [Table 2-5.1] 6500 PSIG 457.6 Kg/CM
2
G
Facing Sketch [Table 2-5.1] (1a); Column II
Diameter at location of gasket load reaction, d ( d represnts G )
When bo is larger than 1/4", d =O.D.of gasket contact face - 2 b 21.5039 INCH 546.1978 MM
[Appendix 2-3]
Factor depending upon method of attachment of head, C [Fig. UG-34, Sketch (j)] 0.3
Gasket moment arm, h
G
=(B.C.D - d)/2 =(C-G)/2 [Table 2-5.2] 1.51185 INCH 38.40109 MM
Calculating the Min. required Thickness of Blind Flange, t:
[UG-34(c)(2)]
When using this formula, the thickness t shall be calculated for
both operating conditions, and gasket seating, and the greater
of the two values shall be used.
3
G
/SEd 1.9Wh + CP/SE d = t
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 78 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 3 of 6
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 14 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
P. Flat Unstayed Circular Blind Flange (Channel Cover) Thickness (item no. 22) (cont.)
[Attached by Bolts] [UG-34 & Fig. UG-34 Sketch (j)]
Calculating the total bolt load, W (for circular heads):
1. For operating conditions, the value of P shall be the design
pressure, and the value of S at the design temperature and W
from Formula (3) of 2-5(e) shall be used.
Flange Design Bolt Load for circular heads, W [Appendix 2-5(e)]
For operating conditions, W =Wm1 (3)
Wm1 =H +Hp =0.785 G
2
P +(2b x 3.14 GmP) (1) [Appendix 2-5(e35243.2 lb 15986.05 Kg
Flange thickness 0.85602 INCH 21.74301 MM
2. For gasket seating, P equals zero, and the values of S at
atmospheric and W from Formula (4) of 2-5(e) shall be used.
[UG-34(c)(2)]
P 0 PSIG 0 Kg/CM
2
G
S 20000 PSIG 1408 Kg/CM
2
G
Flange Design Bolt Load for circular heads, W [Appendix 2-5(e)]
For gasket seating, W =0.5(Am +Ab) Sa (4)
Total required cross-sectional area of bolts, Am =Max (Am1,Am2)
Required bolt load under atmospheric temp.conditions, Wm2 =3.14bGy (2) 119246 lb 54089.04 Kg
* Total cross-sectional area of bolts at root of thread requiired
at operating conditions , Am1 =Wm1/ Sb 1.40973 INCH
2
909.4991 MM
2
* Total cross-sectional area of bolts at root of thread required
gasket seating, Am2 =Wm2/ Sa 4.76983 INCH
2
3077.304 MM
2
Total required cross-sectional area of bolts, Am =Max (Am1,Am2) 4.76983 INCH
2
3077.304 MM
2
For gasket seating, W =0.5(Am +Ab) Sa (4) 252473 lb 114519.9 Kg
1.29857 INCH 32.98372 MM
t =max. of t of operating and gasket seating 1.29857 INCH 32.98372 MM
Use t without corrosion allowance 1.29921 INCH 33 MM
Use t for construction including R.F. 2.00787 INCH 51 MM
N.B. Check which the deflection is considered a governing thickness or not. 2.48031 INCH 63 MM
The deflection is ehe governing thickness
t = d CP / SE +1.9Wh / SEd^ G 3
t = d CP / SE +1.9Wh / SEd^ G 3
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 79 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 4 of 6
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 14 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
P. Flat Unstayed Circular Blind Flange (Channel Cover) Thickness (item no. 22) (cont.)
[Attached by Bolts] [UG-34 & Fig. UG-34 Sketch (j)]
CONCLUSION:
FLANGE SUMMARY
Flange thickness (without C.A.) 1.29857 INCH 32.98372 MM
Use t for construction including R.F. 2.04724 INCH 52 MM
For a proper design of flange :
1. You have to make a check for flange deflection.

GASKET SUMMARY
Gasket width, N 0.59055 INCH 15 MM
Required cross-sectional of bolts, Am 4.76983 INCH
2
3077.304 MM
2
Actual cross-sectional area of bolts, Ab 15.428 INCH
2
9953.528 MM
2
BOLT SUMMARY
No. of bolts 28 Bolt
Size of bolt (the bolt size is represented by its actual cross-sectional area) 1 INCH 25.4 MM
Bolt hole dia. 1.125 INCH 28.575 MM
Total required cross-sectional area of bolts, Am 4.76983 INCH
2
3077.304 MM
2
Total actual cross-sectional area of bolts, Ab 15.428 INCH
2
9953.528 MM
2
Actual cross-sectional area of bolt, [TEMA TABLE D-5] 0.551 INCH
2
355.4832 MM
2
Since the actual bolt area Ab >The required bolt area Am,
the bolts are adequately enough.
N.B. When using bolt with size 0.75 INCH NA
Total required cross-sectional area of bolts, Am 4.76983 INCH
2
Total ctual cross-sectional area of bolts, Ab 8.456 INCH
2
Actual cross-sectional area of bolt, [TEMA TABLE D-5] 0.302 INCH
2
Since the actual bolt area Ab <The required bolt area Am,
the bolts are inadequately enough.
Edge distance, E from drawing =1/2 (A - C) 1.22047 INCH 31 MM
Min. Edge distance, E (for bolt size 0.75") 0.8125 INCH 20.6375 MM
Min. Edge distance, E (for bolt size 1") 1.0625 INCH 26.9875 MM
Min. edge distance, E (for bolt size 1-1/8") [TEMA Table D-5] 1.125 INCH 28.575 MM
Min. Edge distance, E (for bolt size 1.25") 1.25 INCH 31.75 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 80 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 5 of 6
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 14 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
P. Flat Unstayed Circular Blind Flange (Channel Cover) Thickness (item no. 22) (cont.)
[Attached by Bolts] [UG-34 & Fig. UG-34 Sketch (j)]
Actual Bolt spacing, B (c/c) from drawing 2.74622 INCH 69.75387 MM
Min. Bolt spacing, B (for bolt size 0.75") 1.75 INCH 44.45 MM
Min. Bolt spacing, B (for bolt size 7/8") [TEMA Table D-5] 2.0625 INCH 52.3875 MM
Min. Bolt spacing, B (for bolt size 1") 2.25 INCH 57.15 MM
Min. Bolt spacing, B (for bolt size 1-1/8") 2.5 INCH 63.5 MM
Min. Bolt spacing, B (for bolt size 1-1/4") 2.8125 INCH 71.4375 MM
Max. Recommended bolt spacing, Bmax =2 d
B
+6 t / (m +0.5) [TEMA RCB3.94882 INCH 100.3 MM
Check for Flat Channel Cover Deflection [TEMA RCB-9.21]
The effective thickness of a flat channel cover shall be the thickness at the
bottom of the pass partition groove (or the face if there is no groove) minus
corrosion allowance in excess of groove depth. The thickness is to be at
least that required by the appropriate Code formula and thicker if required
to meet proper deflection criteria.
The recommended limit for channel cover deflection is:
0.03" for nominal diameters thru 24" 0.03 INCH 0.762 MM
0.125% of nominal diameters (nominal diameter/800) for larger sizes 0.025 INCH 0.635 MM
Nominal diameter =Shell ID +2 ts 20 INCH 508 MM
A method for calculating of channel cover deflection at the center, Y is:
Where G =Gasket load reaction diameter as defined by the Code 21.5039 INCH 546.1978 MM
E =Modulus of elasticity at design temperature [ASME Sec.II,Part D, TM 31460000 PSI 2214784.07 Kg/CM
2
G
T =Thickness under consideration (minus groove and C.A.) 1.29921 INCH 33 MM
P =Design pressure 71.7082 PSIG 5.04826 Kg/CM
2
G
SB =Allowable bolting stress at design temperature (Wm1) 25000 PSIG 25000 Kg/CM
2
G
AB =Actual total cross-sectional root area of bolts 15.428 INCH
2
9953.528 MM
2
hG =Radial distance from diameter G to bolt circle 1.51185 INCH 38.40109 MM
If the calculated deflection is greater than the recommended limit,
the deflection may be reduced by acceptance methods such as:
(a) Increase channel cover thickness by the cube root of the
ratio of calculated deflection to the recommended limit.
(b) Use of strong backs.
(c) Change type of construction.
Note: For single pass channels, or others in which there is no pass partition
gasket seal against the channel cover, no deflection criteria need be
considered.
( )
G B B
3
3
h A S 5 . 0 + P G 0435 . 0
T E
G
= Y
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 81 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 6 of 6
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 14 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
P. Flat Unstayed Circular Blind Flange (Channel Cover) Thickness (item no. 22) (cont.)
[Attached by Bolts] [UG-34 & Fig. UG-34 Sketch (j)]
The calculated deflection is 0.10054 INCH 2.553795 MM
The recommended deflection limit 0.03 INCH 0.762 MM
Since the calculated deflection exceeds the recommended deflection, we have
to increase the flange tickness by the cubic root of the ratio of deflections,
[TEMA RCB-9.21] 2.88948 INCH 73.39285 MM
0.00914 INCH 0.232149 MM
Easier approach :
1. Assume T, 1.88283 INCH 47.824 MM
2. Find Calculated deflection 0.03303 INCH 0.839054 MM
3. Recommended deflection limit 0.03 INCH 0.762 MM
4. Compare the calculated deflection with the recommended deflection OK
The minimum thickness of channel cover at bottom of pass partition is 1.88283 INCH 47.824 MM
The thickness neglecting corrosion allowance is 1.88976 INCH 48 MM
Conclusion : Checking of Deflection
The min. thickness of channel cover to resist the internal pressure is 1.33858 INCH 34 MM
Where the min. thickness of channel cover to avoid deflection is 1.88976 INCH 48 MM
The min. thickness of channel cover as derived from drawings is 1.9685 INCH 50 MM
The flange thickness increased by 0.07874 INCH 2 MM
Tthickness including groove depth ( 5 MM) 2.08661 INCH 53 MM
Overall thickness including raised faces & groove depth 2.48031 INCH 63 MM
Max. Working Pressure, MWP at New (cold) & Operating (corroded)
at New (cold) P =SE t
2
/d
2
c - 1.9 W h
G
/ d
3
c 104.094 PSIG 7.328196
Kg/CM
2
G
at Operating (corroded) P =SE t
2
/d
2
c - 1.9 W h
G
/ d
3
c 104.094 PSIG 7.328196
Kg/CM
2
G
( )
Y
G
E T
G P S A h
B B G
= +
3
3
00435 05 . .
T T
Y
Y
assumed
calculated
recommended
= + 3
( )
Y
G
E T
G P S A h
B B G
= +
3
3
00435 05 . .
( )
Y
G
E T
G P S A h
B B G
= +
3
3
00435 05 . .
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 82 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 2
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 4 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
Q. TEMA Stationary Tubesheet Thickness Formula-Bending (item No.36) [TEMA RCB-7.132]
Tubesheet material, Carbon Steel ASME SB171 UNS No. 63000
Effective tubesheet thickness, T
Where
F =1.25 For unsupported tubesheet (e.g. U-tube tubesheets) gasketed 1.25
both sides.
F =1 For supported tubesheet (e.g. fixed tubesheets & floating type 1
tubesheets) gasketed both sides.
* For unsupported tubesheet (e.g. U-tube tubesheets) integral
with either or both sides, F shall be the value as determined
by the curve U in Figure RCB-7.132.
* For supported tubesheet (e.g. fixed tubesheets and floating type
tubesheets) integral with either or both sides, F shall be the value
as determined by the curve H in Figure RCB-7.132.
G shall be either in the corroded or uncorrded condition, dependent
upon which condition is under consideration.
G =shell ID for fixed tubesheet exchangers.
* For any floating tubesheet (except divided), G shall be the G used for
the stationary tubesheets using the P as defined for other type exchanger.
* Type T tubesheets shall also be checked using the pressure P
defined above with bolting and using the actual gasket G of the
floating tubesheet.
G =1.41(s) For divided floating tubesheet where s is the length of the
shortest span measured over centerlines of gaskets.
* For other type exchangers, G shall be the diameter over which
the pressure under consideration is acting. (e.g. pressure acting
on the gasketed side of a tubesheet, G =the diameter at the 21.50385 INCH 546.1978 MM
location of the gasket load reaction as defined in the Code. Pressure
acting on an integral side of a tubesheet, G =the inside diameter
of the integral pressure part.)
S =Code allowable stress in tension for tubesheet at design metal temp. 20996 PSIG 1478.118 Kg/CM
2
G
Design temperature 302
o
F 150
o
C
For square or rotated square tube patterns, n' 0.520874 NA
For triangular or rotated triangular tube patterns, n' 0.446411
T
F G P
n S
=
3 '
n
Pitch
Tube OD
'
.
=

1
0785
2
n
Pitch
Tube OD
'
.
=

1
0907
2
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 83 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 2
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 4 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
Q. TEMA Stationary Tubesheet Thickness Formula-Bending (item No.36) [TEMA RCB-7.132]
No of tubes 146
Tube OD 0.984252 INCH 25 MM
Tube length 236.2205 INCH 6000 MM
Tube pitch 1.259843 INCH 32 MM
Tube BWG 13
Tube wall thickness [TEMA Table D-7] 0.098425 INCH 2.5 MM
Tube pattern ( equal angles triangle 60
o
) (square rotated) 30
o
* For other type exchangers, P shall be the design pressure, shell side
or tube side, corrected for vacuum when present on the opposite side,
or differential pressure when specified by the purchaser.
Internal Design Pressure, P (MAWP) [Shell Side] 284.7764 PSIG 20.04826 Kg/CM
2
G
* For floating tubesheets (Type T), where the tubesheet is extended
for bolting to heads with ring type gaskets, the effect of the moment
acting upon the extension is defined in Paragraph RCB-7.162 in
terms of equivalent tube side and shell side bolting pressure except
G shall be the gasket G of the floating tubesheet.
P is given by the greatest absolute value of the following:
P =Pt +P Bt
or P =Ps +PBt
or P =Pt 71.70824 PSIG 5.04826 Kg/CM
2
G
or P =Ps 284.7764 PSIG 20.04826 Kg/CM
2
G
Effective tubesheet thickness, T 1.561785 INCH 39.66934 MM
Ttubesheet thickness with CA 1.811024 INCH 46 MM
Tubesheet raised face (2 x 5) 0.551181 INCH 14 MM
Use tubesheet thickness for construction 2.362205 INCH 60 MM
Tubesheet OD 22.04724 INCH 560 MM
TUBESHEET THICKNESS FORMULA-SHEAR [TEMA RCB-7.132]
Effective tubesheet thickness, T
Note : Shear will not control when
P/S 0.013563
0.076563
Perimeter INCH MM
Area INCH
2
MM
2
Max. Working pressure MWP : Pressure at tube-side is th most severe condition
MWP, New & cold P =n' S (3 T / F G)
2
626.9255 PSIG 44.13556 Kg/CM
2
G
MWP, Operating & corroded P =n' S (3 T / F G)
2
598.3149 PSIG 42.12137 Kg/CM
2
G
T
F G P
n S
=
3 '
T
D
d
Pitch
P
S
L
o
=

