Download - 1 Tempered Water Cooler E-3107
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8/12/2019 1 Tempered Water Cooler E-3107
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CLIENT : THIRUMALAI CHEMICALS LIMITED,
RANIPET
PROJECT : MA PLANT-EQPT DESIGN
ITEM : TEMPERED WATER COOLER (E-3107)
Design Code : ASME SEC VIII DIV 1-2010 / TEMA-CLASS "C"
Type as per TEMA : AEMDwg No : 0546-E3107-L1 R3
Design Doc No : PPC/TCL/Dsn-E3107 R0
1 EQUIPMENT DIMENSION
Shell Inner diameter Di= 540 mm
Tube plate to Tube plate length L = 4260 mm
Installation Horizontal
Shell volume Vs= 1.0 CuM
End connection type Tori spherical
End Connection ID DEi= 540 mm
Inner Crown Radius L = 400 mm
Inner Knuckle Radius r = 75 mm
End Connection height Hi= 140 mm
End Connection volume - 1no VDE= 0.021 CuM
Total volume V = 1.0 CuM
= 997 Litres
2 DESIGN DATA-EQUIPMENT
Design code =
ASME SEC VIII
DIV I /TEMA
CLASS C
Inspection by = -
SHELL SIDE
Service medium-Shell side = Tempered water
Specific gravity-Shell side = 1
Specific gravity considered in design-Shell side s = 1
Operating pressure PO= 3.00 Kg/Sqcm(g)
Operating temperature T = 60 Deg C
Design pressure-Internal P = 490.332 Kpa(g)
= 0.49 Mpa(g)
= 5.00 Kg/Sqcm(g)
= 71 Psi(g)
Design pressure-External Pe = Nil
Design temperature = 90 Deg C
= 194 Deg F
Hydrotest Pressure = 6.50 Kg/Sqcm(g)
Corrosion allowance CA = 3 mm
Radiography = Spot
Weld joint efficiency j = 0.85
Post weld heat treatment = No
Insulation Yes
DESIGN PRESSURE WITH STATIC HEAD
Design Pressure PD= 5.00 Kg/Sqcm(g)
Static head H = 540 mm
= 0.05 Kg/Sqcm(g)
Max design pressure Pd = 5.06 Kg/Sqcm(g)
= 72 Psi(g)
TUBE SIDE
Service medium-Tube side = Cooling water
Specific gravity-Tube side = 1
Specific gravity considered in design-Tube side s = 1
Operating pressure PO= 3.00 Kg/Sqcm(g)
MECHANICAL DESIGN OF TEMPERED WATER COOLER
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CLIENT : THIRUMALAI CHEMICALS LIMITED,
RANIPET
PROJECT : MA PLANT-EQPT DESIGN
ITEM : TEMPERED WATER COOLER (E-3107)
Design Code : ASME SEC VIII DIV 1-2010 / TEMA-CLASS "C"
Type as per TEMA : AEMDwg No : 0546-E3107-L1 R3
Design Doc No : PPC/TCL/Dsn-E3107 R0
MECHANICAL DESIGN OF TEMPERED WATER COOLER
Operating temperature T = 42 Deg C
Design pressure-Internal P = 490.332 Kpa(g)
= 0.49 Mpa(g)
= 5.0 Kg/Sqcm(g)
= 71 Psi(g)
Design pressure (On Tubes)-External Pe = 72 Psi
Design temperature = 60 Deg C
= 140 Deg F
Hydrotest Pressure = 6.50 Kg/Sqcm(g)
Corrosion allowance CA = 3 mm
Radiography = Spot
Weld joint efficiency j = 0.85Weld joint efficiency on dished end jd = 1
Post weld heat treatment = No
Insulation No
DESIGN PRESSURE WITH STATIC HEAD
Design Pressure PD= 5.00 Kg/Sqcm(g)
Static head H = 540 mm
= 0.05 Kg/Sqcm(g)
Max design pressure Pd = 5.06 Kg/Sqcm(g)
= 72 Psi(g)
3 NOZZLE SCHEDULE
a ON SHELL SIDE
a Tempered water inlet N1 = 300 NB
b Tempered water outlet N2 = 300 NB
c Drain N5 = 25 NPTb ON TUBE SIDE
d Cooling water Inlet N3 = 150 NB
e Cooling water Outlet N4 = 150 NB
f Side drain N6 = 25 NPT
4 MATERIAL OF CONSTRUCTION AND ALLOWABLE STRESSES
Material
Allow. Stress,
(@Design
temp) Psi
SHELL SIDE
Shell = SA 285 Gr C 18300Nozzle neck = SA 106 Gr B 17100
Nozzle flange = SA 105 20000
TUBE SIDE
Channel Shell = SA 285 Gr C 18300
Dished end = SA 285 Gr C 18300
Tube Plate = SA 285 Gr C 18300
Channel Flange = SA 285 Gr C 18300
Channel Cover = SA 285 Gr C 18300
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CLIENT : THIRUMALAI CHEMICALS LIMITED,
RANIPET
PROJECT : MA PLANT-EQPT DESIGN
ITEM : TEMPERED WATER COOLER (E-3107)
