Compress Heat Exchanger

[ Mechanical Engineering ]
S&T Heat Exchanger

BASIC CONSTRUCTION AND TEMA TYPE SELECTION
Copyright ⓒ2009
Copyrightⓒ2009 Samsung
Samsung Engineering
Engineering Co.,
Co., Ltd.
Ltd. AllAll rights
rights reserved
reserved
Table of Contents
PART – I
BASIC CONSTRUCTION
What is a Shell and Tube Heat Exchanger

N-2 Nomenclature of Heat Exchanger Components
N-1.2 TEMA Type Designation
RCB-1 TEMA Class Designation
RCB-2 Tubes
RCB-3 Shells and Shell Covers
RCB-4 Baffles and Support Plates
RCB-5 Floating End Construction
RCB-6 Gaskets
RCB-7 Tubesheets
RCB-8 Flexible Shell Elements
RCB-9 Channels, Covers, and Bonnets
RCB-10 Nozzles
Copyright ⓒ2009 Samsung Engineering Co., Ltd. All rights reserved 2

Table of Contents
PART – II
TEMA TYPE SELECTION
1 Classification of STHEs based on Service

2 Front End Head Type and its Application
3 Shell Type and its Applications
4 Rear End Head Type
(Classification of STHE based on Construction)
5 Rear End Head Type (Design Features and Applications)
6 TEMA Type Selection Guide

PART - I
SHELL AND TUBE HEAT EXCHANGER
BASIC CONSTRUCTION

What is a Shell and Tube Heat Exchanger
A shell and tube heat exchanger is a class of heat exchanger designs. It is the most common type of heat exchanger in
oil refineries and other large chemical processes, and is suited for higher pressure applications.
As the name implies, this heat exchanger consist of two sides: the shell side and tube side. Heat is exchanged along
the tube bundle surface by flowing hot fluid on one side, and cold fluid on the other.
Fluid B out
Fluid A in
Fluid A out
Fluid B in
TUBE-SIDE SHELL-SIDE

N-2 Nomenclature of Heat Exchanger Components
Channel Cover
Nozzle Tubes
Girth Flange
TUBE-SIDE SHELL-SIDE
TEMA Type: AES

N-1.2 TEMA Type Designation
Figure N-1.2

RCB-1 TEMA Class Designation
TEMA CLASS APPLICATION
Specify design and fabrication of unfired shell and tube heat

R exchangers for the generally sever requirements of
petroleum and related processing applications.

C exchangers for the generally moderate requirements of
commercial and general process applications.

B
exchangers for chemical process service.

RCB-2 Tubes
RCB-2.2 TWO TYPES OF TUBES: RCB-2.4 TUBE PATTERNS
1. Bare Tubes
Application: General
2. Integrally Finned Tubes

Application: Shell side fluid with a low heat
transfer coefficient
Tube Pitch
= 1.25 d
Smooth Bore
* Flow arrows are perpendicular

to the baffle cut edge.
With Internal Rib

RCB-3 Shells and Shell Covers
Shells and Shell Covers
It is found that a more economical heat exchanger can be designed by making a shell diameter smaller and a shell length
larger according to practical factors as plant layout, installation, and service.
Shell Shell Cover
Saddle
Bracket
Horizontal Heat Exchanger
Reinforcing Pad Shell

Rib
Web
Baseplate
Rib
Baseplate
Saddle Support Bracket Support Vertical Heat Exchanger

APPLICATIONS: RCB-4.5 Spacing of Baffles & Support Plates
(1) For supporting tubes

(2) For maintaining tube spacing
(3) For directing shell-side fluid across or along
tube bundles
RCB-4.1 Types of Transverse Baffles
Per RCB-4.5
Note:
Ideal baffle spacing and baffle cut shall be applied
to avoid occurrence of eddies that will cause
excessive pressure drop on the shell side.

