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According to ASME Code, Sec. VIII, Div. 1, Edition 2001, Addenda 2002 / TEMA "R" 7th Edition 88. Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Page : 76 of 136 Sheet : 1 of 6 Rev. : 0

Project : Design & Fabrication of Heat Exchanger for APRC Refinery Job No. : 7443-33 Dwg. No. : 7443-33-1A, Rev. 0 Exchanger : Residue Cooler, Type : AES, TEMA class : R

Sheet : 14

**Date : 4.7.2003 Location : Alex. Client : APRC
**

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 o o F C Design Temperature 140 60 o o Min. Design Metal Temperature, MDMT F C 53.6 12 o o F C Bolt-up and Gasket Seating Temperature 86 30 Assume corrosion allowance, C [UG-25] 0.19685 INCH 5 MM Kg/CM2G Operating Pressure (tube side) 56.8182 PSIG 4 Internal Design Pressure, P (MAWP) 71.7082 PSIG 5.04826 Kg/CM2G Allowable Stress of Bolt Material, SB : * at design temp.(operating condition), Sb * or at atmospheric temp./bolt-up temp. (gasket seating), Sa Allowable Stress of Flange Material : * at design temp.(operating condition), SfH * or at atmospheric temp./bolt-up temp. (gasket seating), SfC [Table 1A , SubPart 1 , ASME Sec. II , Part D] Joint efficiency, E Bolt Hole, Flange outside diameter, A Bolt circut diameter (B.C.D.), 25000 25000 20000 20000 1 1.10236 26.9685 24.5276

INCH INCH INCH

PSIG PSIG PSIG PSIG

1760 1760 1408 1408

Kg/CM2G Kg/CM2G Kg/CM2G Kg/CM2G

28 685 623

MM MM MM

Fig. UG-34, Sketch (j) Figure (5)

No. of bolts Nominal bolt dia., dB Actual cross-sectional area of each bolt, Total actual cross-sectional area of bolts, Ab Flange face outer diameter Flange face inner diameter

[TEMA Table D-5]

28 1 0.551 15.428 22.1654 19

**INCH INCH2 INCH INCH INCH
**

2

25.4 355.4832 9953.528 563 482.6

MM MM2 MM2

MM MM

22) (cont.C.5 6500 PSIG (1a). TEMA class : R Sheet : 14 Date : 4.59055 0. Rev. d ( d represnts G ) When bo is larger than 1/4". N Gasket Dimensions: Basic gasket seating width.125 22. jacketed asbestos filled.2 b [Appendix 2-3] 21. : 7443-33 Dwg. Flat Unstayed Circular Blind Flange (Channel Cover) Thickness (item no. t: [UG-34(c)(2)] t = d CP/SE +1.5 MM MM MM MM MM 0. d = O. Client : APRC Item : E-323A/B & E-514C/D P.8661 0. Div.D . Abdel Halim Galala.Inside diameter = O.175 560 530 15 7.Width. UG-34. the thickness t shall be calculated for both operating conditions.1] Gasket Factor.2] 1. b = 0. Sketch (j)] 0. No. soft copp[er or brass . Column II 6.D .D.3 Gasket moment arm. Type : AES. and the greater of the two values shall be used. Effective gasket seating width.DESIGN CALCULATIONS OF HEAT EXCHANGER According to ASME Code.2003 Location : Alex. 0 Exchanger : Residue Cooler.d)/2 = (C-G)/2 [Table 2-5.Flat metal.40109 MM Calculating the Min. Edition 2001.) [Attached by Bolts] [UG-34 & Fig.1] Facing Sketch [Table 2-5.1] 0.of gasket contact face . 1. Seating Stress.6 Kg/CM2G Diameter at location of gasket load reaction. Addenda 2002 / TEMA "R" 7th Edition 88. Design General Manager (Assistant) Page : 77 of 136 Sheet : 2 of 6 Rev.Outside diameter . Sec. : 7443-33-1A.5 SQRT(bO) [Table [Table 2-5.5039 INCH 546.0472 20.901087 MM 457.51185 INCH 38.29528 INCH INCH INCH INCH INCH 3.7. SA 193 Grade B7 o F 100 140 PSI 25000 ? ASME SA266 Class 2 o F 100 140 PSI 20000 ? 150 25000 200 20000 . UG-34 Sketch (j)] Gasket Details: .2] Since bo > 1/4 ". and gasket seating. C [Fig. required Thickness of Blind Flange.2717 INCH 3.2N . hG = (B.9W hG /SEd3 When using this formula. m Min. VIII.1978 MM Factor depending upon method of attachment of head. Designed by : Eng. bO = N/2 [Table 2-5. : 0 Project : Design & Fabrication of Heat Exchanger for APRC Refinery Job No. y [Table 2-5.

