A SHELL AND TUBE HEAT EXCHANGER DESIGN

ABSTRACT

Since shell and tube heat exchangers are the most used heat transfer equipment in
industrial processes, a basic understanding of their design, construction and performance is
important. This paper optimized a design of a shell and tube type heat exchanger that heats
150,000 pounds per hour of kerosene from 75 to 120F by cooling 142,105 pounds per hour
gasoline stream entering at 160F. Based on the given inlet and outlet conditions, a thermal
and mechanical design method was achieved to obtain a set of optimum dimensions and
geometry for the heat exchanger. The calculated results were tabulated in a heat exchanger
data sheet and a setting up plan was illustrated in a 2D and 3D model.

1
 I. INTRODUCTION

Transfer of heat from one fluid to another is an important operation for most of
chemical industry. So it is necessary to develop the equipment which transfers the heat
with maximum rate and minimum costs. Such equipment for efficient transfer of heat is
called as heat exchanger. Thus heat exchangers facilitate the exchange of heat between
the fluids that are different temperature while keeping them from mixing with each other.
Heat exchangers have undergone numerous modifications over the ages and have become
quite efficient compared to their predecessors. There are different types of heat
exchangers with different designs, materials and have been customized to meet specific
needs. One of these types is the shell and tube heat exchanger which is one of the most
widely used heat exchanger in oil refineries and other large chemical process.

II. SHELL AND TUBE HEAT EXCHANGER

A. General Description
Shell and tube heat exchangers are the most versatile type of heat exchanger. They
provide relatively large ratios of heat transfer area to volume and weight and they can
be easily cleaned. Shell and tube heat exchangers can be designed for high pressures
relative to the environment and high pressure differences between fluid streams.
Furthermore, it consists of bundle of round tubes mounted in cylindrical shell with
tubes parallel to shell. One fluid flows through tubes, while another fluid flows across
and along the axis of the exchanger. Basically, a service of the shell ant tube heat
exchanger may be single phase such as the cooling or heating of a liquid or gas or
two-phase such as condensing or vaporizing.

B. How it works?
The two fluids that flow through the shell and tube heat exchanger will typically
begin at different temperatures. One fluid will flow through the tube side while the
other fluid will flow outside of the tubes on the shell side. Fluids may be either gases
or liquids. In order to ensure that heat is transferred efficiently, the heat transfer area
should be large. This makes it possible for any heat waste to be utilized, thus
conserving energy.

2
 Shell and tube heat exchangers may feature only one phase, either gas or liquid,
on each side. In this instance, they are known as single-phase or one-phase heat
exchangers. In a two-phase heat exchanger, a liquid can be heated to the point that it
is boiled into a gas or it may be used for the purpose of cooling a vapor so that it can
then be condensed into a liquid. Such phase changes typically take place on the shell
side of the shell and tube heat exchanger. This type of heat exchanger may be used in
a variety of different applications based on the specific needs of that industry. The
shell and tube design can also include a variety of variations based on specific
industrial needs. For instance, the tubes inside the exchanger may be U-shaped or they
may be straight.

C. What are they are used for?

The following nomenclature is usually used:
Heat exchanger - both sides are single phase and process streams.
Cooler - one stream is a process fluid and the other is cooling water or air.
Heater - one stream is a process fluid and the other is a hot utility, such as
steam or hot oil.
Condenser - one stream is a condensing vapor and the other is cooling water or
air.
Chiller - one stream is a process fluid being condensed at sub-atmospheric
temperatures and the other is a boiling refrigerant or process stream.
Reboiler - one stream is a bottoms stream from a distillation column and the
other is a hot utility (steam or hot oil) or a process stream.

D. Components
The principal components of an STHE are:
1. Shell;
2. Tubes;
3. Channel;
4. Channel cover;
5. Tube sheet;
6. Baffles; and
7. Nozzles.

