Proceedings of the ASME 2016 Pressure Vessels and Piping Conference

PVP2016
July 17-21, 2016, Vancouver, British Columbia, Canada

PVP2016-63137

AN IMPROVED DESIGN OF THREADED CLOSURES FOR

SCREW PLUG (BREECH LOCK) HEAT EXCHANGERS

Haresh K. Sippy
Chairman and Managing Director
TEMA India Limited
Hamilton House, 3rd Floor, J.N. Heredia Marg,
Ballard Estate, Maharashtra, Mumbai – 400038, India
Email: sippyhk@gmail.com
Phone: +91-22-66900100

Dr. Dipak K. Chandiramani

Independent Consultant
Flat no. 503, Tower B, Maitri Park CHS,
Chembur, Maharashtra, Mumbai – 400071, India
Email: dipak.chandiramani@outlook.com
Phone: +91-22-25200073

ABSTRACT
Threaded closures for pressure vessels have been in use for
decades. Much work has been done to develop convenient, safe
and economical threaded closures. Threaded closures are used
when there is a need for opening the vessel either for
maintenance or as part of its operation.
A study was undertaken to assess the reasons for bulging of the
end of the channel which caused jamming of the screw threads
and also for leakage through the gasket.
By shrink fitting a ring over the end of the channel, the
deformation was reduced, enabling easy opening of the cover.

Heat Exchangers are a typical application where there is a need
for opening the vessel and cleaning the tubes at regular
intervals to maintain the heat transfer efficiency. These are
known as Breech Lock or Screw Plug Exchangers. These are
basically U-tube exchangers. The channel side operates at high
temperature and pressure and it has a threaded end closure. In
some designs, the shell side may also be at high pressure. The
tube bundle is removable without having to dismantle the
channel or disconnect the nozzles from the pipeline. Thus
screw plug exchangers help to reduce fabrication cost and
reduce time for in-service maintenance.
2) The leakage through the gasket between the shell and tube-
sheet, causing the intermixing of shell and tube-side fluids.
This on analysing was found that the additional forces were
acting on the gasket due to thermal expansion of the internals.
This led to changing to a gasket that could withstand the forces
and pressure.
Leakage through the gasket was prevented by analysing the
additional forces acting on the gasket due to thermal expansion
of the internals and changing to a gasket that could withstand
the forces and pressure.

The major problem encountered with the use of such end NOMENCLATURE AND ABBREVIATIONS
closures are 1) Jamming of the threaded plug, due to
deformation of the channel barrel. Thus the opening of the end
closure by unscrewing becomes a difficult task. With the FEA Finite Element Analysis
increase in operating temperatures and pressures, the problems SCL Stress Classification Line
become more severe, due to which, users are not inclined to use
these type of end closures.

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 INTRODUCTION Threaded closures for pressure vessels have been the subject of
study since decades [2]. ASME Codes [3], [4] permit the use of
To make a marketable heat exchanger, four main requirements threaded end closures for pressure vessels typically as per Table
have to be met: 4.6.1 Detail 9 of ASME Section VIII Div. 2, shown in Figure 1.

1. It should be safe (i.e., comply with all requirements of

Code),
2. It should efficiently exchange heat and
3. It should be easy to maintain (clean)
4. It should be reasonably priced (value for money)

For efficient heat transfer, maintenance becomes a very

essential requirement and therefore Breech Lock Heat
Exchangers become an attractive option provided they function
as intended.

The two main problems associated with Breech Lock Heat

Exchangers are:

1. Leakage through the shell side gasket

2. Flaring of the end of the channel, thereby preventing
easy disassembly of the end cover

In a recent paper, Reeves and Clover [1] have studied the

leakage in Breech Lock Heat Exchangers and made suggestions
for obtaining leak-free performance. FIGURE 1 - PERMITTED THREADED CLOSURE
Even though the threaded closures comply with the Further, it was necessary to determine the reason for jamming
requirements of Code, there are still problems with disassembly of the end cover screw threads and correct the design to prevent
of the closure after hydrotest and during periodic maintenance the same.
due to bell mouthing of the channel causing jamming of screw
threads. A typical configuration of the channel of a screw plug
exchanger is shown in Figure 2 below.
The work reported in this paper, is the result of a detailed study
carried out to determine why the gasket leaked and how bell
mouthing of the channel end could be prevented to avoid
jamming of the threads and thereby permit easy disassembly
for maintenance.

STATEMENT OF THE PROBLEM

We have a situation where a pressure vessel which apparently

meets all Code rules and satisfactorily passed the Code required
hydrostatic test, seems to malfunction after a short period of
operation. Leakage is detected from the shell side gasket and
when attempting to disassemble the screw plug, the threads are
jammed and great effort is required to open the cover.

