1PV Elite 2008 Licensee: ZISHAN ENGINEERS (PVT.) LTD.FileName : ExchangerUtube-PD 5500---------------------------- Tubesheet Analysis: pd55Sample03 Case: 1 7:31p Feb 28,2014

Input Echo, TubeSheet Item 1, Description: pd55Sample03

Tubesheet Design Code PD 5500Shell Desc. MAIN SHELLShell Design Pressure Ps 10.00 barsShell Temperature for Internal Pressure TEMPS 100.00 CShell Material BS1501-151,430AShell Material UNS NumberShell Allowable Stress at Temperature Sos 157.02 N./mm^2Shell Allowable Stress at Ambient Sas 167.02 N./mm^2Shell Thickness Ts 10.0000 mm.Shell Corrosion Allowance Cas 0.0000 mm.Inside Diameter of Shell Ds 500.0000 mm.Mean Metal Temperature for Shell Tm 100.00 C

Channel Desc. LEFT CHANNE SHELLChannel Design Pressure Pc 5.00 barsChannel Temperature for Internal Pressure TEMPC 100.00 CChannel Material BS1501-151,430AChannel Material UNS NumberChannel Allowable Stress at Temperature Soc 157.02 N./mm^2Channel Allowable Stress at Ambient Sac 167.02 N./mm^2Channel Thickness Tc 10.0000 mm.Channel Corrosion Allowance Cac 0.0000 mm.Inside Diameter of Channel Dc 500.0000 mm.Mean Metal Temperature for Tubes tm 75.00 C

Tube Design Temperature Tubtmp 100.00 CTube Material A-106 BTube Allowable Stress at Temperature Sot 147.01 N./mm^2Tube Allowable Stress At Ambient Sat 161.01 N./mm^2Tube Yield Stress At Operating Temperature Syt 220.51 N./mm^2Tube Wall Thickness Tt 1.2000 mm.Tube Corrosion Allowance Catt 0.0000 mm.Number of Tubes Holes Ntubs 300Tube Layout Pattern TriangularTube Outside Diameter do 19.0000 mm.Tube Pitch (Center to Center Spacing) PTube 25.0000 mm.Tube-Tubesheet Joint Classification eTube Joint Reliability Factor fr 0.5000Is Welded Tube Material specified (not Seamless) No

Straight Tube Length, bet. inner tubsht faces RL 500.000 mm.Unsupported Tube Length for max. (k*SL) SL 150.0000 mm.Tube end condition corres. to span (SL) k 1.0000Length of Expanded Portion of Tube l 20.0000 mm.

Tube Bundle Effective outer diameter Do 420.0000 mm.Tube hole diameter dh 19.5000 mm.Number of Grooves in tube hole Ngroove 0Area of untubed Lanes, S 0.00 cm^2

Tubesheet type: U-tube, Integral with ShellTubesheet Design Metal Temperature TEMPTS 100.00 CTubesheet Material BS1501-151,430ATubesheet Allowable Stress at Temperature Sots 157.02 N./mm^2Tubesheet Allowable Stress at Ambient Sats 167.02 N./mm^2Thickness of Tubesheet Tts 30.0000 mm.Tubesheet Corr. Allowance (Shell side) Cats 1.5000 mm.Tubesheet Corr. Allowance (Channel side) Catc 1.5000 mm.Depth of Groove in Tube Sheet hg 0.0000 mm.Tubesheets Clamped: Stationary Clamped / Floating Clamped

Additional Data for Tubesheets Extended as Flanges:Outside Diameter of Flanged Portion A 698.5000 mm.Diameter of Bolt Circle C 635.0000 mm.Thickness of Extended Portion of Tubesheet Tf 40.0000 mm.Nominal Bolt Diameter dB 28.5750 mm.Type of Thread Series TEMA Thread SeriesNumber of Bolts n 40Bolt MaterialBolt Allowable Stress At Temperature Sb 193.03 N./mm^2Bolt Allowable Stress At Ambient Sa 193.03 N./mm^2Weld between Flange and Shell/Channel WLDH 0.0000 mm.Is Bolt Load Transferred to the Tubesheet Yes

