Mex 30207

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
Furnaces - Design Of Tube Supports
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramco’s employees.
Any material contained in this document which is not already in the public
domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.
Chapter : Vessels For additional information on this subject, contact

File Reference: MEX30207 M.Y. Naffa’a
Engineering Encyclopedia Vessels
Furnaces - Design Of Tube Support
Contents Pages
INTRODUCTION................................................................................................................ 1
SPECIFICATIONS .............................................................................................................. 2
MATERIALS ....................................................................................................................... 3
DESIGN CONDITIONS ...................................................................................................... 4

Design Temperatures................................................................................................. 4
Internal Supports and Guides ......................................................................... 4
External Supports .......................................................................................... 4
Allowable Stresses..................................................................................................... 4
CALCULATING REQUIRED THICKNESS OF CONVECTION SECTION TUBE
SUPPORTS.......................................................................................................................... 6
Tube Support Loads.................................................................................................. 8
Weight of Tube.............................................................................................. 9
Weight of Extended Surface........................................................................... 9
Weight of Fluid.............................................................................................. 9
Total Weight of Tubes ..................................................................................10
Distribution of Tube Loads.......................................................................................10
Horizontal Loads ..........................................................................................11
Tube Support Weight ...............................................................................................11
Moments ..................................................................................................................12
Tube Support Geometry...........................................................................................13
Stresses ....................................................................................................................14
DETERMINING REQUIREMENTS OF END TUBE SUPPORTS ....................................19
Loads .......................................................................................................................19
Stresses ....................................................................................................................19
RADIANT SECTION TUBE SUPPORTS AND GUIDES..................................................20
Horizontal Tubes......................................................................................................20
Vertical Tubes..........................................................................................................21
Work Aid 1...................................................................................................26

Work Aid 2...................................................................................................27

Work Aid 3...................................................................................................28
Work Aid 4...................................................................................................29
GLOSSARY........................................................................................................................32
REFERENCE......................................................................................................................33

INTRODUCTION
This module provides information on the design of furnace tube supports. This information will
assist the participant in completing typical tasks, such as:
• Calculating the loads on a tube support.
• Checking the design of a new tube support.
• Determining the adequacy of a tube support for new operating conditions.
Tube supports and guides are used to support the furnace tube coil in the proper location in the
furnace. They also guide the movement of the coil, which is caused by its thermal expansion and
contraction.
Two types of tube supports and guides are used:
• Internal supports and guides. These are located inside the firebox and are exposed to the
flue gases. Consequently, they must be designed for relatively high temperatures of these
gases. This requires the use of high-alloy, temperature-resisting materials for most internal
supports.
• External supports. These are shielded from direct exposure to the hot flue gases and can be
designed for much lower temperatures.
The number of tube supports required for horizontal tubes depends on the length of the tube. The
maximum unsupported length of tube should not exceed 35 times the outside diameter of the
tube, or 20 ft, whichever is less.
Vertical tubes require one support and at least one guide. The support can be located at either the
top or bottom of the tube. If the tube exceeds 30 ft in length, an intermediate tube guide is also
required. This second guide helps reduce undesirable bowing of the tube.
Inadequate supports or guides can lead to several problems. Tubes can become overstressed,
which can result in tube failure. Convection section tubes can settle together, or nest, which can
result in reduced heat transfer or a blocked flue gas flowpath. These problems may eventually
lead to unscheduled shutdowns because repairs are usually difficult or impossible to perform while
the furnace is operating.
Saudi Aramco DeskTop Standards 1

SPECIFICATIONS
Most of the requirements covering furnace tube supports are found in API Standard 560, Fired
Heaters for General Refinery Services. Saudi Aramco Engineering Standard AES-F-001,
Process Fired Heaters, contains a few additions and modifications to Standard 560 which
reflect specific Saudi Aramco requirements.
API Standard 560 covers several aspects of the design of tube supports: materials and their
allowable stresses, loads, and design temperatures.

MATERIALS
Tube support materials are chosen for their high temperature strength and resistance to oxidation.
The materials most commonly used for furnace tube supports and their maximum design
temperatures are the following:
Maximum Design
Temperature, _F
Carbon steel 800
5Cr-1/2Mo 1200
18Cr-8Ni 1500
25Cr-20Ni 2000
Most tube supports and guides made from alloy materials are cast. Carbon steel tube supports are
usually fabricated from structural steel plate material.
In furnaces where the fuel will contain a total of more than 100 ppm vanadium and sodium, steps
must be taken to avoid the high corrosion rates that would be expected on tube supports with a
design temperature of over 1200°F. This is often accomplished by covering the tube support with
a protective layer of heavy castable refractory. The design fuels for recent Saudi Aramco furnaces
contain less than 50 ppm vanadium and sodium, so tube support corrosion is not expected to be a
serious problem.

