Introduction to

Shell & Tube Exchangers

Module 2

EXC 2-1
 Heat Exchangers - Course Content
Module 2 - Introduction to Shell & Tube Exchangers

„ TEMA Nomenclature
„ Selection of TEMA Type Layouts
„ Baffle and Support Plates
„ Tubes and Arrangements
„ Tube to Tubesheet Joints
„ Impingement Plates & Vapor Belts
„ Materials of Construction
„ Procurement and Evaluation

EXC 2-2
 TEMA Data
Sheet

Process Conditions

Mechanical Data

EXC 2-3
Shell and Tube Heat Exchangers

EXC 2-4
TEMA - Tubular Exchanger
Manufacturers Association
Heat Exchanger Nomenclature - Front Heads

A B

C N

EXC 2-5
 TEMA - Tubular Exchanger
Manufacturers Association
„ Heat Exchanger Nomenclature - Shell Types

E J

F K

G X

H
EXC 2-6
 TEMA -
Tubular
L M
Exchanger
Manufacturers
N
P Association
Heat Exchanger
Nomenclature -
S T
Rear Head Types

U W

EXC 2-7
Selection of Exchanger Type

1) Feed preheater
Low pressure
Tubeside - Steam
Shellside - Light naphtha

EXC 2-8
Selection of Exchanger Type
(continued)

1) Feed preheater
Low pressure
Tubeside - Steam
Shellside - Light naphtha

BEU

EXC 2-9
Selection of Exchanger Type
(continued)

2) Feed preheater
Low pressure
Tubeside - Coker fractionator bottoms
Shellside - Light coker naphtha

EXC 2-10
Selection of Exchanger Type
(continued)

2) Feed preheater
Low pressure
Tubeside - Coker fractionator bottoms
Shellside - Light coker naphtha

AES or AET

EXC 2-11
 Baffles

Single Segmental Baffle Cut:

window

cut as % of
shell diameter

Selecting baffle cut:

Larger cut ⇒ lower shellside ∆P
⇒ smaller cross flow worse heat transfer
⇒ larger shell and tubesheet diameter
⇒ more expensive exchanger
EXC 2-12
 Baffles
(continued)

Smaller cut ⇒ higher shellside ∆P

⇒ higher acceleration loss through window
Select baffle cut so that ∆P all windows ≈ 20-25% ∆P total
Double segmental baffles:
windows

Center window area ≈ combined edge window area

EXC 2-13
 Baffles
(continued)

Baffle orientation

Horizontal Vertical Angled

Liquid service Usually horizontal cut baffles

Vapor or 2 phase Use vertical baffles
EXC 2-14
Baffle Types

EXC 2-15
 max
max unsupported
unsupported
tube span
tube span

Flow
FULL
TUBEFIELD
Patterns
max
maxunsupported
unsupported
tube span
tube span

FULL
TUBEFIELD

maxunsupported
max unsupported
tubespan
tube span

empty space empty space

PARTIAL
TUBEFIELD

empty space empty space

EXC 2-16
 Support Plates
„ ∆P limitations on shellside force large baffle spacing
„ Decrease tube vibration add support plates between baffles
(usually NTIW):

baffles support plate

same shape
as tube field

support plates

„ Support plates hold tubes together in a “cage”

„ Vibration is less likely, almost no ∆P cost
EXC 2-17
 Baffle Selection Criteria

„ Single Segmental Baffles

– Standard Arrangement
– Used if neither ∆P nor tube vibration is a problem
„ Double Segmental
– Used if DP must be limited and tube vibration is not
a problem
„ NTIW
– Used if DP must be limited and tube vibration is a
problem
„ Triple Segmental
– Provides lower DP than Single or Double Segmental
– Has a large unsupported tube span

EXC 2-18
 Tubes

„ Diameter
– Tubes range from 1/4" to 2" OD generally.
– Refinery exchangers use: 5/8", 3/4", 1", 1-3/4"
commonly
– General: smaller D ⇒ better heat transfer but
higher ∆P and harder to clean
„ Wall Thickness
– Commonly ranges from 0.065" to 0.109" (1.65 mm
to 2.77 mm)
– FCC Flue Gas Coolers (firetube) often uses
1.75" OD x 0.2" thk (44.45 mm OD x 5.1 mm thick)

