HEAT EXCHANGERS: A Practical Approach to Mechanical Construction, Design, and Calculations M. Podhorsky H. Krips Deutsche Babcock Balcke-Diirr, Diisseldorf, Germany English Edition Editors USA. UK with a Foreword by André Bazergui, Canada Begell House, Inc. New York ¢ Wallingford, U.K. an affiliate of Byelocorp Scientific, Ine. and Supeo, s.r New York - Milan, ItalyHEAT EXCHANGERS: A Practical Approach to Mechanical Construction, Design, and Calculations Copyright © 1998 by Begell House, Inc. All rights reserved. Printed in the United States of America, XCept as permitted under the United States Copyright Act of 1976, no part of this Publication may be reproduced or distributed in any form or by any means, of stored in g «lata base or retrieval yystem, without the prior written permission of the publisher Direct all inquiries to Begell House, Inc., 79 Madison Avenue, New York, NY 10016, ion Data Library of Congress Cataloging-in-Publi Podhorsky, M [Warmetauscher. English] Heat exchangers : a practical approach to mechanical construction, design. and calculations / M. Podhorsky, H. Kips ; E William Begell, Mike Morris p. em, Includes bibliographical references. ISBN 1-56700-117-3 1. Heat exchangers —De M Title T3263.P63 1998 98-1857 621.402'5—de21 cr sh edition editors, and construction, 1. Krips, H.HEAT EXCHANGERShe BDAG Group company, Balcke-Durr GmbH, is one ‘ofthe leading international suppliers of power engineering systems and components for power stations, waste incineration plants as well as for the chemical and gaLcxe-DORA GMBH 0-92 Ratnpn Teor 4821006850 Petrochemical sectors. it supplies heat exchangers and cooling towers, energy-saving systems, decentralized power generation systems and turnkey chemical plants. More than one thousand highly qualified engineers and design draughtsmen are on hand to provide comprehensive expertise and innovative problem solutions. Worldwide, of ‘course. DEUTSCHE BABC CK BDAG GROUPCONTENTS Foreword Preface Introduction Heat Exchangers for Power Stations 1 Heat Exchanger Tubes 1.1 Erosion and Corrosion-Erosion 1.2. Droplet Impact Untube Steam Generator Straight-tube Steam Generator Bibliography 1 I 1 1.1.3. Corrosion 1.14 Crevice Corrosion and Contact Corrosion 1.1.3. Stress Corrosion Cracking 1.1.6 Vibration Damage 1.2 Pressure Shell 1.2.1 Heater Water Box 1.22 Heater Shell 1.2.3 Venting of the Steam Space 1.24 Drain Cooler 1.3. Vessel Shell 1.3.1 Feedwater Tank and Deaerator 14 Multistage Heater 1.5 The Heat Exchanger for Process Heat Recovery ! 1s Calculation of Structural Stresses Using the Force Method 2.1 Introduction 2.2. Application of the Force Method in the Construction of Heat Transfer Equipment 2.3 Flat Heads 24 Dished Heads 2.5 Spherical Shells 2.6 Cylindrical Shells 2.7 Conical Shells 28 Tubesheet 29 — Rings 2.10 Combination of Individual Elements Bibliography 19 19 21 4 26 29 31 31 36 49 60 4 70 Rh 15 BContents, Calculation of Tubesheets 79 3.1 Introduction 9 3.2. Design of the Tubesheet According to Standards 9 3.3. How to Calculate the Perforated Section 80 34 Example of Tubesheet Analysis, 81 Bibliography 4 Design of Flanges for Pressure Vessels 87 4.1 Introduction 87 4.2 Bolt Design 88 4.3 Selection of Gaskets 90 44° Dimensioning Flanges According to Codes Oy 4.5 Dimensioning of Flanges Using the Deformation Calculation 97 4.6 Structure of the Restraint Diagram ug 4.7 Causes of Possible Leaks 126 Bibliography 129 Methods of Fastening Tubes in Tubesheets and Headers 131 5.1 Introduction 131 5.2 Welding of Tubes 132 5.3. Roller Expansion of Tubes 134 54 Hydraulic Expansion of Tubes 143 5.5 Fastening of Tubes by Explosion 175 Bibliography Isl Appendix, Additional Biblio; Topical References aphy List of Standards and Programs List of MateriFOREWORD Thave been aware of and quite impressed by the work of Dr. M. Podhorsky and his co- author, H. Krips, for a number of years, in particular for their exceptional contribution to the development of the hydraulic expansion process for the manufacturing of tube: tubesheet joints. I was therefore delighted and honored to have been invited by Dr. Podhorsky to write a foreword for the English translation of his book on Heat Exchangers. This book offers an interesting overview of procedures for designing heat exchi pressure vessels: although the approach is based mainly on the German Code standards, it regularly refers to and provides comparisons with the ASME Code, The authors draw extensively from their wide industrial experience combined with a thorough understanding of the theory