031
1
.
P
S
d
Pitch
o
<

16 1
2
.
16 1
2
.

d
Pitch
o
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 84 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 2
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 6 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
Q1. TEMA Floating Tubesheet Thickness Formula-Bending (item No.37) [TEMA RCB-7.132]
Tubesheet material, Carbon Steel ASME SB171 UNS No. 63000
Effective tubesheet thickness, T
Where
F =1.25 For unsupported tubesheet (e.g. U-tube tubesheets) gasketed 1.25
both sides.
F =1 For supported tubesheet (e.g. fixed tubesheets & floating type 1
tubesheets) gasketed both sides.
* For unsupported tubesheet (e.g. U-tube tubesheets) integral
with either or both sides, F shall be the value as determined
by the curve U in Figure RCB-7.132.
* For supported tubesheet (e.g. fixed tubesheets and floating type
tubesheets) integral with either or both sides, F shall be the value
as determined by the curve H in Figure RCB-7.132.
G shall be either in the corroded or uncorrded condition, dependent
upon which condition is under consideration.
G =shell ID for fixed tubesheet exchangers.
* For any floating tubesheet (except divided), G shall be the G used for
the stationary tubesheets using the P as defined for other type exchanger.
* Type T tubesheets shall also be checked using the pressure P
defined above with bolting and using the actual gasket G of the
floating tubesheet.
G =1.41(s) For divided floating tubesheet where s is the length of the
shortest span measured over centerlines of gaskets.
* For other type exchangers, G shall be the diameter over which
the pressure under consideration is acting. (e.g. pressure acting
on the gasketed side of a tubesheet, G =the diameter at the 18.18898 INCH 462 MM
location of the gasket load reaction as defined in the Code. Pressure
acting on an integral side of a tubesheet, G =the inside diameter
of the integral pressure part.)
S =Code allowable stress in tension for tubesheet at design metal temp. 20996 PSIG 1478.118 Kg/CM
2
G
Design temperature 302
o
F 150
o
C
For square or rotated square tube patterns, n' 0.520874 NA
For triangular or rotated triangular tube patterns, n' 0.446411
T
F G P
n S
=
3 '
n
Pitch
Tube OD
'
.
=

1
0785
2
n
Pitch
Tube OD
'
.
=

1
0907
2
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 85 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 2
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 6 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
Q1. TEMA Floating Tubesheet Thickness Formula-Bending (item No.37) [TEMA RCB-7.132]
No of tubes 146
Tube OD 0.984252 INCH 25 MM
Tube length 236.2205 INCH 6000 MM
Tube pitch 1.259843 INCH 32 MM
Tube BWG 13
Tube wall thickness [TEMA Table D-7] 0.098425 INCH 2.5 MM
Tube pattern ( equal angles triangle 60
o
) (square rotated) 30
o
* For other type exchangers, P shall be the design pressure, shell side
or tube side, corrected for vacuum when present on the opposite side,
or differential pressure when specified by the purchaser.
Internal Design Pressure, P (MAWP) [Shell Side] 284.7764 PSIG 20.04826 Kg/CM
2
G
* For floating tubesheets (Type T), where the tubesheet is extended
for bolting to heads with ring type gaskets, the effect of the moment
acting upon the extension is defined in Paragraph RCB-7.162 in
terms of equivalent tube side and shell side bolting pressure except
G shall be the gasket G of the floating tubesheet.
P is given by the greatest absolute value of the following:
P =Pt +PBt
or P =Ps +PBt
or P =Pt 71.70824 PSIG 5.04826 Kg/CM
2
G
or P =Ps 284.7764 PSIG 20.04826 Kg/CM
2
G
Effective tubesheet thickness, T 1.321032 INCH 33.5542 MM
Ttubesheet thickness with CA 1.535433 INCH 39 MM
Tubesheet raised face (2 x 5) 0.393701 INCH 10 MM
Use tubesheet thickness 1.929134 INCH 49 MM
Use tubesheet thickness for construction (not less than thk of st. tubesheet) 2.362205 INCH 60 MM
Tubesheet OD 18.58268 INCH 472 MM
TUBESHEET THICKNESS FORMULA-SHEAR [TEMA RCB-7.132]
Effective tubesheet thickness, T
Note : Shear will not control when
P/S 0.013563
0.076563
Perimeter INCH MM
Area INCH
2
MM
2
Max. Working pressure MWP : Pressure at tube-side is th most severe condition
MWP, New & cold P =n' S (3 T / F G)
2
629.8621 PSIG 44.34229 Kg/CM
2
G
MWP, Operating & corroded P =n' S (3 T / F G)
2
601.1175 PSIG 42.31867 Kg/CM
2
G
T
F G P
n S
=
3 '
T
D
d
Pitch
P
S
L
o
=

031
1
.
P
S
d
Pitch
o
<

16 1
2
.
16 1
2
.

d
Pitch
o
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 86 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 1
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 7 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
Q2. TEMA Pass Partition Plate Thickness Calculation (item No.23) [TEMA RCB-9.13]
Pass partition plate material ASME SB171 UNS No. 63000
Min. calculated pass partition plate thickness, 0.193711 INCH 4.920265 MM
[TEMA Table RCB-9.132]
Where
Plate dimension, a 23.62205 INCH 600 MM
Plate dimension, b 19 INCH 482.6 MM
Ratio a/b (long side case) [TEMA Table RCB-9.132] 1.243266
Table value B, to be found from Table RCB-9.132 versus a/b 0.467662
Pressure drop across plate, q 7 PSIG 0.4928 Kg/CM
2
G
S =Code allowable stress in tension for pass partition plate at design metal tem20996 PSIG 1478.118
Kg/CM
2
G
Design temperature 302
o
F 150
o
C
Exchanger Nominal Size 20 INCH 508 MM
TEMA Table RCB 9-131 Carbon Steel Alloy Material
INCH MM INCH MM
Nominal pass partition plate thickness for Nominal size <24" 0.375 9.525 0.25 6.35
Nominal pass partition plate thickness for Nominal size 24" to 60" 0.5 12.7 0.375 9.525
Nominal tabulated plate thickness, ttabulated 0.25 INCH 6.35 MM
Recommended plate thickness, trecom. =Max. (tcalculated, ttabulated) 0.25 INCH 6.35 MM
Corrosion allowance, C [UG-25] 0 INCH 0 MM
Thickness of pass partition including corrosion allowance, 0.25 INCH 6.35 MM
Assume adopted thickness of pass partition, t 0.511811 INCH 13 MM
Fillet weld leg size, 3/4 t [TEMA RCB-9.133] 0.383858 INCH 9.75 MM
RCB-9.133 Pass Partition Weld Size
The pass partition plate shall be attached with fillet welds on each side with
a min. leg of 0.75 t. Other types of attachments are allowed but shall be of
equivalent strength.
t b
qB
S
calculated
=
15 .
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 87 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 12
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 15 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
Q3. FLOATING HEAD & ITS FLANGE [Attached by Bolts] [Appendix 1-6]
Q3a. Min Required Thickness of Floating Head
Floating head type : Spherical-dished cover
Corrosion Allowance (for carbon steel), CA 0.19685 INCH 5 MM
No J oint Efficiency is Required
Backing Ring Material ASME SA266 Class 2
Head & Flange Material ASME SB171 UNS No. C63000
Design Temperature : Shell Side 302
o
F 150
o
C
Tube Side 140
o
F 60
o
C
Min. Design Metal Temperature, MDMT 53.6
o
F 12
o
C
Internal Design Pressure, P (MAWP) (Tube Side) 71.02273 PSIG 5 Kg/CM
2
G
Use Design Pressure, P (MAWP) 71.70824 PSIG 5.04826 Kg/CM
2
G
Design Pressure, (Shell Side) 284.7763 PSIG 20.0483 Kg/CM
2
G
External Design Pressure, Pe 284.7763 PSIG 20.0483 Kg/CM
2
G
Max. Allowable Stress for Head Material @ Design Temp. 140&302
o
F,S 22896 PSIG 1611.88 Kg/CM
2
G
Max. Allowable Stress for Head Material @ Test Temp.,St 24000 PSIG 1689.6 Kg/CM
2
G
Max. Allowable Stress for Flange Material @ Design Temp. 140&302
o
F, SH 22896 PSIG 1611.88 Kg/CM
2
G
Max. Allowable Stress for Flange Material @ Test Temp., SC 24000 PSIG 1689.6 Kg/CM
2
G
Max. Allowable Stress for Backing Ring Material @ Design Temp. 140&302
o
F,S20000 PSIG 1408 Kg/CM
2
G
Max. Allowable Stress for Backing Ring Material @ Test Temp.,St 20000 PSIG 1408 Kg/CM
2
G
[ TABLE 1A , SUBPART 1 , ASME SEC. II , PART D]

Figure (6)
No. of bolts 24
Nominal bolt dia., d
B
1 INCH2 25.4 MM
Actual Root area of each bolt [TEMA Table D-5] 0.551 INCH
2
355.483 MM
2
Bolt hole dia., d 1.102362 INCH 28 MM
Flange & Backing ring outside diameter, A 23.0315 INCH 585 MM
Flange & Backing ring inside diameter, B 17.71654 INCH 450 MM
Bolt circut diameter (B.C.D.), C 20.66929 INCH 525 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 88 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 12
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 15 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
Q3. FLOATING HEAD & ITS FLANGE (cont.) [Attached by Bolts] [Appendix 1-6]
Q3a. Min Required Thickness of Floating Head (cont.)
Gasket Details :
- Gasket Type : Flat metal, jacketed asbestos filled (soft copper or brass)
- Outside diameter =(B.C.D - d) - 10 18.58268 INCH 472 MM
- Inside diameter =O.D - 2N 17.79528 INCH 452 MM
- Width, N 0.393701 INCH 10 MM
Gasket Dimensions:
Basic gasket seating width, b
O
=N/2 [Table 2-5.2] 0.19685 INCH 5 MM
Since bo is less than 1/4 inch,
Effective gasket seating width, b =b
O
[Table 2-5.2] 0.19685 INCH 5 MM

N.B. When bo >1/4 inch, b =0.5*SQRT(b
O
) [Table 2-5.2] 0.221839 INCH 5.63471 MM
Gasket Factor, m [TABLE 2-5.1] 3.5
Min. Seating Stress, y [TABLE 2-5.1] 6500 PSIG 457.6 Kg/CM
2
G
Facing Sketch [TABLE 2-5.1] (1a); Column II
Diameter at location of gasket load reaction, G
When bo is less than 1/4", G =Mean dia. of gasket contact face =(ID +OD) / 218.18898 INCH 462 MM
[APPENDIX 2-3]
Corrosion allowance, C (for carbon steel) 0.19685 INCH 5 MM
Corrosion allowance, C (for copper) 0 INCH 0 MM
Fillet weld size, h1 0.393701 INCH 10 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 89 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 3 of 12
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 15 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
Q3. FLOATING HEAD & ITS FLANGE (cont.) [Attached by Bolts] [Appendix 1-6]
Q3a. Min Required Thickness of Floating Head (cont.)
Dish radius for spherical segment, L ( 0.9-0.82 I.D =0.9 * B approx.) 13.77953 INCH 350 MM
The governing radius depends on the total cross-overbypass area
Q3a.1. For pressure on concave side (internal pressure) [Appendix 1-6(e)(1)(a)]

[1] 0.035964 INCH 0.91347 MM
Thickness t including C.A (CA from outside only, inside there is cla0.035964 INCH 0.91347 MM
Use t for construction 0.51181 INCH 13 MM
Q3a.2. For pressure on convex side (external pressure) [Appendix 1-6(e)(1)(b)] & [UG-33(c)]
Step 1. Assume thickness t without corrosion allowance 0.51181 INCH 13 MM
Outside radius of spherical head segment, Ro =L +t 14.29134 INCH 363 MM
0.004477
Step 2 & 3. Enter Figure NFA-6 of ASME Sec.II, Part D at A value 0.004477
and move vertically to material line for 302
o
F.
Move horizontally to the right and read B value of 11000 PSIG 774.4 Kg/CM
2
G
Step 4. The max. allowable external working pressure for
the assumed head thickness : 393.9386 PSIG 27.7333 Kg/CM
2
G
External design pressure, Pe 284.7763 PSIG 20.0483 Kg/CM
2
G
Since Pa >Pe, the assumed head thickness is satisfactory. OK
t
PL
S
=
5
6
A
R t o
=
0 125 .
( / )
P
B
R t
a
o
=
( / )
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 90 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 4 of 12
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 15 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
Q3. FLOATING HEAD & ITS FLANGE (cont.) [Attached by Bolts] [Appendix 1-6]
Q3b. Min Required Thickness of Ring Flange [Fig. 1-6(d)]
Head-to-ring angle [Appendix 1-6(b)] 39.13399 Degree
1. Bolt loading and size of bolts: [Appendix 2-5(c)]
(a) Total hydrostatic end force, H =0.785 G
2
P [Appendix 2-3] 18445.21 lb 8366.61 Kg
(b) Total joint-contact surface compression load, Hp =2b*3.14GmP 5589.456 lb 2535.34 Kg
(Gasket seating load) [Appendix 2-3]
(c) Min. required bolt load for operating conditions, Wm1 =H +Hp 24034.66 lb 10902 Kg
Use Wm1 =Max (Wm1 Floating head flange , Wm1 Backing ring) [Appendix 2-325021.21 lb 11349.4 Kg
Min. required bolt load for gasket seating, Wm2 =3.14 b G y 73078.15 lb 33147.7 Kg
Use Wm2 =Max (Wm2 Floating head flange , Wm2 Backing ring) [APPENDIX 2-86187.58 lb 39094.1 Kg
Allowable Bolt Stress at atmospheric temp., Sa 25000 PSIG 1760 Kg/CM
2
G
Allowable Bolt Stress at design temp., Sb 25000 PSIG 1760 Kg/CM
2
G
[Table 1A , SubPart 1 , ASME Sec. II , Part D]
(d) Total cross-sectional area of bolts at root of thread required for:
- operating conditions, Am1 =Wm1 / Sb [Appendix 2-3] 1.000849 INCH
2
645.707 MM
2
- Gasket seating, Am2 =Wm2 / Sa [Appendix 2-3] 3.447503 INCH
2
2224.19 MM
2
(e) Total required cross-sectional of bolts, Am =the greater of Am1 & Am2 3.447503 INCH
2
2224.19 MM
2
Actual bolt area, Ab 13.224 INCH
2
8531.6 MM
2
Since the actual bolt area Ab >The required bolt area Am,
the bolts are adequately enough.
(f) Flange design bolt load, W :
- For operating conditions, Wo =Wm1 (3) [Appendix 2-5(d)] 25021.21 lb 11349.4 Kg
- For gasket seating, Wa =0.5(Am +Ab) * Sa (4) [Appendix 2-5(d)] 208393.8 lb 94525.9 Kg
B arc
B
L t
1
2
=
+
sin
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 91 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 5 of 12
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 15 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
Q3. FLOATING HEAD & ITS FLANGE (cont.) [Attached by Bolts] [Appendix 1-6]
Q3b. Min Required Thickness of Ring Flange (cont.) [Fig. 1-6(d)]
2. Total flange moment for design condition: [APPENDIX 2-5(c)]
- Flange Loads: The same as in welding neck flange calculation
plus an additional load from the horizontal component, Hr,
due to the internal pressure load on the spherical head.
(a) Total hydrostatic end force due to pressure, H =0.785 G
2
P [APPENDIX18445.21 lb 8366.6 Kg
(b) Hydrostatic end force on area inside flange, HD =0.785 B
2
P 17668.36 lb 8014.23 Kg
(c) Gasket load (flange design bolt load - total hydrostatic end force), HG
H
G1
=Wo - H =Wm1 - H (design condition) 6576.009 lb 2982.83 Kg
H
G2
=Wa - H =0.5 (Am +Ab) Sa - H (gasket seating) 189948.6 lb 86159.2 Kg
(d) Difference bet. total hydrostatic end force and the hydrostatic end force
on area inside of flange, H
T
=H - H
D
776.8437 lb 352.37 Kg
(e) Floating head load, H
R
=H
D
cot B
1
[J im Far21714.58 lb 9849.57 Kg
Lever arms: h
D
=(C - B) / 2 1.476378 INCH 37.5 MM
h
G
=(C - G) / 2 [TABLE 2-6] 1.240157 INCH 31.5 MM
h
T
=(h
D
+ h
G
) / 2 1.358268 INCH 34.5 MM
Calculating h
R
: [BY : A.H.Galala & J im Farr]
h
R
is obtained by trail using the assumed flange thickness and the
perpendicular head thickness at the head-to-ring intersection.
Assuming thickness of flange, T 3.267717 INCH 83 MM
L1 =t (thk. of floating head)/cos B1 0.659828 INCH 16.7596 MM
h
R
=0.5 (T
assumed
- L1) 1.303944 INCH 33.1202 MM
B1 MM
t = 13
L1
Figure (7)
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 92 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 6 of 12
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 15 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
Q3. FLOATING HEAD & ITS FLANGE (cont.) [Attached by Bolts] [Appendix 1-6]
Q3b. Min Required Thickness of Ring Flange (cont.) [Fig. 1-6(d)]
Flange Moments due to :
End pressure H
D
M
D
=H
D
h
D
26085.18 lb-in. 300.534 Kg-M
Gasket load H
G
M
G
=H
G
h
G
[Appendix 28155.287 lb-in. 93.959 Kg-M
Face pressure H
T
M
T
=H
T
h
T
1055.162 lb-in. 12.1568 Kg-M
Floating head load H
R
M
R
=H
R
h
R
[J im Farr] 28314.61 lb-in. 326.22 Kg-M
Total moment acting upon the flange, Mo :

