Name

: Martin Surya Gunawan

NRP

: 14 2005 028

Subject

PPSDM PROGRAM

: AIK-2

Lecture

: Rony Kurniawan

FINAL EXAMINATION
(26 August 2005)
1. Make a specification of shell and tube heat exchanger to cool down 60000 lb/hr
Acetone from 250 oF to 100 oF with Acetic Acid as the cold fluid which has an
inlet temperature of 90 oF and outlet temperature of 150 oF. The flow in heat
exchanger is counter current where cold fluid flows in the tube which has an
outside diameter of in, BWG 14, and length of 16 ft with the distance of each
baffles is 1/5 time of inside diameter of shell. The shell is made of carbon steel.
These are the following additional data that you can have :
Cp(Acetone)

= 0.57 btu / lb oF

Cp(Acetic Acid)

= 0.51 btu / lb oF

Uo

= 58.8 btu / ft2 hr oF

Ft

= 0.88

Answer.
100 oF

Acetic Acid

150 oF

90 oF

250 oF

Acetone

a. Calculate the mass flow rate of cold fluid (Acetic Acid).

We assume that there is no heat lost in heat exchanger, thus the heat released
from hot fluid will be totally received by cold fluid. We know this as Black
theory.
Q out = Q in
mh. Cph. Th = mc. Cpc. Tc
60000 lb/hr . 0.57 btu/lb oF. (250-100)oF = mc. 0.51 btu/lb oF . (150-90)oF
5130000 lb/hr =mc . 30.6

mc = 167647.06 lb/hr.

b. Determine the type of shell and tube heat exchanger

R

T1 T2
t2 t1

250 100
150 90
R 2 .5
R

and

t2 t1
T1 t1

150 90
250 90
S 0.375
S

From the graph (page : 830), we obtain the value of LMTD correction (Ft)
is about 0.8625. The type of shell and tube HE is 3-6 pass HE.

250 oF
150 oF
100 oF
T1

90 oF

T2 = (250 150) oF
= 100 oF

dan

T1 = ( 100 90 ) oF
= 10 oF

T2

T2 T1
T2

ln
T1

LMTD

LMTD

100 10
o
F
100
ln

10

LMTD 39.0865

o
F = LMTD(c) = LMTD x Ft
LMTD (correction)

= 39.0865 x 0.8625 oF

33.7121 oF

c. determine the number of tube

The global heat transfer area can be stated with the following formula :
A

Q
Uo.LMTD( c )

As we assume before that Q in = Qout = Q = 5130000 btu/hr.

5130000

A
58.8

btu
hrft

2o

A 2587.94 ft

btu
hr

33.7121o F

For ID tube equals to 3/4 in, with the value of BWG is 14 , the area for each
tube is about 0.1529 ft2/ft. the total length for all tubes is :
2587.94 ft 2
ft 2
0.1529
ft
L 16925.70422 ft
L

N=

the total length for all tubes

the length of each tube that has been determined

16925.70422 ft
16 ft
N 1057.8565
N

Based upon the table (Page : 842) , we obtain the number of tubes are about
1100 tubes. From that table we can directly determine the distance of pitch

is about 1 in with inside diameter of shell is 39 in. For the inside diameter
of shell equals 39 in, we obtain the minimum thickness for shell is about
7/16 in.
d. Determine the number, thickness, and distance of baffles.
The minimum distance for baffle is (1/5) inside diameter shell or

1
.39in
5

Equals to 7.8 in. for the distance of baffle less than 24 in where the inside
diameter of shell equals 39 in, we obtain the minimum thickness for each
baffle is 1/4 in. the number of baffles in HE is
16 ft
192in

24.62
7.8in
7.8in

From the calculation above, the number of baffles is about 25 baffles.

2. DESIGN OF TALL TOWER

4m

8m

1.5 m
1m

2m

Erection weight

= 8 ton

Operating weight

= 12 ton

Internal design pressure

= 200 psi

Wind velocity

= 140 mph

= 0.85

OD of bolt circle

= 2.4 m

The material of skirt support and both vessels are

2.5 m

1.5 m

carbon steel ( SA-285, 200 oF). the material of

anchor bolt is carbon steel SA-325. the type of
joint of skirt support to tangent line is Lap Weld.
Seismic zone = 2. fb= 500 psi

D2 = 1.5 m
H2 = 4 m

H1 = 9.5 hmT = 2.5 m

D1 = 2.5 m

h1
h2

1. Thickness of Shell Based Upon Wind Load

a. shear
Pw 0.0025.(140) 2 lb / ft 2
Pw 49lb / ft 2

The moment causes by wind in the tall tower can bestated bey the following
equation.
V Pw.D1, 2 .H 1, 2

The share (cause by wind) at lower section will be :

