How to Select Shell and Tube Heat Exchanger Classes and Types

Drajad Agus Widodo (drajad_aw@yahoo.com)

Fundamentals of Shell and Tube Heat Exchangers

A shell and tube heat exchanger is a cylindrical vessel housing a set of tubes (called the tube bundle) containing a fluid at some temperature and immersed in another fluid at a different temperature. The transfer of heat occurs between the fluid flowing over the tubes and the fluid flowing inside the tubes. The fluid flow inside the tubes is said to be tube side and the fluid flow external to the tube bundle is said to be shell side

seamless or welded and most commonly made of copper or steel alloys. Other alloys of nickel, titanium, or aluminum may also be required for specific applications. The tubes may be either bare or with extended or enhanced surfaces on the outside. Extended or enhanced surface tubes are used when one fluid has a substantially lower heat transfer coefficient than the other fluid. Extended surfaces, (finned tubes) provide two or four times as much heat transfer area on the outside as the corresponding bare tube, and this area ratio helps to outside heat transfer coefficient.

Basic Components of Shell and Tube Heat Exchangers

Fig. 2 Finned Tube More recent developments are: a corrugated tube which has both inside and outside heat transfer enhancement, a finned tube which integral inside turbulators as well as extended outside surface, and tubing which has outside surfaces designed to promote nucleate boiling.

Fig. 1 Shell and Tube Exchanger Components While there is an enormous variety of specific design features that can be used in shell and tube exchangers, the number of basic components is relatively small.

Tube Sheets
The tubes are held in place by being inserted into holes in the tube sheet and there either expanded into grooves cut into the holes or welded to be tube sheet where the tube protrudes from the surface. The tube sheet is usually a single round plate of metal that has been suitably drilled and grooved to take the tubes (in the desired pattern), the gaskets, the spacer rods, and the bolt circle where it is fastened to the shell. However, where mixing between

Tubes
The tubes are the basic component of the shell and tube exchanger, providing the heat transfer surface between one fluid flowing inside the tube and the other fluid flowing across the outside of the tubes. The tubes may be

the two fluids (in the event of leaks where the tube is sealed into the tube sheet) must be avoided, a double tube sheet may be provided. Fig. 3 Tube Sheet The space between the tube sheets is open to the atmosphere so any leakage of either fluid should be quickly detected. Triple tube sheets (to allow each fluid to leak separately to the atmosphere without mixing) and even more exotic designs with inert gas shrouds and/or leakage recycling systems are used in cases of extreme hazard or high value of the fluid. The tube sheet, in addition to its mechanical requirements, must withstand corrosive attach by both fluids in the heat exchanger and must be electrochemically compatible with the tube and all tubeside material. Tube sheets are sometimes made from low carbon steel with a thin layer of corrosion-resisting alloy metallurgically bonded to one side.

Channel Covers
The channel covers are round plates that bolt to the channel flanges and can be removed for tube inspection without disturbing the tube-side piping. In smaller heat exchangers, bonnets with flanged nozzles or threaded connections for the tube-side piping or often used instead of channels and channel covers

Pass Divider
A pass divider is needed in one channel or bonnet for an exchanger having two tube-side passes, and they are needed in both channels or bonnets for an exchanger having more than two passes. The arrangement of the dividers in multiple-pass exchangers is somewhat arbitrary, the usual intent being to provide nearly the same number of tubes in each pass, to minimize the number of tubes lost from the tube count, to minimize the pressure difference across any pass divider (to minimize leakage and therefore the violation of the MTD derivation), to provide adequate bearing surface for the gasket and to minimize fabrication complexity and cost.

