PART UG GENERAL REQUIREMENTS Fig.

UG-34

Center of weld Center of lap

ts
tf min. = 2ts Y
Y t t
ts t Tangent ts tf rmin. = 0.375 in. (10 mm) s Tangent
line for ts 11/2 in. (38 mm) line
r = 3t r = 3tf rmin. = 0.25ts for r = 3t
d ts 11/2 in. (38 mm)
min. min. min.
Taper but need not be greater
d t d t t d t
than 3/4 in. (19 mm)
C = 0.17 or C = 0.17 C = 0.33m C = 0.30
C = 0.10 C min. = 0.20 C = 0.20 or 0.13
(a) (b-1) (b-2) (c)

tw = 2tr min. nor less than 1.2ts

but need not be greater than t
t
0.7ts 0.7ts Projection
0.7ts ts
r = 1/4t beyond weld
min. is optional
0.7ts Bevel is optional
d ts ts Continuation
t d t d t of shell d 45 deg max.
t
optional
C = 0.13
Sketches (e), (f), and (g) circular covers, C = 0.33m, Cmin. = 0.20
(d) (e) (f) (g)

See Fig. UW-13.2 sketches (a) to (g),

See Fig. UW-13.2 sketches (a) to (g), inclusive, for details of outside
inclusive, for details of welded joint welded joint
ts not less than 1.25tr 0.7ts hG hG

ts ts
d d d d
t t t t

C = 0.33 C = 0.33m C = 0.3 C = 0.3

C min. = 0.20 [Use Eq. (2) or (5)] [Use Eq. (2) or (5)]
(h) (i) (j) (k)

Retaining
d d d
ring Threaded ring
t t t

C = 0.30 C = 0.30 C = 0.30

(m) (n) (o)

t1 30 deg min. Seal weld

ts 45 deg max. 3/ t min.
t 4
0.8ts min.
t
d
d
d or
min. t1 = t or ts
t d
t When pipe threads are whichever
used, see Table UG-43 is greater
C = 0.25 C = 0.33 C = 0.33
(p) (r) (s)
C = 0.75
(q)

FIG. UG-34 SOME ACCEPTABLE TYPES OF UNSTAYED FLAT HEADS AND COVERS 01
The Above Illustrations Are Diagrammatic Only. Other Designs That Meet
the Requirements of UG-34 Are Acceptable.

39
4.3.6-2 4.3 SHELL-AND-TUBE DESIGN CODES 4.3.6 TEMA Type AJS

(c) Order calculation For external pressure (shell side), the rules in
UG-33 apply. A thickness is assumed, and the procedure
For a heat exchanger with a floating tubesheet, assuming appropriate to the shape of the formed end is followed.
that the tube layout is known, it is advisable to design From TEMA R-3.13, the minimum allowable corroded
the floating-head cover first. This will confirm if there plate thickness is 6.35 mm. Assume that tfhd = mm
is sufficient space within the shell and outer tube limit and confirm this, using the procedure in
circle diameter to fit the required gasket. The shell, UG-33(c).
channel, and shell cover cylinder thicknesses may then
be calculated. The remaining components may then be 0.125 0.125
designed at random. For this design, the selected tube
wall thickness is checked, followed by the design of the = maximum allowable design pressure
flanges and end enclosures. The tubesheets and nozzles
calculations complete the calculations for components B ch
subjected to pressure. Finally, the dimensions of the (3)
nonpressure components are determined.
From materials chart, Fig. UCS-28.2,
The units used for pressure are and for material
stresses are as specified in the nomenclature = 14 500 = 14 500 X 6.895
(1 = 1 newton per square meter).
= 99 978
Therefore
B. Floating-head cover
99 978
a
(a) Flange and dish
This is less than the shell-side design pressure (2 000
The floating-head cover is a spherically dished cover
therefore assume that 9 mm and repeat the
designed to UA-6 (4)(b), Fig.
calculation.
see also Sec. The minimum dish thickness is the
greater of the tube-side or shell-side requirements. 3
factor A
= tube-side corrosion allowance = 3 mm
factor = 15 200 = 15 200 X 6.895
= shell-side corrosion allowance = 3 mm
= 104 804
For internal pressure (tube side),
Therefore
104 804
a 105
where P = = 500 L is the dish corroded inside
This is greater than the shell-side design pressure; there-
radius (mm), and is the maximum allowable stress =
fore a corroded dish thickness of 9 mm is satisfactory.
121
Assuming that the shell-to-floating tubesheet, = dish uncorroded thickness
radial clearance is mm and assuming a gasket width
15mm
of 13 mm (TEMA minimum = 12.7 mm), then the
flange corroded inside diameter = dish uncorroded inside radius
B = 635 + 13) = 599 mm
The flange uncorroded inside diameter is
(b) Flange design
The flange design thickness is the greatest thickness of
Assume that the dish uncorroded inside radius is 0.75 X
that required for gasket seating, tube-side pressure, and
593 = 445 mm; then
shell-side pressure, or from geometric considerations to
L = 445 + = 445 + 3 = 448 mm allow for sufficient crossover flow area. The positioning
of the dish relative to the flange centroid is an important
Therefore part of the design calculations; there are numerous
= 5 500 448 methods of approach. For this example the procedure
6X 121 used is as follows.