DESIGN CONDITIONS
Tube supports are designed to meet two load conditions:
• Stresses due to gravity loads (dead loads).
• Combined stresses caused by dead loads and frictional loads. Frictional loads are imposed
on the tube supports due to tube movements caused by their thermal expansion and
contraction. Since these loads are imposed on the supports for only a small fraction of the
time (assumed to be about 10% of the time), higher stresses are permitted in the creep-
rupture (high temperature) range.
Design Temperatures
Internal Supports and Guides
• Radiant Section. Calculated flue gas temperature leaving the radiant section, plus 200°F.
(AES-F-001, par. 6.1.1.1)
• Convection Section. Calculated flue gas temperature in contact with the support, plus
100°F. (AES-F-001, par. 6.1.1.3) As the flue gas passes each convection section row and
transfers heat to the tubes, the flue gas temperature is reduced. This flue gas temperature
reduction can be taken into account in determining tube support design temperatures. It is
not necessary to design convection section tube supports for a uniform flue gas temperature.
External Supports
The design temperature of end tube supports is set equal to the design temperature of the return
bends located inside the header box. This is usually the maximum process fluid operating
temperature, plus 50°F. Design conditions for return bends are presented in MEX 105.06.
Allowable Stresses
Allowable stresses for tube supports are listed in Work Aid 1 for cast materials and Work Aid 2
for plate materials. Currently there are no published industry standards covering allowable tube
support stresses. These allowable stresses are based on Exxon Basic Practice 7-1-1 and related
documents. They represent typical values used in the industry. Tube support stresses are being
developed for inclusion in the next revision to API Standard 560, but this revision is not expected
to be released for several years. The allowable stresses in the revised Standard 560 are expected
to be very similar to those in Work Aids 1 and 2.
Allowable stresses are based on the following (from API Standard 560):

• Elastic range (low temperatures). Stresses are not to exceed:
- 1/3 of ultimate tensile strength, or

- 2/3 of yield strength.
• Creep-rupture range (high temperatures). Stresses are not to exceed:
- For Dead Load stresses:
+ 50% of average stress to produce 1% creep in 10,000 hrs, or

+ 50% of average stress to produce rupture in 10,000 hrs.
- For Dead Load + Friction stresses:
+ The average stress to produce 1% creep in 10,000 hrs, or

+ The average stress to produce rupture in 10,000 hrs.
For cast materials, these allowable stresses are multiplied by a casting factor of 0.8.

CALCULATING REQUIRED THICKNESS OF CONVECTION SECTION TUBE

SUPPORTS
Most convection section tubes are supported at the ends by insulated external tube supports, and
with one or more internal intermediate tube supports. The number of supports is dependent upon
the length of the convection section.
Satisfactory design of intermediate tube supports is essential, since these supports cannot be easily
repaired or replaced without removing some convection section tubes.
A typical tube support is shown in Figure 1. It is supported from the convection section sidewalls
by brackets and guides that are attached to the structure. Furnace manufacturers use a number of
tube support designs. Another tube support is shown in Figure 2. This is similar to the supports
used in Furnace 493-F-301.
FIGURE 1 Typical Convection Section Tube Support

where: l = Length between support points, in.

m = Span for distributed tube loads, in.
n = (l - m)/2
m' = Span for distributed weight of tube support
FIGURE 2 Typical Convection Section Tube Support

For most tube supports, the stresses can be calculated using the simple beam equation:
S = Mc
I (Eqn. 1)
where: S = Calculated stress, psi.

M = Moment, lb-in.
These moments are caused by the loads on the tube supports.
c = Distance from the center of gravity of the support to the location where
the stress is being calculated, in.
I = Moment of inertia of the beam, in.4.
Equation 1 can be used for tube supports where the width of the support is more than 2 times its
height. This covers most cases. For tube supports where the width-to-height ratio is less than 2,
there is no simple way to calculate tube support stresses, and this equation is only an estimate. A
finite element analysis is required to determine these stresses.
Tube Support Loads
Stresses in the tube support are caused by the following loads:
• Total weight of the tubes. This includes:
- Weight of the tube.
- Weight of any extended surface.
+ Tube and extended surface weights can be obtained from published tables or
calculated using the following equations.
- Process fluid in the tube.
+ For all-vapor services, this can be ignored.
• Weight of the tube support itself.
The following equations and Work Aid 3 can be used to determine these loads. The sample
problem in Figure 3 illustrates the use of these procedures. The weight of the tubes on each
convection section row is determined individually, with the sum of the loads on each row
equalling the total tube support load. Work Aid 3 is arranged for tube supports carrying up to 6
tube rows, which covers most cases. Use only the number of tube lines required. If the support
carries more than 6 rows, adjust the form accordingly.

