PART UG GENERAL REQUIREMENTS

Fig. UG-34

Center of weld

ts

Y t

tf min. = 2ts
Tangent ts line r = 3t min. t

ts t rmin. = 0.375 in. (10 mm) s for ts 11/2 in. (38 mm) rmin. = 0.25ts for ts 11/2 in. (38 mm) but need not be greater than 3/4 in. (19 mm)

Center of lap

tf r = 3tf min. t C = 0.17

(b-1)

Y t

d t C = 0.33m C min. = 0.20 (b-2)

Taper

d C = 0.17 or C = 0.10 (a)

Tangent line r = 3t min. t

C = 0.30 C = 0.20 or 0.13 (c) tw = 2tr min. nor less than 1.2ts but need not be greater than t

t r = 1/4t
min.

0.7ts

0.7ts

0.7ts

ts

Projection beyond weld is optional Bevel is optional

d t C = 0.13
(d)

ts

0.7ts

ts

Continuation t of shell optional (f)

45 deg max.

Sketches (e), (f), and (g) circular covers, C = 0.33m, Cmin. = 0.20 (e) (g)

See Fig. UW-13.2 sketches (a) to (g), inclusive, for details of welded joint ts not less than 1.25tr

See Fig. UW-13.2 sketches (a) to (g), inclusive, for details of outside welded joint 0.7ts

hG

hG

ts

ts t

d t C = 0.3 [Use Eq. (2) or (5)] (j) t

d C = 0.3 [Use Eq. (2) or (5)] (k)

C = 0.33
(h)

C = 0.33m C min. = 0.20 (i)

d t C = 0.30 (m)

Retaining ring

d t C = 0.30 (n) ts t

Threaded ring

d t C = 0.30 (o)

t1

30 deg min. 45 deg max.

Seal weld 3/ t min. 4 t 0.8ts min. or

d d t C = 0.25 (p)
When pipe threads are used, see Table UG-43

d
min. t1 = t or ts whichever is greater C = 0.33 (r)

d C = 0.33 (s)

C = 0.75 (q)

FIG. UG-34 SOME ACCEPTABLE TYPES OF UNSTAYED FLAT HEADS AND COVERS The Above Illustrations Are Diagrammatic Only. Other Designs That Meet the Requirements of UG-34 Are Acceptable.

01

39

4.3.6-2 (c) Order calculation

4.3 SHELL-AND-TUBE DESIGN CODES

4.3.6 TEMA Type AJS

For a heat exchanger with a floating tubesheet, assuming that the tube layout is known, it is advisable to design the floating-head cover first. This will confirm if there is sufficient space within the shell and outer tube limit circle diameter to fit the required gasket. The shell, channel, and shell cover cylinder thicknesses may then be calculated. The remaining components may then be designed at random. For this design, the selected tube wall thickness is checked, followed by the design of the flanges and end enclosures. The tubesheets and nozzles calculations complete the calculations for components subjected to pressure. Finally, the dimensions of the nonpressure components are determined. and for material The units used for pressure are stresses are as specified in the nomenclature (1 = 1 newton per square meter).

For external pressure (shell side), the rules in UG-33 apply. A thickness is assumed, and the procedure appropriate to the shape of the formed end is followed. From TEMA R-3.13, the minimum allowable corroded plate thickness is 6.35 mm. Assume that tfhd = mm and confirm this, using the procedure in UG-33(c). 0.125 0.125 = maximum allowable design pressure
B ch

(3) From materials chart, Fig. UCS-28.2, = 14 500 = 99 978 Therefore = 14 500 X 6.895

B. Floating-head cover (a) Flange and dish

The floating-head cover is a spherically dished cover designed to UA-6 (4)(b), Fig. see also Sec. The minimum dish thickness is the greater of the tube-side or shell-side requirements. = tube-side corrosion allowance = 3 mm = shell-side corrosion allowance = 3 mm For internal pressure (tube side), a

99 978

This is less than the shell-side design pressure (2 000 therefore assume that 9 mm and repeat the calculation. factor A factor = 15 200 = 104 804 Therefore a 104 804 105
3