1983 Hemisphere Publishing Corporation

4.3 SHELL-AND-TUBE DESIGN CODES 4.3.6 TEMA Type AJS 4.3.6-3

1. Calculate the flange thickness required for gasket

seating. J =
SB A - B
2. Calculate the flange thickness required for the
and
crossover flow area.
3. Use the greater thickness of (1) or (2) and (for internal pressure)
position the outer edge of the dish at the back of the
flange. (for external pressure)
4. Calculate the loads and moments exerted on the (for gasket seating)
flange by the tube-side and shell-side pressures.
5. If the flange is overstressed, hold the dish posi- The flange bolt loads and moments are given in Table 1.
tion (thereby keeping the moments constant) and add Note: is the product of and h,. The dish should
equal increments to both sides of the flange until an be positioned such that is always negative; that is,
acceptable thickness has been obtained. the dish and tubesheet should always be on the opposite
sides of the flange centroid; the absolute value of
The general equation for the flange thickness is is used to determine the flange thickness.
given in UA-6, where For gasket seating,

Therefore
-B) F = O a n d

Table 1 Floating-head cover bolting and flange moments calculations

Design conditions

Tube-side design pressure = 500 Allowable stresses,

Shell-side design pressure = 2 000
Design temperature = 100 C Flange Design temperature 121
Flange and dish material = SA-5 15-70 Atmospheric temperature 121
material = SA-193-B7 Bolting Design temperature 172
Tube-side corrosion allowance = 3.0 mm Atmospheric temperature 172
Shell-side corrosion allowance = 3.0 mm

Gasket and bolting calculations

Gasket-soft steel jacket asbestos filled

625 mm OD X 599 ID X 3, with pass partition webs 10 mm wide
= 6.5 mm b = 6.425 mm m = 3.75 y = 52.4
= gasket OD 2b = 625 2 X 6.425 = 612.15 mm
W = = 647 459 N A,,, = greater of or = 3 764
= = 46 335 N Use 24 M20 bolts
H= x = 147 081 N = 24 X 214.89 = 5 157 mm*
W W= = 767 206 N
= = 588 322 N + 0.661 9 4 1.44
Gasket width check: N TEMA minimum = 12.7 mm, or or where 4.4 mm
and 2.9 mm
B = 599 mm BCD = 660 mm A = 702 mm

Condition Load, N Lever arm, mm Moment, N m

Tube-side operating X 140 829 = = 30.5 295

= = = 23.95 =
252 = + = 27.225 170
159 515 = 20.0 190
= 2 385
Shell-side operating X 563 317 = 6.55 3 690
3.275 82
638 059 = 20.00 761
= -8 989
Gasket seating 767 206 = 23.95 18 374

1983 Hemisphere Publishing Corporation

4.3.6-4 4.3 SHELL-AND-TUBE DESIGN CODES 4.3.6 TEMA Type AJS

18374Nm and = 121

= 1 566.62
121 X 599 702 599
t= 18 374 X
121 X 599
702 + 599
702 - 5 9 9 = t = 8.00 + + 1 566.62 = 48.38 mm