Weight of Tube
wp = 10.68 tavg (Do - tavg) (Eqn. 2)
where: wp = Weight of tube, lb/ft.

Do = Outside diameter of tube, in.
tavg = Average wall thickness of tube, in.
Weight of Extended Surface
Fins:
wf = 10.68 (Do + hf) (hf + 0.03) (tf) (nf) Solid fins (Eqn. 3a)
wf = 10.68 (Do + 0.20) (hf + 0.03) (tf) (nf) Serrated fins (Eqn. 3b)
where: wf = Weight of fins, lb/ft of tube.

hf = Fin length, in.
tf = Fin thickness, in.
nf = Number of fins/in.
If in doubt, use the solid fin equation.
Studs:
ws = 0.222 (ds)2 hs ns nr (Eqn. 3c)
where: ws = Weight of studs, lb/ft of tube.

ds = Stud diameter, in.
hs = Stud length, in.
ns = Number of studs per row.
nr = Number of rows/ft.
For the most common type of stud (0.5-in. diameter studs with 0.625-in. spacing between rows =
19.2 rows/ft), this equation becomes:
ws = 1.068 hs ns (Eqn. 3d)
Weight of Fluid
For water:
ww = 0.3405 (Do - 2tavg)2 (Eqn. 4a)
where: ww = Weight of water (at standard conditions) in coil, lb/ft of tube.

For other process fluids:
wpf = 0.00545 ρ (Do - 2tavg)2 (Eqn. 4b)

= s.g. ww (Eqn. 4c)
where: wpf = Weight of process fluid in coil, lb/ft of tube.

ρ = Density of process fluid, lb/ft3.
s.g. = Density of the fluid at conditions relative to water at standard conditions.
These can usually be determined from the process data.
Total Weight of Tubes
wt = wp + wf (or ws) + wpf (Eqn. 5)
Wt = wtNt (Eqn. 6)
where: wt = Total weight per foot of tube, lb/ft.

Wt = Total weight per convection section row, lb/ft.
Nt = Number of tubes in the row.
Distribution of Tube Loads
The loads on the individual tube supports are not equal and must be calculated. They should be
determined in accordance with procedures in the handbook of the American Institute for Steel
Construction (AISC) for continuous beams on multiple supports.
For furnaces with equally spaced supports, the maximum support loads can be determined using
the following equations:
For intermediate tube supports:
Wr = FiWtLs (Eqn. 7)
For end tube supports:
Wre = FeWtLs (Eqn. 8)
where: Wr = Maximum load on intermediate tube support, lb/tube row.

Wre = Maximum load on end tube support, lb/tube row.
Wt = Total weight per convection section row, lb/ft (from Eqn. 6).
Fi = Intermediate support load factor.
Fe = End support load factor.
Ls = Distance between supports, ft.

The load factors can be determined from the following table:

Number of
Number of Intermediate Fi Fe
Supports Supports (Intermediate) (End)
3 1 1.25 0.44
4 2 1.10 0.40
5 or more 3 or more 1.14 0.40
The first intermediate tube support from the end of the furnace always has the maximum load.
Horizontal Loads
Horizontal loads on the tube supports are caused by friction due to tube movements across the
support. These loads are mainly due to the thermal expansion and contraction of the tubes. For
the design of the tube supports, all tubes are assumed to move in the same direction. These loads
are determined by multiplying the dead loads calculated above by a friction factor of 0.3.
Wrf = 0.3 Wr (Eqn. 9)
Tube Support Weight
In addition to supporting the tubes, the tube support must also support its own weight. Estimated
tube support weights are often listed on the tube support drawings. This weight can be calculated
by determining the tube support volume and multiplying this by the density of the material.
Assume the density is 490 lb/ft3.
Sample Problem - Calculation of Tube Loads
The following sample problem illustrates the use of Work Aid 3 to calculate the loads on a typical
intermediate tube support:
Row Numbers 5-8 Material 25Cr-20Ni ASTM Spec. A297-HK
Convection section length = 40.0 ft
Number of intermediate supports = 2
Tube length between supports, Ls = 13.33 ft
Tubes Extended Surface
Tube Row Do, tavg, Nt, Type, hf/hs, tf/ds, nf/ns, in. nr,
in. in. tubes/row F/S in. in. /row rows/ft
Row #8 5.563 0.258 8 F 1.0 0.05 5.5 -
Row #7 5.563 0.258 8 F 1.0 0.05 5.5 -
Row #6 5.563 0.258 8 F 0.75 0.05 4 -
Row #5 5.563 0.258 8 F 0.75 0.05 4 -
Support load factor, Fi = 1.10

