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By: Baher EL Shaikh

By: Baher EL Shaikh

Mechanical Engineer

Mechanical Engineer

EMetahnex

(2)

Shell and tube heat exchangers are one of

the most common equipment found in all

plants

(3)

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

(4)

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

(5)

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

(6)
(7)

Front Head Type

Front Head Type

(8)

Shell Type

Shell Type

E - Type F - Type

J - Type

(9)

Rear End Head Types

Rear End Head Types

M - Type

S - Type

T - Type

Fixed Tubesheet Floating Head Pull-Through Floating Head

(10)

U-Tube Heat Exchanger

U-Tube Heat Exchanger

Fixed Tubesheet Heat Exchanger

Fixed Tubesheet Heat Exchanger

(11)
(12)
(13)

Terminology

Design data

Material selection

Codes overview

Sample calculations

Hydrostatic test

Sample drawing

(14)

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

(15)

Heat Exchanger Data Sheet :

 Design pressure

 Design temperature  Dimensions / passes

 Tubes ( dimensions, pattern)  Nozzles & Connections

 TEMA type

(16)
(17)

A – Yield

A – Yield

Strength

Strength

 B – Tensile StrengthB – Tensile Strength

C – Rupture

C – Rupture

point

point

A B C

(18)

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

(19)

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

(20)

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 rules

(21)

ASME code overview

(22)

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

(23)

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

(24)

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

(25)

Sample Calculations

Sample Calculations

(26)

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

(27)

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

(28)

Sample Calculations

Sample Calculations

Nozzles and standard flanges:

 Flange Rating (ASME B16.5)

 Nozzle neck thickness calculations  Area replacement calculations

(29)

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

(30)

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

(31)

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

(32)

Tube-to-Tubesheet

Tube-to-Tubesheet

joint

joint

Expanded

Seal welded

Strength welded

(33)

Hydrostatic Test

Hydrostatic Test

Test pressure : 1.3 X MAWPTest Procedure

(34)

Sample drawing

Sample drawing

Construction drawing is the design output

(35)

Baher EL Shaikh

References

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