3
E. Classification

SHELL AND
TUBE ADVANTAGES
EXCHANGERS
Provides maximum Shell side / outside of the tubes
heat transfer area for a
given shell and tube
diameter.
Fixed tube Provides for single and
sheet multiple tube passes to
assure proper velocity.
Less costly than
removable bundle
designs.
Floating tube sheet To provide the floating-head
allows for differential
thermal expansion
between the shell and
the tube bundle.
Both the tube bundle
Floating head and the shell side can
be inspected and
cleaned mechanically.
U-tube design allows Because of U-bend some tubes
for differential thermal
expansion between the
shell and the tube
bundle as well as for
individual tubes.
Both the tube bundle Due to U-tube nesting,
U-tube
and the shell side can
be inspected and
cleaned mechanically.
Less costly than
floating head or packed
floating head designs.
LIMITATIONS
are inaccessible for mechanical
cleaning.
No provision to allow for
differential thermal expansion
developed between the tube
and the shell side. This can be
taken care by providing
expansion joint on the shell
side.
cover it is necessary to bolt it
to the tube sheet. The bolt
circle requires the use of space
where it would be possible to
place a large number of tubes.
Tubes cannot expand
independently so that huge
thermal shock applications
should be avoided.
Packing materials produce
limits on design pressure and
temperature.
are omitted at the center of the
tube bundle.
Because of U-bend, tubes can
be cleaned only by chemical
methods.
individual tube is difficult to
replace.
No single tube pass or true
countercurrent flow is possible.
Tube wall thickness at the U-
bend is thinner than at straight
portion of the tubes.

Table 1: Features of Shell and Tube Type Exchangers

4
III. DESIGN PROBLEM

150,000 lb per hour of kerosene will be heated from 75 to 120F by cooling a 142,105 lb
per hour of gasoline stream which enters at 160F. Inlet pressure will be 50 psia for each
stream and the maximum pressure drop of 7 psi for gasoline and 10 psi for kerosene are
permissible. Design a shell and tube heat exchanger for this service.

IV. DESIGN INPUT

A. Given

Fluid Name Kerosene Gasoline

Mass Flow Rate 150,000 lb/h 142105 lb/h

Temperature (In/Out) 75F / 120F 160F /

Pressure 50 psia 50 psia

Permissible Pressure Drop 10 psi 7 psi

B. Figure

Gasoline
Kerosene
Tci Thi h 142,105
m
lb
lb
c 150,000
m h
h

Tho Tco

Figure 1: Kerosene is heated by cooling a hot gasoline.

5
 C. Physical Properties

Kerosene Value Units

Btu
Specific Heat 0.48
lb F

Btu
Thermal Conductivity 0.083
h ft F

lb
Density 49.8
ft 3
lb
Viscosity 3.872
h ft

Table 2: Physical Properties of 46API Kerosene

Gasoline Value Units

Btu
Specific Heat 0.57
lb F

Btu
Thermal Conductivity 0.075
h ft F
lb
Density 42.7
ft 3

lb
Viscosity 0.484
h ft

Table 3: Physical Properties of 76API Gasoline

V. THERMAL DESIGN
Pressure drop is a major constraint in the thermal design of shell and tube heat
exchangers. A thermal design of a shell and tube heat exchanger is meaningful only when
it is optimum and the extent of the optimality is constrained by the pressure drop.
Optimization of thermal design requires maximization of overall heat transfer coefficient
and effective mean temperature difference so as to minimize the heat transfer area subject
to the constraints, pressure drop being the major one. The main steps of the thermal
design following the Kern method are summarized in the design procedure.

6
A. PROCESS DESIGN

Specification
Define duty
Make energy balance if needed to O
calculate unspecified flow rates or
temperatures

Decide baffle spacing and

estimate shell-side heat transfer
coefficient
Collect physical properties

Calculate overall heat transfer

coefficient including fouling factors,
Assume value of overall Uo,calc
coefficient Uo,ass

Decide number of shell and tube

passes and Calculate Tlm,
correction factor, F, and Tm 0< <30%

Set Uo,ass= Uo,calc

Determine heat transfer area

required: Ao = q/(Uo,ass)(Tm)

Estimate tube- and shell-side

Decide type, tube size, material pressure drops
layout. Assign fluids to shell or
tube side.

Accept Design
Calculate number of tubes

Calculate shell diameter

Estimate tube-size heat transfer

coefficient.