[Appendix 2-6]
- For operating condition M
O1
=M
D
+M
G
+M
T
- M
R
[J im Farr] 6981.021 lb-in. 80.43 Kg-M
Use Mo1 6981.021 lb-in. 80.43 Kg-M
3. Total flange moment for bolt-up condition (Gasket condition) : [APPENDIX 2-6]
Flange Load H
G
=Wa

=(Am +Ab) Sa / 2 208393.8 lb 94525.8 Kg
Lever Arm h
G
=(C - G) / 2 1.240157 INCH 31.5 MM
Flange Moment for gasket condition, M
O2
=H
G
h
G
=Wa (C - G) / 2 (5) 258441.1 lb-in. 2977.56 Kg-M
Use M
O2
=M
O2
(SH/SC) 246552.8 lb-in. 2840.6 Kg-M
4. The min. flange thickness [Appendix 1-6(g)(2)]
4.1. The min. flange thickness for operating condition :
0.027284
0.131943
0.391547 INCH 9.9453 MM
4.2. The min. flange thickness for gasket seating :
F 0
4.659917
2.158684 INCH 54.8306 MM
F
P B L B
S A B
=

4
8
2 2
( )
T F F J = + +
2
J
M
SB
A B
A B
=

02
T F F J = + +
2
J
M
SB
A B
A B
=

01
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 93 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 7 of 12
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 15 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
Q3. FLOATING HEAD & ITS FLANGE (cont.) [Attached by Bolts] [Appendix 1-6]
Q3b. Min Required Thickness of Ring Flange (cont.) [Fig. 1-6(d)]
5. Required thickness for backing ring in case of internal pressure, [Appendix 2-7(b)(9)]
Momenmts for backing ring (1split ring - 2 halfs, lap-type flange) [Fig. 2-4 Sketches (1) ]
Lever arms: h
D
=(C -B) / 2 1.476378 INCH 37.5 MM
h
G
=(C - G) / 2 [Table 2-6] 1.259843 INCH 32 MM
h
T
=(C - G) / 2 1.259843 INCH 32 MM
Backing ring OD contact =Gasket OD 18.58268 INCH 472 MM
Backing ring mid point of contact G =(OD of contact +B ) / 2 [Fig. 2-4, Sk18.14961 INCH 461 MM
End pressure, HD =0.785 B
2
P (11b) 17499.46 lb 7937.62 Kg
Face pressure, HT =H - HD (11c) 865.9855 lb 392.804 Kg
Total hydrostatic, H =0.785 G
2
P (11d) 18365.44 lb 8330.42 Kg
Floating head load, H
R
=H
D
cot B
1
[A. Galala] 21507 lb 9755.41 Kg
To find Am : HP =2 b * 3.14 G m P 6655.772 lb 3019.01 Kg
Gasket seating width, N =(OD - B ) / 2 0.433071 INCH 11 MM
Basic gasket seating width, b
O
=N/2 [Table 2-5.2] 0.216535 INCH 5.5 MM
N.B. When bo >1/4 inch,
Effective gasket seating width, b =0.5 * SQRT (bO) [Table 2-5.2] 0.232667 INCH 5.90974 MM
Wm1 =H +HP 25021.21 lb 11349.4 Kg
Use Wm1 =Max (Wm1 Floating head flange , Wm1 Backing ring) [Appendix 2-3]25021.21 lb 11349.4 Kg
Wm2 =3.14 b G y 86187.58 lb 39094 Kg
Use Wm2 =Max (Wm2 Floating head flange , Wm2 Backing ring) [Appendix 2-5(c)86187.58 lb 39094 Kg
Am1 =Wm1 / Sb 1.000849 INCH
2
645.707 MM
2
Am2 =Wm2 / Sa 3.447503 INCH
2
2224.19 MM
2
Am =Max. (Am1 , Am2) 3.447503 INCH
2
2224.19 MM
2
To find HG1(Gasket load for design condition) HG1 =WO - H =Wm1 - H 6655.772 lb 3019.01 Kg
5.1. Backing ring min. thickness for operating condition :
Moment, Mo3 =MD +MG +MT =HD hD +HG1 hG +HT hT 35312.04 lb-in. 406.839 Kg-M
Tring =SQRT ( 2 * Mo3 * Y / S * B ) [Appendix 2-8(c)] 1.226426 INCH 31.1512 MM
K =A/B 1.3
Factor 7.546382
5.2. Backing ring min. thickness for gasket seating :
Moment, Mo4 =Flange bolt load HG2 * Arm hG =Wa * hG =[(Am +Ab) Sa/2]* hG262543.4 lb-in. 3024.83 Kg-M
Tring =SQRT ( 2 * Mo4 * Y / S * B ) [Appendix 2-8(c)] 3.34411 INCH 84.9404 MM
K =A/B 1.3
Factor 7.546382
Y
K
K Log K
K
=

1
2
10
2
1
066845 571690
1
. .
Y
K
K Log K
K
=

1
2
10
2
1
066845 571690
1
. .
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 94 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 8 of 12
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 15 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
Q3. FLOATING HEAD & ITS FLANGE (cont.) [Attached by Bolts] [Appendix 1-6]
Q3b. Min Required Thickness of Ring Flange (cont.) [Fig. 1-6(d)]
6. In case of flange subjected to external pressure only [Appendix 1-6(g)(2)] & [Appendix 2-11]
Lever arms: h
D
=(C -B) / 2 1.476378 INCH 37.5 MM
h
G
=(C - G) / 2 [Table 2-6] 1.240157 INCH 31.5 MM
h
T
=(hD +hG) / 2 1.358268 INCH 34.5 MM
Gasket seating load, W =(Am2 +Ab) Sa /2 (11a) 208393.8 lb 94525.8 Kg
End pressure, HD =0.785 B
2
Pe (11b) 70166.7 lb 31827.1 Kg
Face pressure, HT =H - HD (11c) 3792.12 lb 1720.08 Kg
Total hydrostatic, H =0.785 G
2
Pe (11d) 73958.82 lb 33547.2 Kg
Floating head load, H
R
=H
D
cot B
1
[A. Galala & J im F86235.53 lb 39115.8 Kg
To find Am2 : HP =2 b * 3.14 G m Pe 22411.76 lb 10165.8 Kg
Wm1 =H +HP 96370.58 lb 43713 Kg
Use Wm1 =Max (Wm1 Floating head flange, Wm1 Backing ring) [Appendix 2-3] 100071.2 lb 45391.5 Kg
Wm2 =3.14 b G y 73078.15 lb 33147.7 Kg
Use Wm2 =Max (Wm2 Floating head flange, Wm2 Backing ring) [Appendix 2-5(c) 86187.58 lb 39094 Kg
Am1 =Wm1 / Sb 4.002848 INCH
2
2582.48 MM
2
Am2 =Wm2 / Sa 3.447503 INCH
2
2224.19 MM
2
Am =Max. (Am1 , Am2) 4.002848 INCH
2
2582.48 MM
2
6.1.The min. flange thickness for operating condition :
Moment, Mo1 =HD(hD - hG) +HT(hT - hG) - HR hR [Appendix 2-11] (10) 95423.64 lb-in. 1099.4 Kg-M
0.1094
1.803533
1.456806 INCH 37.0029 MM
6.2. The min. flange thickness for gasket seating :
Moment, Mo2 =W hG * (SH/SC) =[(Am2+Ab)*Sa/2]*hG ? 246552.8 lb-in. 2840.6 Kg-M
F 0
4.659917
2.158684 INCH 54.8306 MM
J
M
SB
A B
A B
=

02
F
PB L B
S A B
=

4
8
2 2
( )
J
M
SB
A B
A B
=

01
T F F J = + +
2
T F F J = + +
2
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 95 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 9 of 12
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 15 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
Q3. FLOATING HEAD & ITS FLANGE (cont.) [Attached by Bolts] [Appendix 1-6]
Q3b. Min Required Thickness of Ring Flange (cont.) [Fig. 1-6(d)]
7. Required thickness for backing ring in case of external pressure, [APPENDIX 2-7(b)(9)]
Momenmts for backing ring (ones split ring, lap-type flange : [Fig. 2-4 Sketch (1)]
Lever arms: h
D
=(C - B) / 2 1.476378 INCH 37.5 MM
h
G
=(C - G) / 2 [Table 2-6] 1.259843 INCH 32 MM
h
T
=(C - G) / 2 1.259843 INCH 32 MM
Backing ring OD contact 18.58268 INCH 472 MM
Backing ring mid point of contact G =(OD of contact +B ) / 2 [Fig. 2-4, Sk18.14961 INCH 461 MM
End pressure, HD =0.785 B
2
Pe (11b) 70166.7 lb 31827.1 Kg
Face pressure, HT =H - HD (11c) 3472.299 lb 1575.01 Kg
Total hydrostatic, H =0.785 G
2
Pe (11d) 73639 lb 33402.1 Kg
Floating head load, H
R
=H
D
cot B
1
[A. Galala &J 86235.53 lb 39115.8 Kg
To find Am : HP =2 b * 3.14 G m Pe 26432.19 lb 11989.4 Kg
Gasket seating width, N =(OD - B ) / 2 0.433071 INCH 11 MM
Basic gasket seating width, b
O
=N/2 [Table 2-5.2] 0.216535 INCH 5.5 MM
N.B. When bo >1/4 inch,
Effective gasket seating width, b =0.5*SQRT(bO) [Table 2-5.2] 0.232667 INCH 5.90974 MM
Wm1 =H +HP 100071.2 lb 45391.5 Kg
Use Wm1 =Max (Wm1 Floating head flange , Wm1 Backing ring) [Appendix 2-3] 100071.2 lb 45391.5 Kg
Wm2 =3.14 b G y 86187.58 lb 39094 Kg
Use Wm2 =Max (Wm2 Floating head flange , Wm2 Backing ring) [Appendix 2-5(c86187.58 lb 39094 Kg
Am1 =Wm1 / Sb 4.002848 INCH
2
2582.48 MM
2
Am2 =Wm2 / Sa 3.447503 INCH
2
2224.19 MM
2
Am =Max. (Am1, Am2) 4.002848 INCH
2
2582.48 MM
2
To find HG1(Gasket load for design condition) HG1 =WO - H =Wm1 - H 26432.19 lb 11989.4 Kg
7.1.Backing ring min. thickness for operating condition :
Moment, Mo3 =HD (hD - hG) + HT (hT - hG) 15193.58 lb-in. 175.049 Kg-M
Tring =SQRT ( 2 * Mo3 * Y / S * B ) [Appendix 2-8(c)] 0.80447 INCH 20.4335 MM
K =A/B 1.3
Factor 7.546382
7.2. Backing ring min. thickness for gasket seating :
Flange bolt load HG =Wa =0.5(Am2 +Ab) Sa 208393.8 lb 94525.8 Kg
Moment, Mo4 =HG hG * (SH/SC) 250466.4 lb-in. 2885.68 Kg-M
Tring =SQRT ( 2 * Mo4 * Y / S * B ) [Appendix. 2-8(c)] 3.26629 INCH 82.9638 MM
K =A/B 1.3
Factor 7.546382
Y
K
K Log K
K
=