Additional Data for Gasketed Tubesheets:Flange Face Outside Diameter Fod 584.2000 mm.Flange Face Inside Diameter Fid 500.0000 mm.Flange Facing Sketch Code Sketch 1aGasket Outside Diameter Go 584.2000 mm.Gasket Inside Diameter Gi 500.0000 mm.Small end Hub thk. g0 9.5250 mm.Large end Hub thk. g1 34.9250 mm.Gasket Factor, m 2.0000Gasket Design Seating Stress y 11.00 N./mm^2Column for Gasket Seating Code Column IIGasket Thickness tg 9.5250 mm.Full face Gasket Flange Option Program SelectsTubesheet Gasket on which Side Side CHANNEL

Intermediate Calculations For Tubesheets Extended As Flanges:PD 5500 Standard, 2000 Ed., Per Para. 3.8.3

Gasket Contact Width, N = (Goc-Gic) / 2 42.100 mm.Basic Gasket Width, b0 = N / 2.0 21.050 mm.Effective Gasket Width, b = SQRT(b0) * 2.5 11.557 mm.Gasket Reaction Diameter, G = Go-2.0*b 561.086 mm.

Basic Flange and Bolt loads:Hydrostatic End Load due to Pressure[H]: = 0.785 * G * G * Peq = 0.7854 * 561.0855 *561.0855 *4.9997 = 12606.349 Kgf

Contact Load on Gasket Surfaces[Hp]: = 2 * b * PI * G * m * P = 2 * 11.5572 * 3.1416 * 561.0855 * 2.0000 * 5.00 = 4154.650 Kgf

Hydrostatic End Load at Flange ID[Hd]: = 0.785 * Bcor * Bcor * P = 0.785 * 500.0000 * 500.0000 *4.9997 = 10010.856 Kgf

Pressure Force on Flange Face[Ht]: = H - Hd = 12606 - 10010 = 2595.493 Kgf

Operating Bolt Load[Wm1]: = H + Hp + H'p (cannot be < 0) = ( 12606 + 4154 + 0 ) = 16761.000 Kgf

Gasket Seating Bolt Load[Wm2]: = y * b * PI * G + yPart * bPart * lp = 11.00*11.5572*3.141*561.086+11.00*0.0000*0.00 = 22850.578 Kgf

Required Bolt Area[Am]: = Maximum of Wm1/Sb, Wm2/Sa = Maximum of 16761 / 193 , 22850 / 193 = 11.6093 cm^2

Bolting Information for TEMA Imperial Thread Series (Non Mandatory):Distance Across Corners for Nuts 50.851 mm.Circular Wrench End Diameter a 73.025 mm.----------------------------------------------------------------------------- Minimum Actual Maximum-----------------------------------------------------------------------------Bolt Area, cm^2 11.609 187.871Radial distance bet. hub and bolts 28.575 57.500Radial distance bet. bolts and the edge 28.575 31.750Circumferential spacing between bolts 63.500 49.822 153.150-----------------------------------------------------------------------------

Flange Design Bolt Load, Gasket Seating[W]: = Sa * ( Am + Ab ) / 2.0 = 193.03 * ( 11.6093 + 187.8706 ) / 2.0 = 196318.28 Kgf

Gasket Seating Force[Hg]: = Wm1 - H = 16761 - 12606 = 4154.65 Kgf

Moment Arm Calculations:

Distance to Hub Large End[R]: = (C - Bcor) / 2 - g1cor = (635.000 - 500.000 ) / 2 - 34.925 = 32.5750 mm.

Distance to Gasket Load Reaction[hg]: = (C - G ) / 2.0 = ( 635.0000 - 561.0855 ) / 2.0 = 36.9572 mm.

Distance to Face Pressure Reaction[ht]: = ( R + g1cor + hg ) / 2.0 = ( 32.5750 + 34.9250 + 36.9572 ) / 2.0 = 52.2286 mm.

Distance to End Pressure Reaction[hd]: = R + ( g1cor / 2.0 ) = 32.5750 + ( 34.9250 / 2.0 ) = 50.0375 mm.

Summary of Moments for Internal Pressure:Loading Force Distance Bolt Corr MomentEnd Pressure, Md 10011. 50.0375 1.0000 501. Kg-m.Face Pressure, Mt 2595. 52.2286 1.0000 136. Kg-m.Gasket Load, Mg 4155. 36.9572 1.0000 154. Kg-m.Gasket Seating, Ma 196318. 36.9572 1.0000 7256. Kg-m.

