Mechanical Design of Shell and Tube Heat Exchanger

MECHANICAL DESIGN OF SHELL & TUBE HEAT EXCHANGER
1. INTRODUCTION
Heat exchanger is a device, which is used for transfer of heat from fluid to another, usually
separated by walls. Whenever a temperature gradient exists between two fluids, energy is
transferred by heat transfer process.
Classification:
Based on the applications, heat exchangers are classified as boilers, condensers, heaters,
coolers, recuperators etc. Depending on the configuration of fluid flow paths, heat
exchangers are classified as parallel flow(co-flow) heat exchangers, counter current(counter
flow) heat exchangers and single pass cross flow heat exchangers and multi pass cross flow
heat exchangers. The most important difference between the four types lie on the relative
amount of heat transfer surface area required to produce a given temperature rise for a
given temperature difference between the two fluid streams where they benter the heat
exchanger. Heat exchangers are employed in varied installations such as steam power plant,
chemical processing plants, building heating, air-conditioning, refrigeration system etc to
carry away the heat carried by the gases and it cools the gasses to a sufficiently low
temperature, using a suitable fluid.
Regenerative Heat Exchangers

In Regenerative Heat exchangers the hot and cold fluid flow through the one and same
passage and heated surface is alternately exposed to the hot and cold fluids. If the periods
of heating and cooling are of equal duration, continuous heating requires two apparatus in
which the hot fluid is cooled in one apparatus the cold fluid is heated in the other. After that
apparatus is switched over and heat transfer process is reversed. In Regenerative
exchangers the process of heat transfer is transient. The temperature varies as it cools or
heats variation in wall temperature is accompanied by change in fluid temperature with time
and along the heating surface as well.
Regenerators are mainly used in the branches of industry where there is waste gas at high
temperature and is required to heat air at a high temperature i.e. blast furnaces, open hearth
furnaces, coke and glass manufacturing. The performance of regenerators depends on
many factors as thickness of packing, its conductivity, accumulating capacity, duration of
periods and fluid temperature. While in operating conditions the heat transfer co-efficient
may vary due to the burning of gas in the regenerator.
Recuperative heat exchangers

The two fluids performing the exchange of heat in the exchangers can flow (a) with each
other in the same direction (parallel flow) or in opposite direction (counter flow) or (b) at
right angles to one another (cross flow) with both types of flow a single or multi pass
arrangement is possible. The element from which a recuperative matrix is built up is mainly
of two kinds, the fluid flows along the tubes on the inside and along across the tubes on the
outside. The fluid flows between consecutive plates arranged at a certain distance apart. To
reduce the equivalent diameter, the flow channels between the plates may be sub divided in
different ways by a folded or corrugated plate arranged between any two parallel plates
and thus forming a multiplicity of parallel flow channels, the shapes of which depend on the
kind and shape of corrugations. Heat transfer and flow resistance depend on size, shape
and arrangement of above elements. Any reduction in diameter leads to an increase in the
number of tubes for given mass flow and requires new methods for fixing in tubes in plates
of the headers. Further reduction in the equivalent diameter of flow channels about 6mm to
3mm leads to the use of plate type matrix
.
Mixed type Heat Exchangers
The direct contact type heat exchanger is one in which the two fluids are not separated
from one another. If heat is to be transferred between gas and liquid, the gas is either
bubbled through the liquid or is sprayed in form of drops through the other. In this heat
transfer takes place with mass transfer. The heat is carried by the evaporation of cooled
water carried with air. Its performance not only depends upon the temperature difference
but also on relative humidity of air. Common examples of this type are feed heaters, cooling
towers and evaporative condensers. The influence of flow path arrangement on heat
transfer area is dependent on the temperature rise to be achieved for a given inlet
temperature difference the flow path arrangement does not affect heat transfer area. Parallel
flow arrangement should be restricted to this area. The counter flow arrangement requires
least area throughout range while cross flow arrangement requires slightly larger than
counter flow but is much better than parallel flow arrangement. Whenever temperature
changes in one or both fluid streams closely approach the temperature difference between
the entering fluid systems only counter flow arrangement has to be employed. The cross
flow arrangement is classified as single pass and multi pass cross flow. If both fluids
traverse the exchanger only once; the arrangement is called single pass heat exchanger. If
the fluids are made to shuttle back and forth across the heat transfer matrix more than once
that arrangement is called multi pass heat exchanger. If the fluid path on hot side is so
arranged as to make two passes and on the cold side 4-passes, then the heat exchanger is
called 2-4 heat exchanger.
2. LITERATURE SURVEY
Heat exchangers are practical devices used to transfer energy from one
fluid to another to get fluid streams to the right temperature for the next
process to condense vapours, to evaporate liquids, to recover heat to use
elsewhere and to drive a power cycle.
Shell and Tube Heat Exchangers:
Shell and tube heat exchangers come in a wide range of sizes and lengths to many needs.
This large unit features tantalum sheet and tubing to provide long life and corrosion
resistance in severe environments. They are widely used in process industries, especially
petro chemical and petroleum refineries, the use of shell and tube heat exchangers range
from chillers heat removers etc to reboilers, process steam coolers etc. Also there are no
moving parts. The shell and tube heat exchangers are grouped into three as R heat
exchangers, C heat exchangers and B heat exchangers, according to service standards
set by TEMA Class R heat exchangers are designed for severe service requirements
class B, for moderate service requirements and class C for chemical process
service.Although copper tubes and steel shells are the most common materials of
construction a wide range of metals are available for handling various fluids and gasses as
brass, aluminium, stainless steel, titanium and other alloys. Some application use glass or
plastic tubes to resist the attack of extremely corrosive substance or to avoid affecting the
flavour of food.The recent innovations in heat transfer technology had led to greater
efficiency of shell and tube type heat exchangers. Multiple pass, multiple module
constriction help to achieve a significant amount of heat transfer in a limited amount of
space. Even though sufficient space must be left for the cleaning of tubes and the removal of
tube bundles for repair, the units can be located just about anywhere. The shell and tube
heat exchanger is shown in figure 1.
Figure 1. Shell & Tube Heat Exchanger

