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Cairo Oil Refining Co.


  
 

Subsidery of Egyotian Gen. Petroleum Corp.


   

P.O. Box : Heliopolis 11757 Cairo A.R.E.

    :..

Tel. : 202 - 2529821 (5 Lines)

(# ) - :% 

Fax : 202 - 2529826

- :&

corc2000@excite.com:'( 


E-mail : corc2000@excite.com

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 :
Project :
Location :
Item No. :

Amerya Petroleum Refining Co.


(APRC)
Design & Fabrication of Residue Cooler
Alexandria, EGYPT
E-323 A
E-323 B
E-514 C
7443-33-U-2009, 7443-33-U-2010
Serial No. : 7443-33-U-2008,
Title :
Heat Exchanger
Service :
Residue Cooler
Type :
AES
Job No. :
7443-33
Dwg. No. : 7443-33-1A
Rev. : 1

Cooler capacity
Weight of exchanger, empty (erection), W
Weight of contents, Wc
Total weight of vessel and contents, Wt
MAWP :

Shell Side
Tube Side
Tube Side
Design Temp. :
Shell Side
Tube Side
MDMT :
Shell Side
Tube Side
Tube Side

1.910848
4152.911
764
4917
284.776
71.7082
302
140
29
29

PSIG
PSIG
o
F
o
F
o
F
o
F

No. of saddles
No. of anchor bolts per saddle
Anchor bolts size

E-514 C
& 7443-33-U-2011

M3
Kg
Kg
Kg

20.04826 Kg/CM2G
5.04826 Kg/CM2G
o
C
150
o
C
60
o
C
-2
o
C
-2
2
4
28 MM

Saddles
Bolts
Dia.

By

Eng. Abdel Halim Galala


Design General Manager

 +

Design Sector
Page : 1 of 136

Sheet 1 of 2

Date : 11.4.2004

DESIGN CALCULATIONS OF HEAT EXCHANGER


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 : 2 of 136
Sheet : 2 of 2
Rev. : 1

Project
Job No.

: Design & Fabrication of Heat Exchanger for APRC Refinery


: 7443-33

Date : 11.4.2004
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
Serial No. : 7443-33-U-2008,
7443-33-U-2009, 7443-33-U-2010
Title :
Heat Exchanger
Service :
Residue Cooler
Type :
AES
Job No. :
7443-33
Dwg. No. : 7443-33-1A
Rev. : 1

E-514 C
& 7443-33-U-2011

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
0

Rev.

Issued for approval

11.4.2004
A. Halim
Issued for comments
4.7.2003
Designed by
Description
Date

11.4.2004
A.H. Galala
4.7.2003
Reviewed by
Date

Revision Table
Dwg. No. :

7443-33-1A

Rev. : 1

11.4.2004
A.H.G
4.7.2003
Approved by
Date

DESIGN CALCULATIONS OF HEAT EXCHANGER


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)

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

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 - July, 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.

Page : 3 of 136
Sheet : 1 of 1
Rev. : 1
Date : 11.4.2004
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

DESIGN CALCULATIONS OF HEAT EXCHANGER


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)

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

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.

Rev.
0
1
2

Date
4.7.2003
11.4.2004
16.1.2005

Sheet
No.
Revision Description
all
Issued for comments
all
Issued for approval
7
UG-22 : Abnormal pressures

Page : 4 of 136
Sheet : 1 of 1
Rev. : 1
Date : 11.4.2004
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 5 of 136
Sheet : 1 of 2
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

D. Table of Contents.

Description

Page

A. Title.
B. Copyright.
C. Revisions Description.
D. Table of Contents.
E. Applicable Loading Considered in Design.
F. Impact Test Requirements.
G. Standarad ASME B16.5 Flange Rating Class.
H. Cylindrical Main Shell Thickness
1. Under Internal Pressureal (Pipe 20" NPS)
2. Check of Main Shell Thickness for External Pressure (FV).
I. Cylindrical Stationary Head-Channel.
1. Under Internal Pressure
2. Check of Channel Thickness for External Pressure (Full Vacuum)
J. Main Ellipsoidal Head Thickness
Under Internal Pressure.

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K. Max. Internal Working Pressure, MWP at New (cold) & Operating (corroded)

1. For Shell-Side :
2. For Tube-Side :
3. For Tubes : (Item 38)

Page : 15 of 136
Page : 15 of 136
Page : 17 of 136

L. Check for External Pressure (Convex Side), (Tube Side Full Vacuum)

1. Ellipsoidal Head (Stationary Head-Bonnet NA)


2. Channel
3. Tubes
M. Nozzle Neck Thicknesses & Nozzle Openings Compensation :
S1 & S2
6" NPS
M1
300#
WNRF
Sch. 80
T1 & T2
6" NPS
M2
150#
WNRF
Sch. 80
N. Main Shell Flange (item no. 4).
E514FLG
N1. Main Shell Flanges (item no. 3).
E514FLG
N2. Main Shell Flanges (item no. 12).
E514FLG
O. Main Channel Flanges (items no. 18).
E514FLG
P. Channel Cover (blind flange) (item no. 22).
E514FLG
Q. Stationary Tubesheet (item no. 36).
TUBSH514
Q1. Floating Tubesheet (item no. 37).
TUBSH514
Q2. TEMA Pass Partition Plate Thickness Calculation (item nTUBSH514
Q3. Floating Head, Flange & Backing Ring (items no. 29, 30 E514FLG
File

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10.9728
10.9728
5
6
7
9
14
4
6
7
15
Sheet

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DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 6 of 136
Sheet : 2 of 2
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

D. Table of Contents (cont.)


Description

Page

R. Design of Saddle Supports.


S. Lowest MDMT Without Impact Test.
T. Radiography.
U. Hydrostatic Test Pressure.
[UG-99(b)]
[ Refer to
V. Post Weld Heat Treatment (PWHT).
W. Calculation of Exchanger Weight.
X. Stresses in Vessel on Two Saddle Supports Using ZICK's Method.
Y. Check for the Anchor Bolts Due to Seismic and Wind Loading.
Check for the Existing Anchor Bolts Due to Seismic and Wind Loading.
Z. Check for Bundle Pulling.
Z1. Lifting Lugs Thickness Calculations.
Z2. References.
Z3. Notes.

Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
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Figures Index.
Figure (1)
Figure (2)
Figure (3)
Figure (4)
Figure (5)
Figure (6)
Figure (7)
Figure (8)
Figure (9)
Figure (10)
Figure (11)
Figure (12)
Figure (13)
Figure (14)
Figure (15)
Figure (16)
Figure (17)
Figure (18)
Figure (19)
Figure (20)
Figure (21)
Figure (22)

Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page
Page

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DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 7 of 136
Sheet : 1 of 1
Rev. :
2

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)

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

E. Applicable Loading Considered in Design.

Date : 11.4.2004
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

[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.
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.
and insulation.

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
Tube side
Internal design pressure, P (MAWP) Shell side
Tube side
External design pressure, Pex (Tube side)

241.5
42.6
284.0909
71.02273
15

PSIG
PSIG
PSIG
PSIG
PSIG

17
3
20
5
1.056

Kg/cm2G
Kg/cm2G
Kg/cm2G
Kg/cm2G
Kg/cm2G

Exchanger shell ID (fabricated from Pipe 24" NPS, Sch. 30), ID


Water sp. gr.
Fluid sp. gr.

19
1
0.8

INCH

482.6

MM

Max. hydrostatic head at internal bottom of vessel*


Max. internal pressure :
Shell side
Tube side
* p water

0.685511
284.7764
71.70824
0.036127

PSIG
PSIG
PSIG
lb/INCH3

0.04826
20.0483
5.04826
1000

Kg/cm2G
Kg/cm2G
Kg/cm2G
Kg/M3

Max. internal working pressure MAWP for calculation : Shell side


Tube side
External design pressure, Pe (at tube side)

286
73
15

PSIG
PSIG
PSIG

2
20.0483 Kg/cm G
2
5.04826 Kg/cm G
Kg/cm2G
1.056

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 8 of 136
Sheet : 1 of 1
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.
Client : APRC
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
o
o
F
C
Min. Design Metal Temperature, MDMT
28
-2
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

-2

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 oF : Raing 300#
b. Tube side flanges, T1 & T2, 6" NPS : MAWP 72 PSIG & Design temp. 140 oF : Raing 150#

DESIGN CALCULATIONS OF HEAT EXCHANGER


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)

Project
: Design & Fabrication of Heat Exchanger for APRC Refinery
Job No.
: 7443-33
Dwg. No. : 7443-33-1A, Rev. 1
Exchanger : Residue Cooler, Type : AES, TEMA class : R
H. Cylindrical Main Shell Thickness
1. Under Internal Pressureal (Pipe 20" NPS)
Shell material, Killed carbon steel
Operating Temperature : Shell Side
Tube Side
Design Temperature :
Shell Side
Tube Side
Min. Design Metal Temperature, MDMT
Operating Pressure:
Shell Side
Tube Side
Internal Design Pressure: Shell Side
Tube Side
Shell Inside Diameter, D (by using pipe 20" NPS, Sch.30)
Shell Inside Radius, R
Stationary Shell Inside Diameter, Ds
Static Head = Inside Diameter (D)
Static Head Pressure: Shell & Tube Side
Floating Head Side
Internal Design Pressure, P (MAWP): Shell Side
Tube Side
Max. Allowable Stress @ Design Temp., S
Max. Allowable Stress @ Test Temp., St
[ Table 1A , SubPart 1 , ASME Sec. II , Part D]
Hydrostatic Test Pressure, Ph = 1.3*MAWP(St/S)

Ph = 1.5*MAWP(St/S)

[shell side]

Date : 11.4.2004
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

[UG-27(C)]

ASME SA 106 Grade B


o
F
110
230
o
F
40
104
o
F
150
302
o
F
60
140
o
F
-2
28
241.477 PSIG
17
42.6136 PSIG
3
284.091 PSIG
20
71.0227 PSIG
5
19
INCH
482.6
9.5
INCH
241.3
INCH
482.6
19
0.4826
0.68551 PSIG
0.04826
0.68551 PSIG
0.04826
284.776 PSIG
20.04826
71.7082 PSIG
5.04826
17100
PSIG
1203.84
17100
PSIG
1203.84

C
C
o
C
o
C
o
C
o

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

MM
MM
MM
M
Kg/CM2G
Kg/CM2G
Kg/CM2G
Kg/CM2G
Kg/CM2G
Kg/CM2G
2

[UG-99(b)]

[Owner request]

Corrosion Allowance, C
Joint Efficiency, E

Page : 9 of 136
Sheet : 1 of 3
Rev. : 1

[UG-25]
[Table UW-12]

[Spot Radiography], [Table UCS-57]


Value of 0.385 SE
[UG-27C(1)]
Since P does not exceed 0.385 SE , Use Thin Wall Equation:
[1] Min. Wall Thickness for Longitudinal Joints,
[UG-27C(1)]
t1 = PR/(SE - 0.6 P)
[2] Min. Wall Thickness for Circumferential Joints,
t2 = PR/(2SE + 0.4 P)
[UG-27C(2)]

The Min. Thickness shall be the Greater of t1 or t2


By Adding Corrosion Allowance to Wall Tickness, t
Use 20" Pipe with thickness of Construction, t (Sch. 30, 12.7 MM)
20" Pipe wall thickness without tolerance 12.5%
20" Pipe wall thickness without corrosion allowance
Min. Pipe Shell Thickness according to TEMA Table R-3.13

370.2093347

PSIG

26.062738

427.164617

PSIG

30.07239

Kg/CM G

Kg/CM2G

0.19685 INCH
0.85

5595.98 PSIG

393.9567 Kg/CM2G

0.18834 INCH

4.783898 MM

0.0927

INCH

2.354604 MM

0.18834
0.38519
0.5
0.4375
0.24065
0.375

INCH

4.783898
9.783898
12.7
11.1125
6.1125
9.525

INCH
INCH
INCH
INCH
INCH

MM

MM
MM
MM
MM
MM
MM

DESIGN CALCULATIONS OF HEAT EXCHANGER


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)

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

Page : 10 of 136
Sheet : 2 of 3
Rev. : 1
Date : 11.4.2004
Location : Alex.
Client : APRC

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
Height of shell flange-rear head end (flange 6), L6
Total shell length (flange-to-flange), L'

3.70079 INCH
3.74016 INCH
228.346 INCH

94
95
5800

MM
MM
MM

Effective shell length without stiffening,

228.346 INCH

5800

MM

In case of shell with heads, L = 1/3 each head depth + straight

234.68

5960.867 MM

Assume t for internal pressure (corroded)


Do = ID + 2 t

0.24065 INCH
19.4813 INCH

L = L' - (L6 + L7)

L / Do
Do / t

INCH

6.1125
494.825

MM
MM

12.0464 For L/Do > 50, use it = 50


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),


Follow step (6) of UG-28(c), PA = 4B / 3 (Do / t)

5600
PSIG
92.2346 PSIG

Kg/CM2G
394.24
2
6.493318 Kg/CM G

15
OK

1.056

Change t untill PA > 15 PSI (full vacuum)


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)
E = Modulus of elasticity at design temp.
at amp. temp.
The uncorroded shell wall thickness must not lrss than
Use the uncorroded shell wall thickness
Use Thickness of Construction, t (Adopted thickness)

86.4329 PSIG
2.8E+07 PSIG
2.9E+07 PSIG

Corroded Thickness = Adopted thickness + Corrosion allowance


Insulation
Post Weld Heat Treatment, PWHT

PSIG

Yes
N.A.

Kg/CM2G

6.084877 Kg/CM2G
1970355 Kg/CM2G
2055680 Kg/CM2G

DESIGN CALCULATIONS OF HEAT EXCHANGER


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)

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

Page : 11 of 136
Sheet : 3 of 3
Rev. : 1
Date : 11.4.2004
Location : Alex.

Client : APRC
Items : E-323A/B & E-514C/D

[UG-27(C)]

a.2. Floating Shell

Shell material, Killed carbon steel (Pipe 26" Sch. 20)


Operating Temperature : Shell Side
Tube Side
Design Temperature :
Shell Side
Tube Side
Min. Design Metal Temperature, MDMT
Operating Pressure:
Shell Side
Tube Side
Internal Design Pressure: Shell Side
Tube Side
Shell Inside Diameter, D
Shell Inside Radius, R
Stationary Shell Inside Diameter, Ds
Static Head = Inside Diameter (D)
Static Head Pressure: Shell & Tube Side
Floating Head Side
Internal Design Pressure, P (MAWP): Shell Side
Tube Side
Max. Allowable Stress @ Design Temp., S
Max. Allowable Stress @ Test Temp., St

ASME SA 516 Grade 70


o
F
110
230
o
F
40
104
o
F
150
302
o
F
60
140
o
F
-2
28.4
241.477 PSIG
17
42.6136 PSIG
3
284.091 PSIG
20
71.0227 INCH
5
634.6
24.9843 INCH
12.4921 INCH
317.3
19
INCH
482.6
0.6346
0.90142 PSIG
0.06346
0.0009 PSIG
6.35E-05
284.092 PSIG
20.00006
71.9241 PSIG
5.06346
17100
PSIG
1203.84
17100
PSIG
1203.84

C
C
o
C
o
C
o
C
o

Kg/CM2G
Kg/CM2G
Kg/CM2G

MM
MM
MM
MM
M
Kg/CM2G
Kg/CM2G
Kg/CM2G
Kg/CM2G
Kg/CM2G
Kg/CM2G

[ TABLE 1A , SUBPART 1 , ASME SEC. II , PART D]

Hydrostatic Test Pressure, Ph = 1.3*MAWP(St/S)

369.319 PSIG

2
26.00008 Kg/CM G

[ UG-99(b) ]

Corrosion Allowance, C
Joint Efficiency, E

0.19685 INCH
0.85

Value of 0.385 SE
[UG-27C(1)]
Since P does not exceed 0.385 SE , Use Thin Wall Equation:
[1] Min. Wall Thickness for Longitudinal Joints,
t1 = PR/(SE-0.6P)
[UG-27C(1)]
[2] Min. Wall Thickness for Circumferential Joints,
t2 = PR/(2SE+0.4P)
[UG-27C(2)]

5595.98 PSIG

393.9567 Kg/CM2G

0.24706 INCH

6.275335 MM

0.12161 INCH

3.088797 MM

The Min. Thickness shall be the Greater of t1 or t2


By Adding Corrosion Allowance to Wall Tickness, t
Use Plate with thickness of Construction, t
Min. Plate Shell Thickness according to TEMA Table R-3.13
Insulation
Post Weld Heat Treatment, PWHT

0.24706
0.44391
0.5
0.4375
Yes
N.A.

6.275335
11.27533
12.7
11.1125

[UG-25]
[TABLE UW-12]

MM

[Full Radiography], [Table UCS-57]

INCH
INCH
INCH
INCH

MM
MM
MM
MM

DESIGN CALCULATIONS OF HEAT EXCHANGER


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)

Project
: Design & Fabrication of Heat Exchanger for APRC Refinery
Job No.
: 7443-33
Dwg. No. : 7443-33-1A, Rev. 1
Exchanger : Residue Cooler, Type : AES, TEMA class : R
I. Cylindrical Stationary Head-Channel.
1. Under Internal Pressure
Shell material, Killed carbon steel
Operating Temperature : Shell Side
Tube Side
Design Temperature :
Shell Side
Tube Side
Min. Design Metal Temperature, MDMT
Operating Pressure:
Shell Side
Tube Side
Internal Design Pressure: Shell Side
Tube Side
Shell Inside Diameter, D
Shell Inside Radius, R
Stationary Shell Inside Diameter, Ds
Static Head = Inside Diameter (D)
Static Head Pressure: Shell & Tube Side
Floating Head Side
Internal Design Pressure, P (MAWP): Shell Side
Tube Side
Max. Allowable Stress @ Design Temp., S
Max. Allowable Stress @ Test Temp., St

Page : 12 of 136
Sheet : 1 of 2
Rev. : 1
Date : 11.4.2004
Location : Alex.

Client : APRC
Items : E-323A/B & E-514C/D

[UG-27(C)]

ASME SA 106 Grade B


o
F
110
230
o
F
40
104
o
F
150
302
o
F
60
140
o
F
-2
28.4
241.477 PSIG
17
42.6136 PSIG
3
284.091 PSIG
20
71.0227 PSIG
5
INCH
482.6
19
9.5
INCH
241.3
483
19.0157 INCH
0.4826
0.68551 PSIG
0.04826
0.68608 PSIG
0.0483
284.776 PSIG
20.04826
71.7082 PSIG
5.04826
17100
PSIG
1203.84
17100
PSIG
1203.84

C
C
o
C
o
C
o
C
o

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

MM
MM
MM
M
Kg/CM2G
Kg/CM2G
Kg/CM2G
Kg/CM2G
Kg/CM2G
Kg/CM2G

[ TABLE 1A , SUBPART 1 , ASME SEC. II , PART D]


Hydrostatic Test Pressure, Ph = 1.3*MAWP(St/S)

Ph = 1.5*MAWP(St/S)

[tubel side]

[UG-99(b)]

370.2093347

PSIG

26.062738

[Owner request]

427.164617

PSIG

30.07239

Corrosion Allowance, C
Joint Efficiency, E

Kg/CM2G

Kg/CM2G

0.19685 INCH
0.85

Value of 0.385 SE
[UG-27C(1)]
Since P does not exceed 0.385 SE , Use Thin Wall Equation:
[1] Min. Wall Thickness for Longitudinal Joints,
t1 = PR/(SE-0.6P)
[UG-27C(1)]
[2] Min. Wall Thickness for Circumferential Joints,
t2 = PR/(2SE+0.4P)
[UG-27C(2)]

5595.98 PSIG

393.9567 Kg/CM2G

0.04743 INCH

1.204611 MM

0.0927

INCH

2.354604 MM

The Min. Thickness shall be the Greater of t1 or t2


By Adding Corrosion Allowance to Wall Tickness, t
Use plate thickness,

0.0927 INCH
0.28955 INCH
0.51181 INCH

2.354604 MM
7.354604 MM
13
MM

[UG-25]
[TABLE UW-12]

MM

[Full Radiography], [Table UCS-57]

Use 20" Pipe with thickness of Construction, t (Sch. 30, 12.7 MM)

20" Pipe wall thickness without tolerance 12.5%

0.511811024

Plate Thickness less corrosion allowance


Min. Plate thickness
according to TEMA Table R-3.13
20" Pipe wall thickness without corrosion allowance

Min. Pipe Shell Thickness

INCH

0.51181 INCH
INCH
0.375

13

13
9.525

MM

MM
MM

DESIGN CALCULATIONS OF HEAT EXCHANGER


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 : 13 of 136
Sheet : 2 of 2
Rev. : 1

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

Date : 11.4.2004
Location : Alex.
Client : APRC
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
Height of shell flange-rear head end (flange 6), L6
Total shell length (flange-to-flange), L'

4.72441 INCH
5.11811 INCH
23.622 INCH

120
130
600

MM
MM
MM

Effective shell length without stiffening,

23.622

600

MM

L = L' - (L6 + L7)

In case of shell with heads, L = 1/3 each head depth + straight

Assume t for internal pressure (corroded)


Do = ID + 2 t
L / Do
Do / t
a. Enter Fig. G with L / Do and read across to sloping line of Do/t
Read factor A

29.96062992

INCH

0.51181 INCH
20.0236 INCH

761

13
508.6

MM

MM
MM

1.49626 For L/Do > 50, use it = 50


39.1231

0.00038

b. Enter Fig. CS-2 with A (to find factor B), which is off to the left side and can 4750
Follow step (6) of UG-28(c), PA = 4B / 3 (Do / t)
161.882
Change t untill PA > 15 PSI (full vacuum)
15
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
E = Modulus of elasticity at design temp.
3.1E+07
at amp. temp.
2.9E+07
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
Post Weld Heat Treatment, PWHT

INCH

Yes
N.A.

PSIG
PSIG

Kg/CM2G
334.4
2
11.39651 Kg/CM G

PSIG

1.056

PSIG
PSIG
PSIG

14.15267 Kg/CM2G
2214784 Kg/CM2G
2055680 Kg/CM2G

Kg/CM2G

DESIGN CALCULATIONS OF HEAT EXCHANGER


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)

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

Page : 14 of 136
Sheet : 1 of 1
Rev. : 1
Date : 11.4.2004
Location : Alex.
Client : APRC

Items : E-323A/B & E-514C/D

J. Main Ellipsoidal Head Thickness


Under Internal Pressure.
Head Material, Carbon Steel
Design Temperature (shell side)
MIN. Design Metal Temperature, MDMT

[UG-32(d)]
[Semi-ellipsoidal form 2:1 ]
ASME SA 234 WPB
o
F
150
302
o
F
-2
28

Operating Pressure (shell side)


Internal Design Pressure (shell side)

156.25 PSIG
284.091 PSIG

11
20

Kg/CM2G
Kg/CM2G

Internal Design Pressure, P (MAWP)


Head Skirt Inside Diameter, Di
Head Inside Radius, L ( ri )
Static Head
Max. Allowable Stress @ Design Temp., S
Max. Allowable Stress @ Test Temp., St
[TABLE 1A , SUBPART 1 , ASME SEC. II , PART D]

284.992
24.9843
12.4921
0.90142
17100
17100

20.06346
634.6
317.3
0.06346
1203.84
1203.84

Kg/CM2G

Corrosion Allowance, C
Joint Efficiency, E (Spot Radiography)

0.19685 INCH
0.85

MM

Assume Outside Diameter of Head, DO


Outside Radius of Head, RO

25.4751 INCH
12.7375 INCH

647.0672 MM
323.5336 MM

Value of 0.665 SE
Since the value of 0.66SE > P, Use Thin Wall Equation for
Calculating the Min. required Thickness of Head, t:
[UG-32(d)]
t1 = PD /(2SE-0.2P)

9665.78 PSIG

680.4706 Kg/CM2G

(1)

0.24542 INCH

6.233623 MM

Ps = 0.665 SE
Since P < Ps, Calculate Thickness for thin Wall Spherical Shell:
t2 = PR/(2SE-0.2P)
[UG-27(d)]
(2)
Head Thickness due to Internal Pressure: t = MAX ( t1 , t2 )
By adding Corrosion Allowance to Wall Thickness,
Use 26" Cap with thickness of Construction, t (Thk. 14.27 MM)

9665.78 PSIG

680.4706 Kg/CM2G

0.12271
0.24542
0.44227
0.56181

3.116812
6.233623
11.23362
14.27

[UG-25]
[Table UW-12]

PSIG
INCH
INCH

PSIG
PSIG
PSIG

C
C

MM
MM
Kg/CM2G
Kg/CM2G
Kg/CM2G

Compare to Thickness of Seamless Spherical Shell :

INCH
INCH
INCH
INCH

MM
MM
MM
MM

[ t Represents the Min. Thickness after Forming ]

Head required thickness,

tr = P K1 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 K1 D where,
Spherical Radius Factor, K1 (for ellipsoidal head 2:1)
[Table UG-37]
0.9

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 15 of 136
Sheet : 1 of 3
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
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]
o
o
F
C
1. For Shell-Side :
302
150
Main shell (Item 1) :
Kg/CM2G
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/CM2G
MWP, Operating & corroded (9.286 MM) P = SE t /(R + 0.6 t)
455.517 PSIG
32.068
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
MWP, Operating & corroded (9.286 MM), P = 2SE t /(D + 0.2 t)
462.789 PSIG
Nozzle Neck 6" NPS, Sch. 80 for N3 & N4 (item 6) :
MWP, New & cold (7.489 MM-12.5%) neck
MWP, Operating & corroded (4.289 MM) neck N3 & N4
Standard Flange 6" NPS, ANSI 300#, Sch. 80 for N3 & N4 (items 5) :
MWP, New & cold
[TEMA Table D-6.1]
MWP, Operating & corroded
[TEMA Table D-6.1]

43.75937 Kg/CM2G
32.58034 Kg/CM2G

740
664.4

PSIG
PSIG

52.096
46.774

Kg/CM2G
Kg/CM2G

740
655

PSIG
PSIG

52.096
46.112

Kg/CM2G
Kg/CM2G

Non Standard Flange (Item 4) :


MWP, New & cold
MWP, Operating & corroded

425.258 PSIG
335.398 PSIG

29.938
23.612

Kg/CM2G
Kg/CM2G

Non Standard Flange (Item 3) :


MWP, New & cold
MWP, Operating & corroded

425.258 PSIG
335.398 PSIG

29.938
23.612

Kg/CM2G
Kg/CM2G

Non Standard Flange (Item 12) :


MWP, New & cold
MWP, Operating & corroded

425.258 PSIG
335.398 PSIG

29.938
23.612

Kg/CM2G
Kg/CM2G

DESIGN CALCULATIONS OF HEAT EXCHANGER


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)

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

Page : 16 of 136
Sheet : 2 of 3
Rev. : 2
Date : 4.7.2003
Location : Alex.
Client : APRC

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]
o
o
F
C
2. For Tube-Side :
608
320
Channel (Item 17) :
Kg/CM2G
MWP, New & cold (13 MM .) P = SE t /(R + 0.6 t)
[UG-27(c)(1)]
608.569 PSIG
42.843
Kg/CM2G
MWP, Operating & corroded (8 MM) P = SE t /(R + 0.6 t)
455.537 PSIG
32.07
-12.5%

Nozzle Neck 6" NPS, Sch. 80 for N1& N2 (item 20) :


MWP, New & cold (7.489 MM-12.5%) neck
MWP, Operating & corroded (4.289 MM) neck

285
275

PSIG
PSIG

20.064
19.36

Kg/CM2G
Kg/CM2G

Standard Flange 6" NPS, ANSI 150#, Sch. 80 for N1& N2 (item 19) :
MWP, New & cold
[TEMA Table D-6.1]
MWP, Operating & corroded
[TEMA Table D-6.1]

285
260

PSIG
PSIG

20.064
18.304

Kg/CM2G
Kg/CM2G

Non Standard Flanges (Item 18) :


MWP, New & cold
MWP, Operating & corroded

425.258 PSIG
335.368 PSIG

29.938
23.61

Kg/CM2G
Kg/CM2G

Blind Flange (Item 22) : [see page 47 of 80]MWP, New & cold
MWP, Operating & corroded

289.381 PSIG
263.006 PSIG

20.372
18.516

Kg/CM2G
Kg/CM2G

Stationary Tubesheet (Item 36) : [see page 49 of 80]MWP, New & cold
MWP, Operating & corroded

431.681 PSIG
384.282 PSIG

30.39
27.053

Kg/CM2G
Kg/CM2G

Floating Tubesheet (Item 37) : [see page 49 of 80]MWP, New & cold
MWP, Operating & corroded

431.681 PSIG
384.282 PSIG

30.39
27.053

Kg/CM2G
Kg/CM2G

Floating Head Spherical Sector (Item 30) : [see page 49 of 80]MWP, New & c 431.681 PSIG
MWP, Operating & corroded
384.282 PSIG

30.39
27.053

Kg/CM2G
Kg/CM2G

Floating Head Elange (Item 29) : [see page 49 of 80]MWP, New & cold
MWP, Operating & corroded

431.681 PSIG
384.282 PSIG

30.39
27.053

Kg/CM2G
Kg/CM2G

Floating Head Backing Ring (Item 31) : [see page 49 of 80]MWP, New & cold 431.681 PSIG
MWP, Operating & corroded
384.282 PSIG

30.39
27.053

Kg/CM2G
Kg/CM2G

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 17 of 136
Sheet : 3 of 3
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
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
o
o
F
232.2222 C
Max. Temp. Limit
450
o
o
F
C
150
Design Temperature :
Shell Side
302
o
o
F
C
60
Tube Side
140
o
o
F
C
40
Test Pressure Temp. (ambient temp.)
104
o
o
Max. Allowable Stress @ Design Temp.302 F (150 C), S
11492
PSIG
809.0368 Kg/CM2G
Max. Allowable Stress @ Test Temp. 104 oF (40 oC), St
11992
PSIG
844.2368 Kg/CM2G
[Table 1A, SubPart 1, ASME Sec. II, Part D]
No of tubes, n
Tube OD
Tube length, L
Tube pitch, p
Tube BWG
Tube wall thickness, tt

[TEMA Table D-7]


[TEMA Table D-7]
o

Tube pattern (Triangle, equal angles 60 )


MWP (internal), New & cold
MWP (internal), Operating & corroded

30

(square rotated)

[TEMA Table D-9]


[TEMA Table D-9]

Design pressure (tube-side), P


Design temperature (tube-side)
o
o
Max. Allowable Stress @ Design Temp.302 F (150 C), S
Corrosion Allowance, C
[UG-25]
Joint Efficiency, E
[TABLE UW-12]
Tube required thickness,

trn = PRn /(SnEn - 0.6 P)

[UG-27]

Max. Internal Working pressure MWP for whole Exchanger :


Shell side :
MWP, New & cold
MWP, Operating & corroded
Tube side :

MWP, New & cold


MWP, Operating & corroded

146
1
236.22
1.45472
13
0.09843

INCH
INCH
INCH

25.4
6000
36.95

MM
MM
MM

INCH

2.500122 MM

4132.3 PSIG
3963.55 PSIG

290.9139 Kg/CM2G
279.0339 Kg/CM2G

71.0227 PSI
o
F
140
11492
PSIG
0
INCH
1

Kg/CM2G
5
o
C
60
2
Kg/CM
G
809.0368
0
MM

0.0062

0.157561 MM

INCH

425.258 PSIG
335.398 PSIG

29.938
23.612

Kg/CM2G
Kg/CM2G

285
260

20.064
18.304

Kg/CM2G
Kg/CM2G

PSIG
PSIG

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 18 of 136
Sheet : 1 of 3
Rev. : 1

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)

Project
: Design & Fabrication of Heat Exchanger for APRC Refinery
Job No.
: 7443-33
Dwg. No. : 7443-33-1A, Rev. 1
Exchanger : Residue Cooler, Type : AES, TEMA class : R
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
Outside diameter of the head skirt, Do
The equivalent outside spherical, Ro = Ko Do
[UG-33(b)]
Outside height of the ellipsoidal head (measured from head-bend line), ho
Ratio of the major to the minor axis of ellipsoidal head, Do/2ho
Factor depending on the ellipsoidal head proportions Do/2ho, Ko
(use interpolation)
[See Table UG-33.1]

Date : 11.4.2004
Location : Alex.

Client : APRC
Items : E-323A/B & E-514C/D

0.43583
23.7638
20.2171
6.28484
1.89056

INCH
INCH
INCH
INCH

11.07
603.6
513.5147
159.635

MM
MM
MM
MM

PSIG

696.96

Kg/CM2G

0.85075

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
Follow step (4) of UG-28(d), and calculate the value of max. allowable
external working pressure, PA = B / (Ro / t)
Change t untill PA > 15 PSI (full vacuum)

9900

213.417 PSIG
15
OK

PSIG

2
15.02459 Kg/CM G

1.056

Kg/CM2G

1823360

Kg/CM2G

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

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 19 of 136
Sheet : 2 of 3
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
Items : E-323A/B & E-514C/D

L. Check of External Pressure (Convex Side), (Tube Side Full Vacuum) (cont.)
2. Channel
Channel Material
Design Temperature
Corrosion allowance
Channel Diameter, 20" NPS
Channel Thickness (20" Sch. 30)
Channel Thickness (20" Sch. 30) - 12.5%

ASME SA106 Grade B


o
F
60
140
5
0.19685 INCH
20
INCH
508
0.562
INCH
14.2748
0.49175 INCH
12.49045

For external pressure on cylinder, use UG-28 and Subpart 3.


Determine the effective length of shell without stiffening rings, L :

23.622

Assume t for internal pressure (at corroded condition)


Do = ID + 2 t
L / Do
Do / t

0.2949 INCH
20
INCH
1.1811
67.8197 > 10

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.
Follow step (6) of UG-28(c)(1), and calculate the value of max. allowable
external working pressure, PA = 4B / 3 (Do / t)
Change t untill PA > 15 PSI (full vacuum)

E = Modulus of elasticity at design temp.


at amp. temp.

