By: Baher EL Shaikh
By: Baher EL Shaikh
Mechanical Engineer
Mechanical Engineer
EMetahnex
Shell and tube heat exchangers are one of
the most common equipment found in all
plants
Heat Exchanger
Cooler
Heater
Condenser
Reboiler
Both sides single phase and process stream
One stream process fluid and the other cooling water or air
One stream process fluid and heating utility as steam
One stream condensing vapor and the other cooling water or air
One stream bottom stream from a distillation column and the other a hot utility
Code
Standard
Specifications
Is recommended method of doing something
ASME BPV – TEMA
is the degree of excellence required
API 660-ASME B16.5–ASME B36.10M–ASME B36.19-ASME B16.9–ASME B16.11
Is a detailed description of construction, materials,… etc
2- Channel 3- Channel Flange 4- Pass Partition 5- Stationary Tubesheet 6- Shell Flange 8- Shell 9- Baffles
10- Floating Head backing Device11- Floating Tubesheet 12- Floating Head
13- Floating Head Flange 1- Channel Cover
Front Head Type
Front Head Type
Shell Type
Shell Type
E - Type F - Type
J - Type
Rear End Head Types
Rear End Head Types
M - Type
S - Type
T - Type
Fixed Tubesheet Floating Head Pull-Through Floating Head
U-Tube Heat Exchanger
U-Tube Heat Exchanger
Fixed Tubesheet Heat Exchanger
Fixed Tubesheet Heat Exchanger
Terminology
Design data
Material selection
Codes overview
Sample calculations
Hydrostatic test
Sample drawing
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
Heat Exchanger Data Sheet :
Design pressure
Design temperature Dimensions / passes
Tubes ( dimensions, pattern) Nozzles & Connections
TEMA type
A – Yield
A – Yield
Strength
Strength
B – Tensile StrengthB – Tensile Strength
C – Rupture
C – Rupture
point
point
A B C 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
ASME code Overview
ASME code Overview
ASME
BPV
code
Sec.I Power Boilers Sec.II Materials
Sec.III Nuclear Fuel Containers Sec.IV Heating Boilers
Sec. V Non Destructive Examination Sec. VI Operation of heating boilers 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
ASME code overview
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 rulesASME code overview
TEMA code overview
TEMA code overview
TEMA classes:
Class R: Generally severe requirements for petroleum
and related processing applications
Class C: Generally moderate requirements of
commercialand general processing applications
Class B: Chemical Process service
TEMA subsections
Sample Calculations
Sample Calculations
Shell thickness calculations under Internal Pressure:
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)
PR
.
SE – 0.6 P
+ CA
Sample Calculations
Sample Calculations
Channel thickness calculations under Internal Pressure:
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)
PR
.
SE – 0.6 P
+ CA
Sample Calculations
Sample Calculations
Sample Calculations
Sample Calculations
Body Flanges:
Trial and error calculations
Gasket seating 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
Sample Calculations
Sample Calculations
Precautions in body flanges design and installations:
Pairs of flanges
Bolt holes shall straddle center line Corrosion Allowance
Bolts shall be multiple of 4
Bolting shall be allowed to be removed from either side Calculated thickness not include the RF
Sample Calculations
Sample Calculations
Nozzles and standard flanges:
Flange Rating (ASME B16.5)
Nozzle neck thickness calculations Area replacement calculations
Sample Calculations
Sample Calculations
Tubesheet:
• Tubesheet is the principal barrier between shell side and tube side
• 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
• Made from around flat piece of metal with holes drilled for the tubes
Sample Calculations
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
For Square pattern
For Triangular pattern
G: Gasket effective diameter F: Factor
Sample Calculations
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
Tube-to-Tubesheet
Tube-to-Tubesheet
joint
joint
Expanded
Seal welded
Strength welded
Hydrostatic Test
Hydrostatic Test
Test pressure : 1.3 X MAWP Test Procedure
Sample drawing
Sample drawing
Construction drawing is the design output
Baher EL Shaikh