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    F.O.B Cost Estimation of Shell and Tube Heat Exchangers: Surface Area Per Shell

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    VINOD KAMBLE
    The document provides details on estimating the costs of shell and tube heat exchangers. It includes calculations for base costs, correction factors, annual operating costs, and present worth life cycle costs over a 6 year period. Installation, labor, power consumption, preventative maintenance, corrective maintenance, and spare parts are considered. Labor costs contribute the most to annual operating and maintenance costs, accounting for around 85% of the total.

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    F.O.B Cost Estimation of Shell and Tube Heat Exchangers: Surface Area Per Shell

    Uploaded by

    VINOD KAMBLE
    139 views9 pages
    The document provides details on estimating the costs of shell and tube heat exchangers. It includes calculations for base costs, correction factors, annual operating costs, and present worth life cycle costs over a 6 year period. Installation, labor, power consumption, preventative maintenance, corrective maintenance, and spare parts are considered. Labor costs contribute the most to annual operating and maintenance costs, accounting for around 85% of the total.

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    ViNod

    Original Title

    Heat Exchanger

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    The document provides details on estimating the costs of shell and tube heat exchangers. It includes calculations for base costs, correction factors, annual operating costs, and present worth life cycle costs over a 6 year period. Installation, labor, power consumption, preventative maintenance, corrective maintenance, and spare parts are considered. Labor costs contribute the most to annual operating and maintenance costs, accounting for around 85% of the total.

    Copyright:

    © All Rights Reserved
    Download as XLS, PDF, TXT or read online from Scribd
    Download as xls, pdf, or txt
    139 views9 pages

    F.O.B Cost Estimation of Shell and Tube Heat Exchangers: Surface Area Per Shell

    Uploaded by

    VINOD KAMBLE
    The document provides details on estimating the costs of shell and tube heat exchangers. It includes calculations for base costs, correction factors, annual operating costs, and present worth life cycle costs over a 6 year period. Installation, labor, power consumption, preventative maintenance, corrective maintenance, and spare parts are considered. Labor costs contribute the most to annual operating and maintenance costs, accounting for around 85% of the total.

    Copyright:

    © All Rights Reserved
    Download as XLS, PDF, TXT or read online from Scribd
    Download as xls, pdf, or txt
    of 9

    Page 1 of 9

    F.O.B Cost Estimation of Shell and Tube Heat Exchangers

    Base Cost For Shell and Tube Exchangers


    Surface Area per Shell = 2905 Sq feet per shell
    Total Number of Shells per Exchanger = 1 No of shells
    Inside Diameter of Shell = 46 Inches
    Tube Outside Diameter = 1 Inches
    Tube Pitch = 1.25 Inches

    Layout Angle 30 or 60 45 or 90 Construction Welded Seamless


    (in degrees) 0 1 type 1 0

    TEMA (Tubular Exchanger Manufacturers Association) Type
    Front End Stationary Head Type
    A B C D N None
    1 0 0 0 0 0

    Rear End Head Type


    L M N P S T U W
    0 0 0 0 0 1 0 0

    BASE COST FOR THE SHELL AND TUBE EXCHANGER = $9.21  / Sq Fe
    Page 2 of 9

    Correction Cost for Shell and Tube Exchangers

    A. Shell Type

    E F G H J K X None
    0 0 0 0 1 0 0 0

    EFFECT OF SHELL TYPE ON BASE COST = $0.00  / Sq Fe

    B. Tube Length

    <20 ft =20 ft >20 ft


    1 0 0         Actual = 16 feet

    EFFECT OF TUBE LENGTH ON BASE COST = $2.11  / Sq Feet

    C. Tube Passes
    <=2 >2
    No of Tube Passes 0 1         Actual = 4

    EFFECT OF TUBE PASSES ON BASE COST = $0.28  / Sq Feet


    Page 3 of 9

    Correction Cost for Shell and Tube Exchangers

    D. Design Pressure (in psig)
    <=150 >150
    Shell side 1 0         Actual = 50 psig
    Tube Side 0 1         Actual = 410 psig