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)

INCH

C
MM
MM
MM
MM

600

MM

7.49045
508

MM
MM

UG-28(c)(1)

Kg/CM2G

11500

PSIG

809.6

226.09

PSIG

2
15.91672 Kg/CM G

15
OK

PSIG

1.056

Kg/CM2G

2323200
2055680

Kg/CM2G
Kg/CM2G

3.3E+07 PSIG
2.9E+07 PSIG

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 20 of 136
Sheet : 3 of 3
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
Items : E-323A/B & E-514C/D

L. Check of External Pressure (Convex Side), (Tube Side Full Vacuum) (cont.)
3. Tubes
Tube Material
Design Temperature
Corrosion allowance
Tube OD
Tube BWG
Tube Wall Thickness

ASME SB111 UNS No. C68700-061


o
o
F
C
140
60
INCH
0
MM
0
1
INCH
25.4
MM
13
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

0.09843
1
236.22
50
10.1595

INCH
INCH
> 50

2.500122 MM
25.4
MM

>

UG-28(c)(1)

Assume t for internal pressure (at corroded condition)


Do
L / Do
Use L / Do
Do / t
Since Do/t > 10, use UG-28(c)(1)

10

MM

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
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/CM2G

Step 4. Compare the calculated value of Pa with Pe


Change t untill Pa > 15 PSI (full vacuum)

PSIG
PSIG

56.82167 Kg/CM2G
Kg/CM2G
1.056

PSIG

13.0944

Kg/CM2G

PSIG

30.6944

Kg/CM2G

807.126
15
OK
Change t untill Pa > 186 PSI (full vacuum with respect to shell-side)
186
OK
Change t untill Pa > 30.7Kg/cm2 (436 PSI) (hydrostatic test of tube sid 436
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

432.96

Kg/CM2G

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 21 of 136
Sheet : 1 of 5
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
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
Nozzle Material

INCH
150
6
ASME SA 106 Grade B

Design Pressure, P
Design Temperature
For nominated Design Pressure & Temperature, Flange Rating
[ASME B16.5-1996]

284.776 PSIG
o
F
302
300#

20.04826 Kg/CM2G
o
C
150

Max. Allowable Stress of Nozzle Material @ Design Temp.(150 C), Sn


Max. Allowable Stress of Nozzle Materiall @ Test Temp.(40 oC), Snt
[Table 1A, SubPart 1, ASME Sec. II, Part D]

17100
17100

PSIG
PSIG

1203.84
1203.84

Kg/CM2G

Outside Radius of Nozzle, Ron


Joint Efficiency of Nozzle, En (Seamless Pipe)
Nozzle Corrosion Allowance, Can

3.3125 INCH
1
0.19685 INCH

84.1375

MM

MM

0.0548

INCH

1.391917 MM

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,


with Thickness 0.432" ( 10.97 MM ). [Table 2 of ASME B 36.10M-1985-(R-1994)]

0.432

INCH

10.9728

MM

Nozzle Neck Maximum Working Pressure, MWP (New & Operating)


Nozzle wall thickness less tolerance 12.5%
Nozzle wall thickness less tolerance 12.5% - Corrosion allowance
MWP, New & cold (10.97 MM) P = Snt E t /(Ron - 0.4 t)
[App. 1.1]
MWP, Operating & corroded (4.6 MM) P = Sn E t /(Ron - 0.4 t)

0.378
0.18115
2044.67
956.056

INCH
INCH

MM
MM

PSIG
PSIG

9.6012
4.6012
143.944
67.306

Nozzle Flange Maximum Working Pressure, MWP (New & Operating)


MWP, New & cold , 300# @ 100 oF
[ASME B.165, Table 2]
MWP, Operating & corroded, 300# @ 302 oF
[ASME B16.5, Table 2]

740
664.4

PSIG
PSIG

52.096
46.774

DN

Kg/CM2G

Nozzle Thickness Calculation :


Longitudinal Stress, t = PRon /(Sn*En + 0.4 P)
By adding Corrosion Allowance, t

[Appendix 1.1]
[UG-25]

Kg/CM2G
Kg/CM2G

Kg/CM2G
Kg/CM2G

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 22 of 136
Sheet : 2 of 5
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
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
Nozzle Pipe Sch.
Design Pressure, P
Design Temparture

INCH
6
80
185.483 PSIG
o
F
302

Shell Material
Nozzle Material
Reinforcing Pad Material
Allowable Stress of Shell Material, Sv
Allowable Stress of Nozzle Material, Sn
Allowable Stress of Pad Material, Sp

ASME SA106 Grade B


ASME SA 106 Grade B
ASME SA 106 Grade B
17100
PSIG
1203.84
17100
PSIG
1203.84
17100
PSIG
1203.84

Kg/CM2G
Kg/CM2G
Kg/CM2G

Shell Thickness
Shell Corrosion Allowance, Cas
Shell Thickness less Pipe Tolerance 12.5%
Shell Thickness less Corrosion Allowance & 12.5%, t

0.5
0.19685
0.4375
0.24065

INCH
INCH
INCH
INCH

12.7
5
11.1125
6.1125

MM
MM
MM
MM

0.432
0.378
0.19685
0.18115
0.18115
0.5
1
1
1
1
20
19.5187
9.75935

INCH
INCH
INCH
INCH
INCH
INCH

10.9728
9.6012
5
4.6012
4.6012
12.7

MM
MM
MM
MM
MM
MM

INCH
INCH
INCH

508
MM
495.775 MM
247.8875 MM

INCH
INCH
INCH
INCH
INCH
INCH
INCH

168.275
146.3294
0
15.28125
11.503
159.0726
79.5363

(12.5% NA)

(12.5% NA)

Nozzle Wall Nominal Thickness


Nozzle Wall Thickness less Pipe Tolerance 12.5%
Nozzle Corrosion Allowance, Can
Nozzle Wall Thick. less Corr. Allowance & 12.5% , tn
Nozzle Wall Thick.of Internal Projection (less Corr. Allowance & 12.5%), ti

Reinforced Pad Thickness, te


Joint Efficiency of Shell, E
Joint Efficiency of Nozzle, En
Correction Factor, F
[UG-37(a)]
E1
[Nozzle in solid plate]
Shell Outside Diameter, OD
Shell Inside Diameter in Corroded Condition, 2R = OD - 2 t
Shell Inside Radius in Corroded Condition, R
Nozzle Outside Diameter, OD
Nozzle Inside Diameter, ID
Nozzle Projection beyond Inner Vessel Wall, h = min. (h1,h2)
h1 = 2.5 t
h2 = 2.5 ti
Nozzle ID Without Corrosion Allowance & 12.5% , d = OD - 2*tn

Finished Radius of Circular Opening, Rn

6.625
5.761
0
0.60162
0.45287
6.2627
3.13135

150

DN

13.058
150

Kg/CM2G

MM
MM
MM
MM
MM
MM
MM

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 23 of 136
Sheet : 3 of 5
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
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
Dp2 = 2 (Rn + nozzle wall thk. , tn + vessel wall thk. , t )
7.1063 INCH
OD of Reinf. Pad, Dp = the greater of Dp1 or Dp2
12.5254 INCH
[UW-16(c)(2)&Fig.UW-16.1]
Calculating Siz of Fillet Welds :
* For Outward Nozzle Weld
[UW-16(c)(2)&Fig.UW-16.1Sketch (c)]
Calculation of tmin. :
tmin.1 = 0.75 inch
tmin.2 (nozzle wall nominal thickness)
tmin.3 (shell wall thickness)
tmin. = lesser of tmin.1, tmin. & tmin.3
Calculation of tc :
tc1 = 0.25 inch
tc2 = 0.7 t min.
tc = lesser of tc1 & tc2
By Considering Equal Legs Fillet Welds :
Leg of Outward Nozzle Weld = SQRT2 * tc
Use Leg with Dimension E in Dwg. No. 7443-33-1A
[Fig.UW-16 Sketch (c)]
* For Outer Reinforcing Pad Weld
tmin.1 = 0.75 inch
tmin.2 ( te = thk. of reinforcing element)
tmin.3 ( shell wall thickness)
tmin. = lesser of tmin.1, tmin. 2 & tmin.3
1/2 tmin.
By Considering Equal Legs Fillet Welds :
Leg of Outer Pad Weld = SQRT(2)*(tmin./2)
Use Leg with Dimension D in Dwg. No. 7443-33-1A

* Wall Thickness Required :


Shell
Nozzle
* Strength Reduction Factors :

[UG-27(c)(1)]
tr = PR / (SE - 0.6 P)
trn = PRn /(SnEn - 0.6 P)

Sp / Sv
fr1 = Sn / Sv
fr2 = Sn / Sv
fr3 = lesser of Sn/Sv or Sp/Sv
fr4 = Sp / Sv

0.75
0.432
0.56181
0.432
0.25
0.3024
0.25

INCH
INCH
INCH
INCH
INCH
INCH
INCH

318.1452 MM
180.5
MM
318.1452 MM

19.05
10.9728
14.27
10.9728
6.35
7.68096
6.35

MM
MM
MM
MM
MM
MM
MM

0.35355 INCH
0.35433 INCH

8.980256 MM
9
MM

0.75
0.5
0.5
0.5
0.25

19.05
12.7
12.7
12.7
6.35

MM
MM
MM
MM
MM

0.35355 INCH
0.35433 INCH

9
9

MM
MM

0.1255 INCH
0.03419 INCH

3.187732 MM
0.868379 MM

1
1
1
1
1

INCH
INCH
INCH
INCH
INCH

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 24 of 136
Sheet : 4 of 5
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
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

B. Wall Thickness per UG-45(b) :


trnb = Min. (trnb1, trnb2, trnb3, trnb 0.245
Wall Thickness per UG-45(b)(1), trnb1 = Min. (trnb11, trnb12)
0.2906
trnb11 = tr + C.A. (tr for shell or head at E=1)
0.32235
trnb12 = Min Wall Thickness per UG-16(b), see below
0.2906
Wall Thickness per UG-45(b)(2), trnb2 (apply to external pressure only),

INCH
INCH
INCH
INCH

6.223
7.38125
8.187732
7.38125

INCH

#VALUE! MM

INCH

#VALUE! MM

INCH

6.223

MM

INCH

7.112

MM

0.25935 INCH
0.44685 INCH

6.5875
11.35

MM
MM

0.2906

INCH

7.38125

MM

0.2906

INCH

7.38125

MM

INCH
INCH

6.223
9.6012

MM
MM

NA

Wall Thickness per UG-45(b)(3), trnb3 (apply to internal & external pressure)
= Max. (trnb1, trnb2)
NA
Wall Thickness per UG-45(b)(4), trnb4
= Min. thickness of std. wall pipe - 12.5% Max. (including CA)
0.245
(Under tolerance12.5% in accordance with ASME B36.10M)
Nominal thickness of std. pipe wall thickness, NPS 6", Sch. Std.
0.28
Wall Thickness per UG-16(b), trnb12
I - Min. Wall Thickness 1/16" + C.A.
II - Min. Wall Thickness of Unfired Steam Boilers = 1/4" + C.A.
III - Min. Wall Thickness of Shell/Head in Compressed Air
Service, Steam Service, and Water Service = 3/32" + C.A.
Selected Vessel Service in our case is : Case III (compressed air)
So, the Min. Wall Thickness per UG-16(b), trnb12

The min. nozzle wall thk. = Max. thk. determined by UG-45(a), or by UG-45(b)0.245
The min. nozzle thk. provided = t (1-0.125)
0.378
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).

5.868379 MM
MM
MM
MM
MM

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 25 of 136
Sheet : 5 of 5
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
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

Area Available in Shell, A1:


A11 = d (E1 t - F tr) - 2tn (E1 t - F tr)(1-fr1)
A12 = 2 (t + tn)(E1 t - F tr) - 2tn (E1 t - F tr)(1-f r1)
A1 = The Greater of A11 or A12
Area Available in Nozzle Projecting Outward, A2 :
A21 = 5 (tn - trn) fr2 t
A22 = 2 (tn - trn)(2.5tn+te) fr2
A2 = The Lesser of A21 or A22

0.17683 INCH
2
0.28007 INCH
2
0.17683 INCH

Area Available in Inward Nozzle, A3 : (Not applicable)


A31 = 5 t ti fr2
A32 = 5 ti ti fr2
A33 = 2 h ti fr2
A3 = The Greater of A31, A32 or A33

0.21797
0.16408
0
0

Area Available in Outward Nozzle Weld, A41:


2
A41 = (LEG) fr2

2
507.0808 MM

0.72114 INCH
2
0.09714 INCH
2
0.72114 INCH

2
465.2505 MM
2
62.67018 MM
2
465.2505 MM

2
114.0844 MM
2
180.691 MM
2
114.0844 MM

140.6242
105.8552
0
0

MM2
MM2
MM2
MM2

2
0.12555 INCH

81

MM2

Area Available in Outer Reinforcing Pad Weld, A42:


2
A42 = (LEG) fr4

2
0.12555 INCH

81

MM2

Area Available in Inward Nozzle Weld, A43 :


2
A43 = (LEG) fr2

INCH

MM2

Area Available in Reinforcing Pad, A5 :


A5 = (Dp - d - 2tn) te fr4

2.9502

INCH

2
1903.352 MM

Total Area Available, AT :


AT = A1 + A2 + A41 + A42 + A43 + A5

4.09927 INCH

2
2644.686 MM

AT is greater than A, therefore opening is adequately reinforced.


NOTE. No need for Strength Path Calculations.

INCH2
INCH2
INCH2
INCH2

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 26 of 136
Sheet : 1 of 5
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
Items : E-323A/B & E-514C/D

M2. Nozzle Mark : N1 & N2 6" 150# WNRF (Located at Channel) with reinforcement
Nozzle Neck Thickness Calculation
Nozzle Size, NPS
Nozzle Material

[UG-45, UG-27 & APPENDIX 1-1]


INCH
150
DN
6
ASME SA 106 Grade B

Design Pressure, P
Design Temperature
For nominated Design Pressure & Temperature, Flange Rating
[ ASME B16.5-1996]

71.708
140
150#

PSIG
F

5.04826
60

Kg/CM2G
o

Max. Allowable Stress of Nozzle Material @ Design Temp.(60 C), Sn


Max. Allowable Stress of Nozzle Materiall @ Test Temp.(40 oC), Snt
[Table 1A, SubPart 1, ASME Sec. II, Part D]

17100
17100

PSIG
PSIG

1203.84
1203.84

Kg/CM2G

Outside Radius of Nozzle, Ron


Joint Efficiency of Nozzle, En (Seamless Pipe)
Nozzle Corrosion Allowance, Can

3.3125 INCH
1
0.19685 INCH

84.1375

MM

MM

0.01387 INCH

0.352236 MM

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

Nozzle Neck Maximum Working Pressure, MWP (New & Operating)


Nozzle wall thickness less tolerance 12.5%
Nozzle wall thickness less tolerance 12.5% - Corrosion allowance
MWP, New & cold (10.97 MM) P = Snt E t /(Ron - 0.4 t)
[App. 1.1]
MWP, Operating & corroded (4.6 MM) P = Sn E t /(Ron - 0.4 t)

0.378
0.18115
2044.67
956.056

INCH
INCH

MM
MM

PSIG
PSIG

9.6012
4.6012
143.944
67.306

Nozzle Flange Maximum Working Pressure, MWP (New & Operating)


MWP, New & cold , 150# @ 100 oF
[ASME B.165, Table 2]
MWP, Operating & corroded, 150# @ 140 oF
[ASME B16.5, Table 2]

285
275

PSIG
PSIG

20.064
19.36

Kg/CM2G

Nozzle Thickness Calculation :


Longitudinal Stress, t = PRon /(Sn*En + 0.4 P)

[APPENDIX 1.1]

By adding Corrosion Allowance, t

with Thickness 0.432" ( 10.97 MM ).

[UG-25]

[Table 2 of ASME B 36.10M-1985-(R-1994)]

Kg/CM2G
Kg/CM2G

Kg/CM2G
Kg/CM2G

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 27 of 136
Sheet : 2 of 5
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
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
INCH
150
DN
6
Nozzle Pipe Sch.
80
Design Pressure, P
71.708 PSIG
5.048243 Kg/CM2G
o
o
F
C
Design Temparture
140
60
Shell Material
Nozzle Material
Reinforcing Pad Material
Allowable Stress of Shell Material, Sv
Allowable Stress of Nozzle Material, Sn
Allowable Stress of Pad Material, Sp

ASME SA106 Grade B


ASME SA 106 Grade B
ASME SA106 Grade B
17100
PSIG
1203.84
17100
PSIG
1203.84
17100
PSIG
1203.84

Kg/CM2G
Kg/CM2G
Kg/CM2G

Shell Thickness
Shell Corrosion Allowance, Cas
Shell Thickness less Pipe Tolerance 12.5%
Shell Thickness less Corrosion Allowance & 12.5%, t

0.5
0.19685
0.4375
0.24065

INCH
INCH
INCH
INCH

12.7
5
11.1125
6.1125

MM
MM
MM
MM

0.432
0.378
0.19685
0.18115
0.18115
0.5
1
1
1
1
20
19.5187
9.75935

INCH
INCH
INCH
INCH
INCH
INCH

10.9728
9.6012
5
4.6012
4.6012
12.7

MM
MM
MM
MM
MM
MM

INCH
INCH
INCH

508
MM
495.775 MM
247.8875 MM

INCH
INCH
INCH
INCH
INCH
INCH
INCH

168.275
146.3294
0
15.28125
11.503
159.0726
79.5363

(12.5% NA)

(12.5% NA)

Nozzle Wall Nominal Thickness


Nozzle Wall Thickness less Pipe Tolerance 12.5%
Nozzle Corrosion Allowance, Can
Nozzle Wall Thick. less Corr. Allowance & 12.5% , tn
Nozzle Wall Thick.of Internal Projection (less Corr. Allowance & 12.5%), ti

Reinforced Pad Thickness, te


Joint Efficiency of Shell, E
Joint Efficiency of Nozzle, En
Correction Factor, F
[UG-37(a)]
E1
[Nozzle in solid plate]
Shell Outside Diameter, OD
Shell Inside Diameter in Corroded Condition, 2R = OD - 2 t
Shell Inside Radius in Corroded Condition, R
Nozzle Outside Diameter, OD
Nozzle Inside Diameter, ID
Nozzle Projection beyond Inner Vessel Wall, h = min. (h1,h2)
h1 = 2.5 t
h2 = 2.5 ti
Nozzle ID Without Corrosion Allowance & 12.5% , d = OD - 2*tn

Finished Radius of Circular Opening, Rn

6.625
5.761
0
0.60162
0.45287
6.2627
3.13135

MM
MM
MM
MM
MM
MM
MM

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 28 of 136
Sheet : 3 of 5
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
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
Dp2 = 2 (Rn + nozzle wall thk. , tn + vessel wall thk. , t )
OD of Reinf. Pad, Dp = the greater of Dp1 or Dp2
[UW-16(c)(2) & Fig.UW-16.1]
Calculating Size of Fillet Welds :
* For Outward Nozzle Weld [UW-16(c)(2)&Fig.UW-16.1 Sketch (c)]
Calculation of tmin. :
tmin.1 = 0.75 inch
tmin.2 (nozzle wall nominal thickness)
tmin.3 (shell wall thickness)
tmin. = lesser of tmin.1, tmin. & tmin.3
Calculation of tc :
tc1 = 0.25 inch
tc2 = 0.7 t min.
tc = lesser of tc1 & tc2
By Considering Equal Legs Fillet Welds :
Leg of Outward Nozzle Weld = SQRT2 * tc
Use Leg with Dimension E in Dwg. No. 7443-33-1A
[Fig.UW-16 Sketch (c)]
* For Outer Reinforcing Pad Weld
tmin.1 = 0.75 inch
tmin.2 ( te = thk. of reinforcing element)
tmin.3 ( shell wall thickness)
tmin. = lesser of tmin.1, tmin. 2 & tmin.3
1/2 t min.
By Considering Equal Legs Fillet Welds :
Leg of Outer Pad Weld = SQRT(2)*(tmin./2)
Use Leg with Dimension D in Dwg. No. 7443-33-1A

* Wall Thickness Required :


Shell
Nozzle
* Strength Reduction Factors :

[UG-27(c)(1)]
tr = PR / (SE - 0.6 P)
trn = PRn /(SnEn - 0.6 P)

Sp / Sv
fr1 = Sn / Sv
fr2 = Sn / Sv
fr3 = lesser of Sn/Sv or Sp/Sv
fr4 = Sp / Sv

12.5254 INCH
7.1063 INCH
12.5254 INCH

318.1452 MM
180.5
MM
318.1452 MM

0.75
0.432
0.5
0.432
0.25
0.3024
0.25

19.05
10.9728
12.7
10.9728
6.35
7.68096
6.35

INCH
INCH
INCH
INCH
INCH
INCH
INCH

MM
MM
MM
MM
MM
MM
MM

0.35355 INCH
0.35433 INCH

8.980256 MM
9
MM

0.75
0.5
0.5
0.5
0.25

19.05
12.7
12.7
12.7
6.35

MM
MM
MM
MM
MM

0.35355 INCH
0.35433 INCH

9
9

MM
MM

0.04829 INCH
0.03419 INCH

1.226577 MM
0.868379 MM

1
1
1
1
1

INCH
INCH
INCH
INCH
INCH

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 29 of 136
Sheet : 4 of 5
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
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

B. Wall Thickness per UG-45(b) :


trnb = Min. (trnb1, trnb2, trnb3, trnb 0.245
Wall Thickness per UG-45(b)(1), trnb1 = Min. (trnb11, trnb12)
0.24514
trnb11 = tr + C.A. (tr for shell or head at E=1)
0.24514
trnb12 = Min Wall Thickness per UG-16(b), see below
0.2906
Wall Thickness per UG-45(b)(2), trnb2 (apply to external pressure only),

INCH
INCH
INCH
INCH

6.223
6.226577
6.226577
7.38125

INCH

#VALUE! MM

INCH

#VALUE! MM

INCH

6.223

MM

INCH

7.112

MM

0.25935 INCH
0.44685 INCH

6.5875
11.35

MM
MM

0.2906

INCH

7.38125

MM

0.2906

INCH

7.38125

MM

INCH
INCH

6.223
9.6012

MM
MM

NA

Wall Thickness per UG-45(b)(3), trnb3 (apply to internal & external pressure)
= Max. (trnb1, trnb2)
NA
Wall Thickness per UG-45(b)(4), trnb4
= Min. thickness of std. wall pipe - 12.5% Max. (including CA) 0.245
(Under tolerance12.5% in accordance with ASME B36.10M)
Nominal thickness of std. pipe wall thickness, NPS 6", Sch. Std0.28
Wall Thickness per UG-16(b), trnb12
I - Min. Wall Thickness 1/16" + C.A.
II - Min. Wall Thickness of Unfired Steam Boilers = 1/4" + C.A.
III - Min. Wall Thickness of Shell/Head in Compressed Air
Service, Steam Service, and Water Service = 3/32" + C.A.
Selected Vessel Service in our case is : Case III (compressed air)
So, the Min. Wall Thickness per UG-16(b), trnb12

The min. nozzle wall thk. = Max. thk. determined by UG-45(a), or by UG-45(b)0.245
The min. nozzle thk. provided = t (1-0.125)
0.378
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).

5.868379 MM
MM
MM
MM
MM

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 30 of 136
Sheet : 5 of 5
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
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

Area Available in Shell, A1:


A11 = d (E1 t - F tr) - 2tn (E1 t - F tr)(1-fr1)
A12 = 2 (t + tn)(E1 t - F tr) - 2tn (E1 t - F tr)(1-f r1)
A1 = The Greater of A11 or A12
Area Available in Nozzle Projecting Outward, A2 :
A21 = 5 (tn - trn) fr2 t
A22 = 2 (tn - trn)(2.5tn+te) fr2
A2 = The Lesser of A21 or A22

0.17683 INCH
2
0.28007 INCH
2
0.17683 INCH

Area Available in Inward Nozzle, A3 :


A31 = 5 t ti fr2
A32 = 5 ti ti fr2
A33 = 2 h ti fr2
A3 = The Greater of A31, A32 or A33

0.21797
0.16408
0
0

Area Available in Outward Nozzle Weld, A41:


2
A41 = (LEG) fr2

2
195.1147 MM

1.20469 INCH
2
0.16227 INCH
2
1.20469 INCH

2
777.2165 MM
2
104.6926 MM
2
777.2165 MM

2
114.0844 MM
2
180.691 MM
2
114.0844 MM

140.6242
105.8552
0
0

MM2
MM2
MM2
MM2

2
0.12555 INCH

81

MM2

Area Available in Outer Reinforcing Pad Weld, A42:


2
A42 = (LEG) fr4

2
0.12555 INCH

81

MM2

Area Available in Inward Nozzle Weld, A43 :


2
A43 = (LEG) fr2

INCH

MM2

Area Available in Reinforcing Pad, A5 :


A5 = (Dp - d - 2tn) te fr4

2.9502

INCH

2
1903.352 MM

Total Area Available, AT :


AT = A1 + A2 + A41 + A42 + A43 + A5

4.58282 INCH

2
2956.652 MM

AT is greater than A, therefore opening is adequately reinforced.


NOTE. No need for Strength Path Calculations.

INCH
INCH2
INCH2
INCH2

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 31 of 136
Sheet : 1 of 5
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
Items : E-323A/B & E-514C/D

M4a. Nozzle Mark : N1 & N2 6" 150# WNRF (Located at Shell) without reinforcement
Nozzle Neck Thickness Calculation
Nozzle Size, NPS
Nozzle Material

[UG-45 , UG-27 & APPENDIX 1-1]


INCH
150
DN
6
ASME SA 106 Grade B

Design Pressure, P
Design Temperature
For nominated Design Pressure & Temperature, Flange Rating
[ANSI/ASME B16.5-1996]

71.708
140
150#

PSIG
F

5.04826
60

Kg/CM2G
o

Allowable Stress of Nozzle Material @ Design Temp. (60 C), Sn


Max. Allowable Stress of Nozzle Materiall @ Test Temp.(40 oC), Snt
[Table 1A, SubPart 1, ASME Sec. II, Part D]

17100
17100

PSIG
PSIG

1203.84
1203.84

Kg/CM2G

Outside Radius of Nozzle, Ron


Joint Efficiency of Nozzle, En (Seamless Pipe)
Nozzle Corrosion Allowance, Can

3.3125 INCH
1
0.19685 INCH

84.1375

MM

MM

0.01387 INCH

0.352236 MM

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,


with Thickness 0.432" ( 10.97 MM ).
[Table 2 of ANSI B 36.10M-1985-(R-1994)]

0.432

INCH

10.9728

MM

Nozzle Neck Maximum Working Pressure, MWP (New & Operating)


Nozzle wall thickness less tolerance 12.5%
Nozzle wall thickness less tolerance 12.5% - Corrosion allowance
MWP, New & cold (10.97 MM) P = Snt E t /(Ron - 0.4 t)
[App. 1.1]
MWP, Operating & corroded (4.6 MM) P = Sn E t /(Ron - 0.4 t)

0.378
0.18115
2044.67
956.056

INCH
INCH

MM
MM

PSIG
PSIG

9.6012
4.6012
143.944
67.306

Nozzle Flange Maximum Working Pressure, MWP (New & Operating)


MWP, New & cold , 150# @ 100 oF
[ASME B.165, Table 2]
MWP, Operating & corroded, 150# @ 140 oF
[ASME B16.5, Table 2]

285
275

PSIG
PSIG

20.064
19.36

Kg/CM2G

Nozzle Thickness Calculation :


Longitudinal Stress, t = PRon /(Sn*En + 0.4 P)

[APPENDIX 1.1]

By adding Corrosion Allowance, t

[UG-25]

Kg/CM2G
Kg/CM2G

Kg/CM2G
Kg/CM2G

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 32 of 136
Sheet : 2 of 5
Date : 11.4.2004

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)

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

Client : APRC
Location : Alex.

Client : APRC
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
INCH
150
DN
6
Nozzle Pipe Sch.
80
Design Pressure, P
71.708 PSIG
5.048243 Kg/CM2G
o
o
F
C
Design Temparture
140
60
Shell Material
Nozzle Material
Reinforcing Pad Material
Allowable Stress of Shell Material, Sv
Allowable Stress of Nozzle Material, Sn
Allowable Stress of Pad Material, Sp

ASME SA106 Grade B


ASME SA 106 Grade B
N.A.
17100
PSIG
1203.84
17100
PSIG
1203.84
0
PSIG
0

Kg/CM2G
Kg/CM2G
Kg/CM2G

Shell Thickness
Shell Corrosion Allowance, Cas
Shell Thickness less Pipe Tolerance 12.5% (12.5% NA)
Shell Thickness less Corrosion Allowance & 12.5%, t (12.5% NA)

0.5
0.19685
0.4375
0.24065

INCH
INCH
INCH
INCH

12.7
5
11.1125
6.1125

MM
MM
MM
MM

Nozzle Wall Nominal Thickness


Nozzle Wall Thickness less Pipe Tolerance 12.5%
Nozzle Corrosion Allowance, Can

0.432
0.378
0.19685
0.18115
0.18115
0
1
1
1
1
20
19.5187
9.75935

INCH
INCH
INCH
INCH
INCH
INCH

10.9728
9.6012
5
4.6012
4.6012
0

MM
MM
MM
MM
MM
MM

INCH
INCH
INCH

508
MM
495.775 MM
247.8875 MM

INCH
INCH
INCH
INCH
INCH
INCH
INCH

168.275
146.3294
0
15.28125
11.503
159.0726
79.5363

Nozzle Wall Thick. less Corr. Allowance & 12.5% , tn


Nozzle Wall Thick.of Internal Projection (less Corr. Allowance & 12.5%), ti

Reinforced Pad Thickness, te


Joint Efficiency of Shell, E
Joint Efficiency of Nozzle, En
Correction Factor, F
[UG-37(a)]
E1
[Nozzle in solid plate]
Shell Outside Diameter, OD
Shell Inside Diameter in Corroded Condition, 2R = OD - 2 t
Shell Inside Radius in Corroded Condition, R
Nozzle Outside Diameter, OD
Nozzle Inside Diameter, ID
Nozzle Projection beyond Inner Vessel Wall, h = min. (h1,h2)
h1 = 2.5 t
h2 = 2.5 ti
Nozzle ID Without Corrosion Allowance & 12.5% , d = OD - 2*tn

Finished Radius of Circular Opening, Rn

6.625
5.761
0
0.60162
0.45287
6.2627
3.13135

MM
MM
MM
MM
MM
MM
MM

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 33 of 136
Sheet : 3 of 5
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
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
Dp2 = 2 (Rn + nozzle wall thk. , tn + vessel wall thk. , t )
OD of Reinf. Pad, Dp = the greater of Dp1 or Dp2
[UW-16(c)(2)&FIG.UW-16.1]
Calculating Size of Fillet Welds :
* For Outward Nozzle Weld [UW-16(c)(2)&FIG.UW-16.1SKETCH (c)]
Calculation of tmin. :
tmin.1 = 0.75 inch
tmin.2 (nozzle wall nominal thickness)
tmin.3 (shell wall thickness)
tmin. = lesser of tmin.1, tmin. & tmin.3
Calculation of tc :
tc1 = 0.25 inch
tc2 = 0.7 t min.
tc = lesser of tc1 & tc2
By Considering Equal Legs Fillet Welds :
Leg of Outward Nozzle Weld = SQRT2 * tc
Use Leg with Dimension E in Dwg. No. 7443-33-1A

* For Outer Reinforcing Pad Weld (NA) [FIG.UW-16 SKETCH (c)]


tmin.1 = 0.75 inch
tmin.2 ( te = thk. of reinforcing element)
tmin.3 ( shell wall thickness)
tmin. = lesser of tmin.1, tmin. 2 & tmin.3
1/2 t min.
By Considering Equal Legs Fillet Welds :
Leg of Outer Pad Weld = SQRT(2)*(tmin./2)
Use Leg with Dimension D in Dwg. No. 7443-33-1A
* Wall Thickness Required :
Shell
Nozzle

[UG-27(c)(1)]
tr = PR / (SE - 0.6 P)
trn = PRn /(SnEn - 0.6 P)

* Strength Reduction Factors :


Sp / Sv
fr1 = Sn / Sv
fr2 = Sn / Sv
fr3 = lesser of Sn/Sv or Sp/Sv
fr4 = Sp / Sv

12.5254 INCH
7.1063 INCH
0
INCH

318.1452 MM
180.5
MM
0
MM

0.75
0.432
0.5
0.432
0.25
0.3024
0.25

19.05
10.9728
12.7
10.9728
6.35
7.68096
6.35

INCH
INCH
INCH
INCH
INCH
INCH
INCH

MM
MM
MM
MM
MM
MM
MM

0.35355 INCH
0.35433 INCH

8.980256 MM
9
MM

0.75
0
0.5
0
0

INCH
INCH
INCH
INCH
INCH

19.05
0
12.7
0
0

MM
MM
MM
MM
MM

0
0

INCH
INCH

0
0

MM
MM

0.04829 INCH
0.01316 INCH
0
1
1
1
0

1.226577 MM
0.334373 MM

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 34 of 136
Sheet : 4 of 5
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
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

B. Wall Thickness per UG-45(b) :


trnb = Min. (trnb1, trnb2, trnb3, trnb 0.245
Wall Thickness per UG-45(b)(1), trnb1 = Min. (trnb11, trnb12)
0.24514
trnb11 = tr + C.A. (tr for shell or head at E=1)
0.24514
trnb12 = Min Wall Thickness per UG-16(b), see below
0.2906
Wall Thickness per UG-45(b)(2), trnb2 (apply to external pressure only),

INCH
INCH
INCH
INCH

6.223
6.226577
6.226577
7.38125

INCH

#VALUE! MM

INCH

#VALUE! MM

INCH

6.223

MM

INCH

7.112

MM

0.25935 INCH
0.44685 INCH

6.5875
11.35

MM
MM

0.2906

INCH

7.38125

MM

0.2906

INCH

7.38125

MM

INCH
INCH

6.223
9.6012

MM
MM

NA

Wall Thickness per UG-45(b)(3), trnb3 (apply to internal & external pressure)
= Max. (trnb1, trnb2)
NA
Wall Thickness per UG-45(b)(4), trnb4
= Min. thickness of std. wall pipe - 12.5% Max. (icluding CA)
0.245
(Under tolerance12.5% in accordance with ASME B36.10M)
Nominal thickness of std. pipe wall thickness, NPS 6", Sch. Std.
0.28
Wall Thickness per UG-16(b), trnb12
I - Min. Wall Thickness 1/16" + C.A.
II - Min. Wall Thickness of Unfired Steam Boilers = 1/4" + C.A.
III - Min. Wall Thickness of Shell/Head in Compressed Air
Service, Steam Service, and Water Service = 3/32" + C.A.
Selected Vessel Service in our case is : Case III (compressed air)
So, the Min. Wall Thickness per UG-16(b), trnb12

The min. nozzle wall thk. = Max. thk. determined by UG-45(a), or by UG-45(b)0.245
The min. nozzle thk. provided = t (1-0.125)
0.378
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).

5.334373 MM
MM
MM
MM
MM

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 35 of 136
Sheet : 5 of 5
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
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

Area Available in Shell, A1:


A11 = d (E1 t - F tr) - 2tn (E1 t - F tr)(1-fr1)
A12 = 2 (t + tn)(E1 t - F tr) - 2tn (E1 t - F tr)(1-f r1)
A1 = The Greater of A11 or A12
Area Available in Nozzle Projecting Outward, A2 :
A21 = 5 (tn - trn) fr2 t
A22 = 5 (tn - trn) fr2 tn
A2 = The Lesser of A21 or A22

0.20213 INCH
2
0.15215 INCH
2
0.15215 INCH

Area Available in Inward Nozzle, A3 : (Not applicable)


A31 = 5 t ti fr2
A32 = 5 ti ti fr2
A33 = 2 h ti fr2
A3 = The Greater of A31, A32 or A33

0.21797
0.16408
0
0

Area Available in Outward Nozzle Weld, A41:


2
A41 = (LEG) fr2

2
0.12555 INCH

Area Available in Outer Reinforcing Pad Weld, A42:


2
A42 = (LEG) fr4

Area Available in Inward Nozzle Weld, A43 :


2
A43 = (LEG) fr2

Area Available in Reinforcing Pad, A5 : (Not applicable)


A5 = (Dp - d - 2tn) te fr4

Total Area Available, AT :


AT = A1 + A2 + A41 + A42 + A43

1.48239 INCH

AT is greater than A, therefore opening is adequately reinforced.