Multiple pass, multiple module constriction help to achieve a significant amount of heat
transfer in a limited amount of space. Even though sufficient space must be left for the
cleaning of tubes and the removal of tube bundles for repair, the units can be located just
about anywhere.
The main components of shell and tube heat exchangers as mentioned above are the shell,
tube bundle, tube sheets, baffles, channels, flanges and nozzles.
Shell:
The shell consists of a cylinder made from seamless pipe rolled and welded with a bolting
flange at each end. It is often designed so as to withstand a pressure, one and half times its
rated pressure. Shells are often designated by letters E, F, G, H, J, K and X.
Tube bundle:
The tube bundle is made of tubes, tube sheet and cross baffles. Different types of tube
configurations are available. One common type is the U-tube configurations which is the
most economical. It has the fewest components one head assembly, one tube sheet and a
shell with flange opening to accept the tube bundle on one end. Even though the
arrangement features a removable, replaceable bundle, it is difficult to clean the tubes
mechanically. Efforts to overcome this disadvantage resulted in the introduction of straight
tube configuration. This configuration consists of a shell assembly with a flange on each end
and the tube is fixed at the both ends. The unit is durable, can handle higher pressures and
easy to maintain. The major disadvantages include the inability to tolerate large temperature
difference between the shell and tube side fluids, the failure or breaking of tubes from the
tube sheets due to the differential expansion and the nonreplicable bundle. Hybrid designs
are also available to overcome many temperature and pressure drawbacks. The complete
bundle can be removed in a hybrid heat exchanger. The most recent development in shell
and tube designs has the introduction of a double wall construction. The outer tube is rolled
into one header and the inside one extends past the outer tube and is rolled into a second
header. The failure of the tube can be detected by visual inspection or an electronic
monitoring device. The double wall construction offers significant protection and safety.
Tube Sheets:
Tube sheets are used to keep the tubes in position. The tubes can be either square pitched
or triangular pitched. Due care must be taken in the design of tube sheets as it is affected by
longitudinal stresses in shell and tube, tube compressive stress, tube to tube sheet joint
loads etc.
Baffles:
Baffles are used to induce turbulence outside the tubes as turbulence increases the heat
transfer coefficients. Baffles cause the liquid to flow through the shell at right angles to axes
of tubes. The centre to centre distance between baffles is called baffle pitch or baffle
spacing. There are several types of baffles like disks and doughnuts, orifice, strip and
segmental of which segmental baffles are most commonly used. Segmental baffles are
formed by cutting a segment from a disc. Segmental baffles are drilled plates with heights
which are generally 75% of the inside diameter of the shell and these are also called 25%
cut baffles. The cut portion of baffle is often called the window section. Baffle is efficient
and gives good heat transfer rates for pressure drop and power consumed
Flanges:
Flanges are used on the shell of a vessel to permit disassembly and removal or cleaning of
internal parts. They are also used for making connection for piping and nozzle attachments.
The standard types of flanges for different pressure ratings are welding neck type, slip on
type, screwed type, lap joint blind type etc.
Gaskets:
The functions of a gasket are to interpose a semi plastic material between the flange facings,
by which the material seals (through deformation under load) the minute surface
irregularities to prevent the leakage of the fluid. The amount of force required for this
purpose is known as yield or seating force. They are of different types; the most commonly
used are fabricated with a metal jacket and a soft filler (usually of asbestos). Such gaskets
can be used up to temperatures of about 8500 F and require comparatively less bolt load
to seat and keep tight.
Channel:
Channel is a tube side component. It has also got a cylindrical section. The tube side flows
through the channel. Partition plates are made use for multipass flow. The effective
thickness of the channel cover will be the thickness measured at the bottom of the pass
portion groove minus tubeside corrosion allowance.
Nozzles:
In the case of heat exchangers, nozzles are the pass ways for the in and out flow of the hot
and cold fluids. The strength of shell will be reduced due to the drilling of holes for the
insertion of nozzles. If the thickness of the shell is not sufficient to withstand the differential
stress thus developed additional metallic plate must be introduced in order to reinforce the
shell structure.
3. CODES & STANDARDS

Introduction:
The ASME boiler and pressure vessel code (BPVC) section VIII deals with theRules for
construction of pressure vessels (unified). ASME BPVC section VIIIcomprises of the
following three divisions.
Section VIII : Rules for construction of pressure vessels
Division 1
: Rules for construction of pressure vessels
Division 2
: Alternate Rules
Division 3
: Alternate rules for construction of high pressure vessels
The ASME BPVC Section VIII, division is the most widely used code for the design and
construction of pressure vessels.
The ASME Code SECTION VIII, DIVISION 1:

The ASME BPVC Section VIII, division 1 adopts the design by formula (DBF) approach.
Division 1 uses approximate formulas, charts, and graphs in simple calculations, applies a
higher factor- of- safety (resulting in lower allowable stresses), is more tolerant to
fabrication techniques and fabrication defects as compared to other divisions of this section.
The design basis of division 1 is the maximum principal stress theory. The ASME BPVC
Section VIII, division 1is comprises of an introduction,3 subsections, 34 mandatory
appendices and 22 nonmandatory appendices.The sructure of division 1 is as follows.
Subsection
Pertaining to
Introduction
Defines the scope, establishment of design

requirements,
responsibilities
of
manufacturer and authorized inspector,

standards referenced by this code and units
of measurement
Subsection A
Part UG
General Requirements
General methods of all methods of
construction and all materials
Subsection B
Requirements pertaining to methods of

fabrication of pressure vessels
Part UW
Requirements of pressure vessels fabricated

by welding
Part UF

by forging
Part UB

by brazing
Subsection C
Requirements pertaining to classes of

materials
Part UCS
Requirements
of
pressure
vessels
constructed of carbon and low alloy steel

Part UNF
Requirements
for
pressure
vessels
constructed of non ferrous materials

Part UHA
Requirements
for
pressure
vessels
constructed of high alloy steel

Part UCI
Requirements
for
pressure
vessels
pressure
vessels
constructed of cast iron

Part UCL
Requirements
for
constructed of materials with corrosion

resistant integral cladding
Part UCD
Requirements
for
pressure
vessels
constructed of cast ductile iron

Part UHT
Requirements for pressure vessels

constructed of ferrite steels with tensile
properties enhanced by heat treatment
Part UHX
Mandatory Appendices
Rules for shell- and- tube heat exchangers

Mandatory Appendix 1 through 34 (34
nos.)
No mandatory Appendix
No mandatory Appendix A, C, through H,

K, L, M, P, S, T, W, Y DD, EE, FF, GG,
HH and JJ (22 nos.)
Scope of ASME BPVC SECTION VIII, DIVISION 1:

The following pressure vessels are included in the scope of division 1. Vessels designed for
pressure above 15 psig (1.0546kg/cm2 = 1.0342 bar) and not exceeding 3000psig
(210.915 kg/cm2 = 206.84 bar). Vessels having inside diameter above 6 inches (150 to
40mm). Unfired steam boilers, evaporators, heat exchangers. The following pressure
vessels are excluded from the scope of division 1. Vessels covered by other sections.
Pressure containers, which are integral part of rotating machinery. Piping system and
components beyond battery limits. Vessels for human occupancy.
Organisation of the ASME boiler and pressure vessel codes:
The ASME BPVC is divided into many sections, divisions, parts, subparts. Some
of these sections relate to a specific kind of equipment and applications; others relate to a
specific materials and method of application and control of equipment; and others relate to
care and inspection of installed equipments.
Section
Section I
Title
Rules for construction of power boilers
Section II
Materials
Part A
Ferrous materials
Part B
Nonferrous materials
Part C
Specification for welding rods,

electrodes, and filler metals
Part D
Section III
Properties
Nuclear power plant components
This
section
is
further
divided
into
subsection NCA, Division I, Division II and

Division III.Division I is divided into
subsections NB, NC, ND, NE, NF, NG
and NH
Section IV
Recommended rules for care and operation

of heating boilers
Section VII
Recommended guidelines for the care of

power boilers
Section VIII
Rules for construction of Pressure vessels.