Calculate Loads Loads per ft of tube Total Loads

Friction
wp, +wf/ws, +wpf, = wt, Wt, Wr, Wrf,
Tube Row lb/ft lb/ft lb/ft lb/ft lb/row-ft lb/row lb/row
Equation (2) (3a) Given (5) (6) (7) (9)
Row #8 14.62 19.85 0.3 34.77 278.2 4079 1224
Row #7 14.62 19.85 0.3 34.77 278.2 4079 1224
Row #6 14.62 10.52 0.3 25.44 203.5 2984 895
Row #5 14.62 10.52 0.3 25.44 203.5 2984 895
Total Dead Load: 14,126 lb
Equations:
(2) wp = 10.68 tavg (Do - tavg) Bare Tube Weight
(3a) wf = 10.68 (Do + hf)(hf + 0.03)(tf)(nf) Solid fins
(5) wt = wp + wf (or ws) + wpf Total weight per ft per tube
(6) Wt = wtNt Weight per tube row per ft
(7) Wr = FiWtLs Total load on support per row
(9) Wrf = 0.3 Wr Total friction load on support per row
FIGURE 3
Moments
The maximum moment in the tube support is calculated using the tube and support loads as
determined above. It is assumed that the tube support cross section acts as a simple beam. The
tube load can be assumed to be uniformly distributed on the tube support over the distance
between the centers of the extreme tubes. The weight of the tube support can be assumed to be
uniformly distributed over the entire width of the tube support, not counting any small lugs.
These spans are shown in Figure 2. The moments for each load are calculated separately and then
added together to obtain the total vertical moment. The only horizontal moment is caused by the
friction load.
Most tube supports are supported and guided by small brackets that are attached to structural
steel in the convection section sidewalls. The support points are usually flat surfaces several
inches wide. However, for calculating the maximum moments and stresses, assume that there is a
single point contact between the tube support and the brackets, with the maximum possible span
between the two support points. See Figures 1 and 2.
For loads that are uniformly distributed across the tube support:
M max = W m + n
2 4 (Eqn. 10)

where: Mmax = Maximum moment, lb-in.

W = Total load on support, lb.
m = Distance over which distributed load is carried, in.
n = (l - m)/2, in.
l = Distance between support points, in.
Tube Support Geometry
The following equations and Work Aid 4 can be used to determine the tube support properties
that are needed to calculate the tube support stresses. The required dimensions are shown on the
sketch of a typical tube support cross section in Figure 4. The sample problem in Figure 5
illustrates the use of Work Aid 4. In an arrangement similar to Work Aid 3, Work Aid 4
accommodates up to 6 tube support elements, which should cover most cases. Use only the
number of lines required, and adjust the form to include additional tube support elements.
In determining the tube support moment of inertia, the web between the flanges is often
disregarded. Because of the holes in the web, needed for the tubes to pass through, most of the
web is not continuous. However, when the tube rows are widely spaced, there may be a
continuous web deep enough to be counted.
• Center of Gravity.
Σ b i h id i
CG =
(Eqn. 11)
Σ b ih i
where: CG = Distance from bottom of support to center of gravity, in.

b = Width of element, in.
h = Height of element, in.
d = Distance from bottom of support to center of element, in.
The center of each element should be evident from inspection. If not, the
element should probably be split into smaller elements.
• Moment of Inertia - y Axis.
For a single element:
3
I yy = bh
12 (about its own axis) (Eqn. 12a)
3
I yy ' = bh + bhy 2
12 (about tube support center of gravity) (Eqn. 12b)

where: y = Distance from center of gravity to center of element, in.

Iyy = Moment of inertia of an element, about its own y axis, in.4.
Iyy' = Moment of inertia of an element, about the y axis of the tube support, in.4.
For the tube support:
Iyy'' = Sum of Iyy' for each element (Eqn. 12c)
where: Iyy'' = Moment of inertia of the total tube support, about its y axis, in.4.
• Moment of Inertia - x Axis.
For a single element:
3
I xx = hb (Eqn. 13)
12
where: Ixx = Moment of inertia of an element, about its x axis, in.4.
This is the only calculation required, because the tube support is usually symmetrical about the x
axis, and stresses in the x direction are usually calculated for each flange individually.
Stresses
Stresses in the tube support are calculated using Eqn. 1 and the moments and geometry properties
calculated above. These stresses can be compared to the allowable stresses from Work Aid 1
(after applying the 0.8 casting factor) or Work Aid 2.
If the calculated stresses exceed the allowable stresses, the tube support should be revised.

where: b = Width of flange.

h = Height of flange.
d = Distance from bottom of support to center of flange.
c = Distance from center of gravity to outside surface of element.
y = Distance from center of gravity to center of element.
Y-Y = Center of gravity - y axis.
X-X = Center of gravity - x axis.
FIGURE 4 Tube Support Cross Section