Total Moment for Operation, Mo 790. Kg-m.Total Moment for Gaket Seating, Ma 7256. Kg-m.

Tube Properties - Group # 1.10 and S factor: 1.40Tube alpha at Metal Temp. along len. 75.0 0.1172E-04 /CTube Elastic Mod. at Metal Temp. len 75.0 0.2062E+09 KPa.

Shell Properties - Group # 1.10 and S factor: 1.40Shell alpha at Metal Temp. along len. 100.0 0.1190E-04 /CShell Elastic Mod. at Metal Temp. len 100.0 0.2050E+09 KPa.

Tubesheet Properties - Group # 1.10 and S factor: 1.40Tubesheet Elastic Mod. at Design Temp. 100.0 0.2050E+09 KPa.

Channel Properties - Group # 1.10 and S factor: 1.40Channel Elastic Mod. at Design Temp. 100.0 0.2050E+09 KPa.

PD 5500, 2006, Per Para. 3.9 Flat Heat Exchanger Tubesheets:

Tubesheet Min Thk, for tube od < 25.000 is : 0.75 * 19.000 mm. TMIN = 14.2500 mm.Min. Thickness + CATS + MAX(CATC,GROOVE) TREQMIN = 17.2500 mm.

U TUBE EXCHANGER:

Effective Pressure = MAX( |p1 - p2|, |p1|, |p2| ): p = 9.999 bars

Ligament Efficiency - paragraph 3.9.2.1: Mu = (P - dh) / P = (25.000 - 19.500 ) / 25.000 = 0.220

x1 = 1 - N * (d / Do)^2 per 3.9.1 = 1 - 300.000 * (19.000 / 420.000 )^2 0.386

x2 = 1 - N * ((d - 2.et) / Do)^2 per 3.9.1 = 1 - 300.000 * ((19.000 - 1.200 ) / 420.000 )^2 = 0.531

Fs = (x1 + x2)/2 = 0.4587

Because p1 > p2 R = D1/Do = 500.000 /420.000 = 1.1905

C = Co + DELTAC From table 3.9-1 (using R, and Fs) = 0.4330 + 0.0000 = 0.43300

Calculated Tubesheet Thicknesses:For the Bending Condition per 3.9.3.1: eBending = C * Do * ( p / ( Omega * Mu * f )^1/2) = 0.433 * 420.000 * (9.999 / (2.000 * 0.220 * 157.025 )^1/2) = 21.879 mm.

For the Shear Condition per 3.9.3.1: eShear = 0.155 * Do * p / (Lambda * Tau) = 0.155 * 420.000 * 9.999 / (0.220 * 78.512 ) = 3.769 mm.

For the Bolting Moment on Extension per 3.9.3.1: e1 = SQRT(1.909 * Moment / (G * f)) - For the Bolting Moment = SQRT(1.909 * 7255.525 / (561.086 * 167.024 )) = 38.071 mm.

Fo = 1.000 From Note at bottom of Figure 3.9-2/3 Fi = -1.000 From Note at bottom of Figure 3.9-4/5

Computation of Tube Stresses: C = SQRT(2 * Pi^2 * Et / (s * f)) - Tube factor per 3.9.5 = SQRT(2 * 3.142 ^2 * .20624E+09 / (1.400 * 147.008 )) = 140.646

Tube Stresses, Wto & Wti at inside and outside tube bundle per 3.9.3.1: Wto = Do^2/ (4 * N * et * (d - et)) * (p2 * (Fo - x2) - p1 * (Fo - x1)) = 420.000^2/ (4 * 300 * 1.200 * (19.000 - 1.200 )) * (5.000 * (1.000 - 0.531 ) - 9.999 * (1.000 - 0.386 )) = -2.613 N./mm^2

Wti = (Do^2 / (4 * N * et * (d - et)) * (p2 * (Fi + x2) - p1 * (Fi + x1)) = (420.000 ^2 / (4 * 300 * 1.200 * (19.000 - 1.200 )) * (5.000 * (-1.000 + 0.531 ) - 9.999 * (-1.000 + 0.386 ) = -2.613 N./mm^2

