Introduction to Shell and Tube Heat Exchangersmazlan/?download=Introduction+to+Shell+and+Tub… ·...
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TEMA Shell and Tube Heat Exchangers
© Copyright Progressive Thermal Engineering All rights reserved.Page 1-1-1
Introduction to Shell and Tube Heat Exchangers
Introduction
� General Description� Identifying Major Components� TEMA Standards� Vibration
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TEMA Shell and Tube Heat Exchangers
© Copyright Progressive Thermal Engineering All rights reserved.Page 1-1-2
Shell and Tube Heat Exchangers
Tubeside flow (four passes)
Typical Major Components
Floating head
Stationary head
Pass partitions
Pass partitionShellside flow,
one pass
Tubesheet
BaffleTube
Shell
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TEMA Shell and Tube Heat Exchangers
© Copyright Progressive Thermal Engineering All rights reserved.Page 1-1-3
General Description
� The variety of designs and configurations are almost limitless
� Common features:– A collection of tubes manifolded together to
form a “tube bundle”– A chamber formed around the outside of the
tube bundle, the “shell”
� One stream flows inside the tube bundle, the other outside the tube bundle, contained by the shell
Identifying Major Components
� Tubesheets� Channels� Fixed and floating heads� Shell covers� Bundle
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TEMA Shell and Tube Heat Exchangers
© Copyright Progressive Thermal Engineering All rights reserved.Page 1-1-4
Tubesheets
� Within the scope of TEMA, tubes are manifolded together with tubesheets or U-bends
� A tubesheet is a flat, circular plate drilled to allow the tubes to be inserted
� U-bends are used to connect pairs of tubes together to remove the need for a tubesheet at one end of the exchanger
Tubesheets / U-bends
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TEMA Shell and Tube Heat Exchangers
© Copyright Progressive Thermal Engineering All rights reserved.Page 1-1-5
Straight Tube / U-tube
� An exchanger in which two tubesheets are used is called a straight tube exchanger
� An exchanger with one tubesheet and U-bend returns is called a U-tube exchanger
Channels
� In order to direct the tubeside flow in and out of the tubes, a chamber is attached to the tubesheet, called a channel
� Depending on the design this may also be called a bonnet or waterbox
� Selection of channel type is based on balancing access requirements for maintenance against cost
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TEMA Shell and Tube Heat Exchangers
© Copyright Progressive Thermal Engineering All rights reserved.Page 1-1-6
Fixed / Floating Heads
� Tubesheet may be fastened to the shell, or free to move relative to the shell– A tubesheet which is fastened is called a
fixed head– A tubesheet which is free to move is called a
floating head
� A fixed-tubesheet exchanger has both tubesheets fixed
� A floating-head exchanger has one fixed head and one floating
Shell Cover
� In a floating head heat exchanger, a removable cover may be incorporated into the shell at the floating end
� Allows access to the floating head without disturbing the fixed head
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TEMA Shell and Tube Heat Exchangers
© Copyright Progressive Thermal Engineering All rights reserved.Page 1-1-7
Bundles
� The tube bundle comprises:– tubesheets / tubes / U-tubes– baffles / support plates– tie-rods / spacers
� The tubes may be arranged for single pass or multi-pass, using pass partition plates in the channel(s)
Bundle Fabrication
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TEMA Shell and Tube Heat Exchangers
© Copyright Progressive Thermal Engineering All rights reserved.Page 1-1-8
TEMA Size and Type
TEMA Designations
� The TEMA standard contains a coding system to allow the size and configuration of a heat exchanger to be expressed in a concise manner
� This description system is widely accepted and understood
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TEMA Shell and Tube Heat Exchangers
© Copyright Progressive Thermal Engineering All rights reserved.Page 1-1-9
