CODICE IO::',TIFICAZIONE ~

G>:NERAL CRITERIA FOR THE MECHANICAL DESIGN OF Jden: f::..JtJor Code

HEAT EXCHANGERS em,'M Job I :: : C i T , N

11'? .... ·.7:-

1763 .c E I PR 1001
Poi! FCGLlO E'.I I
I 1 I Iss".
$h e e• 2

GENERAL CRITERIA FOR THE

MECHANICAL DESIGN OF HEAT
EXCHANGERS

I I
I I
I

2 I,ssu:: ~S GLJ CELINES ~IR I(}

E_'.
I OIR
0<;1200 \

1 I PR:!.II '1N~RY ISSUE

I CIR
I O';'l. I
I
10/2000

-"
c.
lssc e
I DESCRIZIONE - Desc"~"cn
I eOI.IPILATO
Drawn Up
I APPROVATO
Approved
I
I
Do""ITA
Dale
~
- - --- -
 -,,.._-..::::::-_-~-----------------"""------
IDE~T1FICAZJO~ CODICE
Ident,fic.Uon Code
GENERAL CRITERIA FOR THE MECHANICAL DESIGN OF
HEAT EXCHANGERS CO~·/.I Jcb I I E CiT N

1763 I C ! E IPR 001

IM?."...:-'iO
P~,( I ;:w= Ci..lENr=:
C'Ient ?ef
FOGLIO
S~eel
I 2 I Issue
EM I
2

INDEX

1 SCOPE

2 SHELL & TUBE HEAT EXCHANGERS

21 Tubesneet layout

2.2 DeSIGn of thickness of all pressure parts as cylindrical shells, conical, elliptical or sphericat heads

.8
2.3 Design all nozzles opening on the above mentioned parts
~
§
~S 2.4 Desicn of girth and floating head flanges
6
~i
2.5 DeStfll of tubesheets, expansion JOints and flat covers (Included nozzles opening on flat cover If
~ ~~
~ any)
~
'i
~
~ ~
8-
,.
" 2 6 Carry OL:t mechanical SIzing of whole exchanger
.a ;;
27 Calculation of exchanger supply weight and volumes (shell side and tube side)
~
!,.
J"" 0

2.8 Calculation of Insulated surfaces and painted surfaces

~ ~~
~

2.9 Calculation of loads at base (vertical loads, wind loads, earthquake loads)

2.10 Cerry out the check of shell / support stresses (If necessary)

2 11 Post Weld Heat Treatment

3 DOUBLE PIPE

3.1 Calculation of thicknesses

32 DeSign the nozzle openings on jacket

33 CalcuI2te the differential thermal expansion between the two pipes (only If the two ends of jacket
are welded to Inner pipe)

--3-4---GAeGk--t-l:l€-st-fes-s-es-eA-FlIFl€s-e!tle-t-o-eJ/fferentlaHherma-l-expanSlOn

35 Desicn excansion JOint If required

36 Typical Arrangement

37 Corrcs.cn for pipe consrcennc total Internal & external

 CODICE IDE'iTIFICAZIONE ~
GENERAL CRITERIA FOR THE MECHANICAL DESIGN OF Identlnc.1tJon Code

HEAT EXCHANGERS CCMM-Jco I IE CiT I N

1763 I C : E IPR 1001

,M?!,;.NiO
?Ionl I RIF C~IE ".t TE
Chenl Ref FOGLIO
She~1
I 3 I:oM I 2Issue

1 SCOPE

These general criteria are applicable to the mechanical design of tubular heat exchangers and
double pipes. ."'"-

Scope of this handbook IS not to replace any official Code but give the necessary suggestions and
gUidelines In order to clanfy how to approach the mechanical design of heat exchangers

Anyhow ell Code and project specific requirements shall be fully met

Usually heat exchangers are designed and manufactured according to the applicable class In
TEMA Standard, If no TEMA class has been specified for the project the minimum requirements of
TM 32.1.3 WII! be applied.

Tecrurnont STD's to be used In sedition to TM 314 3 are

TM 302.1

TM 3143
Ww
5%
J)Q
~~ TM 300.1
0'"
2§
z ....
Q~
:~ ,,-HM 30022
.... -=
Zz
~~
:;U.I
ug: TM 30023
w<
~~
Cu;
<'"
....
~'"
-
g:~ TM 30024
0<
~o
08
",0
0==
... :: TM 31423
z::>
l.UU
~~-II---------------------
- ----~ --- - - - - - - - ---------------~··--__tl--

uZ
0-
o::?
0<
_N
",,,,
~:;
::>-=
0::>
 CODIC" IDEI.T1FICAZIONE """
Idenhrlc~tlon Code
GENERAL CRITERIA FOR THE MECHANICAL DESIGN OF
HEAT EXCHANGERS COMM·,c: I E I CiT I N

1763 I C lEi PR 001

IMPtANTO
Planl I j:{IF CLIE ~ 7:
Chent Ret FOGLIO
She"
I 4 'E~t
rsst.e 2

2 SHELL & TUBE HEAT EXCHANGERS

The following steps shall be followed In the design of shell and tube heat exchangers
iv,
21 Tubesheet layout

22 Design of thickness of all pressure parts as cylmdncal shells, conical, elliptical or sphencal neads

23 Design all nozzles opening on the above mentioned parts

24 Design of girth and floating head flanges

2.5 Desicn of tubesheets, expansion JOints and flat covers (Included nozzles opening on fiat cover If
any) •
I •
26

27
-
Carry out mechanical sIzing or whole exchanger

Calculation of exchanger supply weight and volumes (snell side and tube s.de)

