Submitted by:

2014-CH-64
M. Ahmed Khan

Submitted to:
Sir Amir Abbas

SHELL AND TUBE HEAT

UNIVERSITY OF ENGINEERING
EXCHANGER AND TECHNOLOGY,LAHORE
Process Heat transfer 2014-CH-64 Assignment 1

CONTENTS

TEMA Standards 2
Front end head types 3-8
Shell Types 9-14
Rear end head types 15-21
Shell and Tube Heat Exchanger 22-23
References 24

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Process Heat transfer 2014-CH-64 Assignment 1

TEMA STANDARDS
TEMA stands for Tubular Exchanger manufacturing
Association. The association has set some standards
for the manufacturing of shell and tube heat
exchangers, which are given as follow.
The first letter indicates the front-end head
type.
The second letter indicates the shell type
The third letter indicates the rear-end head
type.
For example, the name AEL indicates that the
front end type of geometry A will be used,
shell type of geometry B will be used and the
rear end will be of L geometry. The various
geometries according to TEMA standards will
be described in next part of the assignment.

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Process Heat transfer 2014-CH-64 Assignment 1

Front end head types

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Process Heat transfer 2014-CH-64 Assignment 1

A Type front head

The construction is such that Open-
end heads that are fabricated from cylindrical sections are called
channels. These are fitted with easily removable cover plates so
that tubes can be cleaned without disturbing piping. They are
used widely where fouling conditions are encountered or where
frequent access for inspection is desired. The geometry will looks
like this

The removable cover permits access to the channel and tubes for
inspection or cleaning without the need to remove the tube side
piping. Removable cover channels are provided when frequent
access is required. The limitations of this geometry is that these
type of heads cannot be used when high pressure fluids are to be
operated otherwise there will be leakages problem.

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Process Heat transfer 2014-CH-64 Assignment 1

B type front Head:

The cover of this head is not removable so only
one side of the head needs joints. This is the cheapest type of front
header. It also is more suitable than the A-Type Front Header for high
pressure duties because the header has only one seal. A disadvantage is
that to gain access to the tubes requires disturbance to the pipe work in
order to remove the header. For this type of head low fouling fluid is
required because otherwise cleaning is difficult. The geometry will look
like this

If possible use this type because this is very simple in construction and
most cheap among others

C Type front Head:

The geometry is with removable shell for
hazardous tube-side fluids, heavy bundles or services that need frequent
shell-side cleaning. This type of header is for high pressure applications
(>100 bar). It does allow access to the tube without disturbing the pipe
work but is difficult to repair and replace because the tube bundle is an
integral part of the header. The geometry will look like this

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Process Heat transfer 2014-CH-64 Assignment 1

In this arrangement replacement of bundle is not possible however

individual tubes can be replaced. Interior of tubes can be cleaned both
mechanically and chemically

N Type front head:

This type of geometry has the tube
sheets welded to the shell, as can be appreciated in the detail included in
the figure. This means that once the unit is built, it is not possible to have
access to the shell side for cleaning or inspection. This type of heat
exchanger is called a fixed-tube sheet exchanger. It looks like this.

The construction sequence is as follows:

Tube sheet and baffle holes are drilled.

The tubes are installed in one of the tube sheets.
The baffles and spacers are introduced through the tubes and tie rods.
The shell is placed in position.
The second tube sheet is installed.
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Process Heat transfer 2014-CH-64 Assignment 1

The shell is welded to the tube sheets.

The tubes are rolled into the tube sheets.

The two main disadvantages of this type of unit are

It cannot be disassembled for cleaning or inspection.

If the temperature difference between the fluids is high or the linear
thermal expansion coefficients of the tube and shell materials are very
different, when the exchanger comes into operation, differential
expansion between shell and tubes creates forces acting on the tube-to-
tube sheet joints that can damage the unit. It looks like this

The first of these problems cannot be solved with this type of heat
exchanger. This means that this design is not suitable for cases in which
both fluids have a fouling tendency (if only one fluid is fouling, it can be
allocated to the tube side because the tube interiors can be cleaned
mechanically). In some cases even though a mechanical cleaning of the
tube exteriors is not possible, they can be cleaned chemically by circulating
a solvent or detergent. However, this alternative is not feasible in many
applications where the fouling characteristics of the fluid require
mechanical removal procedures. The second problem, differential
expansion between the shell and tube bundle, can be solved by installing a
shell expansion joint .Such expansion joints act as elastic bellows
absorbing the differential expansion without transmitting forces to the
tube sheets. During mechanical design of the heat exchanger, it is
determined if the installation of an expansion joint is necessary. However,
the most common approach to solving the two previously mentioned
limitations of the fixed tube sheet design is to adopt a removable-bundle
construction