Shell and Shell-side Nozzles

The shell is simply the container for the shell-side fluid, and the nozzles are the inlet and exit ports. The shall normally has a circular cross section and is commonly made by rolling a metal plate of the appropriate dimensions into a cylinder and welding the longitudinal joint (rolled shells). Small diameter shells (up to around 24 inches in diameter) can be made by cutting pipe of the desired diameter to the correct length (pipe shells). The roundness of the shell is important in fixing the maximum diameter of the baffles that can be inserted and therefore the effect of shell-to-shell baffle leakage. Pipe shells are more nearly round than rolled shells unless particular care is taken in rolling. In large exchangers, the shall is made out of low carbon steel wherever possible for reasons of economy, though other alloys can be and are used when corrosion or high temperature strength demands must be met.

Baffles
Baffles serve two functions; Most importantly, they support the tubes in the proper position during assembly and operation and prevent vibration of the tubes caused by flow-induced eddies, and secondly, they guide the shell-side flow back and forth across the tube field, increasing the velocity and the heat transfer coefficient.

Tube-Side Channel and Nozzles

Tube-side channels and nozzles control the flow of the tube-side fluid into and out of the tubes of the exchanger. Since the tube-side fluid is generally the more corrosive, these channels and clan instead of solid alloy.

Fig. 4 Baffle cuts (a) Baffle cuts for single segmental baffles. (b) Baffle cuts for double segmental baffles. (c) Baffle cuts for triple segmental baffles.

Selection of Shell and Tube Heat Exchanger Classes

TEMA Standards provide a Recommended Good Practice for the designers consideration in areas outside of the limits of the specified standards. Guidance and references are noted for seismic design, large diameter exchangers, tube vibration, tube-to-tube sheet stress analysis, nozzle loading analysis, and numerous other design-limiting features. Shell and tube heat exchanger technology for gas, chemical, and petroleum plants has developed a broad. exchangers, tube vibration, tube-to-tube sheet stress analysis, nozzle loading analysis, and numerous other design-limiting features. basis of common understanding through the Standards of Tubular Exchangers Manufacturers Association (TEMA). These TEMA Standards provide nomenclature, dimensional tolerances, manufacturers and purchasers responsibilities, general installation and operating guidelines, and specific design and fabrication practices.

The design and fabrication practices of TEMA are in three classifications, called Class R, C, or B. Class R includes heat exchangers specified for the most severe service in the petroleumchemical processing industry. Safety and durability are required for exchangers designed for such rigorous condition.

Class C includes heat exchangers designed for the generally moderate services and requirements. Economy and overall compactness are the two essential features of this class. Class B are heat exchangers specified for general process service. Maximum economy and optimum compactness are the main criteria of design.

Table 1 Comparison of TEMA Classes R, C and B Exchangers

Para.
1.12 Definition

Topic

R
For the generally severe requirement of petroleum and related processing application 1/8 inch 1.25 x tube OD. 1/4 inch lane.

C
For the generally moderate requirements of commercial and general process application 1/16 inch 1.25 x tube OD. Tube OD = 5/8 or less, may be located 1.2 x tube OD 1/8 inch alloy, 1/4 inch CS 1/4 inch in 6-15 inch Shells Diameter Same as tube flow area 600 psi maximum

B
For chemical process service 1/16 inch 1.25 x tube OD. Lane may be 3/16 inch in 12 inch and smaller shells. Minimum cleaning lanes 1/4" for shell diameter greater 12 1/8 inch alloy, 1/4 inch carbon steel 1/4 inch in 6-15 inch Shells Diameter Same as tube flow area (same as TEMA R)

1.51 2.5

Corrosion allowance on carbon steel Tube pitch and minimum cleaning lane

4.42 4.71 5.11 5.31

Longitudinal baffle thickness Minimum tie rod diameter Floating head cover crossover area Lantern ring construction

1/4 inch minimum 3/8 inch in 6 15 inch Shells Diameter 1.3 times tube flow area 375 oF maxi. 300 psi up to 24 inch diam. Shell 150 psi for 25-42 inch shells 75 psi for 43-60 inch shells Metal jacketed or solid metal for (a) internal floating head cover (b) 300 psi and up. (c) All hydrocarbons Flatness tolerance specified

6.2

Gasket materials

Metal jacketed or solid metal (a) internal floating head (b) 300 psi and up.

