Heat Exchangers
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- Words: 1,105
- Pages: 35
By: Baher EL Shaikh Mechanical Engineer EMetahnex
1
Shell and tube heat exchangers are one of the most common equipment found in all plants How it works?
2
Classification according to service .
Heat Exchanger Both sides single phase and process stream
Cooler
One stream process fluid and the other cooling water or air
Heater
One stream process fluid and heating utility as steam
Condenser
One stream condensing vapor and the other cooling water or air
Reboiler One stream bottom stream from a distillation column and the other a hot utility or process stream 3
Code
Is recommended method of doing something
ASME BPV – TEMA
Standard
is the degree of excellence required API 660-ASME B16.5–ASME B36.10M–ASME B36.19-ASME B16.9–ASME B16.11
Specifications
Is a detailed description of construction, materials,… etc Contractor or Owner specifications
4
1- Channel Cover 2- Channel 3- Channel Flange 4- Pass Partition 5- Stationary Tubesheet 6- Shell Flange 7- Tube
8- Shell 9- Baffles 10- Floating Head backing Device 11- Floating Tubesheet 12- Floating Head 13- Floating Head Flange 14 –Shell Cover 5
6
Front
Head Type
A - Type
B - Type
C - Type
7
Shell Type
E - Type
J - Type
F - Type
K - Type 8
Rear End Head Types
M - Type Fixed Tubesheet
S - Type Floating Head
T - Type Pull-Through Floating Head
9
U-Tube Fixed
Heat Exchanger
Tubesheet Heat Exchanger
Floating
Tubesheet Heat exchanger
10
AES 11
AKT 12
Terminology
Design data
Material selection
Codes overview
Sample calculations
Hydrostatic test
Sample drawing
13
ASME : American Society of Mechanical Engineers TEMA : Tubular Exchanger Manufacturer Association API : American Petroleum Institute MAWP : Maximum Allowable Working Pressure MDMT : Minimum Design Metal Temperature PWHT : Post Weld Heat Treatment NPS – DN – NB – NPT Sch - BWG
14
Heat Exchanger Data Sheet :
TEMA type
Design pressure
Design temperature
Dimensions / passes
Tubes ( dimensions, pattern)
Nozzles & Connections
Baffles (No. & Type)
15
16
B
A – Yield Strength
B – Tensile Strength
C – Rupture point
A
C
17
Creep Strength a slow plastic strain increased by time and temperature (time and temperature dependant) for stressed materials
Fatigue Strength The term “fatigue” refers to the situation where a specimen breaks under a load that it has previously withstood for a length of time
Toughness The materials capacity to absorb energy, which, is dependant upon strength as well as ductility
18
ASME code Overview Sec.I Power Boilers Sec.II Materials Sec.III Nuclear Fuel Containers Sec.IV Heating Boilers
ASME BPV code
Sec. V Non Destructive Examination Sec. VI Operation of heating boilers Sec. VII Operation of power boilers Sec. VIII Pressure vessels Sec. IX Welding and Brazing Sec. X Fiber-Reinforced plastic PV Sec. XI Inspection of nuclear power plant Sec. XII Transport tanks 19
ASME code overview
Sec. II: Materials
Part A : Ferrous material specifications
Part B : Non-Ferrous material specifications
Part C : Specifications of welding rods, electrodes and filler metals Part D : Properties
Sec. VIII: Rules of construction of pressure vessels
Division 1 :
Division 2: Alternative rules
Division 3 : Alternative rules of high pressure
3 Subsections + mandatory Annex + non mandatory Annex
20
ASME code overview
21
TEMA code overview
TEMA classes:
Class R: Generally severe requirements for petroleum and related processing applications
Class C: Generally moderate requirements of commercial and general processing applications
Class B: Chemical Process service
TEMA subsections
10 subsection
22
Sample Calculations
Shell thickness calculations under Internal Pressure:
PR t= + CA + UT . SE – 0.6 P
t : Min. Required Shell Thickness P : Design Pressure of Shell Side S: Max. Allowable Stress of Shell Material R: Shell Inside Radius (corroded conditions) E : Joint Efficiency CA: Corrosion Allowance UT: Under Tolerance (if applicable)
23
Sample Calculations
Channel thickness calculations under Internal Pressure:
PR t= + CA + UT . SE – 0.6 P
t : Min. Required Channel Thickness P : Design Pressure of Tube Side S: Max. Allowable Stress of Channel Material R: Channel Inside Radius (corroded conditions) E : Joint Efficiency CA: Corrosion Allowance UT: Under Tolerance (if applicable)