1
2
10
2
1
066845 571690
1
. .
Y
K
K Log K
K
=

1
2
10
2
1
066845 571690
1
. .
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 96 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 10 of 12
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 15 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
Q3. FLOATING HEAD & ITS FLANGE (cont.) [Attached by Bolts] [Appendix 1-6]
8. CONCLUSION:
8.1. FLOATING HEAD SUMMARY
Floating head thickness for internal pressure: OK 0.51181 INCH 13 MM
Floating head thickness for external pressure: OK 393.9386 PSI > 284.776 PSI
For calculating hr, assume thickness of flange, T 3.267717 INCH 83 MM
Calculated flange thickness, T 3.267717 INCH 83 MM
For a proper design of flange :
1. Adopted thickness of floating head flange 3.464567 INCH 88 MM
2. The centeline of floating head intersects the inside surface
of flange at distance L1/2 0.659828 INCH 16.7596 MM
8.2. GASKET SUMMARY
Gasket width, N 0.393701 INCH 10 MM
Required cross-sectional of bolts, Am 3.447503 INCH
2
2224.19 MM
2
Actual cross-sectional area of bolts, Ab 13.224 INCH
2
8531.6 MM
2
8.3. BOLT SUMMARY
No. of bolts 24 Bolt
Size of bolt 1 INCH 25.4 MM
8.4. Bolting Information for TEMA Thread Series :
1. Actual edge distance, E (from drawing) E =1/2 (A - C) 1.181102 INCH 30 MM
Min. edge distance, E (for bolt size 3/4") 0.8125 INCH 20.6375 MM
Min. edge distance, E (for bolt size 7/8") 0.9375 INCH 23.8125 MM
Min. edge distance, E (for bolt size 1") [TEMA Table D-5] 1.0625 INCH 26.9875 MM
Min. edge distance, E (for bolt size 1-1/8") 1.125 INCH 28.575 MM
2. Actual Bolt spacing, B (c/c) from drawing 2.697884 INCH 68.5263 MM
Min. bolt spacing, B (for bolt size 3/4") 1.75 INCH 44.45 MM
Min. bolt spacing, B (for bolt size 7/8") 2.0625 INCH 52.3875 MM
Min. bolt spacing, B (for bolt size 1") [TEMA Table D-5] 2.25 INCH 57.15 MM
Min. bolt spacing, B (for bolt size 1-1/8") 2.5 INCH 63.5 MM
Max. Recommended bolt spacing, Bmax =2 d
B
+6 t / (m +0.5) [TEMA RCB-16.901575 INCH 175.3 MM
3. Actual radial distance, Rr (from drawing) Rr =(C-B)/2 1.476378 INCH 37.5 MM
Min. radial distance, Rr (for bolt size 3/4") 0.8125 INCH 20.6375 MM
Min. radial distance, Rr (for bolt size 7/8") 0.9375 INCH 23.8125 MM
Min. radial distance, Rr (for bolt size 1") [TEMA Table D-5] 1.0625 INCH 26.9875 MM
Min. radial distance, Rr (for bolt size 1-1/8") 1.125 INCH 28.575 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 97 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 11 of 12
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 15 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
Q3. FLOATING HEAD & ITS FLANGE (cont.) [Attached by Bolts] [Appendix 1-6]
8.5. Moments Summary, Mo (in lb-in.) : Floating head Bcking ring
Flange
Operating Gasket Operating Gasket
Mo1 Mo2 Mo3 Mo4
a. Internal Pressure 6981.021 246552.8 35312 262543
b. External Pressure 95423.64 246552.8 15193.6 250466
8.6. Summary of rerquired thicknesses (in MMS) : Floating Flange Bcking
Head ring
Tubeside (internal pressure), operating condition 0.913474 9.945304 31.1512 MM
Shellside (external pressure), operating condition 13 37.00286 20.4335 MM
Tubeside (internal pressure) gasket seating load 54.83057 84.9404 MM
Shellside (external pressure) gasketing load 54.83057 82.9638 MM
Raised face 5 5 MM
Max. thickness +Corrosion allowance (without raised face) 13 83 92 MM
8.7. Summary of rerquired thicknesses (in INCHES) : Floating Flange Bcking
Head ring
Tubeside (internal pressure), operating condition 0.035964 0.391547 1.22643 INCH
Shellside (external pressure), operating condition 0.51181 1.456806 0.80447 INCH
Tubeside (internal pressure) gasket seating load 2.158684 3.34411 INCH
Shellside (external pressure) gasket seating load 2.158684 3.26629 INCH
Raised face 0.19685 0.19685 INCH
Max. thickness +Corrosion allowance +raised face 0.511811 3.267717 3.62205 INCH
Assumed T = 70 MM is O.K.
Thickness of flange incluiding C.A +5 mm (raised face) 3.464567 INCH 88 MM
Use flange adopted thickness T for construction 3.464567 INCH 88 MM
8.8. Comparison of rerquired thicknesses of floating head flange : Differ erence
Ready INCH MM
2 -1.608452608 -40.85469624
2 -0.543194295 -13.7971351
2 0.158684028 4.030574308
2 0.158684028 4.030574308
8.9. Comparison of rerquired thicknesses of backing ring : Differ erence
Ready INCH MM
4 -2.773573783 -70.44877408
4 -3.195529701 -81.1664544
4 -0.655890236 -16.65961201
4 -0.733710226 -18.63623975
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 98 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 12 of 12
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 0
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 4.7.2003
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 0 Sheet : 15 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Item : E-323A/B & E-514C/D
Q3. FLOATING HEAD & ITS FLANGE (cont.) [Attached by Bolts] [Appendix 1-6]
9. Check for the min. inside depth of floating head cover [TEMA R-5.11]
9.1. Calculation of flow area through the tubes of one pass, Apass
Tube OD, do 1 INCH 25.4 MM
Tube wall thickness (BWG 12) [TEMA Table D-7] 0.098425 INCH 2.5 MM
Tube ID, di 0.80315 INCH 20.4 MM
Total No. of tubes located in tubesheet, N 146
No. of passes 2
No. of tubes per one pass, N1 73
Internal area of one tube, A =PI( )/4*(di)
2
0.506621 INCH
2
326.852 MM
2
Flow area through the tubes per one pass, Apass =N1 * A 36.98333 INCH
2
23860.2 MM
2
9.2. Calculation of cross-over area of flow, A1
Inside Radius of spherical floating head, L 13.77953 INCH 350 MM
Inside Diameter of spherical floating head, D =2 L 27.55906 INCH 700 MM
Depth of floating head, h =L - SQRT [L
2
- (B/2)
2
] 3.224601 INCH 81.9049 MM
Ratio, h / D 0.117007
Parameter, C [TEMA Table D-14] 0.016842
Min. cross-over area, A1 =C * D
2
[TEMA Table D-1412.79117 INCH
2
8252.35 MM
2
9.3. Calculation of cross-over area, A2 =B * H 37.13524 INCH
2
23958.2 MM
2
Flange interference (raised face), R1 =3/16" [TEMA Figure F-3] 0.1875 INCH 5 MM
Tubesheet interference (raised face), R4 =3/16" [TEMA Figure F-3] 0.1875 INCH 3 MM
Tube projection from tubesheet, R6 0.11811 INCH 3 MM
Coorosion allowance, CA 0 INCH 0 MM
9.4. Calculation of total available cross-over area, A = A1 + A2 49.9264 INCH
2
32210.5 MM
2
9.5. Calculation of min. cross-over area = 1.3 Apass [TEMA R-5.11] 48.07834 INCH
2
31018.2 MM
2
9.6. Compare (A1 + A2) & 1.3 Apass
Change radius L untill (A1 +A2) >1.3 Apass [TEMA R-5.11] OK
N.B. Any change in L shall have an effect in the thickness of floating head t,
and may be have an effect in thickness of floating head flange T.
9.7. Total depth of floating head :
Distance from surface of floating tubesheet to inside wall of head
=h +T - [h1+L1 +R1 +R4] 5.320679 INCH 135.145 MM
Cylindrical clear depth, H =T - (h1+L1+R1+R4) 2.096078 INCH 53.2404 MM
Total clear depth of head at middle of inside wall =T+h -(h1+L1) 5.635639 INCH 143.145 MM
Head thickness of construction, t 0.511811 INCH 13 MM
Fillet weld leg, h1 0.393701 INCH 10 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 99 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 7
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
R. Design of Saddle Supports.
The design of saddle supports for horizontal cylindrical pressure
vessel shall include the required plate thicknesses calculations
for the following saddle components :
I. Top flange (reinforcement/wear) thickness , tf.
II. Web (saddle plate) thickness , tw.
III. Stiffener (rip plates) thickness , ts.
IV. Base plate thickness , tb.
The Design Data is as Follows :
Vessel type & position Cylindrical & Horizontal
Design pressure , P 284.776 PSI 20.04826 Kg/CM
2
G
Design temperature 302
o
F 150
o
C
Radiography (only for pressure parts, BW) 85%
Vessel inside dia., I.D. 19 INCH 482.6 MM
Vessel outside dia., O.D. 20 INCH 508 MM
Vessel outside radius, Ro 10 INCH 254 MM
Vessel wall thickness, t 0.5 INCH 12.7 MM
Corrosion allowance, C 0.19685 INCH 5 MM
Material : shell ASME SA106 Grade B
heads ASME SA234 Grade WPB
saddles Steel 37
saddle plate (piece of pipe) ASME SA106 Grade B
Min. tensile stress : shell 75000 PSIG 5280 Kg/CM
2
G
heads 75000 PSIG 5280 Kg/CM
2
G
saddles 55000 PSIG 3872 Kg/CM
2
G
Min. yield stress, sy : shell & heads 45000 PSIG 3168 Kg/CM
2
G
saddles 30000 PSIG 2112 Kg/CM
2
G
Allowable tensile stress: shell 17100 PSIG 1203.84 Kg/CM
2
G
heads 17100 PSIG 1203.84 Kg/CM
2
G
saddles 15700 PSIG 1105.28 Kg/CM
2
G
Vessel weight , empty , W 9156.34 lb 4152.911 Kg
liquid (water), Wc 1685.22 lb 764.3392 Kg
Vessel total weight , Wt 10841.6 lb 4917.25 Kg
Number of saddles used 2
Load per saddle , Q 5420.78 lb 2458.625 Kg
Saddle angle of contact , B 120 Degree
Saddle width, b 5.11811 INCH 130 MM
Ring stiffeners adjacent to saddle N.A.
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 100 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 7
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
R. Design of Saddle Supports (cont.)
Exchanger Layout :
Figure (8)
Shell Inside Diameter, D 22.8921 INCH 581.46 MM
Shell wall thickness, ts 0.5 INCH 12.7 MM
Head wall thickness, th 0.56181 INCH 14.27 MM
Distance from tangent line-to-saddle support, A 47.2441 INCH 1200 MM
Head depth - to - tangent line , Ho =ID / 4 +th 6.28484 INCH 159.635 MM
Shell length from Tangent - to - tangent (T/T) , L 254.843 INCH 6473 MM
Distance from tangent line - to - welding line (Skirt), l 4.13386 INCH 105 MM
Shell length from Welding - to - welding (W/W) , L' 246.575 INCH 6263 MM
Saddle - to - saddle distance (S/S) , L" =L - 2 A 165.354 INCH 4200 MM
Total Ellipsoidal Head depth (external depth), H =Ho +l 10.4187 INCH 264.635 MM
Total vessel overall length =L +2 Ho 267.412 INCH 6792.27 MM
Vessel weight , empty , W 9156.34 lb 4152.911 Kg
liquid (water), Wc 1685.22 lb 764.3392 Kg
Vessel total weight (water), Wt 10841.6 lb 4917.25 Kg
Figure (9)
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 101 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 3 of 7
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
R. Design of Saddle Supports (cont.)
(a)Determining the number of stiffeners (rip plates) and its thickness,t
*An approximate approach for determining the number
of stiffeners, N is :
N =m/24 +1 (impircal formula)
where m =total length of base plate , in.
=0.8 x vessel O.D. , in. 16 INCH 406 MM
N 1.66667
Use 4 stiffeners, n 4
* Total length of base plate m' , can also be calculated
in accordance with saddle angle of contact ,B:
m' =2 (Ro +tf) sin B 17.3205 INCH 439.9409 MM
Use m 20.5512 INCH 522 MM

* The stiffener (rip plate) thickness (ts) is 3/8" (9.5 mm)
min. for vessels up to 6 ft (1830 mm) in diameter ,
Therefore use 4 stiffeners with thickness , ts 0.59055 INCH 15 MM
Baseplate-Stiffeners' fillet weld clearance, cl =Min. (ts , tb) 0.59055 INCH 15 MM
The stiffeners are equaly spaced by, Ss =[m-2(0.5ts+cl)]/(n-1) 6.85039 INCH 174 MM
Use equally spaced stiffeners, Ss 6.85039 INCH 174 MM
Use b 5.11811 INCH 130 MM
Use rip plate width, Rw =1/2[b - (2*cl +tw)] 1.67323 INCH 42.5 MM
Use distance, c 6.82283 INCH 173.3 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 102 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 4 of 7
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
R. Design of Saddle Supports (cont.)
(b) Calculation of top flange (reinforcement) thickness , tf :
Flange thickness , tf =SQRT(6*Mb / Sb)
Where ,
Mb =Bending Moment , lb-in.
Sb =Allowable design bending stress
=0.66 Sy ( per AISC Spesificatiuons) 19800 PSIG 1393.92 Kg/CM
2
G
Pll = Linear load per unit lengh , lb/in.
Q = load per one saddle , lb 5420.78 lb 2458.625 Kg
Ro = Vessel outside radius , in. 10 INCH 254 MM
0 = Angle of contact , deg. 120 Degree
B = 180 - 0 /2 120 Degree
. . PI 441.298 lb/in 7880.703 Kg/M
. . Bending moment , Mb 282.327 lb-in 3.25276 Kg-M
Flange thickness , tf =SQRT(6*Mb / Sb) 0.2925 INCH 7.429384 MM
Use top flange plate thickness , tf 0.5 INCH 12.7 MM
Use top flange plate width, B =2* Rip width +2*(15+25) +tw 7.08661 INCH 180 MM

=---- [ --------------------------
Q 1 +cos B
Ro II - B +cos B * sin B
P
II
= ---- x ---- x ---- = P -----
b 2 4 8
M
P b b b
b II
II
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 103 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 5 of 7
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
R. Design of Saddle Supports (cont.)
(c) Calculation of web (saddle) plate thickness , tw :