(Same as TEMA C)

6.32

Peripheral gasket contact surface

No tolerance specified

No tolerance specified

7.131

Minimum tube sheet thickness with expanded tube joints Tube Hole Grooving Length of expansion Tube sheet pass partition grooves Pipe Tap Connections Pressure Gauge connections Thermometer Connections Minimum bolt size

Outside diameter of the tube

7.44 7.51 7.6

Two grooves Smaller of 2 inch or tube sheet thickness 1/8 3/16 inch deep grooves required 6000 psi coupling with bar stock plug Required in nozzle 2 inch & up with one connection of 3/4 minimum NPS Required in nozzles 4 inch & up with one connection of 1 minimum NPS 3/4 inch

10.3 10.32 10.33 11.1

0.75 x tube OD for 1 inch and smaller. 7/8 inch for 1 1/4 OD 1 inch for 1 1/2 OD 1.25 inch for 2 OD Above 300 psi design pressure and/or above 350 oF design temp: 2 grooves Smaller of 2 x tube OD or tube sheet thickness 1/8 Over 300 psi 3/16 inch deep grooves required or other suitable means for retaining gaskets in place 3000 psi coupling (shall be specified by purchaser) (shall be specified by purchaser) 1/2 inch recommended, smaller bolting may be used

(Same as TEMA C) + In no case shall the total tube sheet thickness, including corrosion allowance, be less than 3/4" (Same as TEMA R) (Same as TEMA R) (Same as TEMA C)

3000 psi coupling with bar stock plug Required in nozzle 2 inch & up with one connection of 1/2 minimum NPS (Same as TEMA R) 5/8 inch

Selection of Shell and Tube Heat Exchanger Types Nomenclature

Fig 5 summarizes the major shell-and-tube exchanger components other than tubes and baffles. The letters are used for a standard nomenclature in the industry. A threeletter type designation in the order of front head type, shell type, and rear head is used. For example, an AJS would have a front head that is removable with a removable cover, a shell that is arranged for divided flow, and a rear floating head with a backing device (usually a split-ring).

Fig. 5 TEMA-type designations for shell and tube heat exchangers.

Principal Type of Construction

Fig. 5 shown details of the construction of the TEMA types of shell-and-tube heat exchangers. These and other types are discussed in the following paragraphs.

appropriate tie rods and spacers. The tube bundle can be removed from the heat-exchanger shell. A tube-side header (stationary head) and a shell with integral shell cover, which is welded to the shell, are provided. Each tube is free to expand or contract without any limitation being placed upon it by the other tubes. The U-tube bundle has the advantage of providing minimum clearance between the outer tube limit and the inside of the shell for any of the removable-tube-bundle constructions. Clearances are of the same magnitude as for fixed-tube-sheet heat exchangers. The number of tube holes in a given shell is less than that for a fixed-tube-sheet exchanger because of limitation of bending tubes of a very short radius. The U-tube design offers the advantage of reducing the number of joints. In high-pressure construction this feature becomes of considerable importance in reducing both initial and maintenance costs. The use of U-tube construction has increased significantly with the development of hydraulic tube cleaners, which can remove fouling residues from both the straight and the Ubend portions of the tubes. Kettle-type reboilers, evaporators, etc., are often U-tube exchangers with enlarged shell sections for vapor-liquid separation. The U-tube bundle replaces the floating-heat bundle of Fig.6e. The U-tube exchanger with copper tubes, cast-iron header, and other parts of carbon steel is used for water and steam services in office buildings, schools, hospitals, hotel, etc. Nonferrous tube sheets and admiralty or 90-10 copper-nickel tubes are the most frequently used substitute materials. These standard exchangers are available from a number of manufacturers at costs far below those of custom-built process-industry equipment.

