MECHANICAL DESIGN

OF SHELL AND TUBE HEAT EXCHANGER

Prepared By:
Amin U. Khalipe
Mechanical
Engineer
Jacobs ZATE

INTRODUCTION
Definition:
Heat exchangers are devices that transfer or exchange heat
from one media to another. It is used either for cooling or for
heating purpose.
The mediums flowing inside the heat exchanger may be gas or
liquid depending upon the service requirements of the process.
The transfer of thermal energy (heat) can be accomplished in
three ways:
Radiation:
The transmission of heat energy through space by the propagation of wave
forms in a medium.

Convection :
The transfer of energy between an object and its environment, due to fluid
motion.

Conduction:
The transfer of energy between objects that are in physical contact.

TYPES OF HEAT EXCHANGER

Shell-and-tube heat exchangers

Air-cooled heat exchangers

Double-pipe heat exchangers

Plate-and-frame heat exchangers

SHELL AND TUBE HEAT EXCHANGER

Introduction:

Shell and tube heat exchanger are of the most common

equipment found in all plants.

Classification of S & T Heat Exchanger:

U-Tube or U-Bend Heat Exchangers.
Fixed Tube sheet Heat Exchangers.
Floating Tubesheet Heat Exchangers.

U-TUBE OR U-BEND HEAT

EXCHANGER
Has only one tube sheet.
Tube bundle can be easily removable for cleaning or
inspection.

U-TUBE OR U-BEND HEAT

EXCHANGER

Application:
The U-tubes permit unlimited thermal expansion hence Used
where temperature difference between shell and tube side
fluids are high. No thermal stress generation.
Fouling fluid at shell side.

FLOATING TUBESHEET HEAT

EXCHANGER
Tube
bundle can be pulled out.

Tube sheet on one side is bolted between channel and

shell.

Tube sheet on the other side floats inside the shell and free
to move horizontally.

Test ring is required for hydro test.

FLOATING TUBESHEET HEAT

EXCHANGER

The floating head take care of any thermal expansion /

contraction
due to heat exchange as shown

FLOATING TUBESHEET HEAT

EXCHANGER
Application:
The floating tubesheet heat exchanger permit unlimited
thermal expansion hence Used where temperature
difference between shell and tube side fluids are high. No
thermal stress generation.
Fouling fluid at both side.

FIXED TUBESHEET HEAT

EXCHANGER
Tube sheet is welded to the shell.

Tube bundle is permanently installed.

Used when the temperature range is limited and shell
side fouling is limited.
Channel cover may be removable.

FIXED TUBESHEET HEAT

EXCHANGER
Application:
Used when the temperature range is limited.
Non-Fouling fluid at shell side.

MAIN COMPONENT OF SHELL AND TUBE

HEAT EXCHANGER

1. Channel
2. Channel
cover
3. Channel
Flange
4. Pass
5. Stationary
partition
Tubesheet
6. Shell flange
7. Tube

8. Shell
9. Baffles
10. Floating head backing
device
11. Floating Tubesheet
12. Floating Head
13. Floating Head flange
14. Shell Cover

FUNCTION OF SHELL AND TUBE HEAT

EXCHANGER COMPONENTs
Tubes: Provide heat transfer surface
Shell or Body: Enclose the area in which fluids flow
Nozzles: Inlet and outlet for fluid flow
Tube Sheet: Hold the tube in place

Baffles: Support the tubes in proper position and guide

the shell side flow to increase heat transfer.

Channel Cover: Allows tube inspection.

Pass Divider: Separate the tube side Flow.

TEMA HEAT
EXCHANGER

TEMA HEAT
EXCHANGER

TEMA HEAT
EXCHANGER

TEMA HEAT
EXCHANGER

TEMA HEAT
EXCHANGER

TEMA HEAT
EXCHANGER

TUBESIDE FLOW
ARRANGEMENT

TUBESIDE FLOW
ARRANGEMENT

BAFFLE TYPE
Baffle are use to support the tubes.
Increase the stay time of fluid.
Create turbulence (Hence enhance heat transfer).

Tube to tubesheet Joint

Code:

DESIGN
CODES

Recommended code for design of S&T hear

exchanger.
ASME BPV TEMA
Standard:
ASME B16.5 - ASMEB36.10M - ASME B36.19 - ASMEB16.9 - ASME
B16.11

Specification:
Is detailed description of construction, materials,. Etc.

HEAT EXCHANGER MECHANICAL DESIGN

Design Data.
Material Selection.
Codes overview.
Mechanical design calculation of heat exchanger
components.
Sample drawing

DESIGN
DATA
Heat Exchanger Datasheet:

TEMA Type
Design pressure (Internal / External)
Design temperature (Internal / External)
Corrosion allowance (Shell / tube side)
PWHT requirements.
Weld efficiency.
Mean metal temperature.
Heat Exchanger overall dimension (Shell /
channel I.D. , Tube length etc.)
No. of tube passes.
Tubes (Dimension and Pattern)
Nozzles & connection.
Baffle No. and type.
DATASHEET SAM
PLE

MATERIAL SELECTION

ASME Code overview

ASME BPV Code Sec VIII : Rule of
construction of pressure vessels:

Division 1
Division 2: Alternative rule.
Division 3: Alternative rule of higher pressure.