7
B. CALCULATIONS

STEP 1:
TUBE DIAMETER
D 0 = 1in = 25.40mm

Di = 0.834in = 21.18mm
TUBE LENGTH
L 16 ft
BWG NUMBER
BWG =14
TUBE PATTERN
Square Pitch, Pt = 1.25 D 0
= 1.25 25.40 mm
= 31.75 mm
STEP 2:
FOULING FACTOR
1
Gasoline (Hot Fluid) : = 0.0005
h id

1
Kerosene (Cold Fluid) : = 0.001
h od

STEP 3:
CARBON STEEL
Btu
k w = 70
h ft F
STEP 4:
Assume three known temperatures,
Th in = 160F Tc in = 75F
Th out = unknown Tc out 120 o F

Then obtain Thout and q using the heat duty equation.

HEAT DUTY EUATION

q = m c cp c (Tc o - Tc i ) or

q = m h cp h (Th i - Th o )

8
 KEROSENE:

q = m c cp c (Tc o - Tc i )
lb Btu
q = (150,000 )(0.48 )[(120 - 75)F]
h lb F
Btu
q = 3,240,000
h

GASOLINE:

q = m h cp h (Th i - Th o )
Btu lb Btu
3,240,000 = (142,105 )(0.57 )[(160F - Th o ]
h h lbF
Th o = 120F

STEP 5:
For Co-Current LMTD (Log Mean Temperature Difference),
(Th i - Th o ) - (Tc o - Tc i )
Tlm =
(Th i - Th o )
ln
(Tc o - Tc i )
(160 - 120)F - (120 - 75)F
Tlm =
(160 - 120)F
ln
(120 - 75)F
Tlm = 42.75F

STEP 6:
Based on the exchanger configuration,

TEMPERATURE CORRECTION FACTOR

Th i - Th o 200 - 90
R= = = 2.9
Tc o - Tc i 78 - 40
Tc o - Tc i 78 - 40
S= = = 0.24
Th i - Tc i 200 - 40

9
 Th i - Th o 160 - 120
R= = = 0.889
Tc o - Tc i 120 - 75
Tc o - Tc i 120 - 75
S= = = 0.529
Th i - Tc i 160 - 75
(1 - S)
(R 2 + 1)ln[ ]
(1 - RS)
Ft =
2 - S(R + 1 - (R 2 + 1)
(R - 1)ln[ ]
2 - S(R + 1 + (R 2 + 1)
(1 - 0.529)
(0.889 2 + 1)ln[ ]
(1 - (0.889)(0. 529)
Ft =
2 - (0.529)[0. 889 + 1 - (0.889 2 + 1) ]
(0.889 - 1)ln[
2 - (0.529)[0. 889 + 1 + 0.889 2 + 1)]
Ft = 0.802 : ACCEPTABLE

STEP 7:
Calculate,
MEAN TEMPERATURE DIFFERENCE
Tm = Ft Tlm
Tm = (0.802)(42 .75F)
Tm = 34.2855F
STEP 8:
Assume,
OVERALL HEAT TRANSFER COEFFICIENT
Btu
U o = 45
h ft 2 F

STEP 9:
Calculate,
PROVISIONAL AREA
q
A=
U o Tm
Btu
(3,240,000 )
A= h
Btu
(45 )(71C)
h ft 2 F
A = 2100 ft 2

10
STEP 10:
Based on the assumed tube diameter Do and tube length L,
NUMBER OF TUBES
A
Nt =
D o L
2100 ft 2
Nt =
1
( ft)(16ft)
12
N t = 502 : make it 518 because it is taken correspond ing to the closest standard
N t = 518 tubes

CHECKING THE NUMBER OF TUBES:

To check the number of tubes, see if the evaluated tube-side velocity looks
reasonable. Tube-side velocity for process fluids should be within 11,811.02362-
23,622.04724 ft/h.

