Main Shell Calculation

MOC SA240 Gr.304

Radius R 175 mm
Design Temperature 135 °C
Design Pressure P 45 Kg/cm²
Stress Value S 1091 Kg/cm²
Joint Efficiency E 0.85
Corrosion Allowance C.A. 0 mm

PR 7875
+ C.A. = + 0 = 8.746
SE - 0.6 P 900.35

Min. Thk req. as per ASME 8.747 mm UG-27 (1)

Min. Thk req. as per TEMA 5 mm R-3.13
Min. Thk req. 9 mm
Thk Consider 9 mm

Channel Shell Calculation

MOC SA240 Gr.304
Radius R 175 mm
Design Temperature 145 °C
Design Pressure P 9 Kg/cm²
Stress Value S 1091 Kg/cm²
Joint Efficiency E 0.85
Corrosion Allowance C.A. 0 mm

PR 1575
+ 0 = 1.708
SE - 0.6 P + C.A. = 921.95

Min. Thk req. as per ASME 1.708 mm UG-27 (1)

Min. Thk req. as per TEMA 5 mm R-3.13
Min. Thk req. 5 mm
Thk Consider 6 mm

Tubesheet Calculation
TEMA RCB-7.132
DESIGN DATA
Shell side internal pressure(negative sign if vacuum) Ps 45 kg/cm2G
℃
Tube side internal pressure(negative sign if vacuum) Pt 9 kg/cm2G
℃
Shell side internal design Temp. Temp-S 135
Tube side internal design Temp. Temp-T 145
Shell outside diameter Ds(Do) 368 mm.
Shell thickness Ts(ts) 9 mm.
Shell inside diameter(corroded codition) Di(G) 350 mm
Shell inside diameter(corroded codition) Di(G) 350 mm.
Inside corrosion allowance of shell Cas 0 mm.
Tube outside diameter Dt 25.4 mm.
Tube thickness Tt 2.1 mm.
Tube pitch Pit 37 mm.
Tube length L 6000 mm.
Number of tube N 53
Tube pattern(2=Square/1=Triangular) 1
Outside diameter of the tubesheet A 479 mm.
Corrosion allowance of tubesheet Cats 0 mm.
Nominal thickness of tubesheet h 32 mm.
Assume tubesheet thickness Tass 50 mm.
MATERIAL SPECIFICATION
TUBESHEET Material： SA182 F304
2
Max. allowable stress at design metal temperature Sts 1091 kg/cm
2
Elastic modulus of tubesheet at metal temperature E 1989688.1 kg/cm
SHELL Material： SA240 Gr.304
Elastic modulus of shell at mean metal temperature Es 1989688.1 kg/cm2
TUBE Material： SA213 TP304
2
Elastic modulus of tube at mean metal temperature Et 1989688.1 kg/cm
CALCULATION
1.FACTOR
K=Es×Ts(Ds-Ts)/(Et×Tt×N(Dt-Tt)) K 1.246
3 0.25
Fq=0.25+(F-0.6)×(300×Ts×Es/(K×L×E)(Di/Tass) ) Fq(Fg) 1.457
F=(17-100(Ts×Di))/15 (Max 1-Min 8) F 0.962
J=1 for shell without expansion joint J 1
2.EQUIVALENT DIFFERENTIAL EXPANSION PRESSURE：
αs=coefficient of thermal expansion of the shell αs 0.000006513 (1/℃)
℃
αt=coefficient of thermal expansion of the tubes αt 0.000006698 (1/℃)
℃
Tm=shell mean metal temperature Tm 28
tm=tube mean metal temperature tm 24
Differential metal growth ,dL=L(tes(Tm-70)-tet(tm-70)) dl 0.207 mm
Pd=4×J×Es×Ts×(dl/Lt)/((Ds-3×Ts)×(1+J×K×Fq) Pd(Pe) 2.59 kg/cm2
3.EQUIVALENT BOLTING PRESSURE：
Mo=Total moment acting under operating conditions Mo 471577.6 kg-mm
Mg=Total momet acting under bolting-up conditions Mg 2044592.5 kg-mm
Pbt=620×Mo/(F2×Di )
3 2
Pbt 7.37 kg/cm
Pbs=620×Mg/(F2×Di3)
2
Pbs 31.95 kg/cm
4.EFFECTIVE SHELL SIDE DESIGN PRESSURE：
fs=1-N×(Dt/Di)2 fs 0.7209
Ps'=Ps(0.4J(1.5+K(1.5+fs/(1+K×Fq))) Ps' 8.23 kg/cm2
1.1 P=(Ps'-Pd)/2 2.82 kg/cm2
2
1.2 P=Ps' 8.23 kg/cm
1.3 P=Pbs 31.95 kg/cm2
2
1.4 P=(Ps'-Pd-Pbs)/2 -13.16 kg/cm
1.5 P=(Pbs+Pd)/2 17.27 kg/cm2
1.6 P=(Ps'-Pbs) -23.72 kg/cm2
5.EFFECTIVE TUBE SIDE DESIGN PRESSURE：
2
ft=1-N((Dt-2×Tt)/Di) ft 0.805548408
2
Pt'=Pt(1+0.4×J×K×(1.5+ft)/(1+J×K×Fq) Pt' 4.75 kg/cm
2.1 P=(Pt'+Pbt+Pd)/2 7.356139218 kg/cm2
2.2 P=Pt'+Pbt 12.12 kg/cm2
6.EFFECTIVE DIFFERENTIAL DESIGN PRESSURE：
2
 3.1 P=Pt'-Ps'+Pbt 3.89 kg/cm
3.2 P=(Pt'-Ps'+Pbt+Pd)/2 3.241139218 kg/cm2
3.3 P=Pbs 31.95 kg/cm2
3.4 P=(Pbs+Pd)/2 17.27324341 kg/cm2
2
3.5 P=Pt'-Ps' -3.48 kg/cm
2
3.6 P=(Pt'-Ps'+Pd)/2 -0.443938228 kg/cm
3.7 P=Pbt 7.37 kg/cm2
The greatest absolute value of Max.P{1.1-3.7} P 31.95 kg/cm2
7.TUBESHEET BENDING FORMULAR：
2 2
η= 1-0.907/(Pit/Dt) or 1-0.785/(Pit/Dt) η 0.572563828
0.5
Tcal=F×Di×/3×(P/(n×Sts)) Tcal(t1) 25.382 mm
8.TUBESHEET SHEAR FORMIULAR：
2
Effective design pressure for shear formular Ph kg/cm