Use 0.5" thick plate min. ( i.e. assume tw =0.5" ) 0.57874 INCH 15 MM
Calculate the max. allowable height h of a 1" wide
strip column 0.5" thick under PII .
Area , a =1 x 0.5 IN.
2
Min. radius of gyration , k =0.289 tw
From
We get h =tw * SQRT [(1500/PII)(18000 tw - PII )] 106.572 INCH 2706.921 MM
where c 6.82283 INCH 173.3 MM
Since c <h OK
Use web ( saddle ) with thickness , tw 0.59055 INCH 15 MM
(d) Calculation of base plate thickness , tb :
tb =SQRT [(Q * b) / 26400 * m] 0.22613 INCH 5.743795 MM
Use base plate with thickness , tb 0.59055 INCH 15 MM
(e) Check for the bearing pressure :
Calculated (actual) bearing pressure, Pact. =Q / (b*m) 51.5365 PSIG 3.628171 Kg/CM
2
G
Allowable bearing pressure, Pallow. 750 PSIG 52.8 Kg/CM
2
G
Bearing pressure ratio =Pact. / Pallow. 0.06872 < 1 Passed
= ---------------------------]
18000
1+ -------- [ ---- ]
P
-----
a
1 h
18000 k
2
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 104 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 6 of 7
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
R. Design of Saddle Supports (cont.)
(f) Stresses in Shell Due to Temperature Expansion :
Expansion dl =a * l * dT
Where dl =
a =Thermal expansion coefficent 7.1E-06
l =Tangent - to - tangent distance (T/T) , in.
dT =Difference in temp. =302-70 232
o
F 111.1111
o
C
(consider ambient temp. 70
o
F ) 70
o
F 21.11111
o
C
Expansion , dl 0.41978 INCH 10.66233 MM
Therefore use slots for anchor bolts located in the sliding saddle with
distance c/c 65 MM , and provide lubrite plates underneath the sliding saddle .
Friction coefficient , fo 0.1
Shear force at the saddle base , fo * Q 542.078 lb 245.8625 Kg
Centroid of saddle arc , xo =ro * sin 60 / rad. 60 8.26993 INCH 210.0563 MM
Use Saddle height under vessel, l =c +tf +tb 0.65945 ft. 201 MM
Distance, c 6.82283 INCH 173.3 MM
Elevation for 1st cooler, Z =Ro +tf +c +tb 17.9134 INCH 455 MM
Height between coolers' centerlines, Z1 37.0079 INCH 940 MM
Elevation for 2nd cooler, Z2 =Z +Z1 54.9213 INCH 1395 MM
(g) Support Saddle Detail :
Figure (10)
m 20.5512 INCH 522 MM
b 5.11811 INCH 130 MM
B 7.08661 INCH 180 MM
Width of outside stiffeners, Sw =2 Rw +tw 3.93701 INCH 100 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 105 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 7 of 7
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
R. Design of Saddle Supports (cont.)
Bending moment =fo * Q ( Z - xo ) 5227.5 lb-in 93352.64 Kg-M
This bending moment is counteracted by the weight of
the vessel, Q * b/2 .
i.e fo * Q ( Z - xo ) =Q * b/2
Therefore, the min. calculated value for b =2 * BM /Q 1.92869 INCH 48.98874 MM
Tthe actual value used for b 5.11811 INCH 130 MM
Since the actual value of b >the calculated value OK
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 106 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
S. Lowest MDMT Without Impact Test. [UG-20(f)] , [UCS-66] & [Fig.UCS-66]
Min. Design Metal Temperature, MDMT 28
o
F -2
o
C
Thickness P No Gr No Curve
1. Pressure Parts Materials INCH MM
a. Main Shell (Smls. Pipe 20" NPS, Sch. 30) : ASME SA106 Grade B 0.5 12.7 1 1 B
Shell Cover Course (NA) ASME SA516 Grade 70 0.5 12.7 1 2 D
Channel plate (Smls. Pipe 20" NPS, Sch. 30) : ASME SA516 Grade 70 0.8 20 1 2 D
b. Formed Heads (Cap) : (26" NPS, Thk 14.27 mm) : ASME SA234 Grade WPB 0.6 14.27 1 1 B
Floating Head (sphere sector) : ASME SB171 UNS No. C63000 0.5 13 1 2 B
c. Nozzle Necks : (Seamless Pipe) ASME SA106 Grade B
N3 & N4, NPS 6", Sch. 80 0.4 10.9728 1 1 B
N1 & N2, NPS 6", Sch. 80 0.4 10.9728 1 1 B

d. Flanges : Standards ASME SA105 (ASME B16.5) 1 2 B
Non-standard : Shell flanges ASME SA266 Class 2 2.16535 55 1 2 B
Channel flanges ASME SA266 Class 2 2.16535 55 1 2 B
Channel cover (blind flange) ASME SA266 Class 2 2.16535 55 1 2 B
Floating Head Flange ASME SA266 Class 2 2.95276 75 1 2 B
Backing Ring ASME SA266 Class 2 3.8189 97 1 2 B
e. Tubesheets : Stationary Tubesheet, ASME SB171 UNS No. C63000 2.2 55 1 1 B
Floating Tubesheet, ASME SB171 UNS No. C63000 2.2 55 1 1 B
f. Pass Partition Plate : ASME SB171 UNS No. C63000
g. Tubes : ASME SB111 UNS No. C68700 (Seamless) 0.09843 2.50012 1 1 B
h. Fittings : Half Coupling, ASME AS105, N1, 1" NPTF, 3000# 0.3 7.25 1 2 B
ASME SA105, N2, 1/2" NPTF, 3000# 0.3 7.25 1 2 B
ASME SA105, N2, 3/4" NPTF, 3000# 0.3 7.25 1 2 B
Elbows, 6" Sch. 80, ASME SA234 Grade WPB 0.432 10.9728 1 1 B
i. Stud Bolts : ASME SA193 Grade B7, Galvanized
Size of Stud Bolts connecting shell-to-channel 1 25.4
Size of Stud Bolts connecting shell-to-shell cover 1 25.4
Size of Stud Bolts connecting channel-to-channel cover 1 25.4
Size of Stud Bolts connecting floating head-to-backing ring 1 25.4
j. Nuts : ASME SA194 Grade 2H, Heavy & Galvaanized
2. Non-Pressure Parts Materials
a. Saddle Plate : ASME SA106 Grade B 0.5 12.7 1 1 B
b. Lifting Lug Reinf. Plate : ASME SA516 Grade 70 (normalized) 0.8 20 1 2 D
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 107 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
S. Lowest MDMT Without Impact Test (cont.) [UG-20(f)] , [UCS-66] & [Fig.UCS-66]
a. For Cylindrical Main Shell (Smls. Pipe 20" NPS, Sch. 30)
Material ASME SA106 Grade B
Condition
Curve B
MDMT 28
o
F -2
o
C
Nominal thickness, tn (adopted thickness) 0.5 INCH 12.7 MM
Point of combination of MDMT & thkickness Below, so we have to check ratio tr.F/(tn-c)
Required thickness, tr 0.13809 INCH 3.507406 MM
Corrosion allowance, C 0.126 INCH 5 MM
J oint efficiency, E =E* 0.85
MDMT without impact testing -7
o
F -21.66667
o
C
Ratio =tr . E / (tn -c) [Fig. UCS-66.2] 0.31383 <0.35 [Fig. UCS-66-1]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1] 135
o
F 57.22222
o
C
Adjusted MDMT w/o impact testing -142
o
F -96.66667
o
C
Impact testing required ? No
For Shell Cover Course (NA)
Material ASME SA516 Grade 70
Condition Normalized
Curve D
MDMT 28.4
o
F -2
o
C
Nominal thickness, tn (adopted thickness) 0.5 INCH 12.7 MM
Point of combination of MDMT & thkickness Below, we have to check ratio tr.F/(tn-c)
Required thickness, tr 0.22088 INCH 5.610261 MM
Corrosion allowance, C 0.19685 INCH 5 MM
J oint efficiency, E =E* 0.85
MDMT without impact testing -55
o
F -48.33333
o
C
Ratio =tr . E / (tn -c) [Fig. UCS-66.1] 0.61931 >0.35 [Fig. UCS-66-1]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1] 95
o
F 35
o
C
Adjusted MDMT w/o impact testing -150
o
F -101.1111
o
C
Impact testing required ? No
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 108 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 3 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
S. Lowest MDMT Without Impact Test (cont.) [UG-20(f)] , [UCS-66] & [Fig.UCS-66]
For Channel plate (Smls. Pipe 20" NPS, Sch. 30)
Material ASME SA516 Grade 70
Condition Normalized
Curve D
MDMT 28
o
F -2
o
C
Nominal thickness, tn (adopted thickness) 0.7874 INCH 20 MM
Point of combination of MDMT & thkickness Below, so we have to check ratio tr.F/(tn-c)
Required thickness, tr 0.04829 INCH 1.226577 MM
Corrosion allowance, C 0 INCH 0 MM
J oint efficiency, E =E* 0.85
MDMT without impact testing -39.6063
o
F -39.78128
o
C
Ratio =tr . E / (tn -c) [Fig. UCS-66.2] 0.05213 <0.35 [Fig. UCS-66-1]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1] 135
o
F 57.22222
o
C
Adjusted MDMT w/o impact testing -174.606
o
F -114.7813
o
C
Impact testing required ? No
b. For formed heads (cap NPS 26", Thk. 14.27 mm)
Material ASME SA 234 WPB
Condition Normalized
Curve B
MDMT 28
o
F -2
o
C
Nominal thickness, tn (adopted thickness) 0.56181 INCH 14.27 MM
Point of combination of MDMT & thkickness Below, we have to check ratio tr.F/(tn-c)
Required thickness, tr 0.22088 INCH 5.610261 MM
Corrosion allowance, C 0.19685 INCH 5 MM
J oint efficiency, E =E* 0.85
MDMT without impact testing -1.06614
o
F -18.37008
o
C
Ratio =tr . E / (tn -c) [Fig. UCS-66.1] 0.51443 <0.35 [Fig. UCS-66-1]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1] 135
o
F 57.22222
o
C
Adjusted MDMT w/o impact testing -136.066
o
F -93.37008
o
C
Impact testing required ? No
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 109 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 4 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Sheet : 3 of 3
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
S. Lowest MDMT Without Impact Test (cont.) [UG-20(f)] , [UCS-66] & [Fig.UCS-66]
For Floating Head (sphere sector)
Material ASME SB171 UNS No. C63000
Condition Normalized
Curve B
MDMT 28
o
F -2
o
C
Nominal thickness, tn (adopted thickness) 0.51181 INCH 13 MM
Point of combination of MDMT & thkickness Below, so we have to check ratio tr.F/(tn-c)
Required thickness, tr 0.375 INCH 9.525 MM
Corrosion allowance, C 0 INCH 0 MM
J oint efficiency, E =E* 0.85
MDMT without impact testing (for thickness 0.551") -5.86614
o
F -21.03675
o
C
Ratio =tr . E / (tn -c) [Fig. UCS-66.2] 0.62279 >0.35 [Fig. UCS-66-1]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1] 35
o
F 1.666667
o
C
Adjusted MDMT w/o impact testing -40.8661
o
F -40.48119
o
C
Impact testing required ? No
For Backing Ring Flange :
- Item (6) :
Material ASME SA266 Class 2
ASME/ANSI Non-Standard
Condition
Curve B
MDMT 28
o
F -2
o
C
Blind thickness, t
A
3.8189 INCH 97 MM
Governing thickness, t
g1
=t
A
/4 0.95472 24.25 MM
[Fig. UCS-66.3(c)]
MDMT without impact testing 28.1024
o
F -2.165354
o
C
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 110 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 5 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
S. Lowest MDMT Without Impact Test (cont.) [UG-20(f)] , [UCS-66] & [Fig.UCS-66]
c. For pipe nozzle at shell-side, S1 & S2 6" Sch. 80 :
Material ASME SA 106 Grade B
Condition
Curve B
MDMT 28
o
F -2
o
C
Nominal thickness, tn (adopted thickness) 0.432 INCH 10.9728 MM
Point of combination of MDMT & thkickness Below, we have to check ratio tr.F/(tn-c)
Required thickness, tr 0.03419 INCH 0.868379 MM
Corrosion allowance, C 0.126 INCH 5 MM
J oint efficiency, E =E* 0.85
MDMT without impact testing -13.616
o
F -25.34222
o
C
Ratio =tr . E / (tn -c) [Fig. UCS-66.1] 0.09497 <0.35 [Fig. UCS-66-1]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1] 135
o
F 57.22222
o
C
Adjusted MDMT w/o impact testing [UCS-66(b)] -148.616
o
F -100.3422
o
C
Impact testing required ? No
For pipe nozzle in tube-side, T1 & T2 6" 300# WNRF :
Material ASME SA 106 Grade B
Condition
Curve B
MDMT 28
o
F -2
o
C
Nominal thickness, tn (adopted thickness) 0.432 INCH 10.9728 MM
Point of combination of MDMT & thkickness Below, we have to check ratio tr.F/(tn-c)
Required thickness, tr 0.03419 INCH 0.868379 MM
Corrosion allowance, C 0.126 INCH 0 MM
J oint efficiency, E =E* 0.85
MDMT without impact testing -13.616
o
F -25.34222
Ratio =tr . E / (tn -c) [Fig. UCS-66.1] 0.09497 <0.35 [Fig. UCS-66-1]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1] 135
o
F 57.22222
o
C
Adjusted MDMT w/o impact testing [UCS-66(b)] -148.616
o
F -100.3422
o
C
Impact testing required ? No
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 111 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 6 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
S. Lowest MDMT Without Impact Test (cont.) [UG-20(f)] , [UCS-66] & [Fig.UCS-66]
d. For Flanges :
For Standard B16.5 flanges :
Material ASME SA105 Ferritic Steel
ASME/ANSI B16.5
Condition
Curve MM
MDMT 28
o
F -2
o
C
Impact testing exemption temp. [UCS-66(c)(1)] -20
o
F -29
o
C
Note. The same condition apply for flanges B16.47, split loose
flanges of SA216 Grade WCB and LWN flanges.
[UCS-66(c)(2),(3)&(4)]
The governing thickness id the thickness of nozzle attached to the flange.
For Channel Blind Flange :
- Item (6) :
Material ASME SA266 Class 2
ASME/ANSI Non-Standard
Condition Cladded
Curve B
MDMT 28
o
F -2
o
C
Blind thickness, t
A
2.16535 INCH 55 MM
Governing thickness, t
g1
=t
A
/4 0.54134 INCH 13.75 MM
[Fig. UCS-66.3(c)]
MDMT without impact testing -3.0315
o
F -19.46194
o
C
For Floating Head Flange (NA) :
- Item (None) :
Material ASME SA266 Class 2
ASME/ANSI Non-Standard
Condition
Curve B
MDMT 28
o
F -2
o
C
Tube Sheet thickness, t
A
2.95276 INCH 75 MM
Governing thickness, t
g1
=t
A
/4 0.73819 18.75 MM
[Fig. UCS-66.3(c)]
MDMT without impact testing 14.0551
o
F -9.969379
o
C
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 112 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 7 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
S. Lowest MDMT Without Impact Test (cont.) [UG-20(f)] , [UCS-66] & [Fig.UCS-66]
e. For Stationary Tubesheet :
Item No. (4)
Material ASME SB171 UNS No. C63000
ASME/ANSI
Condition
Curve B
MDMT 28
o
F -2
o
C
Tubesheet thickness, t
A
2.16535 INCH 55 MM
Governing thickness, t
g1
=t
A
/4 0.54134 13.75 MM
[Fig. UCS-66.3(c)]
MDMT without impact testing -3.0315
o
F -19.46194
o
C
For Floating Tubesheet (NA) :
Item No. (None)
Material ASME Sb171UNS No. C63000
ASME/ANSI
Condition
Curve B
MDMT 28
o
F -2
o
C
Tubesheet thickness, t
A
2.16535 INCH 55 MM
Governing thickness, t
g1
=t
A
/4 0.54134 13.75 MM
[Fig. UCS-66.3(c)]
MDMT without impact testing (for thickness 2.9374016") -3.0315
o
F -19.46194
o
C
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 113 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 8 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
S. Lowest MDMT Without Impact Test (cont.) [UG-20(f)] , [UCS-66] & [Fig.UCS-66]
f. For heat exchanger tubes 1" , BWG 12 :
Material ASME SB111 UNS No. C68700-061
Condition
Curve B
MDMT 28
o
F -2
o
C
Nominal thickness, tn (adopted thickness) 0.09843 INCH 2.500122 MM
Point of combination of MDMT & thkickness Below, we have to check ratio tr.F/(tn-c)
Required thickness, tr 0.0062 INCH 0.157561 MM
Corrosion allowance, C 0 INCH 0 MM
J oint efficiency, E =E* 1
MDMT without impact testing -20
o
F -28.88889
o
C
Ratio =tr . E / (tn -c) [Fig. UCS-66.1] 0.06302 <0.35 [Fig. UCS-66-1]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1] 135
o
F 57.22222
o
C
Adjusted MDMT w/o impact testing [UCS-66(b)] -155
o
F -103.8889
o
C
Impact testing required ? No
g. Fittings : For half coupling in nozzles, N1 1" , NPTF, 3000# :
Material ASME SA105
Condition
Curve B
MDMT 28
o
F -2
o
C
Nominal thickness, tn (adopted thickness) 0.28543 INCH 7.25 MM
Point of combination of MDMT & thkickness Below, we have to check ratio tr.F/(tn-c)
Required thickness, tr 0.03419 INCH 0.868379 MM
Corrosion allowance, C 0.126 INCH 3.2 MM
J oint efficiency, E =E* 0.85
MDMT without impact testing -20
o
F -28.88889
o
C
Ratio =tr . E / (tn -c) [Fig. UCS-66.1] 0.18227 <0.35 [Fig. UCS-66-1]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1] 135
o
F 57.22222
o
C
Adjusted MDMT w/o impact testing [UCS-66(b)] -155
o
F -103.8889
o
C
Impact testing required ? No
Fittings : For 6" NPS, 90o LR Elbows, Sch. 80 : ASME SA234 Grade WPB
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 114 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 9 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
S. Lowest MDMT Without Impact Test (cont.) [UG-20(f)] , [UCS-66] & [Fig.UCS-66]
Fittings : For half coupling in nozzles, N2 1/2" , NPTF, 3000# :
Material ASME SA105
Condition
Curve B
MDMT 28
o
F -2
o
C
Nominal thickness, tn (adopted thickness) 0.28543 INCH 7.25 MM
Point of combination of MDMT & thkickness Below, we have to check ratio tr.F/(tn-c)
Required thickness, tr 0.03419 INCH 0.868379 MM
Corrosion allowance, C 0.126 INCH 3.2 MM
J oint efficiency, E =E* 0.85
MDMT without impact testing -20
o
F -28.88889
o
C
Ratio =tr . E / (tn -c) [Fig. UCS-66.1] 0.18227 <0.35 [Fig. UCS-66-1]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1] 135
o
F 57.22222
o
C
Adjusted MDMT w/o impact testing [UCS-66(b)] -155
o
F -103.8889
o
C
Impact testing required ? No
h. Stud bolts :
Material ASME SA193 Grade B7
Curve
Size 1 INCH 25.4 MM
MDMT 28
o
F -2
o
C
Impact testing exemption [Fig. UCS-66, Bolting] -55
o
F -48
o
C
[Size 1.125" <2.5"]
i. Nuts :
Material ASME SA 194 Grade 2H
Curve
Size 1 INCH 25.4 MM
MDMT 28
o
F -2
o
C
Impact testing exemption [Fig. UCS-66, Bolting] -55
o
F -48
o
C
[Size 1.125" <2.5"]
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 115 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 10 of 10
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
S. Lowest MDMT Without Impact Test (cont.) [UG-20(f)] , [UCS-66] & [Fig.UCS-66]
2. For Non-Pressure Parts :
a. Saddle Plate (tf) :
Material ASME SA106 Grade B
Condition
Curve B
MDMT 28
o
F -2
o
C
Nominal thickness, tn (adopted thickness) (tf) 0.5 INCH 12.7 MM
Point of combination of MDMT & thkickness Below, we have to check ratio tr.F/(tn-c)
Required thickness, tr 0.2925 INCH 7.429384 MM
Corrosion allowance, C 0 INCH 0 MM
J oint efficiency, E =E* 1
MDMT without impact testing -7
o
F -21.66667
o
C
Ratio =tr . E / (tn -c) [Fig. UCS-66.1] 0.58499 >0.35 [Fig. UCS-66-1]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1] 42
o
F 5.555556
o
C
Adjusted MDMT w/o impact testing [UCS-66(b)] -49
o
F -45
o
C
Impact testing required ? No
b. Lifting Lug Reinf. Plate :
Material ASME SA516 Grade 70
Condition Normalized
Curve D
MDMT 28
o
F -2
o
C
Nominal thickness, tn (adopted thickness) 0.7874 INCH 20 MM
Point of combination of MDMT & thkickness Below, we have to check ratio tr.F/(tn-c)
Required thickness, tr 0.3937 INCH 10 MM
Corrosion allowance, C 0 INCH 0 MM
J oint efficiency, E =E* 1
MDMT without impact testing -39.6063
o
F -39.78128
o
C
Ratio =tr . E / (tn -c) [Fig. UCS-66.1] 0.5 >0.35 [Fig. UCS-66-1]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1] 57
o
F 13.88889
o
C
Adjusted MDMT w/o impact testing [UCS-66(b)] -96.6063
o
F -71.44794
o
C
Impact testing required ? No
MDMT without Impact Testing for Shell Side 29
o
F -2
o
C
MDMT without Impact Testing for Tube Side 29
o
F -2
o
C
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 116 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 1
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
T. Radiography. Spot 10%
U. Hydrostatic Test Pressure. [UG-99(b)] [ Refer to Page : 15 of 136 ]