TUBE CROSS - SECTIONALAREA = (D I ) 2
4
1 ft 2
TUBE CROSS - SECTIONALAREA = (0.834 in )
4 12 in
TUBE CROSS - SECTIONALAREA = 3.79367 10 3 ft 2

For Nt = 518 tubes,

Assume 2 PASS:
AREA PER PASS = TUBE PER PASS TUBE CROSS - SECTIONAL AREA
= 259 3.79367 10 3 ft 2
= 0.9826 ft 2

m
VOLUMETRIC FLOW =
mean
lb
(142,105 )
= h
lb
42.7
ft 3
ft 3
= 3327.986
h

11
 VOLUMETRIC FLOW
TUBE SIDE VELOCITY =
AREA PER PASS
3327.986 ft 3 /h
=
42.7 ft 2
ft
= 3,386.918 : VELOCITY IS NOT SATISFACTO RY BECAUSE
h
TUBE SIDE VELOCITY MUST WITHIN 11,811.02362 -
23,622.04724 ft/h
Assume 4 PASS:
AREA PER PASS = 129.5 3.79367 10 3 ft 2
= 0.4913 ft 2
3,327.986 ft 3 /h
TUBE SIDE VELOCITY =
0.4913 ft 2
= 6,773.83676 ft/h : NOT SATISFACTO RY
Assume 6 PASS:
AREA PER PASS = 86.333 3.79367 10 3 ft 2
= 0.32752 ft 2
3,327.986 ft 3 /h
TUBE SIDE VELOCITY =
0.32752 ft 2
= 10,161.1647 ft/h : NOT SATISFACTO RY

At L= 24 ft,
A
Nt =
D o L
2100 ft 2
Nt =
1
( ft)(24ft)
12
N t = 335 : make it 318 because it is taken correspond ing to the closest standard
N t = 318 tubes
Assume 2 PASS:
AREA PER PASS = 159 3.79367 10 3 ft 2
= 0.60319 ft 2
ft 3
3,327.986
TUBE SIDE VELOCITY = h
0.60139 ft 2
ft
= 5,517.278 : NOT SATISFACTO RY
h

12
 Assume 4 PASS,
AREA PER PASS = 79.5 3.79367 10 3 ft 2
= 0.3016 ft 2
ft 3
3,327.986
TUBE SIDE VELOCITY = h
2
0.3016 ft
ft
= 11,034.55621 : NOT SATISFACTO RY
h
Assume 6 PASS,
AREA PER PASS = 53 3.79367 10 3 ft 2
= 0.201064 ft 2
ft 3
3,327.986
TUBE SIDE VELOCITY = h
0.201064 ft 2
ft
= 16,551.83432 : ACCEPTABLE
h
Nt = 318 tubes: 6 passes at L=24 ft

STEP 11:
TUBE PITCH AND BUNDLE DIAMETER
Pt = 1.25DO : TUBE PITCH
Pt = 1.25(1 in)
Pt = 1.25 in

N t n11
Db = D o ( ) : BUNDLEDIAM ETER
K1
For 6 tube passes, square pitch
K 1 = 0.0402
n 1 = 2.617
N t n11
Db = D o ( )
K1
1
318 2.617
Db = (1 in)( )
0.0402
Db = 30.872 in = 0.78 m

13
STEP 12:
TYPE OF FLOAT HEAD OF THE HEAT EXCHANGER AND THE BUNDLE
DIAMETER CLEARANCE (BDC)
Assume Split-Ring Floating Head Exchanger
Since, Db=0.78 mm = 30.872 in
BDC= 67 mm = 2.638 in

STEP 13:
SHELL DIAMETER
Ds = Db + BDC
Ds = 30.872 in + 2.638 in
Ds = 33.51 in 2.7925 ft

STEP 14:
BAFFLE SPACING
Bs = 0.5Ds
Bs = 0.5(33.51 in)
Bs = 16.755 in

STEP 15:
AREA FOR CROSS-FLOW
(Pt - D o )
As = DsBs
Pt
(1.25 - 1) in
As = (33.51 in)(13.404 in)
1.25 in
As = 112.292 in 2
As = 9.358 ft 2

STEP 16:
SHELL-SIDE MASS VELOCITY
shell - side flow - rate
Gs =
As
lb
(142,105 )
Gs = h
2
(9.358 ft )
lb
Gs = 15,185.942
h ft 2