4991 MM2 4.DESIGN CALCULATIONS OF HEAT EXCHANGER According to ASME Code.304 MM2 114519. and the value of S at the design temperature and W from Formula (3) of 2-5(e) shall be used.304 MM2 3077.785 G2P + (2b x 3.2 Flange thickness t = d CP / SE + 1.9 Kg 32. Design General Manager (Assistant) Page : 78 of 136 Sheet : 3 of 6 Rev. VIII. TEMA class : R Sheet : 14 Date : 4. W For gasket seating. * Total cross-sectional area of bolts at root of thread required gasket seating. W = 0.conditions.9Wh G / SEd^ 3 lb INCH 15986. Type : AES.7.F. W [Appendix 2-5(e)] For operating conditions. Client : APRC Item : E-323A/B & E-514C/D P. 22) (cont. Wm2 = 3.14 GmP) (1) [Appendix 2-5(e35243. UG-34 Sketch (j)] Calculating the total bolt load. the value of P shall be the design pressure.48031 INCH2 INCH2 3077. : 7443-33-1A.98372 MM 33 MM 51 MM 63 MM lb INCH INCH INCH INCH INCH t = d CP / SE + 1 .Am2) Required bolt load under atmospheric temp.76983 252473 1.2003 Location : Alex. No.98372 MM 32. Addenda 2002 / TEMA "R" 7th Edition 88. P equals zero. Designed by : Eng.85602 2.29857 1. Abdel Halim Galala. : 7443-33 Dwg. N.05 Kg 21.04 Kg 1. [UG-34(c)(2)] P S [Appendix 2-5(e)] Flange Design Bolt Load for circular heads. of t of operating and gasket seating Use t without corrosion allowance Use t for construction including R. : 0 Project : Design & Fabrication of Heat Exchanger for APRC Refinery Job No.Am2) For gasket seating. Rev. Div. The deflection is ehe governing thickness .40973 INCH2 909. and the values of S at atmospheric and W from Formula (4) of 2-5(e) shall be used. Am2 = Wm2/ Sa Total required cross-sectional area of bolts.74301 MM 0.29921 2. W (for circular heads): 1.14bGy * Total cross-sectional area of bolts at root of thread requiired Am1 = Wm1/ Sb at operating conditions .) [Attached by Bolts] [UG-34 & Fig.29857 1.B. Sec.9Wh G / SEd^ 3 t = max. Check which the deflection is considered a governing thickness or not.00787 2. W = Wm1 (3) Wm1 = H + Hp = 0. Am = Max (Am1. W = 0. 0 Exchanger : Residue Cooler.5(Am + Ab) Sa (4) 0 20000 PSIG PSIG 0 1408 Kg/CM2G Kg/CM2G (2) 119246 lb 54089. Edition 2001.5(Am + Ab) Sa (4) Total required cross-sectional area of bolts. Flange Design Bolt Load for circular heads. For gasket seating. 1.76983 4. Flat Unstayed Circular Blind Flange (Channel Cover) Thickness (item no. Am = Max (Am1. For operating conditions.