28 Calculation of Insulated surfaces and painted surfaces

29 Calculation of loads at base (vertical loads, wind loads, earthquake loads)

2.10 Carry out the check of shell / support stresses (If necessary)

2 11 Post Weld heat Treatment

~~
...,;.;
Vl~

B~
e .....
~§

z~~
u::;
....-~~
§~
::~
~~
-zw
C
<Vl
.... -
u'"
§:ffi
§~
C::c
cg
....,0
o::!
::5
U_U)_-I ---- _
--------------------_._----
~~
u:::
0-
o!:?
_ .....
c<
VI .....
=!~
55
-'='rJl"---'''''''~-'''--r------------------..,..--
CD DICE IDENTIFICAZIDNE ""'"
Ident,'lc't!on Code
-.
GENERAL CRITERIA FOR THE MECHANICAL DESIGN OF
HEAT EXCHANGERS COI.iI.i·Jc~ I E I CiT I N

1763/Ci EiPR/001
.r Q
IM?v-.r
P!.cInl FOGLIO
Sheet
I 5 I ,;.".
".1 I
2

2.1 Tubesheet Layout

- At tne be£inr.lng of neat exchanqers design a tube sheet layout must be prepared

Tube layout means not only :r.e tubes arrangement, but also tie roes, sealing strtps,
dummy tunes. baffles cut orientatron and position, Impmgement plate, pass partruon
grooves, sliding roes or buncle runner arrangement

- aT L. (outer tuoe limit or outside tangent line) IS tne diameter of a circle tangent to
the outer tubes

Usually the a T L c.mensrcn shall be estabhshed for fixed tubesheet ane U tube
bundle as follows

a T L =bafile 0 0 -2 (tunes pitch - tube 0 0 ) 01:)

~~\e...
- 01" L 'r &",.... <

However the baffle 0 D rrnnus 0 T L shall not be less than 8 mm

- For heat exchangers with floating head (Internal or external) type "S" - "T" - "P" or
"W" as a starting POint we can assume the follOWing values

oT L = shell : 0 rrnncs ~5- 55 Type S

o T.L = shell I 0 120-130 Type T
( oT L=
o T.L.=
shell I 0
she!IID minus
70- SO
~O- 50
Type P
TypeW

- --f--
b.
-=--
The distance between two tube rows straddling the pass partuion groove shall be

_~ ~Ith tubes welded to tuoesheet

'J f- :~,
--Q, ,.....:
tube 0.0 + 2 lube thk .,. 5 .,. groove Width
. . ~-
With tubes expanaed to tubesneet.

tube 0 0 + 5 ... groove wicth

Il\~ Remember with square or rotated square pitch, tubes must be always aligned
, 1;--- --

\~
-- Independently of number of tube Side passes for access to
mechanical clearunq

Shell entrance or exrt area (without tmpmqernent plate) according to TEMA Figure
RGP-RCB-4 6221, 4 6222 and 4 6241

- Impingement Plate - ~--------------------------

Impingement plate In fixed tubesheet exchangers shall be welded to the shell, while
In rernovaoie bundle types must be welded to tie rods or sliding rods
The escape area Into tne bundle for the flUid flOWing between the shell periphery at
Inlet nozzle ana the Impingement plate shall not be less than 100% of the Inlet
nozzle area wrtn 150% preferred
Implngeme.,: pla.e shal: be pos.noned over (or under) tubes at a distance of 3 rnrn
minimum

Belt

Instead of Impingement plate, If a belt IS required, to remove tubes nelghbounng the

shell Windows
 CODICE IDEN,I1'ICAZIONE
•. n • _ • '" ""'"
COfo.lr.I·Jce I E I CiT N
- ; : ; TECnlmOnT
J--:;-;-;--:;::;:;--
~ ..,,..., 1,...\ I ~~ Inn
~:-:;;-:::_=?------:--------t-4:7d;a...!~~g.,qJ.oruJ
r-

1~.Ip:l ,...:~iO :; C.el",

=
C~:··7: 1'(;,:-'":0 I 6 I =.7.i'j""""Z"T
p:l~i1l I ~~, S .eel Issue I

_ Longitudinal baffles (I e shell type "F")

Provice adequate space to mstall this kmd of baffle Be careful on rernovabte

bundle
In this case provice acecua:e number of tre rods to position the transverse baffles

For shell thk calculation to adopt '" when use Type" t" of TM
a.. 7 as weldmq efficiency
3142 longitudinal baffle

Bundle Runners

HOrizontal removable bundles shall be provided with adequate devices (I e rods)

located syrnrnemcally aloncs.de the vertical centerline (their onentatron shall not be
less than £5° nor greater than 40°) and extending from stationary tubesheet to the
last baffle or support plate

- The runners shall protrude sufficiently beyond the

bundle to slide smoothly Into the shell
a D. of baffles to enable the

For removable bundles with mess hlgr.er than about 10.000 kg provide acecuate
sliCing rollers

Sealing strips, dummy tubes

Where large tubeless spaces are present In the shell depending on tube layout It is
necessary to Install seeling stnps or dummy tubes In order to avord larqe quantities
of fluid by-oassvio the tubes

Seeling strips and dummy tubes shell extend between the first to the last bafile, and
tocatec within the baffles cut,"If possible

Tne Inner edge of the stnps shall be located as close as possible to the tubes and
: the outer edge shall not protrude t~e 0 D of baffles
<,

Bend radius of U-tubes

The radius of bend for u-tubes measurec on the axis shall not be less than

Tube 0.0. RaaJ1:JS-- -- - ---

~~" (20) 38
-
1" (25) 45

1 %" (30) 60

_ Tubes per pass deviation

Differences on tubes number between passes on respect of median shall be

contained about within ::: 3%

. ~. ~ -------- ... _ _ r_
 r CODICE IDENTIFICAZIONE """'"
Identification Code
GENERAL CRITERIA FOR THE MECHANICAL DESIGN OF
HEAT EXCHANGERS I I CO'.IM-JOD E CiT N
;;TECnlmOnT 1763 I C lEi PR 001
~~----,....."..~:::==----~----+~:;-;-::....L::...~~~
1··:,;..·.7:
='~rt
=OGLIO
Sheet
I 7 =M I
I 'ssue 2

Tie rods /'

:2 Ilc J / 4-.:::
Y(XI£"::::--
-,) r>-I,-.,..,

Tie rOGS shall be rocated such that the max distance between any two of them does
not exceed 450 mm about
• "\p.