Fixed-Tube-Sheet Heat Exchanger

Fixed-tube-sheet exchanger Fig. 6b are used more often than any other type, and the frequency of use has been increasing in recent years. The tube sheets are welded to the shell. Usually these extend beyond the shell and serve as flanges to which to tube-side header are bolted. This construction requires that the shell and tube-sheet materials be weldable to each other. When such welding is not possible, a blind gasket type of construction is utilized. The blind gasket is not accessible for maintenance or replacement once the unit has been constructed. This construction is used for steam surface condensers, which operate under vacuum. The tube-side header (or channel) may be welded to the tube sheet, as shown in Fig 5 for type C and N heads. This type of construction is less costly than types B and M or A and L and still offers the advantage that tubes may be examined and replaced without disturbing the tube-side piping connections. There is no limitation on the number of tube-side passes. Shell-side passes can be one or more, although shells with more than two shell-side passes are rarely used. Tubes can completely fill the heat-exchanger shell. Clearance between the outermost tubes and the shell is only the minimum necessary for fabrication. Between the inside of the shell and the baffles some clearance must be provided so that baffles can slide into the shell. Fabrication tolerances then require some additional clearance between the outside of the baffles and the outermost tubes. The edge distance between the outer of the baffles and the outer tube limit (OTL) and the baffle diameter must be sufficient to prevent vibration of the tube from breaking through the baffle holes. The outermost tube must be contained within the OTL. Tubes can replaced. Tube-side headers, channel covers, gaskets etc., are accessible for maintenance and replacement. Neither the shell-side baffle structure nor the blind gasket is accessible. During tube removal, a tube may break within the shell. When this occurs, it is most difficult to remove or to replace the tube. The usual is to plug the appropriate holes in the tube sheets.

Packed-Lantern-Ring Exchanger (Fig. 6f)

This construction is the least costly of the straight-tube removable bundle types. The shell-and tube-side fluids are each contained by separate rings of packing separated by a lantern ring and are installed at the floating tube sheet. The lantern ring is provided with weep holes. Any leakage passing the packing goes through the weep holes and then drops to the ground. Leakage at the packing will not result in mixing within the exchanger of two fluids. The width of the floating tube sheet must be great enough to allow for the packings, the lantern ring, and differential expansion. Sometimes a small skirt is attached to a thin tube sheet to provide the required bearing surface for packings and lantern ring.

U-Tube Heat Exchanger (Fig. 6d)

The tube bundle consists of the stationary tube sheet, U tubes (or hairpin tubes), baffles or support plates, and

The clearance between the outer tube limit and the inside of the shell is slightly larger than that for fixed-tube-sheet and U-tube exchangers. The use of a floating-tube-sheet skirt increases this clearance. Without the skirt the clearance must make allowance for tubeholes distortion during tube rolling near the outside edge of the tubesheet or tube-end welding at the floating tube sheet. The packed-lantern-ring construction is generally limited to design temperatures below 191 oC (375 oF)and to the mild services of water, steam, air, lubricating oil, etc. Design gauge pressure does not exceed 2068 kPa (300 lbf/in2) for pipe shell exchangers and is limited to 1034 kPa (150 lbf/in2) for 610 to 1067 mm (24 to 42 in.) diameter shells.

A split backing ring and bolting usually hold the floatinghead cover at the floating tube sheet. These are located beyond the end of the shell and within the largerdiameter shell cover. Shell cover, split backing ring, and floating-head cover must be removed before the tube bundle can pass through the exchanger shell. With an even number of tube-side passes the floatinghead cover serves as return cover for the tube-side fluid. With an odd number of passes a nozzle pipe must extend from the floating-head cover through the shell cover. Provision for both differential expansion and tube-bundle removal must be made.

