PV 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 5500

Shell Desc.
Shell Design Pressure
Shell Temperature for Internal Pressure
Shell Material

MAIN SHELL
Ps

10.00

TEMPS

100.00

bars
C

BS1501-151,430A

Shell Material UNS Number

Shell Allowable Stress at Temperature

Sos

157.02

N./mm^2

Shell Allowable Stress at Ambient

Sas

167.02

N./mm^2

Ts

10.0000

mm.

Cas

0.0000

mm.

Inside Diameter of Shell

Ds

500.0000

mm.

Mean Metal Temperature for Shell

Tm

100.00

Shell Thickness
Shell Corrosion Allowance

Channel Desc.
Channel Design Pressure
Channel Temperature for Internal Pressure
Channel Material

LEFT CHANNE SHELL

Pc

5.00

TEMPC

100.00

bars
C

BS1501-151,430A

Channel Material UNS Number

Channel Allowable Stress at Temperature

Soc

157.02

N./mm^2

Channel Allowable Stress at Ambient

Sac

167.02

N./mm^2

Tc

10.0000

mm.

Cac

0.0000

mm.

Inside Diameter of Channel

Dc

500.0000

mm.

Mean Metal Temperature for Tubes

tm

75.00

Tubtmp

100.00

Channel Thickness
Channel Corrosion Allowance

Tube Design Temperature

Tube Material
Tube Allowable Stress at Temperature

A-106 B
Sot

147.01

N./mm^2

PV Elite 2008 Licensee: ZISHAN ENGINEERS (PVT.) LTD.

FileName : ExchangerUtube-PD 5500---------------------------Tubesheet Analysis: pd55Sample03
Case:
1
7:31p Feb 28,2014
Tube Allowable Stress At Ambient

Sat

161.01

N./mm^2

Tube Yield Stress At Operating Temperature

Syt

220.51

N./mm^2

Tt

1.2000

mm.

Catt

0.0000

mm.

Ntubs

300

Tube Wall Thickness

Tube Corrosion Allowance
Number of Tubes Holes
Tube Layout Pattern

Triangular

Tube Outside Diameter

Tube Pitch (Center to Center Spacing)

do

19.0000

mm.

PTube

25.0000

mm.

Tube-Tubesheet Joint Classification

Tube Joint Reliability Factor

fr

0.5000

Is Welded Tube Material specified (not Seamless)

No

Straight Tube Length, bet. inner tubsht faces RL

500.000

mm.
mm.

Unsupported Tube Length for max. (k*SL)

SL

150.0000

Tube end condition corres. to span (SL)

1.0000

Length of Expanded Portion of Tube

20.0000

mm.

Tube Bundle Effective outer diameter

Do

420.0000

mm.

Tube hole diameter

dh

19.5000

mm.

Ngroove

0.00

TEMPTS

100.00

Number of Grooves in tube hole

Area of untubed Lanes,

Tubesheet type:

cm^2

U-tube, Integral with Shell

Tubesheet Design Metal Temperature

Tubesheet Material

BS1501-151,430A

Tubesheet Allowable Stress at Temperature

Sots

157.02

N./mm^2

Tubesheet Allowable Stress at Ambient

Sats

167.02

N./mm^2

Tts

30.0000

mm.

Tubesheet Corr. Allowance (Shell side)

Cats

1.5000

mm.

Tubesheet Corr. Allowance (Channel side)

Catc

1.5000

mm.

Thickness of Tubesheet

PV Elite 2008 Licensee: ZISHAN ENGINEERS (PVT.) LTD.

FileName : ExchangerUtube-PD 5500---------------------------Tubesheet Analysis: pd55Sample03
Case:
1
7:31p Feb 28,2014
Depth of Groove in Tube Sheet
Tubesheets Clamped:

hg

0.0000

mm.

Stationary Clamped / Floating Clamped

Additional Data for Tubesheets Extended as Flanges:

Outside Diameter of Flanged Portion

698.5000

mm.

Diameter of Bolt Circle

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 Series

Number of Bolts

40

Bolt Allowable Stress At Temperature

Sb

193.03

N./mm^2

Bolt Allowable Stress At Ambient

Sa

193.03

N./mm^2

WLDH

0.0000

mm.

Bolt Material

Weld between Flange and Shell/Channel

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 1a

Gasket 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,

2.0000

Gasket Design Seating Stress

11.00

Column for Gasket Seating

Code Column II

Gasket Thickness

tg

Full face Gasket Flange Option

Tubesheet Gasket on which Side

9.5250

Program Selects
Side

CHANNEL

N./mm^2

mm.

PV Elite 2008 Licensee: ZISHAN ENGINEERS (PVT.) LTD.