14
 SHELL-SIDE VELOCITY
Gs
us =

lb
15,185.942
us = h ft 2
lb
42.7 3
ft
ft
u s = 355.643
h

STEP 17:
SHELL EQUIVALENT DIAMETER
For a square pitch arrangement
1.27 2 2
de = (Pt - 0.785D o )
Do
1.27
de = [(1.23 in) 2 - 0.785(1 in) 2 ]
1 in
d e = 0.987 in 0.082 ft

STEP 18:
SHELL-SIDE REYNOLDS NUMBER
u s d e
Re =

ft lb
(355.643 )(0.082 ft)(42.7 3 )
Re = h ft
lb
0.484
ft h
Re 2572.825 z

STEP 19:
SHELL-SIDE PRANDTLS NUMBER
c p
Pr = ft
k
lb Btu
(0.484 )(0.57 )
Pr = ft h lb F
Btu
(0.075 )
h ft F
Pr 3.6784

15
STEP 20:
SHELL-SIDE HEAT TRANSFER COEFFICIENT
1
k
h o = hs = [(j h RePr 3 )( ) 0.14 ] neglect the viscositycorrelation
de w
1
k
ho = (j h RePr 3 )
de
Btu
0.075 1

ho = ( h ft F -2
)[(2.9 10 )(3216.087)(3.6784) 3 ]
0.082 ft
Btu
h o = 155.3
h ft 2 F

STEP 21:
PRESSURE DROP IN THE SHELL

f G s2 D s (n b 1)
Ps =
(7.5 1012 ) De S
Ps =
Ps =
Ps =

STEP 22:
NUMBER OF TUBES PER PASS

Nt
Nt pp =
number of passes
316
Nt pp =
6
Nt pp = 53 tubes per pass

16
STEP 23:
TUBE-SIDE MASS VELOCITY
tube - side flow rate
Gm = 2
D i
Nt pp
4
lb
(150,000 )
Gm = h
1 ft 2
(0.834 in )
(53) 12 in
4
lb
G m = 746,029.32
h ft 2

STEP 24:
TUBE-SIDE VELOCITY
Gm
t =

lb
746,029.32
t = h ft 2
lb
49.8 3
ft
ft
t = 14,980.509
hr

STEP 25:
TUBE-SIDE REYNOLDS NUMBER
dv
Re =

lb ft
(49.8 3 )(0.0695 ft)(1.4,98 0.509 )
Re = ft h
N -s
3.2 10 -3
m
Re = 13390.76

TUBE-SIDE PRANDTLS NUMBER

c p
Pr =
k
lb Btu
(3.872 )(0.48 )
Pr = h ft lb F
Btu
(0.083 )
h lb F
Pr = 22.392
17
STEP 26:
TUBE-SIDE HEAT TRANSFER COEFFICIENT
Since Re>2100,
1
k D
h i = 0.023 (Re) 0.8 (Pr) 3 (1 i ) 0.7
Di L
Btu 1 ft
(0.083 ) 0.834in
h i = 0.023 h ft F (13,390) 0.8 (22.392) 0.33 (1 12 in ) 0.7
1ft 16 ft
(0.834 in )
12in
Btu
h i = 153.86
ft F

STEP 27:
OVERALL HEAT TRANSFER FACTOR

1
Uo =
1 A d di A 1 A
+ R dg o ( o ) + o ( ) o (R ak )
ho A1 2 k w A1 h i A1
1
Uo =
1 0.834

1 (1) 2
(1) 2 1 (1) 2
+ 0.0005 + ( 12 12 ) + ( )+ (0.0001)
155.3 0.834 2 2 70 0.834 2 153.86 0.834 2
( ) ( ) ( )
12 12 12
Btu
U o = 48.3
h ft 2 F

STEP 28:
TUBE-SIDE PRESSURE DROP
8jf L -m i 2
P = (1.5 + N p [2.5 + + ( ) ])
di w 2
8(5.5 10 -3 )(5000) 820(1.52) 2
P = {1.5 + 4[2.5 + ]}( )
14.83 10 -3 2
N
P = 67,103.40 2
m
P = 0.67 bar

18
VI. MECHANICAL DESIGN
Mechanical design involves the design of pressure-retaining and non-pressure-
retaining components and equipment to withstand the design loads, pressure and
temperature and the deterioration in service so that the equipment will function
satisfactorily and reliably throughout its codal life. Mechanical design is done as per the
procedure given in the construction codes and standards. In this mechanical design of
shell and tube heat exchanger, the design standard used is IS:4503.