When p1 is set to zero then: Wto = Do^2/ (4 * N * et * (d - et)) * (p2 * (Fo - x2) - p1 * (Fo - x1)) = 420.000^2/ (4 * 300 * 1.200 * (19.000 - 1.200 )) * (5.000 * (1.000 - 0.531 ) - 0.000 * (1.000 - 0.386 )) = 1.613 N./mm^2

Wti = (Do^2 / (4 * N * et * (d - et)) * (p2 * (Fi + x2) - p1 * (Fi + x1)) = (420.000 ^2 / (4 * 300 * 1.200 * (19.000 - 1.200 )) * (5.000 * (-1.000 + 0.531 ) - 0.000 * (-1.000 + 0.386 ) = 1.613 N./mm^2

When p2 is set to zero then: Wto = Do^2/ (4 * N * et * (d - et)) * (p2 * (Fo - x2) - p1 * (Fo - x1)) = 420.000^2/ (4 * 300 * 1.200 * (19.000 - 1.200 )) * (0.000 * (1.000 - 0.531 ) - 0.000 * (1.000 - 0.386 )) = -4.225 N./mm^2

Wti = (Do^2 / (4 * N * et * (d - et)) * (p2 * (Fi + x2) - p1 * (Fi + x1)) = (420.000 ^2 / (4 * 300 * 1.200 * (19.000 - 1.200 )) * (0.000 * (-1.000 + 0.531 ) - 0.000 * (-1.000 + 0.386 ) = -4.225 N./mm^2

Max Compressive Tube Force, Loss of pressure on One Side: WtoMaxNeg = Min(Wto, Wt1, Wt3) = Min(-2.613 , 1.613 , -4.225 ) = -4.225 N./mm^2

WtiMaxNeg = Min(Wti, Wt2, Wt4) = Min(-2.613 , 1.613 , -4.225 ) = -4.225 N./mm^2

WtoMaxPos = Max(Wto, Wt1, Wt3) = Max(-2.613 , 1.613 , -4.225 ) = 1.613 N./mm^2

WtiMaxPos = Max(Wti, Wt2, Wt4) = Max(-2.613 , 1.613 , -4.225 ) = 1.613 N./mm^2

Tube Compressive and Tensile Allowable Stresses (per 3.9.5): fTensileAllow = 147.008 N./mm^2 (= f)

fCompAllow = s * f / S * ( 1 - Lk/(2*r*C) ) per 3.9.5 (C > Lk / r) = 1.40 * 147.01 / 2.000 * (1 - 150.000 /(2*6.308 *140.646 )) fCompAllow = 94.206 N./mm^2

Actual and Allowable Loads on the Tube to Tubesheet Joint: Actual Load on the Tube/Tubesheet Joint: F = WtMax * TubeArea = 4.225 * 0.671 = 28.911 Kgf

Fmax = Max Stress * TubeArea (Loss of Pressure on One Side) = 4.225 * 0.671 = 28.911 Kgf

Allowable Load on the Tube/Tubesheet Joint, per 3.9.6: Fallow = AreaTube * f * Fe * Fr * Fy (Jt type e Table 3.9-2) = 0.671 * 147.008 * 1.000 * 0.500 * 1.000 = 502.959 Kgf

Summary of Tubesheet Results:------------------------------------------------------------------------Condition Req Thk Actual Thk Actual Allow Result (+CA) (mm.) Stress (N./mm^2)------------------------------------------------------------------------Bending 24.879 30.000 206.22 314.05 OkShear 6.769 30.000 10.96 78.51 OkBolted Exten. 38.071 40.000 151.30 167.02 Ok------------------------------------------------------------------------

Summary of Longitudinal Tube Stresses and Tube-Tubesheet Load:-------------------------------------------------------------------- Actual AllowableCondition Wti Wto Compressive Tensile Result--------------------------------------------------------------------Long. Tube -4.225 -4.225 -94.206 147.008 PassedLong. Tube 1.613 1.613 -94.206 147.008 PassedTube Load -28.911 -28.911 502.959 502.959 Passed--------------------------------------------------------------------

PV Elite 2008 (c)1993-2008 by COADE Engineering Software