FileName : ExchangerUtube-PD 5500---------------------------Tubesheet Analysis: pd55Sample03
Case:
1
7:31p Feb 28,2014
Intermediate Calculations For Tubesheets Extended As Flanges:
PD 5500 Standard, 2000 Ed., Per Para. 3.8.3

Gasket Contact Width,

Basic Gasket Width,

N = (Goc-Gic) / 2
b0 = N / 2.0

Effective Gasket Width,

b = SQRT(b0) * 2.5

Gasket Reaction Diameter,

G = Go-2.0*b

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)

42.100

mm.

21.050

mm.

11.557

mm.

561.086

mm.

PV Elite 2008 Licensee: ZISHAN ENGINEERS (PVT.) LTD.

FileName : ExchangerUtube-PD 5500---------------------------Tubesheet Analysis: pd55Sample03
Case:
1
7:31p Feb 28,2014
= ( 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
Circular Wrench End Diameter

50.851

mm.

73.025

mm.

----------------------------------------------------------------------------Minimum

Actual

Maximum

----------------------------------------------------------------------------Bolt Area, cm^2

11.609

187.871

Radial distance bet. hub and bolts

28.575

57.500

Radial distance bet. bolts and the edge

28.575

31.750

Circumferential 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]:

PV Elite 2008 Licensee: ZISHAN ENGINEERS (PVT.) LTD.

FileName : ExchangerUtube-PD 5500---------------------------Tubesheet Analysis: pd55Sample03
Case:
1
7:31p Feb 28,2014
= 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

Moment

End 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.

PV Elite 2008 Licensee: ZISHAN ENGINEERS (PVT.) LTD.

FileName : ExchangerUtube-PD 5500---------------------------Tubesheet Analysis: pd55Sample03
Case:
1
7:31p Feb 28,2014
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: 1.40

Tube alpha at Metal Temp. along len.

75.0

0.1172E-04 /C

Tube Elastic Mod. at Metal Temp. len

75.0

0.2062E+09 KPa.

Shell Properties - Group # 1.10 and S factor: 1.40

Shell alpha at Metal Temp. along len.

100.0

0.1190E-04 /C

Shell Elastic Mod. at Metal Temp. len

100.0

0.2050E+09 KPa.

Tubesheet Properties - Group # 1.10 and S factor: 1.40

Tubesheet Elastic Mod. at Design Temp.

100.0

0.2050E+09 KPa.

Channel Properties - Group # 1.10 and S factor: 1.40

Channel 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| ):

PV Elite 2008 Licensee: ZISHAN ENGINEERS (PVT.) LTD.

FileName : ExchangerUtube-PD 5500---------------------------Tubesheet Analysis: pd55Sample03
Case:
1
7:31p Feb 28,2014
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:

PV Elite 2008 Licensee: ZISHAN ENGINEERS (PVT.) LTD.

FileName : ExchangerUtube-PD 5500---------------------------Tubesheet Analysis: pd55Sample03
Case:
1
7:31p Feb 28,2014
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 )) *

PV Elite 2008 Licensee: ZISHAN ENGINEERS (PVT.) LTD.

FileName : ExchangerUtube-PD 5500---------------------------Tubesheet Analysis: pd55Sample03
Case:
1
7:31p Feb 28,2014
(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

10

PV Elite 2008 Licensee: ZISHAN ENGINEERS (PVT.) LTD.

FileName : ExchangerUtube-PD 5500---------------------------Tubesheet Analysis: pd55Sample03
Case:
1
7:31p Feb 28,2014

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
(+CA)

Actual Thk
(mm.)

Actual

Allow

Result

Stress

(N./mm^2)

11

PV Elite 2008 Licensee: ZISHAN ENGINEERS (PVT.) LTD.

FileName : ExchangerUtube-PD 5500---------------------------Tubesheet Analysis: pd55Sample03
Case:
1
7:31p Feb 28,2014
-----------------------------------------------------------------------Bending

30.000

206.22

314.05

Ok

6.769

30.000

10.96

78.51

Ok

38.071

40.000

151.30

167.02

Ok

Shear

24.879

Bolted Exten.

------------------------------------------------------------------------

Summary of Longitudinal Tube Stresses and Tube-Tubesheet Load:

-------------------------------------------------------------------Actual
Condition

Wti

Allowable
Wto

Compressive

Tensile

Result

-------------------------------------------------------------------Long. Tube

-4.225

-4.225

-94.206

147.008

Passed

Long. Tube

1.613

1.613

-94.206

147.008

Passed

-28.911

-28.911

502.959

502.959

Passed

Tube Load

--------------------------------------------------------------------

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

12