underlying the code procedures. Their approach is nd easy to follow and they use numerous illustrations to make their point, They went his or systematic cover the field with just necessary details and leave it to the reader to complei her information from the available design codes. Chapter | provides an excellent description of the many types of heat exchangers, found in the field, their applications, and the many practical problems that could be encountered (in particular those related to corrosion and vibration damage), It isan for the experienced and inexperienced designers alike. Detailed design procedures are given in Chapters 2 and 3. While Chapter 2 provides lysis approach for computing the stresses in the various pressure vessel components, Chapter 3 looks particularly at the design of tubesheets, | was particularly interested in the authors’ handling of the gasketed bolted flang joint in Chapter 4. They are among the few who have tackled the problem in a complete ‘manner, .c., a a complex mechanical assembly whose purpose is to operate satisfactorily not only in terms of pressure integrity but also in terms of leak tightness. It is, of course, beyond the scope of this book to cover in detail the extensive research work—more specifically that sponsored by the Pressure Vessel Research Council—that has recently been carried out of gasket evaluation alone, But it is interesting that their approach systematically takes into account the gasket as a full fle analysis. T and a new design procedure for were pioneers in their approach. Chapter 5 on Methods of Fastening Tubes to Tubesheets and Headers is, by itself, a justification to buy this book. It offers an excellent overview of the various: methods available for securing @ tight joint between the tube and the tubesheet. The authors cover all the methods in detail includin pioneered. Hay excha: excellent “entré details on the discontinuity at «d mechanical element in the fact that the ASME code is considering the introduction of new gasket factors isketed flanged joints is an indication that the authors of course, the hydraulic expansion process which they ig personally carried out research on the residual stresses generated in heat tubes by the various expansion processes discussed in the book, | ean only but concur that the hydraulic process is the one that generates the least unwanted residual stresses while ensuring a systematic and uniform tube-tubesheet jointForeword This book, first published in German, was long overdue in its English version. Hopefully it will contribute to a better understanding of two design philosophies which, appear to be different but which are in fact basically quite similar. T wish the authors the best of luck and encourage them to purstie their exeellent work. André Bacerui, Ph.D., Eng. Professor of Mechanical Engineering Director General, Ecole Polstechnique de Montréal Montréal, CanadaPREFACE Heat transfer, mass transfer, and storage are the three most significant elements in pressure vessel de: The sequence in which these are indicated here also reflects the significance in which the respective elements need to be considered. The heat exchanger as a surface heat exchanger is not only the most frequent but often also the most sophisticated component in a plant, The problems connected with this compo- nent will be considered in detail. The procedure diagram below illustrates in rough stages the effects to be taken into account when designing the vessel: it is applicable for all vessels, ‘Standards such as ASME, BS, AD, TRD. etc... set out the minimum requirements for pressure vessel construction. If the conditions specitied in the standards are complied with, then the vessel is des ned appropriately for its operating conditions. This is, however, where the function of the standards ends. It is then the task of the design e that a component desi heer to ensure sd on this basis + optimally fulfils its process funetion. + has a high degree of operating. availability + can be manufactured economically This book is intended to provide assistance in solving the questions that arise in designing a vessel, It is based on the extensive experience gained by the authors during their many years with Balcke-Diirr GmbH. The authors wish to thank the executive board of Balcke-Dirr GmbH for their constructive support and for consenting to the use of the drawings and photographs. ‘eis of Reference i | PRELIMINARY DESIGN Senger “eee Pressure tet tess cortonon cracking, Etosen forte i T 2. DESIGN i 2 FINAL DESIGN