    EFFECT OF DESIGN PRESSURE ON BASE COST

    SHELL SIDE = $0.00  / Sq Feet


    TUBE SIDE = $0.86  / Sq Feet

    E. Materials

    CS SS 304L Titanium Zirconium


    Tube 1 0 0 0
    Shell 0 1 0 0
    Channel 0 1 0 0
    Tubesheet 0 1 0 0

    EFFECT OF MATERIALS ON BASE COST = $6.82  / Sq Feet


    Page 4 of 9

    COST ESTIMATING CALCULATIONS

    1. Base Price = $9.21 / Sq Feet


    2. Corrections for alternatives as fraction of base price
    Corrections for Shell Type = 0.00
    Correction for Tube Length = 0.23
    Correction for Number of Tube Passes = 0.03
    Correction for Shell Side Design Pressure = 0.00
    Correction for Tube Side Design Pressure = 0.09
    Correction for Materials
    - Channel or Bonnet = 0.00
    - Shell = 0.37
    - Tubes = 0.22
    - Tubesheet = 0.15
    Total Correction Factors = 1.09

    3. Exchanger Price (based on Jan'82 Prices) = $32,341


    4. Escalation Index = 1
    5. Current Exchanger Price (F.O.B) = $32,341
    Page 5 of 9

    PERCENTAGE CONTRIBUTION OF DIFF. ELEMENTS TO THE PURCHASE COST

    1
    2
    3
    4
    5
    6

    1 2 3 4 5 6
    Base Shell Length Tu.Pass Material Design Pr.
    47.78% 0.00% 10.95% 1.43% 35.36% 4.48%
    Page 6 of 9

    INSTALLATION, OPERATION AND MAINTENANCE COSTS

    1. Installation Costs = $5,000
    2. Labor
    # of hours of operation per year = 2920 hours
    Total Labor Rate per hour = $28.00
    3. Power Consumption
    Input Power = 10 KW
    Cost($) per Kilowatthour = 0.20
    4. Preventive Maintenance
    Preventive Maintenance Cycle Time = 160 hours
    Time for maintenance = 4 hours
    Total Labor Rate per hour = $26.00
    5. Corrective Maintenance
    Mean Time Between Failure (MTBF) = 500 hours
    Mean Time To Repair (MTTR) = 40 hours
    Total Labor Rate per hour = $26.00
    6. Spare Parts Cost
    Percent of spare parts per year on
    Product Cost = 0.05 %
    Page 7 of 9

    LIFE CYCLE COST FOR ONE YEAR

    1. Purchase Cost = $32,341

    2. Installation Cost = $5,000

    3. Operating Labor Cost = $81,760

    4. Power Cost = $5,840

    5. Preventive Maintenance Cost = $1,898

    6. Corrective Maintenance Cost = $6,074

    7. Spare Parts Cost = $16


    Page 8 of 9

    PRESENT WORTH LIFE CYCLE COSTS

    Econ. Life = 6 years Discount Factor = 10 %

    1. Purchase Cost = $32,341 35.42%

    2. Installation Cost = $5,000 5.48%

    3. Operating Labor Cost = $46,151 50.55%

    4. Power Cost = $3,297 3.61%

    5. Preventive Maintenance Cost = $1,071 1.17%

    6. Corrective Maintenance Cost = $3,428 3.76%

    7. Spare Parts Cost = $9 0.01%

    TOTAL PRESENT WORTH LCC = $91,298 
    Page 9 of 9

    PERCENTAGE CONTRIBUTION OF OPERATIONS AND MAINTENANCE COST

    1
    2
    3
    4
    5

    1 2 3 4 5
    Labor Power Pr.Maint. Co.Maint. Spares
    85.53% 6.11% 1.99% 6.35% 0.02%

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