It was felt that probably the gasket was being subject to loads
additional to what are normally considered in design and so FIGURE 2 - TYPICAL CONSTRUCTION DETAILS OF
detailed analysis of these loads was required. THE CHANNEL OF A SCREW PLUG HEAT
EXCHANGER
Figure 3 - below shows an exploded view of the channel
internals

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FIGURE 3 - EXPLODED VIEW OF CHANNEL
INTERNALS
ASSUMPTIONS
As such, there may be many grades of materials used singly or
in combination for the channel side of a typical breech lock
heat exchanger. For the study reported in this paper, typical
materials more commonly use were selected which are listed
below. The principles of the applied method, could be applied
to all combinations of materials.
Corrosion Allowance
All analyses were carried out on material thicknesses in the
corroded condition.
Materials
Material of channel barrel was SA 336 Gr. F22 Cl 3 which is a
low alloy steel
Material of internals was SA 240 Gr. 321 which is a stainless
steel
Material of bolting was SA 453 Gr. 660 Cl. B which is an
austenitic steel
ANALYSIS PROCEDURE
The analysis was carried out on a typical U-tube heat exchanger
having a diameter of 1275 mm (50 inches) with a length of
5529 mm (18 ft.) constructed of the above materials. The
exchanger was designed and fabricated in accordance with Part
4 of the Code to the extent possible. In addition, an analysis
was carried out to determine if differential thermal expansion of
the tube side component was imposing additional stresses on
the gasket, ultimately leading to its premature failure. Initially
the design considered use of spiral wound gaskets. This type of
gasket was selected as it is known to have good flexibility and
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recovery and can maintain a seal under conditions of high
temperature, high pressure, vibration and mechanical shock.
An analysis was also carried out of stresses at the threaded end
of the channel over the threaded lock ring (holding the channel
cover in place) to determine the magnitude of their radial
component (causing bell mouthing) and take corrective action
to prevent the same. Acme threads conforming to ASME B1.5
were used for the threaded lock ring.
RESULTS AND DISCUSSION
Figure 4(a) shows the model created for FEA of the heat
exchanger channel. Figure 4(b) is a close up of the meshed
threads. Solid 185 elements were used. Mesh sensitivity review
and global equilibrium check were carried out to validate the
numerical model as per Clause 2.3.3.1(c)(2)(-h) of ASME
Section VIII Division 2.
FIGURE 4(a) - TYPICAL MODEL USED FOR
ANALYSIS
FIGURE 4(b) - THREAD MESH DETAIL
Figure 5 shows a typical thermal plot of temperature and
expansion of heated internals relative to the channel, causing
additional compressive stress on the gasket. It is observed that
the differential thermal expansion between the Low Alloy steel
channel barrel and the stainless steel internals caused the spiral
would gasket to compress by 3.722 mm. This additional
deformation of the gasket (which had not been accounted for in
the initial design) lead to its premature failure. A study was
then made to select a gasket which would withstand this
additional load due to expansion. Solid metal gaskets would no
doubt withstand the loads but sealing could be an issue. Finally
it was concluded that a Kammprofile gasket to DIN 2697
should be able to provide the resistance to applied load and
 sealing required. Section of a typical Kammprofile gasket is
shown in Figure 6. Such gaskets are also covered under ASME
B16.20 as “Grooved Metal Gaskets with Covering Layers”.

FIGURE 7(b) - COMPRESSION OF KAMMPROFILE

GASKET

Figures 8(a) shows the deformation of the threaded end in the

radial direction, of the channel barrel when the end cover was
subject to the channel pressure. It may be noted that the
FIGURE 5 - TYPICAL THERMAL PLOT AND threaded end of the channel itself in not subject internal
EXPANSION OF CHANNEL WITH INTERNALS pressure. The value of the maximum deformation of the end of
the channel barrel in the radial direction was 4.541 mm. Such
high deflection would cause the threads to match unevenly
causing high local stress and plastic deformation.

FIGURE 6 - KAMMPROFILE GASKET

When analysis was carried out using the Kammprofile gasket,

the compression caused by differential thermal expansion
reduced to 2.939 mm. This was due to resistance from the
metallic core which could withstand the differential expansion
stresses.
FIGURE 8(a) – DEFORMATION OF THE THREADED
Figures 7(a) and 7(b) show the compression of the gaskets. END OF THE CHANNEL DUE TO END COVER LOAD

It was necessary to reduce the deformation of the threaded end

of the channel. This could be achieved by any of the following
methods:

(a) Increasing the channel thickness

(b) Increasing the thickness of the end of the channel by
welding a thickened end piece

Option (a) would cause an increase in the cost of the heat

exchanger would not be looked upon favourably by purchasers

Option (b) which would entail a circumferential weld seam, is

not permitted by many Client specifications when the channel
FIGURE 7(a) - COMPRESSION OF SPIRAL WOUND is in hydrogen service.
GASKET
Another option then thought of was to shrink fit an additional
steel ring on to the end of the channel prior to threading, which
would reduce the radial deformation of the threaded end and
thereby prevent jamming of the screw threads.