Division 1,Division 2
:Alternate
Rules,
Division 3:Alternate Rules for construction

of high pressure vessels
Section IX
Welding and Brazing Qualification
Section X
Fibre reinforced plastic pressure vessels
Section XI
Rules for in-service inspection of nuclear

power plant components
Section
Rules for construction and continued service

of transport tanks
TEMA Standards
The most widely used consensus standard heat exchanger manufacture is the Standards of
Tubular Manufacturers Association. In short the TEMA standards first published in 1941,
this standard had evolved into something of an international document. Many countries have
accorded it he status of their international codes. TEMA standards specify three classes of
construction namely TEMA-R, TEMA-C, and TEMA-B. The formulas for determining
thickness are the same for all TEMA classes; however empirical guidelines for sizing no
pressure part items vary. TEMA-R, which specifies the most rugged construction, is widely
used in refinery service and nuclear power plant applications. TEMA-C and TEMA-B are
used in other industries. TEMA-B has been promulgated as an American National
Standard (ANSI B-78).
TEMA Nomenclature
As per TEMA, the STHE is divided into three parts, the front head (stationary head), the
shell and rear head (stationary or floating). Exchangers are described by alphabetic codes
for the three sections.
Front (stationary) head type
A, B, C, N & D
Shell type
E, F, G, H, J, K & X
Rear head type
L, M, N, P, S, T, U &
The sequence of designating the shell and tube heat exchanger is: first the front (stationary)
end then the shell and finally the rear end. Various combinations like AES, AEP, CFU,
BEM, AKT, AJW, etc are possible. Each of these types has their relative merits and
demerits. The one most suitable for the specific service is selected by considering the pros
and cons of various constructional features
4. DESIGN FEATURES
In designing the heat exchanger, the following requirements were established. Eliminate or
at least eliminate fouling by not allowing the product to stick to the heated or cooled
surfaces, be opened easily and cleaned thoroughly, eliminate leaking gasket and withstand
high pressure.
The shell and tube heat exchanger meets the non fouling requirements by permitting the
product liquid flow to be set at velocity that can avoid or at least substantially minimise any
deposit even if it means large pressure drop. To prevent any potential deposits from lodging
the pockets, corners, crevices and zones, where the velocity cannot be strictly controlled
were eliminated. During the washing periods the washing liquids should penetrate
thoroughly.
The opening and closing operations were simplified so that even inexperienced workmen
could do them easily. The elements of unit were made sturdy material to avoid damage and
to satisfy all requirements and calculated pressure ratings, permanently. The flow channels
are completely smooth to avoid changes of cross-section. Change in the velocity of flow to
utilise the overall pressure drop to generate actual velocity and not be lost in return flow or
at sharp edges. In this way many irregularities in the flow patterns and changes of
cross-sections are avoided.
The pressure rating of each element must be calculated individually, independent of others.
The design is flexible enough to establish any velocity to be calculated. It is not desirable to
have more than one flow path in parallel. For this reason the parallel pipes used in shell and
tube heat exchanger avoided
Thermal Design:
The thermal design is very important in design of shell and tube heat exchanger.
The thermal design is accomplished using one of the simple methods as narrated by D Q
Kern. The heat transfer and coefficient pressure drop as predicted, particularly on the shell
side could vary considerably from the actual values obtained in operation. The search has
been instituted to develop more accurate predictive methods for thermal design. This is
particularly relevant for optimum use of more expensive materials of construction coupled
with the necessity for the increased reliability in operation.
The flow distribution, physical property variation, temperature correction, velocity
consideration and fouling factors are some of the criteria to be given due weightage to
accurately predict thermal performance.
Mechanical Design:
The mechanical designs of heat exchanger are based on reputed codes and standards. The
most common standard used in TEMA. The Tubular Exchanger Manufactures Association
(TEMA) was founded in the late 1930s in an attempt establish standards for high quality
shell and tube heat exchanger. TEMA in turn refers to ASME section VIII wherever
necessary. ANSI and ASTM (American Standard for Testing Materials) are also referred.
The code provides only basic frame work at minimum acceptable practices with which
compliance is necessary to obtain a vessel that is structurally safe at the design temperature
and pressure. Additional requirements are left to the judgement of the user and designer.
Codes contain guidelines and recommendation covering design, material, fabrication,
inspection and testing. Simplified rules based on theory of elasticity and consolidated
experience are outlined for calculating thickness of pressure components along with the
permitted configurated and recommended shapes. Stress tables for various materials, weld
joints details and testing requirements are stipulated.
Heat Exchanger Design-An Over View:

Heat exchanger is the work home of the chemical industry and nuclear and thermal power
plants. As it is the most commonly used equipment, it is imperative that improvements are
continuously made in the design, for maximum cost effectiveness.
The total design involves the thermal design and mechanical design. In thermal design,
attempt is made to obtain a value, as realistic as possible, for the overall heat transfer
coefficient and pressure drops on the shell and tube sides. The heat transfer correlations for
the tube sides have a valid theoretical foundation, but those on the shell side are primarily
empirical in nature because of the difficulties encountered in mathematically analysing the
shell side flow.
After the thermal design comes the mechanical design. In small heat exchangers, there is no
need for stress analysis. However, with increasingly large chemical plants, nuclear and
thermal plants, such analysis also comes important. The mechanical design is covered by
ASME codes and TEMA standards
5. MECHANICAL DESIGN
Design Specifications:
The design specifications for TEMA class R 610-2438 BEM type heat exchanger is shown
below.
1. Component: Shell Cylinder

[As per ASME SECTION VIII, DIVISION II]
Material selected: SA 516 GR 60
P= Shell side design pressure = 0.735 Mpa
IR=inside radius of shell = 304.8 mm
S=Maximum allowable stress =118MPa [From ASME SECTION II, Part D]
E=Joint efficiency =0.85
Corrosion allowance =3
Required wall thickness of the cylinder, greater of:
Circumferential stress
t = (P*IR / (S*E-0.6*P)) +CAI+CAO+tol = 5.27 mm
[UG-27(c)(1)]
Longitudinal stress
t = (P*IR / (2*S*E+0.4*P)) +CAI+CAO+tol = 4.13 mm [UG-27(c)(2)]
Actual wall thickness of cylinder: tnom = 12 mm
2. Component: Front and Rear Head Cylinder

Material selected: SA 516 GR 60
P =1.4715 Mpa
S=Maximum allowable stress= 118MPa [From ASME SECTION II, Part D]
E= 1
t = (P*IR / (S*E-0.6*P)) +CAI+CAO+tol = 6.87 mm
[UG-27(c)(1)]
Longitudinal stress
t = (P*IR / (2*S*E+0.4*P)) +CAI+CAO+tol = 4.92 mm [UG-27(c) (2)]
Actual wall thickness of cylinder: tnom = 12 mm
3. Component: Front and Rear Head Cover

ASME Section VIII-1 2004 A06 UG-32 Formed Heads, and Sections,
Pressure on Concave Side
Ellipsoidal Cover Internal Pressure with t/L >= 0.002
Material: SA 516 GR 60
Design pressure P = 0.15 kg/mm2
Design temperature T = 170 C
Radiography = Full Joint efficiency E = 1
Design stress S = 12.022 kg/mm2

TEMA min. thickness tm = 9.5 mm
Inside corrosion allowance CAI = 3 mm
Major/minor rat. D/2h = 2.0
Forming tolerance Tol = 0 mm
Corroded min. thk t = 3.85 mm
Equiv.dish radius L = 554 mm
Ratio t/L = 0.01263
Outside diameter OD = 629.6 mm
Corroded diameter ID = 615.6 mm
Proportion factor K = 0.1667*(2+ (D/2h) ^2) = 1.0002
Required wall thickness of the cover:
4. Component: Tubes
Material selected: SA179
P=1.471 Mpa
OR=25 mm
S = 92.4 Mpa
E= 1
Corrosion allowance=3
t = (P*OR / (S*E+0.4*P)) +CAI+CAO+tol = 0.2 mm [APP.1-1(A)]
Longitudinal stress
t = (P*IR / (2*S*E+0.4*P)) +cai+cao+tol = - [UG-27(c) (2)]
Actual wall thickness of cylinder: tnom = 1.25 mm
ASME Section VIII-1 2004 A06 UG-28 Thickness of Shells under External Pressure
Material: SA-179
Inside corr. allow. CAI = 0 mm
Corrosion allowance CAO = 0 mm
Radiography = Full Material tol.
Tol = 0 mm
Cylinder outside diameter Do = 25 mm
Cylinder length EP L = 2438 mm
Nominal thickness tnom = 1.25 mm (tnom-CAI-CAO-Tol) t = 1.25 mm
L/Do ratio Ldo = 97.52
Do/t Dot = 20.08
(2*S) or (0.9*yield) SE = - Modules of elasticity ME = 19649 kg/mm2
A factor, A = 0.002734 [From ASME SECTION II, Part D, figure G]
B factor CS-1, B = 8.52 [From ASME SECTION II, Part D, figure CS-1]
Max allowed external pressure:
Pa = 4*B / (3*Dot) = 0.5653 kg/mm2