Tie roes shall not be positioned In such a way that cleaning lanes between tubes
are blocked, In addition they must not obstruct the flow at Inlet and outlet nozzles.

Tie rods shall De located to connect all the corners of baffles and support plates

22 De siqn of thicknesses of pressure parts such as cylindrical shells, conical, elliptical or

sphencalheads

All these pressure parts shall be calculated In accordance With the rules of the Code to be
_ used for :he plant

However thicknesses shall not be ~elJhan

those specified In the applicable Class of
TEMA stanoarc, If TEM?, IS not applicable, minimum trnckness shall be In accordance With
TM 31.:1 3 per 9 2

2.3 Design of nozzles openings

Desicn shal' be made followmq the rules of the Code to be used for the plant.
~~
~Q For the minimum thickness of the nozzles neck see also TM 300.3.1
~~
c ...
~§ Where compensation of the opening IS necessary, and self-reinforcing nozzles are not
Q~ mandatory apply a remforcmc plate havmq the Iollowmc rmn.rnurn Width"
...:~
Zz
~
I I I I
I
i I
Nozzle ON ~"4 ' 6"- 8" 10" 12" 1~" 1,0
-" 18" I 20"
~~
z~
i . I I I I i ! I
I !
, ,
u.
;:~
::;z
-l..l
, Width
I
(mm)
wp
, . 45
1 I 50 II 65 i
I
70 ,
I
75 I
I 85
I 100
I 105 , 120 i
<.n
t;;::J
2:::
6;:
g:~ Remember:
3g
..,0
0;; Since piping loads can Impose forces and moments In three geometnc planes,
-~a-I----------peaeA-I3Ip1H§-IGaOs-sb.o.uld __be_evaluatecj_§? a combination of forces and moments
B~ Nozzle reactions from piping are transmitted to the pressure confalnmentwall-of-!;fl-e-A€-2t- -
go exchanger and could result In an over stressed condition In this area
0<
t?~
~= If not otherwise specifiec by the Client's documents the shell parts are able to Withstand
5::
loads shown In the TM 300 1 Par 2 1 3. constdered as s.rnultaneously acting In corroded
conditions
 CODICE IDENTI;:'CAZIONE ""'"
IdentlfiC3t'cn Code
GENERAL CRITERIA FOR THE MECHANICAL DESIGN OF
HEAT EXCHANGERS COMM·Joo I E I CiT I rl

-- -,.-= 1763 I C ! E PR 1001

,M?I..,,~7:J
P!.anl I
~
.... ,1"" ,-_::,.

C',ent :;'e'
FOG.'O I
She~l I
8 :.\
1 J;s... e
I2

2.4 Girth and floating head flanges

A) Girth Flanges

Before starting. with the cesrqn, tne flange shall be pre cimensroned uSing the ro:la'.·.. me
parameters ..... -
,
t h ! i, ......!
I , I
,
, I
"1
~
xi, ,
I u '
I
0

i I
:.no -+- - - f-- ---'

1a/--J- ~
f-- I
i
I 'lrL
~

>- ~ : JL L~ g, i
o!
(;1 =1 ~I
t (/11
, ,
:::r---
I
j
'-----k ---.-:
)-t---{
0 ol.-~I':~----'
0"
• ~-----.;) =;j,
I

C" ---v;"j

h = 20 or 2 S (minimum) h = 20 or 2 S (minimum)
n = 04-:: a ~ t (maximum) h=04 - a 6 t (maximum) I
Go =S I
i go = S .... 4 ! go =(2 4 S) + a
g 1 = go - (h tg :c) g1 = go - (h tg :c)
:c:=12° (max 18°) ;:c:=12°
G I.D (min) = I.D + 2c ; a = 1 5 mm up to 39" a = 1 5 mm up to 39"
Where 2 0 mm from 40" up to 60" 2 a mm from 40" up to 60"
c =corroslon allowance I
I 3 0 mm over 60" 3 0 mm over 60"
! d = 6 mm min weld deposit d = 6 mm min weld deposit

W = Gasker wrcth (see minimum requirements of TEMA - RCB 6.3)

x= { 4 5 mm up to 30" I D

6 mm over 30" I D

Rh, Rr, E from table TEMA - TABLE D-51 D-5M

t min' = bolt holes dra

0f = bolt dla + 3 mm

Maximum recommended bolt spacing

6r
(m -'- 0.5)

B max =2 W B (by TCM suggested)

B = Bolt spacing, centerline to centerline

dB = Nominal bolt diameter

t = Flange thickness (- Increased about 5 mm from t calculated)

m = Gasket factor adopted In the Code flenge calculation

1
Note: For exchanger With rnultrpass partition take account the total gasket area InVC' .ec

J
<,

-- -_.
 eOOICE IDEN'IFICAZIONE """
IdenUflc.ollon Cod,
GENERAL CRITERIA FOR THE MECHANICAL DESIGN OF
HEAT EXCHANGERS eOMM J=o I I I
E e TIN