Design Temperature : Shell-Side 302
o
F 150
o
C
Tube-Side 140
o
F 60
o
C
Test Temperature 104
o
F 40
o
C
Internal Design Pressure, P (MAWP) : Shell-Side 284.776 PSIG 20.04826 Kg/CM
2
G
Tube-Side 71.7082 PSIG 5.04826 Kg/CM
2
G
Max. Allowable Stress @ Design Temperature, S
17100 PSIG 1203.840039
Kg/CM
2
G
Max. Allowable Stress @ Test Temperature, St
17100 PSIG 1203.840039
Kg/CM
2
G
[Table 1A, SubPart 1, ASME Sec. II, Part D]
a. Hydrostatic Test Pressure as per ASME Code Requirements, P
h
=1.3 * MAWP * (St/S) MAWP =Design Press.
Shell-Side 370.209 PSIG 26.06274 Kg/CM
2
G
Tube-Side 93.2207 PSIG 6.562738
Kg/CM
2
G
b. Hydrostatic Test Pressure as per Client Request, Ph =1.5 * MAWP * (St/S)
Shell-Side 427.164617 PSIG 30.07239
Kg/CM
2
G
Tube-Side 107.5623545 PSIG 7.57239
Kg/CM
2
G
c. Hydrostatic Test Pressure as a Client Request for new&cold, Ph =1.5 * MWP
Shell-Side 637.8835023 PSIG 44.907
Kg/CM
2
G
Tube-Side 427.4999863 PSIG 30.096
Kg/CM
2
G
d. Hydrostatic Test Pressure for operating & corroded, P
h
=1.3 * MWP
Shell-Side 436.017 PSIG 30.6956 Kg/CM
2
G
Tube-Side 338 PSIG 23.7952
Kg/CM
2
G
V. Post Weld Heat Treatment (PWHT). [UW-40 & Table UCS-56]
Shell Material ASME SA 106 Grade B
P- No. 1
Gr. No. 1
Max. Welded Nominal Thickness 0.562 INCH 12.7 MM
According to UW-40 & UCS-56(f), the material is exempted from PWHT
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 117 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 4
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
W. Calculation of Exchanger Weight.
1. Volume of vessel :
Shell volume =3.14 (D/2)
2
* L' 358041 INCH
2
1.803618 M
3
Head volume =3.14 (D/2)
2
* (2*KD/3 + Skirt) 9.40505 INCH
2
0.053615 M
3
( where KD =Depth of head ), K = 0.25
Head skirt 4.13386 INCH 105 MM
Total volume of vessel 425772 INCH
2
1.910848 M
3
Tangent - to - Tangent distance (T/T) , L 254.843 INCH 6473 MM
Welding - to - Welding distance (W/W) , L' 6263 MM
2. Weight of liquid water , Wc 4212.74 lb 1910.848 Kg
Total Oveall Length =L +2 H
0
267.412 INCH 6792.27 MM
3. Weight of vessel empty , W :
a. weight of shell =II *(Ro^2 - Ri^2 ) * L' * $ 2894.77 lb 1313.032 Kg
( where $ =steel density ) 490.059 lb/ft
3
7850 Kg/M
3
b.weight of ellipsoidal heads
=(II/4) * (D^2) * (4/3) * KD *$ =(II/3)*K*(Do^3 -Di^3)*$ 147.05 lb 66.7 Kg
=8*(II/3)*K*(Ro^3 -Ri^3)*$ +weight of 2 skirts
Weight of skirt of two ellipsoidal heads =II *(Ro^2 - Ri^2 ) * 2 Skirt* $ 97.0624 lb 44.02631 Kg
c. weight of saddles :
- Base plate, (12+1472+12)x305x20 18.4262 lb 8.357895 Kg
Saddle plate length 25.3937 MM 645 MM
- Saddle plate , 1896x320x15 25.5179 lb 11.57459 Kg
Web plate ( saddle plate ) height, h =Z - (R
o
+t
f
) cos(B/2) 12.6634 INCH 321.65 MM
Web plate ( saddle plate ) width, Lw =m - 2*(ts +cl) 18.189 INCH 462 MM
angle b =B/2 60 Degree
where h1 =height of segment 5.84055 INCH 148.35 MM
y =m - m' =(m-2 cl) - 2 (Ro+tf) sin(B/2) 8.87008 INCH 225.3 MM
Area of segment, As =(R
o
+t
f
)
2
[(3.14 * b)/180 - Sin b* Cos b] 67.7139
INCH
2
0.043686
M
2
Area of web plate excluding segment, A =(m -2cl) * h - As - 2y
2
/SQRT(3) 86.727 INCH
2
0.055953 M
2
- Weight of web plate (457x349.5x14) =A * tw * $ 14.5252 lb 6.588443 Kg
Rip plates weights (per saddle) :
Rip plates, thickness, t
s
0.59055 INCH 15 MM
Rip plates #1 width, Rw 1.67323 INCH 42.5 MM
Rip plates #1 , height 7.39721 INCH 187.8891 MM
Weight of rip plates #1 (no. off 4 ), 372x95x10 8.29183 lb 3.761071 Kg
Rip plates #2 width, Sw 3.93701 INCH 100 MM
Rip plates #2 height, h 12.6634 INCH 321.65 MM
Rip plates #2 (no. off 2 ), 349.5x100x10 16.6999 lb. 7.574858 Kg
- rip plates ( per one saddle ) 24.9917 lb 11.33593 Kg
- Weight of one saddle 83.4609 lb 37.85686 Kg
- Weight of two ( 2 ) saddles 166.922 lb 75.71371 Kg
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 118 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 4
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
W. Calculation of Exchanger Weight (cont.)
d. Weight of Nozzle
- Weight of Nozzle, S1& S2 6" Sch. 80, WNRF 300#:
- weight of WN flange 83.7765 lb 38 Kg
- weight of nozzle pipe (145 MM) 14.2702 lb 6.4728 Kg
- weight of Blind Flange 0 lb 0 Kg
- weight of Stud Bolts 13.6512 lb 6.192 Kg
- Weight of Nozzle, T1 & T2 6" Sch. 80, WNRF 150#:
- weight of WN flange 47.6203 lb 21.6 Kg
- weight of nozzle pipe (145 MM) 14.2702 lb 6.4728 Kg
- weight of Blind Flange 0 lb 0 Kg
- weight of Stud Bolts 13.6512 lb 6.192 Kg
- Weight of Nozzle, B&C X" Sch. 160, WNRF 150#:
- weight of WN flange 0 lb 0 Kg
- weight of nozzle pipe (175 MM) 0 lb 0 Kg
- Weight of Nozzle, A X" Sch. 160, WNRF 150#:
- weight of WN flange 0 lb 0 Kg
- weight of nozzle pipe (1490 MM) 0 lb 0 Kg
- Weight of Nozzle, D X" Sch. 80, WNRF 150#:
- weight of WN flange 0 lb 0 Kg
- weight of nozzle pipe (61 MM) 0 lb 0 Kg
- weight of 90
o
elbow, LR 0 lb 0 Kg
- Weight of Nozzle, N4 1", half coupling 3000#: 2.20465 lb 1 Kg
- Weight of Nozzle, N5 1/2", half coupling 3000#: 1.76372 lb 0.8 Kg
Total weight of nozzles 191.208 lb 86.7296 Kg
e. Weight of Shell Flanges =(3.14/4) (Do
2
- Di
2
) T p 288.097 lb 130.6775 Kg
- Weight of Stud Bolts, dia. 1-1/8", 270 LG, Q'ty 20 97.0044 lb 44 Kg
(including weight of hex. nuts)
f. Weight of Channel
- Weight of Channel Flanges =2 (3.14/4) (Do2 - Di2) T p 576.195 lb 261.3549 Kg
- Weight of Channel Course (incl. in weight of shell) 0 lb 0 Kg
- Weight of Channel Blind Flange =(3.14/4) Do
2
T p 722.276 lb 327.6157 Kg
- Weight of Stud Bolts, dia. 1-1/8", Heavy, Q'ty 40 97.0044 lb 44 Kg
(including weight of hex. nuts)
- Weight of Pass Partition, 44.0929 lb 20 Kg
Total Weight of items e and f 1824.67 lb 827.6481 Kg
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 119 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 3 of 4
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
W. Calculation of Exchanger Weight (cont.)
g. Weight of Bundlel
- Weight of tubes, BWG 13, 2726.82 lb 1236.853 Kg
No. of Tubes, n 146
Tube OD 1 INCH 25.4 MM
Tube Length, L 0.23622 INCH 6 M
Tube Wall Thickness, t
t
0.09843 INCH 2.500122 MM
Tube ID 0.80314 INCH 20.39976 MM
- Weight of Floating Tubesheet, 98.2564 lb 44.5679 Kg
Tubesheet OD 1047.21 INCH 475 MM
Tubesheet Thickness 121.255 INCH 55 MM
No. of Holes 146
Hole Diameter 55.998 INCH 25.4 MM
- Weight of Floating Head Flange 139.679 lb 63.35663 Kg
Floating Head Flange OD 1289.72 INCH 585 MM
Floating Head Flange ID 998.704 INCH 453 MM
Floating Head Flange Thickness 165.348 INCH 75 MM
- Weight of Floating Head Backing Ring 180.651 lb. 81.94124 Kg
Floating Head Backing Ring OD 1289.72 INCH 585 MM
Floating Head Backing Ring ID 998.704 INCH 453 MM
Floating Head Backing Ring Thickness 213.851 INCH 97 MM
- Weight of Floating Head Sperical Segment =(3.14/6)[(Di+90.8997 lb 41.23097 Kg
Spherical Segment Thickness, t 0.51181 INCH 13 MM
Spherical Sector, Sphere Diameter, Di 1543.25 INCH 700 MM
Spherical Segment Height, h 189.048 INCH 85.75 MM
- Stud Bolts & Hex Nuts (floating head) 86.7748 lb 39.36 Kg
- Stud Bolt Size 1 INCH 25.4 MM
- No. of Stud Bolts (with 2 nuts) 24
- Stud Bolt Length 9.44882 INCH 240 MM
- Weight of Stud Bolt +2 Nuts 3.61562 lb 1.64 Kg
- Weight of Stationary Tubesheet 164.025 lb 74.39984 Kg
Tubesheet OD 22.0472 INCH 560 MM
Tubesheet Thickness 2.16535 INCH 55 MM
No. of Holes 146
Hole Diameter 1 INCH 25.4 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 120 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 4 of 4
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
W. Calculation of Exchanger Weight (cont.)
- Weight of Baffels : 134.403 lb. 60.96364 Kg
No. off Baffels 24
Baffel OD 18.7008 INCH 475 MM
Baffel Thickness 0.19685 INCH 5 MM
Cut Ratio 0.4
- Weight of Tube Support : 57.6416 lb. 26.14553 Kg
Tube Support OD 18.7008 INCH 475 MM
Tube Support Thickness 0.3937 INCH 10 MM
Tube Support Inside Hole (rectangular) 200 x 200 MM
- Weight of Tie-Rods, OD 1/2", 3650 LG 13.154 lb 5.966481 Kg
No. of Tie Rods 4
Tie Rod OD 0.5 INCH 12.7 MM
Tie Rod Length 236.22 INCH 6 M
- Weight of Spacers, OD 1", 3600 LG 92.5951 lb 42 Kg
- Weight of Impengment Plate, 150 x 150 x 6 thk 6.61394 lb 3 Kg
- Weight of Seal Strip 30, 5600x60x6 thk, Q'ty 2 69.7797 lb 31.6512 Kg
- Weight of Seal Strip 31, 5600x60x6 thk., Q'ty 2 69.7797 lb 31.6512 Kg
Total weight of bundle 3931.08 lb 1783.087 Kg
Weight of exchanger, empty (erection), W 9155.7 lb 4152.911 Kg
Weight of contents, Wc 1685.1 lb 764.3392 Kg
Total weight of exchanger and contents, Wt
10840.2 lb 4917 Kg
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 121 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 8
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
X. Stresses in Vessel on Two Saddle Supports Using ZICK's Method.
Shell material ASME SA106 Grade B
Heads material ASME SA234 Grade WPB
Saddles material ASME SA106 Grade B
Heads type Ellipsoidal 2:1
Design temperature 302
o
F 150
o
C
Vessel internal pressure, P 284.776 PSIG 20.04826 Kg/CM
2
G
Allowable stress in shell, Sts 17100 PSIG 1203.84 Kg/CM
2
G
Allowable stress in heads, Sth 17100 PSIG 1203.84 Kg/CM
2
G
Allowable stress in web, Sw 15700 PSIG 1105.28 Kg/CM
2
G
Shell compression yield point, Y 45000 PSIG 3168 Kg/CM
2
G
Saddle & anchor bolt compression yield point, Re 30000 PSIG 2112 Kg/CM
2
G
Outer shell diameter, Do 20 INCH 508 MM
Wall nominal thickness of shell, ts 0.5 INCH 12.7 MM
Wall nominal thickness of heads, th 0.5 INCH 12.7 MM
Corrosion allowance for shell & heads, CA 0.197 INCH 5 MM
Shell joint efficiency, Es 0.85
Head joint efficiency, Eh 0.85
Head internal depth, h 5.785 INCH 146.935 MM
Head depth -to- tangent line (external depth), Ho 6.285 INCH 159.635 MM
Insulation thickness, tis 0 INCH 0 MM
Wear (reinf./top flange) plate width, B 7.087 INCH 180 MM
Wear (reinf./top flange) plate thickness, tf 0.5 INCH 12.7 MM
Wall corroded thickness of shell 0.366 INCH 9.28625 MM
Wall corroded thickness of heads 0.366 INCH 9.28625 MM
Wall corroded thickness of shell +reinf. plate 0.866 INCH 21.98625 MM
Outer shell radius, Ro =Do / 2 10 INCH 254 MM
Shell length from Tangent - to - tangent (T/T) , L 254.843 INCH 6473 MM
Saddle - to - saddle distance (S/S) , L" 165.354 INCH 4200 MM
Transverse distance between anchor bolts, Y 21.6535 INCH 550 MM
Distance from tangent line -to- center of saddle support , A 47.244 INCH 1200 MM
Saddle contact angle, B 120 Degree
Longitudinal width of saddle at shell, b 7.087 INCH 180 MM
Transverse width of saddle at shell (baseplate length), m 20.551 INCH 522 MM
Height of saddle to vessel center line, Z 17.913 INCH 455 MM
Web width of saddle, hs =m - 2 cl 19.37 INCH 492 MM
Web thickness of saddle, tw 0.591 INCH 15 MM
Equivalent diameter of vessel, Deq =1.5 (Do +2 * tis) 30 INCH 762 MM
Equivalent length of vessel, Leq =L +2Ho +2 tis 267.412 INCH 6792.27 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 122 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 8
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
X. Stresses in Vessel on Two Saddle Supports Using ZICK's Method (cont.)
1. Seismic & wind forces on vessel
a. Seismic force UBC-1997
Total design force or shear at the base, F =z . I . C . Wt / Rw 1490.53 lb 676.0875 Kg
Seismic Zone 2A :
For zone 2A : z =Seismic zone factor [Table No. 23-I] 0.15
I =Importance factor [Table No. 23-L] 1
C =Numerical coefficient [Table No. 23-P] 2.75 Max.
Rw =Numerical coefficient [TableS NoS. 23-O & 23-Q] 3
=3 ( horizontal vessel on pier)
Total vessel dead weight, Wt 10840.2 lb 4917 Kg
b. Wind force ANSI A58.1
F =Cf . Gh . qz . Af
qz =0.00256 . kz . (I V)
2
27.0848 PSF 13.49792 N/M
2
For exposure C :
h =Height 0-15 ft
kz =Velocity pressure exposure coefficient 0.8
Wind Velocity, V =Basic wind speed 115 MPH 51.399 M/Sec.
Gh =Gust response factor 1.32
Cf =Force coefficient 0.8
c. Forces in longitudinal direction
Figure (11)
Seismic longitudinal force, Fls =z . I . C . Wt / Rw 1490.53 lb 676.0875 Kg
Wind longitudinal exposed area, Afl =(pi/8*Deq +Z) * Deq 6.18624 ft
2
0.574721 M
2
Wind longitudinal force, Flw =Cf . Gh . qz . Afl 176.936 lb 80.25607 Kg
Fl =Greater value of Fls & Flw 1490.53 lb 676.0875 Kg
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 123 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 3 of 8
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
X. Stresses in Vessel on Two Saddle Supports Using ZICK's Method (cont.)
d. Forces in transverse direction
Figure (12)
Seismic transverse force, Fts =0.5 Fls =0.5 x z x I x C x Wt / Rw 745.267 lb 338.0438 Kg
Wind transvere exposed area, Aft =Deq * Leq 55.7108 Ft
2
5.175706 M
2
Wind transverse force, Ftw =0.5 x Cf x Gh x x qz x Aft 796.708 lb 361.377 Kg
Ft =Greater value of Fts & Ftw 796.708 lb 361.377 Kg
2. Reaction force per saddle support
a. Reaction due to full vessel weight, Qo =Wt/2 5420.12 lb 2458.5 Kg
b. Reaction in longitudinal direction due to earthquake & wind :
By taking moments about saddle support : Fl . Z =Ql . L"
Ql =Fl . Z / L" 161.471 lb 73.24138 Kg
c. Reaction in transverse direction due to earthquake & wind :
By taking moments about saddle support : Ft . Z =Qt . (m/2)
Qt =3 ( 2 . Ft . Z / m) 4166.64 lb 1889.936 Kg
d. Max. reaction due to earthquake & wind, Qmax. =Max. (Ql , Qt) 4166.64 lb 1889.936 Kg
e. Total reaction due to full vessel weight, earthquake and wind, Q
Total longitudinal reaction, Qlt =Qo +Ql 5581.59 lb 2531.741 Kg
Total transverse reaction, Qtt =Qo +Qt 9586.76 lb 4348.436 Kg
Q =Greater value of Qlt & Qtt 9586.76 lb 4348.436 Kg
3. Modified stresses at saddles :
Ratio (Qo +Qmax.) / Qo 1.76874
a. Modified circumferential stresses, SIG 5' =Ratio . < OK
SIG 5' =Ratio . < OK
SIG 4' =Ratio . < OK
SIG 4' =Ratio . < OK
b. Modified tangential stresses, SIG 2' =Ratio . < OK
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 124 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 4 of 8
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
X. Stresses in Vessel on Two Saddle Supports Using ZICK's Method (cont.)
a. Stresses in longitudinal direction
Longitudinal force, Fl 1490.53 lb 676.0953 Kg
Max. moment, Mmax. =Fl . Z 26699.9 lb-in. 307.6167 Kg-M
Figure (13)
Cross-sectional Area, A =Lw * tw +2 Sw * ts+2(n-2) Rw * ts 15.3915 INCH
2
9930 MM
2
Moment of inertia, Ix-x =Lw*tw
3
/12 +2ts*Sw
3
/12+(n-2) ts(Sw
3
-tw
3
)/12 12.3045 INCH
4
5121500 MM
4
Section modulus, Wx-x =Lw*tw
2
/6+2ts*Sw
2
/6+2ts(Sw
3
-tw
3
)/(6 Sw) 7.14931 INCH
3
117156.3 MM
3
Dimension, X1 =Ix-x / Wx-x 1.72107 INCH 43.71512 MM
Bending stress, Sb =Mmax. / Wx-x 3734.61 PSI 262.9168 Kg/CM
2
G
Allowable bending stress, S' =1.2 . S 18840 PSI 1326.336 Kg/CM
2
G
OK
Shear stress, T =Fl / A 96.8411 PSIG 6.817615 Kg/CM
2
G
Allowable shear stress, S' =0.5 . S 7850 PSIG 552.64 Kg/CM
2
G
OK
b. Stresses in transverse direction
Transverse force, Ft 796.708 lb 361.3811 Kg
Max. moment, Mmax. =Ft . Z 14271.4 lb-in. 164.4249 Kg-M
Figure (14)
Cross-sectional Area, A 15.3915 INCH
2
9930 MM
2
Moment of inertia, Iy-y =tw*Lw
3
/12+Sw[(Lw+2ts)
3
-Lw
3
]/12+2Rw((Ss(n-1-2)+ts727.502 INCH
4
3.03E+08 MM
4
Section modulus, Wy-y =tw*Lw
2
/6+Sw*[(Lw+2ts)
3
-Lw
3
]/6(Lw+2ts)+2Rw[(Ss+ts87.4027 INCH
3
1432273 MM
3
Dimension Y1 =Iy-y / Wy-y 8.32357 INCH 211.4187 MM
Bending stress, Sb =Mmax. / Wy-y 163.284 PSIG 11.49517 Kg/CM
2
G
Allowable bending stress, S' =1.2 . S 18840 PSIG 1326.336 Kg/CM
2
G
OK
Shear stress, T =Ft / A 51.7628 PSIG 3.644098 Kg/CM
2
G
Allowable shear stress, S' =0.5 . S 7850 PSIG 552.64 Kg/CM
2
G
OK
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 125 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 5 of 8
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
X. Stresses in Vessel on Two Saddle Supports Using ZICK's Method (cont.)
1. Bending moment & bending stress at saddles
Bending moment at saddle in tension & compression, M
1
452744 lb-in 5216.177 Kg-M
Longitudinal bending stress in tension, S
1
=M
1
/ K
1
R
2
ts 2883.72 PSIG 203.0137
Kg/CM
2
G
Longitudinal bending stress in compression, S
1
=- M
1
/ K8 R
2
ts -15016.4 PSIG -1057.153
Kg/CM
2
G
2. Bending moment & bending stress at midspan
Bending moment at midspan, M
2
558078 lb-in 6429.767 Kg-M
Longitudinal bending stress at midspan, S
1
' =- M
1
'
/ 3.14 R
2
ts -3552.84 PSIG -250.1198
Kg/CM
2
G
3. Stress in the shell due to internal pressure,
S =P R / (2 Es ts) 3350.31 PSIG 235.8619 Kg/CM
2
G