Actual external design pressure:
P = 0.075 kg/mm2
t = (P*ID*K / (2*S*E-0.2*P)) +CAI+CAO+tol = 6.85 mm [App. 1-4(c)]
Actual wall thickness of cover: tnom = 10 mm
5. Tube-to-Tubesheet Welds
ASME Section VIII Div.1 2004 A06 UW-20 Tube-To-Tubesheet Welds
Fig UW-20.1 Sketch (a) Full Strength G
Tubesheet material: SA-105 K03504 Forgings
Tubes material: SA-179 K01200 Smls. Tube
Allowable stress Tubes St = 14.06 Kg/mm2
Allowable Stress tubes Sa = 9.42 Kg/mm2
Allowable stress weld Sw = 9.42 Kg/mm2
Tube OD do = 25 mm
Tube thickness t = 1.25 mm
Design temperature Tubesheet = 170 C
Design temp. Tubes = 170 C
Fillet weld leg af = 2.05 mm
Groove weld leg ag = 0 mm
Minimum length ac acmin = 2.04 mm
Total length ac = af+ag = 2.05 mm
Fillet weld strength Ff = 0.55*Pi*af*(do+0.67*af)*Sw Ff = 882 kgf

Groove weld strength Fg = 0.85*Pi*ag*(do+0.67*ag)*Sw Fg = 0 kgf
Tube strength Ft = Pi * t * (do - t) * Sa Ft = 875 kgf
Design Strength Fd = 875 kgf
Fillet weld strength Ff = min (Ff, Ft) Ff = 875 kgf
Groove weld strength Fg = min (Fg, Ft) Fg = 0 kgf
Weld strength factor fw = Sa / Sw
fw = 1
Ratio fd = Fd / Ft
fd = 1
Ratio ff = 1 - Fg / (fd * Ft)
ff = 1
Minimum required length of the weld leg(s), ar
ar = SQRT((0.75*do)^2 + 2.73*t(do-t)*fw*fd) - 0.75*do
ar = 2.04 mm
UW-18(d) - Allowable load on fillet/groove welds
Weld Leg = 2.05 mm
Allowable Load = PI * do * Weld Leg * Sw * 0.55 = 836 kgf
Maximum Allowable Axial Loads, Lmax
Pressure only = LmaxP = Ft LmaxP = 875 kgf
Other loads = LmaxO = 2*Ft LmaxO = 1751 kgf
Total weld throat dimension = 1.45 mm
6. Component: Front Pass Partition

Pass Partition Plate Max. Allowed Pressure Differential (TEMA 1999 RCB-9.132)
Pass plate material: SA 516 GR 60 Plate
Thickness t = 12.7 mm
Allow. Pressure drop qa = 0 kg/cm2
Design stress S = 12.02 Kg/mm2
Max. Allowable pressure drop:
q = (1.5*S*((t-c)/b) ^2)/B = see table below
Table1: B-Factor
4. Component: Flange Design

ASME Section VIII-1 2004 A06 App. 2 Bolted Flange with Ring Type Gaskets
Flange type: Integral tapered hub - code fig.2-4(6)
Flange material: SA-105 K03504 Forgings
Int. design pressure PI = 0.15 Kg/mm2
Ext. design pressure PE = 0 Kg/mm2
B1 = B+g1 or B +go
B1 = 624.6 mm
Outside corrosion allowance CAO = 0 mm
Stress (operating) SFO = 14.06 Kg/mm2
Stress (atmos.) SFA = 14.06 Kg/mm2
Outside diameter A = 737 mm
Inside diameter B = 615.6 mm
Hub thickness g1 = 31.75 mm
Bolt circle diameter C = 695 mm
Hub thickness at attach. go = 9 mm
Mean gasket diameter G = 638 mm
Weld leg/hub length h = 70 mm
Hub to bolt circle R = 7.95 mm
Bolt circle to OD = 21 mm
Flange thickness t = 55 mm
Gasket material: Spiral-Wound Metal Fiber Stainless
Gasket outside dia. ODG = 650 mm
Gasket width Wth = 12 mm
Gasket thickness = 2 mm
Gasket factor m = 3.000
Gasket seating stress y = 7.03 Kg/mm2
Gasket eff. width b = 6 mm
Gasket rib length Rib = 1878 mm

Seating width bo = 6 mm
Gasket rib effective width Br = 4.76 mm (Table 2-5.2 facing 1a/1b Col. II)
Bolt material: SA-193 G41400 GR B7 Bolt (<= 2 1/2)
Bolt diameter = 16 mm No. of bolts No. = 42
Bolt root area = 138.32 mm2
Stress (operating) SB = 17.58 Kg/mm2
Stress (atmos.) SA = 17.58 Kg/mm2
Joint-contact compressive load
HP = 6.2832*b*G*PI*m+2*Br*m*PI*RIB = 18873 kgf
Hydrostatic end force H = 0.7854*G*G*PI = 47954 kgf
Hydrostatic end force He= 0.7854*G*G*PE = 0 kgf
Operating conditions:
Min. calc. bolt load WM1 = HP+H = 66827 kgf
Min. used bolt load WM1 = max of 2 mating flanges = 66827 kgf
Bolting up conditions:
Minimum bolt load WM2 = b*3.1416*G*Y+Br*Y*RIB = 147434 kgf
Min. used bolt load WM2 = max of 2 mating flanges = 147434 kgf
Required bolt area AM = WM2/SA or WM1/SB = 8388 mm2
Available bolt area AB = No.Bolt*Area = 5809.6 mm2
Design bolt load W = 0.5*(AM+AB)*SA = 124774 kgf
Minimum gasket width NMIN = AB*SA/ (6.283*y*G) = 3.62 mm
Loads: Integral Flange Calculations (Operating conditions):

Hydrostatic end load HD = 0.785*B*B*PI = 44646 kgf
Hydrostatic end load HDe= 0.785*B*B*PE = 0 kgf
Gasket load HG = WM1-H = 18873 kgf
Result hydrostatic force HT = H-HD = 3308 kgf
Gasket load HG = W = 124774 kgf
Hydrostatic lever arm hd = R+0.5*g1 = 23.82 mm
Gasket load lever arm hg = (C-G)/2 = 28.5 mm
Result hydrostatic lever arm ht = (R+g1+hg)/2.0 = 34.1 mm
Gasket load lever arm hg = (C-G)/2 = 28.5 mm
Hydrostatic moment MD = HD*hd = 1064 kgf*m
Gasket moment MG = HG*hg = 538 kgf*m
Result hydrostatic moment MT = HT*ht = 113 kgf*m
Total operating moment MOP = MD+MG+MT = 1714 kgf*m
Total operating moment MOPe= HDe(hd-hg)+HTe(ht-hg) = 0 kgf*m
Bolt up moment MATM = W*hg = 3556 kgf*m
Effective bolt moment MB = MATM*SFO/SFA = 3556 kgf*m
Total moment MO = MOP or MB = 3556 kgf*m