RCB-4.6 Impingement Protection RCB-4.7 Tie Rods and Spacers

Erosion of tube bundle components should be prevented or The baffle system is tied together with tie rods and
minimized at the entrance in case of high velocity fluids. spacers. ( Qty x Size = min. 4 x 9.5 dia. )
Spacer Tie Rod
Baffle System
RCB-4.8 Sealing Devices
Sealing devices should be installed when necessary to
prevent excessive by-passing of a fluid around or through
the tube bundle.
Tube Layout without Sealing Devices Tube Layout with Sealing Devices:
(Excessive bypassing of a fluid) (1) Seal Strips (2) Dummy Tubes (3) Tie Rods w/ Spacers

RCB-4.9 Kettle Type Reboilers Skid Bar Application for Bundle Removal
For kettle type reboilers, skid bars and a API 660 recommends skid bar application for all removable
bundle hold-down may be provided. bundles with a mass of more than 5,450kg to facilitate bundle
removal.
Sliding Shoe and/or Guide Rail (For kettle type application)
Bundle Hold Down

(Support Band) Sliding Shoe (For non-kettle type application)

RCB-5 Floating End Construction
Floating End Construction
FLOATING HEAD
RCB-5.1 BACKING DEVICE
INTERNAL FLOATING HEAD
FLOATING HEAD
COVER FLANGE
FLOATING HEAD COVER
SHELL COVER
PACKING BOX
FLOATING PACKING GLAND

TUBESHEET
SLIP-ON
BACKING FLANGE
RCB-5.2
SPLIT SHEAR RING
FLOATING
TUBESHEET SKIRT
PACKING BOX
PACKING
RCB-5.3 FLOATING
TUBESHEET
PACKING
LANTERN RING

RCB-6 Gaskets
Gaskets
A gasket is a mechanical seal that fills the space between two objects, generally to prevent leakage between the two
objects under compression. Illustration below shows typical gasket locations for heat exchanger applications.

RCB-6 Gaskets
Type of Gasket Cross Section / Parts Application
- suitable for both low and high

Spiral Wound (SW) pressure and temperature
applications
outer ring
METALLIC
(center ring) filler inner ring

SEMI
double jacket - for internal floating head joints

Metal Jacketed (MJ) jacket
filler
- all joints w/ pressure 300psi & over
single jacket - all joints in contact w/ hydrocarbon
- suitable for high pressure and

Ring Type Joint (RTJ) oval section temperature applications since high
loads are required to seat gasket to
METALLIC
octagonal section mating flange
- for internal floating head joints

Solid Flat Metal (SFM)
- all joints w/ pressure 300psi & over
- all joints in contact w/ hydrocarbon
- for low pressure class application
METALLIC
Non Asbestos (NA)

- usually applied on internal flanges
NON
Polytetrafluoroethylene - for low pressure class application

(PTFE) - usually applied on internal flanges

RCB-7 Tubesheet
Tubesheet RCB-7.3 Tube to Tubesheet Joint
It is the principal barrier between the shell-side and

tube-side fluids. Below are some typical tubesheet
connections to channel and shell.
Removable Non Removable

Tube Bundle Tube Bundle
RCB-7.513 Tube Projection
The maximum tube projection shall be 0.5 x Tube OD. In

case of vertical heat exchangers, tubes shall be flush on
the top tubesheet.

Flexible shell elements or expansion joints are

applied for accommodating differential thermal
expansion of heat exchanger shells and tube
bundle carrying high temperature fluids.
Flexible shell elements, or

expansion joints

RCB-9 Channels, Covers, and Bonnets
RCB-9.1 Channels and Bonnets RCB-9.13 Pass Partition Plates