Design Code : ASME SEC VIII DIV 1-2010 / TEMA-CLASS "C"
Type as per TEMA : AEMDwg No : 0546-E3107-L1 R3
Design Doc No : PPC/TCL/Dsn-E3107 R0
MECHANICAL DESIGN OF TEMPERED WATER COOLER
Tubes =
BS 3059 Part 1
ERW 13400
Nozzle neck = SA 106 Gr B 17100
Nozzle flange = SA 105 20000
Blind flange = SA 105 20000
Coupling = SA 105 -
Note : BS 3059 PART 1 is considered to be equivalent to SA 179
5 SHELL SIDE THICKNESS CALCULATION (INTERNAL PRESSURE)-UG-27
a SHELL
Joint Efficiency, E : 0.85
Inner diameter-Corroded Dic= 546 mmMin. Shell thick, ts : ts = PRi/(SE-0.6P)+Ca
= 4.3 mm
Min shell thk reqd as per TEMA (CB 3.13) = 7.9 mm
Shell thickness as per dwg Tsi= 8 mm
Shell OD DO= 556 mm
Selected thickness is safe for the internal pressure
6 TUBE SIDE THICKNESS CALCULATION (INTERNAL PRESSURE)-UG-27
a CHANNEL SHELL
Joint Efficiency, E : 0.85
Inner diameter-Corroded Dic= 546
Min. Shell thick, ts : ts = PRi/(SE-0.6P)+Ca= 4.27 mm
Min shell thk reqd as per TEMA (RCB 3.13) = 7.9 mm
Shell thickness as per dwg 8 mm
Shell OD DO= 556 mm
Selected thickness is safe for the internal pressure
TORISPHERICAL DISHED END DESIGN (UG-32)-Internal pressure
Material : = SA 285 Gr C
Inside Diameter IDde= 540 mm
Inside Diameter-Corroded IDdec= 546 mm
= 21.5 Inches
Inner Crown Radius L = 400 mm
Inner Knuckle Radius r = 75 mm
Factor L/r = 5.3
Straight flange SF = 40 mm
Factor M = (1/4)(3+(L/r)^0.5)
= 1.3
Joint Efficiency E = 1.0
Min. Dished end Thk tdmin = PLM/(2SE-0.2P) + CA
= 4.04 mm
Forming Allowance f = 1.5 mm
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CLIENT : THIRUMALAI CHEMICALS LIMITED,
RANIPET
PROJECT : MA PLANT-EQPT DESIGN
ITEM : TEMPERED WATER COOLER (E-3107)
Design Code : ASME SEC VIII DIV 1-2010 / TEMA-CLASS "C"
Type as per TEMA : AEMDwg No : 0546-E3107-L1 R3
Design Doc No : PPC/TCL/Dsn-E3107 R0
MECHANICAL DESIGN OF TEMPERED WATER COOLER
Min required Dishes End Thk td = tdmin+f
= 5.54 mm
Selected thickness Tdi = 8 mm
Selected thickness is safe for the internal pressure
CHANNEL COVER DESIGN (UG-34)
Flange cover material = SA 285 Gr C
Short span/cover diameter d = 556 mm
21.9 in
Corrosion allowance Ca = 3 mm0.1 in
Gasket material = G1
CAF - 3 mm thk
Gasket OD Go= 581 mm
22.9 in
Gasket ID Gi= 561 mm
22.1 in
Gasket load reaction diameter G = 565.1 mm
= 22.2 inBasic gasket seating surface width bo= 10.0 mm
0.4 in
Effective gasket seating surface width b = 0.314 in
Gasket factor m = 2
Gasket seating stress y = 1600 psi
Number of bolts Nb= 20Metric Bolt size M16
Bolt diameter Db= 16 mm
= 0.63 in
Bolt circle diameter Cb= 612 mm
= 24.09 in
Factor depending on the attachment of cover C = 0.3
Maximum allowable stress at design temp S = 18300 psi
Total hydrostatic end force H = 0.785*G^2*P
= 27935 lbs
Total joint-contact surface compression load Hp= 2b*3.14GmP
= 6306 lbs
Required bolt load for operating conditions Wm1 = H+Hp
= 34241 lbs
Required bolt load for gasket seating conditions Wm2= PI()*b*G*y
= 35082 lbs
o a cross-sec ona area o o s a roo o rea
required for operating conditions Am1= Wm1/Sb
= 1.82 sq.ino a cross-sec ona area o o s a roo o rea
required for gasket seating conditions Am2= Wm2/Sa
= 1.87 sq.in
total cross-sectional area of bolts Am= Greater of Am1 and Am2
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CLIENT : THIRUMALAI CHEMICALS LIMITED,
RANIPET
PROJECT : MA PLANT-EQPT DESIGN
ITEM : TEMPERED WATER COOLER (E-3107)
Design Code : ASME SEC VIII DIV 1-2010 / TEMA-CLASS "C"
Type as per TEMA : AEMDwg No : 0546-E3107-L1 R3
Design Doc No : PPC/TCL/Dsn-E3107 R0
MECHANICAL DESIGN OF TEMPERED WATER COOLER