4. Sum of tensile stress
Value of S
1
+S 6234.03 PSIG 438.8756
Kg/CM
2
G
Value of S
1
'
+S -202.527 PSIG -14.2579
Kg/CM
2
G
Greater value of (S
1
+S) & (S
1
'
+S) 6234.03 PSIG 438.8756
Kg/CM
2
G
Shell allowable tensile stress 17100 PSIG 1203.84 Kg/CM
2
G
Stress ratio =Greater stress/Allowable stress 0.36456 < 1 Passed
5.Tangential shear stress, S
2
5.a. Tangential shear stress on shell, S
2
In case of A >R/2 and ring not used or rings are adjacent to the saddle.
1367.78 PSIG 96.29196 Kg/CM
2
G
Shell allowable tangential stress =0.8 S 13680 PSIG 963.072 Kg/CM
2
G
Stress ratio =S
2
/ 0.8 S 0.09998 < 1 Passed

+
=
L 3
H 4
1
L A 2
H R
L
A
1
1 A Q M
2 2
1
M QL
R H
L
H
L
A
L
1
2 2
2
1 2
1
4
3
4
'
=
+

+

S
K Q
R t
L A
L
H
s
2
2
2
4
3
=

+

DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 126 of 136


According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 6 of 8
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
X. Stresses in Vessel on Two Saddle Supports Using ZICK's Method (cont.)
5.b. Tangential shear stress on shell, S
2
In case of A >R/2 and ring used in plane of saddle.
372.607 PSIG 26.23154 Kg/CM
2
G
Shell allowable tangential stress =0.8 S 13680 PSIG 963.072 Kg/CM
2
G
Stress ratio =S
2
/ 0.8 S 0.02724 < 1 Passed
5.c. Tangential shear stress on head, S
2h
In case of A >R/2 and ring not used or rings are adjacent to th saddle.
1367.78 PSIG 96.29196 Kg/CM
2
G
Head allowable tangential stress =0.8 S 13680 PSIG 963.072 Kg/CM
2
G
Stress ratio =S
2
/ 0.8 S 0.09998 < 1 Passed
5.d. Tangential shear stress on shell
In case of A <=R/2 S
2
=K
4
Q / R ts 1687.27 PSIG 118.7838
Kg/CM
2
G
Shell allowable tangential stress =0.8 S 13680 PSIG 963.072 Kg/CM
2
G
Stress ratio =S2 / 0.8 S 0.12334 < 1 Passed
5.e. Tangential shear stress on head
In case of A <=R/2 S
2
=K
4
Q / R t
h
1687.27 PSIG 118.7838
Kg/CM
2
G
Shell allowable tangential stress =0.8 S 13680 PSIG 963.072 Kg/CM
2
G
Stress ratio =S
2
/ 0.8 S 0.12334 < 1 Passed
5.f. Additional tangential shear stress in head
In case of A <=R/2 S
3
=K
5
Q / R t
h
768.858 PSIG 54.12761
Kg/CM
2
G
S
3
+stress due to int. pres. (PR/(2Es ts) 3350.31 PSIG 235.8619
Kg/CM
2
G
Head allowable tensile stress =1.25 S 21375 PSIG 1504.8 Kg/CM
2
G
Stress ratio =S
3
/ 1.25 S 0.15674 < 1 Passed