1763 I C I E I PR 1001
11 1 :; ' ..... 7,:,
P!.al"'l
FOGLIO
Sneet
I 9 : :'.1
I I;sue
I2

- Suggested minimum bolt diameter with reference to a given pressure/shell drarneter

(Attention to TEMA "R" requirements of min ~"bolts size)

{ shell diameter 28" 38" 48" 60" >60"

Pressure s 21 kg/cm~ <!>~
bolt diameter
~

Yo" :y." ~" Ys" . 1"

(1'.116) (M20) (M20) (M22) (M27)

" { shell diameter 18" 28" 38" 48" 60" >60"

Pressure >21 ~ 32 kc/crn"
- bolt diameter :y." Jj." Y." 1" 1 Y." 1Yo"
(M20) (M20) (M22) (M27) (M30) (iv133)

{ shell diameter 14" 20" 28" 38" 48" 60"

Pressure >32 s 64 kg/cm 2
bolt. diameter %" 1" 1Yo" 1;h" 1o/a " pi"
I'

(M22) (M27) (M33) (M39) (M42) (MaS)

-
As gener21 rule, dUring the calculation of number of bolts (multiple of 4), ace to the
minimum required number of bolts

For pressure ~ 32 kg/cm2 + 4 bolts

For pressure> 32 s 64 kg/cm 2 + 4 bolts

For pressure> 64 kg/cm 2 + 2 bolt

Remember: Calculation main girth flanges for nqicrty designed according to

ASME Section VIII D,y 1 Appendix S.

(\
---{---~------"----I----
j

\
 COOICE IOENTiFICAZIONE ""'"
Idlntlne>:lon Codl
GENERAL CRITERIA FOR THE MECHANICAL DESIGN OF
HEAT EXCHANGERS COMM.JC_! E ! eli I N

1763 : C IE: PR 1001

IM='I,.. rc -IF ., :.-:
1 : ...
I
1"\ ...... _ _
FCG~IO I
~

?Iar:: Chen: ~el Sr •• , l O r 1;••• 1 2

B) Floating Head Flange

STYLE" B" (TEMA FIGURE RCB 5.141 - Usually selected by TCM)

';:;:::--::J
~:=-{
r I
I
I
l......ol
........ _
L J. __

1 I
til;
!
=1
-s,

c= Corrosion allowance t2 =thk min 0f (Butt Strap)

C= Z+2(1.5"T"X) } "'0f
the higher
= I.DJ"T" 2E (min)

Uw
C:z
-'0 I.D f = o T L. + 2y + 3
~~ = IDs - 2 ( b + W + tube side carr allow)
o;::j
::l2
- ...
""0

2:l ,,~
:~ Z = o T.L.+ 2 ( Y + 1 5 + tube side corr allow + W )
...Zz
~ = IDs - 2b
o~
~w
Za:
u"-
~;S y = 3 mm for tubes expanded to tubesheet
-z
~~ = 5 mm for tubes welded to tubesheet
:;;i=:l
-a:
g:~
0<
1i:c b = 3 mm for s 18" shell diameter (I D s)
58
,-,0
o~ ~ 5 mm for > 18 s 40" shell diameter (I D.s)
... Z
-~-5,-i1------------~----------------- - ---------- ------------------::---~

~'l!
uz
6 mm for > 40 s 60" shell diameter (I D.s)
g~
0<
_N 8 mm for > 60" she!1 diameter (I.D.s)
",N
u~
:;)~
0:;)
E= from table TEMA - T AS LE 0-5 / 0-5M

Remember: Check the minimum cross-over area for flow between successrve tube
passes IS at least 1 3 times the flow area trough the tubes of one pass
Floating head flange with nubbin
, CODICE IDENTIFICAZIONE """lil
Identlne.tlen Cede
GENERAL CRITERIA FOR THE MECHANICAL DESIGN OF
HEAT EXCHANGERS COMM'Jc~ I E Ie! TIN
; : ; TECmmOnT
1-;;-;:;-:-:-==----...,.--;;;;~:_;::_------.-----+~;--T-=.1....=.......:;:.~
1763 I C I E I PR 1001
..... ::..... ~Ir- FOGLIO' 11 ,EI.I I
If.·:: ...... -;-:
::.a- !. I C'renl R.et
1;
Sheet I : .ssce 2

25 Design of tubesheets, expansion joints, flat covers & relevant openings

In no case the tubesheet or flat cover flanged extension thickness shall be less than
the con hole diameter

_ Des.en s~211 be executed accorcinq to the relevant Coce. or accorcmc to TE:p.~-\ std
par RCB-7- RCB-B. when required.

_ Flat covers with grooves for pass partition plate shall be also checked with TE:MA
formula RCB-9 21

Remember· Effective tubesheets and flat covers trnchkness shall Include allowance of
about 5 mrn

2.6 Mechanical SIZing of whole exchanger

-:-A.t the end of thickness calculation of all pressure retaining Darts, we can proceec to the
mechanical sIzing of the whole exchanger

a) Nozzle location

o As general rule nozzles shall be located nearest to the tubesheet or girth flanges,
provlCIng that minimum distance between welds IS satisfied.

b) Fixed tubesheets (shell side)

t,..,,,l 5 G("'t) _ :...
') il "I

lf 8 ----. 1)\ ,

!II
\~~ ~
'~I'(
I

-it=-]
i

rt========~j! ~.E: : : U= =i
St~ I j-__
===::::;=
I

i
i

1 =
e
=I =1=;= -~
cc 'a! b
Sc n
t f
I
,Od
I I
e

r I C or P p i? c or

11 11
II

11
P

b == 50 mm
/ J
v./ Sd
C =e - a _ a _ b _ __ (With rrnpmcernent plate)
2
C = e _ d _ f _ Sd (Without Impingement plate)
2

f(mln) = St"'- Sd (f min = 15 mm)