NOTE. No need for Strength Path Calculations.

2
195.1147 MM

1.20469 INCH
2
0.16227 INCH
2
1.20469 INCH

2
777.2165 MM
2
104.6926 MM
2
777.2165 MM

2
130.4049 MM
2
98.16263 MM
2
98.16263 MM

INCH2
INCH2
INCH2
INCH2

140.6242
105.8552
0
0

MM2
MM2
MM2
MM2

81

MM2

INCH2

MM2

INCH

MM2

INCH2

MM2

2
956.3792 MM

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 1 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

N. Integral Type (WN) Main Shell Flange Thickness (item no. 4)


Flange Material,
[Attached by Bolts]
Design Temperature (shell side)
Min. Design Metal Temperature, MDMT
Bolt-up and Gasket Seating Temperature
Assume no corrosion, C
[UG-25]
Operating Pressure (shell side)
Internal Design Pressure, P (MAWP)
Allowable Stress of Bolt Material (ASME SA193 Gr. B7), SB :

Sheet : 5

Item : E-323A/B & E-514C/D


[Appendix 2] [FIG. 2-4, Sketch (6a)]

ASME SA266 ClassSubjected to internal press.


o
o
F
C
302
150
o
o
F
C
53.6
12
o
o
F
C
86
30
0.19685 INCH
5
MM
Kg/CM2G
241.477 PSIG
17
284.776 PSIG
20.0483 Kg/CM2G
25000
25000

PSIG
PSIG

1760
1760

Kg/CM2G
Kg/CM2G

20000

PSIG

1408

Kg/CM2G

* or at atmospheric temp./bolt-up temp. (gasket seating), SfC


20000
Allowable Stress of Nozzle neck, Vessel or Pipe wall Material (ASME SA106 Gr. B) :
* at design temp.(operating condition), SnH
17100

PSIG

1408

Kg/CM2G

PSIG

2
1203.84 Kg/CM G

PSIG

2
1203.84 Kg/CM G

INCH

25.4

MM

28
685
482.6
623
12.7

MM
MM
MM
MM
MM

25.4
38
40
44

MM
MM
MM
MM

6.35
6
5
31

MM
MM
MM
MM

* at design temp.(operating condition), Sb


* or at atmospheric temp./bolt-up temp. (gasket seating), Sa
Allowable Stress of Flange Material (ASME SA266 Class 2) :
* at design temp.(operating condition), SfH

* or at atmospheric temp./bolt-up temp.(gasket seating), SnC

17100

[Table 1A , SubPart 1 , ASME Sec. II , Part D]

FIG. 2-4, Sketch (6a)


Figure (1)

Nominal bolt dia., dB

No. of bolts

28
1

Bolt Hole, d
Flange outside diameter, A
Flange inside diameter, B
Bolt circut diameter (B.C.D.), C = B + 2(g1 + h1+ R) [Appendix 2-3]
Hup thickness at small end, go = Shell Thickness t

1.10236
26.9685
19
24.5276
0.5

INCH
INCH
INCH
INCH

Hup thickness at back of flange, g1 (assume g1 = 2 go)


R must not less than 1.5 the bolt hole (see TEMA Table D-5)
Hup length, h (must greater than 1.5 go) [FIG. 2-4, Sketch 6]
Use max. slope 1:3, h = 3.5 g0
Slope angle, Y = arc Tan [(g1-go)/h]
Fillet radius, r = 0.25 g1 [but not less than 3/16"(4.7625 MM)] [FIG. 2-4, Sketch 6, Note a]
Use r
h1 = r * Tan (45-Y/2)
E = (A-C)/2

1
1.5
1.5748
1.73228
16.1001
0.25
0.23622
0.17768
1.22047

INCH

(Check D292 )

INCH
INCH
INCH
INCH

Degree
INCH
INCH
INCH
INCH

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 2 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 5

Item : E-323A/B & E-514C/D

N. Integral Type (W.N.) Main Shell Flange Thickness, item no. 4 (cont.)
[Attached by Bolts]
Nominal shell (pipe) size
Pipe Schedule
No. of bolts
Nominal bolt dia., dB
Bolt diameter at root of thread

Subjected to internal pressure


20"
30
28
1
INCH
25.4
MM
0.88189 INCH
22.4
MM

Actual cross-sectional area of each bolt,


Total actual cross-sectional area of bolts, Ab

0.551
15.428

[Appendix 2] [FIG. 2-4, Sketch (6a)]

[TEMA Table D-5]

Flange outside diameter, A


Flange inside diameter, B
Bolt circut diameter (B.C.D.), C
Gasket Details: - Flat metal, jacketed asbestos filled, iron or soft steel
- Outside diameter = (B.C.D - d) - 2*13
- Inside diameter = O.D - 2N
- Width, N
Gasket Dimensions:
[Table 2-5.2]
Basic gasket seating width, bO = N/2
Since bo > 1/4 inch (6.35 MM),
[Table 2-5.2]
Effective gasket seating width, b = 0.5*SQRT(bO)
[Table 2-5.2]
Gasket Factor, m
[Table 2-5.1]
Min. Seating Stress, y
[Table 2-5.1]
Facing Sketch
[Table 2-5.1]
Diameter at location of gasket load reaction, G
When bo is larger than 1/4", G = O.D.of gasket contact face - 2 b

685
482.6
623

MM
MM
MM

22.0472 INCH
20.8661 INCH
0.59055 INCH

560
530
15

MM
MM
MM

0.29528 INCH

7.5

MM

0.2717
INCH
3.75
7600
PSIG
(1a); Column II

6.90109 MM

21.5039 INCH

546.198 MM

[Table 2-5.2]

N.B. When b > 1/4", the effective gasket seating width, b = 0.5*SQRT(bO)

INCH2

2
355.483 MM
2
9953.53 MM

26.9685 INCH
19
INCH
24.5276 INCH

[ Appendix 2-3]

N.B. When b < 1/4", the effective gasket seating width, b = bo

INCH2

[Table 2-5.2]

535.04

Kg/CM2G

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 3 of 10
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

Date : 4.7.2003
Location : Alex.

Client : APRC

Sheet : 5

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 G2 P
[Appendix 2-3]
(b) Total joint-contact surface compression load, Hp =2b*3.14GmP

103373
39182.8

lb
lb

46889.2 Kg
17773
Kg

142556
139426

lb
lb

64662.2 Kg
63242.6 Kg

25000
25000

PSIG
PSIG

1760
1760

5.70222
5.57703

INCH2
INCH2

2
3678.84 MM
2
3598.08 MM

5.70222
15.428
OK

INCH2
INCH2

2
3678.84 MM
2
9953.53 MM

142556
264128

lb
lb

64662.2 Kg
119806 Kg

80701.4

lb

36605.6 Kg

39182.8

lb

17773

22671.4

lb

10283.6 Kg

[Table 2-6]

2.17768

INCH

55.3131 MM

hG = (C - G) / 2

[Table 2-6]

1.51185

INCH

38.4011 MM

hT = (R' + g1 + hG) / 2

[Table 2-6]

2.09477

INCH

53.2071 MM

1.67768

INCH

42.6131 MM

[Appendix 2-3]

(c) Min. required bolt load for operating conditions, Wm1 = H + Hp


Min. required bolt load for gasket seating, Wm2 = 3.14 b G y
Allowable Bolt Stress at atmospheric temp., Sa
Allowable Bolt Stress at design temp., Sb

Kg/CM2G
Kg/CM2G

[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
- Gasket seating,
Am2 = Wm2 / Sa
[Appendix 2-3]
Total required cross-sectional of bolts, Am = the greater of Am1 & Am2

Actual bolt area Ab


Since area Ab > area Am, the bolts are adequately enough.
(e) Flange design bolt load, W :
- For operating conditions, Wo = Wm1
[Appendix 2-5(d)]
- For gasket seating, Wa = 0.5(Am + Ab) * Sa
[Appendix 2-5(d)]
2. Total flange moment for design condition:
[Appendix 2-5(c)]
Flange Loads:
Hydrostatic end force on area inside flange, HD = 0.785 B2 P
Gasket load (flange design bolt load - total hydrostatic end force), HG

Gasket seating force

H G = Wm1 - H

Kg

Difference bet. total hydrostatic end force and the hydrostatic end force on area inside of flange, HT

HT = H - HD
Lever arms:
hD = R' + 0.5 g1

Where R' = R + h1

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 4 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 5

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 HD, MD = HD hD

[Appendix 2-3]

175742

lb-in

2024.77 Kg-M

Component of moment due to HG, MG = HG hG

[Appendix 2-3]

59238.6

lb-in

682.503 Kg-M

Component of moment due to HT, MT = HT hT

[Appendix 2-3]

47491.3

lb-in

547.16

282472
23539.3

lb-in
lb-ft

3254.43 Kg-M

264128

lb

119806

Total moment acting upon the flange, Mo:


- For operating condition

Kg-M

[Appendix 2-6]

MO1 = MD + MG + MT

3. Total flange moment for bolt-up condition (Gasket condition):


[Appendix 2-6]

Flange Load:

HG = W A = 0.5 (Am + Ab) * Sa

Lever Arm., hG = (C - G) / 2
Flange Moment for gasket condition, M O2 = HG hG = W A (C - G) / 2

(5)

Mo2 * (SfH / SfC )


4. MO = The greater of MO1 or MO2 (SfH/SfC)

Kg

1.51185 INCH

38.4011 MM

399323

lb-in

4600.7

Kg-M

399323
399323
33276.9

lb-in
lb-in
lb-ft

4600.7
4600.7

Kg-M
Kg-M

5. Shape constants for flange:


K=

From Appendix 2, FIG. 2-7.1:

T =
Z=

1.41939

K (1 + 8.55246 Log10 k ) 1
(1.04720 + 1.9448 k 2 )( k 1)
2

1.74578

K2 + 1

2.97106

K2 1

K Log10 K
1
0.66845 + 5.71690
K 1
K2 1

2
K (1 + 8.55246 Log K ) 1
10
U =
1.36136 ( K 2 1)( K 1)
2

Y =

From Appendix 2, FIG. 2-7.2:


From Appendix 2, FIG. 2-7.3:
From Appendix 2, FIG. 2-7.6:

g1/go
ho = SQRT(B go)
h/ho
F
V
f

d = (U/V) ho go2 (for integral type flanges) [APPENDIX 2-3]


e = F / ho
(for integral type flanges) [APPENDIX 2-3]

5.71057
6.27534
2
3.08221
0.56203
0.81225
0.21166
1.02557
22.8457 INCH3
0.26353 INCH-1

3
374374 MM
-1
0.01038 MM

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 5 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 5

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

[Attached by Bolts]

6. Calculation of flange actual stresses


Assume t
Factor L =

te + 1 t ^ 3
+
d
T

Where t = flange thickness


factor e = F/ ho (for integral type flanges)
e = FL/ ho (for loose type flanges)
F = factor for integral type flanges
T = factor involving K
d = (U/V) ho go2

[Appendix 2-3]
[Appendix 2-3]
[Appendix 2-3]
[Fig. 2-7.2]
[Fig. 2-7.1]
[Appendix 2-3]

For integral type flange, actual stresses (calculated) : [Fig. 2-4, Sketch (6a)]
1. a. Longitudinal hub stress, operating SH = f Mo / L g12 B (6) [Appendix 2-7(a)]
b. Longitudinal hub stress, seating
SH = f Mo2 / L g12 B (6) [Appendix 2-7(a)]

1.45669
0.928

INCH

0.26353 INCH-1
NA
0.81225
1.74578
22.8457 INCH3

37

MM

-1
0.01038 MM

374374

MM3

23226.7

PSIG

2
1635.16 Kg/CM G

23226.7

PSIG

2
1635.16 Kg/CM G

2. a. Radial flange stress, operating SR = (1.33 t e +1) Mo / L t2 B (7) [Appendix 2-7(a 16135.7

PSIG

2
1135.96 Kg/CM G

SR = (1.33 t e +1) Mo2 / L t2 B (7) [Appendix 2-7(a 16135.7

PSIG

2
1135.96 Kg/CM G

3. a. Tangential flange stress, operating ST = (Y Mo / t2 B) - Z SR (8) [Appendix 2-7(a)] 8620.34

PSIG

2
606.872 Kg/CM G

ST = (Y Mo2 / t2 B) - Z SR (8) [Appendix 2-7(a)8620.34

PSIG

2
606.872 Kg/CM G

b. Radial flange stress, seating

b. Tangential flange stress, seating


4. a. Flange stress, operating

0.5 (SH + SR)

[Appendix 2-8(a)(4)]

19681.2

PSIG

2
1385.56 Kg/CM G

b. Flange stress, seating

0.5 (SH + SR)

[Appendix 2-8(a)(4)]

19681.2

PSIG

2
1385.56 Kg/CM G

5. a. Flange stress, operating

0.5 (SH + ST)

[Appendix 2-8(a)(4)]

15923.5

PSIG

2
1121.02 Kg/CM G

b. Flange stress, seating


0.5 (SH + ST)
6. a. Bolt stress, operating = Wm1 / Ab
b. Bolt stress, seating = Wm2 / Ab
7. a. Shear stress carried by the fillet weld

[Appendix 2-8(a)(4)]

15923.5
9240.05
9037.19
0

PSIG
PSIG
PSIG
PSIG

1121.02
650.5
636.219
0

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
Allowable design stress of nozzle/vessel at operating condition, Sn
17100
PSIG
Assume flange thickness (without C.A), toperating
1.45669 INCH
Allowable stresses
PSIG

Longitudinal Hub Stress SH1 = 1.5 Sf

[Appendix 2-8(a)(1)(b)]

30000

Longitudinal Hub Stress SH2 = 2 Sn

[Appendix 2-8(a)(1)(b)]

34200

The calculated (actual) hub stress S H < SH (min.) allowable


Radial Flange Stress SR = Sf

[Appendix 2-8(a)(2)]

The calculated (actual) radial stress S R < SR allowable

Kg/CM2

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

Kg/CM2G
1408
1203.84 Kg/CM2G
37
MM

Actual stresses
(Calculated )
Kg/CM2
PSIG

30000

>

23226.7

20000

>

16135.7

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 6 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 5

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)]

20000

Subjected to internal pressure


>
8620.34

0.5(SH + SR) = Sf
< Allowable stress

20000

>

19681.2

0.5(SH + ST) = Sf
< Allowable stress

20000

>

15923.5

25000

>

9240.05

Tangential Flange Stress ST = Sf

[Appendix 2-8(a)(3)]

The calculated (actual) tangential stress S T < ST allowable

The calculated (actual) stress

The calculated (actual) stress


Bolt stress = Wm1 / Ab
The calculated (actual) stress

< Allowable stress

7.b. For Gasket Seating :


20000
PSIG
17100
PSIG
1.45669 INCH

Allowable design stress of flange at gasket seating, Sf


Allowable design stress of nozzle/vessel at gasket seating, Sn

Assume flange thickness (without C.A), tgasket

Allowable stresses
PSIG

Longitudinal Hub Stress SH1 = 1.5 Sf

[Appendix 2-8(a)(1)(b)]

30000

Longitudinal Hub Stress SH2 = 2 Sn

[Appendix 2-8(a)(1)(b)]

34200

The calculated (actual) hub stress S H < SH (min.) allowable

Kg/CM2

Kg/CM2G
1408
1203.84 Kg/CM2G
37
MM

Actual stresses
(Calculated )
Kg/CM2
PSIG

30000

>

23226.7

20000

>

16135.7

20000

>

8620.34

20000

>

19681.2

The calculated (actual) stress

0.5(SH + SR) = Sf
< Allowable stress
0.5(SH + ST) = Sf
< Allowable stress

20000

>

15923.5

The calculated (actual) stress


Bolt stress = Wm2 / Ab
The calculated (actual) stress

25000

>

9037.19

< Allowable stress

Radial Flange Stress SR = Sf

[Appendix 2-8(a)(2)]

The calculated (actual) radial stress S R < SR allowable


Tangential Flange Stress ST = Sf

[Appendix 2-8(a)(3)]

The calculated (actual) tangential stress S T < ST allowable

The min. flange thickness, t = Max. (toperating, tgasket)

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 7 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 5

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
Gasket width, N
Total required cross-sectional area of bolts
Actual bolt cross-sectional area, Ab
Nominal bolt dia., dB

1.41939
0.59055 INCH
5.70222 INCH2
INCH2
15.428
1
INCH

15
3678.84
9953.53
25.4

MM
MM2
MM2
MM

1. Actual Edge distance, E from drawing = 1/2 (A - C)


1.22047 INCH
Min. Edge distance, E (for bolt size 0.75")
0.8125
INCH
Min. Edge distance, E (for bolt size 7/8")
0.9375
INCH
Min. Edge distance, E (for bolt size 1")
1.0625
INCH
Min. Edge distance, E (for bolt size 1-1/8")
[TEMA Table D-5]
1.125
INCH
Min. Edge distance, E (for bolt size 1-1/4")
1.25
INCH
2. Actual Bolt spacing, B from drawing
2.74622 INCH
Min. Bolt spacing, B (for bolt size 0.75")
1.75
INCH
Min. Bolt spacing, B (for bolt size 7/8")
2.0625
INCH
Min. Bolt spacing, B (for bolt size 1")
2.25
INCH
Min. Bolt spacing, B (for bolt size 1-1/8")
[TEMA Table D-5]
2.5
INCH
Min. Bolt spacing, B (for bolt size 1-1/4")
2.8125
INCH
Max. Recommended bolt spacing, Bmax = 2 dB + 6 t / (m + 0.5) [TEMA RCB-11.224.05651 INCH
3. Actual Radial distance, Rh from drawing = (C-B)/2-(g1+h1)
1.56693 INCH
Min. Radial distance, Rh (for bolt size 0.75")
1.125
INCH
Min. Radial distance, Rh (for bolt size 7/8")
1.25
INCH
Min. Radial distance, Rh (for bolt size 1")
1.375
INCH
Min. Radial distance, Rh (for bolt size 1-1/8")
[TEMA Table D-5]
1.5
INCH
Min. Radial distance, Rh (for bolt size 1-1/4")
1.75
INCH

31
20.6375
23.8125
26.9875
28.575
31.75
69.7539
44.45
52.3875
57.15
63.5
71.4375
103.035
39.8
28.575
31.75
34.925
38.1
44.45

MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 8 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

N. Integral Type (W.N.) Main Shell Flange Thickness, item no. 4 (cont.)
FLANGE FACTORS
(a) For Integral Flanges
E
F =
Factor F per Fig. 2-7.2 is then solved by
(1 + A )
C
6

V =

Factor V per Fig. 2-7.3 is then solved by

2.7 3

]1/ 4

Sheet : 5

Item : E-323A/B & E-514C/D


[Appendix 2] [FIG. 2-4, Sketch (6a)]

Subjected to internal pressure


0.81225

E4
2.73 1/ 4
[
]
(1 + A ) 3
C

0.21166

h/SQRT(BGo 0.562026971
f = C36 / (1 + A)
1.02557
The values used in the above equations are solved using Eqs. (1) through (45) below based on the values g1, g0, h and ho

Factor f per Fig. 2-7.6 is then solved by

as defined by 2-3. When g1 = go, F = 0.908920, V = 0.550103, and f = 1; thus Eqs. (1) through (45) need not be solved.
(b) For Loose Hub Flanges
Factor FL per Fig. 2-7.4 is solved by

FL =

1
C 18
+
2

11A
A
A
A
1
1
1
+
+

+ C 21
+ C 24

4
70
40
6
84
105
72
1/ 4
3
(1 + A )
C

2 .7 3
C

Factor VL per Fig. 2-7.5 is solved by

VL

1
3C 21
C
24
C18
4
5
2
=
1/ 4
2.73
(1 + A ) 3

1.435

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 g1, g0, h, and ho as defined by 2-3.
go

0.5

INCH

12.7

MM

g1
h
ho = SQRT(B go), Effective hub length
B

1
1.73228
3.08221
19

INCH
INCH
INCH
INCH

25.4
44
78.2881
482.6

MM
MM
MM
MM

(1)
(2)
(3)

A = (g1/go) - 1
C = 43.68(h/ho)4
C1 = 1/3 + A/12

1
4.35824
0.41667

(4)

C2 = 5/42 + 17 A / 336

0.16964

(5)

C3 = 1/210 + A/360

0.00754

(6)

C4 = 11/360 + 59 A/5040 + (1+3 A)/C

0.96006

(7)

C5 = 1/90 + 5 A/1008 - (1+ A)3/C

-1.81953

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 9 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 5

Item : E-323A/B & E-514C/D

N. Integral Type (W.N.) Main Shell Flange Thickness, item no. 4 (cont.)
FLANGE FACTORS (CONT.)
(8)
C6 = 1/120 + 17 A/5040 +1 /C

[Appendix 2] [FIG. 2-4, Sketch (6a)]

Subjected to internal pressure


0.24116

(9)

C7 = 215/2772 + 51 A/1232 + (60/7 + 225 A/14 + 75A2/7 + 5 A3/2)/C

(10)

C8 = 31/6930 + 128 A/45045 + (6/7 + 15 A/7 + 12A2/7 + 5 A3/11)/C

1.19331

(11)

C9 = 533/30240 + 653 A/73920 + (1/2 + 33 A/14 + 39 A2/28 + 25 A3/84)/C

1.06991

(12)

C10 = 29/3780 + 3 A/704 - (1/2 + 33 A/14 + 81 A2/28 + 13 A3/12)/C

-1.55598

(13)

C11 = 31/6048 + 1763 A/665280 + (1/2 + 6 A/7 + 15 A2/28 + 5 A3/42)/C

0.46941

(14)

C12 = 1/2925 + 71 A/300300 + (8/35 + 18 A /35 + 156 A2/385 + 6 A3/55)/C 0.28903


C13 = 761/831600 + 937 A/1663200 + (1/35 + 6 A /35 + 11 A2/70 + 3 A3/70)/0.09326

(15)

8.80529

(17)

C14 = 197/415800 + 103 A/332640 - (1/35 + 6 A /35 + 17 A2/70 + A3/10)/C -0.12378


C15 = 233/831600 + 97 A/554400 + (1/35 + 3 A /35 + A2/14 + 2 A3/105)/C 0.04744

(18)

C16 = C1C7C12 + C2C8C3 + C3C8C2 - (C32C7 + C82C1 + C22C12)

0.46133

(19)

C17 = [C4C7C12 + C2C8C13 + C3C8C9 - (C13C7C3 + C82C4 + C12C2C9)] / C16

2.2676

(20)
(21)

C18 = [C5C7C12 + C2C8C14 + C3C8C10 - (C14C7C3 + C82C5 + C12C2C10)] / C16 -4.32293


C19 = [C6C7C12 + C2C8C15 + C3C8C11 - (C15C7C3 + C82C6 + C12C2C11)] / C16 0.55926

(22)

C20 = [C1C9C12 + C4C8C3 + C3C13C2 - (C32C9 + C13C8 C1 + C12C4C2)] / C16

(16)

(C32C10
(C32C11

(23)

C21 = [C1C10C12 + C5C8C3 + C3C14C2 -

(24)

C22 = [C1C11C12 + C6C8C3 + C3C15C2 -

(25)

C23 = [C1C7C13 + C2C9C3 + C4C8C2 - (C3C7C4 + C8C9 C1 + C22C13)] / C16

0.0956

+ C14C8 C1 + C12C5C2)] / C16 -0.11503


+ C15C8 C1 + C12C6C2)] / C16 0.05056

(26)

C24 = [C1C7C14 + C2C10C3 + C5C8C2 - (C3C7C5 + C8C10 C1 +

(27)

C25 = [C1C7C15 + C2C11C3 + C6C8C2 - (C3C7C6 + C8C11 C1 +

C22C14)]
C22C15)]

-0.13119

/ C16

0.15946

/ C16

-0.05919

1/4

(28)

C26 = - (C/4)

-1.02168

(29)

C27 = C20 - C17 - 5/12 + C17C26

-4.90543

(30)

C28 = C22 - C19 - 1/12 + C19C26

-1.16343

(31)

1/2

C29 = - (C/4)

-1.04382

(32)

C30 = - (C/4)3/4

-1.06644

(33)

C31 = 3 A/2 - C17 C30

3.91827

(34)

C32 = 1/2 - C19 C30

1.09642

(35)

C33 = 0.5 C26C32 + C28C31C29 - (0.5 C30C28 + C32C27C29)

-2.03619

(36)

C34 = 1/12 + C18 - C21 - C18C26

-8.54118

(37)

C35 = - C18 (C/4)3/4

4.61016

(38)

C36 = (C28C35C29 - C32C34C29)/C33

2.05114

(39)

C37 = [0.5 C26C35 + C34C31C29 - (0.5 C30C34 + C35C27C29)] / C33

-2.16975

(40)

E1 = C17C36 + C18 + C19C37

-0.88522

(41)

E2 = C20C36 + C21 + C22C37

-0.02864

(42)

E3 = C23C36 + C24 + C25C37

0.01881

(43)

E4 = 1/4 + C37/12 + C36/4 - E3/5 - 3E2/2 - E1

1.50639

(44)

E5 = E1 (1/2 + A/6) + E2(1/4 + 11A/84) + E3(1/70 + A/105)

-0.60061

(45)

E6 = E5 - C36(7/120 +A/36 + 3A/C) - 1/40 - A/72 - C37(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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 10 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 5

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 SH = f * Mo /( L * g12 * B).
20 * g1
B

20
19

INCH
INCH

508
482.6

MM
MM

B1 = B + g1 for loose & integral type flanges have f <1 ( the min. f permitted is 1)
B1 = B + go for integral type flanges when f = > 1

20
19.5

INCH
INCH

508
495.3

MM
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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 1 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

N1. Integral Type (WN) Main Shell Flange Thickness (item no. 3)
Flange Material,
[Attached by Bolts]
Design Temperature (shell side)
Min. Design Metal Temperature, MDMT
Bolt-up and Gasket Seating Temperature
Assume no corrosion, C
[UG-25]
Operating Pressure (shell side)
Internal Design Pressure, P (MAWP)
Allowable Stress of Bolt Material (ASME SA193 Gr. B7), SB :

Sheet : 6

Item : E-323A/B & E-514C/D


[Appendix 2] [FIG. 2-4, Sketch (6a)]

ASME SA266 ClassSubjected to internal press.


o
o
F
C
302
150
o
o
F
C
53.6
12
o
o
F
C
86
30
0.19685 INCH
5
MM
Kg/CM2G
241.477 PSIG
17
284.776 PSIG
20.0483 Kg/CM2G
25000
25000

PSIG
PSIG

1760
1760

Kg/CM2G
Kg/CM2G

20000

PSIG

1408

Kg/CM2G

* or at atmospheric temp./bolt-up temp. (gasket seating), SfC


20000
Allowable Stress of Nozzle neck, Vessel or Pipe wall Material (ASME SA106 Gr. B) :
* at design temp.(operating condition), SnH
17100

PSIG

1408

Kg/CM2G

PSIG

2
1203.84 Kg/CM G

PSIG

2
1203.84 Kg/CM G

INCH

25.4

MM

28
840
482.6
778
12.7

MM
MM
MM
MM
MM

25.4
38
40
44

MM
MM
MM
MM

6.35
6
5
31

MM
MM
MM
MM

* at design temp.(operating condition), Sb


* or at atmospheric temp./bolt-up temp. (gasket seating), Sa
Allowable Stress of Flange Material (ASME SA266 Class 2) :
* at design temp.(operating condition), SfH

* or at atmospheric temp./bolt-up temp.(gasket seating), SnC

17100

[Table 1A , SubPart 1 , ASME Sec. II , Part D]

FIG. 2-4, Sketch (6a)


Figure (2)

Nominal bolt dia., dB

No. of bolts

32
1

Bolt Hole, d
Flange outside diameter, A
Flange inside diameter, B
Bolt circut diameter (B.C.D.), C = B + 2(g1 + h1+ R) [Appendix 2-3]
Hup thickness at small end, go = Shell Thickness t

1.10236
33.0709
19
30.6299
0.5

INCH
INCH
INCH
INCH

Hup thickness at back of flange, g1 (assume g1 = 2 go)


R must not less than 1.5 the bolt hole (see TEMA Table D-5)
Hup length, h (must greater than 1.5 go) [FIG. 2-4, Sketch 6]
Use max. slope 1:3, h = 3.5 g0
Slope angle, Y = arc Tan [(g1-go)/h]
Fillet radius, r = 0.25 g1 [but not less than 3/16"(4.7625 MM)] [FIG. 2-4, Sketch 6, Note a]
Use r
h1 = r * Tan (45-Y/2)
E = (A-C)/2

1
1.5
1.5748
1.73228
16.1001
0.25
0.23622
0.17768
1.22047

INCH

(Check D292 )

INCH
INCH
INCH
INCH

Degree
INCH
INCH
INCH
INCH

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 2 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 6

Item : E-323A/B & E-514C/D

N1. Integral Type (W.N.) Main Shell Flange Thickness, item no. 3 (cont.)
[Attached by Bolts]
Nominal shell (pipe) size
Pipe Schedule
No. of bolts
Nominal bolt dia., dB
Bolt diameter at root of thread

Subjected to internal pressure


20"
30
32
1
INCH
25.4
MM
0.88189 INCH
22.4
MM

Actual cross-sectional area of each bolt,


Total actual cross-sectional area of bolts, Ab

0.551
17.632

[Appendix 2] [FIG. 2-4, Sketch (6a)]

[TEMA Table D-5]

Flange outside diameter, A


Flange inside diameter, B
Bolt circut diameter (B.C.D.), C
Gasket Details: - Flat metal, jacketed asbestos filled, iron or soft steel
- Outside diameter = (B.C.D - d) - 2*13
- Inside diameter = O.D - 2N
- Width, N
Gasket Dimensions:
[Table 2-5.2]
Basic gasket seating width, bO = N/2
Since bo > 1/4 inch (6.35 MM),
[Table 2-5.2]
Effective gasket seating width, b = 0.5*SQRT(bO)
[Table 2-5.2]
Gasket Factor, m
[Table 2-5.1]
Min. Seating Stress, y
[Table 2-5.1]
Facing Sketch
[Table 2-5.1]
Diameter at location of gasket load reaction, G
When bo is larger than 1/4", G = O.D.of gasket contact face - 2 b

840
482.6
778

MM
MM
MM

27.9528 INCH
26.7717 INCH
0.59055 INCH

710
680
15

MM
MM
MM

0.29528 INCH

7.5

MM

0.2717
INCH
3.75
7600
PSIG
(1a); Column II

6.90109 MM

27.4094 INCH

696.198 MM

[Table 2-5.2]

N.B. When b > 1/4", the effective gasket seating width, b = 0.5*SQRT(bO)

INCH2

2
355.483 MM
2
11375.5 MM

33.0709 INCH
19
INCH
30.6299 INCH

[ Appendix 2-3]

N.B. When b < 1/4", the effective gasket seating width, b = bo

INCH2

[Table 2-5.2]

535.04

Kg/CM2G

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 3 of 10
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

Date : 4.7.2003
Location : Alex.

