By: Baher EL Shaikh

Mechanical Engineer
EMetahnex

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 Shell and tube heat exchangers are one of
the most common equipment found in all
plants
 How it works?

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 Classification according to service .
 Heat Exchanger
Both sides single phase and process stream

 Cooler
One stream process fluid and the other cooling water or air

 Heater
One stream process fluid and heating utility as steam

 Condenser
One stream condensing vapor and the other cooling water or air

 Reboiler
One stream bottom stream from a distillation column and the other a hot
utility
or process stream

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 Code
Is recommended method of doing something
ASME BPV – TEMA

 Standard
is the degree of excellence required
API 660-ASME B16.5–ASME B36.10M–ASME B36.19-ASME B16.9–ASME B16.11

 Specifications
Is a detailed description of construction, materials,… etc
Contractor or Owner specifications

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1- Channel Cover 8- Shell
2- Channel 9- Baffles
3- Channel Flange 10- Floating Head backing
4- Pass Partition Device
11- Floating Tubesheet
5- Stationary Tubesheet 12- Floating Head
6- Shell Flange 13- Floating Head Flange
7- Tube 14 –Shell Cover

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 Front Head Type

A - Type B - Type C - Type

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 Shell Type

E - Type F - Type

J - Type
K - Type
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 Rear End Head Types

M - Type S - Type T - Type

Fixed Tubesheet Floating Head Pull-Through
Floating Head

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 U-Tube Heat Exchanger

 Fixed Tubesheet Heat Exchanger

 Floating Tubesheet Heat exchanger

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AES
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AKT
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 Terminology

 Design data

 Material selection

 Codes overview

 Sample calculations

 Hydrostatic test

 Sample drawing

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 ASME : American Society of Mechanical Engineers
 TEMA : Tubular Exchanger Manufacturer Association
 API : American Petroleum Institute
 MAWP : Maximum Allowable Working Pressure
 MDMT : Minimum Design Metal Temperature
 PWHT : Post Weld Heat Treatment
 NPS – DN – NB – NPT
 Sch - BWG

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 Heat Exchanger Data Sheet :
 TEMA type
 Design pressure
 Design temperature
 Dimensions / passes
 Tubes ( dimensions, pattern)
 Nozzles & Connections
 Baffles (No. & Type)

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16
 B
A
 A – Yield C
Strength
 B – Tensile Strength

 C – Rupture
point

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 Creep Strength
a slow plastic strain increased by time and temperature
(time and temperature dependant) for stressed materials

 Fatigue Strength
The term “fatigue” refers to the situation where a
specimen breaks under a load that it has previously
withstood for a length of time

 Toughness
The materials capacity to absorb energy, which, is
dependant upon strength as well as ductility

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ASME code Overview
Sec.I Power Boilers

Sec.II Materials

Sec.III Nuclear Fuel Containers

Sec.IV Heating Boilers

ASME Sec. V Non Destructive Examination

BPV Sec. VI Operation of heating boilers

code Sec. VII Operation of power boilers

Sec. VIII Pressure vessels

Sec. IX Welding and Brazing

Sec. X Fiber-Reinforced plastic PV

Sec. XI Inspection of nuclear power plant

Sec. XII Transport tanks

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ASME code overview
 Sec. II: Materials
 Part A : Ferrous material specifications
 Part B : Non-Ferrous material specifications
 Part C : Specifications of welding rods, electrodes and filler
metals
 Part D : Properties

 Sec. VIII: Rules of construction of pressure vessels

 Division 1 : 3 Subsections + mandatory Annex + non mandatory Annex

 Division 2: Alternative rules

 Division 3 : Alternative rules of high pressure

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ASME code overview

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TEMA code overview
 TEMA classes:
 Class R: Generally severe requirements for petroleum
and related processing applications

 Class C: Generally moderate requirements of

commercial
and general processing applications

 Class B: Chemical Process service

 TEMA subsections
 10 subsection

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 Sample Calculations
 Shell thickness calculations under Internal Pressure:

PR
t= . + CA + UT
SE – 0.6 P
 t : Min. Required Shell Thickness
 P : Design Pressure of Shell Side
 S: Max. Allowable Stress of Shell Material
 R: Shell Inside Radius (corroded conditions)
 E : Joint Efficiency
 CA: Corrosion Allowance
 UT: Under Tolerance (if applicable)

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 Sample Calculations
 Channel thickness calculations under Internal Pressure:

PR
t= . + CA + UT
SE – 0.6 P
 t : Min. Required Channel Thickness
 P : Design Pressure of Tube Side
 S: Max. Allowable Stress of Channel Material
 R: Channel Inside Radius (corroded conditions)
 E : Joint Efficiency
 CA: Corrosion Allowance
 UT: Under Tolerance (if applicable)

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Sample Calculations
 Body Flanges:

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Sample Calculations
 Body Flanges:
 Trial and error calculations
 Gasket seating conditions
 Operating conditions

 No. of bolts and size

 Bolt circle diameter
 Inside and outside diameters

 Check min. and max. bolt spacing

 Detailed analysis of the flange

 Forces calculations
 Moment calculations
 Stresses calculations

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Sample Calculations
 Precautions in body flanges design and installations:

 Pairs of flanges
 Bolt holes shall straddle center line
 Corrosion Allowance
 Cladding
 Bolts shall be multiple of 4
 Bolting shall be allowed to be removed from either side
 Calculated thickness not include the RF

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Sample Calculations
 Nozzles and standard flanges:

 Flange Rating (ASME B16.5)

 Area replacement calculations

 Nozzle neck thickness calculations

 Impingement protection

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Sample Calculations
 Tubesheet:
• Tubesheet is the principal barrier between shell side and tube
side
• Made from around flat piece of metal with holes drilled for the
tubes
• Tubes shall be uniformly distributed

• Tubesheet thickness shall be designed for both sides

• Tubesheet shall be designed for bending stresses and shear

stresses
• Corrosion allowance

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Sample Calculations
 Tubesheet:
• Tubesheet thickness for bending

T: Effective tubesheet thickness

S: Allowable stress
P: Design pressure corrected for vacuum if applicable at the other side
η: Ligament efficiency
G: Gasket effective diameter
F: Factor
For Square For Triangular
pattern pattern

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Sample Calculations
 Tubesheet:
• Tubesheet thickness for Shear:

T: Effective tubesheet thickness

DL: Effective diameter of the tube center parameter DL=4A/C

C: Perimeter of the tube layout

A: Total area enclosed by the Perimeter C
P: Design pressure
S: Allowable stress
do: Outside tube diameter

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Tube-to-Tubesheet
joint
 Expanded

 Strength welded

 Seal welded

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Hydrostatic Test

 Test pressure : 1.3 X MAWP

 Test Procedure

 Gasket change

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Sample drawing
 Construction drawing is the design output

Sample drawing 1 Sample drawing 2

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Baher EL Shaikh
baherfm@yahoo.com

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