For crossover flow area, from TEMA R-8.12 the actual Therefore, with the dish positioned at the back of
crossover flow area is to be at least 1.3 times the flow the flange, a corroded flange thickness of 57 mm is
area through one tube pass. There are 468 tubes, satisfactory. The cover will have a pass partition plate
19.05 mm OD X 2.11 mm wall thickness, arranged in 13 mm thick, tapered at one end to 10 mm to suit the
four tube passes. gasket web; see TEMA R-8.13. The flange will be re-
cessed to confine the gasket. The cover dimensions
Flow area/tube pass = (19.05 2 X 2.1 are given in Fig. and a summary of the flange dimen-
sions is given in Table 11 (flange no. 6).

(c) Floating-head backing device

The total required crossover area is
The backing device clamps the floating-head cover to
the tubesheet. There are various types; for this design
The segmental area of the dish = 46 012 a single split ring is used, designed to UG-53(a).
If the effect of the pass partition plates is neglected, The split ring is designed as if it were a solid flange
the area available under the dish for crossover flow per (without splits) using 200% of the greater of or
pass is calculated in the mating flange design. From Table
46 012 X 0.5 = 23 006 is greater than for either the tube-side or
side operating conditions.
If the dish is excluded, the depth of flange required The effective thickness,
for crossover flow area per pass is

(7)
593 x 0.5
Obviously, even allowing for the dish, the gasket seat- Shape constant,
ing will require a greater thickness than that for cross-
over flow area.
B 599
Assume a corroded flange thickness of 57 mm and
position the dish at the back of the flange; check the Hence
thickness for internal and external pressures.
Y = 12.31 from Fig. UA-5 1
For internal pressure (tube side):
18374Nm from Table 1
121 B = 599 mm
121
where = 12.31 X 18 374 X 2
500 X X X 121 x 599 x
8X 599) There will be a recess (5 mm) deep to locate the spit
ring on the tubesheet. The dimensions of the backing
= 415.64 ring are given in Table 11 (flange no. and in Fig. 1.
121 X 599 702 599

C. Cylindrical shells
For external pressure (shell side):
The minimum allowable wall thickness for cylindrical
shells is the greater of the or TEMA require-
S= = 121 ments; see also Sec.
The minimum thickness, exclusive of corrosion
where
allowance will be the greater thickness from the for-
2 000 X X X 8 mulas in UG-27.
8X 599) For circumferential stress (longitudinal joints):

1983 Hemisphere Publishing Corporation

 4.3 SHELL-AND-TUBE DESIGN CODES 4.3.6 TEMA Type AJS 4.3.6-S

24 HOLES 24 DIA

Figure 1 Floating-head cover and backing device.

wall thickness is usually the preferred gauge from TEMA

Table R, C, or B, -2.21. The tube length plays an im-
portant part in the thermal performance of the ex-
For longitudinal stress (circumferential joints): changer, so the length should not be altered without
the agreement of the thermal designer.

= tube outside diameter = 19.05 mm

For this example the weld examination is spot tube wall thickness = 2.11 mm
throughout, thus the joint efficiency E = 0.85 for all
welded joints (see UW-12); Eq. (9) can therefore = tube-side (internal) pressure = 500
be neglected. The calculations of cylinder thickness are = shell-side (external) pressure = 2 000
summarized in Table 2.
In practice, the selected plate thickness is not S = maximum allowable stress = 121
necessarily the minimum allowable thickness rounded E= joint efficiency = 1
up to the nearest millimeter. The availability of material
may be the deciding factor, or the designer may select = tube inside radius = 2 X 2.11)
a thicker wall to increase the area available for reinforce- = 7.415 mm
ment at the nozzle locations. The channel will have pass
partition plates, of the same material, 13 mm thick, For internal pressure the minimum allowable thick-
tapered at both ends to 10 mm thick to suit the webs of ness is calculated using Eq. (8):
the gaskets.
- - = 500 x
D. Tubes
X 7.415
The minimum allowable wall thickness is determined = 0.031 mm
121 X 1.00 -0.6 X 500 X
from UG-31; see also Sec. The tube
dimensions are specified by the thermal designer. The For external pressure the rules in UG-28 are

1983 Hemisphere I Corporation