2
~r""-~~--"------------------""'-------
CODICE IDENTiFICAZIONE
,..flI': f .. ,..
"""
COMM·Jc~ I: I C i T I N

1763 I c IE! PR 1001

I =\\ I
11 1 ;) ::7:) ;:,,= CL'E",E
12 I Issue
I
...
=OGLiO
P!arL Cdenl ~ef Sheet 2

Where

wp =see pornt 2 3
Sd = baffles thickness

St =nozzle thickness
P =bafile pitch as specified on process datasheet, that can be rnocifiec within =3%
In case the value of C calculated by the above formulas IS less than pitch spec:f;ed by
process data sheet, It Will assumed C=P

c) Floating head ("S" type)

-
x z

8:
I--j

e
, I
C or P

bf /2 = max 70 - 80 mm

Y=Z-X-~ Sp = baffle support plate thk TEMA RCB-4.41 (column over 60)
2
TEMA RCB-5.15

d Sd (With Impingement plate)

Z=--a-b--
2 2
- - - - --- - - --~---------------c---- .. ---

Sd d (Without Impingement plate)

Z=--f--
2 2

• __ ~.,,-r-- __ -
 CODICE IDENTIFICAZIONE
,., ""n, , ,,..", """
COMM'Jo~ I : I CIT I N

17631C!ElpRfo01
11P",,'110
j:)l.nt FOGclO I
S~e'l I
13 I :'1
,I;s~e
I 2

d) "U'' tube type

! J;--n.
I I n n

-I-,~~I~
f( 1"'=
!
= !so-501 p {

--Remember: Calculate the maximum unsupported length of each mdrvrcual tube,

considering the lengths of bend plus the two free adjacent straight lengths up
to the support or bofile

\ \
\ d
~I_I
fl T-=i1 S!
-'",
C::z
Uo
~~
U",
-0'"
25
Q~
:~
!----
FU LL sUP PORT
~ I:i;f;==='=== t~
/~!5...::.0_-0.::...."'O.::....!_ _--=-----=---
c or P --,-I
Sc

P
r
1
-;::
PLA, I E:
5~
;;...u
5g:
:=;:5
c5
-:'::'" C = d + 150 (with Impingement plate)
wi;;

~5
g~ C = d _ 2St (Sd - Sp)
<;:0 -r- (without Impingement plate)
-0
Co 2
..,0
0:::
.---lB_II w_h_e_r_e.._s_,---p=_s_u.-,---Pport plate thk TEMA RCB~. 4'1Jcolumn oV~L6Q),_. . . _
~<!
<."z
8§
!:~ In case that the calculate value of C IS less tnan pitch P
en'"
..,:;
::>;:: assume C=p
0::>
 CODICE IDENTlFIC;';:'C'lE
Id.ntlflcatlon Coca
GENERAL CRITERIA FOR THE MECHANICAL DESIGN OF
HEAT EXCHANGERS COMM·Job E C i 7 : N

1763 C I E IPR 001

1t.1?:..... :~i"O
?'ant I RI; Cl'EN7"
C len I Ref
F~~~IO I 14 II;:~. i 2

e) Type "F" • Fixed tubesheet shells

-
i T \",

~
i~
~
~
~
~
~
~
~
~
1- ......
@~
'-
I
!I
(0 6-0 8) P · t1 I 130-50

f)- Type "F" • "U" Tube bundle

I
I

~ ~ ~
!~ ~ ~
I I
Ii
I!
! I 30-50

g) Belt sizing
c

i
~_~L
I ~~_~_

~2
:- ....
<
- '"

I D =0 D -'- 0,75 d

n= number of slots

Note: number of slots shall be selected based on the type of baffles provided

--------------------"-------
 CODICE IOEN,IFICAZIONE "'"
Idenllflc'l:cn Cod.
GENERAL CRITERIA FOR THE MECHANICAL DESIGN OF
HEAT EXCHANGERS COMM·Job I I:: I ' I
E N

1763 Ie! E: PR 1001

FOGLIO I 15 :',1 I
- -,__
RIr,,", 1='-=
IM?IANTO
I
~I_

I
Pliilnt Cle'11 ::.Ief Sheel ;sue I 2

h) Floating head "S" type sizIng

Remember: Check that the rrururnurn cross-over area for flow between success.ve tUDe
passes IS at least 1 3 times the flow area th~ough the tubes of one pass

If the floating head assembly (flange of floating hea~cover, tube sheet, sclu ring,
backinG ring, bolts) IS cornooseo of different rnatenals take Into cons.cera' en 'he
different expansion that can occur between them (to avoid detachment cUring
operation)
As general rule assembly of cmerent materials should be avorded

.8-
~§ -il
u~ 1-'

-;~

-
I
i'l j
.?;-~ I

~
I
S! Eo.
/j-
d
:'i I >50
'-=---
L, ! r
i
!!
~=
8- I ~O
o-~
,
~~
- 1:1
."
c:; b
.. I
I <
~
I
e;;; I ~o
~i-
I

- - w
:=,,Jf_:
E!l
... ::l
I /
/ .. Vll~

~c
Uu
<:::-
~Q
~::!
e-,
= 3 mm for 18" she!1 Dia and lower
eN
=>='
=-:5
§~ ,~
= 45 mm for .10" shell Dia and lower