= 1.87 sq.incross-sec ona area o e o s usng e roo
diameter of the thread Ab= 0.22 sq.in
Flange design bolt load for operating conditions W = Wm1
= 34240.76 lbs
Flange design bolt load for gasket seating conditions W = (Am + Ab)*Sb/2
= 19607.70 lbsradial distance from gasket load reaction to the bolt
circle hG= (Cb-G)/2
= 0.92 in
Total bolt load for circular heads W = Greater of= 34240.76 lbs
Minimum cover thickness required tc= +(1.9*W*h G
= 0.96 in
= 24.48 mm
Selected thickness Tsi = 35 mm
Selected thickness is safe for the internal pressure
TUBE THICKNESS CALCULATION
Tube Material =
BS 3059 Part 1
ERW
Tube OD = 25.4 mm
= 1.0 Inch
No. of Tubes = 188Joint Efficiency, E = 1
Min. Tube thick ts = PRo/(SE+0.4P)
= 0.07 mm
Tube thickness = 12 BWG
Tube thickness as per dwg Tsi= 0.109 Inch
= 2.769 mm
Selected thickness is safe for the internal pressure
Tube length = 4276 mm
DESIGN OF TUBE FOR EXTERNAL PRESSURE (UG-28)
Tube OD do = 25.4 mm
Tube thickness t = 0.11 mm
Tube length Leff = 4276 mmExternal design pressure on Tube Pv = 72 Psi
Ratio LEFF/do = 168.35
Ratio do/t = 233.03
Young's modulus E = 29000000 Psi
External pressure chart to be referred = CS 1
FROM FIG G of code, Factor A = 0.015
FROM FIG CS 1 of code, Factor B = 13900 Psi
Allowable external pressure on Tube Pa = 4B/3(Dot)
= 80 Psi
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CLIENT : THIRUMALAI CHEMICALS LIMITED,
RANIPET
PROJECT : MA PLANT-EQPT DESIGN
ITEM : TEMPERED WATER COOLER (E-3107)
Design Code : ASME SEC VIII DIV 1-2010 / TEMA-CLASS "C"
Type as per TEMA : AEMDwg No : 0546-E3107-L1 R3
Design Doc No : PPC/TCL/Dsn-E3107 R0
MECHANICAL DESIGN OF TEMPERED WATER COOLER
Tube thickness is safe for the external pressure
Tube sheet thickness - BendingTube Plate material SA 285 Gr C
Design Pressure P = 71.90 psi
Allow. Stress S = 18300 psi
Shell wall thk/Shell ID = 0.0148
Factor F = 1
Gasket Dia G = 590 mm
Tube Pitch Pt = 31.75 mm
Tube OD do = 25.4 mm
Ligament Eff. e = 1-((0.907)/(Pt/do)^2)
= 0.420
Tube sheet thk T = (FG/3)*(P/eS)^0.5
= 19.0 mm
Inclusive of CA & Groove
T = 19.0 mm
Thickness as per dwg T = 35 mm
Tube Plate thickness is satisfactory as per code
DESCRIPTION SYMBOL VALUE UNIT
Design Conditions
Shell side design pressure Ps= 5.06 Kg/sq.cm
= 72 Psig
Tube side design pressure Pt= 5.06 Kg/sq.cm
= 72 Psig
Shell side design temperature Ts = 90 Deg C
= 194.0 Deg F
Tube side design temperature ts = 60 Deg C
= 140.0 Deg F
Design Temperature T = 90.0 Deg C
194.0 Deg F
Shell side CA Cas= 3 mm
= 0.12 in
Tube side CA Cat= 3 mm
= 0.12 in
TUBE SIDE DATA
Tube material BS 3059 Part 1 ERW
Outside diameter Dto= 25.4 mm
= 1.00 in
Thickness Th= 12 BWG
= 0.11 in
2.77 mm
Tube Length L = 4276 mm
= 168 in
Number of tubes in the shell N = 188
Pitch pt = 32 mm
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CLIENT : THIRUMALAI CHEMICALS LIMITED,
RANIPET
PROJECT : MA PLANT-EQPT DESIGN
ITEM : TEMPERED WATER COOLER (E-3107)
Design Code : ASME SEC VIII DIV 1-2010 / TEMA-CLASS "C"
Type as per TEMA : AEMDwg No : 0546-E3107-L1 R3
Design Doc No : PPC/TCL/Dsn-E3107 R0
MECHANICAL DESIGN OF TEMPERED WATER COOLER
(Triangular) = 1.3 in
Mean Tube wall metal temperature Tw= 75 Deg C
= 167.0 Deg F
SHELL SIDE DATA
Shell material CS8
SA 285 Gr.C
Shell OD DO= DO= 556.0 mm
21.9 in
Shell ID Di= Di= 540 mm
= 21.26 in
Corroded dia 22.76 inThickness Ths= 8 mm
= 0.3 in
Corroded thickness 0.43 in
Mean Shell wall metal temperature Tws= 90 Deg C
= 194 Deg F
J = 0
Maximum expansion joint inside diameter DJ= 540 mm21.3 in
Wall thickness/Shell ID Ths/Di = 0.0148