Cf= 1
Bolt spacing correction M = MO*Cf = 3556 kgf*m (TEMA 1999 RCB-11.23)
Flange shape constants:
K = A/B = 1.1972 ho = SQ (B*G0) = 74.4339
TF = Fig.2-7.1 = 1.8401 h/ho = h/ho = 0.9404
Z = Fig.2-7.1 = 5.6158 F = Fig.2-7.2 = 0.6901
Y = Fig.2-7.1 = 10.8856 V = Fig.2-7.3 = 0.07
U = Fig.2-7.1 = 11.9621 f = Fig.2-7.6 = 1.3099
G1/G0 = G1/Go = 3.5278 e = F/ho = 0.0093
t = 55 mm
D = U*ho*g0*g0/V = 1029855 Alpha = t*e+1.0 = 1.5099
Beta = 1.333*t*e+1.0 = 1.6797 Gamma = Alpha/TF = 0.8206
Delta = t*t*t/D = 0.1616 Lambda = Gamma +Delta = 0.9821
Stress calculations, Allowable stress:
Longitudinal hub SH = (f*M)/(Lambda*g1**2*B1) = 7.53 Kg/mm2
1.5*SFO=21.09Kg/mm2
Radial SR = Beta*M/(Lambda*t**2*B) = 3.27 Kg/mm2
SFO =14.06 Kg/mm2
Tangential ST1 = M*Y/(t**2*B)-(Z*SR) = 2.45 Kg/mm2
SFO =14.06 Kg/mm2
(Greater) ST2 = (SH+SR)/2 or (SH+ST1)/2 = 5.4 Kg/mm2
SFO =14.06 Kg/mm2

ASME Section VIII Div.1 2004 A06, Appendix 2, 2-14 Flange Rigidity
Factor V = 0.07
Factor L = 0.9821
Modulus elastic design T Ed = 19649 Kg/mm2 Modulus elastic atm. T Ea = 20530
Kg/mm2
Thickness g0 = 9 mm
Factor h0 = 74.4 mm
Factor KI = 0.3
Factor KL = 0.2
Corrosion allowance CA = 3 mm
Factor K = 1.1972
Thickness T = 55 mm
Rigidity index, J, integral flange type
Gasket seating J = 52.14 * Ma * V / (L * E * G0 ** 2 * ho * KI) = 0.356
Operating J = 52.14 * Mo * V / (L * E * G0 ** 2 * ho * KI) = 0.1793
5. Component: Tubesheets:
The materials of construction and design conditions for tubesheet design are given below.
Table 2: Materials and Design Conditions
COMPONENTS
SHELL
CHANNEL
TUBESHEET
TUBES
MATERIALS
SA-516 GR 60
SA-516 GR 60
SA-105
SA-179
DESIGN PRESSURE
0.075
0.15
0.15
0.15
DESIGN TEMP. (deg C)
65
170
170
170
ALLOWABLE STRESS
12.02
12.02
14.06
9.42
50
50
170
165
20361
20361
19649
19675
0.0000117
0.0000117
0.0000125
0.0000125
220
220
205
180
(Kg/mm2)
(Kg/mm2)
MEAN METAL TEMP.
(deg C)
MOD.OF
ELAS/M.M.T.(Kg/mm2)
COEF.TH.EXP/M.M.T.
(mm/mm/C)
CORROSION
ALLOWANCE (mm)
YIELD STRESS, SY (Mpa)
RCB-7.134 Tubesheet Formula - Tubesheet Flange Extension

RCB-7.1341 Fixed Tubesheet or Floating Tubesheet Exchangers
Design temperature TS = 170 C
TS allowable stress S = 14.06 Kg/mm2
Tubesheet OD A = 737 mm
Reaction diameter G = 616 mm
Ratio A/G r = 1.1972
Equivalent diameter DL = 415.9 mm
Flange moment M = 3556 kgf*m
:5
T r = 0:98
(M (r 2 1+3:71r 2 ln (r) ))
(S(AG)(1+1:86r 2 ))
= 27:5 mm
Relative expansion between shell and tubes (TEMA T-4.5)

Shell metal temp. = 28.9 C
Tube metal temp. = 143.9 C
Tube length L = 2438 mm
DeltaL = (Alphas*Thetas-Alphat*Thetat)*L = -3.56 mm
RCB-7.13 Required Effective Tubesheet Thickness
Tubesheet details with effective thicknesses (no corrosion added), mm
Effective thickness definition as per TEMA 1999 RCB-7.12
Corroded conditions refer to head and shell dimensions only
Bending:
T = (F*G/3)*Sqrt (P/Eta*S)
Factor Eta = 0.4195
Shear:
T = 0.31*DL*(P/S)/ (1-do/Pitch)
The tubesheet required effective thickness under corroded and uncorroded conditions are
given in table.
Table 3: Required Effective Tubesheet Thickness
WITHOUT
WITH EXP.JOINT
EXP.JOINT
CONDITION
UNCORRODED
CORRODED
UNCORRODED
CORRODED
USER SPECIFIED
52
52
52
52
THICKNESS
EFFECTIVE
47
43
46.5
42.6
40.9
36.4
14.2
11.7
12
9.5
THICKNESS
REQ. TKS. SHELL
SIDE (BENDING)
REQ. TKS. TUBE
SIDE (BENDING)
REQ. TKS. SHELL
SIDE (SHEAR)
REQ. TKS. TUBE
SIDE (SHEAR)
Shell and tube stresses, (tube-to-TS loads and effective pressures

Stresses, Kg/mm2 mean stress exceeds allowable).
Table 4: Shell and Tube Stresses
WITHOUT
WITH
EXP.JOINT
EXP.JOINT
CONDITIONS
UNCORRODED
CORRODED
UNCORRODED
CORRODED
SHELL LONGITUDINAL
4.54
5.13
TUBE LONGITUDINAL
1.36
1.73
STRESS Kg/mm2
TUBE COMPRESSIVE
-22.1
-21.46
126.8
160.9
STRESS Kg/mm2
SHELL COMPRESSIVE
STRESS Kg/mm2
STRESS Kg/mm2
TUBE-TO-TUBESHEET
LOAD Wj kgf
EFF.PRES.SHELL SIDE
0.31
0.254
0.239
0.185
0.31
0.254
0.262
0.208
(BEND.) Kg/mm2
EFF.PRES.TUBE SIDE
(BEND.) Kg/mm2
EFF.PRES.SHELL SIDE
(SHEAR) Kg/mm2
EFF.PRES.TUBE SIDE
(SHEAR) Kg/mm2
RCB-7.161 Equivalent Differential Expansion Pressure, Pd, Kg/mm2