Outside-Packed Floating-Head Exchanger (Fig. 6c)

The shell-side fluid is contained by rings of packing, which are compressed within a stuffing box by a packing follower ring. This construction was frequently used in the chemical industry, but in recent years usage has decreased. The removable-bundle construction accommodates differential expansion between shell and tubes and is used for shell-side service up to 4137 kPa gauge pressure (600 lbf/in2) at 316 oC (600 oF). There are no limitations upon the number of tube-side passes or upon the tube-side design pressure and temperature. The outside-packed floating-head exchanger was the most commonly used type of removable-bundle construction in chemical-plant service. The floating-tube-sheet skirt, where in contact with the rings of packing, has fine machine finish. A split shear ring is inserted into a groove in the floating-tube-sheet skirt. A slip-on backing flange, which in service is held in place by the shear ring, bolts to the external floatinghead cover. The floating-head cover is usually a circular disk. With an odd number of tube-side passes, an axial nozzle can be installed in such a floating-head cover. If a side nozzle is required, the circular disk is replaced by either a disked head or a channel barrel (similar to Fig. 6f) bolted between floating-head cover and floating-tube-sheet skirt.

Pull-Through (Fig. 6e)

Floating-Head

Exchanger

Construction is similar to that of the internal-floatinghead split-backing-ring exchanger except that the floating-head cover bolts directly to the floating tube sheet. The tube bundle can be withdrawn from the shell without removing either shell cover or floating-head cover. This feature reduces maintenance time during inspection and repair. The large clearance between the tubes and the shell must provide for both the gasket and the bolting at the floating-head cover. This clearance is about 2 to 2 times that required by the split-ring design. Sealing strips or dummy tubes are often installed to reduce bypassing of the tube bundle.

Internal Floating-Head Exchanger (Fig. 6a)

The internal floating-head design is used extensively in petroleum-refinery service, but in recent years there has been a decline in usage.

1. Stationary Head Channel 2. Stationary Head Bonnet 3. Stationary Head Flange Channel or Bonnet 4. Channel Cover 5. Stationary Head Nozzle 6. Stationary Tube sheet 7. Tubes 8. Shell 9. Shell Cover 10. Shell Flange Stationary Head End 11. Shell Flange Rear Head End 12. Shell Nozzle 13. Shell Cover Flange 14. Expansion Joint 15. Floating Tube sheet 16. Floating Head Cover

20. Slip-On Backing Flange 21. Floating Head Cover - External 22. Floating Tube sheet Skirt 23. Packing Box Flange 24. Packing 25. Packing Gland 26. Lantern Ring 27. Tie-Rods and Spacers 28. Transverse Baffles or Support Plates 29. Impingement Plate 30. Longitudinal Baffle 31. Pass Partition 32. Vent Connection 33. Drain Connection 34. Instrument Connection 35. Support Saddle

17. Floating Head Flange 18. Floating Head Backing Device 19. Split Shear Ring

36. Lifting Lug 37. Support Bracket 38. Weir 39. Liquid Level Connection

Fig. 6 Heat-Exchanger-Component nomenclature. (a) Internal-floating-heat exchanger (with floating-head backing device). Type AES. (b) Fixed-tube-sheet exchanger. Type BEM. (c) Outside-packed floating-head exchanger. Type AEP. (d) U-tube heat exchanger. Type CFU. (e) Kettle-type floating-head reboiler. Type AKT. (f) Exchanger with packed floating tube sheet and lantern ring. Type AJW. (Standard of Tubular Exchanger Manufacturers Association)

Table 2 Features of TEMA Shell and Tube Type Exchangers

Type of design Fixed tubesheet L or M or N B U-tube Packed lantern-ring floating head W C Internal floating head (split backing ring) S E Outsidepacked floating head P D Pullthrough floating head T E

TEMA rear-head type Relative cost increases from A (least expensive) through E (most expensive) Provision for differential expansion Removable bundle Replacement bundle possible Individual tubes replaceable Tube cleaning by chemicals inside and outside Interior tube cleaning mechanically Exterior tube cleaning mechanically: Triangular pitch Square pitch Hydraulic-jet cleaning: Tube interior Tube exterior Double tubesheet feasible Number of tube passes Internal gaskets eliminated