= 15 200 X 6.895

where P = = 500 L is the dish corroded inside radius (mm), and is the maximum allowable stress = 121 Assuming that the shell-to-floating tubesheet, radial clearance is mm and assuming a gasket width of 13 mm (TEMA minimum = 12.7 mm), then the flange corroded inside diameter
B = 635 +

This is greater than the shell-side design pressure; therefore a corroded dish thickness of 9 mm is satisfactory. = dish uncorroded thickness 15mm = dish uncorroded inside radius

13) = 599 mm

The flange uncorroded inside diameter is

(b) Flange design

Assume that the dish uncorroded inside radius is 0.75 X 593 = 445 mm; then
L = 445 + = 445 + 3 = 448

mm

Therefore
=

500 448 6X 121

The flange design thickness is the greatest thickness of that required for gasket seating, tube-side pressure, and shell-side pressure, or from geometric considerations to allow for sufficient crossover flow area. The positioning of the dish relative to the flange centroid is an important part of the design calculations; there are numerous methods of approach. For this example the procedure used is as follows.

1983 Hemisphere Publishing Corporation

4.3 SHELL-AND-TUBE DESIGN CODES

4.3.6 TEMA Type AJS

4.3.6-3

1. Calculate the flange thickness required for gasket seating.

2. Calculate the flange thickness required for the

J = and

SB

A - B

crossover flow area. 3. Use the greater thickness of (1) or (2) and
position the outer edge of the dish at the back of the

(for internal pressure)

flange.
4. Calculate the loads and moments exerted on the

(for external pressure) (for gasket seating) The flange bolt loads and moments are given in Table 1. Note: is the product of and h,. The dish should is always negative; that is, be positioned such that the dish and tubesheet should always be on the opposite sides of the flange centroid; the absolute value of is used to determine the flange thickness. For gasket seating,

flange by the tube-side and shell-side pressures. 5. If the flange is overstressed, hold the dish position (thereby keeping the moments constant) and add equal increments to both sides of the flange until an
acceptable thickness has been obtained.

The general equation for the flange thickness is given in UA-6, where

Therefore -B)
F = O

a n d

Table 1 Floating-head cover bolting and flange moments calculations

Design conditions Tube-side design pressure = 500 Shell-side design pressure = 2 000 Design temperature = 100 C Flange and dish material = SA-5 15-70 material = SA-193-B7 Tube-side corrosion allowance = 3.0 mm Shell-side corrosion allowance = 3.0 mm Allowable stresses, Flange Bolting Design temperature Atmospheric temperature Design temperature Atmospheric temperature 121 121 172 172

Gasket and bolting calculations Gasket-soft steel jacket asbestos filled 625 mm OD X 599 ID X 3, with pass partition webs 10 mm wide = 6.5 mm b = 6.425 mm m = 3.75 y = 52.4 = gasket OD 2b = 625 2 X 6.425 = 612.15 mm = = 647 459 N A,,, = greater of or = 3 764 W = = 46 335 N Use 24 M20 bolts x = 147 081 N = 24 X 214.89 = 5 157 mm* H= W W= = 767 206 N = = 588 322 N + 0.661 9 4 1.44 TEMA minimum = 12.7 mm, or or where Gasket width check: N and 2.9 mm A = 702 mm B = 599 mm BCD = 660 mm Condition Tube-side operating = 252 159 515 Shell-side operating
X

4.4 mm

Load, N X 140 829

Lever arm, mm = = = = 20.0 = 30.5 = 23.95 = 27.225

Moment, N m 295 = 170 190 = 2 385 3 690 82 761 = -8 989 18 374

563 317

638 059 Gasket seating 767 206

= 6.55 3.275 = 20.00 = 23.95

1983 Hemisphere Publishing Corporation

4.3.6-4
18374Nm and 702 + 599 702 - 5 9 9 = = 121

4.3 SHELL-AND-TUBE DESIGN CODES

4.3.6 TEMA Type AJS

t=

121 X 599 702 18 374 X 121 X 599 t = 8.00 +

599

= 1 566.62

+ 1 566.62 = 48.38 mm

For crossover flow area, from TEMA R-8.12 the actual crossover flow area is to be at least 1.3 times the flow area through one tube pass. There are 468 tubes, 19.05 mm OD X 2.11 mm wall thickness, arranged in four tube passes. Flow area/tube pass = (19.05 2 X 2.1