Shell-side flow Partition plates attached to channels or bonnets control tube-side passes.
Pass Partition Plate No. U-TUBE STRAIGHT TUBE
2 PASS of
Pass
Tube Side Flow
FRONT BACK FRONT BACK
1 1 1 1 1
2
2 2 2 2
2
Shell Side
Flow
1 1
Channel Cover Channel Bonnet 1 2 1 2
4 3 2 3 2
4 3 4 3
4 4
NOTE:
(1) Two phase flow on the tube side is best 1 1
1 2 1 2
kept in a single straight tube or in a U-tube. 6 3 2 3 2
4 3 4 3
(2) Odd number of passes are uncommon, 4 5 4 5
5 6 5 6 6 6
and may result in mechanical and thermal
problems in fabrication and operation.
Commonly Used Pass Partition Layout corresponding to No. of Tube Pass

RCB-10 Nozzles
TYPE ILLUSTRATION APPLICATION
WELDING Type-1
NECK With Reinforcing Pad
Flange Flange
- Normal application
Boss Type-2
Neck
Self Reinforced Nozzle
Pad - Heavy wall vessel application
Type-2A
Type-2A Type-2 Type-1 - For cyclic service & low alloy
vessel application
LONG - Small nozzle application,
WELDING normally 2” and below
NECK
FORGED - Small nozzle application,

NECK normally 2” and below on heavy
wall vessel, cyclic service, and
low alloy application

RCB-10 Nozzles
TYPE OF FLANGES
Welding Neck Lap Joint Socket Weld Slip-On Threaded

(Normally Applied)
Severe Service The flange swivels Suitable for a Requires less Low pressure
Provides greatest freely on the stub small nozzle accuracy in pipe application
safety factor and and permits bolt where an internal cutting and
fatigue strength. hole alignment. weld is difficult. permits bolt hole
For sizes 4” and alignment.
smaller, it has
same strength as
slip-on flanges.
TYPE OF FLANGE FACE BOLTING
(Normally Applied)
Minimum Bolt: ¾”
≤ 1” - Coarse Thread Series
> 1” - 8UN Thread Series

Accessories

Accessories
JACK SCREW DOWEL PINS

PART - II
TEMA TYPE SELECTION

1. Classification of STHE based on Service
Heat Exchanger – both sides are process streams (that is, not a utility).
Cooler – one stream of a process fluid, and the other of cooling water or air.

Heater – one stream of a process fluid, and the other a hot utility, such as steam or hot oil
Condenser - one stream of a condensing vapor, and the other cooling water or air.

Chiller – one stream of a process fluid being condensed at sub-atmospheric temperatures, and the other a
boiling refrigerant or process stream
Reboiler - one stream of a bottom one from a distillation column, and the other a hot utility (steam or hot oil)
or a process stream

2. Front End Head Type and its Applications
Front End Type Applications
A Fouling tube side

Cooling water in the tube side
Channel &
Removable Cover
B Clean tube side

High pressure
Bonnet
Toxic service
(Integral Cover)
C Very toxic service in the tube side

(A tubesheet is fixed to a channel to avoid
Channel Integral gasketed joints that may cause leakage.)
with Tubesheet &
Removable Cover
N Very toxic service in the tube and shell sides

(A tubesheet is fixed to the channel and shell to
Channel Integral avoid gasketed joints that may cause leakage.)
with Tubesheet &
Removable Cover
D Special high pressure closure application
Special High
Pressure Closure

3. Shell Type and its Applications
Shell Type Applications Remarks

E Normally applied Single phase or two phase fluid application
except in cases
One-Pass Shell
below
F Temperature cross High heat transfer efficiency but increased pressure drop
Two-Pass Shell
Rarely used because of the problem associated with longitudinal baffle
joints in the shell side
G Vaporizing Low pressure drop, usually employed in a horizontal thermosyphon

≤ 3m tube length reboiler
Split Flow
Liquid (at the inlet) and liquid/vapor (two phases at the outlet)
H Vaporizing Low pressure drop, usually employed in a horizontal thermosyphon

> 3m tube length reboiler
Double Split Flow
Liquid (at the inlet) and liquid/vapor (two phases at the outlet)
J Condensing Low pressure drop like condensing in vacuum

Vapor (at the inlet) and vapor/liquid (two phases at the outlet)
Divided Flow
X Condensing Extremely low pressure drop like condensing in vacuum

Cross Flow
K Partially vaporizing Kettle shell serving as vapor disengaging space

shell fluid
Kettle Type Reboiler

4. Rear End Head Type
CLASSIFICATION OF STHE BASED ON CONSTRUCTION
Fixed Tube Sheet Exchanger U-Tube Exchanger Floating Head Exchanger
Normally applied
See section 5 for
comparison of
design features.