Ph/Sts
1.6(1-Dt/Pit)2
2
Check：if Ph/Sts<1.6(1-Dt/Pit) shear will not control
t2 mm
9.TUBESHEET FORMULAR-TUBESHEET FLANGE EXTENSION：
min. thickness of the extended portion ;Tr
r=A/Di r 1.368914286
M=freater of Mo and Mg M 2044592.49 kg-mm
Tr=0.98{M(r2-1+3.71×r2×lnr)/(Sts(A-Di)×(1+1.86×r ))}
2 0.5
Tr 30.852 mm
Tmin=max{Tcal(t1),(t2),Tr(tr)}+2×Cats Tmin 30.852 mm
CONCLUSION：
The minimum tubesheet design thickness is 30.9 mm
Therefore selecting tubesheet thickness of 32.0 mm
#SATISFACTORY#
NOTE：

Integral Weld Neck Flange Calculation

ASME VIII Apprendix 2 2-7 a) (6)
DESIGN DATA
Outside diameter of flange A 479 mm
Inside diameter of flange(corroded) B 350 mm
Bolt-circle diameter C 432 mm
Number of bolt n 28 set
Size of bolt Db 20 mm
2
Cross section area per a bolt Ar 217.05 mm
Outside diameter of gasket do 394 mm
Width of gasket used to determine the basic gasket seating N 13 mm
Thickness of gasket Tg 4.5 mm
Thickness of hub at small end go 6 mm
Thickness of hub at back of flange g1 9.0 mm
Hub length h 12.0 mm
Corrosion allowance CA 0 mm
Internal design pressure P 9 Kg/cm2G
Flange thickness t 60 mm
MATERIAL SPECIFICATION
FLANGE: SA182 F304
Max. allowable stress at design temperature Sfb 1091 Kg/cm2
Max. allowable stress at atm temperature Sfa 1407 Kg/cm2
Gasket : Spiral Wound
Gasket or joint contact-surface unit seating load y 7.03 Kg/cm2
Gasket factor m 3
BOLT: SA193 Gr.B7
Allowable bolt stress at design temperature Sb 1757.7 Kg/cm2
Allowable bolt stress at atm temperature Sa 1757 7 Kg/cm2
Allowable bolt stress at atm temperature Sa 1757.7 Kg/cm
CALCULATION
1.FACTOR：
Ratio of outside diameter of flange to inside diameter of flange ,K=A/B K 1.369
Factor involving K T 1.768
U 6.971
Y 6.344
Z 3.289
0.5
Factor ho=(B×go) ho 45.826 mm
g1 /go= 1.500
h / ho= 0.262
Factor for intergral type flanges ,V V #N/A
Factor for intergral type flanges ,F F #N/A
Hub stress correction factor integral type flanges , f f #N/A
2 3
Factor d,d=(u/v)×ho×go d #N/A mm
Factor e,e=F/ho e #N/A 1/mm
3
Factor L,L=(te+1)/T+t /d L #N/A
2.BOLT LOADS：
Basic gasket seating width , bo=N/2 bo 6.50 mm
Effective gasket or joint contact surface seating width b 6.42 mm
b=0.5(bo)0.5 for bo>6.35mm(0.25in) or b=bo for bo<=6.35mm ? 6.42
Diameter at location of gasket load reaction G 380.65 mm
Min required bolt load for the operating conditions Wm1 14385.66 Kg
2
Wm1=0.785×G ×P+2×b×3.14159×m×P
Min required bolt load for gasket seating Wm2 54011.77 Kg
Wm2=3.14159×b×G×y
3.FLANGE MOMENT：
For the operating conditions..