ASME BPV Code Sec. II Materials:

Part A: Ferrous material specification.
Part B: Non ferrous material specification.
Part C: Specification of welding rod, electrodes and filler
metals.
Part D: Properties.

TEMA Code overview

TEMA Classes:
Class R: Generally severe requirement of petroleum and
related processing application
Class C: Generally moderate requirement of commercial
and general processing Applications.
Class B: Chemical process service.

Calculation
Shell thickness Calculation Under Internal Pressure:

Calculation

Shell thickness Calculation Under Internal Pressure:

t=

PR
+ CA + UT
SE 0.6P

t : Min. Required Shell Thickness

P: Design Pressure Of Shell Side + Static
head
S: Max. Allowable stress of shell material
R: Shell Inside Radius (corroded condition)
E: Joint Efficiency
CA: Corrosion Allowance
UT: Under tolerance (If applicable)
PV-Elite

TEMA

Calculation

Calculation
Channel thickness Calculation Under Internal Pressure:

Calculation

Channel thickness Calculation Under Internal Pressure:

t=

PR
+ CA + UT
SE 0.6P

t : Min. Required Shell Thickness

P: Design Pressure Of Shell Side + Static
head
S: Max. Allowable stress of shell material
R: Shell Inside Radius (corroded condition)
E: Joint Efficiency
CA: Corrosion Allowance
UT: Under tolerance (If applicable)
PV-Elite

TEMA

Calculation

Calculation
Body / Girth flanges Calculation :

Calculation

Body / Girth flanges Calculation :

Trial and Error calculation:
o Gasket seating condition: Gasket are use to create a
static seal between two body / girth flanges under
operating condition . Gasket provide the seal by
external forces (torque the bolt) flowing the gasket
material in to imperfections between the mating
surfaces.

Calculation

Body / Girth flanges Calculation :

o Operating condition: Hold the flange together against
the internal pressure.
Design Steps:
o Obtain the below flange dimension :
Flange O.D.
Flange I.D.
Flange Face O.D.
Flange Face I.D.
Gasket O.D.
Gasket I.D.
Bolt circle diameter
Hub length
Girth / Body Flange Dimension

Calculation

Body / Girth flanges Calculation :

o Calculate Operating bolt load (Wm1) and Gasket
seating bolt load
(Wm2)
o Calculate required bolt area :
Required Bolt Area = Max (Wm1, Wm2) / Sb
Where Sb= Bolt Allowable stress
o Calculate required no. of bolts :
Required nos. of bolts = Required bolt area / Bolt
root area.
o Check Min. and Max. bolt spacing.
o Detail analysis of flange
Moment calculation
Stress calculation
PV Elite Calculation
PV Elite Input
Flange rigidity calculation (Optional)

Calculation

Precaution in Body / Girth flanges design and Calculation :

o Bolt hole shall be straddle to center line
o Corrosion Allowance.
o Cladding
o Bolts shall be multiple of 4.
o Bolt shall be allowed to remove from either side.
o Calculated thickness not include the RF

Calculation

Nozzles and standard flanges:

o Flange rating (ASME B16.5).
o Nozzle neck calculation. : (As per UG-45 of ASME Sec.
VIII Div.1)
o Area replacement calculation.

PV-Elite Input

PV-Elite
calculation

Calculation
Tube sheet :
o Tubesheet is the principle barrier between shell side and
tube side.
o Tubesheet is made from flat piece of metal with hole drill for
the tubes.
o Tubes are uniformly distributed.
o Tubesheet thickness shall be design for both sides.
o Tubessheet design for bending stress and shear stess.
o Corrosion allowance.

Calculation
Tube sheet calculation as per TEMA :
Tubesheet thickness for bending:

T: Effective tubesheet thickness.

S: Allowable stress value.
P: Design pressure corrected for vacuum if applicable at
other side.
n : Ligament efficiency
G: gasket effective diameter.
F: Factor
PV Elite
Calculation
PV Elite Input

Calculation
Tube sheet calculation as per TEMA :
Tubesheet thickness for Shear:

T: Effective tubesheet thickness.

S: Allowable stress value.
P: Design pressure corrected for vacuum if applicable at
other side.
DL: Effective diameter of the tube center parameter. D L
= 4A/C
C: Perimeter of tube layout.
A: Total area enclosed by perimeter C.
do: Outside tube diameter.

Calculation
Tube sheet calculation as per ASME :
Design Of U-Tube sheet: As per UHX-12.
Design of fixed tubesheet: As per UHX-13.
Design of floating tubesheet: As per UHX-14.

THANKS