Shell and Tube Heat Exchanger

Part 1

Lecturer:

Ir. I Made Astina, M.Eng., Ph.D.

Associate Professor of Mechanical Engineering

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 Content
 Configuration
 Component
 Scope of Application
 TEMA Standard
 Type of Attachment of Tube on Tubesheet
 Tube Passes

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 Learning Objective
 Able to explain configuration, components of
shell and tube heat exchanger and scope of
application
 Introduce TEMA Standard
 Understanding of type of attachment of tube on
tube sheet, and tube passes

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 Shell and Tube Heat Exchangers

 The shell and tube heat exchanger is the most common style found
in industry.
 It is accounted for 85% of new exchangers supplied to oil-
refining, chemical, petrochemical and power companies
 As the tube side flow enters the exchanger, flow is directed into
tubes that run parallel to each other. These tubes run through a
shell that has a fluid passing through it
 It can be designed for almost any duty with a very wide range of
temperatures and pressures
 It can be built in many materials

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 Cont’d
 There are many suppliers
 Repair can be done by non-specialists
 Design methods and mechanical codes have been established
from many years of experience
 Heat energy is transferred through the tube wall into the cooler
fluid
 Heat transfer occurs primarily through conduction and
convection

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 Scope of shell-and-tube Hex
 Maximum pressure
 Shell 300 bar (4500 psia)
 Tube 1400 bar (20000 psia)
 Temperature range
 Maximum 600oC (1100oF) or even 650oC
 Minimum -100oC (-150oF)
 Fluids
 Subject to materials
 Available in a wide range of materials
 Size per unit 100 - 10000 ft2 (10 - 1000 m2)
Can be extended with special designs/materials

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 Construction
 Bundle of tubes in large cylindrical shell
 Baffles used both to support the tubes and to direct into
multiple cross flow
 Gaps or clearances must be left between the baffle and the
shell and between the tubes and the baffle to enable assembly

Shell

Tubes

Baffle

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Fixed head, single pass heat exchanger
 Plate Mark

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 TEMA standards

 The design and construction is usually based on TEMA 9th

Edition 2008 or newer  TEMA 10th 2019
 Supplements pressure vessel codes like ASME and BS 5500
 Sets out constructional details, recommended tube sizes,
allowable clearances, terminology etc.
 Provides basis for contracts
 Tends to be followed rigidly even when not strictly
necessary
 Many users have their own additions to the standard which
suppliers must follow
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 TEMA Type Code

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 TEMA terminology

Rear end
Front end head type
Shell
stationary head type

 Letters given for the front end, shell and rear end types
 Exchanger given three letter designation
 Above is AEL

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 Front head type
 A-type is standard for dirty tube side
 B-type for clean tube side duties. Use if possible since cheap and
simple.

A B

Channel and removable cover Bonnet (integral cover)

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 More front-end head types
 C-type with removable shell for hazardous tube-side
fluids, heavy bundles or services that need frequent
shell-side cleaning
 N-type for fixed for hazardous fluids on shell side
 D-type or welded to tube sheet bonnet for high pressure
(over 150 bar)

C N D

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 Shell type
 E-type shell should be used if possible but
 F shell gives pure counter-current flow with two tube passes
(avoids very long exchangers)

Longitudinal baffle
E F

One-pass shell Two-pass shell

Note, longitudinal baffles are difficult to seal with

the shell especially when reinserting the shell after
maintenance
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 More Shell types
 G and H shells normally only used for horizontal
thermosyphon reboilers
 J and X shells if allowable pressure drop can not be achieved
in an E shell

G H
Longitudinal
Split flow baffles Double split flow

J X

Divided flow Cross flow

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 Rear Head type
These fall into three general types
 fixed tube sheet (L, M, N)
 U-tube
 floating head (P, S, T, W)
Use fixed tube sheet if T below 50oC, otherwise use other
types to allow for differential thermal expansion
You can use bellows in shell to allow for expansion but these
are special items which have pressure limitations (max. 35
bar)

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 Fixed Rear Head types

Fixed tube sheet

 L is a mirror of the A front end head

 M is a mirror of the bonnet (B) front end
 N is the mirror of the N front end

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 Floating Heads and U Tube

Allow bundle removal and mechanical cleaning on

the shell side
 U tube is simple design but it is difficult to clean the tube
side round the bend

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 Floating Heads
T S

Pull through floating head Similar to T but with smaller shell/

Note large shell/bundle gap bundle gap

Split backing ring

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 Other Floating Heads
 Not used often and then with small exchangers

Outside packing to give Externally sealed floating tube sheet

smaller shell/bundle gap maximum of 2 tube passes

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Shell and Tube Heat Exchanger: Head
The head can be classified as front-end or rear-end
types, the front-end head has five primary designs,
the rear-end has eight possible designs

Head Designs 24
Shell and Tube Heat Exchanger: Shell

 In most cases, the shell is designed to withstand the

greatest temperature and pressure condition
 The shell is the largest single part of the heat exchanger
 The shell can be classified as single-pass, double-pass,
split flow, double split flow, divided flow, cross-flow