Slope (From Fig R,C,B-7.132) M = 6.67
F = 1.000
TUBESHEETS DATA
Tubesheet material SA 285 Gr C
Design metal temperature T = 60 Deg C
= 140 Deg F
Corrosion allowance (shell side) Cas= 3.0 mm
0.1 in
Pass partition grooves Pgt = 5 mm
= 0.2 in
MATING FLANGE
Flange material SA 285 Gr C
Bolt material SA 193 B7
Flange ID B = 562 mm
= 22.1 in
Flange OD A = 650 mm
25.6 in
Thickness of Hub at small end go= 8.00 mm
0.3 in
Corroded value 0.43 in
Thickness of Hub at back of flange g1= 16.0 mm
0.6 in
Corroded value 0.87
Hub length h = 5.0 mm
0.2 in
Gasket material = G1
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CLIENT : THIRUMALAI CHEMICALS LIMITED,
RANIPET
PROJECT : MA PLANT-EQPT DESIGN
ITEM : TEMPERED WATER COOLER (E-3107)
Design Code : ASME SEC VIII DIV 1-2010 / TEMA-CLASS "C"
Type as per TEMA : AEMDwg No : 0546-E3107-L1 R3
Design Doc No : PPC/TCL/Dsn-E3107 R0
MECHANICAL DESIGN OF TEMPERED WATER COOLER
CAF - 3 mm thk
Basic gasket seating surface width bo= 11.1 mm
0.4 in
Effective gasket seating surface width b = 0.331 in
Gasket load reaction diameter G = 571 mm
= 22.5 in
Gasket OD Go= 581.0 mm
22.9 in
Gasket ID Gi= 561.0 mm
22.1 inGasket factor m = 2
Gasket seating stress y = 1600 psi
Number of bolts Nb= 20
Metric Bolt size M16
Bolt diameter Db= 16.00 mm
= 0.63 in
Bolt circle diameter C = 612.0 mm
= 24.09 in
Tube sheet thickness(assumed) Tts= 1 in
33 mm
EQUIVALENT DIFFERENTIAL EXPANSION PRESSURE (R,C,B-7.161)
Tube length between inner tubesheet faces Li = 4210.0 mm
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CLIENT : THIRUMALAI CHEMICALS LIMITED,
RANIPET
PROJECT : MA PLANT-EQPT DESIGN
ITEM : TEMPERED WATER COOLER (E-3107)
Design Code : ASME SEC VIII DIV 1-2010 / TEMA-CLASS "C"
Type as per TEMA : AEMDwg No : 0546-E3107-L1 R3
Design Doc No : PPC/TCL/Dsn-E3107 R0
MECHANICAL DESIGN OF TEMPERED WATER COOLER
= 165.7 in
Tube length between outer tubesheet faces Lo = 4276 mm
= 168.3 in
Coefficient of thermal expansion for shell material as = 0.0001 mm/mm/Deg C
= 0.0001 in/in/Deg F
Coefficient of thermal expansion for tube material at = 0.0001 mm/mm/Deg C
= 0.0001 in/in/Deg FMean Shell wall metal temperature Tws= 90 Deg C
= 194 Deg F
Mean Tube wall metal temperature Tw= 75.0 Deg C
= 167.0 Deg FDifferential thermal growth Dl= Lo{as(Tws-70)-at(tw-70)}
= 0.3 in
= 6.4 mmElastic modulus of the shell material at mean metal
temperature Es= 21800000 psi
= 1532729 kg/sq.cmas c mo u u s o e u e ma er a a mean me a
temperature Et = 29000000 psi
= 2038951.0 kg/sq.cm
Elastic modulus of the tube sheet material at mean
metal temperature E = 21800000 psi
1532729 kg/sq.cm
Outside diameter of shell Do= 556 mm
= 103 in
Outside diameter of tube Dto= 25.4 mm= 1.0 in
Thickness of shell Ths= 8.0 mm
= 0.3 in
BWG Th= 12.0
= 2.8 mm
Value in inches = 0.1 in
Gasket load reaction diameter G = 571.0 mm
22.5 in
Spring rate of the expansion joint Sj = 1000.0
OR
= (Do-Ths)*Ths*Es/10Li
= 565666.6
(for shell without expansion joint J = 1.0
(for expansion joint) = Sj*Li/{Sj*Li+PI()*(Do-Ths)*Ths*Es}
0.0010636
J = 0
If Sj < (Do-ts)*ts*Es/10Li, then J = 0
K = Es*Ths*(Do-Ths)/(Et*th*N*(dto-th))
0.1
Fq = 0.25+(F-0.6){300*Ths*Es(G/Tts)^3/K*Li*E}^0.25
6.4 OR
6.4
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CLIENT : THIRUMALAI CHEMICALS LIMITED,
RANIPET
PROJECT : MA PLANT-EQPT DESIGN
ITEM : TEMPERED WATER COOLER (E-3107)
Design Code : ASME SEC VIII DIV 1-2010 / TEMA-CLASS "C"
Type as per TEMA : AEMDwg No : 0546-E3107-L1 R3
Design Doc No : PPC/TCL/Dsn-E3107 R0
MECHANICAL DESIGN OF TEMPERED WATER COOLER