Tube OD do = 25 mm
Tube Number N = 264
Tube pitch = 31.25 mm
Tube Length Lt = 2438 mm
Modulus of Elasticity E = 19649 Kg/mm2
Modulus of Elasticity Es = 20361 Kg/mm2
Modulus of Elasticity Et = 19675 Kg/mm2
Pd = 4*J*Es*ts*(DeltaL/Lt)/ (Do-3*ts)*(1+J*K*Fq)
J = Sj*L/Sj*L+Pi*(Do-ts)*ts*Es K = Es*ts*(Do-ts)/ET*tt*N*(do-tt)
Fq = 0.25+ (F-0.6)*((300*ts*Es/K*L*E)*(G/T)^3)^0.25
Table 5: Equivalent Differential Expansion Pressure
WITHOUT
EXP.JOINT
WITH EXP.JOINT
CONDITION
UNCORRODED
CORRODED
UNCORRODED
CORRODED
FACTOR F SHELL
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
609.6
615.6
609.6
615.6
609.6
615.6
609.6
615.6
SHELL OD DO mm
633.601
633.601
633.601
633.601
SHELL THICKNESS
12.0
9.0
12.0
9.0
2332
2346
J=1;W/O EXP.JOINT J
1.0
1.0
J=0;Sj<
RIGIDITY FACTOR K
0.9887
0.7451
0.9887
0.7451
Fq kg/mm2
3.0676
3.5613
Pd kg/mm2
-0.593
-0.483
SIDE F FS mm
FACTOR F TUBE
SIDE F = Ft mm
DIA. G SHELL SIDE G
= Gs mm
DIA. G TUBE SIDE G =
Gt mm
Ts mm
SPRING RATE,
kgf/mm Sj
EFFECTIVE TUBE
LENGTH L mm
(DO-TS)*TS*ES/10*L
RCB-7.162 Equivalent Bolting Pressure, Pb, Kg/mm2

Table 6: Equivalent Bolting Pressure
WITHOUT
EXP.JOINT
WITH EXP.JOINT
CONDITION
UNCORRODED
CORRODED
UNCORRODED
CORRODED
EQUIV. BOLTING
0.047
0.046
0.047
0.046
0.097
0.095
0.097
0.095
PRESSURE Pbt
EQUIV. BOLTING
PRESSURE Pbs
Operating moment M1 = 1714 kgf*m

Bolting-up moment M2 = 3556 kgf*m
Operating - Pbt = (6:2 M 1)=(F^2 Gs^3 )
Bolting up - Pbs = (6:2 M 2)=(F^2 Gs^3)
RCB-7.163 Effective Shell Side Design Pressure, P, Kg/mm2

Table 7: Effective Shell Side Design Pressure
WITHOUT
WITH EXP.JOINT
EXP.JOINT
CONDITION
P = (Ps'-Pd)/2
UNCORRODED
0.31
CORRODED
0.254
UNCORRODED
0
CORRODED
0
P = Ps'
0.026
0.025
P = PBs
0.097
0.095
P = (Ps'-Pd-PBs)/2
0.261
0.207
P = (PBs+Pd)/2
-0.248
-0.194
P = Ps'-PBs
-0.071
-0.07
G = Gs = Shell I.D., mm
609.6
615.6
609.6
615.6
fs = 1-N*(do/G)**2
0.556
0.5646
0.556
0.5646
Dj = expansion joint
609.6
615.6
0.026
0.025
ID, mm
Ps'
P s = P s(
0:4J(1:5+K (1:5+fs))((1J)=2)(Dj2=G21))
)
1 + J K Fq
RCB-7.164 Effective Tube Side Design Pressure, P, Kg/mm2

Table 8: Effective Tube Side Design Pressure
WITHOUT
WITH EXP.JOINT
EXP.JOINT
CONDITION
UNCORRODED
CORRODED
UNCORRODED
CORRODED
P = (Pt'+PBt+Pd)/2, If
-0.239
-0.185
0.116
0.113
-0.252
-0.198
0.089
0.088
0.64
0.647
0.64
0.647
609.6
615.6
609.6
615.6
Ps' is positive
P = Pt'+PBt, If Ps' is
positive
P = (Pt'-Ps'+PBt+Pd)/2,
If Ps' is negative
P = Pt'-Ps'+PBt, If Ps' is
negative
P=
Pt+(Ps/2)*((Dj/G)**2-1
)+PBt, When J=0 and
Ps and Pt are both
positive
ft =
1-N*((do-2*tt)/G)**2
Pt'
P t0 = P t
609.6
1 + 0:4 J K (1:5 + ft)

1 + J K Fq
615.6
RCB-7.22 Shell Longitudinal Stress, Ss, Kg/mm2

Ss = (Cs * (Do - ts) * (Ps*)) / 4 * ts
Table 9: Shell Longitudinal Stress
WITHOUT
WITH EXP.JOINT
EXP.JOINT
CONDITION
UNCORRODED
CORRODED
UNCORRODED
CORRODED
Tensile stress (shell),
12.02
12.02
12.02
12.02
stress
Tensile stress Ss
4.54
5.13
Compressive stress
11.64
12.02
11.64
12.02
Compressive stress Ss
Ps* = Pt-Pt'
0.081
0.083
Ps* = Ps'
0.026
0.025
Ps* = -Pd
0.593
0.483
0.64
0.647
Ps* = Pt-Pt'+Ps'
0.108
0.108
Ps* = Pt-Pt'-Pd
0.674
0.566
Ps* = Ps'-Pd
0.619
0.508
Ps* = Pt-Pt'+Ps'-Pd
0.7
0.591
Kg/mm2 Allowable
(shell), Kg/mm2
Allowable stress
RCB-7.23 Tube Longitudinal Stress-Periphery of Bundle, St, Kg/mm2

St = (Ct * Fq * (Pt*) * G^2) / 4 * N * tt * (do-tt)
Table 10:Tube Longitudinal Stress-Periphery of Bundle
WITHOUT
WITH EXP.JOINT
EXP.JOINT
CONDITION
UNCORRODED
CORRODED
UNCORRODED
CORRODED
G = Gs = Shell I.D
609.6
615.6
609.6
615.6
Fs = 3.25-0.5*Fq
1.72
1.47
Tensile stress (tubes),
9.42
9.42
9.42
9.42
Tensile stress St
1.36
1.73
Compressive stress
9.42
9.42
Compressive stress St
-22.1
-21.4
P2 = Pt'-(ft*Pt/Fq)
0.037
0.04
P3 = Ps'-(fs*Ps/Fq)
0.013
0.013
Pt* = P2
0.037
0.04
Pt* = -P3
-0.013
-0.013
Pt* = Pd
-0.593
-0.483
Pt* = P2-P3
0.025
0.027
Pt* = P2+Pd
-0.555
-0.443
Pt* = -P3+Pd
-0.605
-0.497
Pt* = P2-P3+Pd
-0.568
-0.456
Kg/mm2
Allowable stress
(tubes), Kg/mm2
Allowable stress Sc
RCB-7.24 Allowable Tube Compressive Stress-Periphery of Bundle, Sc, Kg/mm2

Sc = Pi^2 * Et/(Fs*(kl/r)^2 when Cc <= kl/r k = 0.80
Sc = (Sy/Fs)*(1-(kl/r)/ (2*Cc)) when Cc > kl/r l = 425.5 mm
Cc = Sqrt(2*Pi^2*Et/Sy)
Cc = 156 kl/r = 40.47

r = 0.25*Sqrt(do^2+(do-2*tt)^2) = 8.41 mm
RCB-7.25 Tube-to-Tubesheet Joint Loads-Periphery of Bundle, Wj, kgf
Wj = Pi * Fq * (Pt*) G^2 / (4 * N)
Table 11: Tube -to-Tubesheet Joint Loads-Periphery of Bundle
WITHOUT
WITH EXP.JOINT
EXP.JOINT
CONDITION
UNCORRODED
CORRODED
UNCORRODED
CORRODED
609.6
615.6
609.6
615.6
Tube-to-tubesheet
126.8
160.9
Pt* = P2
0.037
0.04
Pt* = -P3
-0.013
-0.013
Pt* = P2-P3
0.025
0.027
load, Wj
RCB-7.25 Tube-to-Tubesheet Joint Loads-Periphery of Bundle, Wj, kgf