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Process Heat transfer 2014-CH-64 Assignment 1

D type front head:

This is the most expensive type of front
header. It is for very high pressures (> 150 bar). It does allow access to the
tubes without disturbing the pipe work but is difficult to repair and replace
because the tube bundle is an integral part of the header. The geometry
will look something like this

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Process Heat transfer 2014-CH-64 Assignment 1

SHELL TYPES

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Process Heat transfer 2014-CH-64 Assignment 1

E type Shell:
The E shell is a single-pass shell that is
economical and usually has the most efficient thermal
arrangement (i.e., it has the highest mean temperature
difference correction factor). This is most commonly used shell
type, suitable for most duties and applications. Other shell types
only tend to be used for special duties or applications. It is very
simple in construction. The figure looks like this

F Type Shell:
This type of shell is also known as two
pass shell. In this shell geometry shell is separated into two parts
by longitudinal baffle. This is generally used when pure
countercurrent flow is required in a two tube side pass unit. This
is achieved by having two shells side passesthe two passes
being separated by a longitudinal baffle. The main problem with
this type of unit is thermal and hydraulic leakage across this
longitudinal baffle unless special precautions are taken.

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Process Heat transfer 2014-CH-64 Assignment 1

Longitudinal baffles are difficult to seal with the shell especially

when reinserting the shell after maintenance. This type of
geometry reduces the ae required for heat exchangers. The
figure looks like this

G Type Shell:
Split-flow exchangers are often used when
the permissible pressure drop of the shell-side fluid is so small
that the fluid cannot be permitted to travel the full length of the
shell. The fluid is admitted at the center of the shell and the flow
is split as shown in Figure.

The pressure drop through the shell of an exchanger may be

approximately considered as directly proportional to the length
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Process Heat transfer 2014-CH-64 Assignment 1

Of the path and to the square of the mass velocity of the shell
aide fluid. Since in a split-flow exchanger, both the mass velocity
and the length of the path are reduced by a factor of 2, the
resultant pressure drop is approximately one eighth that of a
conventional exchanger. The G shell is used in many applications,
with the shell side thermosiphon and forced convective boiling as
one of the common applications.

H Type Shell:
This is used for similar applications to G-Type
Shell but tends to be used when larger units are required. This is
just like the G Type Shell with only two longitudinal baffles thats
why it is also called as double split flow heat exchanger.

J-Type shell:
This tends to be used when the
maximum allowable pressure drop is exceeded in an E-Type Shell
even when double segmental baffles are used. It is also used when
tube vibration is a problem. The divided flow on the shell side
reduces the flow velocities over the tubes and hence reduces the
pressure drop and the likelihood
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Process Heat transfer 2014-CH-64 Assignment 1

Of tube vibration. When there are two inlet nozzles and one outlet
nozzle this is sometimes referred to as an I-Type Shell.

X Type Shell:
This is used if the maximum shell side
pressure drop is exceeded by all other shell and baffle type
combinations. The main applications are shell side condensers and
gas coolers

K-Type shell:
This is used only for reboilers to provide
a large disengagement space in order to minimize shell side liquid
carry over. Alternatively a K-Type Shell may be used as a chiller. In
this case the main process is to cool the tube side fluid by boiling a
fluid on the shell side

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Process Heat transfer 2014-CH-64 Assignment 1

These all were the types of shell side. Different shells can
be used depending upon the operating conditions and the nature
of fluids.

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Rear Head Type

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Process Heat transfer 2014-CH-64 Assignment 1

These fall into three general types

Fixed tube sheet (L, M, N)
U-tube
Floating head (P, S, T, W)

Use fixed tube sheet if T below 50 degree C, otherwise

use other types to allow for differential thermal expansion

We can use bellows in shell to allow for expansion but

these are special items which have pressure limitations
(max. 35 bar).Brief description of every type is given below.

L-Type rear header:

This type of header is for use with fixed
tube sheets only, since the tube sheet is welded to the shell and
access to the outside of the tubes is not possible. The main
advantages of this type of header are that access can be gained to
the inside of the tubes without having to remove any pipework and
the bundle to shell clearances are small. The main disadvantage is
that a bellows or an expansion roll are required to allow for large
thermal expansions and this limits the permitted operating
temperature and pressure as shown in the figure.