Pressure due to Diff.Thermal Expansion Pd = 4*J*Es*Ths*(Dl/Lo)/[(Do-3Ths)(1+J*K*Fq)]
0
UNCORRODED CONDITION
EQUIVALENT BOLTING PRESSURE (R,C,B-7.162)
Internal Design Pressure P = 5.06 kg/sq.cm
72 psi
Allowable bolt stress at Atm. temperature Sa = 25000 psi
1757.7 kg/sq.cm
Allowable bolt stress at design temperature S b = 18800 psi
1321.8 kg/sq.cm
Allowable flange material stress at Atm. temperature Sf = 18300 psi
1286.6 kg/sq.cm
Allowable shell stress at design Temp Ss= 18300 psi
1286.6 kg/sq.cm
Root area of bolts Ab= 2 sq.mm
0.0 sq.in
Nominal thk of shell tn= 0.3 in
(for integral flange) tx= 0.6 in
(for loose flange) 0.6 in
Minimum weld size (smaller of tnor tx) Wm= 0.3 in
Radial dist.from bolt circle to point of intersection of
hub & back of flange R = (C-B)/2-g1
0.4 inTotal Hydrostatic end force H = 0.785*G^2*P
28524.6 lbs
Gasket Load HG= W-H
8886.6 lbs
Radial distance from gasket load reaction to bolt circle hG= (C-G)/2
0.81 in
Hydrostatic end force on area inside of flange HD= 0.785*B^2*P
27632.5 lbs
Radial dist.from bolt circle to the circle on which HDacts hD= R+0.5g1
0.7 in
H-HD HT= 892.1 lbs
a a s . rom e o c rc e o e c rc e on w c Tacts hT= (R+g1+hG)/2
= 0.9 inTotal joint-contact surface compression load HP= 2b*3.14GmP
8886.6 lb
Required Bolt load for operating conditions Wm1= H + HP
37411.2 lbs
Required bolt load for gasket seating conditions Wm2= PI()*b*G*y
37370.7 lbs
Root area of bolts required for operating conditions Am1= Wm1/Sb
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CLIENT : THIRUMALAI CHEMICALS LIMITED,
RANIPET
PROJECT : MA PLANT-EQPT DESIGN
ITEM : TEMPERED WATER COOLER (E-3107)
Design Code : ASME SEC VIII DIV 1-2010 / TEMA-CLASS "C"
Type as per TEMA : AEMDwg No : 0546-E3107-L1 R3
Design Doc No : PPC/TCL/Dsn-E3107 R0
MECHANICAL DESIGN OF TEMPERED WATER COOLER
2.0 sq.inoo area o o s requ re or gas e sea ng
conditions Am2= Wm2/Sa
1.5 sq.ino a cross-sec ona area req m or m ,
whichever is greater) AM= 2.0 sq.in
Actual cross-sectional area provided ( > or = Am) Aactual= 0.1 sq.in
Actual Flange Bolt load for the Operating conditions WO= Wm1
37411.2 lbsActual Flange Bolt load for the Gasket seating
conditions WG= (Am+Ab)Sa/2
25649.5 lbs
Flange design bolt (WO or WG, whichever is greater) W = 37411.2 lbs
Moment due to HD MD= HD*hD
18494.2 lb-in
Moment due to HG MG= HG*hG
7172.3 lb-in
Moment due to HT MT= HT*hT
799.0 lb-in
Moment due to Operating conditions MOO= MD+MG+MT
26465.5 lb-in
Moment due to gasket seating conditions MOG= W(C-G)/2
30194.1 lb-in
Actual moment (MOOor MOG, whichever is greater) MO= 30194.1 lb-in
A-Factor hO= (Bg0)^0.5
= 67.1 mm
= 2.6 in
Flange OD/ID Kf= 1.2
L = [txe+1)/Tk+ tx^3/d]
-371.25
Factor involving Kf Tk=
1.3
Factor involving KfFactor involving Kf U =
= 10.0
Y =
13.41
Z = (Kf 2+1)/(Kf 2-1)
= 6.92
A factor for integral type flanges FF= (-E6/((C/2.73)^0.25(1+A)^3/C)
-26.22
Hub stress correction factor f = C36/(1+A)
0.00
Factor for integral type flanges V = E4/[(2.73/C)^0.25(1+A) 3]
Kf 2[(1+8.55246Log10Kf)-
1]/[(1.04720+1.9448Kf 2)(Kf-1)]
Kf 2[(1+8.55246Log10Kf)-1]/[1.36136(Kf 2-1)(Kf-
1)]
[1/(Kf-1)]*[0.66845+5.71690[(Kf 2Log10Kf)/(Kf 2-1)]]
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CLIENT : THIRUMALAI CHEMICALS LIMITED,
RANIPET
PROJECT : MA PLANT-EQPT DESIGN
ITEM : TEMPERED WATER COOLER (E-3107)
Design Code : ASME SEC VIII DIV 1-2010 / TEMA-CLASS "C"
Type as per TEMA : AEMDwg No : 0546-E3107-L1 R3
Design Doc No : PPC/TCL/Dsn-E3107 R0
MECHANICAL DESIGN OF TEMPERED WATER COOLER
-3915.76
Factor d = (U/V)*h0*g0
= 0.00 in3
Factor e = F/h0
= 0.4 in-1