24
Sample Calculations
Body Flanges:
25
Sample Calculations
Body Flanges:
Trial and error calculations
Gasket seating conditions
Operating conditions
No. of bolts and size
Bolt circle diameter
Inside and outside diameters
Check min. and max. bolt spacing
Detailed analysis of the flange
Forces calculations
Moment calculations Stresses calculations
26
Sample Calculations
Precautions in body flanges design and installations:
Pairs of flanges
Bolt holes shall straddle center line
Corrosion Allowance
Cladding
Bolts shall be multiple of 4
Bolting shall be allowed to be removed from either side
Calculated thickness not include the RF
27
Sample Calculations Nozzles and standard flanges:
Flange Rating (ASME B16.5)
Area replacement calculations
Nozzle neck thickness calculations
Impingement protection
28
Sample Calculations Tubesheet: • Tubesheet is the principal barrier between shell side and tube side • Made from around flat piece of metal with holes drilled for the tubes
• Tubes shall be uniformly distributed • Tubesheet thickness shall be designed for both sides • Tubesheet shall be designed for bending stresses and shear stresses • Corrosion allowance
29
Sample Calculations Tubesheet: • Tubesheet thickness for bending
T: Effective tubesheet thickness S: Allowable stress P: Design pressure corrected for vacuum if applicable at the other side η: Ligament efficiency G: Gasket effective diameter F: Factor For Square pattern
For Triangular pattern
30
Sample Calculations Tubesheet: • Tubesheet thickness for Shear:
T: Effective tubesheet thickness DL: Effective diameter of the tube center parameter
DL=4A/C
C: Perimeter of the tube layout A: Total area enclosed by the Perimeter C P: Design pressure S: Allowable stress do: Outside tube diameter
31
Tube-to-Tubesheet joint Expanded
Strength welded Seal welded
32
Hydrostatic Test Test pressure : 1.3 X MAWP Test Procedure Gasket change
33
Sample drawing Construction drawing is the design output
Sample drawing 1
Sample drawing 2
34
Baher EL Shaikh [email protected]
35
1
Shell and tube heat exchangers are one of the most common equipment found in all plants How it works?
2
Classification according to service .
Heat Exchanger Both sides single phase and process stream
Cooler
One stream process fluid and the other cooling water or air
Heater
One stream process fluid and heating utility as steam
Condenser
One stream condensing vapor and the other cooling water or air
Reboiler One stream bottom stream from a distillation column and the other a hot utility or process stream 3
Code
Is recommended method of doing something
ASME BPV – TEMA
Standard
is the degree of excellence required API 660-ASME B16.5–ASME B36.10M–ASME B36.19-ASME B16.9–ASME B16.11
Specifications
Is a detailed description of construction, materials,… etc Contractor or Owner specifications
4
1- Channel Cover 2- Channel 3- Channel Flange 4- Pass Partition 5- Stationary Tubesheet 6- Shell Flange 7- Tube
8- Shell 9- Baffles 10- Floating Head backing Device 11- Floating Tubesheet 12- Floating Head 13- Floating Head Flange 14 –Shell Cover 5
6
Front
Head Type
A - Type
B - Type
C - Type
7
Shell Type
E - Type
J - Type
F - Type
K - Type 8
Rear End Head Types
M - Type Fixed Tubesheet
S - Type Floating Head
T - Type Pull-Through Floating Head
9
U-Tube Fixed
Heat Exchanger
Tubesheet Heat Exchanger
Floating
Tubesheet Heat exchanger
10
AES 11
AKT 12
Terminology
Design data
Material selection
Codes overview
Sample calculations
Hydrostatic test
Sample drawing
13
ASME : American Society of Mechanical Engineers TEMA : Tubular Exchanger Manufacturer Association API : American Petroleum Institute MAWP : Maximum Allowable Working Pressure MDMT : Minimum Design Metal Temperature PWHT : Post Weld Heat Treatment NPS – DN – NB – NPT Sch - BWG
14
Heat Exchanger Data Sheet :
TEMA type
Design pressure
Design temperature
Dimensions / passes
Tubes ( dimensions, pattern)
Nozzles & Connections
Baffles (No. & Type)
15
16
B
A – Yield Strength
B – Tensile Strength
C – Rupture point
A
C
17
Creep Strength a slow plastic strain increased by time and temperature (time and temperature dependant) for stressed materials
