Shell & Tube Heat Exchanger Design

PART-1

- INTRODUCTION TO STHE

- GIRTH FLANGE DESIGN

- TUBESHEET DESIGN
Introduction to STHE

 Heat Exchanger Components

Component
Introduction to STHE

 TEMA Type heat exchanger

TEMA Type HE
Introduction to STHE

Component
Component
Component
Introduction to STHE

 U-Tube Heat Exchanger

Heat exchanger with one stationary tubesheet and
contains of U-tube bundle.
Introduction to STHE

 Fixed Tubesheet Heat Exchanger

Heat exchanger with two stationary tubesheets and
contains of straight tubes connecting both tubesheets.
Introduction to STHE

 Floating Tubesheet Heat Exchanger

Heat exchanger with one stationary tubesheet and one
floating tubesheet that can move axially, and contains of
straight tubes connecting both tubesheets.
Introduction to STHE

 Major component of Heat Exchanger:

- Girth Flange
- Tubesheet
Design of Girth Flange

 Applicable Code & Standard:

1. Appendix 2 of ASME VIII Div.1
2. Table D-5 of TEMA

 Design considerations
Hydraulic pressure
Gasket seating force
Flange rigidity
(refer to App.2-4, flange rigidity as a mandatory
requirement in ASME VIII Div.1)
Design of Girth Flange

 Calculation procedure:
1. Determination of Bolt Circle Diameter
BCD = The greater of BCD-1 and BCD-2:
BCD-1 = (g1 + Rh) x 2 + ID
BCD-2 = [IR + W G + OR +1.5 + 5 +(3 + bolt dia/2)] x 2 + ID

2. Determination of OD Flange
OD = BCD + E

3. Determination of Bolt Loads (per App.2-5)

Bolt Loads > Gasket seating force + Hydraulic pressure

4. Flange Moments (per App. 2-6)

5. Calculation of Flange Stress (per App.2-7)

Design of Girth Flange

 Allowable Flange Design Stresses per App.2-8

- for integral hub flange:
SH (max)  smaller of 1.5Sf or 2.5Sn
SR (max)  Sf
ST (max)  Sf
Combine stresses
(SH + SR)/2 (max)  Sf
(SH + ST)/2 (max)  Sf
Other consideration for design of flange

 Flange type:

1. Loose Type
Fig. 2-4 sketches (1), (1a), (2), (2a), (3), (3a), (4), and (4a)

this flange has no direct connection to the shell, and designs

where the method of attachment is not considered to give the
mechanical strength equivalent of integral attachment.
Other consideration for design of flange
Other consideration for design of flange

2. Integral Type
Fig. 2-4 sketches (5), (6), (6a), (6b), and (7)

this flange has an integrally hub connection to the shell,

or butt weld construction which is equivalent as integral structure.
Other consideration for design of flange
Other consideration for design of flange

3. Optional Type
Fig. 2-4 sketches (8), (8a), (9), (9a), (10), (10a) and (11)

this type of flange shall be calculated as an integral

flange,
or it can be calculated as a loose type with none of the
following value is exceeded:
go = 5/8 in (16 mm)
B/go = 300
P =300 psi (2 MPa)
operating temperature = 700°F (370°C)
Other consideration for design of flange
Other consideration for design of flange

 Gasket width
TEMA recommendation RC-6.31 or B-6.31:
min width 9.5mm  for shell nom. Dia. up to 23” (584mm),
12.7mm  larger shell diameter.
for internal (floating head flange) RCB-6.32
min width 6.4mm  for all shell size

gasket rib area for gasket seating (for pass partition ribs) to be
considered in calculation.
Other consideration for design of flange

 Bolt spacing
the minimum spacing per Table D-5 TEMA

 Bolt diameter

Recommended minimum bolt size (except floating head):

shell ID < 700mm : 3/4” (M20)
700 < shell ID <= 1000 : 7/8” (M22)
shell ID > 1000mm : 1” (M22)
floating head flange:
shell ID < 700mm : 3/4” (M20)
shell ID > 700mm : 1” (M22)
Design of TUBESHEET

 Applicable Code & Standard

1. Part UHX of ASME VIII Div.1
2. TEMA RCB-7

Note:
TEMA Notice of tubesheet calculation (Dec. 2004)
Effective December 31, 2004 ASME Code case 2429, which allows
tubesheet design to be per TEMA requirements, will expire. At this time,
section UHX of the ASME Code will be mandatory for all tubesheets that
fall whithin its scope. It is not intent of TEMA to require tubesheet
calculations to be performed by both methods. TEMA calculation methods
will be maintained for tubesheets outside the scope of UHX or for
replacement bundles designed to a previous issue of the ASME code.
Design of TUBESHEET