A. DESIGN TEMPERATURE AND PRESSURE

According to the IS:4503 standard, the design pressure should be 10% greater than the
maximum allowable working pressure and the design temperature should be 10C
greater than the maximum allowable temperature.

i. Design Temperature
10C greater than the maximum allowable temperature
T 1.1 160 F
T 176 F (80 C)
ii. Design Pressure
10% greater than the maximum allowable working pressure
P 1.1 50 psia
N
P 55psia (0.38 )
mm 2

B. MATERIALS OF CONSTRUCTION

i. Carbon Steel
Allowable Fluid Temperatur e 540 C (1004 F)
N
Permissibl e Stress 100.6
mm 2
Corrosion Allowance 3mm

19
C. DESIGN COMPONENT CALCULATION

i. Shell Thickness
PD s
t s:
fJ 0.6p
where : t s shell thickness
P design pressure
f maximum allowable stress
J joint efficiency
N
(0.38 )(787.4mm)
ts mm 2
N N
(100.6 2
)(0.8) (0.6)(0.38 )
mm mm 2
t s 3.72mm C
t s 6.72mm : Including corrosion allowance
: Use 8 mm thickness

ii. Torispherical Head

Inside depth of the head

1
D D 2
h i R i (R i s )(R i s ) 2ri
2 2
where : h i inside depth of the head
R i crown radius D s
ri knuckle radius 6% of D s
D s shell ID
1
784mm 784mm 2
h i (784mm) (784mm )(784mm ) 2(47.24mm)
2 2
h i 105.42mm

Effective Exchanger Length

L eff L t (2 h i )
where : L eff effective exchanger length
h i inside depth of the head
L t exchanger total length
L eff 6.096m (2 0.1054m)
L eff 6.306m

20
 Thickness of the Head

PR i W
th
(2fJ 0.2p)
where : R i crown radius D
P design pressure
f permissibl e stress
J joint efficiency
1 Ri
W (3 ) 1.77mm
4 ri
N
(0.38 2
)(787.4mm) (1.77mm)
th mm
N N
2(1)(100.6 mm 2 ) (0.2)(0.38 mm 2 )
t h 2.63mm C
t h 5.63mm : Including corrosion allowance
: Use 8 mm, same thickness as for shell

iii. Channel Cover Thickness

Channel cover material: Carbon Steel

D c C1 P
t cc ( )
10 f
where : D c outside shell diameter
kgf
(0.3)(3.88 )
803.4mm cm 2
t cc ( )
10 kgf
(10.26 )
cm 2
t cc 8.45mm C
t cc 11.45mm : Including corrosion allowance
: Use 12mm

21
iv. Tube Sheet Thickness
FG p P
t ss ()
3 kf
where : G p diameter over which pressure is acting D s
F 1 (for fixed tube sheet)
f allowance stress
k 0.5 (for square pitch)
P pressure
N
(0.38
(1)(787.4m m) mm 2
t ss ( )
3 N
(0.5)(100. 6 )
mm 2
t ss 22.8mm : Satisfies the IS : 4503 specificat ion for 1in. outside diameter t ube

v. Impingement Plate
k density of kerosene
g
k 0.8
cm 3
kg
k 800 3
m
k mass flow rate of kerosene
m
kg
k 18.91
m
s
lb
150,000
m
h
k velocity of kerosene
mk
k 2
D
( n ) k
4
where : D n Nozzle diameter
203.2mm 0.2032m
kg
18.91
k s
(0.2032m) 2 kg
(800 3 )
4 m
m
k 0.73
s

22
 Impingemen t Parameter, v 2 (0.8)(0.73 ) 2
v 2 0.426 125
The impingemen t protection is not required

vi. Nozzle Thickness

PD n
tn C
2fJ P
where : C Corrosion allowance
D n Nozzle diameter
P Design pressure
f Allowable stress
J Joint efficiency
N
(0.38 2
)(203.2mm)
tn mm 3mm
N N
2(100.6 )(0.8) (0.38 )
mm 2 mm 2
t n 3.48mm : Including corrosion allowance
: Use 6mm thickness