EXC 2-19
 Tube Pitch
Pitch

30 60 90 45

Triangular (2 kinds) and square (2 kinds)

FEATURE USE PATTERN:
lower ∆P on shellside square (effective only at low Re number)
shellside fouling square - easier cleaning
horizontal shellside square - prevent vapor blanketing
boiling
decrease shell size fit 15% more tubes if triangular pitch used

EXC 2-20
Tube Pass Geometry and Pass Partitions
Separation of fluids in each pass must be maintained since
leakage would short circuit the exchanger.
The term “Pass” used in exchangers is not the same as the
term pass is used in fired heaters. The number of passes in
an exchanger is the number of times one fluid passes through
the other fluids compartment.
Ribbon
Inlet

In In

Out Out

In In

Out Out

Front head Outlet Rear head

EXC 2-21
 Tube to Tubesheet Designs

„ Most difficult mechanical

design component
„ Large potential for
internal leakage
– 3 main types
— Expanded
— Seal Welded
— Strength Welded

EXC 2-22
 Impingement Plates
„ Used to avoid damage to tubes from incoming fluids on shell side
„ TEMA Guidelines
– Based on ρV2 on inlet nozzle, provide impingement protection
when -
— For non-corrosive, non abrasive, single phase fluids if ρV2 >
1500 lb/ft-sec2
— For all other liquids (including liquids at its boiling point) if
ρV2 > 500 lb/ft-sec2
— For all gases and vapors (including saturated vapors)
— For all liquid and vapor mixtures

EXC 2-23
 Materials of Construction
„ Materials must suit temperature and fluids
„ Example of selection criteria
„ High H2 partial pressure
– Killed carbon steel
„ High temperature, high H2 partial pressure
– 410 or Cr-Mo
„ Sea-water cooling
– Admiralty brass or 70-30 Cu-Ni
„ Wet H2S service
– Killed carbon steel (Special heat treatment)
„ Hot HF service
– Monel
„ Hot acids
– Alloy 20, 904L, 316 SS, Titanium
EXC 2-24
Procurement and Evaluation

„ Purchasing
„ Specifications
„ Bid Evaluations
„ Fabrication
„ Quality Control

EXC 2-25
 Purchasing

„ Preparation of Specification
– Operational Requirements including
alternative operations, special
startup/shutdown issues
– Drawing/Data/Calculation Requirements
– Materials of Construction
– Codes and Local Law/Rules
„ Vendor/Bidder Selection
– Vendor Capabilities

EXC 2-26
 Specifications

„ Standard Industrial Codes/Specifications

– ASME B&PV Code Section VIII – Pressure Vessels
– ASME B&PV Code Section II – Materials
– ASME B&PV Code Section IX – Welding
– ASME B&PV Code Section I – Power Boilers
– TEMA
– API 660/ISO 16812 – Shell & Tube Heat Exchangers
– EJMA – Expansion Joints
– HEI – Surface Condensers
„ Customer Requirements

EXC 2-27
 Bid Evaluations

„ Technical Evaluations
„ Commercial Evaluations
„ Purposes:
– Verify compliance to specifications
– Completeness of offering
– Lowest overall cost – total cost of ownership
— Initial purchase price
— Operating cost
— Maintenance cost
— Disposal/replacement cost

EXC 2-28
 Fabrication

„ Depends on vendor facilities

„ Limitations on
– Materials
– Size
– Weight
– Speed of Fabrication

EXC 2-29
 Fabrication
(continued)

„ Typical Fabrication Sequence

– Roll plate for channels, shells
– Drill tubesheets, baffles
– Machine flanges
– Cut and weld nozzles to shell
– Assemble bundle, shells and channels, and
structural supports
– Test assemble removable bundles in shell
– Hydrostatic test
– Paint

EXC 2-30
 Quality Control

„ Incoming materials inspection – alloy

verification, defects
„ Welding procedures
„ NDE procedures (UT, PT, RT, etc.)
„ ASTM 450 tube inspection
„ Tube-tubesheet mockups
„ Hydrostatic/pneumatic testing
„ Helium/halogen leak testing

EXC 2-31