Client : APRC

Sheet : 6

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 G2 P
[Appendix 2-3]
(b) Total joint-contact surface compression load, Hp =2b*3.14GmP

167947
49943.3

lb
lb

76179.4 Kg
22653.9 Kg

217890
177716

lb
lb

98833.4 Kg
80610.6 Kg

25000
25000

PSIG
PSIG

1760
1760

8.7156
7.10863

INCH2
INCH2

2
5622.96 MM
2
4586.2 MM

8.7156
17.632
OK

INCH2
INCH2

2
5622.96 MM
2
11375.5 MM

217890
329345

lb
lb

98833.4 Kg
149389 Kg

80701.4

lb

36605.6 Kg

49943.3

lb

22653.9 Kg

87245.4

lb

39573.9 Kg

[Table 2-6]

2.17768

INCH

55.3131 MM

hG = (C - G) / 2

[Table 2-6]

1.61028

INCH

40.9011 MM

hT = (R' + g1 + hG) / 2

[Table 2-6]

2.14398

INCH

54.4571 MM

1.67768

INCH

42.6131 MM

[Appendix 2-3]

(c) Min. required bolt load for operating conditions, Wm1 = H + Hp


Min. required bolt load for gasket seating, Wm2 = 3.14 b G y
Allowable Bolt Stress at atmospheric temp., Sa
Allowable Bolt Stress at design temp., Sb

Kg/CM2G
Kg/CM2G

[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
- Gasket seating,
Am2 = Wm2 / Sa
[Appendix 2-3]
Total required cross-sectional of bolts, Am = the greater of Am1 & Am2

Actual bolt area Ab


Since area Ab > area Am, the bolts are adequately enough.
(e) Flange design bolt load, W :
- For operating conditions, Wo = Wm1
[Appendix 2-5(d)]
- For gasket seating, Wa = 0.5(Am + Ab) * Sa
[Appendix 2-5(d)]
2. Total flange moment for design condition:
[Appendix 2-5(c)]
Flange Loads:
Hydrostatic end force on area inside flange, HD = 0.785 B2 P
Gasket load (flange design bolt load - total hydrostatic end force), HG

Gasket seating force

H G = Wm1 - H

Difference bet. total hydrostatic end force and the hydrostatic end force on area inside of flange, HT

HT = H - HD
Lever arms:
hD = R' + 0.5 g1

Where R' = R + h1

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 4 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 6

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 HD, MD = HD hD

[Appendix 2-3]

175742

Component of moment due to HG, MG = HG hG

[Appendix 2-3]

Component of moment due to HT, MT = HT hT

[Appendix 2-3]

Total moment acting upon the flange, Mo:


- For operating condition

lb-in

2024.77 Kg-M

80422.7

lb-in

926.571 Kg-M

187052

lb-in

2155.08 Kg-M

443217
36934.7

lb-in
lb-ft

5106.42 Kg-M

329345

lb

149389

[Appendix 2-6]

MO1 = MD + MG + MT

3. Total flange moment for bolt-up condition (Gasket condition):


[Appendix 2-6]

Flange Load:

HG = W A = 0.5 (Am + Ab) * Sa

Lever Arm., hG = (C - G) / 2
Flange Moment for gasket condition, M O2 = HG hG = W A (C - G) / 2

(5)

Mo2 * (SfH / SfC )


4. MO = The greater of MO1 or MO2 (SfH/SfC)
5. Shape constants for flange:
K =

From Appendix 2, FIG. 2-7.1:


T =
Z=

Kg

1.61028 INCH

40.9011 MM

530337

lb-in

6110.16 Kg-M

530337
530337
44194.8

lb-in
lb-in
lb-ft

6110.16 Kg-M
6110.16 Kg-M

1.74057

K (1 + 8.55246 Log10 k ) 1
(1.04720 + 1.9448 k 2 )( k 1)
2

+1

K2 1

K 2 Log10 K
0.66845 + 5.71690
Y =

K 1
K2 1

2
K (1 + 8.55246 Log K ) 1
10
U =
1.36136 ( K 2 1)( K 1)

1.60851
1.98542

From Appendix 2, FIG. 2-7.2:


From Appendix 2, FIG. 2-7.3:
From Appendix 2, FIG. 2-7.6:

g1/go
ho = SQRT(B go)
h/ho
F
V
f

d = (U/V) ho go2 (for integral type flanges) [APPENDIX 2-3]


e = F / ho
(for integral type flanges) [APPENDIX 2-3]

3.67613
4.03969
2
3.08221
0.56203
0.81225
0.21166
1.02557
14.7067 INCH3
0.26353 INCH-1

3
241000 MM
-1
0.01038 MM

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 5 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 6

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

[Attached by Bolts]

6. Calculation of flange actual stresses


Assume t
Factor L =

te + 1 t ^ 3
+
d
T

Where t = flange thickness


factor e = F/ ho (for integral type flanges)
e = FL/ ho (for loose type flanges)
F = factor for integral type flanges
T = factor involving K
d = (U/V) ho go2

[Appendix 2-3]
[Appendix 2-3]
[Appendix 2-3]
[Fig. 2-7.2]
[Fig. 2-7.1]
[Appendix 2-3]

For integral type flange, actual stresses (calculated) : [Fig. 2-4, Sketch (6a)]
1. a. Longitudinal hub stress, operating SH = f Mo / L g12 B (6) [Appendix 2-7(a)]
b. Longitudinal hub stress, seating
SH = f Mo2 / L g12 B (6) [Appendix 2-7(a)]

1.59449
1.15857

INCH

0.26353 INCH-1
NA
0.81225
1.60851
14.7067 INCH3

40.5

MM

-1
0.01038 MM

241000

MM3

24708.2

PSIG

2
1739.46 Kg/CM G

24708.2

PSIG

2
1739.46 Kg/CM G

2. a. Radial flange stress, operating SR = (1.33 t e +1) Mo / L t2 B (7) [Appendix 2-7(a 14785.2

PSIG

2
1040.88 Kg/CM G

SR = (1.33 t e +1) Mo2 / L t2 B (7) [Appendix 2-7(a 14785.2

PSIG

2
1040.88 Kg/CM G

3. a. Tangential flange stress, operating ST = (Y Mo / t2 B) - Z SR (8) [Appendix 2-7(a)] 11004.8

PSIG

2
774.737 Kg/CM G

ST = (Y Mo2 / t2 B) - Z SR (8) [Appendix 2-7(a)11004.8

PSIG

2
774.737 Kg/CM G

b. Radial flange stress, seating

b. Tangential flange stress, seating


4. a. Flange stress, operating

0.5 (SH + SR)

[Appendix 2-8(a)(4)]

19746.7

PSIG

2
1390.17 Kg/CM G

b. Flange stress, seating

0.5 (SH + SR)

[Appendix 2-8(a)(4)]

19746.7

PSIG

2
1390.17 Kg/CM G

5. a. Flange stress, operating

0.5 (SH + ST)

[Appendix 2-8(a)(4)]

17856.5

PSIG

1257.1

Kg/CM2G

b. Flange stress, seating


0.5 (SH + ST)
6. a. Bolt stress, operating = Wm1 / Ab
b. Bolt stress, seating = Wm2 / Ab
7. a. Shear stress carried by the fillet weld

[Appendix 2-8(a)(4)]

17856.5
12357.6
10079.2
0

PSIG
PSIG
PSIG
PSIG

1257.1
869.979
709.573
0

Kg/CM2G

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
Allowable design stress of nozzle/vessel at operating condition, Sn
17100
PSIG
Assume flange thickness (without C.A), toperating
1.59449 INCH
Allowable stresses
PSIG

Longitudinal Hub Stress SH1 = 1.5 Sf

[Appendix 2-8(a)(1)(b)]

30000

Longitudinal Hub Stress SH2 = 2 Sn

[Appendix 2-8(a)(1)(b)]

34200

The calculated (actual) hub stress S H < SH (min.) allowable


Radial Flange Stress SR = Sf

[Appendix 2-8(a)(2)]

The calculated (actual) radial stress S R < SR allowable

Kg/CM2

Kg/CM2G
Kg/CM2G
Kg/CM2G

Kg/CM2G
1408
1203.84 Kg/CM2G
40.5
MM

Actual stresses
(Calculated )
Kg/CM2
PSIG

30000

>

24708.2

20000

>

14785.2

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 6 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 6

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)]

20000

Subjected to internal pressure


>
11004.8

0.5(SH + SR) = Sf
< Allowable stress

20000

>

19746.7

0.5(SH + ST) = Sf
< Allowable stress

20000

>

17856.5

25000

>

12357.6

Tangential Flange Stress ST = Sf

[Appendix 2-8(a)(3)]

The calculated (actual) tangential stress S T < ST allowable

The calculated (actual) stress

The calculated (actual) stress


Bolt stress = Wm1 / Ab
The calculated (actual) stress

< Allowable stress

7.b. For Gasket Seating :


20000
PSIG
17100
PSIG
1.59449 INCH

Allowable design stress of flange at gasket seating, Sf


Allowable design stress of nozzle/vessel at gasket seating, Sn

Assume flange thickness (without C.A), tgasket

Allowable stresses
PSIG

Longitudinal Hub Stress SH1 = 1.5 Sf

[Appendix 2-8(a)(1)(b)]

30000

Longitudinal Hub Stress SH2 = 2 Sn

[Appendix 2-8(a)(1)(b)]

34200

The calculated (actual) hub stress S H < SH (min.) allowable

Kg/CM2

Kg/CM2G
1408
1203.84 Kg/CM2G
40.5
MM

Actual stresses
(Calculated )
Kg/CM2
PSIG

30000

>

24708.2

20000

>

14785.2

20000

>

11004.8

20000

>

19746.7

The calculated (actual) stress

0.5(SH + SR) = Sf
< Allowable stress
0.5(SH + ST) = Sf
< Allowable stress

20000

>

17856.5

The calculated (actual) stress


Bolt stress = Wm2 / Ab
The calculated (actual) stress

25000

>

10079.2

< Allowable stress

Radial Flange Stress SR = Sf

[Appendix 2-8(a)(2)]

The calculated (actual) radial stress S R < SR allowable


Tangential Flange Stress ST = Sf

[Appendix 2-8(a)(3)]

The calculated (actual) tangential stress S T < ST allowable

The min. flange thickness, t = Max. (toperating, tgasket)

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 7 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 6

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
Gasket width, N
Total required cross-sectional area of bolts
Actual bolt cross-sectional area, Ab
Nominal bolt dia., dB

1.74057
0.59055 INCH
INCH2
8.7156
INCH2
17.632
1
INCH

15
5622.96
11375.5
25.4

MM
MM2
MM2
MM

1. Actual Edge distance, E from drawing = 1/2 (A - C)


1.22047 INCH
Min. Edge distance, E (for bolt size 0.75")
0.8125
INCH
Min. Edge distance, E (for bolt size 7/8")
0.9375
INCH
Min. Edge distance, E (for bolt size 1")
1.0625
INCH
Min. Edge distance, E (for bolt size 1-1/8")
[TEMA Table D-5]
1.125
INCH
Min. Edge distance, E (for bolt size 1-1/4")
1.25
INCH
2. Actual Bolt spacing, B from drawing
3.00226 INCH
Min. Bolt spacing, B (for bolt size 0.75")
1.75
INCH
Min. Bolt spacing, B (for bolt size 7/8")
2.0625
INCH
Min. Bolt spacing, B (for bolt size 1")
2.25
INCH
Min. Bolt spacing, B (for bolt size 1-1/8")
[TEMA Table D-5]
2.5
INCH
Min. Bolt spacing, B (for bolt size 1-1/4")
2.8125
INCH
Max. Recommended bolt spacing, Bmax = 2 dB + 6 t / (m + 0.5) [TEMA RCB-11.224.25104 INCH
3. Actual Radial distance, Rh from drawing = (C-B)/2-(g1+h1)
4.61811 INCH
Min. Radial distance, Rh (for bolt size 0.75")
1.125
INCH
Min. Radial distance, Rh (for bolt size 7/8")
1.25
INCH
Min. Radial distance, Rh (for bolt size 1")
1.375
INCH
Min. Radial distance, Rh (for bolt size 1-1/8")
[TEMA Table D-5]
1.5
INCH
Min. Radial distance, Rh (for bolt size 1-1/4")
1.75
INCH

31
20.6375
23.8125
26.9875
28.575
31.75
76.2573
44.45
52.3875
57.15
63.5
71.4375
107.976
117.3
28.575
31.75
34.925
38.1
44.45

MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 8 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

N1. Integral Type (W.N.) Main Shell Flange Thickness, item no. 3 (cont.)
FLANGE FACTORS
(a) For Integral Flanges
E
F =
(1 + A )
C
Factor F per Fig. 2-7.2 is then solved by
[
]

Sheet : 6

Item : E-323A/B & E-514C/D


[Appendix 2] [FIG. 2-4, Sketch (6a)]

Subjected to internal pressure

1/ 4

2.7 3

Factor V per Fig. 2-7.3 is then solved by

V =

0.81225

E4
2.73 1/ 4
[
]
(1 + A ) 3
C

0.21166

h/SQRT(BGo 0.562026971
f = C36 / (1 + A)
1.02557
The values used in the above equations are solved using Eqs. (1) through (45) below based on the values g1, g0, h and ho

Factor f per Fig. 2-7.6 is then solved by

as defined by 2-3. When g1 = go, F = 0.908920, V = 0.550103, and f = 1; thus Eqs. (1) through (45) need not be solved.
(b) For Loose Hub Flanges
Factor FL per Fig. 2-7.4 is solved by

FL =

1
C 18
+
2

11A
A
A
A
1
1
1
+
+

+ C 21
+ C 24

4
70
40
6
84
105
72
1/ 4
(1 + A ) 3
C

2 .7 3
C

Factor VL per Fig. 2-7.5 is solved by

VL

1
3C 21
C
24
C18
4
5
2
=
1/ 4
2.73
(1 + A ) 3

1.435

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 g1, g0, h, and ho as defined by 2-3.
go

0.5

INCH

12.7

MM

g1
h
ho = SQRT(B go), Effective hub length
B

1
1.73228
3.08221
19

INCH
INCH
INCH
INCH

25.4
44
78.2881
482.6

MM
MM
MM
MM

(1)
(2)
(3)

A = (g1/go) - 1
C = 43.68(h/ho)4
C1 = 1/3 + A/12

1
4.35824
0.41667

(4)

C2 = 5/42 + 17 A / 336

0.16964

(5)

C3 = 1/210 + A/360

0.00754

(6)

C4 = 11/360 + 59 A/5040 + (1+3 A)/C

0.96006

(7)

C5 = 1/90 + 5 A/1008 - (1+ A)3/C

-1.81953

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 9 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 6

Item : E-323A/B & E-514C/D

N1. Integral Type (W.N.) Main Shell Flange Thickness, item no. 3 (cont.)
FLANGE FACTORS (CONT.)
(8)
C6 = 1/120 + 17 A/5040 +1 /C

0.24116

(9)

C7 = 215/2772 + 51 A/1232 + (60/7 + 225 A/14 + 75A2/7 + 5 A3/2)/C

8.80529

(10)

C8 = 31/6930 + 128 A/45045 + (6/7 + 15 A/7 + 12A2/7 + 5 A3/11)/C

1.19331

(11)

C9 = 533/30240 + 653 A/73920 + (1/2 + 33 A/14 + 39 A2/28 + 25 A3/84)/C

1.06991

(12)

C10 = 29/3780 + 3 A/704 - (1/2 + 33 A/14 + 81 A2/28 + 13 A3/12)/C

-1.55598

(13)

C11 = 31/6048 + 1763 A/665280 + (1/2 + 6 A/7 + 15 A2/28 + 5 A3/42)/C

0.46941

(14)

C12 = 1/2925 + 71 A/300300 + (8/35 + 18 A /35 + 156 A2/385 + 6 A3/55)/C 0.28903


C13 = 761/831600 + 937 A/1663200 + (1/35 + 6 A /35 + 11 A2/70 + 3 A3/70)/0.09326

(15)

[Appendix 2] [FIG. 2-4, Sketch (6a)]

Subjected to internal pressure

(17)

C14 = 197/415800 + 103 A/332640 - (1/35 + 6 A /35 + 17 A2/70 + A3/10)/C -0.12378


C15 = 233/831600 + 97 A/554400 + (1/35 + 3 A /35 + A2/14 + 2 A3/105)/C 0.04744

(18)

C16 = C1C7C12 + C2C8C3 + C3C8C2 - (C32C7 + C82C1 + C22C12)

0.46133

(19)

C17 = [C4C7C12 + C2C8C13 + C3C8C9 - (C13C7C3 + C82C4 + C12C2C9)] / C16

2.2676

(20)
(21)

C18 = [C5C7C12 + C2C8C14 + C3C8C10 - (C14C7C3 + C82C5 + C12C2C10)] / C16 -4.32293


C19 = [C6C7C12 + C2C8C15 + C3C8C11 - (C15C7C3 + C82C6 + C12C2C11)] / C16 0.55926

(22)

C20 = [C1C9C12 + C4C8C3 + C3C13C2 - (C32C9 + C13C8 C1 + C12C4C2)] / C16

(16)

(C32C10
(C32C11

(23)

C21 = [C1C10C12 + C5C8C3 + C3C14C2 -

(24)

C22 = [C1C11C12 + C6C8C3 + C3C15C2 -

(25)

C23 = [C1C7C13 + C2C9C3 + C4C8C2 - (C3C7C4 + C8C9 C1 + C22C13)] / C16

0.0956

+ C14C8 C1 + C12C5C2)] / C16 -0.11503


+ C15C8 C1 + C12C6C2)] / C16 0.05056

(26)

C24 = [C1C7C14 + C2C10C3 + C5C8C2 - (C3C7C5 + C8C10 C1 +

(27)

C25 = [C1C7C15 + C2C11C3 + C6C8C2 - (C3C7C6 + C8C11 C1 +

C22C14)]
C22C15)]

-0.13119

/ C16

0.15946

/ C16

-0.05919

1/4

(28)

C26 = - (C/4)

-1.02168

(29)

C27 = C20 - C17 - 5/12 + C17C26

-4.90543

(30)

C28 = C22 - C19 - 1/12 + C19C26

-1.16343

(31)

1/2

C29 = - (C/4)

-1.04382

(32)

C30 = - (C/4)3/4

-1.06644

(33)

C31 = 3 A/2 - C17 C30

3.91827

(34)

C32 = 1/2 - C19 C30

1.09642

(35)

C33 = 0.5 C26C32 + C28C31C29 - (0.5 C30C28 + C32C27C29)

-2.03619

(36)

C34 = 1/12 + C18 - C21 - C18C26

-8.54118

(37)

C35 = - C18 (C/4)3/4

4.61016

(38)

C36 = (C28C35C29 - C32C34C29)/C33

2.05114

(39)

C37 = [0.5 C26C35 + C34C31C29 - (0.5 C30C34 + C35C27C29)] / C33

-2.16975

(40)

E1 = C17C36 + C18 + C19C37

-0.88522

(41)

E2 = C20C36 + C21 + C22C37

-0.02864

(42)

E3 = C23C36 + C24 + C25C37

0.01881

(43)

E4 = 1/4 + C37/12 + C36/4 - E3/5 - 3E2/2 - E1

1.50639

(44)

E5 = E1 (1/2 + A/6) + E2(1/4 + 11A/84) + E3(1/70 + A/105)

-0.60061

(45)

E6 = E5 - C36(7/120 +A/36 + 3A/C) - 1/40 - A/72 - C37(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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 10 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 6

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 SH = f * Mo /( L * g12 * B).
20 * g1
B

20
19

INCH
INCH

508
482.6

MM
MM

B1 = B + g1 for loose & integral type flanges have f <1 ( the min. f permitted is 1)
B1 = B + go for integral type flanges when f = > 1

20
19.5

INCH
INCH

508
495.3

MM
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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 1 of 10
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
N2. Integral Type (WN) Main Shell Flange Thickness (item no. 12)
Flange Material,
[Attached by Bolts]
Design Temperature (shell side)
Min. Design Metal Temperature, MDMT
Bolt-up and Gasket Seating Temperature
Assume no corrosion, C
[UG-25]
Operating Pressure (shell side)
Internal Design Pressure, P (MAWP)
Allowable Stress of Bolt Material (ASME SA193 Gr. B7), SB :

Sheet : 7

Date : 4.7.2003
Location : Alex.
Client : APRC
Item : E-323A/B & E-514C/D
[Appendix 2] [FIG. 2-4, Sketch (6a)]

ASME SA266 Class2


o
F
302
o
F
53.6
o
F
86
0.19685 INCH
241.4773 PSIG
284.7764 PSIG

Subjected to internal press.

25000
25000

PSIG
PSIG

1760
1760

Kg/CM2G
Kg/CM2G

20000

PSIG

1408

Kg/CM2G

* or at atmospheric temp./bolt-up temp. (gasket seating), SfC


20000
Allowable Stress of Nozzle neck, Vessel or Pipe wall Material (ASME SA106 Gr. B) :
* at design temp.(operating condition), SnH
17100
* or at atmospheric temp./bolt-up temp.(gasket seating), SnC
17100

PSIG

1408

Kg/CM2G

PSIG

1203.84

Kg/CM2G

PSIG

1203.84

Kg/CM2G

INCH

25.4

MM

28
840
635.46
775.62
12.7

MM
MM
MM
MM
MM

25.4
38
40
44

MM
MM
MM
MM

6.35
6
5
32.19

MM
MM
MM
MM

* at design temp.(operating condition), Sb


* or at atmospheric temp./bolt-up temp. (gasket seating), Sa
Allowable Stress of Flange Material (ASME SA266 Class 2) :
* at design temp.(operating condition), SfH

o
C
150
o
C
12
o
C
30
5
MM
Kg/CM2G
17
20.04826 Kg/CM2G

[Table 1A , SubPart 1 , ASME Sec. II , Part D]

FIG. 2-4, Sketch (6a)


Figure (3)

Nominal bolt dia., dB

No. of bolts

32
1

Bolt Hole, d
Flange outside diameter, A
Flange inside diameter, B
Bolt circut diameter (B.C.D.), C = B + 2(g1 + h1+ R) [Appendix 2-3]
Hup thickness at small end, go = Shell Thickness t

1.102362
33.07087
25.01811
30.53622
0.5

INCH
INCH
INCH
INCH

Hup thickness at back of flange, g1 (assume g1 = 2 go)


1
R must not less than 1.5 the bolt hole (see TEMA Table D-5)
1.5
Hup length, h (must greater than 1.5 go) [FIG. 2-4, Sketch 6]
1.574803
Use max. slope 1:3, h = 3.5 g0
1.732283
Slope angle, Y = arc Tan [(g1-go)/h]
16.10006
Fillet radius, r = 0.25 g1 [but not less than 3/16"(4.7625 MM)] [FIG. 2-4, Sketch 6, Note a]0.25
Use r
0.23622
h1 = r * Tan (45-Y/2)
0.177682
E = (A-C)/2
1.267323

INCH

(Check D292 )

INCH
INCH
INCH
INCH

Degree
INCH
INCH
INCH
INCH

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 2 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 7

Item : E-323A/B & E-514C/D

N2. Integral Type (W.N.) Main Shell Flange Thickness, item no. 12 (cont.)
[Attached by Bolts]
Nominal shell (pipe) size
Pipe Schedule
No. of bolts
Nominal bolt dia., dB
Bolt diameter at root of thread

32
1
0.88189

Actual cross-sectional area of each bolt,


Total actual cross-sectional area of bolts, Ab

0.551
17.632

[TEMA Table D-5]

Flange outside diameter, A


Flange inside diameter, B
Bolt circut diameter (B.C.D.), C
Gasket Details: - Flat metal, jacketed asbestos filled, iron or soft steel
- Outside diameter = (B.C.D - d) - 2*13
- Inside diameter = O.D - 2N
- Width, N
Gasket Dimensions:
[Table 2-5.2]
Basic gasket seating width, bO = N/2
Since bo > 1/4 inch (6.35 MM),
[Table 2-5.2]
Effective gasket seating width, b = 0.5*SQRT(bO)
[Table 2-5.2]
Gasket Factor, m
[Table 2-5.1]
Min. Seating Stress, y
[Table 2-5.1]
Facing Sketch
[Table 2-5.1]
Diameter at location of gasket load reaction, G
When bo is larger than 1/4", G = O.D.of gasket contact face - 2 b

[Appendix 2] [FIG. 2-4, Sketch (6a)]

Subjected to internal pressure


26"

INCH
INCH2
INCH2

MM
MM

2
355.4832 MM
2
11375.46 MM

840
635.46
775.62

MM
MM
MM

27.95276 INCH
26.77165 INCH
0.590551 INCH

710
680
15

MM
MM
MM

0.295276 INCH

7.5

MM

0.271696 INCH
3.75
7600
PSIG
(1a); Column II

6.901087 MM

27.40936 INCH

[Table 2-5.2]

N.B. When b > 1/4", the effective gasket seating width, b = 0.5*SQRT(bO)

25.4
22.4

33.07087 INCH
25.01811 INCH
30.53622 INCH

[ Appendix 2-3]

N.B. When b < 1/4", the effective gasket seating width, b = bo

INCH

[Table 2-5.2]

535.04

Kg/CM2G

696.1978 MM

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 3 of 10
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

Date : 4.7.2003
Location : Alex.

Client : APRC

Sheet : 7

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 G2 P
[Appendix 2-3]
(b) Total joint-contact surface compression load, Hp =2b*3.14GmP

167946.7 lb
49943.35 lb

76179.45 Kg
22653.95 Kg

217890.1 lb
177715.8 lb

98833.4 Kg
80610.61 Kg

25000
25000

1760
1760

[Appendix 2-3]

(c) Min. required bolt load for operating conditions, Wm1 = H + Hp


Min. required bolt load for gasket seating, Wm2 = 3.14 b G y
Allowable Bolt Stress at atmospheric temp., Sa
Allowable Bolt Stress at design temp., Sb

PSIG
PSIG

Kg/CM2G
Kg/CM2G

[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
- Gasket seating,
Am2 = Wm2 / Sa

2
8.715603 INCH
2
7.108631 INCH

2
5622.959 MM
2
4586.204 MM

2
8.715603 INCH
INCH2
17.632
OK

2
5622.959 MM
2
11375.46 MM

217890.1 lb
329345
lb

98833.4 Kg
149388.6 Kg

139920.9 lb

63467.14 Kg

49943.35 lb

22653.95 Kg

[Appendix 2-3]
Total required cross-sectional of bolts, Am = the greater of Am1 & Am2

Actual bolt area Ab


Since area Ab > area Am, the bolts are adequately enough.
(e) Flange design bolt load, W :
- For operating conditions, Wo = Wm1
[Appendix 2-5(d)]
- For gasket seating, Wa = 0.5(Am + Ab) * Sa
[Appendix 2-5(d)]
2. Total flange moment for design condition:
[Appendix 2-5(c)]
Flange Loads:
Hydrostatic end force on area inside flange, HD = 0.785 B2 P
Gasket load (flange design bolt load - total hydrostatic end force), HG

Gasket seating force

H G = Wm1 - H

Difference bet. total hydrostatic end force and the hydrostatic end force on area inside of flange, HT

HT = H - HD

28025.81 lb

12712.31 Kg

[Table 2-6]

2.177682 INCH

55.31312 MM

hG = (C - G) / 2

[Table 2-6]

1.563429 INCH

39.71109 MM

hT = (R' + g1 + hG) / 2

[Table 2-6]

2.120555 INCH

53.8621

1.677682 INCH

42.61312 MM

Lever arms:
hD = R' + 0.5 g1

Where R' = R + h1

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 4 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 7

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 HD, MD = HD hD

[Appendix 2-3]

304703.2 lb-in

3510.565 Kg-M

Component of moment due to HG, MG = HG hG

[Appendix 2-3] 78082.86 lb-in

899.6129 Kg-M

Component of moment due to HT, MT = HT hT

[Appendix 2-3] 59430.27 lb-in

684.7116 Kg-M

Total moment acting upon the flange, Mo:


- For operating condition

[Appendix 2-6]

MO1 = MD + MG + MT

442216.4 lb-in
36851.36 lb-ft

5094.89

Kg-M

329345

149388.6 Kg

3. Total flange moment for bolt-up condition (Gasket condition):


[Appendix 2-6]

Flange Load:

HG = W A = 0.5 (Am + Ab) * Sa

Lever Arm., hG = (C - G) / 2
Flange Moment for gasket condition, M O2 = HG hG = W A (C - G) / 2

(5)

Mo2 * (SfH / SfC )


4. MO = The greater of MO1 or MO2 (SfH/SfC)

lb

1.563429 INCH

39.71109 MM

514907.5 lb-in

5932.383 Kg-M

514907.5 lb-in
514907.5 lb-in
42908.96 lb-ft

5932.383 Kg-M
5932.383 Kg-M

5. Shape constants for flange:


K =

From Appendix 2, FIG. 2-7.1:


T =
Z=

K (1 + 8.55246 Log10 k ) 1
(1.04720 + 1.9448 k 2 )( k 1)

1.321877

+1

K2 1

K 2 Log10 K
0.66845 + 5.71690
Y =

K 1
K2 1

2
K (1 + 8.55246 Log K ) 1
10
U =
1.36136 ( K 2 1)( K 1)

1.78802
3.67609

From Appendix 2, FIG. 2-7.2:


From Appendix 2, FIG. 2-7.3:
From Appendix 2, FIG. 2-7.6:

g1/go
ho = SQRT(B go)
h/ho
F
V
f

d = (U/V) ho go2 (for integral type flanges) [APPENDIX 2-3]


e = F / ho
(for integral type flanges) [APPENDIX 2-3]

7.109344
7.812448
2
3.536814
0.489786
0.82792
0.230119
1.261692
30.01842 INCH3
0.234086 INCH-1

3
491913.7 MM
-1
0.009216 MM

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 5 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 7

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

[Attached by Bolts]

6. Calculation of flange actual stresses


Assume t
Factor L =

te + 1 t ^ 3
+
T
d

Where t = flange thickness


factor e = F/ ho (for integral type flanges)
e = FL/ ho (for loose type flanges)
F = factor for integral type flanges
T = factor involving K
d = (U/V) ho go2

[Appendix 2-3]
[Appendix 2-3]
[Appendix 2-3]
[Fig. 2-7.2]
[Fig. 2-7.1]
[Appendix 2-3]

1.692913 INCH
0.942541

43

0.234086 INCH-1
NA
0.82792
1.78802
30.01842 INCH3

-1
0.009216 MM

For integral type flange, actual stresses (calculated) : [Fig. 2-4, Sketch (6a)]
1. a. Longitudinal hub stress, operating SH = f Mo / L g12 B (6) [Appendix 2-7(a) 27550.39 PSIG
b. Longitudinal hub stress, seating
SH = f Mo2 / L g12 B (6) [Appendix 2-7(a)]27550.39 PSIG

MM

3
491913.7 MM

2
1939.547 Kg/CM G
2
1939.547 Kg/CM G

2. a. Radial flange stress, operating SR = (1.33 t e +1) Mo / L t2 B (7) [Appendix 2- 11644.84 PSIG
b. Radial flange stress, seating SR = (1.33 t e +1) Mo2 / L t2 B (7) [Appendix 2 11644.84 PSIG

2
819.7971 Kg/CM G

3. a. Tangential flange stress, operating ST = (Y Mo / t2 B) - Z SR (8) [Appendix 2-7 8247.083 PSIG


b. Tangential flange stress, seating ST = (Y Mo2 / t2 B) - Z SR (8) [Appendix 2- 8247.083 PSIG

2
580.5946 Kg/CM G

4. a. Flange stress, operating

0.5 (SH + SR)

[Appendix 2-8(a)(4)]

19597.61 PSIG

2
1379.672 Kg/CM G

b. Flange stress, seating

0.5 (SH + SR)

[Appendix 2-8(a)(4)]

19597.61 PSIG

2
1379.672 Kg/CM G

5. a. Flange stress, operating

0.5 (SH + ST)

[Appendix 2-8(a)(4)]

17898.73 PSIG

2
1260.071 Kg/CM G

b. Flange stress, seating


0.5 (SH + ST)
6. a. Bolt stress, operating = Wm1 / Ab
b. Bolt stress, seating = Wm2 / Ab
7. a. Shear stress carried by the fillet weld

[Appendix 2-8(a)(4)]

17898.73
12357.65
10079.16
0

1260.071
869.9786
709.573
0

Kg/CM2G

1408
1203.84
43

Kg/CM2G
Kg/CM2G

PSIG
PSIG
PSIG
PSIG

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
Allowable design stress of nozzle/vessel at operating condition, Sn
17100
PSIG
Assume flange thickness (without C.A), toperating
1.692913 INCH
Allowable stresses
Kg/CM2

PSIG

Longitudinal Hub Stress SH1 = 1.5 Sf

[Appendix 2-8(a)(1)(b)]

30000

Longitudinal Hub Stress SH2 = 2 Sn

[Appendix 2-8(a)(1)(b)]

34200

The calculated (actual) hub stress S H < SH (min.) allowable


Radial Flange Stress SR = Sf

[Appendix 2-8(a)(2)]

The calculated (actual) radial stress S R < SR allowable

2
819.7971 Kg/CM G

2
580.5946 Kg/CM G

Kg/CM2G
Kg/CM2G
Kg/CM2G

MM

Actual stresses
(Calculated )
Kg/CM2
PSIG

30000

>

27550.39

20000

>

11644.84

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 6 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 7

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)]

20000

Subjected to internal pressure


>
8247.083

0.5(SH + SR) = Sf
< Allowable stress

20000

>

19597.61

0.5(SH + ST) = Sf
< Allowable stress

20000

>

17898.73

25000

>

12357.65

Tangential Flange Stress ST = Sf

[Appendix 2-8(a)(3)]

The calculated (actual) tangential stress S T < ST allowable

The calculated (actual) stress

The calculated (actual) stress


Bolt stress = Wm1 / Ab
The calculated (actual) stress

< Allowable stress

7.b. For Gasket Seating :


20000
PSIG
17100
PSIG
1.692913 INCH

Allowable design stress of flange at gasket seating, Sf


Allowable design stress of nozzle/vessel at gasket seating, Sn

Assume flange thickness (without C.A), tgasket

Allowable stresses
Kg/CM2

PSIG

Longitudinal Hub Stress SH1 = 1.5 Sf

[Appendix 2-8(a)(1)(b)]

30000

Longitudinal Hub Stress SH2 = 2 Sn

[Appendix 2-8(a)(1)(b)]

34200

The calculated (actual) hub stress S H < SH (min.) allowable

1408
1203.84
43

>

27550.39

20000

>

11644.84

20000

>

8247.083

20000

>

19597.61

The calculated (actual) stress

0.5(SH + SR) = Sf
< Allowable stress
0.5(SH + ST) = Sf
< Allowable stress

20000

>

17898.73

The calculated (actual) stress


Bolt stress = Wm2 / Ab
The calculated (actual) stress

25000

>

10079.16

< Allowable stress

[Appendix 2-8(a)(2)]

MM

Actual stresses
(Calculated )
Kg/CM2
PSIG

30000

Radial Flange Stress SR = Sf

Kg/CM2G
Kg/CM2G

The calculated (actual) radial stress S R < SR allowable


Tangential Flange Stress ST = Sf

[Appendix 2-8(a)(3)]

The calculated (actual) tangential stress S T < ST allowable

The min. flange thickness, t = Max. (toperating, tgasket)

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 7 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 7

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
Gasket width, N
Total required cross-sectional area of bolts
Actual bolt cross-sectional area, Ab
Nominal bolt dia., dB

1.321877
0.590551
8.715603
17.632
1

INCH2
INCH

15
5622.959
11375.46
25.4

MM
MM2
MM2
MM

1. Actual Edge distance, E from drawing = 1/2 (A - C)


1.267323
Min. Edge distance, E (for bolt size 0.75")
0.8125
Min. Edge distance, E (for bolt size 7/8")
0.9375
Min. Edge distance, E (for bolt size 1")
1.0625
Min. Edge distance, E (for bolt size 1-1/8")
[TEMA Table D-5]
1.125
Min. Edge distance, E (for bolt size 1-1/4")
1.25
2. Actual Bolt spacing, B from drawing
2.993073
Min. Bolt spacing, B (for bolt size 0.75")
1.75
Min. Bolt spacing, B (for bolt size 7/8")
2.0625
Min. Bolt spacing, B (for bolt size 1")
2.25
Min. Bolt spacing, B (for bolt size 1-1/8")
[TEMA Table D-5]
2.5
Min. Bolt spacing, B (for bolt size 1-1/4")
2.8125
Max. Recommended bolt spacing, Bmax = 2 dB + 6 t / (m + 0.5) [TEMA RCB-114.389995
3. Actual Radial distance, Rh from drawing = (C-B)/2-(g1+h1)
1.562205
Min. Radial distance, Rh (for bolt size 0.75")
1.125
Min. Radial distance, Rh (for bolt size 7/8")
1.25
Min. Radial distance, Rh (for bolt size 1")
1.375
Min. Radial distance, Rh (for bolt size 1-1/8")
[TEMA Table D-5]
1.5
Min. Radial distance, Rh (for bolt size 1-1/4")
1.75

INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH

32.19
20.6375
23.8125
26.9875
28.575
31.75
76.02405
44.45
52.3875
57.15
63.5
71.4375
111.5059
39.68
28.575
31.75
34.925
38.1
44.45

MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM

INCH
INCH2

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 8 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

N2. Integral Type (W.N.) Main Shell Flange Thickness, item no. 12 (cont.)
FLANGE FACTORS
(a) For Integral Flanges
E
F =
Factor F per Fig. 2-7.2 is then solved by
(1 + A )
C
6

Factor V per Fig. 2-7.3 is then solved by

V =

2.7 3

]1/ 4

Sheet : 7

Item : E-323A/B & E-514C/D


[Appendix 2] [FIG. 2-4, Sketch (6a)]

Subjected to internal pressure


0.82792

E4
2.73 1/ 4
[
]
(1 + A ) 3
C

0.230119

h/SQRT(BGo) 0.48978638
f = C36 / (1 + A)
1.261692
The values used in the above equations are solved using Eqs. (1) through (45) below based on the values g1, g0, h and ho

Factor f per Fig. 2-7.6 is then solved by

as defined by 2-3. When g1 = go, F = 0.908920, V = 0.550103, and f = 1; thus Eqs. (1) through (45) need not be solved.
(b) For Loose Hub Flanges
Factor FL per Fig. 2-7.4 is solved by

FL =

1
C 18
+
2

11A
A
A
A
1
1
1
+
+

+ C 21
+ C 24

4
70
40
6
84
105
72
1/ 4
3
(
1
)
C
A
+

2 .7 3
C

Factor VL per Fig. 2-7.5 is solved by

VL

C
1
3C 21
24
C18
4
5
2
=
1/ 4
2.73
(1 + A ) 3

1.641051

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 g1, g0, h, and ho as defined by 2-3.
go

0.5

INCH

12.7

MM

g1
h
ho = SQRT(B go), Effective hub length
B

1
1.732283
3.536814
25.01811

INCH
INCH
INCH
INCH

25.4
44
89.83508
635.46

MM
MM
MM
MM

(1)
(2)
(3)

A = (g1/go) - 1
C = 43.68(h/ho)4
C1 = 1/3 + A/12

1
2.513677
0.416667

(4)

C2 = 5/42 + 17 A / 336

0.169643

(5)

C3 = 1/210 + A/360

0.00754

(6)

C4 = 11/360 + 59 A/5040 + (1+3 A)/C

1.633556

(7)

C5 = 1/90 + 5 A/1008 - (1+ A)3/C

-3.166517

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 9 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

N2. Integral Type (W.N.) Main Shell Flange Thickness, item no. 12 (cont.)
FLANGE FACTORS (CONT.)
(8)
C6 = 1/120 + 17 A/5040 +1 /C
(9)

C7 = 215/2772 + 51 A/1232 + (60/7 + 225 A/14 + 75A2/7 + 5 A3/2)/C

(10)

C8 = 31/6930 + 128 A/45045 + (6/7 + 15 A/7 + 12A2/7 + 5 A3/11)/C

Sheet : 7

Item : E-323A/B & E-514C/D


[Appendix 2] [FIG. 2-4, Sketch (6a)]

Subjected to internal pressure


0.40953
15.17942

(11)

2.063598
C9 = 533/30240 + 653 A/73920 + (1/2 + 33 A/14 + 39 A2/28 + 25 A3/84)/C1.83561

(12)

C10 = 29/3780 + 3 A/704 - (1/2 + 33 A/14 + 81 A2/28 + 13 A3/12)/C

(14)

-2.706528
C11 = 31/6048 + 1763 A/665280 + (1/2 + 6 A/7 + 15 A2/28 + 5 A3/42)/C 0.808159
C12 = 1/2925 + 71 A/300300 + (8/35 + 18 A /35 + 156 A2/385 + 6 A3/55)/C0.500699

(15)

C13 = 761/831600 + 937 A/1663200 + (1/35 + 6 A /35 + 11 A2/70 + 3 A3/70.160608

(16)

C14 = 197/415800 + 103 A/332640 - (1/35 + 6 A /35 + 17 A2/70 + A3/10)/-0.215178

(17)

C15 = 233/831600 + 97 A/554400 + (1/35 + 3 A /35 + A2/14 + 2 A3/105)/0.081914

(18)

C16 = C1C7C12 + C2C8C3 + C3C8C2 - (C32C7 + C82C1 + C22C12)

(13)

(19)

1.382461
C17 = [C4C7C12 + C2C8C13 + C3C8C9 - (C13C7C3 + C82C4 + C12C2C9)] / C16 3.884126

(20)

C18 = [C5C7C12 + C2C8C14 + C3C8C10 - (C14C7C3 + C82C5 + C12C2C10)] / C -7.555421

(21)

C19 = [C6C7C12 + C2C8C15 + C3C8C11 - (C15C7C3 + C82C6 + C12C2C11)] / C 0.963379

(22)

C20 = [C1C9C12 + C4C8C3 + C3C13C2 - (C32C9 + C13C8 C1 + C12C4C2)] / C16 0.095208


C21 = [C1C10C12 + C5C8C3 + C3C14C2 - (C32C10 + C14C8 C1 + C12C5C2)] / C1-0.115776

(23)
(24)
(25)

C22 = [C1C11C12 + C6C8C3 + C3C15C2 - (C32C11 + C15C8 C1 + C12C6C2)] / C10.0505


C23 = [C1C7C13 + C2C9C3 + C4C8C2 - (C3C7C4 + C8C9 C1 + C22C13)] / C16 -0.130112

(27)

C24 = [C1C7C14 + C2C10C3 + C5C8C2 - (C3C7C5 + C8C10 C1 + C22C14)] / C16 0.161181


C25 = [C1C7C15 + C2C11C3 + C6C8C2 - (C3C7C6 + C8C11 C1 + C22C15)] / C16 -0.05904

(28)

C26 = - (C/4)1/4

-0.890353

(29)

C27 = C20 - C17 - 5/12 + C17C26

-7.66383

(30)

C28 = C22 - C19 - 1/12 + C19C26

-1.853961

(26)

(31)

1/2

C29 = - (C/4)

-0.792729

(32)

C30 = - (C/4)3/4

-0.705809

(33)

C31 = 3 A/2 - C17 C30

4.241451

(34)

C32 = 1/2 - C19 C30

1.179962

(35)

C33 = 0.5 C26C32 + C28C31C29 - (0.5 C30C28 + C32C27C29)

-2.114621

(36)

C34 = 1/12 + C18 - C21 - C18C26

-14.0833

(37)

C35 = - C18 (C/4)3/4

5.332683

(38)

C36 = (C28C35C29 - C32C34C29)/C33

2.523383

(39)

C37 = [0.5 C26C35 + C34C31C29 - (0.5 C30C34 + C35C27C29)] / C33

-3.599076

(40)

E1 = C17C36 + C18 + C19C37

-1.221557

(41)

E2 = C20C36 + C21 + C22C37

-0.057285

(42)

E3 = C23C36 + C24 + C25C37

0.045348

(43)

E4 = 1/4 + C37/12 + C36/4 - E3/5 - 3E2/2 - E1

1.879338

(44)

E5 = E1 (1/2 + A/6) + E2(1/4 + 11A/84) + E3(1/70 + A/105)

(45)

-0.835114
E6 = E5 - C36(7/120 +A/36 + 3A/C) - 1/40 - A/72 - C37(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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 10 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

N2. Integral Type (W.N.) Main Shell Flange Thickness, item no. 12 (cont.)