~;;
0-;:: = 6 mm for 60" shell 012 and lower
6~
~u
4<:::
u~ = 8 mm for 61" shell Dia and higher
=;S
;sz
U
<Ill e min = 6 mm for 18" shell Dra and lower
;;:3
=u
c. ...
c< = 8 mm for 40" shell 012 and lower
~c
-0
Co
...,0
o:::l:
= 10 mm for 60" shell Dia. and lower
_z
--==-::>
uU
~~
t.:::
=
0-
cO
c<
...
... N
Ill::: a (rrun.) { =25 +1 5 bolt Dla }' the greater
5g 2.5 bolfOia
0:;,

a (max ) = .cO'" 1 5 bolt 012

 ,
CODICE IDE'ITiFICAZIONE
II': ,I.., ,.. """
i E I CiT N COMM·Job
;;TEcmmonT I c I E IPR 001 1763
~~:-----~:;=;-;o~-----.----+~;,.-+-::....L..::..+-:;;~~
FOGLIO I 16 I ~.~ I
IM?I,.. ..rj~
?r;rt Sheel :;~ue 2

I) Saddles Positioning

- "'7"'---- - -
, I
,
I

; ~ -.L
x
d : ')bl
I v
I
a
l ~

tube straight length

X = a7 L Y= {a~b~~~dL} the greater

c (min) = 90
o to check this distance

Remember: Performance stress analysis on shell Induced by saddles supports reaction

according to L.P. Zick

5;
Vl~
J) Nozzles Projection
~~-
.....
•::> ..... Refer to TM 3143
~5
2~ When Instrument connections of flanged tyee are required, they shall be
:~
.... ;:
~~ Temperature = 1 Y2" DN - PN same as nozzle rating
::~
Uc.
~~ Pressure = 1" DN - PN same as nozzle rating
c~
<Vl
~N For carbon and low alloy steel they shall be LWN type, for 8.S. or high alloy steel WN
~ffi type shall be considered
g~
i;:O In this event the nozzle projections can Increase With respect to TM 314 3
3g
...,0
~~
z::>
k) Saddles Projection
-~~- - - - - - _ . _ - - - - - - - - - - - - - - - - - - - - - --
... z
_20
.....
~< ~

=~o
"' .....
u::;
::>;:
I
0::>
!
I, ,
fl!..J--
r-..l ,
It x', I xl
rr:
I
I
x!
! I
,
--,
xl
I 1
X = 50 mm
Saddles projection shall be 50 mm more than the most protruding part of exchanger
- - f - -.........--,-------------"r-----~
COOICE IOENTIFICAZIONE """
Identlflc.t1on Code
GENERAL CRITERIA FOR THE MECHANICAL DESIGN OF

;:;TEcmmonT
HEAT EXCHANGERS CCMM-JOb' E I CiT I N

tIM?L~---lRiFCLiE~---~---__t_;~+S~~
1763 I C lEi PR 1001
IMPt;.,7:
?!,;r:. FOGLIO
Sheer
I 17 I';sL.eI
"l,f
2

I) Stacked Exchangers

r \:) --. ~IA

i,

~i Ifill
"'I ' "- " '
L- r 1~--7++t---+
~i ~
-
~!

I Il-:--II

L rL~ ~--++ij++----+

fl I 11

a = projection of nozzles connected to extemal piping

b = nozzles projection of nozzles connecting the stackec excnanqers (the projection on shell
side and tube side must be equal)

It can be a =b

d = a ... 50

e = b - ( c .,. 50 )
----- ------~----- --- - - - - - ---

9 = 10 (shims for assembly)

c = nozzle gasket truckness

Remember for moaerate high temperature performance also thermal stress

analysis between nozzles Intermediate connections
-rr-~--I--------- --, ....
COOICE IOENTIFICAZIONE
I~. "n.. .,. ""'"
UTEcnlmonT CO'.IM·Jab I E I r; I TIN
RIF CL,E~a; 17C., 1,.../ ... 1n .... I001
I C',erai'ef
I t'S:J.(,-"~
S~ee[
I ~.\
18 I 'SSue I 2

2i Calculation of weight and volumes'

a) Weight . ."
(1) Shell kg
(2) Shell cone (kettle) kg
(3) Shell cover (cylinder) kg
(4) Shell cover (elliptrcal) kg
(5) Expansion JOint kg
(6) Pot kg
~

(7) Belt kg
- (8)
(9)
Heads (cone)
Heads (cylinder)
kg
kg
(10) Heads cover (elliptical) -
kg
(11) Heads cover (flat) kg
(12) Girth flanges (shell side) kg
(13) Girth flanges (tube side) kg
(14) Floating flange kg
(15) Spilt and backing ring kg
(16) Floating heed dish kg
(17) Tubesheets kg
.J (18) Baffles kg
(19) Tie rods, slicing rods, sealIng stnps kg
(20) Nozzles kg
(21) Supports (saddles, brackets) kg
(22) Tubes kg

Supply weight = [(: (1) -(21) x 105) + (22) x 1.1]= kg

--+1;J8€-!:;H;JA6-I-e-\-v€ I £lMt-""i(- (-11-)-+ -(1-B} -)-+-( 19t t x1-:Ll5j T i 2 2 t } ( - n ] = l r g - -

Up to 1000 kg round off the weight to next 10 kg

Over 1000 kg up to 5000 kg round - off the weight to next 50 kg

Over 5000 kg round-of the weight to next 100 kg

b) Capacity

C21c~12te the volume of operating liquid that can be contained in the shelf s.ce and
tube side

Then calculate the corresponding weight of hqurd contained in shell side and tube
side, uSing the density Indicated on process data sheet

When the medium IS steam use a density of 500 kg/m~ (Polypropylene plant)
r"----~--,---------------..,....----_
IDE~TIFICAZJONE CODICE "'"
IdenUn~lIon Cod,
GENERAL CRITERIA FOR THE MECHANICAL DESIGN OF
HEAT EXCHANGERS I !: I C i T N CCMM·JCD
UTECnlmOOT
1763 I C ! E ! PR 001
~;;;:;:m----~r::::=:::;::-----.----h~+=-~~~
C' -. - ~I-
FOGUO I 19 1;:'.\ I
IM?!AN"T:J
I
~!.ar:...
5".1,
t"\ -
Cuent
1.1:"
;J~f
2
'::

ISS".