TEMA Type Code
� A three letter code is used to describe the configuration:
B E MB E MFront head
Shell type
Rear head
TEMA Shell Types
� Selection of shell type is primarily a process/thermal design decision
� Different types create different flow paths through the shell
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TEMA Shell and Tube Heat Exchangers
© Copyright Progressive Thermal Engineering All rights reserved.Page 1-1-10
TEMA Shell Types
Divided flow
One-pass shell Two-pass shell, longitudinal baffle
E F
J
TEMA Shell Types
Double-split flowSplit flow
Crossflow
X
H
Kettle reboiler
K
G
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TEMA Shell and Tube Heat Exchangers
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TEMA Front Head Types
� Selection of front head type is primarily a mechanical design decision
� Different types provide various levels of access for maintenance
� Cost and pressure-integrity become factors at higher pressure
TEMA A Type
Channel and removable cover
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TEMA Shell and Tube Heat Exchangers
© Copyright Progressive Thermal Engineering All rights reserved.Page 1-1-12
TEMA B Type
Bonnet (integral cover)
TEMA C Type
Channel integral with tubesheet and removable cover
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TEMA Shell and Tube Heat Exchangers
© Copyright Progressive Thermal Engineering All rights reserved.Page 1-1-13
TEMA N Type
Channel integral with tubesheet and removable cover
TEMA D Type
Special High Pressure Closure
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TEMA Shell and Tube Heat Exchangers
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TEMA Rear Head Types
� Selection of rear head type is primarily a mechanical design decision
� Different types provide various levels of access for maintenance
� Types L, M and N imply a fixed-tubesheet construction
� Types P, S, T, U and W are floating head types (bundle free to expand relative to shell)
TEMA L, M and N Type
L M
N
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TEMA Shell and Tube Heat Exchangers
© Copyright Progressive Thermal Engineering All rights reserved.Page 1-1-15
TEMA U Type
TEMA P, S, T and W TypesML
P
S T
W
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TEMA Shell and Tube Heat Exchangers
© Copyright Progressive Thermal Engineering All rights reserved.Page 1-1-16
TEMA Size Code
� A two-number code� First number is the shell id to the nearest
whole inch� Second number is the tube length to the
nearest whole inch� Example: TEMA size 31-240
(31” ID shell with 240” (20’) tubes)
TEMA Size Code
� For U-tube exchangers, the tube length is the length of the straight leg
� For kettle reboilers, the shell diameter is expressed as two numbers, the port ID then the shell ID:
Length
Port IDShell ID
E.g. Size 17/43 - 192
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TEMA Shell and Tube Heat Exchangers
© Copyright Progressive Thermal Engineering All rights reserved.Page 1-1-17
Tube Bundle Construction
Heat Exchanger Tubes
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TEMA Shell and Tube Heat Exchangers
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Heat Exchanger Tubing
� Welded vs Seamless Tube� Average vs Minimum Wall� U-tube bending� Tube pitches
Seamless vs Welded
Drawn from a solid billet or forged
cylinder
Rolled from a flat strip and welded along longitudinal seam
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TEMA Shell and Tube Heat Exchangers
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Which to use?
� Welded tube is cheaper and more readily available
� Quality of welded tube can be very high:– continuous testing of weld– Individual tube pressure testing– heat treatment of weld– no significant weld bead outside tube section
� Use seamless only for lethal service, very high integrity, or very high pressure
Wall Thickness Tolerance
� Important to understand the difference between minimum wall and average wall tubes
� Tolerances are controlled by the ASTM material spec. (e.g. SA-213 is a minimum wall spec., SA-249 is an average wall spec.)