Sheet : 7

Item : E-323A/B & E-514C/D


[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 SH = f * Mo /( L * g12 * B).
20 * g1
B

20
INCH
25.01811 INCH

508
635.46

MM
MM

B1 = B + g1 for loose & integral type flanges have f <1 ( the min. f permitted is 1) 26.01811 INCH
B1 = B + go for integral type flanges when f = > 1
25.51811 INCH

660.86
648.16

MM
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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 1 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

O. Integral Type (WN) Main Channel Flanges Thickness (items no. 18)
Flange Material,
[Attached by Bolts]
Design Temperature (tube side)
Min. Design Metal Temperature, MDMT
Bolt-up and Gasket Seating Temperature
Assume no corrosion, C
[UG-25]
Operating Pressure (tube side)
Internal Design Pressure, P (MAWP)
Allowable Stress of Bolt Material (ASME SA193 Gr. B7), SB :

Sheet : 9

Item : E-323A/B & E-514C/D


[Appendix 2] [FIG. 2-4, Sketch (6a)]

ASME SA266 Class2+ SB171 C63000


o
o
F
C
60
140
o
o
F
C
53.6
12
o
o
F
C
86
30
0.19685 INCH
5
MM
Kg/CM2G
42.61364 PSIG
3
71.70824 PSIG
5.04826 Kg/CM2G
25000
25000

PSIG
PSIG

1760
1760

Kg/CM2G
Kg/CM2G

20000

PSIG

1408

Kg/CM2G

* or at atmospheric temp./bolt-up temp. (gasket seating), SfC


20000
Allowable Stress of Nozzle neck, Vessel or Pipe wall Material (ASME SA106 Gr. B) :
* at design temp.(operating condition), SnH
17100
* or at atmospheric temp./bolt-up temp.(gasket seating), SnC
17100

PSIG

1408

Kg/CM2G

PSIG

1203.84

Kg/CM2G

PSIG

1203.84

Kg/CM2G

INCH

25.4

MM

28
685
482.6
623
12.7

MM
MM
MM
MM
MM

25.4
38
40
44

MM
MM
MM
MM

6.35
6
5
31

MM
MM
MM
MM

* at design temp.(operating condition), Sb


* or at atmospheric temp./bolt-up temp. (gasket seating), Sa
Allowable Stress of Flange Material (ASME SA266 Class 2) :
* at design temp.(operating condition), SfH

[Table 1A , SubPart 1 , ASME Sec. II , Part D]

FIG. 2-4, Sketch (6a)


Figure (4)

Nominal bolt dia., dB

No. of bolts

28
1

Bolt Hole, d
Flange outside diameter, A
Flange inside diameter, B
Bolt circut diameter (B.C.D.), C = B + 2(g1 + h1+ R) [Appendix 2-3]
Hup thickness at small end, go = Shell Thickness t

1.102362
26.9685
19
24.52756
0.5

INCH
INCH
INCH
INCH

Hup thickness at back of flange, g1 (assume g1 = 2 go)


1
R must not less than 1.5 the bolt hole (see TEMA Table D-5)
1.5
Hup length, h (must greater than 1.5 go) [FIG. 2-4, Sketch 6]
1.574803
Use max. slope 1:3, h = 3.5 g0
1.732283
Slope angle, Y = arc Tan [(g1-go)/h]
16.10006
Fillet radius, r = 0.25 g1 [but not less than 3/16"(4.7625 MM)] [FIG. 2-4, Sketch 6, Note a 0.25
Use r
0.23622
h1 = r * Tan (45-Y/2)
0.177682
E = (A-C)/2
1.220472

INCH

(Check D292 )

INCH
INCH
INCH
INCH

Degree
INCH
INCH
INCH
INCH

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 2 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 9

Item : E-323A/B & E-514C/D

O. Integral Type (WN) Main Channel Flanges Thickness (item no. 18) (cont.)
[Attached by Bolts]
Nominal shell size
Pipe Schedule
No. of bolts
Nominal bolt dia., dB
Bolt diameter at root of thread

20"
30
28
1
0.88189

Actual cross-sectional area of each bolt,


Total actual cross-sectional area of bolts, Ab

0.551
15.428

[TEMA Table D-5]

Flange outside diameter, A


Flange inside diameter, B
Bolt circut diameter (B.C.D.), C
Gasket Details: - Flat metal, jacketed asbestos filled, soft copp[er or brass
- Outside diameter = (B.C.D - d) - 2*13
- Inside diameter = O.D - 2N
- Width, N
Gasket Dimensions:
[Table 2-5.2]
Basic gasket seating width, bO = N/2
Since bo > 1/4 inch (6.35 MM),
[Table 2-5.2]
Effective gasket seating width, b = 0.5*SQRT(bO)
[Table 2-5.2]
Gasket Factor, m
[Table 2-5.1]
Min. Seating Stress, y
[Table 2-5.1]
Facing Sketch
[Table 2-5.1]
Diameter at location of gasket load reaction, G
When bo is larger than 1/4", G = O.D.of gasket contact face - 2 b

[Appendix 2] [FIG. 2-4, Sketch (6a)]

Subjected to internal pressure

INCH
INCH2
INCH2

MM
MM

2
355.4832 MM
2
9953.528 MM

685
482.6
623

MM
MM
MM

22.04724 INCH
20.86614 INCH
0.590551 INCH

560
530
15

MM
MM
MM

0.295276 INCH

7.5

MM

0.271696 INCH
3.5
6500
PSIG
(1a); Column II

6.901087 MM

21.50385 INCH

[Table 2-5.2]

N.B. When b > 1/4", the effective gasket seating width, b = 0.5*SQRT(bO)

25.4
22.4

26.9685 INCH
19
INCH
24.52756 INCH

[ Appendix 2-3]

N.B. When b < 1/4", the effective gasket seating width, b = bo

INCH

[Table 2-5.2]

457.6

Kg/CM2G

546.1978 MM

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 3 of 10
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

Date : 4.7.2003
Location : Alex.

Client : APRC

Sheet : 9

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 G2 P
[Appendix 2-3]
(b) Total joint-contact surface compression load, Hp =2b*3.14GmP

26029.82 lb
9208.667 lb

11806.94 Kg
4176.986 Kg

35238.49 lb
119245.8 lb

15983.93 Kg
54089.04 Kg

25000
25000

1760
1760

[Appendix 2-3]

(c) Min. required bolt load for operating conditions, Wm1 = H + Hp


Min. required bolt load for gasket seating, Wm2 = 3.14 b G y
Allowable Bolt Stress at atmospheric temp., Sa
Allowable Bolt Stress at design temp., Sb

PSIG
PSIG

Kg/CM2G
Kg/CM2G

[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
- Gasket seating,
Am2 = Wm2 / Sa

2
1.40954 INCH
2
4.769831 INCH

2
909.3785 MM
2
3077.304 MM

2
4.769831 INCH
INCH2
15.428
OK

2
3077.304 MM
2
9953.528 MM

35238.49 lb
252472.9 lb

15983.93 Kg
114519.9 Kg

20321.04 lb

9217.479 Kg

9208.667 lb

4176.986 Kg

[Appendix 2-3]
Total required cross-sectional of bolts, Am = the greater of Am1 & Am2

Actual bolt area Ab


Since area Ab > area Am, the bolts are adequately enough.
(e) Flange design bolt load, W :
- For operating conditions, Wo = Wm1
[Appendix 2-5(d)]
- For gasket seating, Wa = 0.5(Am + Ab) * Sa
[Appendix 2-5(d)]
2. Total flange moment for design condition:
[Appendix 2-5(c)]
Flange Loads:
Hydrostatic end force on area inside flange, HD = 0.785 B2 P
Gasket load (flange design bolt load - total hydrostatic end force), HG

Gasket seating force

H G = Wm1 - H

Difference bet. total hydrostatic end force and the hydrostatic end force on area inside of flange, HT

HT = H - HD

5708.784 lb

2589.464 Kg

[Table 2-6]

2.177682 INCH

55.31312 MM

hG = (C - G) / 2

[Table 2-6]

1.511854 INCH

38.40109 MM

hT = (R' + g1 + hG) / 2

[Table 2-6]

2.094768 INCH

53.2071

1.677682 INCH

42.61312 MM

Lever arms:
hD = R' + 0.5 g1

Where R' = R + h1

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 4 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 9

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 HD, MD = HD hD

[Appendix 2-3] 44252.75 lb-in

509.8475 Kg-M

Component of moment due to HG, MG = HG hG

[Appendix 2-3] 13922.16 lb-in

160.4008 Kg-M

Component of moment due to HT, MT = HT hT

[Appendix 2-3] 11958.58 lb-in

137.7779 Kg-M

Total moment acting upon the flange, Mo:


- For operating condition

[Appendix 2-6]

MO1 = MD + MG + MT

70133.49 lb-in
5844.457 lb-ft

808.0261 Kg-M

252472.9 lb

114519.9 Kg

3. Total flange moment for bolt-up condition (Gasket condition):


[Appendix 2-6]

Flange Load:

HG = W A = 0.5 (Am + Ab) * Sa

Lever Arm., hG = (C - G) / 2
Flange Moment for gasket condition, M O2 = HG hG = W A (C - G) / 2
Mo2 * (SfH / SfC )
4. MO = The greater of MO1 or MO2 (SfH/SfC)

(5)

1.511854 INCH

38.40109 MM

381702.1 lb-in

4397.689 Kg-M

381702.1 lb-in
381702.1 lb-in
31808.51 lb-ft

4397.689 Kg-M
4397.689 Kg-M

5. Shape constants for flange:


K =

From Appendix 2, FIG. 2-7.1:


T =
Z=

1.419395

K 2 (1 + 8.55246 Log10 k ) 1
(1.04720 + 1.9448 k 2 )( k 1)

K2 + 1

2.971061

K2 1

K Log10 K
1
0.66845 + 5.71690
K 1
K2 1

2
K (1 + 8.55246 Log K ) 1
10
U =
1.36136( K 2 1)( K 1)

Y =

From Appendix 2, FIG. 2-7.2:


From Appendix 2, FIG. 2-7.3:
From Appendix 2, FIG. 2-7.6:

1.745783

g1/go
ho = SQRT(B go)
h/ho
F
V
f

d = (U/V) ho go2 (for integral type flanges) [APPENDIX 2-3]


e = F / ho
(for integral type flanges) [APPENDIX 2-3]

5.710574
6.275343
2
3.082207
0.562027
0.812252
0.211658
1.02557
22.84569 INCH3
0.263529 INCH-1

3
374373.9 MM
-1
0.010375 MM

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 5 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 9

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

[Attached by Bolts]

6. Calculation of flange actual stresses


Assume t
Factor L =

te + 1 t ^ 3
[Appendix 2-3]
+
T
d

Where t = flange thickness


factor e = F/ ho (for integral type flanges)
e = FL/ ho (for loose type flanges)
F = factor for integral type flanges
T = factor involving K
d = (U/V) ho go2

[Appendix 2-3]
[Appendix 2-3]
[Fig. 2-7.2]
[Fig. 2-7.1]
[Appendix 2-3]

1.397638 INCH
0.903288

35.5

0.263529 INCH-1
NA
0.812252
1.745783
22.84569 INCH3

-1
0.010375 MM

For integral type flange, actual stresses (calculated) : [Fig. 2-4, Sketch (6a)]
1. a. Longitudinal hub stress, operating SH = f Mo / L g12 B (6) [Appendix 2-7(a)22809.2
b. Longitudinal hub stress, seating
SH = f Mo2 / L g12 B (6) [Appendix 2-7(a) 22809.2

MM

3
374373.9 MM

PSIG

2
1605.768 Kg/CM G

PSIG

2
1605.768 Kg/CM G

2. a. Radial flange stress, operating SR = (1.33 t e +1) Mo / L t2 B (7) [Appendix 2 16976.81 PSIG
b. Radial flange stress, seating SR = (1.33 t e +1) Mo2 / L t2 B (7) [Appendix 2 16976.81 PSIG

2
1195.167 Kg/CM G

3. a. Tangential flange stress, operating ST = (Y Mo / t2 B) - Z SR (8) [Appendix 2-78291.077 PSIG


b. Tangential flange stress, seating ST = (Y Mo2 / t2 B) - Z SR (8) [Appendix 2- 8291.077 PSIG

2
583.6918 Kg/CM G

4. a. Flange stress, operating

0.5 (SH + SR)

[Appendix 2-8(a)(4)]

19893

PSIG

2
1400.467 Kg/CM G

b. Flange stress, seating

0.5 (SH + SR)

[Appendix 2-8(a)(4)]

19893

PSIG

2
1400.467 Kg/CM G

5. a. Flange stress, operating

0.5 (SH + ST)

[Appendix 2-8(a)(4)]

15550.14 PSIG

1094.73

Kg/CM2G

b. Flange stress, seating


0.5 (SH + ST)
6. a. Bolt stress, operating = Wm1 / Ab
b. Bolt stress, seating = Wm2 / Ab
7. a. Shear stress carried by the fillet weld

[Appendix 2-8(a)(4)]

15550.14
2284.061
7729.18
0

1094.73
160.7979
544.1343
0

Kg/CM2G

1408
1203.84
35.5

Kg/CM2G
Kg/CM2G

PSIG
PSIG
PSIG
PSIG

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
Allowable design stress of nozzle/vessel at operating condition, Sn
17100
PSIG
Assume flange thickness (without C.A), toperating
1.397638 INCH
Allowable stresses
Kg/CM2

PSIG

Longitudinal Hub Stress SH1 = 1.5 Sf

[Appendix 2-8(a)(1)(b)]

30000

Longitudinal Hub Stress SH2 = 2 Sn

[Appendix 2-8(a)(1)(b)]

34200

The calculated (actual) hub stress S H < SH (min.) allowable


Radial Flange Stress SR = Sf

[Appendix 2-8(a)(2)]

The calculated (actual) radial stress S R < SR allowable

2
1195.167 Kg/CM G

2
583.6918 Kg/CM G

Kg/CM2G
Kg/CM2G
Kg/CM2G

MM

Actual stresses
(Calculated )
Kg/CM2
PSIG

30000

>

22809.2

20000

>

16976.81

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 6 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 9

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)]

20000

Subjected to internal pressure


>
8291.077

0.5(SH + SR) = Sf
< Allowable stress

20000

>

19893

0.5(SH + ST) = Sf
< Allowable stress

20000

>

15550.14

25000

>

2284.061

Tangential Flange Stress ST = Sf

[Appendix 2-8(a)(3)]

The calculated (actual) tangential stress S T < ST allowable

The calculated (actual) stress

The calculated (actual) stress


Bolt stress = Wm1 / Ab
The calculated (actual) stress

< Allowable stress

7.b. For Gasket Seating :


20000
PSIG
17100
PSIG
1.397638 INCH

Allowable design stress of flange at gasket seating, Sf


Allowable design stress of nozzle/vessel at gasket seating, Sn

Assume flange thickness (without C.A), tgasket

Allowable stresses
Kg/CM2

PSIG

Longitudinal Hub Stress SH1 = 1.5 Sf

[Appendix 2-8(a)(1)(b)]

30000

Longitudinal Hub Stress SH2 = 2 Sn

[Appendix 2-8(a)(1)(b)]

34200

The calculated (actual) hub stress S H < SH (min.) allowable

1408
1203.84
35.5

>

22809.2

20000

>

16976.81

20000

>

8291.077

20000

>

19893

The calculated (actual) stress

0.5(SH + SR) = Sf
< Allowable stress
0.5(SH + ST) = Sf
< Allowable stress

20000

>

15550.14

The calculated (actual) stress


Bolt stress = Wm2 / Ab
The calculated (actual) stress

25000

>

7729.18

< Allowable stress

[Appendix 2-8(a)(2)]

MM

Actual stresses
(Calculated )
Kg/CM2
PSIG

30000

Radial Flange Stress SR = Sf

Kg/CM2G
Kg/CM2G

The calculated (actual) radial stress S R < SR allowable


Tangential Flange Stress ST = Sf

[Appendix 2-8(a)(3)]

The calculated (actual) tangential stress S T < ST allowable

The min. flange thickness, t = Max. (toperating, tgasket)

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 7 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 9

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
Gasket width, N
Total required cross-sectional area of bolts
Actual bolt cross-sectional area, Ab
Nominal bolt dia., dB

1.419395
0.590551
4.769831
15.428
1

INCH2
INCH

15
3077.304
9953.528
25.4

MM
MM2
MM2
MM

1. Actual Edge distance, E from drawing = 1/2 (A - C)


1.220472
Min. Edge distance, E (for bolt size 0.75")
0.8125
Min. Edge distance, E (for bolt size 7/8")
0.9375
Min. Edge distance, E (for bolt size 1")
1.0625
Min. Edge distance, E (for bolt size 1-1/8")
[TEMA Table D-5]
1.125
Min. Edge distance, E (for bolt size 1-1/4")
1.25
2. Actual Bolt spacing, B from drawing
2.746215
Min. Bolt spacing, B (for bolt size 0.75")
1.75
Min. Bolt spacing, B (for bolt size 7/8")
2.0625
Min. Bolt spacing, B (for bolt size 1")
2.25
Min. Bolt spacing, B (for bolt size 1-1/8")
[TEMA Table D-5]
2.5
Min. Bolt spacing, B (for bolt size 1-1/4")
2.8125
Max. Recommended bolt spacing, Bmax = 2 dB + 6 t / (m + 0.5) [TEMA RCB-1 4.096457
3. Actual Radial distance, Rh from drawing = (C-B)/2-(g1+h1)
1.566929
Min. Radial distance, Rh (for bolt size 0.75")
1.125
Min. Radial distance, Rh (for bolt size 7/8")
1.25
Min. Radial distance, Rh (for bolt size 1")
1.375
Min. Radial distance, Rh (for bolt size 1-1/8")
[TEMA Table D-5]
1.5
Min. Radial distance, Rh (for bolt size 1-1/4")
1.75

INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH

31
20.6375
23.8125
26.9875
28.575
31.75
69.75387
44.45
52.3875
57.15
63.5
71.4375
104.05
39.8
28.575
31.75
34.925
38.1
44.45

MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM

INCH
INCH2

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 8 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 9

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
E
F =
Factor F per Fig. 2-7.2 is then solved by
0.812252
(1 + A )
C
6

V =

Factor V per Fig. 2-7.3 is then solved by

2.7 3

]1/ 4

E4
2.73 1/ 4
[
]
(1 + A ) 3
C

0.211658

h/SQRT(BGo) 0.56202697
f = C36 / (1 + A)
1.02557
The values used in the above equations are solved using Eqs. (1) through (45) below based on the values g1, g0, h and ho

Factor f per Fig. 2-7.6 is then solved by

as defined by 2-3. When g1 = go, F = 0.908920, V = 0.550103, and f = 1; thus Eqs. (1) through (45) need not be solved.
(b) For Loose Hub Flanges
Factor FL per Fig. 2-7.4 is solved by

FL =

1
C 18
+
2

11A
A
A
A
1
1
1
+
+

+ C 21
+ C 24

4
70
40
6
84
105
72
1/ 4
3
(1 + A )
C

2 .7 3
C

Factor VL per Fig. 2-7.5 is solved by

VL

1
3C 21
C
24
C18
4
5
2
=
1/ 4
2.73
(1 + A ) 3

1.435003

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 g1, g0, h, and ho as defined by 2-3.
go

0.5

INCH

12.7

MM

g1
h
ho = SQRT(B go), Effective hub length
B

1
1.732283
3.082207
19

INCH
INCH
INCH
INCH

25.4
44
78.28806
482.6

MM
MM
MM
MM

(1)
(2)
(3)

A = (g1/go) - 1
C = 43.68(h/ho)4
C1 = 1/3 + A/12

1
4.358241
0.416667

(4)

C2 = 5/42 + 17 A / 336

0.169643

(5)

C3 = 1/210 + A/360

0.00754

(6)

C4 = 11/360 + 59 A/5040 + (1+3 A)/C

0.960063

(7)

C5 = 1/90 + 5 A/1008 - (1+ A)3/C

-1.819531

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 9 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 9

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)
C6 = 1/120 + 17 A/5040 +1 /C
0.241157
(9)
C7 = 215/2772 + 51 A/1232 + (60/7 + 225 A/14 + 75A2/7 + 5 A3/2)/C
8.805292
(10)

C8 = 31/6930 + 128 A/45045 + (6/7 + 15 A/7 + 12A2/7 + 5 A3/11)/C

(11)

1.193305
C9 = 533/30240 + 653 A/73920 + (1/2 + 33 A/14 + 39 A2/28 + 25 A3/84)/C1.069912

(12)

C10 = 29/3780 + 3 A/704 - (1/2 + 33 A/14 + 81 A2/28 + 13 A3/12)/C

(14)

-1.555977
C11 = 31/6048 + 1763 A/665280 + (1/2 + 6 A/7 + 15 A2/28 + 5 A3/42)/C 0.469408
C12 = 1/2925 + 71 A/300300 + (8/35 + 18 A /35 + 156 A2/385 + 6 A3/55)/ 0.28903

(15)

C13 = 761/831600 + 937 A/1663200 + (1/35 + 6 A /35 + 11 A2/70 + 3 A3/ 0.093259

(16)

C14 = 197/415800 + 103 A/332640 - (1/35 + 6 A /35 + 17 A2/70 + A3/10) -0.123775

(17)

C15 = 233/831600 + 97 A/554400 + (1/35 + 3 A /35 + A2/14 + 2 A3/105) 0.047438

(18)

C16 = C1C7C12 + C2C8C3 + C3C8C2 - (C32C7 + C82C1 + C22C12)

(13)

(19)

0.461325
C17 = [C4C7C12 + C2C8C13 + C3C8C9 - (C13C7C3 + C82C4 + C12C2C9)] / C162.267604

(20)

C18 = [C5C7C12 + C2C8C14 + C3C8C10 - (C14C7C3 + C82C5 + C12C2C10)] / C-4.322926

(21)

C19 = [C6C7C12 + C2C8C15 + C3C8C11 - (C15C7C3 + C82C6 + C12C2C11)] / C0.559263

(22)

C20 = [C1C9C12 + C4C8C3 + C3C13C2 - (C32C9 + C13C8 C1 + C12C4C2)] / C16 0.095599

(23)

C21 = [C1C10C12 + C5C8C3 + C3C14C2 - (C32C10 + C14C8 C1 + C12C5C2)] / C -0.115034

(24)

C22 = [C1C11C12 + C6C8C3 + C3C15C2 - (C32C11 + C15C8 C1 + C12C6C2)] / C 0.050557

(25)
(26)

C23 = [C1C7C13 + C2C9C3 + C4C8C2 - (C3C7C4 + C8C9 C1 + C22C13)] / C16 -0.131187


C24 = [C1C7C14 + C2C10C3 + C5C8C2 - (C3C7C5 + C8C10 C1 + C22C14)] / C16 0.159461

(27)

C25 = [C1C7C15 + C2C11C3 + C6C8C2 - (C3C7C6 + C8C11 C1 + C22C15)] / C16 -0.059193

(28)

C26 = - (C/4)1/4

-1.021675

(29)

C27 = C20 - C17 - 5/12 + C17C26

-4.905425

(30)

C28 = C22 - C19 - 1/12 + C19C26

-1.163425

1/2

(31)

C29 = - (C/4)

-1.04382

(32)

C30 = - (C/4)3/4

-1.066445

(33)

C31 = 3 A/2 - C17 C30

3.918274

(34)

C32 = 1/2 - C19 C30

1.096424

(35)

C33 = 0.5 C26C32 + C28C31C29 - (0.5 C30C28 + C32C27C29)

-2.036188

(36)

C34 = 1/12 + C18 - C21 - C18C26

-8.541184

(37)

C35 = - C18 (C/4)3/4

4.610162

(38)

C36 = (C28C35C29 - C32C34C29)/C33

2.051141

(39)

C37 = [0.5 C26C35 + C34C31C29 - (0.5 C30C34 + C35C27C29)] / C33

-2.169755

(40)

E1 = C17C36 + C18 + C19C37

-0.885216

(41)

E2 = C20C36 + C21 + C22C37

-0.028644

(42)

E3 = C23C36 + C24 + C25C37

0.018814

(43)

E4 = 1/4 + C37/12 + C36/4 - E3/5 - 3E2/2 - E1

1.506391

(44)

E5 = E1 (1/2 + A/6) + E2(1/4 + 11A/84) + E3(1/70 + A/105)


-0.600608
E6 = E5 - C36(7/120 +A/36 + 3A/C) - 1/40 - A/72 - C37(1/60 +A/120 + 1/C) -1.675933

(45)

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 10 of 10
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 9

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 SH = f * Mo /( L * g12 * B).
20 * g1
B

20
19

B1 = B + g1 for loose & integral type flanges have f <1 ( the min. f permitted is 1) 20
B1 = B + go for integral type flanges when f = > 1
19.5

INCH
INCH

508
482.6

MM
MM

INCH
INCH

508
495.3

MM
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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 14

Item : E-323A/B & E-514C/D

P. Flat Unstayed Circular Blind Flange(Channel Cover) Thickness (item no. 22)
[Attached by Bolts]

[UG-34 & Fig. UG-34 Sketch (j)]

Subjected to internal pressure

Blind Cover Material, Clad Metal : SB171 UNS No. C63000


Stud bolt material
Design Temperature
Min. Design Metal Temperature, MDMT
Bolt-up and Gasket Seating Temperature
Assume corrosion allowance, C
[UG-25]
Operating Pressure (tube side)
Internal Design Pressure, P (MAWP)
Allowable Stress of Bolt Material, SB :

ASME SA266 Class 2


SA 193 Grade B7
o
F
140
60
o
F
53.6
12
o
F
86
30
0.19685 INCH
5
56.8182 PSIG
4
71.7082 PSIG
5.04826

* 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

25000
25000

PSIG
PSIG

1760
1760

Kg/CM2G
Kg/CM2G

20000

PSIG

1408

Kg/CM2G

* or at atmospheric temp./bolt-up temp. (gasket seating), SfC

20000

PSIG

1408

Kg/CM2G

INCH
INCH
INCH

28
685
623

MM
MM
MM

28
1

INCH

25.4

MM

0.551
15.428
22.1654
19

INCH2
INCH2
INCH
INCH

355.4832
9953.528
563
482.6

MM2
MM2

C
C
o
C
MM
o

Kg/CM2G
Kg/CM2G

[Table 1A , SubPart 1 , ASME Sec. II , Part D]

Joint efficiency, E

Bolt Hole,
Flange outside diameter, A
Bolt circut diameter (B.C.D.),

1.10236
26.9685
24.5276

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]

MM
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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 2 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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 14

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
- Outside diameter
- Inside diameter = O.D - 2N
- Width, N
Gasket Dimensions:
[Table 2-5.2]
Basic gasket seating width, bO = N/2
[Table
Since bo > 1/4 ", Effective gasket seating width, b = 0.5 SQRT(bO)
Gasket Factor, m
[Table 2-5.1]
Min. Seating Stress, y
[Table 2-5.1]
Facing Sketch
[Table 2-5.1]

0.125
22.0472
20.8661
0.59055

INCH
INCH
INCH
INCH

3.175
560
530
15

MM
MM
MM
MM

0.29528

INCH

7.5

MM

0.2717
INCH
3.5
6500
PSIG
(1a); Column II

6.901087 MM

21.5039

INCH

546.1978 MM

Factor depending upon method of attachment of head, C [Fig. UG-34, Sketch (j)] 0.3
[Table 2-5.2]
Gasket moment arm, hG = (B.C.D - d)/2 = (C-G)/2
1.51185

INCH

38.40109 MM

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

457.6

Kg/CM2G

[Appendix 2-3]

Calculating the Min. required Thickness of Blind Flange, t:


t = d CP/SE +1.9W hG /SEd3

[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.

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 3 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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 14

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)
2
Wm1 = H + Hp = 0.785 G P + (2b x 3.14 GmP)
(1) [Appendix 2-5(e35243.2

lb

15986.05 Kg

Flange thickness

0.85602

INCH

21.74301 MM

0
20000

PSIG
PSIG

0
1408

lb

54089.04 Kg

t = d CP / SE + 1.9Wh G / SEd^ 3

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
S
Flange Design Bolt Load for circular heads, W
[Appendix 2-5(e)]
For gasket seating,
W = 0.5(Am + Ab) Sa
(4)

Kg/CM2G
Kg/CM2G

Total required cross-sectional area of bolts, Am = Max (Am1,Am2)


Required bolt load under atmospheric temp.conditions, Wm2 = 3.14bGy

(2) 119246

* Total cross-sectional area of bolts at root of thread requiired


at operating conditions ,
Am1 = Wm1/ Sb

1.40973

INCH2

909.4991 MM2

* Total cross-sectional area of bolts at root of thread required


gasket seating,
Am2 = Wm2/ Sa

4.76983

INCH2

3077.304 MM2

4.76983

INCH2

3077.304 MM2

252473

lb

114519.9 Kg

1.29857

INCH

32.98372 MM

1.29857
1.29921
2.00787

INCH
INCH
INCH

32.98372 MM
33
MM
51
MM

2.48031

INCH

63

Total required cross-sectional area of bolts, Am = Max (Am1,Am2)


For gasket seating,

W = 0.5(Am + Ab) Sa

(4)

t = d CP / SE + 1.9Wh G / SEd^ 3

t = max. of t of operating and gasket seating


Use t without corrosion allowance
Use t for construction including R.F.
N.B. Check which the deflection is considered a governing thickness or not.
The deflection is ehe governing thickness

MM

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 4 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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 14

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.)
Use t for construction including R.F.
For a proper design of flange :
1. You have to make a check for flange deflection.