5. Rear End Head Type (Design Features and Applications)
FIXED TUBESHEET U-TUBE FLOATING HEAD

L/M U S
General Application Clean Shell side Clean Tube side Fouling on Tube Side
Design Pressure and
High or Low High or Low Up to 4.0 MPa
Temperature
Applicable Fluid Volatile or Toxic Volatile or Toxic Volatile or Toxic
Multi Pass
No. of Tube Pass Single or Multi Pass Single or Multi Pass
(Single Pass design is not possible.)
Bundle Removal No Yes Yes
Outer Tube Only
Tube Replacement Yes Yes
(Difficult to replace inside tubes)
Yes
Yes
Thermal Expansion (Each tube can expand or contract Yes
(Expansion joints are used.)
independently.)
Heat Surface for a

3 2 1
given Shell ID
Cost Comparison 1
2 3
(1 as cheapest) (If no expansion joint)
Basically, for horizontal STHE:  Type T is suited for kettle type

 Type L is for single pass. reboiler where U-tube cannot be
employed.
 Type M is multi pass. Not suited for vertical heat
REMARKS  Type P and W are for non-
exchangers.
volatile and non-toxic service
 Type N is applied for high with design pressure limited by
pressure and very toxic service. its packing material.

6. TEMA Type Selection Guide
To select the most suitable TEMA type for each given application, lots of design factors are involved as follows:
Design Conditions Service Fluid Mechanical Aspect Application
 Design Pressure  Toxicity  Vertical/Horizontal  Heat Exchanger
 Thermal Expansion  Fouling Resistance  No. of tube pass  Cooler or Heater
 Vaporizing/Condensing  Nozzle Location  Condenser
 Pressure Drop  Cleaning Method  Chiller or Reboiler
Typical TEMA Type Configurations:
U-TUBE FIXED TUBESHEET FLOATING HEAD
BEU BJU AEM AEL AES
AKU
AJS AES
BHU BGU BEM BEL BEM

6. TEMA Type Selection Guide
Obviously, it is not possible to cover all aspects of design or all available TEMA types of heat exchangerd in this guide.
As a General Guide for TEMA Type Selection, simple guideline is layout below:
Select an applicable case and determine a type of rear end head:

CASE-1 CASE-2 CASE-3 CASE-4
Shell Side Tube Side Shell Side Tube Side Shell Side Tube Side Shell Side Tube Side
Clean Clean Fouling Clean Clean Fouling Fouling Fouling
(1 pass) (1 pass) (Clean) (Clean-Foul)

FIXED FLOATING
STEP-1
U-TUBE FIXED FLOATING

STANDARD FORM
B E U A E M A E L A E S
(multi pass) (multi pass) (single pass)
Standard Form Compliance Check:

STEP-2
 Shell type shall conform with Section-3.

 Front end head shall conform with Section-2.
 Equipment orientation and nozzle location are to be considered. See Typical TEMA Type Configurations.
NOTES: (1) Clean service has a fouling resistance of < 0.0002 m2-K/W or < 0.00034 m2-K/W + chemical cleaning.
(2) Clean-Foul has a fouling resistance of 0.0002 m2-K/W to < 0.00034 m2-K/W.
(3) Fouling service has a fouling resistance of ≥ 0.00034 m2-K/W.