Allowable Loads per ASME Section VIII Div. 1 2004 A06 Appendix A
Table 12: Joint Types
Type
Joint
No Test
Test
description
Strength
fr
Lmax
fr
Lmax
0.8
700
875
0.55
481
0.7
613
0.8
700
875
welded only
b
Seal welded
only
strength
welded and
expanded
f
Seal welded
0.75
657
0.95
832
0.65
569
0.85
744
0.5
438
0.7
613
0.7
613
0.9
788
0.65
569
0.8
700
0.5
438
0.6
525
and exp.with 2
grooves
g
Seal welded
and exp.with 1
groove
Seal welded
and exp.with
no grooves
Expanded with
2 grooves
Expanded with
1 groove
Expanded with
no grooves
.
For joints types a,b,b-1,c,d,e : Lmax = At*Sa*fr
For joints types f,g,h, : Lmax = At*Sa*fe*fr*fy
For joints types i,j,k : Lmax = At*Sa*fe*fr*fy,ft
Cross-sectional area At = 92.91 mm2
Tube allowable stress Sa = 9.42 kgf/mm2
Factor fe (l/do or 1) fe = 1
Ratio fy fy = 1.38
ft = (Po+Pt)/Po ft = 1
Min Yield Str SigmaM = 18.28 kg/mm2

(ft = 1 if max exceeded)
Tube OD do = 25 mm
Tubes yield str (min) st = 18.28 kg/mm2
Joint operating Temp T = 1.2 C
Tubes Mod.Elasticity EtT = 19649 kg/mm2
TubSh Mod.Elast. EsT = 19649 kg/mm2
Tubes Coef.Th.Exp. at = 0.0000125
TubSh Coef.Th.Exp. as = 0.0000125
Po = (4*(do*t-t^2)*st)/do^2 Po = 3.46 kg/mm2
Pt = ((T-Tamb)*(at-as)*(EtT*EsT)/(EtT+EsT)
For joint types i, j, k:
Po + Pt <= 0.58*SigmaM
3.46 kg/mm2 <= 10.6 kg/mm2
6. Component: Nozzle
ASME VIII-1 2004 A06 UG-27 Thickness of Cylinders under Internal Pressure
Material: SA-106 K03006 GR B Smls. Pipe
Radiography = Spot Joint efficiency E = 1
Design stress S = 12.022 kg/mm2

Material tolerance = 1.09 mm
Minimum thickness tmin = 6.02 mm
Outside diameter OD = 60.33 mm
Corroded radius OR = 30.16 mm
Minimum thickness not less than UG-45(a), UG-16(b), UG-45(b):
UG-45(a) internal pressure:
t = (P*OR / (S*E+0.4*P)) +CAI+CAO+tol = 4.28 mm APP.1-1(A)
UG-45(a) external pressure+CAI+CAO+tol = 0 mm
UG-16(b) minimum thickness+CAI+CAO+tol = 5.68 mm
UG-45(b) Smaller of: t = 6.02 mm
UG-45(b) (4) standard pipe*0.875+CAI+CAO+tol = 7.51 mm
UG-45(b) Greater of: t = 6.02 mm
UG-45(b) (1) +CAI+CAO+tol = 6.02 mm
UG-45(b) (2) +CAI+CAO+tol = 0 mm
Minimum thickness: tmin = 6.02 mm
Nominal thickness: tnom = 8.74 mm
7. Component: Reinforcement Nozzle

ASME Section VIII-1 2004 A06 UG-37 Reinforcement Required for Openings in
Shells and Formed Heads

Int. design pressure PI = 0.075 Kg/mm2
Ext. design pressure PE = 0 Kg/mm2
Design temperature T = 65 C Fig.UW-16.1 Sketch (c)
Vessel material: SA-516 K02100 GR 60 Plate
Vessel design stress Sv = 12.02 Kg/mm2
Joint efficiency E = 1
Vessel outside diameter Do = 633.6 mm
Corroded radius IR = 307.8 mm
Nominal thickness tnom = 12 mm
Reinforcement limit lp = 48.8 mm
Required thickness internal pressure tr = 1.93 mm
Required thickness external pressure tre = 0 mm
Corroded thickness t = 9 mm
Reinforcement efficiency E1 = 1.0
Attachment Material: SA-106 K03006 GR B Smls. Pipe
Nozzle design stress Sn = 12.02 Kg/mm2
Joint efficiency E = 1
Nozzle outside dia. Don = 60.33 mm

Corroded radius OR = 30.16 mm
Nominal thickness tnom = 8.74 mm
Reinforcement limit ln = 14.34 mm
Required thickness internal pressure trn = 0.19 mm
Required thickness external pressure trne = 0 mm
Corroded thickness tn = 5.74 mm
Nozzle Projection h = 0 mm
Reinforcement element material:
Limit of reinforcement Dp = 0 mm
Nominal thickness te = 0 mm
Outside diameter = 0 mm
Design stress Se = 0 Kg/mm2
Minimum weld size tmin = 5.74 mm
Leg size (1/2*tmin) (Act) = 0 mm
1/2 * tmin (minimum) = 0 mm
1/2 * tmin (actual) = 0 mm
Weld tw (minimum) = 4.02 mm
Weld tw (actual) = 0 mm
Weld tc (minimum) = 4.02 mm
Weld tc (actual) = 4.02 mm
Smaller |6.35 mm | Leg size tw (actual) = 0 mm
tc of |0.7 * tmin| Leg size tc (actual) = 5.74 mm

Outward nozzle weld L1 = 5.74 mm
fr1 = Sn/Sv = 1.0
Outer element weld L2 = 0 mm
fr2 = Sn/Sv = 1.0
Inward nozzle weld L3 = 0 mm
fr3 = Sn/Sv or Se/Sv = 1.0
Inward nozzel weld new = 0 mm
fr4 = Se/Sv = 1.0
Corroded int.proj.thk ti = 0 mm
Corroded inside diameter d = 48.8 mm
Vessel wall length available for reinforcement 2*Lp-d = 48.8 mm
Plane correction factor (Fig.UG-37) F = 1
Offset distance from centerline doff = 0 mm
Reinforcement areas (internal pressure condition) ASME 2004 UG-37
A1 = Vessel wall. Larger of:
|2*(t+tn)*(E1*t-F*tr)-2*tn*(E1*t-F*tr)*(1-fr1)| = 208.5 mm2
A1 = 345.5 mm2
A2 = Nozzle wall outward | 5*(tn-trn)*fr2*t | = 249.7 mm2
Smaller of: | 5*(tn-trn)*fr2*tn | = 159.2 mm2
A2 = 159.2 mm2
A3 = Nozzle wall inward | 5*t*ti*fr2 | = 0 mm2
Smallest of: | 5*ti*ti*fr2 | = 0 mm2

| 2*h*ti*fr2 | = 0 mm2
A3 = 0 mm2
A41 = Outward nozzle weld = (L1^2)*fr3 = 32.9 mm2
A42 = Outer element weld = (L2^2)*fr4 = 0 mm2
A43 = Inward nozzle weld = (L3^2)*fr2 = 0 mm2
A4 = 32.9 mm2
A5 = Reinforcement pad Area = (Dp-d-2*tn)*te*fr4 A5 = 0 mm2
Aa = Area Available = A1+A2+A3+A4+A5 Aa = 537.6 mm2
A = Area required = (d*tr*F) +2*tn*tr*F*(1-f1) A = 94.2 mm2
Per UG-36(c) (3) (a), this opening does not required additional reinforcement other than
the inherent in the construction.
Nozzle attachment weld loads - UG-41 - Strength of reinforcement
ASME - Weld strength calculations not required per UW-15(b).
Weld load for strength path 1-1 (UG-41(b)(1)
W (1-1) = (A2+A5+A41+A42)*Sv W (1-1) = 2310 kgf
Weld load for strength path 2-2 (UG-41(b) (1)
W (2-2) = (A2+A3+A41+A43+2*tn*t*fr1)*Sv W (2-2) = 3552 kgf
Nozzle attachment weld loads - ASME 2004 UG-41 - Strength of reinforcement
Unit stresses - UW15(c) and UG-45(c)
Inner fillet weld shear = 5.89 Kg/mm2
Groove weld tension = 8.9 Kg/mm2
Nozzle wall shear = 8.42 Kg/mm2