1.29857
2.04724

INCH
INCH

32.98372 MM
52
MM

GASKET SUMMARY
Gasket width, N
Required cross-sectional of bolts, Am
Actual cross-sectional area of bolts, Ab

0.59055
4.76983
15.428

INCH
INCH2
INCH2

15
MM
3077.304 MM2
9953.528 MM2

BOLT SUMMARY
No. of bolts
Size of bolt (the bolt size is represented by its actual cross-sectional area)
Bolt hole dia.
Total required cross-sectional area of bolts, Am
Total actual cross-sectional area of bolts, Ab
Actual cross-sectional area of bolt,
[TEMA TABLE D-5]

28
1
1.125
4.76983
15.428
0.551

INCH
INCH
INCH2
INCH2
INCH2

25.4
28.575
3077.304
9953.528
355.4832

0.75
4.76983
8.456
0.302

INCH
INCH2
INCH2
INCH2

NA

1.22047
0.8125
1.0625
1.125
1.25

INCH
INCH
INCH
INCH
INCH

31
20.6375
26.9875
28.575
31.75

Bolt
MM
MM
MM2
MM2
MM2

Since the actual bolt area Ab > The required bolt area Am,
the bolts are adequately enough.
N.B. When using bolt with size
Total required cross-sectional area of bolts, Am
Total ctual cross-sectional area of bolts, Ab
Actual cross-sectional area of bolt,
[TEMA TABLE D-5]
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)
Min. Edge distance, E (for bolt size 0.75")
Min. Edge distance, E (for bolt size 1")
Min. edge distance, E (for bolt size 1-1/8")
[TEMA Table D-5]
Min. Edge distance, E (for bolt size 1.25")

MM
MM
MM
MM
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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 5 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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 14

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
Min. Bolt spacing, B (for bolt size 0.75")
1.75
[TEMA Table D-5]
Min. Bolt spacing, B (for bolt size 7/8")
2.0625
Min. Bolt spacing, B (for bolt size 1")
2.25
Min. Bolt spacing, B (for bolt size 1-1/8")
2.5
Min. Bolt spacing, B (for bolt size 1-1/4")
2.8125
Max. Recommended bolt spacing, Bmax = 2 dB + 6 t / (m + 0.5) [TEMA RCB 3.94882
Check for Flat Channel Cover Deflection

G
Y =
0.0435G 3 P+0.5S B A B h G
ET 3

Where

69.75387
44.45
52.3875
57.15
63.5
71.4375
100.3

MM
MM
MM
MM
MM
MM
MM

INCH
INCH
INCH

0.762
0.635
508

MM
MM
MM

[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"
0.125% of nominal diameters (nominal diameter/800) for larger sizes
Nominal diameter = Shell ID + 2 ts
A method for calculating of channel cover deflection at the center, Y is:

INCH
INCH
INCH
INCH
INCH
INCH

INCH

0.03
0.025
20

G = Gasket load reaction diameter as defined by the Code


21.5039
E = Modulus of elasticity at design temperature [ASME Sec.II,Part D, TM 31460000
T = Thickness under consideration (minus groove and C.A.)
1.29921
P = Design pressure
71.7082
SB = Allowable bolting stress at design temperature (Wm1)
25000
AB =Actual total cross-sectional root area of bolts
15.428
hG = Radial distance from diameter G to bolt circle
1.51185

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.

INCH
PSI
INCH
PSIG
PSIG
INCH2
INCH

546.1978 MM
2

2214784.07 Kg/CM G

33
5.04826
25000
9953.528
38.40109

MM
Kg/CM2G
Kg/CM2G

MM2
MM

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 6 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

Date : 4.7.2003
Location : Alex.

Client : APRC

Sheet : 14

Item : E-323A/B & E-514C/D

P. Flat Unstayed Circular Blind Flange (Channel Cover) Thickness (item no. 22) (cont.)
[Attached by Bolts]
Y =

The calculated deflection is

G
E T3

(0.0435 G

[UG-34 & Fig. UG-34 Sketch (j)]


P + 0.5 S B AB hG

0.10054

INCH

2.553795 MM

0.03

INCH

0.762

2.88948

INCH

73.39285 MM

0.00914

INCH

0.232149 MM

1.88283

INCH

47.824

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


The thickness neglecting corrosion allowance is

1.88283
1.88976

INCH
INCH

47.824
48

MM
MM

Conclusion : Checking of Deflection


The min. thickness of channel cover to resist the internal pressure is
Where the min. thickness of channel cover to avoid deflection is
The min. thickness of channel cover as derived from drawings is
The flange thickness increased by

1.33858
1.88976
1.9685
0.07874

INCH
INCH
INCH
INCH

34
48
50
2

MM
MM
MM
MM

Tthickness including groove depth ( 5 MM)


Overall thickness including raised faces & groove depth

2.08661
2.48031

INCH
INCH

53
63

MM
MM

Max. Working Pressure, MWP at New (cold) & Operating (corroded)


at New (cold)
P = SE t2 /d2 c - 1.9 W h G / d3 c

104.094

PSIG

2
7.328196 Kg/CM G

104.094

PSIG

2
7.328196 Kg/CM G

The recommended deflection limit

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,
Tassumed = T +

Y =

Ycalculated
[TEMA RCB-9.21]
Yrecommended

G
0.0435 G 3 P + 0.5 S B AB hG
E T3

Easier approach :
1. Assume T,
2. Find Calculated deflection

Y =

at Operating (corroded)

G
0.0435 G 3 P + 0.5 S B AB hG
E T3

P = SE t2 /d2 c - 1.9 W h G / d3 c

MM

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 1 of 2
Rev. : 0

Project
: Design & Fabrication of Heat Exchanger for APRC Refinery
Job No.
: 7443-33
Dwg. No. : 7443-33-1A, Rev. 0
Sheet : 4
Exchanger : Residue Cooler, Type : AES, TEMA class : R

Date : 4.7.2003
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

Q. TEMA Stationary Tubesheet Thickness Formula-Bending (item No.36)


Tubesheet material,

ASME SB171 UNS No. 63000

Carbon Steel

Effective tubesheet thickness, T

[TEMA RCB-7.132]

T=

G
3

P
n'

Where
F = 1.25 For unsupported tubesheet (e.g. U-tube tubesheets) gasketed
both sides.
F = 1 For supported tubesheet (e.g. fixed tubesheets & floating type
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.

1.25
1

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
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
o
F
Design temperature
302
n' = 1

0.785
2

Pitch
Tube OD

0.907
n' = 1
2
Pitch
For triangular or rotated triangular tube patterns, n'
Tube OD

For square or rotated square tube patterns, n'

0.520874

0.446411

NA

546.1978 MM

1478.118 Kg/CM2G
o
C
150

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 83 of 136
Sheet : 2 of 2
Rev. : 0

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)

Project
: Design & Fabrication of Heat Exchanger for APRC Refinery
Job No.
: 7443-33
Dwg. No. : 7443-33-1A, Rev. 0
Sheet : 4
Exchanger : Residue Cooler, Type : AES, TEMA class : R
Q. TEMA Stationary Tubesheet Thickness Formula-Bending (item No.36)
No of tubes
146
Tube OD
0.984252
Tube length
236.2205
Tube pitch
1.259843
Tube BWG
13
Tube wall thickness
[TEMA Table D-7]
0.098425
o
30o
Tube pattern ( equal angles triangle 60 )
* 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
* 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 + P Bt
or
P = Pt
71.70824
or
P = Ps
284.7764
F G
P
Effective tubesheet thickness, T
1.561785
T=
3
n
'
S
Ttubesheet thickness with CA
1.811024
Tubesheet raised face (2 x 5)
0.551181
Use tubesheet thickness for construction
2.362205
Tubesheet OD
22.04724
TUBESHEET THICKNESS FORMULA-SHEAR
[TEMA RCB-7.132]

Date : 4.7.2003
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

[TEMA RCB-7.132]

INCH
INCH
INCH

25
6000
32

MM
MM
MM

INCH

2.5

MM

PSIG

20.04826 Kg/CM2G

PSIG
PSIG
INCH
INCH
INCH
INCH
INCH

5.04826
20.04826
39.66934
46
14
60
560

(square rotated)

T =

Effective tubesheet thickness, T

P
S

Note : Shear will not control when

Kg/CM2G
Kg/CM2G

MM
MM
MM
MM
MM

0.31 DL P

do S

1 Pitch

do

< 16
. 1
Pitch

P/S

0.013563

do

16
. 1
Pitch

0.076563
Perimeter
Area
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
MWP, Operating & corroded
P = n' S (3 T / F G)2
598.3149

INCH
2
INCH
PSIG
PSIG

MM
MM2
44.13556 Kg/CM2G
42.12137 Kg/CM2G

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 84 of 136
Sheet : 1 of 2
Rev. : 0

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)

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 : 6

Date : 4.7.2003
Location : Alex.
Client : APRC
Item : E-323A/B & E-514C/D

Q1. TEMA Floating Tubesheet Thickness Formula-Bending (item No.37)


Tubesheet material,

ASME SB171 UNS No. 63000

Carbon Steel

Effective tubesheet thickness, T

[TEMA RCB-7.132]

T=

G
3

P
n'

Where
F = 1.25 For unsupported tubesheet (e.g. U-tube tubesheets) gasketed
both sides.
F = 1 For supported tubesheet (e.g. fixed tubesheets & floating type
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.

1.25
1

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
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
o
F
Design temperature
302
For square or rotated square tube patterns, n'

n' = 1

0.785
Pitch

Tube OD

For triangular or rotated triangular tube patterns, n'n' = 1

0.520874

0.907
Pitch
Tube OD

0.446411

NA

462

MM

1478.118 Kg/CM2G
o
C
150

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 85 of 136
Sheet : 2 of 2
Rev. : 1

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)

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
Q1. TEMA Floating Tubesheet Thickness Formula-Bending (item No.37)
No of tubes
Tube OD
Tube length
Tube pitch
Tube BWG
Tube wall thickness
[TEMA Table D-7]
Tube pattern ( equal angles triangle 60o)
* 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]
* 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 + P Bt
or
P = Pt
or
P = Ps
(square rotated)

Note : Shear will not control when

[TEMA RCB-7.132]

146
0.984252
236.2205
1.259843
13
0.098425
30o

INCH
INCH
INCH

25
6000
32

MM
MM
MM

INCH

2.5

MM

284.7764 PSIG

20.04826 Kg/CM2G

71.70824 PSIG
284.7764 PSIG

5.04826 Kg/CM2G
20.04826 Kg/CM2G

1.321032
1.535433
0.393701
1.929134
2.362205
18.58268

33.5542
39
10
49
60
472

T=
Effective tubesheet thickness, T
3
n' S
Ttubesheet thickness with CA
Tubesheet raised face (2 x 5)
Use tubesheet thickness
Use tubesheet thickness for construction (not less than thk of st. tubesheet)
Tubesheet OD
[TEMA RCB-7.132]
TUBESHEET THICKNESS FORMULA-SHEAR
0.31 DL P
T =

Effective tubesheet thickness, T
do S

Pitch

P
S

Sheet : 6

Date : 4.7.2003
Location : Alex.
Client : APRC
Item : E-323A/B & E-514C/D

do

< 16
. 1
Pitch

P/S

INCH
INCH
INCH
INCH
INCH
INCH

MM
MM
MM
MM
MM
MM

0.013563

do

16
. 1
Pitch

0.076563
Perimeter
Area
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
MWP, Operating & corroded
P = n' S (3 T / F G)2
601.1175

INCH
INCH2
PSIG
PSIG

MM
MM2
44.34229 Kg/CM2G
42.31867 Kg/CM2G

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 86 of 136
Sheet : 1 of 1
Rev. : 0

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)

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

Date : 4.7.2003
Location : Alex.
Client : APRC

Sheet : 7

Items : E-323A/B & E-514C/D

Q2. TEMA Pass Partition Plate Thickness Calculation (item No.23)


Pass partition plate material

Min. calculated pass partition plate thickness,

[TEMA RCB-9.13]

ASME SB171 UNS No. 63000


t calculated = b

qB
15
. S

0.193711 INCH

4.920265 MM

23.62205 INCH
19
INCH
1.243266
0.467662
7
PSIG

600
482.6

MM
MM

0.4928

Kg/CM2G

[TEMA Table RCB-9.132]

Where
Plate dimension, a
Plate dimension, b
[TEMA Table RCB-9.132]
Ratio a/b (long side case)
Table value B, to be found from Table RCB-9.132 versus a/b
Pressure drop across plate, q

S = Code allowable stress in tension for pass partition plate at design metal tem 20996

PSIG
F

2
1478.118 Kg/CM G
o
C
150

508

Design temperature

302

Exchanger Nominal Size

20

INCH

TEMA Table RCB 9-131

Carbon Steel
INCH
MM
0.375
9.525
0.5
12.7

Nominal pass partition plate thickness for Nominal size < 24"
Nominal pass partition plate thickness for Nominal size 24" to 60"

MM

Alloy Material
INCH
MM
0.25
6.35
0.375
9.525

Nominal tabulated plate thickness, ttabulated


Recommended plate thickness, trecom. = Max. (tcalculated, ttabulated)

0.25
0.25

INCH
INCH

6.35
6.35

MM
MM

Corrosion allowance, C

INCH

MM

[UG-25]

Thickness of pass partition including corrosion allowance,


Assume adopted thickness of pass partition, t

0.25
INCH
0.511811 INCH

6.35
13

MM
MM

Fillet weld leg size, 3/4 t

0.383858 INCH

9.75

MM

[TEMA RCB-9.133]

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.

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 1 of 12
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

Date : 4.7.2003
Location : Alex.
Client : APRC

Q3. FLOATING HEAD & ITS FLANGE

Sheet : 15

Item : E-323A/B & E-514C/D


[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 Joint Efficiency is Required
Backing Ring Material
ASME SA266 Class 2
Head & Flange Material
ASME SB171 UNS No. C63000
o
o
F
C
Design Temperature :
Shell Side
302
150
o
o
F
C
Tube Side
140
60
o
o
F
C
Min. Design Metal Temperature, MDMT
53.6
12
2
Kg/CM
G
Internal Design Pressure, P (MAWP)
(Tube Side)
71.02273 PSIG
5
2
Use Design Pressure, P (MAWP)
71.70824 PSIG
5.04826 Kg/CM G
Design Pressure,
(Shell Side)
284.7763 PSIG
20.0483 Kg/CM2G
External Design Pressure, Pe
284.7763 PSIG
20.0483 Kg/CM2G
o
Max. Allowable Stress for Head Material @ Design Temp. 140&302 F,S
22896
PSIG
1611.88 Kg/CM2G
Max. Allowable Stress for Head Material @ Test Temp.,St
24000
PSIG
1689.6 Kg/CM2G
o
Max. Allowable Stress for Flange Material @ Design Temp. 140&302 F, SH
22896
PSIG
1611.88 Kg/CM2G
Max. Allowable Stress for Flange Material @ Test Temp., SC
24000
PSIG
1689.6 Kg/CM2G
o
Kg/CM2G
Max. Allowable Stress for Backing Ring Material @ Design Temp. 140&302 F,S20000
PSIG
1408
Kg/CM2G
Max. Allowable Stress for Backing Ring Material @ Test Temp.,St
20000
PSIG
1408
[ TABLE 1A , SUBPART 1 , ASME SEC. II , PART D]

Figure (6)

No. of bolts
Nominal bolt dia., dB
Actual Root area of each bolt
Bolt hole dia., d
Flange & Backing ring outside diameter, A
Flange & Backing ring inside diameter, B
Bolt circut diameter (B.C.D.), C

24
1
[TEMA Table D-5]

0.551
1.102362
23.0315
17.71654
20.66929

INCH2

25.4

MM

INCH2

355.483
28
585
450
525

MM2
MM
MM
MM
MM

INCH

INCH
INCH
INCH

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
Job No.
: 7443-33
Dwg. No. : 7443-33-1A, Rev. 0
Exchanger : Residue Cooler, Type : AES, TEMA class : R
Q3. FLOATING HEAD & ITS FLANGE (cont.)

Date : 4.7.2003
Location : Alex.

Client : APRC

Sheet : 15

Item : E-323A/B & E-514C/D


[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
- Outside diameter = (B.C.D - d) - 10
- Inside diameter = O.D - 2N
- Width, N
Gasket Dimensions:
[Table 2-5.2]
Basic gasket seating width, bO = N/2
Since bo is less than 1/4 inch,
Effective gasket seating width, b = bO
[Table 2-5.2]
N.B. When bo > 1/4 inch,

b = 0.5*SQRT(bO)

Gasket Factor, m
Min. Seating Stress, y
Facing Sketch

or brass)
18.58268 INCH
17.79528 INCH
0.393701 INCH

472
452
10

MM
MM
MM

0.19685

INCH

MM

0.19685

INCH

MM

[Table 2-5.2]

0.221839 INCH

5.63471 MM

[TABLE 2-5.1]
[TABLE 2-5.1]
[TABLE 2-5.1]

3.5
6500
PSIG
(1a); Column II

457.6

Kg/CM2G

462

MM

5
0

MM
MM

10

MM

Diameter at location of gasket load reaction, G


When bo is less than 1/4", G = Mean dia. of gasket contact face = (ID + OD) / 2 18.18898 INCH
[APPENDIX 2-3]

Corrosion allowance, C (for carbon steel)


Corrosion allowance, C (for copper)

0.19685
0

Fillet weld size, h1

0.393701 INCH

INCH
INCH

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 3 of 12
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
Q3. FLOATING HEAD & ITS FLANGE (cont.)
Q3a. Min Required Thickness of Floating Head (cont.)
Dish radius for spherical segment, L ( 0.9-0.82 I.D = 0.9 * B approx.)
The governing radius depends on the total cross-overbypass area
Q3a.1. For pressure on concave side (internal pressure)

Date : 4.7.2003
Location : Alex.

Item : E-323A/B & E-514C/D


[Attached by Bolts]

[Appendix 1-6]

13.77953 INCH

350

5PL
[1]
0.035964
6S
(CA from outside only, inside there is cla 0.035964

0.51181

INCH
INCH
INCH

0.91347 MM
0.91347 MM
13
MM

[Appendix 1-6(e)(1)(b)] & [UG-33(c)]

Step 1. Assume thickness t without corrosion allowance


Outside radius of spherical head segment, Ro = L + t
A=

MM

[Appendix 1-6(e)(1)(a)]

t=

Thickness t including C.A


Use t for construction
Q3a.2. For pressure on convex side (external pressure)

Client : APRC

Sheet : 15

0. 125
(Ro / t )

0.51181 INCH
14.29134 INCH

13
363

MM
MM

774.4

Kg/CM2G

0.004477

Step 2 & 3. Enter Figure NFA-6 of ASME Sec.II, Part D at A value


and move vertically to material line for 302 oF.
Move horizontally to the right and read B value of

11000

Step 4. The max. allowable external working pressure for


the assumed head thickness :
Pa =

393.9386 PSIG

27.7333 Kg/CM2G

284.7763 PSIG
OK

20.0483 Kg/CM2G

B
(Ro / t )

External design pressure,


Pe
Since Pa > Pe, the assumed head thickness is satisfactory.

0.004477
PSIG

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 4 of 12
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
Q3. FLOATING HEAD & ITS FLANGE (cont.)
B1 = arc sin

Client : APRC

Sheet : 15

Item : E-323A/B & E-514C/D


[Attached by Bolts]

[Appendix 1-6]

[Fig. 1-6(d)]

Q3b. Min Required Thickness of Ring Flange

Head-to-ring angle

Date : 4.7.2003
Location : Alex.

B
2L + t

1. Bolt loading and size of bolts:


(a) Total hydrostatic end force, H = 0.785 G2 P

[Appendix 1-6(b)]

39.13399 Degree

[Appendix 2-5(c)]

18445.21 lb

8366.61 Kg

(b) Total joint-contact surface compression load, Hp =2b*3.14GmP


5589.456 lb
[ Appendix 2-3]
(Gasket seating load)

2535.34 Kg

(c) Min. required bolt load for operating conditions, W m1 = H + Hp


24034.66 lb
Use W m1 = Max (W m1 Floating head flange , W m1 Backing ring) [Appendix 2-3 25021.21 lb

10902
Kg
11349.4 Kg

Min. required bolt load for gasket seating,


W m2 = 3.14 b G y
73078.15 lb
Use W m2 = Max (W m2 Floating head flange , W m2 Backing ring) [APPENDIX 2- 86187.58 lb

33147.7 Kg
39094.1 Kg

[Appendix 2-3]

Allowable Bolt Stress at atmospheric temp., Sa


Allowable Bolt Stress at design temp., Sb

25000
25000

PSIG
PSIG

1760
1760

Kg/CM2G
Kg/CM2G

[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 = W m1 / Sb
[Appendix 2-3]
- Gasket seating,
Am2 = W m2 / Sa
[Appendix 2-3]

2
1.000849 INCH
2
3.447503 INCH

2
645.707 MM
2
2224.19 MM

(e) Total required cross-sectional of bolts, Am = the greater of Am1 & Am2
Actual bolt area, Ab

2
3.447503 INCH
INCH2
13.224

2
2224.19 MM
2
8531.6 MM

25021.21 lb
208393.8 lb

11349.4 Kg
94525.9 Kg

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
- For gasket seating, Wa = 0.5(Am + Ab) * Sa

(3) [Appendix 2-5(d)]


(4) [Appendix 2-5(d)]

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 5 of 12
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
Q3. FLOATING HEAD & ITS FLANGE (cont.)

Date : 4.7.2003
Location : Alex.

Client : APRC

Sheet : 15

Item : E-323A/B & E-514C/D


[Attached by Bolts]

[Appendix 1-6]

[Fig. 1-6(d)]

Q3b. Min Required Thickness of Ring Flange (cont.)

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 G2 P [APPENDIX 18445.21 lb
(b) Hydrostatic end force on area inside flange, HD =0.785 B2 P
17668.36 lb
(c) Gasket load (flange design bolt load - total hydrostatic end force), HG
HG1 = Wo - H = Wm1 - H
(design condition)
6576.009 lb
HG2 = Wa - H = 0.5 (Am + Ab) Sa - H (gasket seating)
189948.6 lb
(d) Difference bet. total hydrostatic end force and the hydrostatic end force
on area inside of flange,
HT = H - HD
776.8437 lb
(e) Floating head load,
Lever arms:

HR = HD cot B1

[Jim Far 21714.58

hD = (C - B) / 2
hG = (C - G) / 2
hT = (hD + hG) / 2

[TABLE 2-6]

lb

8366.6 Kg
8014.23 Kg
2982.83 Kg
86159.2 Kg
352.37

Kg

9849.57 Kg

1.476378 INCH

37.5

MM

1.240157 INCH

31.5

MM

1.358268 INCH

34.5

MM

[BY : A.H.Galala & Jim Farr]


Calculating hR :
hR 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
L1 = t (thk. of floating head)/cos B1
0.659828 INCH
hR = 0.5 (Tassumed - L1)
1.303944 INCH

83
MM
16.7596 MM
33.1202 MM

B1

t=
L1

Figure (7)

MM
13

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 6 of 12
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
Q3. FLOATING HEAD & ITS FLANGE (cont.)
Q3b. Min Required Thickness of Ring Flange (cont.)
Flange Moments due to :
End pressure HD

MG = HG hG

Face pressure HT

MT = HT hT

Floating head load H R

MR = HR hR

[Appendix 28155.287

lb-in.

1055.162 lb-in.
[Jim Farr] 28314.61

lb-in.

300.534 Kg-M
93.959

Kg-M

12.1568 Kg-M
326.22

Kg-M

80.43
80.43

Kg-M
Kg-M

[Appendix 2-6]

MO1 = MD + MG + MT - MR

[Jim Farr] 6981.021

lb-in.
6981.021 lb-in.

Mo1

[APPENDIX 2-6]

hG = (C - G) / 2

Flange Moment for gasket condition, MO2 = HG hG = Wa (C - G) / 2


Use

[Appendix 1-6]

[Fig. 1-6(d)]

3. Total flange moment for bolt-up condition (Gasket condition) :


Flange Load HG = Wa = (Am + Ab) Sa / 2
Lever Arm

Item : E-323A/B & E-514C/D

26085.18 lb-in.

Total moment acting upon the flange, Mo :


- For operating condition
Use

Client : APRC

Sheet : 15

[Attached by Bolts]

MD = HD hD

Gasket load HG

Date : 4.7.2003
Location : Alex.

208393.8 lb

94525.8 Kg

1.240157 INCH

31.5

(5) 258441.1 lb-in.

MO2 = MO2(SH/SC)

246552.8 lb-in.

MM

2977.56 Kg-M
2840.6

Kg-M

9.9453

MM

[Appendix 1-6(g)(2)]
4. The min. flange thickness
4.1. The min. flange thickness for operating condition :
F =

PB
4 L2 B 2
8 S (A B )

M A + B
J = 01

SB A B
T = F +

+ J

4.2. The min. flange thickness for gasket seating :


F
M A + B
J = 02

SB A B
T = F +

+ J

0.027284
0.131943
0.391547 INCH

0
4.659917
2.158684 INCH

54.8306 MM

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 7 of 12
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

Date : 4.7.2003
Location : Alex.

Client : APRC

Sheet : 15

Item : E-323A/B & E-514C/D

Q3. FLOATING HEAD & ITS FLANGE (cont.)


[Attached by Bolts]
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:
hD = (C -B) / 2
1.476378 INCH
[Table 2-6]
hG = (C - G) / 2
1.259843 INCH
hT = (C - G) / 2
Backing ring OD contact = Gasket OD
Backing ring mid point of contact G = (OD of contact
End pressure,
HD = 0.785 B2 P
Face pressure,
HT = H - HD
Total hydrostatic,
H = 0.785 G2 P
Floating head load,
HR = HD cot B1
HP = 2 b * 3.14 G m P
To find Am :
Gasket seating width,
N = (OD - B ) / 2
Basic gasket seating width, bO = N/2
N.B. When bo > 1/4 inch,
Effective gasket seating width, b = 0.5 * SQRT (bO)

1.259843 INCH

+B)/2
(11b)
(11c)
(11d)

18.58268 INCH
INCH
17499.46 lb
865.9855 lb
18365.44 lb
[A. Galala] 21507
lb
[Fig. 2-4, Sk 18.14961

[Appendix 1-6]

37.5

MM

32

MM

32

MM

472
461
7937.62
392.804
8330.42
9755.41

MM
MM
Kg
Kg
Kg
Kg

6655.772 lb
0.433071 INCH
0.216535 INCH

3019.01 Kg
11
MM
5.5
MM

[Table 2-5.2] 0.232667 INCH

5.90974 MM

[Table 2-5.2]

W m1 = H + HP
25021.21
Use W m1 = Max (W m1 Floating head flange , W m1 Backing ring) [Appendix 2-3] 25021.21
W m2 = 3.14 b G y
86187.58
Use W m2 = Max (W m2 Floating head flange , W m2 Backing ring) [Appendix 2-5(c) 86187.58
Am1 = W m1 / Sb
1.000849
Am2 = W m2 / Sa
3.447503
Am = Max. (Am1 , Am2)
3.447503
To find HG1(Gasket load for design condition)
HG1 = W O - H = W m1 - H
6655.772
5.1. Backing ring min. thickness for operating condition :
Moment, Mo3 = MD + MG + MT = HD hD + HG1 hG + HT hT
35312.04
Tring = SQRT ( 2 * Mo3 * Y / S * B )
[Appendix 2-8(c)]
1.226426
K = A/B
1.3

lb
lb
lb
lb
INCH2
INCH2
INCH2
lb

11349.4
11349.4
39094
39094
645.707
2224.19
2224.19
3019.01

lb-in.
INCH

406.839 Kg-M
31.1512 MM

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.
Tring = SQRT ( 2 * Mo4 * Y / S * B )
[Appendix 2-8(c)]
3.34411 INCH
K = A/B
1.3
2

3024.83 Kg-M
84.9404 MM

Factor

Y =

K 2 Log10 K
0.66845 + 5.71690

K 1
K2 1

Y =

Factor

K Log10 K
1
0.66845 + 5.71690
K 1
K2 1

Kg
Kg
Kg
Kg
MM2
MM2
MM2
Kg

7.546382

7.546382

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 94 of 136
Sheet : 8 of 12
Rev. : 0

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)

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
Q3. FLOATING HEAD & ITS FLANGE (cont.)
Q3b. Min Required Thickness of Ring Flange (cont.)

To find Am2 :

Item : E-323A/B & E-514C/D

[Appendix 1-6]

[Fig. 1-6(d)]
[Appendix 1-6(g)(2)] & [Appendix 2-11]

[Table 2-6]

Gasket seating load, W = (Am2 + Ab) Sa /2


End pressure,
HD = 0.785 B2 Pe
Face pressure,
HT = H - HD
Total hydrostatic,
H = 0.785 G2 Pe
Floating head load,
HR = HD cot B1

Client : APRC

Sheet : 15

[Attached by Bolts]

6. In case of flange subjected to external pressure only


Lever arms:
hD = (C -B) / 2
hG = (C - G) / 2
hT = (hD + hG) / 2

Date : 4.7.2003
Location : Alex.

1.476378 INCH

37.5

MM

1.240157 INCH
1.358268 INCH

31.5
34.5

MM
MM

94525.8
31827.1
1720.08
33547.2
39115.8

Kg
Kg
Kg
Kg
Kg

(11a)
(11b)
(11c)
(11d)

208393.8
70166.7
3792.12
73958.82
[A. Galala & Jim F86235.53

HP = 2 b * 3.14 G m Pe

lb
lb
lb
lb
lb

22411.76 lb

10165.8 Kg

W m1 = H + HP
96370.58 lb
Use W m1 = Max (W m1 Floating head flange, W m1 Backing ring) [Appendix 2-3] 100071.2 lb

43713
Kg
45391.5 Kg

W m2 = 3.14 b G y
73078.15 lb
Use W m2 = Max (W m2 Floating head flange, W m2 Backing ring) [Appendix 2-5(c) 86187.58 lb

33147.7 Kg
39094
Kg

Am1 = W m1 / Sb
Am2 = W m2 / Sa
Am = Max. (Am1 , Am2)
6.1.The min. flange thickness for operating condition :
Moment, Mo1 = HD(hD - hG) + HT(hT - hG) - HR hR [Appendix 2-11] (10)
PB 4 L B
8 S (A B )
2

F =

2
2582.48 MM
2
2224.19 MM
2
2582.48 MM

95423.64 lb-in.

1099.4

Kg-M

0.1094

M 01 A + B
J =

SB A B

1.803533

T = F +

1.456806 INCH

37.0029 MM

246552.8 lb-in.
0

2840.6

+ J

6.2. The min. flange thickness for gasket seating :


Moment, Mo2 = W h G * (SH/SC) = [(Am2+Ab)*Sa/2]*hG ?
F
M A + B
J = 02

SB A B

T = F +

2
4.002848 INCH
2
3.447503 INCH
2
4.002848 INCH

F2 + J

Kg-M

4.659917
2.158684 INCH

54.8306 MM

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 95 of 136
Sheet : 9 of 12
Rev. : 0

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)

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
Q3. FLOATING HEAD & ITS FLANGE (cont.)
Q3b. Min Required Thickness of Ring Flange (cont.)
7. Required thickness for backing ring in case of external pressure,
Momenmts for backing ring (ones split ring, lap-type flange :
Lever arms:
hD = (C - B) / 2

Date : 4.7.2003
Location : Alex.

Item : E-323A/B & E-514C/D


[Attached by Bolts]

[APPENDIX 2-7(b)(9)]
[Fig. 2-4 Sketch (1)]

1.476378 INCH

W m1 = H + HP
100071.2
Use W m1 = Max (W m1 Floating head flange , W m1 Backing ring) [Appendix 2-3] 100071.2
W m2 = 3.14 b G y
86187.58
Use W m2 = Max (W m2 Floating head flange , W m2 Backing ring) [Appendix 2-5(c86187.58

Factor

Y =

K 2 Log10 K
1
0.66845 + 5.71690
K 1
K2 1

7.2. Backing ring min. thickness for gasket seating :


Flange bolt load HG = Wa = 0.5(Am2 + Ab) Sa
Moment, Mo4 = HG hG * (SH/SC)
Tring = SQRT ( 2 * Mo4 * Y / S * B )
[Appendix. 2-8(c)]
K = A/B
2
Y =

Factor

K Log10 K
1
0.66845 + 5.71690
K 1
K2 1

[Appendix 1-6]

[Fig. 1-6(d)]

[Table 2-6]
hG = (C - G) / 2
1.259843
hT = (C - G) / 2
1.259843
Backing ring OD contact
18.58268
Backing ring mid point of contact G = (OD of contact + B ) / 2 [Fig. 2-4, Sk 18.14961
(11b)
End pressure,
HD = 0.785 B2 Pe
70166.7
(11c)
Face pressure,
HT = H - HD
3472.299
(11d)
Total hydrostatic,
H = 0.785 G2 Pe
73639
[A. Galala &J 86235.53
Floating head load,
HR = HD cot B1
To find Am :
HP = 2 b * 3.14 G m Pe
26432.19
Gasket seating width,
N = (OD - B ) / 2
0.433071
[Table 2-5.2] 0.216535
Basic gasket seating width, bO = N/2
N.B. When bo > 1/4 inch,
Effective gasket seating width, b = 0.5*SQRT(bO)
[Table 2-5.2] 0.232667

Am1 = W m1 / Sb
Am2 = W m2 / Sa
Am = Max. (Am1, Am2)
To find HG1(Gasket load for design condition)
HG1 = W O - H = Wm1 - H
7.1.Backing ring min. thickness for operating condition :
Moment, Mo3 = HD (hD - hG) + HT (hT - hG)
Tring = SQRT ( 2 * Mo3 * Y / S * B )
[Appendix 2-8(c)]
K = A/B

Client : APRC

Sheet : 15

4.002848
3.447503
4.002848
26432.19

37.5

MM

INCH

32

MM

INCH
INCH
INCH
lb
lb
lb
lb
lb
INCH
INCH

32
472
461
31827.1
1575.01
33402.1
39115.8
11989.4
11
5.5

MM
MM
MM
Kg
Kg
Kg
Kg
Kg
MM
MM

INCH

5.90974 MM

lb
lb
lb
lb

45391.5
45391.5
39094
39094

Kg
Kg
Kg
Kg

INCH2
INCH2
INCH2
lb

2582.48
2224.19
2582.48
11989.4

MM2
MM2
MM2
Kg

15193.58 lb-in.
0.80447 INCH
1.3

175.049 Kg-M
20.4335 MM

7.546382

208393.8 lb
250466.4 lb-in.
3.26629 INCH
1.3
7.546382

94525.8 Kg
2885.68 Kg-M
82.9638 MM

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 96 of 136
Sheet : 10 of 12
Rev. : 0

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)

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
Q3. FLOATING HEAD & ITS FLANGE (cont.)

Date : 4.7.2003
Location : Alex.