• Stresses in tubesheet

 Stationary tubesheet  Fixed Tubesheet:

- bending stress
- bending stress
- shear stress
- shear stress
- differential thermal
expansion adjacent to the
tubesheet
- stresses in the shell/channel
integral with the tubesheet
Design of U-Tube TUBESHEET

 Load cases:

1. Load case-1: Tube side pressure, Pt

2. Load case-2: Shell side pressure, Ps
3. Load case-3: Ps and Pt acting simultaneously
Design of U-Tube TUBESHEET

 U-Tube type  UHX-12

step-1 to step-5; to determine coefficients factor.

step-6 &7 to determine the max moment.
step-8: to calculate tubesheet bending stress
step-9: to calculate shear stress in the tubesheet
step-1 to step-9 for stationary tubesheet type (configuration d of UHX-12.1)

step-10: to calculate the stresses shell/channel integral with the

tubesheet.
(for fixed tubesheet type as configuration a,b,c,e,f of UHX-12.1)

step-11:optional
Design of U-Tube TUBESHEET
Design of U-Tube TUBESHEET

 Allowable stress / acceptance criteria:

- bending stress (step-8), s < 2S
- shear stress (step-9), t < 0.8S
- total axial stress (step-10) < 1.5Ss and/or 1.5Sc
Design of Fixed TUBESHEET

 Load cases:

1. Load case-1: Tube side pressure, Pt

2. Load case-2: Shell side pressure, Ps
3. Load case-3: Ps and Pt acting simultaneously

4. Load case-4: Differential thermal expansion

5. Load case-5: Pt + thermal expansion

6. Load case-6: Ps + thermal expansion
7. Load case-7: Ps + Pt + thermal expansion acting simultaneously
Design of Fixed TUBESHEET

 Fixed Tubesheet type  UHX-13

step-1 to step-5; to determine coefficients factor.

step-6: to calculate the effective pressure.
step-7: to calculate tubesheet bending stress
step-8: to calculate shear stress in the tubesheet
step-9: to calculate combine stress due to differential thermal
expansion, buckling stress on tube
step-1 to step-9 for stationary tubesheet type (configuration d of UHX-13.1)

step-10: to calculate the stresses shell/channel integral with the

tubesheet.
(for fixed tubesheet type as configuration a,b,c, of UHX-13.1)

step-11:optional
Design of Fixed TUBESHEET
Design of Fixed TUBESHEET

 Allowable stress / acceptance criteria:

- bending stress (step-8), s < 2S
- shear stress (step-9), t < 0.8S, (load case-1,2,3)
t < 2S, (load case-4,5,6,7)
and t < Stb
- stresses in the shell and/or channel integral w/
the tubesheet (step-10) < 1.5Ss and/or 1.5Sc
(load case-1,2,3)
s < Sps, (load case-4,5,6,7)
Design of Floating TUBESHEET

 Load cases:
1. Load case-1: Tube side pressure, Pt
2. Load case-2: Shell side pressure, Ps
3. Load case-3: Ps and Pt acting simultaneously

4. Load case-4: Radial differential thermal expansion

5. Load case-5: Pt + thermal expansion

6. Load case-6: Ps + thermal expansion
7. Load case-7: Ps + Pt + thermal expansion acting
simultaneously
Design of Floating TUBESHEET

 Floating Tubesheet type  UHX-14

step-1 to step-5; to determine coefficients factor.

step-6: to calculate the effective pressure.
step-7: to calculate tubesheet bending stress
step-1 to step-7 for floating tubesheet (configuration A,B,D of UHX-14.3)

step-8: to calculate shear stress in the tubesheet

step-9: to calculate combine stress due to differential thermal
expansion, buckling stress on tube
step-1 to step-9 for stationary tubesheet type (configuration d of UHX-14.2)

step-10: to calculate the stresses shell/channel integral with the tubesheet.

(for fixed tubesheet type as configuration a,b,c, of UHX-14.2)

step-11:optional
Design of Floating TUBESHEET
Design of Floating TUBESHEET
Design of Floating TUBESHEET
Design of Floating TUBESHEET

 Allowable stress / acceptance criteria:

- bending stress (step-7), s < 1.5S (load case-1,2,3)
s < SPS (load case-4,5,6,7)
- shear stress (step-8), t < 0.8S,

- stresses in the outermost tube rows (step-9)

s t,o < St (load case-1,2,3)
s t,o < 2St (load case-4,5,6,7)
if, s t,o is negative  check tubes for bukling, s t,o < Stb

- stresses in the shell and/or channel integral w/ the tubesheet (step-10)

< 1.5Ss and/or 1.5Sc (load case-1,2,3)
s < SPS, shell side and tube side (load case-4,5,6,7)