Radial flange stress (for loose type flanges) SR= 0.0 psi
Tangential flange stress ST= Sf
18300.0 psi
Longitudinal hub stress (for loose type flanges) SH= 0.0 psi
Calculated Thickness of flange Tc = YMO/STB+Cas+Cat
1.2 in
31.4 mm
Actual Thickness of flange t = 32.0 mm
1.3 Inchqu va en o ng pressure w en u e s e pressure s
acting PBT= 6.2M1/F2DI
3
0.4 psiEquivalent bolting pressure when tube side pressure is
not acting PBS= 6.2M2/F2DI
3
0.4 psi
EFFECTIVE SHELL SIDE DESIGN PRESSURE (R,C,B-7.163)
Maximum expansion joint inside diameter DJ= 540.0 mm21.3 in
Shell side design pressure Ps= 71.9 psi
fS= 1-N(DTO/DI)^2
0.58
PS' = PS(-1/2)(DJ^2/DI^2-1)
PS' = 0.0 psi
PS'
Effective shell design pressure P = 0.0 psi
PBS
OR P = 0.4 psi
PS'-PBS
OR P = -0.4 psi
P = 0.4 psi
EFFECTIVE TUBE SIDE DESIGN PRESSURE (R,C,B-7.164)
f1= 1-N[(DTO-2Th)/DI]^2
0.7 psi
Pt' = PT[1+0.4JK(1.5+f1)]/(1+JKFq)
when J =0 & Pd= 0 Pt' = PT
71.9 psi
Effective tube design pressure P = Pt'-PS'+PBT
72.3 psi
TUBESHEET FORMULA BENDING (R,C,B-7.132)
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CLIENT : THIRUMALAI CHEMICALS LIMITED,
RANIPET
PROJECT : MA PLANT-EQPT DESIGN
ITEM : TEMPERED WATER COOLER (E-3107)
Design Code : ASME SEC VIII DIV 1-2010 / TEMA-CLASS "C"
Type as per TEMA : AEMDwg No : 0546-E3107-L1 R3
Design Doc No : PPC/TCL/Dsn-E3107 R0
MECHANICAL DESIGN OF TEMPERED WATER COOLER
Design pressure P = 72.3 psi
Allowable design stress of the tubesheet material at
the design metal temperature S = 18300.0 psi
Tubesheet thickness Tts= (FG/3)*sqrt(P/S)
0.69 in
Tts+ pass
partition
groove depth 0.88 in
= 22.47 mm
Thickness as per dwg for extended tube plate T = 24 mm
THK AS PER DWG IS SATISFACTORY
7 NOZZLE NECK THICKNESS CHECK - UG - 45
SHELL SIDE NOZZLES
a Tempered water inlet N1 = 300 NB
No of nozzles 1
Location of nozzle On shell
Wall thk. Per UG- 45( a ) tr1 :
Nozzle neck size, = 12 NB, Inch
OD of Pipe = 323.9 mm
Material = SA 106 Gr B
Allowable stress = 17100 Psi
Joint Efficiency E = 1
Min. Nozzle thickness ta= PRo/(SE+0.4P)+Ca
= 3.68 mm= 3.7 mm
Wall thk. Per UG- 45 :
Required shell thk for internal pressure tb1= 4.3 mm
= 4.3 mm
Required shell thk for external pressure tb2= 0.0 mm
= 1.6 mm
Wall thk. Per UG- 16( b ) = 1.6 mm
Min pipe wall thk per table UG - 45 tb3= 11.34 mm
The greater of tb1 and tb2 = 4.3 mm
The lesser of tb3 and (greater of tb1 & tb2) tb= 4.30
Required per UG - 45 = Larger of ta or tb :
= 4.30 mm
Nozzle neck thickness as per dwg = Sch 40
= 10.31 mm
THICKNESS AS PER DWG SATISFIES CODE REQUIREMENT
Design Check for RF Pad
Opening size on shell d = 303.2 mm
Joint Efficiency E = 1
Min. Shell thickness ts = PRo/(SE+0.4P)+CA
(When E = 1) = 4.1 mm
Minimum shell thk reqd tr = 4.1 mm
Page 13 of 18
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8/12/2019 1 Tempered Water Cooler E-3107
14/18
CLIENT : THIRUMALAI CHEMICALS LIMITED,
RANIPET
PROJECT : MA PLANT-EQPT DESIGN
ITEM : TEMPERED WATER COOLER (E-3107)
Design Code : ASME SEC VIII DIV 1-2010 / TEMA-CLASS "C"
Type as per TEMA : AEMDwg No : 0546-E3107-L1 R3
Design Doc No : PPC/TCL/Dsn-E3107 R0
MECHANICAL DESIGN OF TEMPERED WATER COOLER
Area required for reinforcement Ar = tr*d
= 1243.2 Sqmm
Excess thickness available in the shell = 3.9 mm
Shell dia availed for nozzle reinforcement ds = 648 mm
RF pad dia made available for reinforcement dp = 0 mm
RF pad thickness tp = 0 mm
Area available for reinforcement = (ds-d)*(Ts-tr)+(dp-d)*tp
= 1343.4 Sqmm
Area available for reinforcement is more than the area
required for reinforcement.Hence opening is
adequately reinforced.