Sample Problem - Convection Section Intermediate Tube Support

The following sample problem illustrates the use of Work Aid 4 to calculate the stresses on a
typical intermediate tube support:
Row Numbers 5-8 Material 25Cr-20Ni ASTM Spec. A297-HK
Flue gas temperatures, top of support: Calculated 1050 °F, Design 1150 °F
bottom of support: Calculated 1350 °F, Design 1450 °F
Given: Tube support dimensions as follows:
1. Calculate maximum moments on tube support.

a. Dead Load. Calculated for total tube support.
W, Total Mmax
load, lb m l n lb-in.
Tubes 14,126 75 91 8 188,924
Support 1420 91 91 0 16,153
Total Mmax, lb-in.: 205,077
Maxim um Mom ent, M m ax = W m + n
2 4 (Eqn. 10)
FIGURE 5

Sample Problem - Convection Section Intermediate Tube Support (Cont'd)
b. Horizontal Loads (Friction). Calculated for each flange supporting a tube row.
Wrf, Friction Mmax,

Flange load, lb m l n lb-in.
Top 1224 75 91 8 16,366
Int. #3 1224 75 91 8 16,366
Int. #2 895 75 91 8 11,972
Bottom 895 75 91 8 11,972
2. Calculate Center of Gravity.
From Drawing: Calculated:

Flange Dimensions Area bh, bhd,
Flange b h d in.2 in.3 c y = c-h/2
Top 5 0.75 26.355 3.75 98.83 13.37 12.99
Int. #3 5 0.75 17.695 3.75 66.36 4.71 4.33
Int. #2 5 0.75 9.035 3.75 33.88 4.71 4.33
Bottom 5 0.75 0.375 3.75 1.41 13.37 12.99
Totals: 15.0 200.48
Sum of bhd 200.48

CG = = = 13.37 in. above bottom of tube support (Eqn. 11)
Sum of bh 15.0
where: b = Width of flange, in.

h = Thickness of flange, in.
d = Distance from bottom surface of tube support to center of flange, in.
c = Distance from center of gravity to outside surface of flange, in.
y = Distance from center of gravity to center of flange, in.
FIGURE 5 (CONT'D)

Sample Problem - Convection Section Intermediate Tube Support (Cont'd)
3. Calculate Moments of Inertia.
Iyy, in.4 Ixx, in.4

bh 3 2 hb 3 cx,
12
+ Ay = Iyy' 12
Flange in.
Equation: (12a) (12b) (13)
Top 0.18 632.78 632.95 7.81 2.5
Int. #3 0.18 70.31 70.48 7.81 2.5
Int. #2 0.18 70.31 70.48 7.81 2.5
Bottom 0.18 632.78 632.95 7.81 2.5
Total 1406.87 4
in. (12c)
Iyy''
4. Tube Support Stresses.
Dead Load + Friction Stress, psi

Design Dead Load Stress, psi Calculated
Flange Temperature, °F Calculated Allowable Friction DL + Fr Allowable
Top 1150 1948 7000 5237 7185 14,000
Int. #3 1250 686 6120 5237 5923 12,224
Int. #2 1350 686 4480 3831 4517 8960
Bottom 1450 1948 3040 3831 5779 6080
S = Mc (Eqn. 1)
I
Allowable Stress = Design Stress x Casting Factor

Material: 25Cr-20Ni
Source: Work Aid 3
Casting factor: 0.8
FIGURE 5 (CONT'D)

DETERMINING REQUIREMENTS OF END TUBE SUPPORTS
The tube supports at the ends of the convection section are usually external supports, consisting
of a stiffened structural steel plate with a refractory lining on the hot flue gas side. The plate is
typically 1/2-in. carbon steel. This tube support makes up one side of the header box. These tube
supports are sometimes referred to as tubesheets.
In some cases, uninsulated end tube supports are used. In these cases, the tube support design
temperature would be the same as that of the intermediate tube supports. The support itself is
often the same design as the intermediate supports.
Loads
Calculation of the loads on end tube supports is similar to that for intermediate tube supports.
These loads consist of the following:
• Tube loads from the hot flue gas side. Calculations are similar to those for intermediate
supports (Eqn. 8, Distribution of Tube Loads).
• The weight of the length of tube that extends into the header box. Part of this length will
usually have extended surface. Dimensions can be determined from the furnace drawings.
For preliminary estimates, assume that the tubes extend 12 in. beyond the hot face of the
refractory lining. Assume that the extended surface extends 9 in. beyond the hot face.
• The weight of connecting return bends. Unless otherwise indicated, the weight of return
bends can be estimated by assuming a bent pipe having the same wall thickness as the tubes.
Stresses
Since end tube supports usually operate at relatively low temperatures, their allowable stresses are
high. Consequently, the dead loads are usually not a problem. However, the structural steel plate
often must be stiffened to accommodate the horizontal friction loads.