Therefore, with the dish positioned at the back of the flange, a corroded flange thickness of 57 mm is satisfactory. The cover will have a pass partition plate 13 mm thick, tapered at one end to 10 mm to suit the gasket web; see TEMA R-8.13. The flange will be recessed to confine the gasket. The cover dimensions are given in Fig. and a summary of the flange dimensions is given in Table 11 (flange no. 6).

The total required crossover area is

(c) Floating-head backing device

The backing device clamps the floating-head cover to the tubesheet. There are various types; for this design UG-53(a). a single split ring is used, designed to The split ring is designed as if it were a solid flange (without splits) using 200% of the greater of or calculated in the mating flange design. From Table is greater than for either the tube-side or side operating conditions. The effective thickness, (7) Shape constant,
B 599

The segmental area of the dish = 46 012 If the effect of the pass partition plates is neglected, the area available under the dish for crossover flow per pass is 46 012 X 0.5 = 23 006 If the dish is excluded, the depth of flange required for crossover flow area per pass is 593 x 0.5 Obviously, even allowing for the dish, the gasket seating will require a greater thickness than that for crossover flow area. Assume a corroded flange thickness of 57 mm and position the dish at the back of the flange; check the thickness for internal and external pressures. For internal pressure (tube side):

Hence Y = 12.31 from Fig. UA-5 1 from Table 1

B = 599

18374Nm 121 where 500 X 8X 121 X 599 702 599 X X 599) = 415.64
=

121

mm

12.31 X 18 374 X 2 121 x 599 x

There will be a recess (5 mm) deep to locate the spit ring on the tubesheet. The dimensions of the backing ring are given in Table 11 (flange no. and in Fig. 1.

For external pressure (shell side):

C. Cylindrical shells
The minimum allowable wall thickness for cylindrical shells is the greater of the or TEMA requirements; see also Sec. The minimum thickness, exclusive of corrosion allowance will be the greater thickness from the formulas in UG-27. For circumferential stress (longitudinal joints):

S= where

= 121

2 000 X 8X

X 599)

1983 Hemisphere Publishing Corporation

4.3 SHELL-AND-TUBE DESIGN CODES

4.3.6 TEMA Type AJS

4.3.6-S

24

HOLES 24 DIA

Figure 1

Floating-head cover and backing device.

For longitudinal stress (circumferential joints):

wall thickness is usually the preferred gauge from TEMA Table R, C, or B, -2.21. The tube length plays an important part in the thermal performance of the exchanger, so the length should not be altered without the agreement of the thermal designer. = tube outside diameter = 19.05 mm

For this example the weld examination is spot throughout, thus the joint efficiency E = 0.85 for all welded joints (see UW-12); Eq. (9) can therefore be neglected. The calculations of cylinder thickness are summarized in Table 2. In practice, the selected plate thickness is not necessarily the minimum allowable thickness rounded up to the nearest millimeter. The availability of material may be the deciding factor, or the designer may select a thicker wall to increase the area available for reinforcement at the nozzle locations. The channel will have pass partition plates, of the same material, 13 mm thick, tapered at both ends to 10 mm thick to suit the webs of the gaskets.

tube wall thickness = 2.11 mm = tube-side (internal) pressure = 500 = shell-side (external) pressure = 2 000 S = maximum allowable stress = 121
E=

joint efficiency = 1 = tube inside radius = = 7.415 mm 2 X 2.11)

For internal pressure the minimum allowable thickness is calculated using Eq. (8): - - = 500 x

D. Tubes
X The minimum allowable wall thickness is determined UG-31; see also Sec. The tube from dimensions are specified by the thermal designer. The
1983 Hemisphere I

7.415 121 X 1.00 -0.6 X 500 X

= 0.031 mm UG-28 are

For external pressure the rules in

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