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

Base Cost For Shell and Tube Exchangers

SurfaceAreaperShell = 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(TubularExchangerManufacturersAssociation)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 /SqFe
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Correction Cost for Shell and Tube Exchangers

A.ShellType

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 /SqFe

B.TubeLength

<20 ft =20 ft >20 ft

1 0 0 Actual = 16 feet

EFFECT OF TUBE LENGTH ON BASE COST = $2.11 /SqFeet

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

EFFECT OF TUBE PASSES ON BASE COST = $0.28 /SqFeet

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Correction Cost for Shell and Tube Exchangers

D.DesignPressure(inpsig)
<=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 /SqFeet

TUBE SIDE = $0.86 /SqFeet

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 /SqFeet

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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
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PERCENTAGE CONTRIBUTION OF DIFF. ELEM ENTS 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%
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INSTALLATION, OPERATION AND MAINTENANCE COSTS

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

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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%

TOTALPRESENTWORTHLCC = $91,298
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PERCENTAGE CONTRIBUTION OF OPERATIONS AND M AINTENANCE 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%