RADIANT SECTION TUBE SUPPORTS AND GUIDES
The procedures used in the design of radiant section tube supports are similar to those used for
the convection section. There are some differences in the design of the supports, depending upon
the orientation of the radiant coil.
Horizontal Tubes
Horizontal radiant section tubes are supported at several points, similar to convection section
tubes. The tube supports are bolted to the furnace sidewall structure and extend through the
sidewall refractory. Often each tube support carries only one tube. A typical support of this type
is shown in Figure 6. In other cases, several supports are combined into one casting, resembling
several “fingers.” In some cases, retainers, or “keepers,” are attached to the ends of the supports
to restrict movement of the coil. Because of differences in temperature around the tube, some
tubes can severely distort, or bow, and move off the supports. Figure 6 shows a small retainer
that can fit over the end of the tube support.
Maximum Moment
(at attachment to structure)
M max= Wa, lb-in.
Moment at Refractory Wall
M = Wb, lb-in.
Modified with permission from Petro-Chem Development Co.
FIGURE 6 Support For Horizontal Tubes

In furnaces where return bends are used, the radiant section return bends are usually located in the
firebox, and the end tube supports are identical to the intermediate supports. When plug headers
are used, the headers are always located in header boxes.
Loads on radiant tube supports are determined using the same procedure used in the convection
section. The point of greatest concern on the support is usually that with the maximum moment
at the design temperature. This is at the face of the furnace refractory wall.
Vertical Tubes
The supports for top-supported vertical coils are very similar to those used for horizontal tubes,
except that the vertical loads are greater and the horizontal (friction) loads are often negligible.
Each tube support must support the entire weight of two radiant tubes and two return bends. A
typical vertical tube support is shown in Figure 7.

FIGURE 7 Radiant Section Tube Top Support

For bottom-supported vertical coils, the design of the tube support is usually not of concern. The
support usually consists of a casting mounted on the furnace floor and buried in the floor
refractory. Consequently, its temperature is relatively low, and allowable stresses are high.
Vertical tubes must also be guided to restrict movement other than that required due to thermal
expansion. Figure 8 shows a typical guide used at the top of a bottom-supported coil. It guides
two tubes. One piece is bolted to the structure. A pin is used to attach the second piece after the
tubes are installed. This guide can also be used as a midpoint guide for long vertical tubes.
Top-supported tubes are usually guided at the bottom by a guide pin attached to the return bend,
as shown in Figure 9. This pin fits into a sleeve mounted in the furnace floor.

FIGURE 8 Radiant Section Tube Guide

FIGURE 9 Radiant Section Bottom Tube Guide

Work Aid 1
ALLOWABLE STRESSES FOR CAST TUBE SUPPORT MATERIALS
Dead Load Stress Plus

Temperature, °F (1) Dead Load Stress, psi (2) Frictional Stress, psi (3)
5Cr-1/2Mo (A217, Gr C 5)
800 and below 8750 17500
900 7350 14700
1000 4250 8500
1100 2500 500
1150 1850 3700
18Cr-8Ni (A297, Gr HF)
800 and below 6750 13500
900 6600 13200
1000 6350 12700
1100 5600 11200
1200 4000 8000
1300 2350 4700
1400 1500 3000
25Cr-20Ni (A351, Gr HK 40)
1200 and below 8750 17500
1300 6650 13300
1400 4600 9200
1500 3050 6100
1600 2000 4000
1700 1300 2600
1800 790 1580
1900 410 820
2000 130 260
25Cr-35Ni (HP 45)
1800 960 1920
1900 500 1000
2000 250 500
2100 130 260
2200 80 160
NOTES:
(1) For intermediate temperatures, allowable stresses may be obtained from a smooth curve through the data
points.
(2) Casting factor has not been applied for these stress values.

Work Aid 2
ALLOWABLE STRESSES FOR WROUGHT TUBE SUPPORT MATERIALS
Dead Load Stress Plus Frictional

Temperature, °F (1) Dead Load Stress, psi (2) Stress, psi (2)
Carbon Steel, A285 Gr C
800 and below 10700 21400
Carbon Steel, A242 Type 1
(thickness less than 0.5 in)
800 and below 23500 47000
Carbon Steel, A242 Type 2
(thickness over 0.5 in.)
800 and below 19000 38000
5Cr-1/2Mo A357
800 and below 11500 23000
900 7500 15000
1000 4500 9000
1100 2500 5000
1150 1875 3750
18CR-8Ni A240, A167 Type 304
(0.4% carbon minimum)
1000 and below 12750 25500
1100 8250 16500
1200 5400 10800
1300 3500 7000
1400 2300 4600
19Cr-35Ni, Si Mn SB536
1400 1800 3600
1500 1325 2650
1600 900 1800
1700 470 940
1800 260 520
1900 165 330
2000 113 225
Ni-Fe-Cr, B-409 Alloy 800H
1200 7000 10800
1300 4100 8200
1400 2750 5500
1500 1800 3600
1600 1400 2800
1700 650 1300
1800 500 1000
NOTES:
(1) For intermediate temperatures, allowable stresses may be obtained from a smooth curve through the data points.
(2) A casting factor is not required.