Total hydrostatic end force, H=0.785×G2×P H 10236.82 Kg
Hydrostatic end force on area inside of flange ,HD=0.785×B2×P HD 8658.92 Kg
Difference between total hydrostatic end force and the hydrostatic end force
HT=H-HD HT 1577.89 Kg
Gasket load HG=Wm1-H HG 4148.84 Kg
3.1For intergral flange
Radial distance from BCD to point of intersection of hub and hub flange
R=(C-B)/2-g1 R 31.750 mm
Radial distance from the bolt circle to the circle on which HD acts=R+0.5×g1 Hd 36.250 mm
Radial distance from the bolt circle to the circle on which HT acts=(R+g1+hG)/2 Ht 33.087 mm
Radial distance from gasket load reaction to the bolt circle hG=(C-G)/2 Hg 25.425 mm
Component of moment due to HD , MD=HD×Hd MD 313886.02 kg-mm
Component of moment due to HG , MG=HG×Hg MG 105483.32 kg-mm
Component of moment due to HT , MT=HT×Ht MT 52208.30 kg-mm
Total flange moment for the operating conditions Mo=MD+MG+MT Mo 471578 kg-mm
3.2For gasket seating
2
Total cross-sectional area of bolts at root of thread required for the operting conditions Am1 818.4 mm
2
Total cross-sectional area of bolts at root of thread required for gaster seating Am2 3072.9 mm
Total required cross-sectional area of bolts, taken as the greater of Am1 and Am2 Am 3072.9 mm2
Cross-section area of the bolts using the root diameter of the thread Ab 6077.4 mm2
Flange design bolt load , Wg=(Am+Ab)×Sa/2 Wg 80417.4 kg
Total flange moment for gasket seating , Mg=Wg×(C-G)/2 Mg 2044592.5 kg-mm
4.CALCULATION OF FLANGE STRESSES：
Longitudinal hub stress ,SH=f×Mo/(L×g12×B) SH1 #N/A Kg/cm2
2 2
Longitudinal hub stress ,SH=f×Mg/(L×g1 ×B) SH2 #N/A Kg/cm
2
Radial flange stress ,SR=(1.33×t×e+1)Mo/(L×t ×B) SR1 #N/A Kg/cm2
2 2
Radial flange stress ,SR=(1.33×t×e+1)Mg/(L×t ×B) SR2 #N/A Kg/cm
2
Tangential flange stress ,ST=Y×Mo/(t ×B)-Z×SR1 ST1 #N/A Kg/cm2
Tangential flange stress ,ST=Y×Mg/(t2×B)-Z×SR2 ST2 #N/A Kg/cm2
5.CHECKED CODITIONS：
SH is not greater then 1.5*Sf SH= #N/A #N/A 1.5*Sf= 2636.55 Kg/cm2
SR is not greater then Sf SR= #N/A #N/A Sf= 1757.7 Kg/cm2
ST is not greater then Sf ST= #N/A #N/A Sf= 1757.7 Kg/cm2
(SH+SR)/2 is not greater then Sf = #N/A #N/A Sf= 1757.7 Kg/cm2
(SH+ST)/2 is not greater then Sf = #N/A #N/A Sf= 1757.7 Kg/cm2
#N/A
6.MIX. USED THICKNESS OF FLANGE
The required for the not operting conditions t1 t1 51.32 mm
The required for the operting conditions t2 t2 27.99 mm
Design thickness of flange ,Tm=Mix.{t1,t2}+CA Tm 51.32 mm
The design thickness of flange is 51 mm.
Therefore the norminal thickness used of 60 mm. #SUFFICIENT#
NOTE：