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 It was proposed to use a seamless ring of the same material as
the channel. The inside diameter of the ring would require to be
precisely machined to match the outside diameter of the
channel which would also have to be machined and provide
some interference to create initial compression in the channel.
The amount of interference depends on the material of the
channel and ring. For plain carbon steel, there could be more
interference but for low alloy steels, excessive interference
could cause cracking during machining of the threads.
FIGURE 10 - PEAK STRESS IN THREADS DURING
The purpose of the shrink fit ring was primarily to provide OPERATING CONDITION (WITH RING)
support to the threaded end of the channel and reduce the radial
deformation and not to create compressive stresses. The ring SCLs taken through the root of the threads indicated a PL value
thickness was finalized after few trials. of 241.12 MPa without added ring. This reduced to 131.12
MPa when the ring was fitted. The permitted value was 234.6
Analysis carried out using the additional ring indicated a MPa. Other stresses were within limits in both cases.
reduction in the radial deflection to 3.807 mm as shown in
Figure 8(b). Figure 11 is a photograph of precise measurement being made
of the inside diameter of the added steel.

FIGURE 8(b) – DEFORMATION OF THE THREADED

END OF THE CHANNEL DUE TO END COVER LOAD
(SHOWN WITHOUT ADDED METAL RING)

Peak stresses in the thread root without additional ring are
shown in Figure 9 which shows a peak stress of 387 MPa in the
operating condition.
FIGURE 11
Calculations were made to determine the temperature at which
the ring was required to be heated prior to shrink fitting it on
the shell based on compressive stress that would be generated
in the shell upon cooling.

The ring was heated by electrical heating elements.

FIGURE 9 - PEAK STRESS IN THREADS DURING
OPERATING CONDITION
With the addition of the ring, these stresses reduced to 294 MPa
for the operating condition. This is shown in Figure 10 below.
Thermocouples were attached on the circumference of the ring
to ensure uniform heating of the ring (within +/- 5 deg.C from
the specified temperature at any point). Dimension of the inside
diameter of the channel was measured prior to fitting of the
ring and also after the ring was fit and cooled to room
temperature.
Depending upon the material of the channel, the deformation of
the channel after shrink fitting was kept within specified limits.
The two ends of the ring were then welded to the channel. The
entire assembly was then subject to PWHT in accordance with

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 Code requirements. The channel internal threads were then
machined.

Figure 12 is a photograph of the channel with added ring fitted,

after PWHT.

FIGURE 14

The tube bundle was inserted after completion and channel

internals were inserted in sequence. The channel was then
hydrostatically tested.

FIGURE 12 - CHANNEL AFTER PWHT
Figure 13 is a photograph of cutting internal threads on the
channel and Figure 14 is a photograph of the finished channel
barrel.
After hydrostatic test, the lock ring was opened. Easy opening
of the lock ring indicated that no local deformations had
occurred in the threads and the assembly was correctly made.
Figure 15 is a photograph of the finished product

FIGURE 15
FIGURE 13
CONCLUSIONS

Study of the reasons for failure of tubesheet gasket and

jamming of lock ring screw threads of breech lock heat
exchangers indicated the following:

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 1. The tube side internals which were of stainless steel
had a higher thermal coefficient of expansion that the
channel barrel.
2. This cause differential thermal expansion leading to
additional compression and failure of the tube sheet
gasket.
3. As the material of the internals could not be changed
due to reasons of corrosion resistance required, it was
necessary to use a gasket that could withstand the
additional load due to thermal expansion of the
internals.
4. Solid metal gaskets were considered, but due to
possibility of leakage, it was finally decided to use a
Kamprofile gasket to DIN 2697.
5. Use of the Kamprofile gasket resulted in leak free joint
between the tubesheet and shell.
6. To understand the flaring of the end of the channel, a
finite element analysis was carried out to determine its
nature and magnitude.
7. While there were various options to reducing the
magnitude of flaring, the most cost effective method
of applying an additional ring shrink fit on the
channel.
radial deformations and considerable reduction in
stresses at the root of the threads ultimately resulting
in no permanent deformations and hence easy removal
of the screwed cover.
REFERENCES
[1] Reeves, D. and Clover, D. “Breech Lock
Exchangers, Obtaining Leak Free Performance”,
PVP2014-28174, ASME Pressure Vessels &
Piping Conference, Anaheim, California, USA,
July 2014
[2] Fryer, D.M. and Smith, C.W., “Threaded
Closures for Large High Pressure Vessels”,
ASME, Pressure Vessels and Piping: Design and
Analysis, Vol. 4, 1976.
[3] Rules for Construction of Pressure Vessels,
Section VIII Division 1: 2015, The American
Society of Mechanical Engineers, USA.
[4] Rules for Construction of Pressure Vessels,
Section VIII Division 2: 2015, The American
Society of Mechanical Engineers, USA.

8. Analysis carried out on the threaded portion of the

channel with the added metal ring indicated lower

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