Work Aid 3
TUBE SUPPORT LOADS CALCULATION SHEET
The following procedure can be used to determine loads on the tube supports:
Furnace Unit Plant Location
Row Numbers Material ASTM Spec.
Convection section length = ft
Number of intermediate supports =
Tube length between supports, Ls = ft
Tubes Extended Surface
Tube Row Do, tavg, Nt, Type, hf/hs, tf/ds, nf/ns, nr,
in. in. tubes/row F/S in. in. in./row rows/ft
Row #
Row #
Row #
Row #
Row #
Row #
Support load factor, Fi =
Calculate Loads:
Loads per ft of tube Total Loads
Friction
wp, +wf/ws, +wpf, = wt, Wt, Wr, Wrf,
Tube Row lb/ft lb/ft lb/ft lb/ft lb/row-ft lb/row lb/row
Row #
Row #
Row #
Row #
Row #
Row #
Total Dead Load: lb
Equations:
(2) wp = 10.68 tavg (Do - tavg) Bare Tube Weight
(3a) wf = 10.68 (Do + hf)(hf + 0.03)(tf)(nf) Solid fins
(3b) wf = 10.68 (Do +0.20)(hf + 0.03)(tf)(nf) Serrated fins
(3c) ws = 0.222 (ds)2 hs ns nr Studs
(3d) ws = 1.068 hs ns 1/2 in. dia. studs, 19.2 rows per ft
(4b) wpf = 0.00545 ρ (Do - 2tavg)2 or: Process Fluid
= 0.3405 (s.g.) (Do - 2tavg)2
(5) wt = wp + wf (or ws) + wpf Total weight per ft per tube
(6) Wt = wtNt Weight per tube row per ft
(7) Wr = FiWtLs Total load on support per row
(9) Wrf = 0.3 Wr Total friction load on support per row

Work Aid 4
TUBE SUPPORT STRESSES CALCULATION SHEET
The following procedure can be used to calculate stresses on intermediate convection section tube
supports.
Furnace Unit Plant Location

Row Numbers Material ASTM Spec.
Flue gas temperatures, Top of support: Calculated °F, Design °F

Bottom of support: Calculated °F, Design °F
Determine the required dimensions from a drawing of the tube support.
Drawing Number:
1. Calculate Maximum Moments on Tube Support.
a. Dead Load. Calculated for total tube support.
W, Total Mmax
load, lb m l n lb-in.
Tubes
Support
Total Mmax, lb-in.:
Maxim um Mom ent, M m ax = W m + n

2 4 (Eqn. 10)
b. Horizontal Loads (Friction). Calculated for each flange supporting a tube row.
Wrf, Friction Mmax

Flange load, lb m l n lb-in.
Top
Int. #
Int. #
Int. #
Int. #
Bottom

TUBE SUPPORT STRESSES CALCULATION SHEET (CONT'D)
2. Calculate Center of Gravity.
Given: Calculated:
Flange Dimensions Area bh, bhd,
Flange b h d in.2 in.3 c y = c-h/2
Top
Int. #
Int. #
Int. #
Int. #
Bottom
Totals:
Σ bhd
CG = = = in. above bottom of tube support
Σ bh
(Eqn. 11)
where: b = Width of flange, in.

h = Thickness of flange, in.
d = Distance from bottom surface of tube support to center of flange, in.
c = Distance from center of gravity to outside surface of flange, in.
y = Distance from center of gravity to center of flange, in.
3. Calculate Moments of Inertia.
Iyy, in.4 Ixx, in.4

bh 3 2 hb 3 cx,
+ Ay = Iyy'
Flange 12 12 in.
Top
Int. #
Int. #
Int. #
Int. #
Bottom
Total Iyy'': in.4

4. Tube Support Stresses.
Dead Load + Friction Stress, psi

Design Dead Load Stress, psi Calculated
Flange Temperature, °F Calculated Allowable Friction DL + Fr Allowable
Top
Int. #
Int. #
Int. #
Int. #
Bottom
S = Mc (Eqn. 1)
I
Allowable Stress = Design Stress x Casting Factor