Div. Client : APRC Item : E-323A/B & E-514C/D P. Ab BOLT SUMMARY No.98372 MM 52 MM GASKET SUMMARY Gasket width. VIII. E from drawing = 1/2 (A . 1.76983 15. No.B. Sec. Edge distance. Am Total ctual cross-sectional area of bolts. When using bolt with size Total required cross-sectional area of bolts. Edition 2001.) [Attached by Bolts] [UG-34 & Fig. N Required cross-sectional of bolts.59055 4.25") 0. [TEMA TABLE D-5] Since the actual bolt area Ab < The required bolt area Am. Type : AES. : 7443-33-1A. E (for bolt size 1. : 0 Project : Design & Fabrication of Heat Exchanger for APRC Refinery Job No. : 7443-33 Dwg.29857 2.2003 Location : Alex.04724 INCH INCH 32. Am Actual cross-sectional area of bolts. edge distance. Abdel Halim Galala.528 355.575 3077.) Use t for construction including R. Rev.4832 MM MM MM2 MM2 MM2 Since the actual bolt area Ab > The required bolt area Am. 0 Exchanger : Residue Cooler.A.125 1.428 0.C) Min. Addenda 2002 / TEMA "R" 7th Edition 88.75") Min.302 INCH INCH2 INCH2 INCH2 NA 1.528 MM2 28 1 1. the bolts are inadequately enough. Ab Actual cross-sectional area of bolt.75 MM MM MM MM MM . [TEMA TABLE D-5] 0.75 4.25 INCH INCH INCH INCH INCH 31 20. Total required cross-sectional area of bolts. Ab Actual cross-sectional area of bolt.6375 26. TEMA class : R Sheet : 14 Date : 4.428 INCH INCH2 INCH2 15 MM 3077.F.4 28.0625 1.22047 0.304 MM2 9953.551 Bolt INCH INCH INCH2 INCH2 INCH2 25. the bolts are adequately enough. You have to make a check for flange deflection. Am Total actual cross-sectional area of bolts. For a proper design of flange : 1.304 9953. 22) (cont.76983 15.76983 8. Edge distance. E (for bolt size 1-1/8") [TEMA Table D-5] Min. Flat Unstayed Circular Blind Flange (Channel Cover) Thickness (item no. E (for bolt size 1") Min. E (for bolt size 0.575 31. N.8125 1.7. UG-34 Sketch (j)] CONCLUSION: FLANGE SUMMARY Flange thickness (without C. of bolts Size of bolt (the bolt size is represented by its actual cross-sectional area) Bolt hole dia.DESIGN CALCULATIONS OF HEAT EXCHANGER According to ASME Code.456 0. Designed by : Eng. Edge distance.9875 28. Edge distance. 1.125 4. Design General Manager (Assistant) Page : 79 of 136 Sheet : 4 of 6 Rev.

762 0. : 0 Project : Design & Fabrication of Heat Exchanger for APRC Refinery Job No. 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. Bolt spacing. Note: For single pass channels.75 INCH Min.A.5039 E = Modulus of elasticity at design temperature [ASME Sec. Abdel Halim Galala.5 INCH Min.8125 INCH Max. Design General Manager (Assistant) Page : 80 of 136 Sheet : 5 of 6 Rev.2003 Location : Alex. B (for bolt size 0. Addenda 2002 / TEMA "R" 7th Edition 88. The thickness is to be at least that required by the appropriate Code formula and thicker if required to meet proper deflection criteria. . Designed by : Eng.635 508 MM MM MM ( ) INCH PSI INCH PSIG PSIG INCH2 INCH 546. 1.40109 MM Kg/CM2G Kg/CM2G MM2 MM If the calculated deflection is greater than the recommended limit.7.) [Attached by Bolts] [UG-34 & Fig. TEMA class : R Sheet : 14 Date : 4. 0 Exchanger : Residue Cooler. B (for bolt size 7/8") [TEMA Table D-5] 2. B (c/c) from drawing 2. no deflection criteria need be considered.4375 100.428 hG = Radial distance from diameter G to bolt circle 1.7082 SB = Allowable bolting stress at design temperature (Wm1) 25000 AB =Actual total cross-sectional root area of bolts 15.) 1. 22) (cont.5 71.0435G 3 P+0. Bolt spacing.75387 44. Recommended bolt spacing. or others in which there is no pass partition gasket seal against the channel cover.0625 INCH Min. Div.03" for nominal diameters thru 24" 0.025 INCH 20 INCH Nominal diameter = Shell ID + 2 ts A method for calculating of channel cover deflection at the center. No.51185 33 5. Edition 2001.75") 1.45 52.03 INCH 0.74622 INCH Min. : 7443-33 Dwg.94882 INCH Check for Flat Channel Cover Deflection [TEMA RCB-9.5S B A B h G ET 3 69.21] 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 recommended limit for channel cover deflection is: 0. Rev.II. UG-34 Sketch (j)] Actual Bolt spacing.Part D. B (for bolt size 1-1/8") 2. Client : APRC Item : E-323A/B & E-514C/D P. Bolt spacing. Type : AES. TM-31460000 T = Thickness under consideration (minus groove and C.04826 25000 9953. Y is: G Y = 0. Bolt spacing.125% of nominal diameters (nominal diameter/800) for larger sizes 0. Flat Unstayed Circular Blind Flange (Channel Cover) Thickness (item no. : 7443-33-1A.3875 57. B (for bolt size 1-1/4") 2.5) [TEMA RCB 3. (b) Use of strong backs.528 38.1978 MM 2214784.3 MM MM MM MM MM MM MM 0.29921 P = Design pressure 71. Bolt spacing. B (for bolt size 1") 2. (c) Change type of construction.DESIGN CALCULATIONS OF HEAT EXCHANGER According to ASME Code. Bmax = 2 dB + 6 t / (m + 0.07 Kg/CM G 2 Where G = Gasket load reaction diameter as defined by the Code 21. VIII.15 63.25 INCH Min. Sec.