� Min. wall usually -0% +20% thickness� Av. wall usually -10% +10% thickness
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TEMA Shell and Tube Heat Exchangers
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U-tube Bending
� The process of forming a U-bend from a straight tube will:– thin the wall on the outside of the bend– tend to flatten the tube on the outside of the
bend– tend to crimp the inside of the bend– work-harden the tube material
� These effects limit the diameter of the bend to a minimum value (typically 3Do)
� Heat treatment may be required
U-Bend Forming
TEMA limits wall thinning to 17% for non-work hardening materials (equivalent to R = 1.5Do)
Crimping
Flattening
Thinning
R
Do
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TEMA Shell and Tube Heat Exchangers
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Tube Pitches
60° layout
Pt
30° layout
Pt
90° layout
Pt
45° layout
Pt
Tube Pitch
� A minimum value of Pt must be maintained:– To retain mechanical strength in tubesheet– To allow any welding of tube end– To allow cleaning outside tubes
� Typical: Pt = 1.25 x Dt
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TEMA Shell and Tube Heat Exchangers
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Tube-to-Tubesheet Attachment
� Tubes need to be attached to:– prevent interstream leakage– transmit mechanical loads
� Attachment may be by welding, expansion or both
� Type of attachment affects tube pitch requirement
� Attachment type has impact on ease of re-tubing
Types of Attachment
� Expansion:– Used as an attachment process providing
both sealing and strength functions– Light expansion used to remove crevice at
back face of tubesheet
� Welding:– Seal weld creates a better seal than
expansion, especially at high temperatures– Strength weld (weld strength ≥ tube strength)
provides both sealing and strength
� Explosive expansion and welding are also used
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TEMA Shell and Tube Heat Exchangers
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Welded Only
Tubesheet
Tube
Weld
Expanded Only
Tubesheet
Tube
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TEMA Shell and Tube Heat Exchangers
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Welded and Expanded
Tubesheet
Tube
Weld
Back-Face Welding
Tubesheet
Tube
Weld
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TEMA Shell and Tube Heat Exchangers
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Tube Passes
Tubepasses
� Multiple passes are used to:– increase tubeside velocity– reduce overall length– allow U-tube/floating head designs
� Single pass designs used to retain counter-current flow
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TEMA Shell and Tube Heat Exchangers
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Pass Partitions
Pass partition
2-Pass, B-Type Head
Tubesheet
Drain hole
Weld
Gasket
Pass Lane
Pass Arrangements
4-Passquadrant
6-Passribbon-banded
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TEMA Shell and Tube Heat Exchangers
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Pass Arrangements
Quadrant(good for U-tubes)
Ribbon-banded(good pass lane
orientation)
1 2
4 3 1
2
3
4
56
1
2 3
45
6
H-banded(good tube count
distribution)
Pass Considerations
� Number of passes and arrangement is mainly driven by thermal design
� Limitations:– construction of pass partitions– thermal gradients– effect on tubecount (total and pass-to-pass)– gasket seating– shellside bypassing
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TEMA Shell and Tube Heat Exchangers
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Baffles
Shellside Baffles
� Baffles have two main purposes:– To direct the shellside fluid in crossflow, to
improve heat transfer– To support the tubes against sagging and
vibration
� Described by type, cut and pitch
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TEMA Shell and Tube Heat Exchangers
© Copyright Progressive Thermal Engineering All rights reserved.Page 1-1-29
Baffle Types
Single Segmental
Double Segmental
Baffle Pitch and CutPitch
hCut % = (h/Ds) x 100
End Space(often greater than pitch) Ds
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TEMA Shell and Tube Heat Exchangers
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No-Tubes-in-Window
Standard Single Segmental
No-Tubes-in-Window
Baffle Construction
Triple Segmental
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TEMA Shell and Tube Heat Exchangers
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Tie-Rod / Spacer
� This system allows accurate alignment of the baffles during construction
Tie-rod Spacer tube
Baffle
� Permits condenser drainage
� Better end zone distribution
� Prevents separation or stratification
Baffle Orientation
Perpendicular cut(perpendicular to nozzle centreline)
Nozzle
Baffle cut
Parallel cut(parallel to nozzle centreline)
Baffle cut
Nozzle
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TEMA Shell and Tube Heat Exchangers
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Baffle Selection
� Selection depends on
– Pressure drop requirements
– Tube support requirements
– Heat transfer requirements
Typical Tubesheet Layout
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TEMA Shell and Tube Heat Exchangers
© Copyright Progressive Thermal Engineering All rights reserved.Page 1-1-33
Tubesheet Layout