Shell Side Nozzle Calculation

ASME VIII UG-45
SHELL INPUTS

Internal pressure P kgf/cm2 45

Internal diameter of the shell D mm 350
Reqd. thickness of shell (corresponding to internal pressure) tr,int mm 8.74660
Reqd. thickness of shell (corresponding to external pressure) tr,ext mm 0
Allowable stress in shell at given temp Sv kgf/cm2 1091
Corrosion allowance of shell c.a.,shell mm 0
Shell thickness provided t' mm 9

NOZZLE INPUTS
type of nozzle set in nozzle with pad
Nozzle O.D. d' mm 273.1
Nozzle wall thickness provided tn ' mm 8
nozzle projection outside the vessel wall Lpr1 mm 150
allowable stress in nozzle Sn kgf/cm2 1366
Offset distance Off mm 0
reqd. nozzle thickness(corresponding to external pressure) tr n,ext mm 1.34

REINFORCING PAD INPUTS

outside diameter of reinforcing pad Dp mm 400
thickness of reinforcing pad te mm 9
is it split type padding NO

INTEGRAL NOZZLE INPUTS

hub height of integral nozzle h mm 0
height of beveled transition L' mm 0
hub thickness of integral nozzle X mm 0

WELD LEGS INPUTS

weld leg between pad and shell leg1 mm 0
weld leg between nozzle and pad/shell leg2 mm 0
E1 input according to location of opening 1

CERTAIN DERIVED PARAMETERS

corrosion allowance of nozzle (internal only) c.a.,nozzle mm 0
allowable stress in reinforcing pad at given temp Sp kgf/cm2 1091
Shell thickness after corrosion t mm 0
Nozzle wall thickness after corrosion tn mm 8
inside diameter of nozzle d mm 257.1
width of reinforcing pad W mm 63.45
layout angle θ radian 0
reqd. nozzle thk tr n mm #REF!
Reqd. thickness of shell (governing the case) tr mm 8.746599

MIN NOZZLE THICKNESS (ACCORDING TO UG-45)

ta
mm 4.439848
(P(d')/(2(Sn+(0.4*P)))+c.a.,nozzle

tb1
mm 8.746599
tint+c.a.,nozzle

tb2
mm 0
text+c.a.,nozzle

tb3
mm 8.34
from table +c.a.,nozzle

min nozzle thickness(tug45)

mm 8.34
max(ta,.min(tb3,max(tb2,tb1)))

Tube Side Nozzle Calculation

ASME VIII UG-45
SHELL INPUTS

Internal pressure P kgf/cm2 9

Internal diameter of the shell D mm 350
Reqd. thickness of shell (corresponding to internal pressure) tr,int mm 1.70834
Reqd. thickness of shell (corresponding to external pressure) tr,ext mm 0
Allowable stress in shell at given temp Sv kgf/cm2 1091
Corrosion allowance of shell c.a.,shell mm 0
Shell thickness provided t' mm 6

NOZZLE INPUTS
type of nozzle set in nozzle with pad
Nozzle O.D. d' mm 355.6
Nozzle wall thickness provided tn ' mm 8
nozzle projection outside the vessel wall Lpr1 mm 150
allowable stress in nozzle Sn kgf/cm2 1366
Offset distance Off mm 0
reqd. nozzle thickness(corresponding to external pressure) tr n,ext mm 1.34

REINFORCING PAD INPUTS

outside diameter of reinforcing pad Dp mm 530
thickness of reinforcing pad te mm 6
is it split type padding NO
INTEGRAL NOZZLE INPUTS
hub height of integral nozzle h mm 0
height of beveled transition L' mm 0
hub thickness of integral nozzle X mm 0

WELD LEGS INPUTS

weld leg between pad and shell leg1 mm 0
weld leg between nozzle and pad/shell leg2 mm 0
E1 input according to location of opening 1

CERTAIN DERIVED PARAMETERS

corrosion allowance of nozzle (internal only) c.a.,nozzle mm 0
allowable stress in reinforcing pad at given temp Sp kgf/cm2 1091
Shell thickness after corrosion t mm 0
Nozzle wall thickness after corrosion tn mm 8
inside diameter of nozzle d mm 339.6
width of reinforcing pad W mm 87.2
layout angle θ radian 0
reqd. nozzle thk tr n mm #REF!
Reqd. thickness of shell (governing the case) tr mm 1.708336

MIN NOZZLE THICKNESS (ACCORDING TO UG-45)

ta
mm 1.16837
(P(d')/(2(Sn+(0.4*P)))+c.a.,nozzle

tb1
mm 1.708336
tint+c.a.,nozzle

tb2
mm 0
text+c.a.,nozzle

tb3
mm 8.34
from table +c.a.,nozzle

min nozzle thickness(tug45)

mm 1.708336
max(ta,.min(tb3,max(tb2,tb1)))