(Note: Area available in welds and nozzle projections are not included in available area)
b Tempered water outlet N2 = 300 NB
No of nozzles 1
Location of nozzle On shell
Wall thk. Per UG- 45( a ) tr1 :
Nozzle neck size, = 12 NB, Inch
OD of Pipe = 323.9 mm
Material = SA 106 Gr B
Allowable stress = 17100 Psi
Joint Efficiency E = 1
Factor y = 0.6
Min. Nozzle thickness tr1 = PRo/(SE+0.4P)+Ca
= 3.68 mm
= 3.7 mm
Wall thk. Per UG- 45 :
Required shell thk for internal pressure tb1= 4.3 mm= 4.3 mm
Required shell thk for external pressure tb2= 4.3 mm
= 4.3 mm
Wall thk. Per UG- 16( b ) = 1.6 mm
Min pipe wall thk per table UG - 45 tb3= 11.34 mm
The greater of tb1 and tb2 = 4.3 mm
The lesser of tb3 and (greater of tb1 & tb2) tb= 4.30
Required per UG - 45 = Larger of ta or tb :
= 4.30 mm
Nozzle neck thickness as per dwg = Sch 40
= 10.31 mm
THICKNESS AS PER DWG SATISFIES CODE REQUIREMENT
Design Check for RF PadOpening size on shell d = 303.2 mm
Joint Efficiency E = 1
Factor y = 0.6
Min. Shell thickness ts = PRo/(SE+0.4P)+CA
(When E = 1) = 4.1 mm
Minimum shell thk reqd tr = 4.1 mm
Area required for reinforcement Ar = tr*d
= 1243.2 Sqmm
Page 14 of 18
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8/12/2019 1 Tempered Water Cooler E-3107
15/18
CLIENT : THIRUMALAI CHEMICALS LIMITED,
RANIPET
PROJECT : MA PLANT-EQPT DESIGN
ITEM : TEMPERED WATER COOLER (E-3107)
Design Code : ASME SEC VIII DIV 1-2010 / TEMA-CLASS "C"
Type as per TEMA : AEMDwg No : 0546-E3107-L1 R3
Design Doc No : PPC/TCL/Dsn-E3107 R0
MECHANICAL DESIGN OF TEMPERED WATER COOLER
Excess thickness available in the shell = 3.9 mm
Shell dia availed for nozzle reinforcement ds = 648 mm
RF pad dia made available for reinforcement dp = 0 mm
RF pad thickness tp = 0 mm
Area available for reinforcement = (ds-d)*(Ts-tr)+(dp-d)*tp
= 1343.4 Sqmm
Area available for reinforcement is more than the area
required for reinforcement.Hence opening is
adequately reinforced.
(Note: Area available in welds and nozzle projections are not included in available area)
c Drain N5 = 25 NPT
No of nozzles 1
Location of nozzle On shell
Nozzle neck size, = 1 NB, Inch
OD of Pipe = 33.4 mm
Material = SA 106 Gr B
Pipe rating = #3000
Since Nozzle size is
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8/12/2019 1 Tempered Water Cooler E-3107
16/18
CLIENT : THIRUMALAI CHEMICALS LIMITED,
RANIPET
PROJECT : MA PLANT-EQPT DESIGN
ITEM : TEMPERED WATER COOLER (E-3107)
Design Code : ASME SEC VIII DIV 1-2010 / TEMA-CLASS "C"
Type as per TEMA : AEMDwg No : 0546-E3107-L1 R3
Design Doc No : PPC/TCL/Dsn-E3107 R0
MECHANICAL DESIGN OF TEMPERED WATER COOLER
Design Check for RF Pad
Opening size on shell d = 154.1 mm
Joint Efficiency E = 1
Factor y = 0.6
Min. Shell thickness ts = PRo/(SE+0.4P)+CA
(When E = 1) = 4.1 mm
Minimum shell thk reqd tr = 4.1 mm
Area required for reinforcement Ar = tr*d
= 631.6 Sqmm
Excess thickness available in the shell = 3.9 mm
Shell dia availed for nozzle reinforcement ds = 337 mm
RF pad dia made available for reinforcement dp = 0 mm
RF pad thickness tp = 0 mm
Area available for reinforcement = (ds-d)*(Ts-tr)+(dp-d)*tp
= 711.7 SqmmArea available for reinforcement is more than the area
required for reinforcement.Hence opening is
adequately reinforced.