=
3
H 4
L
A 2 L
t R
Q K
S
h
2
h 2

=
3
H 4
L
A 2 L
t R
Q K
S
s
3
2
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 127 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 7 of 8
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
X. Stresses in Vessel on Two Saddle Supports Using ZICK's Method (cont.)
6. Circumferential stress
6.a. Circumferential stress at saddle horn
In case of L >=8 R (unstiffened)
-3074.71 PSIG -216.4598 Kg/CM
2
G
Shell allowable circumferential stress =1.5 S 25650 PSIG 1805.76 Kg/CM
2
G
Stress ratio =S4 / 1.5 S 0.11987 < 1 Passed
6.b. Circumferential stress at saddle horn
In case of L <8 R (unstiffened)
-1410.27 PSIG -99.2832 Kg/CM
2
G
Shell allowable circumferential stress =1.5 S 25650 PSIG 1805.76 Kg/CM
2
G
Stress ratio =S
4
/ 1.5 S 0.05498 < 1 Passed
6.c. Circumferential stress at bottom of shell
(stiffened or unstiffened)
-1377.92 PSIG -97.00559 Kg/CM
2
G
0.5 compression yield point of shell material 22500 PSIG 1584 Kg/CM
2
G
Stress ratio =S
5
/ 0.5 S 0.06124 < 1 Passed
7. Check tension in web saddle
Horizontal force in web, Fw =K
8
Q 5780.82 lb 2622.107 Kg
Effective web area, Aw =h
s
tw 11.4477
INCH
2
7385.579
MM
2
Stress in web, Sw =Fw / Aw 504.977 PSIG 35.55042 Kg/CM
2
G
Allowable stress in web, Saw =0.6 Y 18000 PSIG 1267.2 Kg/CM
2
G
Stress ratio =Sw / 0.6 Y 0.02805 < 1 Passed
Vertical force in web, Fv =Q 9586.76 lb 4348.436 Kg
Stress in web, Sv =Fv / Aw 837.442 PSIG 379.8534 Kg/CM
2
G
Allowable stress in web (compressiuon), Saw =0.33 Y 9900 PSIG 696.96 Kg/CM
2
G
Stress ratio =Sv / 0.33 Y 0.08459 < 1 Passed
2
s
6
s s
4
t 2
Q K 3
t R 56 1 b t 4
Q
S
+
=
) . (
2
s
6
s s
4
t L
R Q K 12
t R 56 1 b t 4
Q
S
+
=
) . (
) . (
s s
7
5
t R 56 1 b t
Q K
S
+
=
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 128 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 8 of 8
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
X. Stresses in Vessel on Two Saddle Supports Using ZICK's Method (cont.)
8. Check of the saddle at the lowest section (web plate thickness) :
The saddle at the lowest section must resist the horizontal force (F).
The effective cross section of the saddle to resist this load is R/3.
Figure (15)
F =K11 . Q 1955.7 lb 887.0809 Kg
To resist this force, the effective area of web plate, A =(R/3) . tw 1.9685 INCH
2
1270 MM
2
The calculated stress, Scal. =F / A 993.495 PSIG 69.94205 Kg/CM
2
G
The allowable stress, Sall. =(2/3) Sw 10466.7 PSIG 736.8534 Kg/CM
2
G
Stress ratio =Scal. / Sall. 0.09492 < 1 Passed
So, the thickness of the web plate is satisfactory for horizontal force (F).
Values of Constant K
For contact angle B =120
o
: 120 Degree
K
1
(K
1
=3.14 if the shell is stiffened by ring or head, A >R/2) 0.335 or 3.14 [A >R/2]
K
2
1.171
K
3
(K
3
is constant for any contact angle) 0.319
K
4
0.88
K
5
0.401
K
6
(K6 depends on the ratio A/R, see chart in vessel handbook)
K
6
for A/R >1.00 0.053
K
6
for A/R <0 0.5 0.013
A 47.244 INCH 1199.998 MM
R 10 INCH 254 MM
A/R 4.7244
R/2 5 INCH 127 MM
K
7
0.76
K
8
0.603
K
11
0.204
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 129 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 1
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
Y. Check for the Anchor Bolts Due to Seismic and Wind Loading.
1. For longitudinal forces, Fl
Figure (16)
Fl 1490.53 lb. 676.0875 Kg
Max. moment, Mmax. =Fl . Z +Fl . Z2 [for 2 coolers] 108562 lb-in. 1250.77 Kg-M
Assume anchor bolt size dn, 7/8" 0.875 INCH 22.225 MM
Cross-sectional area per anchor bolt, Ab 0.419 INCH
2
270.322 MM
2
No. of anchor bolts per saddle, nb 4 each
Total cross-sectional area of anchor bolts, A =nb . Ab 1.676 INCH
2
1081.288 MM
2
Shear stress, T =2 * Fl / A [for 2 coolers] 1778.68 PSIG 125.219 Kg/CM
2
G
Bending stress, Sb =2 * Mmax. / (A . L") [for 2 coolers] 0.73824 PSIG 0.051972 Kg/CM
2
G
Resultant stress, Si =SQRT (Sb
2
+3 T
2
) 3080.76 PSIG 216.8857 Kg/CM
2
G
Allowable stress, S' =0.5 . Re 15000 PSIG 1056 Kg/CM
2
G
OK
2. For transverse forces, Ft
Figure (17)
Ft 796.708 lb. 361.3811 Kg
Max. moment, Mmax. =Ft . Z +Ft . Z2 [for 2 coolers] 58027.6 lb-in. 668.5515 Kg-M
Cross-sectional area per anchor bolt, Ab 0.419 INCH
2
270.322 MM
2
No. of anchor bolts per saddle, nb 4 each
Total cross-sectional area of anchor bolts, A =nb . Ab 1.676 INCH
2
1081.288 MM
2
Shear stress, T =2 [Ft / A] [for 2 coolers] 950.726 PSIG 66.93108 Kg/CM
2
G
Bending stress, Sb =2 [2 Mmax. / (A . Y)] [for 2 coolers] 6395.76 PSIG 450.2613 Kg/CM
2
G
Resultant stress, Si =SQRT (T
2
+3 Sb
2
) 11118.5 PSIG 782.7422 Kg/CM
2
G
Allowable stress, S' =0.5 . Re 15000 PSIG 1056 Kg/CM
2
G
OK
Use anchor bolt with size (add corrosion allowance) 711.2 INCH 28 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 130 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 1
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
Check for the Existing Anchor Bolts Due to Seismic and Wind Loading.
1. For longitudinal forces, Fl
Figure (16b)
Fl 1490.53 lb. 676.0875 Kg
Max. moment, Mmax. =Fl . Z +Fl . Z2 [for 2 coolers] 108562 lb-in. 1250.77 Kg-M
Assume anchor bolt size dn, 11/16" 0.6875 INCH 17.4625 MM
Cross-sectional area per anchor bolt, Ab 0.252 INCH
2
162.5803 MM
2
No. of anchor bolts per saddle, nb 2 each
Total cross-sectional area of anchor bolts, A =nb . Ab 0.504 INCH
2
325.1606 MM
2
Shear stress, T =2* Fl / A [for 2 coolers] 5914.81 PSIG 416.4029 Kg/CM
2
G
Bending stress, Sb =Mmax. / (A . L") 0.111 PSIG 0.007814 Kg/CM
2
G
Resultant stress, Si =SQRT (Sb
2
+3 T
2
) 10244.8 PSIG 721.231 Kg/CM
2
G
Allowable stress, S' =0.5 . Re 15000 PSIG 1056 Kg/CM
2
G
OK
2. For transverse forces, Ft
Figure (17b)
Ft 796.708 lb. 361.3811 Kg
Max. moment, Mmax. =Ft . Z +Ft . Z2 58027.6 lb-in. 668.5515 Kg-M
Cross-sectional area per anchor bolt, Ab 0.252 INCH
2
162.5803 MM
2
No. of anchor bolts per saddle, nb 2 each
Total cross-sectional area of anchor bolts, A =nb . Ab 0.504 INCH
2
325.1606 MM
2
Shear stress, T =2 [Ft / A] [for 2 coolers] 1580.77 PSIG 111.2862 Kg/CM
2
G
Bending stress, Sb =2 [2 Mmax. / (A .Y)] [for 2 coolers] 3197.88 PSIG 225.1306 Kg/CM
2
G
Resultant stress, Si =SQRT (T
2
+3 Sb
2
) 5760.04 PSIG 405.5071 Kg/CM
2
G
Allowable stress, S' =0.5 . Re 15000 PSIG 1056 Kg/CM
2
G
OK
Use anchor bolt with size (add corrosion allowance) 484.0224009 INCH 19.05600003 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 131 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 2
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
Z. Check for Bundle Pulling.
Weight of empty vessel 9155.7 lb 4152.911 Kg
Weight of full vessel 10840.2 lb 4917 Kg
Reaction force full vessel 5420.12 lb 2458.5 Kg
Bundle weight 3931.08 lb 1783.087 Kg
Dimension l =c+t
f
+t
b
7.91339 INCH 201 MM
Figure (18)
Reaction force empty W / Reaction force full =Weight empty / Weight full
Reaction force empty W =(Weight empty / Weight full) x Rection force full 4577.85 lb 2076.456 Kg
Reaction force empty F =1.5 x Bundle weight [API 660] 5896.61 lb 2674.631 Kg
Figure (19)
Saddle cross-sectional area, A 15.3915 INCH
2
9930 MM
2
Moment of inertia, Ix-x 12.3045 INCH
4
5121500 MM
4
Section modulus, Wx-x =Ix-x / X 7.14931 INCH
3
117156.3 MM
3
Max. moment, Mmax. =0.5 F l 23331.1 lb-in. 268.8004 Kg-M
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 132 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 2
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
Z. Check for Bundle Pulling (cont.)
Calculated Bending stress, Sb =Mmax. / Wx-x 3263.4 PSIG 229.7435 Kg/CM
2
G
Allowable bending stress, S' =0.9 . Re 27000 PSIG 1900.8 Kg/CM
2
G
Stress ratio =Sb / S' 0.12087 < 1 Passed
Calculated Shear stress, T =F / A 383.108 PSIG 26.97078 Kg/CM
2
G
Allowable shear stress, S' =0.4 . Re 12000 PSIG 844.8 Kg/CM
2
G
Stress ratio =T / S' 0.03193 < 1 Passed
Figure (20)
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 133 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 2
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
Z1. Lifting Lugs Thickness Calculations.
(Reference : Pressure Vessel Handbook)
Check of the thickness of lifting lugs :
Material ASME SA 516 Grade 70
Allowable tensile strength, St 17100 PSIG 1203.84 Kg/CM
2
G
Allowable shear strength, Sallow. =0.49 St 8379 PSIG 589.8816 Kg/CM
2
G
By neglecting the effect of both wind loads and pipe thrust,
assume 2 (two) lifting lugs with dimensions shown in Figure (7).
Leg of fillet weld, h =the thinner of thicknesses joined
=10 MM (0.394 INCH)
Figure (21)
Height of lifting lug, L 1.5748 INCH 40 MM
Thickness of lifting lug, b 0.7874 INCH 20 MM
Fillet weld, h 0.3937 INCH 10 MM
Length of lifting lug, l 3.93701 INCH 100 MM
F =Wt / (SQRT2) 7665.21 lb 3476.844 Kg
Vertical component of F, F1 =F/ SQRT2 5420.12 lb 2458.5 Kg
Horizontal component of F, F2 =F1 5420.12 lb 2458.5 Kg
Average unit stress =0.707 * F1 / h * I 2692.57 PSIG 1.89557 Kg/MM
2

Max. expected normal stress, Sexp. =F2 / (h*I *(b+h))*SQRT(2L
2
+(b+h)
2
)) 1174.44 PSIG 0.826805 Kg/MM
2
Allowable shear strength, Sallow. 8379 PSIG 589.8816 Kg/CM
2
G
Stress ratio =Sexp. / Sallow. 0.14016 < 1 Passed
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 134 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 2 of 2
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
Z1. Lifting Lugs Thickness Calculations (cont.)
(Reference : Pressure Vessel Handbook)
Figure (22)
L 1.5748 INCH 40 MM
b 0.7874 INCH 20 MM
l 3.93701 INCH 100 MM
R 1.37795 INCH 35 MM
r 0.59055 INCH 15 MM
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 135 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 1
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
Z2. References.
The following references are used in the design calculations of
saddles and lifting lugs of pressure vessel under considerations.
1. ASME Boiler and Pressure Vessel Code, Section VIII,
Division 1, Edition 1998, AddendA 2000.
2. TEMA Tubular Exchanger Manufacturer Association,
1988, 7th Edition,
25 North Broadway Tarrytown, New York 10591, Richard C. Byrne, Secretary
3. ASME Boiler and Pressure Vessel Code, Section II, Part A
& Part D, Edition 1998, Addenda 2000.
4. " Pressure Vessel Design Handbook" , Edition 1981,
by Henry H. Bednar, P.E. published by Van Nostrand Reinhold
Co. 135 west 50th. street, New York, N.Y. 10020, USA.
5. " Pressure Vessel Handbook" , Fifth Edition J anuary 1981,
by Eugene F. Megyese, Publishing Inc., P.O. Box 35365,
Tulsa, OK 74135, USA.
6. " Pressure Vessel Design Manual " , Procedure 3-9,
by Dennis R. Moss.
7. " Modern Welding Technology" , Edition 1989, by Howard B.
Carry, Prentice Hall, Englewood Cliffs, New J ersey 07632, USA..
DESIGN CALCULATIONS OF HEAT EXCHANGER Page : 136 of 136
According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Sheet : 1 of 1
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant) Rev. : 1
Project : Design & Fabrication of Heat Exchanger for APRC Refinery Date : 11.4.2004
Job No. : 7443-33 Location : Alex.
Dwg. No. : 7443-33-1A, Rev. 1 Client : APRC
Exchanger : Residue Cooler, Type : AES, TEMA class : R Items : E-323A/B & E-514C/D
Z3. Notes.

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