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Process Heat transfer 2014-CH-64 Assignment 1

L is a mirror of the A front end head

M-Type rear header:

This type of header is similar to the L-
Type Rear Header but it is slightly cheaper. However, the header
has to be removed to gain access to the inside of the tubes. Again,
special measures have to be taken to cope with large thermal
expansions and this limits the permitted operating temperature
and pressure.

This is the mirror of Bonnet (B) front head type.

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Process Heat transfer 2014-CH-64 Assignment 1

N-Type rear header:

The advantage of this type of header is
that the tubes can be accessed without disturbing the pipe work.
However, they are difficult to maintain and replace since the
header and tube sheet are an integral part of the shell.

N Type rear header is the mirror of N Type front head.

P-Type rear header:

This is an outside packed floating rear
header. It is, in theory, a low cost floating head design which allows
access to the inside of the tubes for cleaning and also allows the
bundle to be removed for cleaning. The main problems with this
type of header are:

large bundle to shell clearances required in order to pull

the bundle
It is limited to low pressure nonhazardous fluids, because
it is possible for the shell side fluid to leak via the packing
rings

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Process Heat transfer 2014-CH-64 Assignment 1

Only small thermal expansions are permitted.

In practice it is not a low cost design, because the shell has to be

rolled to small tolerances for the packing to be effective.

S-Type rear header:

This is a floating rear header with backing
device. It is the most expensive of the floating head types but does
allow the bundle to be removed and unlimited thermal expansion
is possible. It also has smaller shell to bundle clearances than the
other floating head types. However, it is difficult to dismantle for
bundle pulling and the shell diameter and bundle to shell
clearances are larger than for fixed head type exchangers.

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Process Heat transfer 2014-CH-64 Assignment 1

T-Type rear header:

This is a pull through floating head
having large shell/Bundle gap. It is cheaper and easier to remove
the bundle than with the S-Type Rear Header, but still allows for
unlimited thermal expansion. It does, however, have the largest
bundle to shell clearance of all the floating head types and is more
expensive than fixed header and U-tube types.

W-Type rear header:

This is a packed floating tube sheet
with lantern ring. It is the cheapest of the floating head designs,
allows for unlimited thermal expansion and allows the tube bundle
to be removed for cleaning. The main problems with this type of
head are:

The large bundle to shell clearances required to pull the

bundle and;

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Process Heat transfer 2014-CH-64 Assignment 1
The limitation to low pressure nonhazardous fluids
(because it is possible for both the fluids to leak via the
packing rings).

It is also possible for the shell and tube side fluids to become mixed
if leakage occurs.

U-tube:
This is the cheapest of all removable bundle designs, but
is generally slightly more expensive than a fixed tube sheet design
at low pressures. However, it permits unlimited thermal expansion,
allows the bundle to be removed to clean the outside of the tubes,
has the tightest bundle to shell clearances and is the simplest
design. A disadvantage of the U-tube design is that it cannot
normally have pure counter flow unless an F-Type Shell is used.
Also, U-tube designs are limited to even numbers of tube passes.

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Process Heat transfer 2014-CH-64 Assignment 1

Shell and tube heat exchanger

1. Stationary Head-Channel
2. Stationary Head-Bonnet
3. Stationary Head Flange
Channel or Bonnet
4. Channel Cover
5. Stationary Head Nozzle
6. Stationary Tube sheet
7. Tubes
8. Shell
9. Shell Flange
Stationary Head End
10. Shell Flange
Rear Head End
11. Shell Nozzle
12. Shell Cover Flange

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Process Heat transfer 2014-CH-64 Assignment 1
13. Floating Tube sheet
14. Floating Head Cover
15. Floating Head cover Flange
16. Floating Head backing device
17. Tie rods and spacers
18. Baffles
19. Impingement plates
20. Vent connection
21. Drain connection
22. Instrument connection
23. Support Saddle
24. Lifting Lug
25. Pass partition

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References
Books:
Robert W. Serth, Thomas G. Lestina, Process Heat Transfer:
Principles, Applications and Rules of Thumb, 2014, 2nd Edition,
Academic Press, Elsevier.
Eduardo Cao, Heat Transfer in Process Engineering
J.P Holman, Heat Transfer, Tenth Edition

Web Links:
http://www.hcheattransfer.com/shell_and_tube.html
http://wermac.org/equipment/heatexchanger_part5.html
http://www.engineeringpage.com/heat_exchangers/tema.html
http://www.thermopedia.com/content/1121/

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