Strength of connection elements
Inner fillet weld shear = 3202 kgf
Nozzle wall shear = 4139 kgf
Groove weld tension = 4835 kgf
Possible paths of failure
1-1 4139 + 3202 = 7341 kgf
2-2 3202 + 4835 = 8037 kgf
Nozzle attachment weld loads - ASME 2004 UG-41 - Strength of reinforcement
Welds strong enough if path greater than the smaller of W or W (path)
Path 1-1 > W or W11
7341 kgf > 2310 kgf OK
Path 2-2 > W or W22
8037 kgf > 3552 kgf OK
Tubesheet Layout Drawing:
Setting plan drawing:
CONCLUSION
Heat exchangers find wide application in various fields of engineering like space heating,
refrigeration, air conditioning, power plants, chemical plants, petrochemical plants,
petroleum refineries, and natural gas processing. Two fluids, of different starting
temperatures, flow through the heat exchanger. One flows through the tubes (the tube side)
and the other flows outside the tubes but inside the shell (the shell side). Heat is transferred
from one fluid to the other through the tube walls, either from tube side to shell side or vice
versa. The fluids can be either liquids or gases on either the shell or the tube side. In order
to transfer heat efficiently, a large heat transfer area should be used, leading to the use of
many tubes. In this way, waste heat can be put to use. This is an efficient way to conserve
energy. The heat exchanger selected for the design is shell and tube heat exchanger of fixed
tube sheet type. The various parameters were considered and mechanical design was
completed using ASME and TEMA standards. The mechanical design is analysed using
B-JAC software and finds out that the design is safe.
1.
2.
3.
4.
5.
6.
REFERENCES
Mechanical design of heat exchanger & process vessel components K.P. Singh
& A.I. Soler
Heat & Mass Transfer- S.C. Arora & S. Domkundwar
ASME Boiler and Pressure Vessel Code
TEMA Standards and Codes
Heat & Mass Transfer R.C. Sachdeva
Process Heat Transfer- D.Q. Kern
APPENDIX
1. Reinforcing Element UG-37.1
2. Values of Spherical Radius Factor UG-37
3. Chart for Determining Shell Thickness of Components Under External Pressure CS1
4. Modulus of Elasticity Table D-10M(TEMA)
5.Mean Coefficients of Thermal Expansion Table D-11M(TEMA)
6.Pass Partition Dimension Factors Table RCB-9.132
7. TEMA Nomenclature Figure N-1
8.Baffle Cut for Segmented Baffles Figure RCB-4.1
9.Figure RCB-7.132
10.Tubesheet Layout Figure RCB-7.133
11. Principle Dimensions of Typical Heads Figure 1-4
12. Values of Factor M Table 1-4.2
13. Types of Flanges Figure 2-4
14. Gasket Materials and Contact Facings Table 2-5.1
15. Effective Gasket Width Table 2-5.2

Mechanical Design of Shell and Tube Heat Exchanger

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MECHANICAL DESIGN OF SHELL & TUBE HEAT EXCHANGER

Regenerative Heat Exchangers

MECHANICAL DESIGN OF SHELL & TUBE HEAT EXCHANGER

Recuperative heat exchangers

MECHANICAL DESIGN OF SHELL & TUBE HEAT EXCHANGER

MECHANICAL DESIGN OF SHELL & TUBE HEAT EXCHANGER

MECHANICAL DESIGN OF SHELL & TUBE HEAT EXCHANGER

MECHANICAL DESIGN OF SHELL & TUBE HEAT EXCHANGER

Figure 1. Shell & Tube Heat Exchanger

MECHANICAL DESIGN OF SHELL & TUBE HEAT EXCHANGER

MECHANICAL DESIGN OF SHELL & TUBE HEAT EXCHANGER

MECHANICAL DESIGN OF SHELL & TUBE HEAT EXCHANGER

3. CODES & STANDARDS

: Rules for construction of pressure vessels

: Alternate rules for construction of high pressure vessels

MECHANICAL DESIGN OF SHELL & TUBE HEAT EXCHANGER

The ASME Code SECTION VIII, DIVISION 1:

Defines the scope, establishment of design

manufacturer and authorized inspector,

Requirements pertaining to methods of

Requirements of pressure vessels fabricated

MECHANICAL DESIGN OF SHELL & TUBE HEAT EXCHANGER

Requirements of pressure vessels fabricated

Requirements of pressure vessels fabricated

Requirements pertaining to classes of

constructed of carbon and low alloy steel

constructed of non ferrous materials

constructed of high alloy steel

constructed of cast iron

constructed of materials with corrosion

constructed of cast ductile iron

Requirements for pressure vessels

MECHANICAL DESIGN OF SHELL & TUBE HEAT EXCHANGER

Rules for shell- and- tube heat exchangers

No mandatory Appendix A, C, through H,

Scope of ASME BPVC SECTION VIII, DIVISION 1:

MECHANICAL DESIGN OF SHELL & TUBE HEAT EXCHANGER

Specification for welding rods,

subsection NCA, Division I, Division II and

Recommended rules for care and operation

Recommended guidelines for the care of

Rules for construction of Pressure vessels.

Division 3:Alternate Rules for construction

Welding and Brazing Qualification

Fibre reinforced plastic pressure vessels

MECHANICAL DESIGN OF SHELL & TUBE HEAT EXCHANGER

Rules for in-service inspection of nuclear

Rules for construction and continued service

MECHANICAL DESIGN OF SHELL & TUBE HEAT EXCHANGER

for the three sections.

Front (stationary) head type

Rear head type

MECHANICAL DESIGN OF SHELL & TUBE HEAT EXCHANGER

MECHANICAL DESIGN OF SHELL & TUBE HEAT EXCHANGER

MECHANICAL DESIGN OF SHELL & TUBE HEAT EXCHANGER

Heat Exchanger Design-An Over View:

MECHANICAL DESIGN OF SHELL & TUBE HEAT EXCHANGER

1. Component: Shell Cylinder

MECHANICAL DESIGN OF SHELL & TUBE HEAT EXCHANGER

2. Component: Front and Rear Head Cylinder

3. Component: Front and Rear Head Cover

MECHANICAL DESIGN OF SHELL & TUBE HEAT EXCHANGER

Design stress S = 12.022 kg/mm2

Pa = 4B / (3Dot) = 0.5653 kg/mm2

Fillet weld strength Ff = 0.55Piaf(do+0.67af)*Sw Ff = 882 kgf

Smallest of: | 5titi*fr2 | = 0 mm2