Client : APRC

Sheet : 15

Item : E-323A/B & E-514C/D


[Attached by Bolts]

[Appendix 1-6]

0.51181
393.9386
3.267717
3.267717

13
284.776
83
83

MM
PSI
MM
MM

3.464567 INCH

88

MM

0.659828 INCH

16.7596 MM

8.2. GASKET SUMMARY


Gasket width, N
Required cross-sectional of bolts, Am
Actual cross-sectional area of bolts, Ab

0.393701 INCH
2
3.447503 INCH
INCH2
13.224

10
MM
2
2224.19 MM
2
8531.6 MM

8.3. BOLT SUMMARY


No. of bolts
Size of bolt

24
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)
Min. edge distance, E (for bolt size 3/4")
Min. edge distance, E (for bolt size 7/8")
Min. edge distance, E (for bolt size 1")
[TEMA Table D-5]
Min. edge distance, E (for bolt size 1-1/8")

1.181102
0.8125
0.9375
1.0625
1.125

INCH
INCH
INCH
INCH
INCH

30
20.6375
23.8125
26.9875
28.575

MM
MM
MM
MM
MM

2. Actual Bolt spacing, B (c/c) from drawing


2.697884
Min. bolt spacing, B (for bolt size 3/4")
1.75
Min. bolt spacing, B (for bolt size 7/8")
2.0625
Min. bolt spacing, B (for bolt size 1")
[TEMA Table D-5] 2.25
Min. bolt spacing, B (for bolt size 1-1/8")
2.5
Max. Recommended bolt spacing, Bmax = 2 dB + 6 t / (m + 0.5) [TEMA RCB-16.901575

INCH
INCH
INCH
INCH
INCH
INCH

68.5263
44.45
52.3875
57.15
63.5
175.3

MM
MM
MM
MM
MM
MM

3. Actual radial distance, Rr (from drawing) Rr = (C-B)/2


Min. radial distance, Rr (for bolt size 3/4")
Min. radial distance, Rr (for bolt size 7/8")
Min. radial distance, Rr (for bolt size 1")
Min. radial distance, Rr (for bolt size 1-1/8")

INCH
INCH
INCH
INCH
INCH

37.5
20.6375
23.8125
26.9875
28.575

MM
MM
MM
MM
MM

8. CONCLUSION:
8.1. FLOATING HEAD SUMMARY
Floating head thickness for internal pressure: OK
Floating head thickness for external pressure: OK
For calculating hr, assume thickness of flange, T
Calculated flange thickness, T
For a proper design of flange :
1. Adopted thickness of floating head flange
2. The centeline of floating head intersects the inside surface
of flange at distance L1/2

1.476378
0.8125
0.9375
[TEMA Table D-5] 1.0625
1.125

INCH
PSI >
INCH
INCH

Bolt

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 97 of 136
Sheet : 11 of 12
Rev. : 0

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)

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
Q3. FLOATING HEAD & ITS FLANGE (cont.)
8.5. Moments Summary, Mo (in lb-in.) :

a. Internal Pressure
b. External Pressure
8.6. Summary of rerquired thicknesses (in MMS) :
Tubeside (internal pressure), operating condition
Shellside (external pressure), operating condition
Tubeside (internal pressure) gasket seating load
Shellside (external pressure) gasketing load
Raised face
Max. thickness + Corrosion allowance (without raised face)
8.7. Summary of rerquired thicknesses (in INCHES) :
Tubeside (internal pressure), operating condition
Shellside (external pressure), operating condition
Tubeside (internal pressure) gasket seating load
Shellside (external pressure) gasket seating load
Raised face
Max. thickness + Corrosion allowance + raised face

Date : 4.7.2003
Location : Alex.

Client : APRC

Sheet : 15

Item : E-323A/B & E-514C/D

[Appendix 1-6]

[Attached by Bolts]

Floating head
Bcking ring
Flange
Operating Gasket
Operating Gasket
Mo1
Mo2
Mo3
Mo4
6981.021 246552.8 35312 262543
95423.64 246552.8 15193.6 250466
Floating Flange
Head
0.913474 9.945304
13
37.00286
54.83057
54.83057
5
13
83

Bcking
ring
31.1512
20.4335
84.9404
82.9638
5
92

MM
MM
MM
MM
MM
MM

Floating Flange
Head
0.035964 0.391547
0.51181 1.456806
2.158684
2.158684
0.19685
0.511811 3.267717

Bcking
ring
1.22643
0.80447
3.34411
3.26629
0.19685
3.62205

INCH
INCH
INCH
INCH
INCH
INCH

Assumed T = 70 MM is O.K.
Thickness of flange incluiding C .A + 5 mm (raised face)
Use flange adopted thickness T for construction

3.464567 INCH
3.464567 INCH

8.8. Comparison of rerquired thicknesses of floating head flange :

88
88

MM
MM

Differ erence

Ready

INCH

-1.608452608

-0.543194295

-13.7971351

0.158684028

4.030574308

0.158684028

8.9. Comparison of rerquired thicknesses of backing ring :

MM

-40.85469624

4.030574308

Differ erence

Ready

INCH

MM

-2.773573783

-70.44877408

-3.195529701

-81.1664544

-0.655890236

-16.65961201

-0.733710226

-18.63623975

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 98 of 136
Sheet : 12 of 12
Rev. : 0

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)

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
Q3. FLOATING HEAD & ITS FLANGE (cont.)
9. Check for the min. inside depth of floating head cover

Date : 4.7.2003
Location : Alex.

Client : APRC

Sheet : 15

Item : E-323A/B & E-514C/D


[Attached by Bolts]

[Appendix 1-6]

[TEMA R-5.11]

9.1. Calculation of flow area through the tubes of one pass, Apass
Tube OD, do
Tube wall thickness (BWG 12)
[TEMA Table D-7]
Tube ID, di
Total No. of tubes located in tubesheet, N
No. of passes
No. of tubes per one pass, N1
Internal area of one tube, A = PI( )/4*(di)2
Flow area through the tubes per one pass, Apass = N1 * A

1
0.098425
0.80315
146
2
73
0.506621
36.98333

INCH
INCH
INCH

25.4
2.5
20.4

INCH2
INCH2

2
326.852 MM
2
23860.2 MM

13.77953
27.55906
Depth of floating head, h = L - SQRT [L2 - (B/2)2]
3.224601
Ratio, h / D
0.117007
Parameter, C
[TEMA Table D-14]
0.016842
Min. cross-over area, A1 = C * D2
[TEMA Table D-14 12.79117

INCH
INCH
INCH

350
MM
700
MM
81.9049 MM

INCH2

2
8252.35 MM

INCH2

9.2. Calculation of cross-over area of flow, A1


Inside Radius of spherical floating head, L
Inside Diameter of spherical floating head, D = 2 L

9.3. Calculation of cross-over area, A2 = B * H


Flange interference (raised face), R1 = 3/16"
Tubesheet interference (raised face), R4 = 3/16"
Tube projection from tubesheet, R6
Coorosion allowance, CA

MM
MM
MM

MM2
MM
MM
MM
MM

37.13524
0.1875
0.1875
0.11811
0

INCH
INCH
INCH
INCH

23958.2
5
3
3
0

9.4. Calculation of total available cross-over area, A = A1 + A2

49.9264

INCH2

2
32210.5 MM

9.5. Calculation of min. cross-over area = 1.3 Apass

2
48.07834 INCH

2
31018.2 MM

9.6. Compare (A1 + A2) & 1.3 Apass


Change radius L untill (A1 + A2) > 1.3 Apass

[TEMA Figure F-3]


[TEMA Figure F-3]

[TEMA R-5.11]

[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]
Cylindrical clear depth, H = T - (h1+L1+R1+R4)
Total clear depth of head at middle of inside wall = T+ h -(h1+L1)
Head thickness of construction, t
Fillet weld leg, h1

5.320679
2.096078
5.635639
0.511811
0.393701

INCH
INCH
INCH
INCH
INCH

135.145
53.2404
143.145
13
10

MM
MM
MM
MM
MM

DESIGN CALCULATIONS OF HEAT EXCHANGER


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)

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

Page : 99 of 136
Sheet : 1 of 7
Rev. : 1
Date : 11.4.2004
Location : Alex.

Client : APRC
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
Design pressure , P
Design temperature
Radiography (only for pressure parts, BW)
Vessel inside dia., I.D.
Vessel outside dia., O.D.
Vessel outside radius, Ro
Vessel wall thickness, t
Corrosion allowance, C
Material :
shell
heads
saddles
saddle plate (piece of pipe)
Min. tensile stress : shell
heads
saddles
Min. yield stress, sy : shell & heads
saddles
Allowable tensile stress: shell
heads
saddles
Vessel weight ,
empty , W
liquid (water), Wc
Vessel total weight , Wt
Number of saddles used
Load per saddle , Q
Saddle angle of contact , B
Saddle width, b
Ring stiffeners adjacent to saddle

Cylindrical & Horizontal


284.776 PSI
20.04826
o
F
302
150
85%
19
INCH
482.6
INCH
508
20
INCH
254
10
INCH
12.7
0.5
5
0.19685 INCH
ASME SA106 Grade B
ASME SA234 Grade WPB
Steel 37
ASME SA106 Grade B
75000
PSIG
5280
75000
PSIG
5280
55000
PSIG
3872
45000
PSIG
3168
30000
PSIG
2112
17100
PSIG
1203.84
17100
PSIG
1203.84
15700
PSIG
1105.28
9156.34 lb
4152.911
1685.22 lb
764.3392
10841.6 lb
4917.25
2
5420.78 lb
2458.625
Degree
120
130
5.11811 INCH
N.A.

Kg/CM2G
o

MM
MM
MM
MM
MM

Kg/CM2G
Kg/CM2G
Kg/CM2G
Kg/CM2G
Kg/CM2G
Kg/CM2G
Kg/CM2G
Kg/CM2G
Kg
Kg
Kg
Kg
MM

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 100 of 136


Sheet : 2 of 7
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
Items : E-323A/B & E-514C/D

R. Design of Saddle Supports (cont.)


Exchanger Layout :

Figure (8)

Shell Inside Diameter, D


Shell wall thickness, ts
Head wall thickness, th
Distance from tangent line-to-saddle support, A
Head depth - to - tangent line , Ho = ID / 4 + th
Shell length from Tangent - to - tangent (T/T) , L
Distance from tangent line - to - welding line (Skirt), l
Shell length from Welding - to - welding (W/W) , L'
Saddle - to - saddle distance (S/S) , L" = L - 2 A

22.8921
0.5
0.56181
47.2441
6.28484
254.843
4.13386
246.575
165.354

INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH

581.46
12.7
14.27
1200
159.635
6473
105
6263
4200

MM
MM
MM
MM
MM
MM
MM
MM
MM

Total Ellipsoidal Head depth (external depth), H = Ho + l


Total vessel overall length = L + 2 Ho

10.4187 INCH
267.412 INCH

264.635
6792.27

MM
MM

9156.34 lb
1685.22 lb
10841.6 lb

4152.911 Kg
764.3392 Kg
4917.25 Kg

Vessel weight ,

empty , W
liquid (water), Wc
Vessel total weight (water), Wt

Figure (9)

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 101 of 136


Sheet : 3 of 7
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
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.
N
Use 4 stiffeners, n

16
INCH
1.66667

406

MM

* Total length of base plate m' , can also be calculated


in accordance with saddle angle of contact ,B:
m' = 2 (Ro + tf) sin B
Use m

17.3205 INCH
20.5512 INCH

439.9409 MM
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)


Use equally spaced stiffeners, Ss

6.85039 INCH
6.85039 INCH

174
174

MM
MM

5.11811 INCH
1.67323 INCH
6.82283 INCH

130
42.5
173.3

MM
MM
MM

Use b
Use rip plate width, Rw = 1/2[b - (2*cl + tw)]
Use distance, c

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 102 of 136


Sheet : 4 of 7
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
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)
P
b
b
M b = ----II x ---- x ---- = P
b
2
4

II

Kg/CM2G

19800

PSIG

1393.92

5420.78
10
120
120

lb
INCH
Degree
Degree

2458.625 Kg
254
MM

b
----8

Pll = Linear load per unit lengh , lb/in.

Q
1 + cos B
P = ---- [ -------------------------II
Ro II - B + cos B * sin B
Q = load per one saddle , lb
Ro = Vessel outside radius , in.
0 = Angle of contact , deg.
B

= 180 - 0 /2

. . PI

441.298 lb/in

7880.703 Kg/M

. . Bending moment , Mb

282.327 lb-in

3.25276

Flange thickness ,
tf = SQRT(6*Mb / Sb)
Use top flange plate thickness , tf

0.2925
0.5

7.429384 MM
12.7
MM

Use top flange plate width, B = 2* Rip width + 2*(15+25) + tw

7.08661 INCH

INCH
INCH

180

Kg-M

MM

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 103 of 136


Sheet : 5 of 7
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
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" )
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

0.57874 INCH

15

We get h = tw * SQRT [(1500/PII)(18000 tw - PII )]


where c
Since c < h

106.572 INCH
6.82283 INCH
OK

2706.921 MM
173.3
MM

Use web ( saddle ) with thickness , tw

0.59055 INCH

15

tb = SQRT [(Q * b) / 26400 * m]

0.22613 INCH

5.743795 MM

Use base plate with thickness , tb

0.59055 INCH

15

51.5365 PSIG
750
PSIG
0.06872 < 1

3.628171 Kg/CM2G
Kg/CM2G
52.8
Passed

From

----=
a

MM

18000
---------------------------]
1
h
1+ -------[ ---] 2
18000

MM

(d) Calculation of base plate thickness , tb :

(e) Check for the bearing pressure :


Calculated (actual) bearing pressure, Pact. = Q / (b*m)
Allowable bearing pressure, Pallow.
Bearing pressure ratio = Pact. / Pallow.

MM

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 104 of 136


Sheet : 6 of 7
Rev. : 1

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)

Project
: Design & Fabrication of Heat Exchanger for APRC Refinery
Job No.
: 7443-33
Dwg. No. : 7443-33-1A, Rev. 1
Exchanger : Residue Cooler, Type : AES, TEMA class : R
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
l = Tangent - to - tangent distance (T/T) , in.
dT = Difference in temp. = 302-70
o
(consider ambient temp. 70 F )
Expansion , dl

Date : 11.4.2004
Location : Alex.

Client : APRC
Items : E-323A/B & E-514C/D

7.1E-06
o

111.1111 C
o
21.11111 C
10.66233 MM

lb

245.8625
210.0563
201
173.3
455
940
1395

Kg
MM
MM
MM
MM
MM
MM

522
130
180
100

MM
MM
MM
MM

F
232
o
F
70
0.41978 INCH

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
Shear force at the saddle base , fo * Q
Centroid of saddle arc , xo = ro * sin 60 / rad. 60
Use Saddle height under vessel, l = c + tf + tb
Distance, c
Elevation for 1st cooler,
Z =Ro + tf + c + tb
Height between coolers' centerlines, Z1
Elevation for 2nd cooler,
Z2 = Z + Z1
(g) Support Saddle Detail :

0.1
542.078
8.26993
0.65945
6.82283
17.9134
37.0079
54.9213

INCH
ft.
INCH
INCH
INCH
INCH

Figure (10)

m
b
B
Width of outside stiffeners, Sw = 2 Rw + tw

20.5512
5.11811
7.08661
3.93701

INCH
INCH
INCH
INCH

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 105 of 136


Sheet : 7 of 7
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
Items : E-323A/B & E-514C/D

R. Design of Saddle Supports (cont.)


Bending moment = fo * Q ( Z - xo )

5227.5

lb-in

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
Tthe actual value used for b
Since the actual value of b > the calculated value

1.92869 INCH
5.11811 INCH
OK

93352.64 Kg-M

48.98874 MM
130
MM

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 106 of 136


Sheet : 1 of 10
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.

Client : APRC
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

Thickness

1. Pressure Parts Materials


a. Main Shell (Smls. Pipe 20" NPS, Sch. 30) : ASME SA106 Grade B
Shell Cover Course
ASME SA516 Grade 70
:
ASME SA516 Grade 70
Channel plate

-2
P No Gr No

Curve

INCH

MM

0.5
0.5
0.8

12.7
12.7
20

1
1
1

1
2
2

B
D
D

b. Formed Heads (Cap) : (26" NPS, Thk 14.27 mm) : ASME SA234 Grade WPB
Floating Head (sphere sector) :
ASME SB171 UNS No. C63000

0.6
0.5

14.27
13

1
1

1
2

B
B

c. Nozzle Necks : (Seamless Pipe) ASME SA106 Grade B


N3 & N4,
NPS 6", Sch. 80
N1 & N2,
NPS 6", Sch. 80

0.4
0.4

10.9728
10.9728

1
1

1
1

B
B

2.16535
2.16535
2.16535
2.95276
3.8189
2.2
2.2

55
55
55
75
97
55
55

1
1
1
1
1
1
1
1

2
2
2
2
2
2
1
1

B
B
B
B
B
B
B
B

1
1
1
1
1

1
2
2
2
1

B
B
B
B
B

1
1

1
2

B
D

(NA)

(Smls. Pipe 20" NPS, Sch. 30)

d. Flanges :

Standards
ASME SA105
(ASME B16.5)
Non-standard : Shell flanges
ASME SA266 Class 2
Channel flanges ASME SA266 Class 2
Channel cover (blind flange)
ASME SA266 Class 2
Floating Head Flange
ASME SA266 Class 2
Backing Ring
ASME SA266 Class 2
e. Tubesheets : Stationary Tubesheet, ASME SB171 UNS No. C63000
Floating Tubesheet, ASME SB171 UNS No. C63000
f. Pass Partition Plate :
g. Tubes :
h. Fittings :

i. Stud Bolts :

ASME SB171 UNS No. C63000

ASME SB111 UNS No. C68700 (Seamless)


Half Coupling, ASME AS105, N1, 1" NPTF, 3000#
ASME SA105, N2, 1/2" NPTF, 3000#
ASME SA105, N2, 3/4" NPTF, 3000#
Elbows, 6" Sch. 80, ASME SA234 Grade WPB
ASME SA193 Grade B7, Galvanized

Size of Stud Bolts connecting shell-to-channel


Size of Stud Bolts connecting shell-to-shell cover
Size of Stud Bolts connecting channel-to-channel cover
Size of Stud Bolts connecting floating head-to-backing ring
j. Nuts :

0.09843 2.50012
0.3
7.25
0.3
7.25
0.3
7.25
0.432 10.9728
1
1
1
1

25.4
25.4
25.4
25.4

0.5
0.8

12.7
20

ASME SA194 Grade 2H, Heavy & Galvaanized

2. Non-Pressure Parts Materials


a. Saddle Plate :
ASME SA106 Grade B
b. Lifting Lug Reinf. Plate : ASME SA516 Grade 70 (normalized)

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 107 of 136


Sheet : 2 of 10
Rev. : 1

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)

Project
: Design & Fabrication of Heat Exchanger for APRC Refinery
Job No.
: 7443-33
Dwg. No. : 7443-33-1A, Rev. 1
Exchanger : Residue Cooler, Type : AES, TEMA class : R
S. Lowest MDMT Without Impact Test (cont.)
a. For Cylindrical Main Shell (Smls. Pipe 20" NPS, Sch. 30)
Material
Condition
Curve
MDMT
Nominal thickness, tn (adopted thickness)
Point of combination of MDMT & thkickness
Required thickness, tr
Corrosion allowance, C
Joint efficiency, E = E*
MDMT without impact testing
Ratio = tr . E / (tn -c)
[Fig. UCS-66.2]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1]
Adjusted MDMT w/o impact testing
Impact testing required ?
For Shell Cover Course
Material
Condition
Curve
MDMT
Nominal thickness, tn (adopted thickness)
Point of combination of MDMT & thkickness
Required thickness, tr
Corrosion allowance, C
Joint efficiency, E = E*
MDMT without impact testing
Ratio = tr . E / (tn -c)
[Fig. UCS-66.1]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1]
Adjusted MDMT w/o impact testing
Impact testing required ?

Date : 11.4.2004
Location : Alex.

Client : APRC
Items : E-323A/B & E-514C/D

[UG-20(f)] , [UCS-66] & [Fig.UCS-66]

ASME SA106 Grade B


B
28
0.5

F
INCH

-2
12.7

C
MM

Below, so we have to check ratio tr.F/(tn-c)

0.13809 INCH
0.126
INCH
0.85
o
F
-7
0.31383 < 0.35
o
F
135
o
F
-142
No

3.507406 MM
5
MM
o

-21.66667 C
[Fig. UCS-66-1]
o
57.22222 C
o
-96.66667 C

(NA)

ASME SA516 Grade 70


Normalized
D
o
o
F
C
28.4
-2
0.5
INCH
12.7
MM
Below, we have to check ratio tr.F/(tn-c)
0.22088 INCH
5.610261 MM
0.19685 INCH
5
MM
0.85
o
o
F
-48.33333 C
-55
0.61931 > 0.35 [Fig. UCS-66-1]
o
o
F
C
95
35
o
o
F
-101.1111 C
-150
No

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 108 of 136


Sheet : 3 of 10
Rev. : 1

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)

Project
: Design & Fabrication of Heat Exchanger for APRC Refinery
Job No.
: 7443-33
Dwg. No. : 7443-33-1A, Rev. 1
Exchanger : Residue Cooler, Type : AES, TEMA class : R
S. Lowest MDMT Without Impact Test (cont.)
For Channel plate
Material
Condition
Curve
MDMT
Nominal thickness, tn (adopted thickness)
Point of combination of MDMT & thkickness
Required thickness, tr
Corrosion allowance, C
Joint efficiency, E = E*
MDMT without impact testing
Ratio = tr . E / (tn -c)
[Fig. UCS-66.2]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1]
Adjusted MDMT w/o impact testing
Impact testing required ?

Date : 11.4.2004
Location : Alex.

Client : APRC
Items : E-323A/B & E-514C/D

[UG-20(f)] , [UCS-66] & [Fig.UCS-66]

(Smls. Pipe 20" NPS, Sch. 30)

b. For formed heads (cap NPS 26", Thk. 14.27 mm)


Material
Condition
Curve
MDMT
Nominal thickness, tn (adopted thickness)
Point of combination of MDMT & thkickness
Required thickness, tr
Corrosion allowance, C
Joint efficiency, E = E*
MDMT without impact testing
Ratio = tr . E / (tn -c)
[Fig. UCS-66.1]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1]
Adjusted MDMT w/o impact testing
Impact testing required ?

ASME SA516 Grade 70


Normalized
D
o
F
28
-2
0.7874 INCH
20

C
MM

Below, so we have to check ratio tr.F/(tn-c)

0.04829
0
0.85
-39.6063
0.05213
135
-174.606
No

INCH
INCH

1.226577 MM
0
MM

-39.78128 C
[Fig. UCS-66-1]
o
57.22222 C
o
-114.7813 C

F
< 0.35
o
F
o
F

ASME SA 234 WPB


Normalized
B
o
F
-2
28
0.56181 INCH
14.27

C
MM

Below, we have to check ratio tr.F/(tn-c)

0.22088
0.19685
0.85
-1.06614
0.51443
135
-136.066
No

INCH
INCH

5.610261 MM
5
MM

-18.37008 C
[Fig. UCS-66-1]
o
57.22222 C
o
-93.37008 C

F
< 0.35
o
F
o
F

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 109 of 136


Sheet : 4 of 10
Sheet : 3 of 3

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)

Project
: Design & Fabrication of Heat Exchanger for APRC Refinery
Job No.
: 7443-33
Dwg. No. : 7443-33-1A, Rev. 1
Exchanger : Residue Cooler, Type : AES, TEMA class : R
S. Lowest MDMT Without Impact Test (cont.)
For Floating Head (sphere sector)
Material
Condition
Curve
MDMT
Nominal thickness, tn (adopted thickness)
Point of combination of MDMT & thkickness
Required thickness, tr
Corrosion allowance, C
Joint efficiency, E = E*
MDMT without impact testing (for thickness 0.551")
Ratio = tr . E / (tn -c)
[Fig. UCS-66.2]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1]
Adjusted MDMT w/o impact testing
Impact testing required ?
For Backing Ring Flange :
- Item (6) :
Material
ASME/ANSI
Condition
Curve
MDMT
Blind thickness, tA

Date : 11.4.2004
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

[UG-20(f)] , [UCS-66] & [Fig.UCS-66]

ASME SB171 UNS No. C63000


Normalized
B
o
o
F
C
28
-2
0.51181 INCH
13
MM
Below, so we have to check ratio tr.F/(tn-c)

0.375
0
0.85
-5.86614
0.62279
35
-40.8661
No

INCH
INCH

9.525
0

-21.03675 C
[Fig. UCS-66-1]
o
1.666667 C
o
-40.48119 C

F
> 0.35
o
F
o
F

MM
MM
o

ASME SA266 Class 2


Non-Standard
B
28
3.8189

Governing thickness, tg1 = tA/4

0.95472

[Fig. UCS-66.3(c)]
MDMT without impact testing

28.1024

F
INCH

-2
97

24.25

MM

C
MM

o
-2.165354 C

DESIGN CALCULATIONS OF HEAT EXCHANGER


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)

Project
: Design & Fabrication of Heat Exchanger for APRC Refinery
Job No.
: 7443-33
Dwg. No. : 7443-33-1A, Rev. 1
Exchanger : Residue Cooler, Type : AES, TEMA class : R
S. Lowest MDMT Without Impact Test (cont.)

c. For pipe nozzle at shell-side, S1 & S2 6" Sch. 80 :


Material
Condition
Curve
MDMT
Nominal thickness, tn (adopted thickness)
Point of combination of MDMT & thkickness
Required thickness, tr
Corrosion allowance, C
Joint efficiency, E = E*
MDMT without impact testing
Ratio = tr . E / (tn -c)
[Fig. UCS-66.1]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1]
Adjusted MDMT w/o impact testing [UCS-66(b)]
Impact testing required ?
For pipe nozzle in tube-side, T1 & T2 6" 300# WNRF :
Material
Condition
Curve
MDMT
Nominal thickness, tn (adopted thickness)
Point of combination of MDMT & thkickness
Required thickness, tr
Corrosion allowance, C
Joint efficiency, E = E*
MDMT without impact testing
Ratio = tr . E / (tn -c)
[Fig. UCS-66.1]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1]
[UCS-66(b)]
Adjusted MDMT w/o impact testing
Impact testing required ?

Page : 110 of 136


Sheet : 5 of 10
Rev. : 1
Date : 11.4.2004
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

[UG-20(f)] , [UCS-66] & [Fig.UCS-66]

ASME SA 106 Grade B

B
o
o
F
C
-2
28
0.432
INCH
10.9728 MM
Below, we have to check ratio tr.F/(tn-c)
0.03419 INCH
0.868379 MM
0.126
INCH
5
MM
0.85
o
o
-25.34222 C
-13.616 F
0.09497 < 0.35 [Fig. UCS-66-1]
o
o
F
135
57.22222 C
o
o
-148.616 F
-100.3422 C
No

ASME SA 106 Grade B


B
o
o
F
C
28
-2
0.432
INCH
10.9728 MM
Below, we have to check ratio tr.F/(tn-c)
0.03419 INCH
0.868379 MM
0.126
INCH
0
MM
0.85
o
-25.34222
-13.616 F
0.09497 < 0.35 [Fig. UCS-66-1]
o
o
F
135
57.22222 C
o
o
-148.616 F
-100.3422 C
No

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 111 of 136


Sheet : 6 of 10
Rev. : 1

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)

Project
: Design & Fabrication of Heat Exchanger for APRC Refinery
Job No.
: 7443-33
Dwg. No. : 7443-33-1A, Rev. 1
Exchanger : Residue Cooler, Type : AES, TEMA class : R
S. Lowest MDMT Without Impact Test (cont.)
d. For Flanges :
For Standard B16.5 flanges :
Material
ASME/ANSI
Condition
Curve
MDMT
Impact testing exemption temp.

Date : 11.4.2004
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

[UG-20(f)] , [UCS-66] & [Fig.UCS-66]

ASME SA105
B16.5

[UCS-66(c)(1)]

MM
28
-20

F
F

Ferritic Steel

-2
-29

C
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/ANSI
Condition
Curve
MDMT
Blind thickness, tA

ASME SA266 Class 2


Non-Standard
Cladded
B
o
F
-2
28
2.16535 INCH
55

Governing thickness, tg1 = tA/4

0.54134 INCH

[Fig. UCS-66.3(c)]
MDMT without impact testing

-3.0315

:
For Floating Head Flange
- Item (None) :
Material
ASME/ANSI
Condition
Curve
MDMT
Tube Sheet thickness, tA

13.75

C
MM

MM

o
-19.46194 C

(NA)

Governing thickness, tg1 = tA/4

ASME SA266 Class 2


Non-Standard
B
o
F
28
2.95276 INCH

-2
75

0.73819

18.75

MM

C
MM

[Fig. UCS-66.3(c)]
MDMT without impact testing

14.0551

-9.969379 C

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 112 of 136


Sheet : 7 of 10
Rev. : 1

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)

Project
: Design & Fabrication of Heat Exchanger for APRC Refinery
Job No.
: 7443-33
Dwg. No. : 7443-33-1A, Rev. 1
Exchanger : Residue Cooler, Type : AES, TEMA class : R
S. Lowest MDMT Without Impact Test (cont.)

Date : 11.4.2004
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

[UG-20(f)] , [UCS-66] & [Fig.UCS-66]

e. For Stationary Tubesheet :


Item No. (4)
Material
ASME/ANSI
Condition
Curve
MDMT
Tubesheet thickness, tA

ASME SB171 UNS No. C63000

Governing thickness, tg1 = tA/4

B
o
F
28
2.16535 INCH

-2
55

0.54134

13.75

MM

C
MM

[Fig. UCS-66.3(c)]

MDMT without impact testing

For Floating Tubesheet :


Item No. (None)
Material
ASME/ANSI
Condition
Curve
MDMT
Tubesheet thickness, tA

-3.0315

o
-19.46194 C

(NA)

Governing thickness, tg1 = tA/4

ASME Sb171UNS No. C63000

B
o
F
28
2.16535 INCH

-2
55

0.54134

13.75

MM

C
MM

[Fig. UCS-66.3(c)]
MDMT without impact testing (for thickness 2.9374016")

-3.0315

o
-19.46194 C

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 113 of 136


Sheet : 8 of 10
Rev. : 1

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)

Project
: Design & Fabrication of Heat Exchanger for APRC Refinery
Job No.
: 7443-33
Dwg. No. : 7443-33-1A, Rev. 1
Exchanger : Residue Cooler, Type : AES, TEMA class : R
S. Lowest MDMT Without Impact Test (cont.)

f. For heat exchanger tubes 1" , BWG 12 :


Material
Condition
Curve
MDMT
Nominal thickness, tn (adopted thickness)
Point of combination of MDMT & thkickness
Required thickness, tr
Corrosion allowance, C
Joint efficiency, E = E*
MDMT without impact testing
Ratio = tr . E / (tn -c)
[Fig. UCS-66.1]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1]
[UCS-66(b)]
Adjusted MDMT w/o impact testing
Impact testing required ?

Date : 11.4.2004
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

[UG-20(f)] , [UCS-66] & [Fig.UCS-66]

ASME SB111 UNS No. C68700-061


B
o
o
F
C
-2
28
0.09843 INCH
2.500122 MM
Below, we have to check ratio tr.F/(tn-c)
0.0062 INCH
0.157561 MM
0
INCH
0
MM
1
o
o
F
-28.88889 C
-20
0.06302 < 0.35 [Fig. UCS-66-1]
o
o
F
135
57.22222 C
o
o
F
-155
-103.8889 C
No

g. Fittings : For half coupling in nozzles, N1 1", NPTF, 3000# :


Material
Condition
Curve
MDMT
Nominal thickness, tn (adopted thickness)
Point of combination of MDMT & thkickness
Required thickness, tr
Corrosion allowance, C
Joint efficiency, E = E*
MDMT without impact testing
Ratio = tr . E / (tn -c)
[Fig. UCS-66.1]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1]
[UCS-66(b)]
Adjusted MDMT w/o impact testing
Impact testing required ?

B
o
o
F
C
28
-2
0.28543 INCH
7.25
MM
Below, we have to check ratio tr.F/(tn-c)
0.03419 INCH
0.868379 MM
0.126
INCH
3.2
MM
0.85
o
o
F
-28.88889 C
-20
0.18227 < 0.35 [Fig. UCS-66-1]
o
o
F
135
57.22222 C
o
o
F
-155
-103.8889 C
No

Fittings : For 6" NPS, 90o LR Elbows, Sch. 80 :

ASME SA234 Grade WPB

ASME SA105

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 114 of 136


Sheet : 9 of 10
Rev. : 1

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)

Project
: Design & Fabrication of Heat Exchanger for APRC Refinery
Job No.
: 7443-33
Dwg. No. : 7443-33-1A, Rev. 1
Exchanger : Residue Cooler, Type : AES, TEMA class : R
S. Lowest MDMT Without Impact Test (cont.)
Fittings : For half coupling in nozzles, N2 1/2", NPTF, 3000# :
Material
Condition
Curve
MDMT
Nominal thickness, tn (adopted thickness)
Point of combination of MDMT & thkickness
Required thickness, tr
Corrosion allowance, C
Joint efficiency, E = E*
MDMT without impact testing
Ratio = tr . E / (tn -c)
[Fig. UCS-66.1]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1]
[UCS-66(b)]
Adjusted MDMT w/o impact testing
Impact testing required ?
h. Stud bolts :
Material
Curve
Size
MDMT
Impact testing exemption

Date : 11.4.2004
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

[UG-20(f)] , [UCS-66] & [Fig.UCS-66]

ASME SA105
B
o
o
F
C
28
-2
0.28543 INCH
7.25
MM
Below, we have to check ratio tr.F/(tn-c)
0.03419 INCH
0.868379 MM
0.126
INCH
3.2
MM
0.85
o
o
F
-28.88889 C
-20
0.18227 < 0.35 [Fig. UCS-66-1]
o
o
F
135
57.22222 C
o
o
F
-155
-103.8889 C
No

ASME SA193 Grade B7

[Fig. UCS-66, Bolting]


[Size 1.125" < 2.5"]

1
28
-55

INCH
F
o
F
o

25.4
-2
-48

MM
C
o
C
o

i. Nuts :
Material
Curve
Size
MDMT
Impact testing exemption

ASME SA 194 Grade 2H

[Fig. UCS-66, Bolting]


[Size 1.125" < 2.5"]

1
28
-55

INCH
F
o
F
o

25.4
-2
-48

MM
C
o
C
o

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 115 of 136


Sheet : 10 of 10
Rev. : 1

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)

Project
: Design & Fabrication of Heat Exchanger for APRC Refinery
Job No.
: 7443-33
Dwg. No. : 7443-33-1A, Rev. 1
Exchanger : Residue Cooler, Type : AES, TEMA class : R
S. Lowest MDMT Without Impact Test (cont.)
2. For Non-Pressure Parts :

Date : 11.4.2004
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

[UG-20(f)] , [UCS-66] & [Fig.UCS-66]

a. Saddle Plate (tf) :


Material
Condition
Curve
MDMT
Nominal thickness, tn (adopted thickness) (tf)
Point of combination of MDMT & thkickness
Required thickness, tr
Corrosion allowance, C
Joint efficiency, E = E*
MDMT without impact testing
Ratio = tr . E / (tn -c)
[Fig. UCS-66.1]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1]
Adjusted MDMT w/o impact testing [UCS-66(b)]
Impact testing required ?

B
o
o
F
C
28
-2
0.5
INCH
12.7
MM
Below, we have to check ratio tr.F/(tn-c)
0.2925 INCH
7.429384 MM
0
INCH
0
MM
1
o
o
F
-21.66667 C
-7
0.58499 > 0.35 [Fig. UCS-66-1]
o
o
F
42
5.555556 C
o
o
F
C
-49
-45
No

b. Lifting Lug Reinf. Plate :


Material
Condition
Curve
MDMT
Nominal thickness, tn (adopted thickness)
Point of combination of MDMT & thkickness
Required thickness, tr
Corrosion allowance, C
Joint efficiency, E = E*
MDMT without impact testing
Ratio = tr . E / (tn -c)
[Fig. UCS-66.1]
Reduction in MDMT [Temp. versus ratio in Fig. UCS-66.1]
[UCS-66(b)]
Adjusted MDMT w/o impact testing
Impact testing required ?