2.8 Insulation and Painting

a) Insulation

Tne s.ce (s) to be thermally msulatec IS specified on tne process data snee:
The type and thickness of msulatron rs defined In accordance with tne general
specification applicable for the project, uSing the highest operating temoeran.re (or
the lowest operating temperature for cold Insulation) for each side.
Then the surface and the wercnt of Insulation can be calculated

b) Painting

Similarly the painting cycle IS defined usmc the controlling highest or lowest
operating temperature for eacn side
Than the painting surface can be calculated

2.9 Calculation of loads at base

-a) Vertical loads (V)

Operating

VOP = Suoply weight + shell side medium werpht - tube side rneciurn weiqnt»
Insulation weight

Hydrotest

V hy = Supply weight T shell side water weight + tube side water weigh!

v= Shall be Increased by 5% and rounded off to tne next 100 Kg

b) Calculation of wind and earthquake loads

When the calculation of vert/cal loads has been completed, then proceed to the
calculation of shear and moment according to the reievant Code spec.flee on the
general specification Issued for the project.

210 Vertical! horizontal exchanger supports

The choice of the type and the number (2 or 4) of lugs (Sto TM 30022) shall be made
taking Into account the mass of the exchanger. Tne subtype (A or B) depencs from the
thickness of the Insulation up to 30mm thk of Insulation the type A IS adopted, over 30mm
type B shall be used
-----~--------------~---I.-- .
In any case for shell dia higher than 600mm A. lugs shall be adopted and for shell
dra higher than 1000 rnrn lugs. type 3 or 4 shall be used.
If the calculations evidence that the shell IS unable to withstand the Induced localized
tresses so that more than 4 lugs are necessary, then support nng shall be used ,,

HOrizontal exchanger supports shall be In accordance With Std TM 314 23

The movement of sliding saddle shall be calculated uSing the shell Side design
temperature, the value of thermal movement to be indicated on the mechanical
specrfication shall be 1 25 times the calculated value

2 11 Post weld heat treatment

Also If not required, by TEMA Standard the channel and floating heads shall be post weld
heat treated In accordance With Par 6.6 4 and 6.6.6 of API 660.
 r~--....:~--r-----------------r--------..
IOE~ COOICE TiFICAZJONE ""
Identlfk';l.on Cod,
GENERAL CRITERIA FOR THE MECHANICAL DESIGN OF
HEAT EXCHANGERS I i: I CiT COMM·Jo:: N
UTEcnlmonT 1763 I C ~ E I PR 001
t-;;:;;;::-,;;n-----,-;;;;r:;-:;:;:;::-------;------+o;:;;::~:...-:....:.._=++.~
IM?\..-..NTO
P~nt I RIF C:'.:"'li:
Client ~el
FOGLIO
Shee,
I 2 a 1"1.4 I
ISSue 2

3 DOUBLE PIPE

Tne fo;!owlng steps shall be considered dUring the design (In addition to appucabte/relevant steps
listed In shell and tube heat exchangers)

3.1 C21c~12te of thicknesses of

a) External pipe

b) Internal pipe (for Internal and external pressure, taking Into account If a full V2C:Jum is
specified)

c) Jacket closures

d) Connecting elbows

3.2 Desl~n the nozzle openings on Jacket

3.3 CalcJlate the differential thermal expansion between the two pipes (only If the two ends of Jacket
are welded to Inner pipe).

3.4 Check the stresses on pipes due to differential thermal expansion

3.5 Desl~:l expansion JOint If required

3.6 Typical arrangement

37 Corrosion for Inner pipe considering total Internal & external

UJUJ
5",0z
~::l
o;:j
~§
§~
:;;;:::
...

5~
~loJ
8E:
... ~
.5ffi
-<<Il
:UN
~§
0<
g:C
015
.... 0
O~
... z
z::>
~ ~ - ~_------- -------- ------_~---- -- -- - --- . - - - - - --- - - - - - - . -- -- - - - - - - - - - - 0 - - - - - - 1 - - -
::>
uz
8§
0<
~~
u .....
::>;::
0::>
 COOICE IDENT,rlCAZIONE
,.., r,.. .l ..... ,... """
COMM-Jcc I I E CIT I N

1763 I C lEi PR 1001

I".~;;l ","~7': I :.="r:: :,\ I
I'2 1 I";':.
:::;'1;: : ...
i'CGL'O
?<m' I c e-. C::ef Shee' 2

31 Calculation of thicknesses

Usually on process cata sneet the thicknesses of pipes ere already incrcated, therefore It IS
necessary :0 cneck these trncknesses
Fer ex:ernal pliJe use cede formulas to find the minimum th-; and add the corrosion al!owance
plus the pipe under tolerance and then select the nearest hlgner plpE"schedule

Note Pipe under:olerance to be usee shall be referred to the pipe schedule selectee

For Internal pipe, follow the same procedure, after havmo calculated the thickness due :0 Internal
and external pressure

3.2 Desiqn of nozzle openings

DeSign shall be made followmc the regulation of the Code to be used for the plant

For the minimum thrckness of the nozzles neck see also TM 300 3.i
Where to compensate the opening It IS necessary to apply a reinforcmp plate, the cirnens.ons of
reinforcing plate shall be accordmq to point 2 3 of shell and tube heat exchangers secnon of this
specificanon.