U A

Expansion joint in shell No No Yes Yes Yes

Individual tubes free to expand Yes Yes Only those in outside row Yes Special tools required

Floating head Yes Yes Yes Yes Yes

Floating head Yes Yes Yes Yes Yes

Floating head Yes Yes Yes Yes Yes

Floating head Yes Yes Yes Yes Yes

No Yes Yes No Yes No practical limitations Yes

No Yes Special tools required Yes Yes Any even number possible Yes

No Yes Yes Yes No Limited to one or two passes Yes

No Yes Yes Yes No No practical limitations No

No Yes Yes Yes Yes No practical limitations Yes

No Yes Yes Yes No No practical limitations No

NOTE : Relative costs A and B are not significantly different and interchange for long lengths of tubing. U-tube bundles have been built with tube supports which permit the U-bends to be spread apart and tubes inside of the bundle replaced. Normal triangular pitch does not permit mechanical cleaning. With a wide triangular pitch, which is equal to 2 (tube diameter plus cleaning lane)/ 3, mechanical cleaning is possible on removable bundles. This wide spacing is infrequently used. For odd number of tube side passes, floating head requires packed joint or expansion joint.

Table 3 Application Shell and Tube Types

Type Significant Feature Designation Fixed Tube Both tube sheets fixed to sheet shell Applications Best Suited Condensers; liquid-liquid; gas-gas; cooling and heating, horizontal or vertical, reboiling High temperature differentials, above about 200 oF. Extremes; dirty fluids requiring cleaning of inside as well as outside of shell, horizontal or vertical. High temperature differentials which might require provision for expansion in fixed tube units. Clean service or easily cleaned conditions on both tube side and shell side. Horizontal or vertical. Boiling fluid on shell side, as refrigerant, or process fluid being vaporized. Chilling or cooling of tube side fluid in refrigerant evaporation on shell side Limitation Temperature difference at extremes of about o 200 F. Due to differential expansion Internal gaskets offer danger of leaking. Corrosiveness of fluids on shell side floating parts. Usually confined to horizontal units Bends must be carefully made or mechanical damage and danger of rupture can result. Tube side velocities can cause erosion of inside of bends. Fluid should be free of suspended particles For horizontal installation. Physically large for other applications Relative Cost in Carbon Steel Construction 1.0

Floating Head or Tube sheet (removable and nonremovable bundles) U-Tube; UBundle

One tube sheet floats in shell or with shell, tube bundle may or may not be removable from shell, but back cover can be removed to expose tube ends Only one tube sheet required. Tubes bent in Ushape. Bundle is removable

1.28

1.08

Kettle

Tube bundle removable as U-type or floating head. Shell enlarged to allow boiling and vapor disengaging

1.2 1.4

References
1. 2. 3. 4. Standard of Tubular Exchanger Manufacturers Association, Eight Edition 1999 Perrys Chemical Engineers Handbook, Copyright 1999 by The McGraw-Hill Company, Inc. A. Keith Escoe, Mechanical Design of Process Systems Volume 2, 1986 Wolverine Engineering Data Book II by Wolverine Tube, Inc Research and Development Team, 2001 thought and suggest to

THE AUTHOR
Drajad AW is a Mechanical Engineer with PT Technip Indonesia responsible for Package Equipments. After graduating from Sepuluh Nopember Institute of Technology (ITS) with a B.Sc degree in Marine Engineering, he joined PT. Mafhindo Utama, PT Indo-Laval, PT. Erraenersi Konstruksindo, PT. Rekayasa Industri, PT. Istana Karang Laut, Malaysia Marine and Heavy Engineering SDN BHD. He was for eight years the Static Engineer (Pressure Vessels, Tanks, Filters, etc) and Package Equipments Engineer.

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