Fatigue Strength The term “fatigue” refers to the situation where a specimen breaks under a load that it has previously withstood for a length of time
Toughness The materials capacity to absorb energy, which, is dependant upon strength as well as ductility
18
ASME code Overview Sec.I Power Boilers Sec.II Materials Sec.III Nuclear Fuel Containers Sec.IV Heating Boilers
ASME BPV code
Sec. V Non Destructive Examination Sec. VI Operation of heating boilers Sec. VII Operation of power boilers Sec. VIII Pressure vessels Sec. IX Welding and Brazing Sec. X Fiber-Reinforced plastic PV Sec. XI Inspection of nuclear power plant Sec. XII Transport tanks 19
ASME code overview
Sec. II: Materials
Part A : Ferrous material specifications
Part B : Non-Ferrous material specifications
Part C : Specifications of welding rods, electrodes and filler metals Part D : Properties
Sec. VIII: Rules of construction of pressure vessels
Division 1 :
Division 2: Alternative rules
Division 3 : Alternative rules of high pressure
3 Subsections + mandatory Annex + non mandatory Annex
20
ASME code overview
21
TEMA code overview
TEMA classes:
Class R: Generally severe requirements for petroleum and related processing applications
Class C: Generally moderate requirements of commercial and general processing applications
Class B: Chemical Process service
TEMA subsections
10 subsection
22
Sample Calculations
Shell thickness calculations under Internal Pressure:
PR t= + CA + UT . SE – 0.6 P
t : Min. Required Shell Thickness P : Design Pressure of Shell Side S: Max. Allowable Stress of Shell Material R: Shell Inside Radius (corroded conditions) E : Joint Efficiency CA: Corrosion Allowance UT: Under Tolerance (if applicable)
23
Sample Calculations
Channel thickness calculations under Internal Pressure:
PR t= + CA + UT . SE – 0.6 P
t : Min. Required Channel Thickness P : Design Pressure of Tube Side S: Max. Allowable Stress of Channel Material R: Channel Inside Radius (corroded conditions) E : Joint Efficiency CA: Corrosion Allowance UT: Under Tolerance (if applicable)
24
Sample Calculations
Body Flanges:
25
Sample Calculations
Body Flanges:
Trial and error calculations
Gasket seating conditions
Operating conditions
No. of bolts and size
Bolt circle diameter
Inside and outside diameters
Check min. and max. bolt spacing
Detailed analysis of the flange
Forces calculations
Moment calculations Stresses calculations
26
Sample Calculations
Precautions in body flanges design and installations:
Pairs of flanges
Bolt holes shall straddle center line
Corrosion Allowance
Cladding
Bolts shall be multiple of 4
Bolting shall be allowed to be removed from either side
Calculated thickness not include the RF
27
Sample Calculations Nozzles and standard flanges:
Flange Rating (ASME B16.5)
Area replacement calculations
Nozzle neck thickness calculations
Impingement protection
28
Sample Calculations Tubesheet: • Tubesheet is the principal barrier between shell side and tube side • Made from around flat piece of metal with holes drilled for the tubes
• Tubes shall be uniformly distributed • Tubesheet thickness shall be designed for both sides • Tubesheet shall be designed for bending stresses and shear stresses • Corrosion allowance
29
Sample Calculations Tubesheet: • Tubesheet thickness for bending
T: Effective tubesheet thickness S: Allowable stress P: Design pressure corrected for vacuum if applicable at the other side η: Ligament efficiency G: Gasket effective diameter F: Factor For Square pattern
For Triangular pattern
30
Sample Calculations Tubesheet: • Tubesheet thickness for Shear:
T: Effective tubesheet thickness DL: Effective diameter of the tube center parameter
DL=4A/C
C: Perimeter of the tube layout A: Total area enclosed by the Perimeter C P: Design pressure S: Allowable stress do: Outside tube diameter
31
Tube-to-Tubesheet joint Expanded
Strength welded Seal welded
32
Hydrostatic Test Test pressure : 1.3 X MAWP Test Procedure Gasket change
33
Sample drawing Construction drawing is the design output
Sample drawing 1
Sample drawing 2
34
Baher EL Shaikh [email protected]
35
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