CODES AND STANDARDS
CODES AND STANDARDS OF SHELL AND TUBE HEAT EXCHANGERS
1. TEMA 9th Edition - Standards of the Tubular Exchanger Manufacturer’s Association

2. API 660 7th Edition – S&T Heat Exchangers for General Refinery Services
3. ASME VIII, Part UHX 2008 Edition – Rules for Shell and Tube Heat Exchangers
CODES AND STANDARDS OF NOZZLE FLANGES
1. ASME B16.5 2003 Edition – Pipe Flanges and Flange Fittings (up to NPS 24)
2. ASME B16.47 2006 Edition – Large Diameter Steel Flanges (NPS 26 – NPS 60)
*** END ***

Compress Heat Exchanger

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[ Mechanical Engineering ]

S&T Heat Exchanger

What is a Shell and Tube Heat Exchanger

Copyright ⓒ2009 Samsung Engineering Co., Ltd. All rights reserved 2

1 Classification of STHEs based on Service

Copyright ⓒ2009 Samsung Engineering Co., Ltd. All rights reserved 3

SHELL AND TUBE HEAT EXCHANGER

Copyright ⓒ2009 Samsung Engineering Co., Ltd. All rights reserved 4

SHELL AND TUBE HEAT EXCHANGER

Copyright ⓒ2009 Samsung Engineering Co., Ltd. All rights reserved 5

TEMA Type: AES

Copyright ⓒ2009 Samsung Engineering Co., Ltd. All rights reserved 6

Copyright ⓒ2009 Samsung Engineering Co., Ltd. All rights reserved 7

TEMA CLASS APPLICATION

Specify design and fabrication of unfired shell and tube heat

Specify design and fabrication of unfired shell and tube heat

Specify design and fabrication of unfired shell and tube heat

Copyright ⓒ2009 Samsung Engineering Co., Ltd. All rights reserved 8

RCB-2.2 TWO TYPES OF TUBES: RCB-2.4 TUBE PATTERNS

2. Integrally Finned Tubes

* Flow arrows are perpendicular

With Internal Rib

Copyright ⓒ2009 Samsung Engineering Co., Ltd. All rights reserved 9

Shells and Shell Covers

Shell Shell Cover

Reinforcing Pad Shell

Saddle Support Bracket Support Vertical Heat Exchanger

Copyright ⓒ2009 Samsung Engineering Co., Ltd. All rights reserved 10

APPLICATIONS: RCB-4.5 Spacing of Baffles & Support Plates

(1) For supporting tubes

RCB-4.1 Types of Transverse Baffles

Copyright ⓒ2009 Samsung Engineering Co., Ltd. All rights reserved 11

RCB-4.6 Impingement Protection RCB-4.7 Tie Rods and Spacers

Spacer Tie Rod

Copyright ⓒ2009 Samsung Engineering Co., Ltd. All rights reserved 12

Sliding Shoe and/or Guide Rail (For kettle type application)

Bundle Hold Down

Copyright ⓒ2009 Samsung Engineering Co., Ltd. All rights reserved 13

Floating End Construction

FLOATING HEAD COVER

FLOATING PACKING GLAND

Copyright ⓒ2009 Samsung Engineering Co., Ltd. All rights reserved 14

Copyright ⓒ2009 Samsung Engineering Co., Ltd. All rights reserved 15

Type of Gasket Cross Section / Parts Application

- suitable for both low and high

(center ring) filler inner ring

double jacket - for internal floating head joints

- suitable for high pressure and

octagonal section mating flange

- for internal floating head joints

Non Asbestos (NA)

Polytetrafluoroethylene - for low pressure class application

Copyright ⓒ2009 Samsung Engineering Co., Ltd. All rights reserved 16

Tubesheet RCB-7.3 Tube to Tubesheet Joint

It is the principal barrier between the shell-side and

Removable Non Removable

RCB-7.513 Tube Projection

The maximum tube projection shall be 0.5 x Tube OD. In

Copyright ⓒ2009 Samsung Engineering Co., Ltd. All rights reserved 17

RCB-8 Flexible Shell Elements

Flexible shell elements or expansion joints are

Flexible shell elements, or

Copyright ⓒ2009 Samsung Engineering Co., Ltd. All rights reserved 18

* END *