Note:
The pressure at the entry point of both shell and tube fluids are same. Therefore,
the same nozzle specification can be used for the tube side fluid also.

vii. Design of Gaskets

m = Gasket factor = 3.75

Y = Minimum design seating stress = 5.35 kgf/mm2

D OG Y Pm

D IG Y P(m 1)
kgf kgf
5.35 (0.0388 )(3.75)
D OG mm 2
mm 2

D IG kgf kgf
5.35 2
(0.0388 )(3.75 1)
mm mm 2
D OG
1.05
D IG

23
 DIG 787.4mm 0.25 787.65mm
DOG 830mm

Gasket Width
D OG D IG
N
2
830mm 787.65mm
N
2
N 22mm : Use 35mm

Mean Gasket Diameter

D OG D IG
G
2
830mm 787.65mm
G
2
G 808mm

Basic Gasket Seating Width

N
bo
2
35mm
bo
2
b o 17.5mm

Effective Gasket Seating Width

b 0.5 b o
b 0.5 (17.5mm)
b 2.09mm

24
viii. Bolts

The bolt load due to gasket reaction under atmospheric condition is given:
Wm1 bGY
N
Wm1 (2.09mm)( 808mm)(52. 4835 )
mm 2
Wm1 278,5151N

The bolt load under light pressure

2
Wm2 2b m P G P
4
N N
Wm2 2(2.09mm)(808mm)(3 .75)(0.38 2
) (808mm) 2 (0.38 )
mm 4 mm 2
Wm2 209,968N

Wm1 is the controllin g load because Wm1 Wm2

The minimum bolt cross-sectional area (both material is carbon steel, fa=fb)
Wm1
Am
fa
278,515N
Am
N
100.6
mm 2
A m 2,769mm 2

Bolt circle diameter C b 860mm

Number of bolts 32 bolts
Bolt root diameter 18mm

Corresponding actual bolt circle diameter

Ab (d br ) 2 number of bolts
4

A b (18mm) 2 32
4
A b 8,143mm 2
Since Ab>Am, therefore the selected bolts are suitable.

25
ix. Flange Thickness

a. For the gasket seating condition

(A m A b )f a
W
2
N
(2769mm 2 8143mm 2 )(100.6 )
W mm 2
2
W 548,874N : flange bolt load
W(C b G)
M f
2
(548,874N)(860mm 808mm)
M f
2
M f 14,270,714N mm 2 : flange moment

b. For operating condition

Hydrostatic end force on area inside of the flange

B 2 P
HD
4
N
(803.4mm) 2 (0.38 )
HD mm 2
4
H D 192,635N

Moment due to HD
MD HDh D
(C b B)
where :h D
2
(860 803.4)mm
hD
2
h D 28.3mm
M D (192,635N)(28.3mm)
M D 5,451,570N mm

26
 Gasket load under operating conditions
HG W H
G 2 P
where : H
4
N
(808mm) 2 (0.38 )
H mm 2
4
H 194,848N
W Wm2
H G 207,870N 194,848N
H G 13,022N

Moment due to HG
MG HGhG
(C b G)
where :h G
2
(860 808)mm
hG
2
h G 26mm
M G (13,022N)(26mm)
M G 334,572N mm

Pressure force on the flange face

HT H HD
H T 194,848N 192,635N
H T 2,213N

Moment due to HT
MT HThT
h P h G
where :h T
2
28.3mm 26mm
hT
2
h T 17.15mm
M T (2,213N)(27.15mm)
M T 60,083N mm

27
 Summation moments under operating condition
Mf MD MT MG
M f (5,451,570 60,083 338,572)N mm
M f 5,850,225N mm

M f is the controllin g moment since M f M f

Flange thickness (carbon steel)

Mf Y
tf
ff a B
(14,270,714N mm)(18)
tf
N
(100.6 )(803.4mm)
mm 2
t f 56.4mm

28
VII. THE OPTIMIZED DESIGN

A. Thermal Design Data Sheet

B. Mechanical Design Data Sheet

VIII. SETTING UP PLAN

A. 2D Model
B. 3D Model

29