Working Pressure. Flat Unstayed Circular Blind Flange (Channel Cover) Thickness (item no. Tassumed = T + 3 Ycalculated [TEMA RCB-9.88976 0.553795 MM 0.1. Edition 2001.094 104.39285 MM Y = Easier approach : 1.328196 Kg/CM G 2 7. Abdel Halim Galala.88976 1. thickness of channel cover to avoid deflection is The min.5 S B AB hG ) 0. 1.839054 MM 0. : 0 Project : Design & Fabrication of Heat Exchanger for APRC Refinery Job No.9 W hG / d3 c at Operating (corroded) P = SE t2 /d2 c . Assume T.0435 G 3 P + 0.762 MM 4. TEMA class : R Date : 4. : 7443-33 Dwg.07874 2.0435 G 3 P + 0.328196 Kg/CM G .33858 1. Compare the calculated deflection with the recommended deflection The minimum thickness of channel cover at bottom of pass partition is The thickness neglecting corrosion allowance is Conclusion : Checking of Deflection The min.48031 INCH INCH INCH INCH INCH INCH 34 48 50 2 53 63 MM MM MM MM MM MM 104.7. Div.03 OK 1. G 0.10054 0.232149 MM 1.5 S B AB hG E T3 ( ) 0.9685 0. thickness of channel cover as derived from drawings is The flange thickness increased by Tthickness including groove depth ( 5 MM) Overall thickness including raised faces & groove depth Max. 22) (cont.88283 Y = G 0.094 PSIG PSIG 2 7. Sheet : 14 Client : APRC Item : E-323A/B & E-514C/D P.00914 INCH 0. Design General Manager (Assistant) Page : 81 of 136 Sheet : 6 of 6 Rev. thickness of channel cover to resist the internal pressure is Where the min. Rev. Addenda 2002 / TEMA "R" 7th Edition 88. Type : AES.88948 INCH 73.03303 0.) [Attached by Bolts] [UG-34 & Fig.762 MM The recommended deflection limit Since the calculated deflection exceeds the recommended deflection.9 W hG / d3 c INCH INCH 47.1.88283 1.5 S B AB hG E T3 INCH INCH INCH 47. Sec.824 MM 2. Recommended deflection limit ( ) 0. VIII.0435 G 3 P + 0. MWP at New (cold) & Operating (corroded) at New (cold) P = SE t2 /d2 c . 0 Exchanger : Residue Cooler. No.08661 2. : 7443-33-1A.2003 Location : Alex. Designed by : Eng. UG-34 Sketch (j)] The calculated deflection is Y = G E T3 (0.824 48 MM MM 1.03 INCH INCH 2. we have to increase the flange tickness by the cubic root of the ratio of deflections.DESIGN CALCULATIONS OF HEAT EXCHANGER According to ASME Code. Find Calculated deflection 3.21] Yrecommended 2.

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