33 Calculation of thermal expansion

The clfferentlel thermal expansions (~l) between Inner ana outer pipe shall be calculated for all
known conoitrons

- operating
- outer Side stan-up (no fluid Inner Side)
~~ - Inner Side start-up (no flUid outer Side)
t;§ - steam out or other cleaning procedures, when specified
~~ - other COnGI,IOnS, when specmec on process data sheet
-ON
:J-
;§
- v'e
('0"'1 :'2r ~ t\NO ~css ::;tl''',es
::- .. - ...-? =:'::'\Jt? C?IC,,_,I:::-
.;.;;: ~
:~
... .,:
::Z a) The Inner pipe elongation IS higher than the outer pipe, (In trus case the value resulting (~I)
§~
~ ;;_W Sh211 be negative)
U~
~~
Offi b) The outer pipe elongation IS hiGher than the Inner pipe (in this case the value resulting (6.1)
<111
tiN shall be POSitive)
~§
~C5 3.4 Check of stresses on pipes
:0
Co
...,0
~~ Case a) Here we have the outer pipe In tension and the Inner pioe In compression.
--fEil-.----~-----_SO__lr:J__t~~S__G2SB__compaJ"e-tl:le--str:ess-ol"l-outel"_plpe--W~tl:l-3-tll+les--tl:le_ajjow_a.Qle__str_es?-1n--
--
B~ tension multiplied for the welcmp efficiency
g§ For the Inner pipe, In this case under compression, compare the stress with the lesser
~~ value oetween factor B and the allowable stress as per Code
UJ~
:J;:
0:J
Case b) In thrs case we have the outer pipe In compression, and the Inner pipe In tension, so
.
to compare the stresses as per case a) for the allowable stresses In compression or
tension accoromcly

If POint 3 4 IS not satrsftec, proceed In the two ways as noted below

 '-r~----==:;;;:--..,..----------------~------
CODICE IDENTIFICAZIONE ""'"
Idonllflc.:Jon Cod.
GENERAL CRITERIA FOR THE MECHANICAL DESIGN OF
HEAT EXCHANGERS COM~·Jco I I E CiT I N

1763 I C! E I PR!001
IM;:l~·."'ja
~~"ll
FOGL'O
Shoo:
I 22 II,suo
~'.I I
2

3.5 Design of expansion JOint

If the stresses on pipes are not within the allowable values we can proceed in t\'J0 ways

1) To add an expansion JOint

'\- ..
Everywhere possiole stancaro rnoncwall type expansion JOints available on the market shall
be adopted. provided that materials are adequate to the process and the design, tabncation
and testing of expansion JOints IS in accordance with the code specified for the project
As general rule the use of rnultiwall expansion JOints shall be avoided.

When the expansion JOint need to be specifically cesrqned It shall be monowall type and
shall be calculated accordrnc to EJMA std when the code adopted for the desicn of double
pipe exchanger IS ASME VII' Orv 1, wrth the definition of the number of cycles according to
Appendix CC

When the deSign code of double pipe IS different from ASME the expansion JOint snail be

2)
-
deSigned according to the spec.nee code

To modify the jacket closure at one end (insteac of welcec to make a packed floating head
type - If process requirements are ne:)

3) Usually Coce for Expansion JOint des.en (recommended by TCM):

• VESSEL, REACTORS (LOOP), DOUBLE PIPE:

BELLOW TYPE: EJMA - ASME VIII DIV 1 APP 26

~l# FLANGE AND FLU ED EJMA + ASME VIII DIV 1 APP CC
t;Q
~~
e .... • SHELL AND TUBE HEAT EXCHANGER:
E:§
~~
-<
FLANG= AND FLUED TEMA - ASME VIII DIV 1 APP CC
...J>

§~
~w
u~
",-

:~
C4
<til
:;;::;
-c::
t~
!2<
=0
=-0

Co
..,0
0:::
_z
::~
... u
~s~~ ------------~------~------------------- --------- -------------~---------- -
uz
gg
~~
"
='~
....

55

- .. _..,--_ ....
 COOICE IOE'lTIFICAZIONE ""'"
ldentlflc3t!on Cod.
GENERAL CRITERIA FOR THE MECHANICAL DESIGN OF
I HEAT EXCHANGERS COt.11.1 J=~ IE! CiT N
I
I 1763 IC i E IPR 001
IM? ..... ~O
c~r.l I RIF c..:=:'''=:
eller' =ef
FOGL~
S'i!'!{
I 23 I ~M I 2
Isst..e

'1
j
36 Some typical arrangement of double pipe equipment
-. I

--"~---I~

....
~_.
 COOICE IOE'lTiFICAZIONE
IdentJncotion Cod.
~1
GENERAL CRITERIA FOR THE MECHANICAL DESIGN OF
, HEAT EXCHANGERS C:'!'\.J:'! E I CiT N

~IF c, Eon:
1763 I C I E IPR 001
-..,,
,"~ ~"'-J
=!.ai"'! C ,er" ~~f ?h~~:'O I 24 II:s~e I 2

If- - ..
SIX pipes - :--,-

--,--

Four prpes . - -..... ----- - - - - - --'4-+

I

_ _ _ _ _ _ -J

-.:r'-+
---'------
------- ~I

II---i'-~--
-=-----1-' ___