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 Shell-side flow

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 Shell and Tube Heat Exchanger: Tube

 Tube can be plain or dinned

 Plain tubes are commonly used in fabrication
 Finned tube are starting to make an impact, fins can be located
externally or internally
 Tube materials include brass, carbon, …

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Shell and Tube Heat Exchanger: Tubesheet

 Tubesheets are often described as fixed or floating, single

or double
 Tubesheets have carefully drilled hole, the ends of the
tubes in a heat exchanger are fixed by rolling, welding,
or both
 Double tubesheets are used to prevent tube side leakage
of highly corrosive fluids

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Shell and Tube Heat Exchanger: Tube Sheet

 Engineering specifications take into account thermal

tube expansion
 If the tube sheet is welded or bolted to the shell, it is
called fixed
 If the tube sheet is independently secured to the tub head
and is allowed to move freely inside the shell, it is called
floating

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 Shell and Tube Heat Exchanger: Baffle

 Baffles provide the framework to support and

secure the tubes and prevent vibration
 The baffle layout increases or decreases fluid and
directs flow at specific points
 Tube side baffles are built into the heads to direct
tube side flow
 In multi-pass exchangers, cost goes up with each
pass, provide adequate fluid velocities to prevent
fouling and to control heat transfer

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Shell and Tube Heat Exchanger: Baffle(cont’d)

 Each segmental baffle supports half of the tubes

 Baffles are evenly spaced
 Segmental baffles may be horizontal or vertical cut
 Systems transferring large quantities of suspended solids may use
vertical arrangement, which allows liquid and solids to flow around
baffles
 Horizontal baffles are used in clean service with notches at the bottom
to allow liquid drainage on removal from serve

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Shell and Tube Heat Exchanger: Baffle (cont’d)

 Impingement baffles are used to protect tubing from direct

fluid impact
 Longitudinal baffles are used inside the shell to split or
divide the flow, increase velocity, and provide superior heat
transfer capabilities, longitudinal baffles do not extend the
entire length of the exchanger since at some point the fluid
must flow around it.

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 Shell and Tube Heat Exchanger: Tie Rod

 Tie rods and concentric tube spacers keep the

baffles in place and evenly spaced
 Each hole in the baffle plates is 1/64” larger than
the tube’s outside diameter

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 Shell and Tube Heat Exchanger
: Nozzles and Accessory Part

 Nozzles and accessory part

 Inlet and outlet nozzles are sized for pressure drop and
velocity considerations
 Thermowells, pressure indicator connections, safety and
relief valves, product drains, vents, block valves and
control valves

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 Shell and Tube Heat Exchanger
: Fixed Head

 In a fixed head, single pass shell and tube heat

exchangers, the tubes are connected to two tube
sheets which are firmly attached to the shell
 In the multi pass Shell and tube heat exchangers,
the baffle added to the channel head and the lack of
a tube side outlet on the discharge head
 Temperature differential is less to 200oC

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 Shell and Tube Heat Exchanger
: Floating Head

 One side of the tube bundle is fixed to the channel head,

the other side is unsecured.
 Floating head exchangers, with their high cross-sectional
areas (fins), are designed for high temperature
differentials and high flow rate, produces the highest heat
transfer efficiency.

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 Shell and Tube Heat Exchanger
: U-Tube

The tube sheet connects a series of tubes bent in a U

shape, the ends of the tubes are secured to the tube sheet
 The total number of tubes is limits
 Large temperature differentials
 Each complete U tube has a single fundamental frequency

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 Tube Passes
 A pass is when liquid flows all the way across from one end to the other of
the exchanger. We will count shell passes and tube passes.
 An exchanger with one shell pass and two tube passes is a 1-2 exchanger.
Almost always, the tube passes will be in multiples of two (1-2, 1-4, 2-4,
etc.)
 Odd numbers of tube passes have more complicated mechanical stresses,
etc. An exception: 1-1 exchangers are sometimes used for vaporizers and
condensers.
 A large number of tube passes are used to increase the tube side fluid
velocity and heat transfer coefficient and minimize fouling.
 This can only be done when there is enough pumping power since the
increased velocity and additional turns increases the pressure drop
significantly.
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 Tube Passes (cont’d)
 The number of tube passes depends on the available pressure drop.
 Higher velocities in the tube result in higher heat transfer coefficients,
at the expense of increased pressure drop.
 Therefore, if a higher pressure drop is acceptable, it is desirable to have
fewer but longer tubes (reduced flow area and increased flow length).
 Long tubes are accommodated in a short shell exchanger by multiple
tube passes.
 The number of tube passes in a shell generally range from 1 to 10
 The standard design has one, two, or four tube passes.
 An odd number of passes is uncommon and may result in mechanical
and thermal problems in fabrication and operation.

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 Multiple Shell-Side Passes
 In an attempt to offset the disadvantage of values of F less than 1.0
resulting from the multiple tube side passes, some manufacturers
regularly design shell and tube exchangers with longitudinal shell-side
baffles.

The two streams are always countercurrent to one another,

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therefore superficially giving F = 1.0.
 Multiple Shells in Series

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 Discussion

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