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

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 KAMBLE
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790 views9 pages

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

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.

Uploaded by

VINOD KAMBLE
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as XLS, PDF, TXT or read online on Scribd
You are on page 1/ 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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