V1 Pw.D1 .H 1
lb
.2.5m.9.5m
ft 2
lb
V1 49 2 .8.2021 ft .31.168 ft
ft
V1 12526.5096.lb
V1 49

The share (cause by wind) at upper section

V2 Pw.D2 .H 2
lb
.1.5m.4m
ft 2
lb
V2 49 2 .4.9213 ft.13.123 ft
ft
V2 13164.5288.lb
V2 49

Total share = V1 + V2 = V = 25691.0384 lb

c. Moment
H 1 9.5

m 4.75m
2
2
h1 15.584 ft
h1

H2
4
9.5m m 11.5m
2
2
h2 37.7297. ft
h2 H 1

The wind moment occurs in both upper and lower vessel can be stated by the
following formula.
M Pw.D1, 2 .H 1, 2 .h1, 2
M V1, 2 .h1, 2

The wind moment occurs in lower section

M 1 V1 .h1
M 1 12526.5096.lb.15.584 ft
M 1 195213.1256.lbft

The wind moment occurs in upper section

M 2 V2 .h2
M 2 13164.5288.lb.37.7297 ft
M 2 496693.7223.lbft

Total wind moment = M1 + M2 = M = 691906.8479 lb.ft

Moment at height hT = 1.5 m
M T M hT .(V 0.5.Pw.D1 .hT )
lb
.2.5m.1.5.m)
ft 2
lb
.691906.8479lbft 4.9213. ft.( 25691.0384.lb 0.5.49 2 .8.2021 ft.4.9213 ft )
ft
691906.8479.lb. ft 4.9213 ft.(25691.0384.lb 988.94237.lb )

M T 691906.8479.lb. ft 1.5.m.(25691.0384.lb 0.5.49

MT
MT

M T 691906.8479.lb. ft 121566.4252.lb. ft
M T 570340.4227.lb. ft

Requirement thickness of shell can be stated with the following formula :

12.M T
R 2 .S .E

we know that the type of material used for both vessels are carbon steel SA-285,
200oF. The value of S (see page 149) is 13800 psi. Where
1 2
.m
and E = 85%.
2 2
R
2.46063. ft
2

Thus, the requirement thickness of vessel is :

12.570340.4227.lb.in
0.75m. 2 .13800 lb2 .0.85
in
6844085.072.lb.in
t
lb
( 29.5276.in) 2 .13800 2 .0.85
in
t 0.21312.in
t

Use in, thick of shell.

2. Thickness of shell Based Upon weight of the vessel.

t

W (operating )
S .c

c .ODshell
1 2
c .
.m
2
c 185.433.in

12000.kg
lb
13800 2 .185.433.in
in
26431.718.lb
t
lb
13800 2 .185.433.in
in
t 0.010329.in
t

3. vibration
As a result of wind tall towers develop vibration. The period of the vibration
should be limited, for large natural periods of vibration can lead to fatigue
failure. The allowable period has been computed from the maximum permissible
deflection.

Determine the actual period of vibration

H
T 0.0000265.

w.D
.
t

Where w is weight of tower (operating weight) per foot of height (lb). t is

thickness of skirt at base (in), and D is out side diameter of shell (in).
Thickness of skirt at base

12.M T
W (operating )

2
.D.S .E
R . .S .E
12.570340.4227.lbin
12000kg

2
lb
(1.m) .13800.0.45
.2.m.13800 2 .0.45
in
12.570340.4227.lbin
26431.718

2
lb
(39.37.in) .13800.0.45
.78.74.13800 2 .0.45
in
0.22644 0.017215.in
0.243655.in

t
t

t
t
t

Use in thick of skirt.

E = 0.45 for lap weld (see page 68).
w

W
12000.kg
26431.718.lb
lb

49.7308
H
( 4 9.5).m
531.496.in
in
2

w.D
H
T 0.0000265.
.
t
D

2.

13.5.m

T 0.0000265.
2 1

.m

2

lb 2 1
..
.m
in 2
0.25.in

49.7308

lb
.59.055.in
in
T 0.0000265.(9).
0.25.in
T 0.0000265.(9).(108.3855).s
T 0.02585.s
49.7308

We are in the second seismic zone, based upon the seismic coefficient table (see
page 55) for T less than 0.4 s the value of C will be 0.1.
The maximum allowable period of vibration
From the calculation above, we got 0.1 for the seismic coefficient, so the value
of shell will be : V C.W = 0.1. 12000 kg = 2643.172 lb

Ta 0.8
Ta 0.8.