(Note: Area available in welds and nozzle projections are not included in available area)
e Cooling water Outlet N4 = 150 NB
No of nozzles 1
Location of nozzle
On RHS
Channel
Wall thk. Per UG- 45( a ) tr1 :
Nozzle neck size, = 6 NB, Inch
OD of Pipe = 168.3 mmMaterial = SA 106 Gr B
Allowable stress = 17100 Psi
Joint Efficiency E = 1
Factor y = 0.6
Min. Nozzle thickness tr1 = PRo/(SE+0.4P)+Ca
= 3.35 mm
= 3.4 mm
Wall thk. Per UG- 45 :
Required channel shell thk for internal pressure tb1= 4.3 mm
= 4.3 mm
Required channel shell thk for external pressure tb2= 0.0 mm
= 1.6 mm
Wall thk. Per UG- 16( b ) = 1.6 mm
Min pipe wall thk per table UG - 45 tb3= 9.22 mm
The greater of tb1 and tb2 = 4.3 mmThe lesser of tb3 and (greater of tb1 & tb2) tb= 4.30
Required per UG - 45 = Larger of ta or tb :
= 4.30 mm
Nozzle neck thickness as per dwg = Sch 40
= 7.11 mm
THICKNESS AS PER DWG SATISFIES CODE REQUIREMENT
Design Check for RF Pad
Page 16 of 18
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8/12/2019 1 Tempered Water Cooler E-3107
17/18
CLIENT : THIRUMALAI CHEMICALS LIMITED,
RANIPET
PROJECT : MA PLANT-EQPT DESIGN
ITEM : TEMPERED WATER COOLER (E-3107)
Design Code : ASME SEC VIII DIV 1-2010 / TEMA-CLASS "C"
Type as per TEMA : AEMDwg No : 0546-E3107-L1 R3
Design Doc No : PPC/TCL/Dsn-E3107 R0
MECHANICAL DESIGN OF TEMPERED WATER COOLER
Opening size on shell d = 154.1 mm
Joint Efficiency E = 1
Factor y = 0.6
Min. Shell thickness ts = PRo/(SE+0.4P)+CA
(When E = 1) = 4.1 mm
Minimum shell thk reqd tr = 4.1 mm
Area required for reinforcement Ar = tr*d
= 631.6 Sqmm
Excess thickness available in the shell = 3.9 mm
Shell dia availed for nozzle reinforcement ds = 337 mm
RF pad dia made available for reinforcement dp = 0 mm
RF pad thickness tp = 0 mm
Area available for reinforcement = (ds-d)*(Ts-tr)+(dp-d)*tp
= 711.7 Sqmmrea ava a e or re n orcemen s more an e area
required for reinforcement.Hence opening is
adequately reinforced.
(Note: Area available in welds and nozzle projections are not included in available area)
f Side drain N6 = 25 NPT
No of nozzles 1
Location of nozzle On LHS Channel
Nozzle neck size, = 1 NB, Inch
OD of Pipe = 33.4 mm
Material = SA 106 Gr B
Pipe rating = #3000Since Nozzle size is
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8/12/2019 1 Tempered Water Cooler E-3107
18/18
CLIENT : THIRUMALAI CHEMICALS LIMITED,
RANIPET
PROJECT : MA PLANT-EQPT DESIGN
ITEM : TEMPERED WATER COOLER (E-3107)
Design Code : ASME SEC VIII DIV 1-2010 / TEMA-CLASS "C"
Type as per TEMA : AEMDwg No : 0546-E3107-L1 R3
Design Doc No : PPC/TCL/Dsn-E3107 R0
MECHANICAL DESIGN OF TEMPERED WATER COOLER
ON SHELL SIDE
N1 = Tempered water inlet SA 106 Gr B 4.30 10.31 Thk safe
N2 = Tempered water outlet SA 106 Gr B 4.3 10.31 Thk safe
N5 = Drain SA 106 Gr B - #3000 Thk safe
ON TUBE SIDE
N3 = Cooling water Inlet SA 106 Gr B 4.30 7.11 Thk safe
N4 = Cooling water Outlet SA 106 Gr B 4.30 7.11 Thk safe
N6 = Side drain SA 106 Gr B - #3000 Thk safe
From above, it may be noted that all available
thicknesses are more than thickness required as per
code. Hence the equipment meets code requirement.
Page 18 of 18