Material:
Source:
Casting Factor:

GLOSSARY
bridgewall The temperature of the flue gas leaving the radiant

temperature section. The term comes from the old horizontal box
heaters, where a bridgewall physically separated the
radiant and convection sections.
coil A series of straight tube lengths connected by 180°
return bends, forming a continuous path through which
the process fluid passes and is heated.
convection section The portion of a heater, consisting of a bank of tubes,
which receives heat from the hot flue gases, mainly by
convection.
extended service Surface added to the outside of bare tubes in the
convection section to provide more heat transfer area.
This may consist of cylindrical studs butt-welded to the
tubes or fins continuously wound around and welded to
the tubes.
flue gas A mixture of gaseous products resulting from
combustion of the fuel.
header The fitting which connects two tubes in a coil. In
common usage, “header” refers to cast or forged 180°
“U-bends” (“return bends”).
header box The compartment at the end of the convection section
where the headers are located. There is no flue gas flow
in the header box, since it is separated from the inside of
the heater by an insulated tubesheet. Header boxes are
sometimes used in the radiant section also.
radiant section The section of the fired heater in which heat is
transferred to the heater tubes, primarily by radiation
from high-temperature flue gas.
tube guide Device used to restrict the movement of tubes.
tubesheet A large tube support plate supporting a number of
tubes, usually located at the ends of the convection
section.
tube support A metal part that supports the weight of the tube.

REFERENCE
Saudi Aramco Standards
AES-F-001 Process Fired Heaters
API Publications
Standard 560 Fired Heaters for General Refinery Services
ASTM Publications
Material Specifications
AISC Publications
Manual of Steel Construction
Exxon Basic Practices
BP 7-1-1 Fired Heaters

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Engineering Encyclopedia

Saudi Aramco DeskTop Standards

Furnaces - Design Of Tube Supports

Chapter : Vessels For additional information on this subject, contact

DESIGN CONDITIONS ...................................................................................................... 4

Saudi Aramco DeskTop Standards

Work Aid 2...................................................................................................27

Saudi Aramco DeskTop Standards

• Calculating the loads on a tube support.

• Checking the design of a new tube support.

• Determining the adequacy of a tube support for new operating conditions.

Two types of tube supports and guides are used:

Saudi Aramco DeskTop Standards 1

Saudi Aramco DeskTop Standards 2

Saudi Aramco DeskTop Standards 3

Tube supports are designed to meet two load conditions:

• Stresses due to gravity loads (dead loads).

Internal Supports and Guides

Saudi Aramco DeskTop Standards 4

• Elastic range (low temperatures). Stresses are not to exceed:

- 1/3 of ultimate tensile strength, or

• Creep-rupture range (high temperatures). Stresses are not to exceed:

- For Dead Load stresses:

+ 50% of average stress to produce 1% creep in 10,000 hrs, or

- For Dead Load + Friction stresses:

+ The average stress to produce 1% creep in 10,000 hrs, or

Saudi Aramco DeskTop Standards 5

CALCULATING REQUIRED THICKNESS OF CONVECTION SECTION TUBE

FIGURE 1 Typical Convection Section Tube Support

Saudi Aramco DeskTop Standards 6

where: l = Length between support points, in.

FIGURE 2 Typical Convection Section Tube Support

Saudi Aramco DeskTop Standards 7

where: S = Calculated stress, psi.

Tube Support Loads

Stresses in the tube support are caused by the following loads:

• Total weight of the tubes. This includes:

- Weight of the tube.

- Weight of any extended surface.

- Process fluid in the tube.

+ For all-vapor services, this can be ignored.

• Weight of the tube support itself.

Saudi Aramco DeskTop Standards 8

wp = 10.68 tavg (Do - tavg) (Eqn. 2)

where: wp = Weight of tube, lb/ft.

Weight of Extended Surface

where: wf = Weight of fins, lb/ft of tube.

If in doubt, use the solid fin equation.

where: ws = Weight of studs, lb/ft of tube.

ws = 1.068 hs ns (Eqn. 3d)

ww = 0.3405 (Do - 2tavg)2 (Eqn. 4a)

where: ww = Weight of water (at standard conditions) in coil, lb/ft of tube.

Saudi Aramco DeskTop Standards 9

For other process fluids:

wpf = 0.00545 ρ (Do - 2tavg)2 (Eqn. 4b)

where: wpf = Weight of process fluid in coil, lb/ft of tube.

Total Weight of Tubes

wt = wp + wf (or ws) + wpf (Eqn. 5)

where: wt = Total weight per foot of tube, lb/ft.

Distribution of Tube Loads

For intermediate tube supports:

For end tube supports:

Wre = FeWtLs (Eqn. 8)