ASME SA516 Grade 70


Normalized
D
o
o
F
C
28
-2
0.7874 INCH
20
MM
Below, we have to check ratio tr.F/(tn-c)
0.3937 INCH
10
MM
0
INCH
0
MM
1
o
o
-39.78128 C
-39.6063 F
> 0.35 [Fig. UCS-66-1]
0.5
o
o
F
57
13.88889 C
o
o
-96.6063 F
-71.44794 C
No

MDMT without Impact Testing for Shell Side


MDMT without Impact Testing for Tube Side

29
29

ASME SA106 Grade B

F
F

-2
-2

C
C

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 116 of 136


Sheet : 1 of 1
Rev. : 1

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)

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

T. Radiography.

U. Hydrostatic Test Pressure.


Design Temperature :

Date : 11.4.2004
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

Spot

[UG-99(b)]

[ Refer to

Shell-Side
Tube-Side

Test Temperature
Internal Design Pressure, P (MAWP) : Shell-Side
Tube-Side
Max. Allowable Stress @ Design Temperature, S

Max. Allowable Stress @ Test Temperature, St

10%

Page : 15 of 136

o
F
302
o
F
140
o
F
104
284.776 PSIG
71.7082 PSIG

o
C
150
o
C
60
o
C
40
20.04826 Kg/CM2G
5.04826 Kg/CM2G

17100

17100

PSIG

PSIG

1203.840039

1203.840039

2
Kg/CM G

2
Kg/CM G

[Table 1A, SubPart 1, ASME Sec. II, Part D]

a. Hydrostatic Test Pressure as per ASME Code Requirements, Ph = 1.3 * MAWP * (St/S)
Shell-Side
370.209 PSIG
Tube-Side
93.2207 PSIG

MAWP = Design Press.

26.06274 Kg/CM2G
2
6.562738 Kg/CM G

b. Hydrostatic Test Pressure as per Client Request, Ph = 1.5 * MAWP * (St/S)

Shell-Side

427.164617

PSIG

30.07239

Tube-Side

107.5623545

PSIG

7.57239

Shell-Side

637.8835023

PSIG

44.907

Tube-Side

427.4999863

PSIG

30.096

Kg/CM2G

Kg/CM2G

c. Hydrostatic Test Pressure as a Client Request for new & cold, Ph = 1.5 * MWP

d. Hydrostatic Test Pressure for operating & corroded, Ph = 1.3 * MWP


Shell-Side
Tube-Side

V. Post Weld Heat Treatment (PWHT).


Shell Material
P- No.
Gr. No.
Max. Welded Nominal Thickness
According to UW-40 & UCS-56(f), the material is exempted from PWHT

436.017 PSIG
338
PSIG

30.6956
23.7952

[UW-40 & Table UCS-56]


ASME SA 106 Grade B
1
1
0.562
INCH
12.7

Kg/CM2G

Kg/CM2G

Kg/CM2G
Kg/CM2G

MM

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 117 of 136


Sheet : 1 of 4
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

W. Calculation of Exchanger Weight.


1. Volume of vessel :
Shell volume = 3.14 (D/2)2 * L'
Head volume = 3.14 (D/2)2 * (2*KD/3 + Skirt)

358041 INCH2
9.40505 INCH2

4212.74 lb
267.412 INCH
2894.77 lb
3
490.059 lb/ft

1313.032 Kg
Kg/M3
7850

147.05

66.7

( where KD = Depth of head ), K =

Head skirt
Total volume of vessel
Tangent - to - Tangent distance (T/T) , L
Welding - to - Welding distance (W/W) , L'
2. Weight of liquid water , Wc
Total Oveall Length = L + 2 H0
3. Weight of vessel empty , W :
a. weight of shell = II *(Ro^2 - Ri^2 ) * L' * $
( where $ = steel density )
b.weight of ellipsoidal heads
= (II/4) * (D^2) * (4/3) * KD *$ = (II/3)*K*(Do^3 -Di^3)*$
= 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* $
c. weight of saddles :
- Base plate, (12+1472+12)x305x20
Saddle plate length
- Saddle plate , 1896x320x15
Web plate ( saddle plate ) height, h = Z - (Ro+tf) cos(B/2)
Web plate ( saddle plate ) width, Lw = m - 2*(ts + cl)
angle b = B/2
where h1 = height of segment
y = m - m' = (m-2 cl) - 2 (Ro+tf) sin(B/2)
2
Area of segment, As = (Ro+tf) [(3.14 * b)/180 - Sin b* Cos b]
Area of web plate excluding segment, A = (m -2cl) * h - As - 2y2/SQRT(3)
- Weight of web plate (457x349.5x14) = A * tw * $
Rip plates weights (per saddle) :
Rip plates, thickness, ts
Rip plates # 1 width, Rw
Rip plates # 1 , height
Weight of rip plates # 1 (no. off 4 ), 372x95x10
Rip plates # 2 width, Sw
Rip plates # 2 height, h
Rip plates # 2 (no. off 2 ), 349.5x100x10
- rip plates ( per one saddle )
- Weight of one saddle
- Weight of two ( 2 ) saddles

M3
M3

1.803618
0.053615
0.25
105
1.910848
6473
6263
1910.848
6792.27

4.13386 INCH
425772 INCH2
254.843 INCH

lb

MM
M3
MM
MM
Kg
MM

Kg

97.0624 lb

44.02631 Kg

18.4262
25.3937
25.5179
12.6634
18.189
60
5.84055
8.87008
67.7139

lb
MM
lb
INCH
INCH
Degree

8.357895
645
11.57459
321.65
462

INCH
INCH
INCH2

148.35
MM
225.3
MM
2
0.043686 M

Kg
MM
Kg
MM
MM

86.727 INCH2
14.5252 lb

2
0.055953 M
6.588443 Kg

0.59055
1.67323
7.39721
8.29183
3.93701
12.6634
16.6999
24.9917
83.4609
166.922

15
42.5
187.8891
3.761071
100
321.65
7.574858
11.33593
37.85686
75.71371

INCH
INCH
INCH
lb
INCH
INCH
lb.
lb
lb
lb

MM
MM
MM
Kg
MM
MM
Kg
Kg
Kg
Kg

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 118 of 136


Sheet : 2 of 4
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.
Client : APRC
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
- weight of nozzle pipe (145 MM)
- weight of Blind Flange
- weight of Stud Bolts

83.7765
14.2702
0
13.6512

lb
lb
lb
lb

38
6.4728
0
6.192

Kg
Kg
Kg
Kg

- Weight of Nozzle, T1 & T2 6" Sch. 80, WNRF 150# :


- weight of WN flange
- weight of nozzle pipe (145 MM)
- weight of Blind Flange
- weight of Stud Bolts

47.6203
14.2702
0
13.6512

lb
lb
lb
lb

21.6
6.4728
0
6.192

Kg
Kg
Kg
Kg

0
0

lb
lb

0
0

Kg
Kg

- Weight of Nozzle, A X" Sch. 160, WNRF 150# :


- weight of WN flange
- weight of nozzle pipe (1490 MM)

0
0

lb
lb

0
0

Kg
Kg

- Weight of Nozzle, D X" Sch. 80, WNRF 150# :


- weight of WN flange
- weight of nozzle pipe (61 MM)
o
- weight of 90 elbow, LR
- Weight of Nozzle, N4 1", half coupling 3000# :
- Weight of Nozzle, N5 1/2", half coupling 3000# :

0
0
0
2.20465
1.76372

lb
lb
lb
lb
lb

0
0
0
1
0.8

Kg
Kg
Kg
Kg
Kg

191.208 lb

86.7296

Kg

288.097 lb
97.0044 lb

130.6775 Kg
44
Kg

576.195
0
722.276
97.0044

261.3549
0
327.6157
44

- Weight of Nozzle, B&C X" Sch. 160, WNRF 150# :


- weight of WN flange
- weight of nozzle pipe (175 MM)

Total weight of nozzles


e. Weight of Shell Flanges = (3.14/4) (Do2 - Di2) T p
- Weight of Stud Bolts, dia. 1-1/8", 270 LG, Q'ty 20
(including weight of hex. nuts)

f. Weight of Channel
- Weight of Channel Flanges =2 (3.14/4) (Do2 - Di2) T p
- Weight of Channel Course (incl. in weight of shell)
2
- Weight of Channel Blind Flange = (3.14/4) Do T p
- Weight of Stud Bolts, dia. 1-1/8", Heavy, Q'ty 40

lb
lb
lb
lb

Kg
Kg
Kg
Kg

(including weight of hex. nuts)

- Weight of Pass Partition,


Total Weight of items e and f

44.0929 lb
1824.67 lb

20
Kg
827.6481 Kg

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 119 of 136


Sheet : 3 of 4
Rev. : 1

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)

Project
: Design & Fabrication of Heat Exchanger for APRC Refinery
Job No.
: 7443-33
Dwg. No. : 7443-33-1A, Rev. 1
Exchanger : Residue Cooler, Type : AES, TEMA class : R
W. Calculation of Exchanger Weight (cont.)
g. Weight of Bundlel
- Weight of tubes, BWG 13,
No. of Tubes, n
Tube OD
Tube Length, L
Tube Wall Thickness, tt
Tube ID

Date : 11.4.2004
Location : Alex.

Client : APRC
Items : E-323A/B & E-514C/D

2726.82 lb
1
0.23622
0.09843
0.80314

INCH
INCH
INCH
INCH

Kg

Kg
MM
MM

MM
M
MM
MM

- Weight of Floating Tubesheet,


Tubesheet OD
Tubesheet Thickness
No. of Holes
Hole Diameter

55.998

INCH

44.5679
475
55
146
25.4

- Weight of Floating Head Flange


Floating Head Flange OD
Floating Head Flange ID
Floating Head Flange Thickness

139.679
1289.72
998.704
165.348

lb
INCH
INCH
INCH

63.35663
585
453
75

Kg
MM
MM
MM

- Weight of Floating Head Backing Ring


Floating Head Backing Ring OD
Floating Head Backing Ring ID
Floating Head Backing Ring Thickness

180.651
1289.72
998.704
213.851

lb.
INCH
INCH
INCH

81.94124
585
453
97

Kg
MM
MM
MM

- Weight of Floating Head Sperical Segment =(3.14/6)[(Di+90.8997


Spherical Segment Thickness, t
0.51181
Spherical Sector, Sphere Diameter, Di
1543.25
Spherical Segment Height, h
189.048

lb
INCH
INCH
INCH

41.23097
13
700
85.75

Kg
MM
MM
MM

39.36
25.4
24
240
1.64

Kg
MM

74.39984
560
55
146
25.4

Kg
MM
MM

- Stud Bolts & Hex Nuts (floating head)


- Stud Bolt Size
- No. of Stud Bolts (with 2 nuts)
- Stud Bolt Length
- Weight of Stud Bolt + 2 Nuts
- Weight of Stationary Tubesheet
Tubesheet OD
Tubesheet Thickness
No. of Holes
Hole Diameter

98.2564 lb
1047.21 INCH
121.255 INCH

1236.853
146
25.4
6
2.500122
20.39976

86.7748 lb
1
INCH
9.44882 INCH
3.61562 lb
164.025 lb
22.0472 INCH
2.16535 INCH
1

INCH

MM

MM
Kg

MM

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 120 of 136


Sheet : 4 of 4
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

W. Calculation of Exchanger Weight (cont.)


- Weight of Baffels :
No. off Baffels
Baffel OD
Baffel Thickness
Cut Ratio

134.403 lb.
18.7008 INCH
0.19685 INCH

60.96364 Kg
24
475
MM
5
MM
0.4

- Weight of Tube Support :


Tube Support OD
Tube Support Thickness
Tube Support Inside Hole (rectangular)

57.6416
18.7008
0.3937
200

lb.
INCH
INCH
x

26.14553
475
10
200

- Weight of Tie-Rods, OD 1/2", 3650 LG


No. of Tie Rods
Tie Rod OD
Tie Rod Length

13.154

lb

0.5
236.22

INCH
INCH

5.966481 Kg
4
12.7
MM
6
M

- Weight of Spacers, OD 1", 3600 LG


- Weight of Impengment Plate, 150 x 150 x 6 thk
- Weight of Seal Strip 30, 5600x60x6 thk, Q'ty 2
- Weight of Seal Strip 31, 5600x60x6 thk., Q'ty 2

92.5951
6.61394
69.7797
69.7797

lb
lb
lb
lb

42
3
31.6512
31.6512

Total weight of bundle

Kg
MM
MM
MM

Kg
Kg
Kg
Kg

3931.08 lb

1783.087 Kg

Weight of exchanger, empty (erection), W


Weight of contents, Wc

9155.7
1685.1

4152.911 Kg
764.3392 Kg

Total weight of exchanger and contents, Wt

10840.2 lb

lb
lb

4917

Kg

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 121 of 136


Sheet : 1 of 8
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

X. Stresses in Vessel on Two Saddle Supports Using ZICK's Method.


Shell material
Heads material
Saddles material
Heads type
Design temperature
Vessel internal pressure, P
Allowable stress in shell, Sts
Allowable stress in heads, Sth
Allowable stress in web, Sw
Shell compression yield point, Y
Saddle & anchor bolt compression yield point, Re
Outer shell diameter, Do
Wall nominal thickness of shell, ts
Wall nominal thickness of heads, th
Corrosion allowance for shell & heads, CA
Shell joint efficiency, Es
Head joint efficiency, Eh

ASME SA106 Grade B


ASME SA234 Grade WPB
ASME SA106 Grade B
Ellipsoidal 2:1
o
F
150
302
284.776 PSIG
20.04826
17100
PSIG
1203.84
17100
PSIG
1203.84
15700
PSIG
1105.28
45000
PSIG
3168
30000
PSIG
2112
20
INCH
508
INCH
12.7
0.5
0.5
INCH
12.7
0.197
INCH
5
0.85
0.85

Head internal depth, h


Head depth -to- tangent line (external depth), Ho
Insulation thickness, tis
Wear (reinf./top flange) plate width, B
Wear (reinf./top flange) plate thickness, tf
Wall corroded thickness of shell
Wall corroded thickness of heads
Wall corroded thickness of shell + reinf. plate
Outer shell radius, Ro = Do / 2
Shell length from Tangent - to - tangent (T/T) , L
Saddle - to - saddle distance (S/S) , L"
Transverse distance between anchor bolts, Y

5.785
6.285
0
7.087
0.5
0.366
0.366
0.866
10
254.843
165.354
21.6535

INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH
INCH

146.935
159.635
0
180
12.7
9.28625
9.28625
21.98625
254
6473
4200
550

MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM

Distance from tangent line -to- center of saddle support , A


Saddle contact angle, B
Longitudinal width of saddle at shell, b
Transverse width of saddle at shell (baseplate length), m
Height of saddle to vessel center line, Z
Web width of saddle, hs = m - 2 cl
Web thickness of saddle, tw
Equivalent diameter of vessel, Deq = 1.5 (Do + 2 * tis)
Equivalent length of vessel, Leq = L + 2Ho + 2 tis

47.244
120
7.087
20.551
17.913
19.37
0.591
30
267.412

INCH
Degree
INCH
INCH
INCH
INCH
INCH
INCH
INCH

1200

MM

180
522
455
492
15
762
6792.27

MM
MM
MM
MM
MM
MM
MM

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

MM
MM
MM
MM

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 122 of 136


Sheet : 2 of 8
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.
Client : APRC
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
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

676.0875 Kg

= 3 ( horizontal vessel on pier)

Total vessel dead weight, Wt

10840.2 lb

b. Wind force
F = Cf . Gh . qz . Af
2
qz = 0.00256 . kz . (I V)
For exposure C :
h = Height
kz = Velocity pressure exposure coefficient
Wind Velocity, V = Basic wind speed
Gh = Gust response factor
Cf = Force coefficient

ANSI A58.1

4917

Kg

27.0848 PSF

13.49792 N/M2

0-15
0.8
115
1.32
0.8

51.399

M/Sec.

676.0875
0.574721
80.25607
676.0875

Kg
M2
Kg
Kg

ft
MPH

c. Forces in longitudinal direction

Figure (11)

Seismic longitudinal force, Fls = z . I . C . Wt / Rw


Wind longitudinal exposed area, Afl = (pi/8*Deq + Z) * Deq
Wind longitudinal force, Flw = Cf . Gh . qz . Afl
Fl = Greater value of Fls & Flw

1490.53
6.18624
176.936
1490.53

lb
2
ft
lb
lb

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 123 of 136


Sheet : 3 of 8
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.
Client : APRC
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


Wind transvere exposed area, Aft = Deq * Leq
Wind transverse force, Ftw = 0.5 x Cf x Gh x x qz x Aft
Ft = Greater value of Fts & Ftw

338.0438
5.175706
361.377
361.377

Kg
M2
Kg
Kg

5420.12 lb

2458.5

Kg

161.471 lb

73.24138 Kg

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
Total transverse reaction, Qtt = Qo + Qt
Q = Greater value of Qlt & Qtt

5581.59 lb
9586.76 lb
9586.76 lb

2531.741 Kg
4348.436 Kg
4348.436 Kg

3. Modified stresses at saddles :


Ratio (Qo + Qmax.) / Qo

1.76874

2. Reaction force per saddle support


a. Reaction due to full vessel weight, Qo = Wt/2
b. Reaction in longitudinal direction due to earthquake & wind :
By taking moments about saddle support : Fl . Z = Ql . L"
Ql = Fl . Z / L"
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)

a. Modified circumferential stresses, SIG 5' = Ratio .

745.267
55.7108
796.708
796.708

lb
2
Ft
lb
lb

<

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


Sheet : 4 of 8
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.
Client : APRC
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
Max. moment, Mmax. = Fl . Z
26699.9 lb-in.

676.0953 Kg
307.6167 Kg-M

Figure (13)

Cross-sectional Area, A = Lw * tw + 2 Sw * ts+ 2(n-2) Rw * ts


Moment of inertia, Ix-x = Lw*tw3/12 + 2ts*Sw3/12+ (n-2) ts(Sw3-tw3)/12
Section modulus,
Wx-x = Lw*tw2/6+2ts*Sw2/6+2ts(Sw3-tw3)/(6 Sw)
Dimension,
X1 = Ix-x / Wx-x
Bending stress,
Sb = Mmax. / Wx-x
Allowable bending stress, S' = 1.2 . S
Shear stress,
T = Fl / A
Allowable shear stress, S' = 0.5 . S
b. Stresses in transverse direction
Transverse force,
Ft
Max. moment,
Mmax. = Ft . Z

15.3915
12.3045
7.14931
1.72107
3734.61
18840
OK
96.8411
7850
OK

INCH2
INCH4
INCH3
INCH
PSI
PSI

9930
5121500
117156.3
43.71512
262.9168
1326.336

PSIG
PSIG

6.817615 Kg/CM2G
Kg/CM2G
552.64

796.708 lb
14271.4 lb-in.

MM2
MM4
MM3
MM
Kg/CM2G
Kg/CM2G

361.3811 Kg
164.4249 Kg-M

Figure (14)

Cross-sectional Area, A
15.3915
Moment of inertia, Iy-y = tw*Lw3/12+Sw[(Lw+2ts)3-Lw3]/12+2Rw((Ss(n-1-2)+ts727.502
Section modulus, Wy-y =tw*Lw2/6+Sw*[(Lw+2ts)3-Lw3]/6(Lw+2ts)+2Rw[(Ss+ts87.4027
Dimension
Y1 = Iy-y / Wy-y
8.32357
Bending stress,
Sb = Mmax. / Wy-y
163.284
Allowable bending stress, S' = 1.2 . S
18840
OK
Shear stress,
T = Ft / A
51.7628
Allowable shear stress, S' = 0.5 . S
7850
OK

INCH2
INCH4
INCH3
INCH
PSIG
PSIG

9930
3.03E+08
1432273
211.4187
11.49517
1326.336

MM2
MM4
MM3
MM

PSIG
PSIG

3.644098 Kg/CM2G
Kg/CM2G
552.64

Kg/CM2G
Kg/CM2G

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 125 of 136


Sheet : 5 of 8
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.
Client : APRC
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

R 2 H
A

1
+
L
2A L

= Q A 1
4H

1+

3L

452744

lb-in

5216.177 Kg-M

2
Longitudinal bending stress in tension, S1 = M1 / K1 R ts

2883.72 PSIG

2
203.0137 Kg/CM G

Longitudinal bending stress in compression, S1 = - M1 / K8 R2 ts

-15016.4 PSIG

2
-1057.153 Kg/CM G

558078

6429.767 Kg-M

2. Bending moment & bending stress at midspan


Bending moment at midspan, M2

R 2 H2
1+ 2

2
4 A
'
L

M1 = Q L

4H

L
1+

3L

lb-in

2
Longitudinal bending stress at midspan, S1' = - M1' / 3.14 R ts

-3552.84 PSIG

2
-250.1198 Kg/CM G

3. Stress in the shell due to internal pressure,


S = P R / (2 Es ts)

3350.31 PSIG

235.8619 Kg/CM2G

4. Sum of tensile stress


Value of S1 + S

6234.03 PSIG

2
438.8756 Kg/CM G

Value of S1' + S

-202.527 PSIG

-14.2579

Greater value of (S1 + S) & (S1' + S)


Shell allowable tensile stress
Stress ratio = Greater stress/Allowable stress

6234.03 PSIG
17100
PSIG
0.36456 < 1

Passed

1367.78 PSIG

96.29196 Kg/CM2G

13680
PSIG
0.09998 < 1

963.072

Kg/CM2G

2
438.8756 Kg/CM G
1203.84 Kg/CM2G

5.Tangential shear stress, S2


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.
S2 =

K2 Q L 2 A

4 H
R ts
L +

Shell allowable tangential stress = 0.8 S


Stress ratio = S2 / 0.8 S

Passed

Kg/CM2G

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 126 of 136


Sheet : 6 of 8
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.
Client : APRC
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.

K 3Q
L 2A
4H
R ts
L+
3

372.607 PSIG

26.23154 Kg/CM2G

13680
PSIG
0.02724 < 1

963.072
Passed

1367.78 PSIG

96.29196 Kg/CM2G

Head allowable tangential stress = 0.8 S


Stress ratio = S2 / 0.8 S

13680
PSIG
0.09998 < 1

963.072

5.d. Tangential shear stress on shell


In case of A <= R/2
S2 = K4 Q / R ts
Shell allowable tangential stress = 0.8 S
Stress ratio = S2 / 0.8 S

1687.27 PSIG
13680
PSIG
0.12334 < 1

5.e. Tangential shear stress on head


In case of A <= R/2
S2 = K4 Q / R th
Shell allowable tangential stress = 0.8 S
Stress ratio = S2 / 0.8 S

1687.27 PSIG
13680
PSIG
0.12334 < 1

Passed

5.f. Additional tangential shear stress in head


In case of A <= R/2
S3 = K5 Q / R th

768.858 PSIG

2
54.12761 Kg/CM G

S3 + stress due to int. pres. (PR/(2Es ts)

3350.31 PSIG

2
235.8619 Kg/CM G

Head allowable tensile stress = 1.25 S


Stress ratio = S3 / 1.25 S

21375
PSIG
0.15674 < 1

S2 =

Shell allowable tangential stress = 0.8 S


Stress ratio = S2 / 0.8 S

Kg/CM2G

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.
S

2h

K 2 Q L 2A
=
4H
R th
L+
3

Kg/CM2G

Passed

2
118.7838 Kg/CM G
963.072 Kg/CM2G

Passed

2
118.7838 Kg/CM G
963.072 Kg/CM2G

1504.8
Passed

Kg/CM2G

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 127 of 136


Sheet : 7 of 8
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.
Client : APRC
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)

S4 =

3K6 Q

-3074.71 PSIG

-216.4598 Kg/CM2G

25650
PSIG
0.11987 < 1

1805.76
Passed

-1410.27 PSIG

-99.2832

Kg/CM2G

25650
PSIG
0.05498 < 1

1805.76

Kg/CM2G

Passed

-1377.92 PSIG

-97.00559 Kg/CM2G

22500
PSIG
0.06124 < 1

1584
Passed

Effective web area, Aw = hs tw


Stress in web, Sw = Fw / Aw
Allowable stress in web, Saw = 0.6 Y
Stress ratio = Sw / 0.6 Y

5780.82 lb
2
11.4477 INCH

2622.107 Kg
2
7385.579 MM

504.977 PSIG
18000
PSIG
0.02805 < 1

35.55042 Kg/CM2G
Kg/CM2G
1267.2

Vertical force in web, Fv = Q


Stress in web, Sv = Fv / Aw
Allowable stress in web (compressiuon), Saw = 0.33 Y
Stress ratio = Sv / 0.33 Y

9586.76
837.442
9900
0.08459

4ts (b+1.56 Rts )

2ts2

Shell allowable circumferential stress = 1.5 S


Stress ratio = S4 / 1.5 S

Kg/CM2G

6.b. Circumferential stress at saddle horn


In case of L < 8 R (unstiffened)

S4 =

Q
4 ts (b +1.56 R ts )

12K6 QR
Lts2

Shell allowable circumferential stress = 1.5 S


Stress ratio = S4 / 1.5 S
6.c. Circumferential stress at bottom of shell
(stiffened or unstiffened)

S5 =

t s ( b + 1 . 56

R ts )

0.5 compression yield point of shell material


Stress ratio = S5 / 0.5 S
7. Check tension in web saddle
Horizontal force in web, Fw = K8 Q

lb
PSIG
PSIG
<1

Kg/CM2G

Passed

4348.436 Kg
379.8534 Kg/CM2G
Kg/CM2G
696.96
Passed

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 128 of 136


Sheet : 8 of 8
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.
Client : APRC
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
To resist this force, the effective area of web plate, A = (R/3) . tw
The calculated stress, Scal. = F / A
The allowable stress, Sall. = (2/3) Sw
Stress ratio = Scal. / Sall.
So, the thickness of the web plate is satisfactory for horizontal force (F).

1955.7
1.9685
993.495
10466.7
0.09492

lb
INCH2
PSIG
PSIG
<1

887.0809
1270
69.94205
736.8534

Kg
MM2

Passed

o
For contact angle B = 120 :
K1 (K1 = 3.14 if the shell is stiffened by ring or head, A > R/2)

120
0.335

Degree
or

3.14

K2

1.171

K3 (K3 is constant for any contact angle)

0.319

K4

0.88

K5

0.401

INCH
INCH

1199.998 MM
254
MM

INCH

127

Kg/CM2G
Kg/CM2G

Values of Constant K

[A > R/2]

K6 (K6 depends on the ratio A/R, see chart in vessel handbook)


K6 for A/R > 1.00

0.053

K6 for A/R < 0 0.5


A
R
A/R
R/2
K7

0.013
47.244
10
4.7244
5
0.76

K8

0.603

K11

0.204

MM

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 129 of 136


Sheet : 1 of 1
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.
Client : APRC
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
Max. moment, Mmax. = Fl . Z + Fl . Z2
[for 2 coolers]
Assume anchor bolt size dn, 7/8"
Cross-sectional area per anchor bolt, Ab
No. of anchor bolts per saddle, nb
Total cross-sectional area of anchor bolts, A = nb . Ab

1490.53
108562
0.875
0.419
4
1.676

lb.
lb-in.
INCH
2
INCH
each
2
INCH

676.0875
1250.77
22.225
270.322

Shear stress,
T = 2 * Fl / A
Bending stress, Sb = 2 * Mmax. / (A . L")
Resultant stress, Si = SQRT (Sb2 + 3 T2 )
Allowable stress, S' = 0.5 . Re

1778.68
0.73824
3080.76
15000
OK

PSIG
PSIG
PSIG
PSIG

125.219
0.051972
216.8857
1056

[for 2 coolers]
[for 2 coolers]

Kg
Kg-M
MM
MM2

2
1081.288 MM

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

2. For transverse forces, Ft

Figure (17)

Ft
Max. moment, Mmax. = Ft . Z + Ft . Z2
[for 2 coolers]
Cross-sectional area per anchor bolt, Ab
No. of anchor bolts per saddle, nb
Total cross-sectional area of anchor bolts, A = nb . Ab

796.708
58027.6
0.419
4
1.676

lb.
lb-in.
INCH2
each
2
INCH

361.3811 Kg
668.5515 Kg-M
2
270.322 MM

Shear stress,
T = 2 [Ft / A]
Bending stress, Sb = 2 [2 Mmax. / (A . Y)]
Resultant stress, Si = SQRT (T2 + 3 Sb2 )
Allowable stress, S' = 0.5 . Re

950.726
6395.76
11118.5
15000
OK
711.2

PSIG
PSIG
PSIG
PSIG

66.93108
450.2613
782.7422
1056

Kg/CM2G
Kg/CM2G

INCH

28

MM

[for 2 coolers]
[for 2 coolers]

Use anchor bolt with size (add corrosion allowance)

2
1081.288 MM

Kg/CM2G
Kg/CM2G

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.
Designed by : Eng. Abdel Halim Galala, Design General Manager (Assistant)

Sheet : 1 of 1
Rev. : 1

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

Date : 11.4.2004
Location : Alex.
Client : APRC
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
Max. moment, Mmax. = Fl . Z + Fl . Z2
[for 2 coolers]
Assume anchor bolt size dn, 11/16"
Cross-sectional area per anchor bolt, Ab
No. of anchor bolts per saddle, nb
Total cross-sectional area of anchor bolts, A = nb . Ab

1490.53
108562
0.6875
0.252
2
0.504

lb.
lb-in.
INCH
2
INCH
each
2
INCH

676.0875
1250.77
17.4625
162.5803

Shear stress,
T = 2* Fl / A
Bending stress, Sb = Mmax. / (A . L")
Resultant stress, Si = SQRT (Sb2 + 3 T2 )
Allowable stress, S' = 0.5 . Re

5914.81
0.111
10244.8
15000
OK

PSIG
PSIG
PSIG
PSIG

416.4029
0.007814
721.231
1056

[for 2 coolers]

Kg
Kg-M
MM
MM2

2
325.1606 MM

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

2. For transverse forces, Ft

Figure (17b)

Ft
Max. moment, Mmax. = Ft . Z + Ft . Z2
Cross-sectional area per anchor bolt, Ab
No. of anchor bolts per saddle, nb
Total cross-sectional area of anchor bolts, A = nb . Ab

796.708
58027.6
0.252
2
0.504

lb.
lb-in.
INCH2
each
2
INCH

361.3811 Kg
668.5515 Kg-M
2
162.5803 MM

Shear stress,
T = 2 [Ft / A]
Bending stress, Sb = 2 [2 Mmax. / (A .Y)]
Resultant stress, Si = SQRT (T2 + 3 Sb2 )
Allowable stress, S' = 0.5 . Re

1580.77
3197.88
5760.04
15000
OK

PSIG
PSIG
PSIG
PSIG

111.2862
225.1306
405.5071
1056

Use anchor bolt with size (add corrosion allowance)

[for 2 coolers]
[for 2 coolers]

484.0224009

INCH

2
325.1606 MM

19.05600003

Kg/CM2G
Kg/CM2G
Kg/CM2G
Kg/CM2G
MM

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 131 of 136


Sheet : 1 of 2
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

Z. Check for Bundle Pulling.


Weight of empty vessel
Weight of full vessel
Reaction force full vessel
Bundle weight
Dimension l = c+ tf + tb

9155.7
10840.2
5420.12
3931.08
7.91339

lb
lb
lb
lb
INCH

4152.911
4917
2458.5
1783.087
201

Kg
Kg
Kg
Kg
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
Reaction force empty F = 1.5 x Bundle weight
[API 660]

4577.85 lb
5896.61 lb

2076.456 Kg
2674.631 Kg

Figure (19)

Saddle cross-sectional area, A


Moment of inertia, Ix-x

2
15.3915 INCH
4
12.3045 INCH

9930
5121500

MM2
MM4

Section modulus, Wx-x = Ix-x / X


Max. moment, Mmax. = 0.5 F l

3
7.14931 INCH
23331.1 lb-in.

3
117156.3 MM
268.8004 Kg-M

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 132 of 136


Sheet : 2 of 2
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

Z. Check for Bundle Pulling (cont.)


Calculated Bending stress, Sb = Mmax. / Wx-x
Allowable bending stress, S' = 0.9 . Re
Stress ratio = Sb / S'

3263.4 PSIG
27000
PSIG
0.12087 < 1

229.7435 Kg/CM2G
Kg/CM2G
1900.8
Passed

Calculated Shear stress,


Allowable shear stress,
Stress ratio = T / S'

383.108 PSIG
12000
PSIG
0.03193 < 1

26.97078 Kg/CM2G
Kg/CM2G
844.8
Passed

T=F /A
S' = 0.4 . Re

Figure (20)

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 133 of 136


Sheet : 1 of 2
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

Z1. Lifting Lugs Thickness Calculations.


(Reference : Pressure Vessel Handbook)
Check of the thickness of lifting lugs :
Material
Allowable tensile strength, St
Allowable shear strength, Sallow. = 0.49 St
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)

ASME SA 516 Grade 70


17100
PSIG
1203.84 Kg/CM2G
8379
PSIG
589.8816 Kg/CM2G

Figure (21)

Height of lifting lug, L


Thickness of lifting lug, b
Fillet weld, h
Length of lifting lug, l
F = Wt / (SQRT2)
Vertical component of F,
F1 = F/ SQRT2
Horizontal component of F, F2 = F1
Average unit stress
= 0.707 * F1 / h * I

1.5748
0.7874
0.3937
3.93701
7665.21
5420.12
5420.12
2692.57

INCH
INCH
INCH
INCH
lb
lb
lb
PSIG

2
2
Max. expected normal stress, Sexp. = F2 / (h*I *(b+h))*SQRT(2L +(b+h) )) 1174.44 PSIG
Allowable shear strength, Sallow.
8379
PSIG
Stress ratio = Sexp. / Sallow.
0.14016 < 1

40
20
10
100
3476.844
2458.5
2458.5
1.89557

MM
MM
MM
MM
Kg
Kg
Kg
Kg/MM2

0.826805 Kg/MM2
589.8816 Kg/CM2G
Passed

DESIGN CALCULATIONS OF HEAT EXCHANGER

Page : 134 of 136


Sheet : 2 of 2
Rev. : 1

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)

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

Date : 11.4.2004
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

Z1. Lifting Lugs Thickness Calculations (cont.)


(Reference : Pressure Vessel Handbook)

Figure (22)

L
b
l
R
r

1.5748
0.7874
3.93701
1.37795
0.59055

INCH
INCH
INCH
INCH
INCH

40
20
100
35
15

MM
MM
MM
MM
MM

DESIGN CALCULATIONS OF HEAT EXCHANGER


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)

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

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 January 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 Jersey 07632, USA..

Page : 135 of 136


Sheet : 1 of 1
Rev. : 1
Date : 11.4.2004
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D

DESIGN CALCULATIONS OF HEAT EXCHANGER


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)

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

Z3. Notes.

Page : 136 of 136


Sheet : 1 of 1
Rev. : 1
Date : 11.4.2004
Location : Alex.
Client : APRC
Items : E-323A/B & E-514C/D