W .H
V .g
12000.kg .13.5m
ft
1200.kg .32.2 2
s

26431.718.lb.44.29134 ft
ft
2643.172.lb.32.2 2
s
Ta 2.967.s
Ta 0.8

G is the gravitation force, 32.2 ft/s2

The actual vibration doesnt exceed the allowable vibration
4. deflection
Towers should be designed to deflect no more than 6 in per 100 feet of height.
the maximum deflection (at the top M) can be stated as the following equation :
M

Pw.D1 .H .(12.H ) 3
8.E.I

Where D1 is width of tower with insulation (OD base ring (in)), I is moment of
inertia ( R 3 . .t ) and E is modulus elasticity, psi. Based on the table ( see page
148 ) the value of E at temperature 200 oF is 28.7 x 106 psi.
2
1

2
I 2
2

.m. .0.25.in

I 29.5276.in . .0.25.in
.3

I 20209.348.in 4

Pw.D.H .(12.H ) 3
8.E.I
lb
49 2 2.5mft.13m.(12.13.5m) 3
ft

lb
8. 28.7.10 6 2 20209.348.in 4
in
lb
49 2 8.2021 ft .44.29134 ft.(12.44.29134.in) 3
ft

lb
8. 28.7.10 6 2 20209.348.in 4
in
0.576.in

M
M

The maximum allowable deflection 6 in per 100 ft of height :

For H = 13.5 m = 44.29134 ft =

44.29134. ft.6.in
2..6575.in
100. ft

The actual deflection is less than the maximum deflection, thus the design for
the thickness of shell is satisfactory already.
5. Determine the number and size of anchor bolt
Vertical vessel and towers must be fastened to the concentrate foundation, skid
or other structural frame by means of anchor bolts and ring. The number of
anchor bolts must be in multiple of four and for tall towers it is preferred to use
minimum eight bolts.
These are the following specification of anchor bolts we have :
material of anchor bolt

= SA-325

Diameter of bolt circle

= 2.4 m (94.4882 in).

The number of anchor bolts (N) are about 14. The area within bolt circle is :

1
. .D 2
4
1
2
AB . . 94.4882 .in
4
AB 7008.4956.in 2
AB

The circumference of bolt circle :

C B .D
C B .(94.4882.in)
C B 296.693.in

From the previous calculation we got already the value of M (moment) is about
691906.8479 lb ft.
The required area of bolts shall be calculated for empty condition. The
maximum tension of anchor bolts can be stated by the following equation :
T

12.M
W

AB
CB

12.691906.8479lb.in
8000kg

2
296.693.in
7008.4956.in
12.691906.8479lb.in 17621.1454lb
T

296.693.in
7008.4956.in 2
lb
T 1184 .688 59.392
in
lb
T 1224.08
in
T

The required Area of one bolt :

BA

T .C B
S B .N

Where SB is the maximum allowable stress value of bolt material , the value is
15000 psi ( see page 69).

lb
.296.693.in
in
BA
lb
15000 2 14
in
2
B A 1.7294.in
1224.08

Use 1 in bolt size (see page 69 table A). Adding 0.125 in for corrosion, thus
the size of anchor bolt which should be use is (1 + 2x 0.125) in equal to 2 in.
Use 1.744 in2 for bolt area.
Evaluate the stress at anchor bolt (SB).
SB

T .C B
B A .N

lb
.296.693.in
in
SB
1.744.in 2 .14
S B 14910.96193. psi
1224.08

SB doesnt exceed the maximum allowable stress (15000 psi), thus the number
and size of anchor bolt used are already satisfactory.
6. the thick and width of base ring
The bearing surface of the base ring shall be large enough to distribute the load
uniformly on the concentrate foundation and thus not to exceed the allowable
bearing load of the foundation. The thickness of the base ring shall resist the
bending stress induced by wind of earthquake.
From the previous calculation we already have the value of M (moment based
upon the wind load) is approximately 691906.8479 lb.ft.

The area within the skirt :

1
. .OD 2 skirt
4
1
2
As . 2 m
4
1
As . .(78.74.in) 2
4
As 4867.009.in 2
As

Circumference on OD of skirt :
Cs .ODskirt
Cs .2m
Cs .78.74.in
Cs 247.2436.in

The maximum compression.

12.M Woperating

As
Cs
12.691906.8479.lb.in 26431.718.lb
Pc

247.2436.in
4867.009in 2
lb
Pc (1705.952 106.9056)
in
lb
Pc 1812.8576
in
Pc

Approximate width of base ring.

l

Pc
fb

Where fb is safe bearing load on concentrate, the value is 500 psi.

l

1812.8576

lb
in 2
l 3.626.in

lb
in

500

We have the size of anchor bolt is 2 in. The minimum dimension for l 2 is 2.5 in
and for l3 is 2 in (see table B page 69).

Approximate thickness of base ring.

t B 0.32.(l 2 l3 )
t B 0.32.(4.5)in
t B 1.44.in

Use 1 in for thickness of base ring.

l2

= 2.5 in

l3

=2

= 0.25 in

toleration

= 1 in

= 5.75 in

thus, the width of base ring will be 5.75 in.