The Mechanical Design of Shell-and-Tube Heat

Baslc Gomponents of Shell and Tube Heat

Exchangels
There are various components to a shell and tube heat
exchanger, but the following are the essential ones:

1.

Tubes

2. Baffles
3. Tie rods
4. Tubesheets
Tubes
There are basically two types-finned tubes and bare
tubes. Finned tubes have external fins mounted by various mechanical means. The necessity of having external
fins mounted on tubes is to provide more heat transfer
area and thus more heat influx to the tube fluid. Finned
tubes are most common where there is a gasJiquid or
gas-gas transfer of heat with the gas always being external to the tubes. Typical applications of finned tubes are
waste heat recovery exchangers, waste heat boilers, gas
turbine regenerators, and air-cooled exchangers. Examples of some finned tube designs are shown later.
Plain or bare tubes are the most common in shell and
tube design. These tubes come in two basic types-solid
wall construction and duplex construction. The duplex
design consists ofa tube within a tube in which the outer
tube is mechanically drawn over the inner tube. The
solid wall tube is what the name implies, a simple tube of
solid wall construction. Tubing is available in almost as
many materials as piping and is available in standard
gauge sizes listed in Table 7-3, along with diamerers and
section properties.
In applying the U-tube exchanger design, tubes must
be bent 180'. Thble 7-4 lists the recommended minimum
bend radii.

Baffles
Baffles serve several functions and consequently the
design of each is dependent on its purpose. Baffles can
act as:

2.
3.

Structural supports for the tubes.

Dampers against vibration.
Devices 1o control and direct flow Datterns of the
shell-side liquid.

Baffles as Tube Structural Supports. Like piping,

tubes behave as structural beams and consequently will
develop excessive deflection, or sag, if left unsupported.
Baffles act as the structural supports in the shell and tube
exchanger. Another structural function of baffles is to
add stiffness to the tubes so that each tube. in effect. is

Exchangers

1o7

constrained at each baffle. Thus, the hole in the baffle,

being larger by varying amounts than the outside tube diameter, acts as a limit stop for the tube. In piping mechanics (see Chapter 2) a limit stop is a restraint that limits the amount of pipe (in this case, tube) movement to
the distance between the hole diameter and the outside
diameter of the tube. In other words, the tube can translate in the lateral direction perpendicular to the tube axis
only by the amount of clearance between the tube OD
and the hole diameter. Translation is mentioned instead
of rotation because even though the tube rotates, it is insignificant. Thus, the baffle hole acts as a limit stop and
prevents lateral buckling of the tubes when they are induced to thermal expansion by temperature differentials.
In this sense the tubes are much stiffer and stronger than

they would be without the baffle supports. The consequences of strengthened tubes affect the integrity of tube
joint connections in the tubesheets and this will be discussed shortly. We see from this discussion that the baffle plates act as both structural supports and as buckiing
stabilizers.

Baftles as Tube Vibralion Dampers. Figure 7-6

shows baffles of circular rings with rods that run vertically in the first two rings and horizontally in the second
two rings, thus damping vibration much in the same way
as helical vortex strakes on stacks (Chapter 5). The rods
break up forming vortices that induce vibrations, a phenomenon discussed in Chapters 4 and 5 called vortex
shedding. The rods also reduce turbulence to below res-

onant levels of the natural frequency of the tubes and

they reduce fluid elastic vibration.

Baffles Conlrol and Direct the Flow Pattern of the

Shell-Side Fluid. There are various types of baffles that
direct and/or control the flow ofthe shell side fluid. Fieures 7-l and 7-2 are examples of baffles guiding or d'irecting the flow in the vertical direction. Fig]ure 7-7
shows baffles diverting flow in the horizontal direction.
The flow direction is a function of the orientation of the
baffles and their respective geometries and is dependent
upon process requirements. The arrangement in Figure
7-7 is said to be vertically cut and the arrangements in
Figures 7-l and 7-2 arc said to be horizontally cut.
Often, process conditions require the shell-side fluid
to flow horizontally, parallel to the longitudinal axis of
the exchanger. This arrangement, called a longitudinal
baffle, is shown in Figure 7-8. Figure 7-8a shows a twopass shell-side arrangement and Figure 7-8b shows a
four-pass shell-side arrangement. The baffles control the
flow in the sense that both the direction and flow rate are
dependent on orientation and number of passes, respectively. With the same inlet flow rate, the fluid velocity

108

Mechanical Design of Process Systems

Table 7-3
Characteristics of Tubing

Sq.

tt.

Sq. Ft.

o.D.

Y.

tt

B.W.C.
Gage
22
24
2?

yt

t8

%
%
Yl

20
22
?4

l8
20

v,

22

%
%

t2

%
vs
%

l3

l4
l5

Sq.Inch
.028
.018
.016

.0360
.0313

.049
.035
.028

.0603
.0731
.0799

.0962
.09E2
.0982

.0725
.0798
.0835

.022

.0850

_0982

.0E57

.065

.1075
.1269

.1309

.035
.028

.t452

.1309
.1309

.1546

.1309

.109
.095

.1301
.14E6
.1655
.1817
.1924
.2035

-049

.0E3

17

.05E

20

t/.

l0

.134

.1E25

.t20

.2043

.109
.063

.2223
.2463
.2679

.0t2

.2884

.055
.056
.049
.035

.3019
.3157

.165
.134

\2
%
%
1A

l3
l4
l5
t7

l8
20

.0508
_0539
.0560

.022

l6

II

lengrtl

.0655
.0655
.0655
.0555

.072
.065

l8
l9

LenAtlr

.0295
.0333

.049
.042
.035

',|

WGisht

len8th

Tube

.095

.218t
-2298
.2419

.1636
.1636
.1636
.1636

.0570

[21

Steel

Tubo
t.D.

Ssctlon

.194

.054
.045

.26

.00012
.00011

.2t4

.040

.218

.00009
.00008

,lil

.277

.00083
.00071

.0810
.0E?4

52

t.2t4
l.16E

LI46

.0195
.0159
.0t31

1.354

.0502

1.233

.0374
.0305

.00064

.0829

56
56

_l164

94

.1556
.1606

_305

.319

.00045

.083

.331

.00036

.0969

.302

.0022

.00E5

.1052

.236

.0018

.l t26
.l162

.@72

.171

.370
.402
.430

.00t4

_0056

.0012

.0046

.1066
.1139

.602
.537

.019i

.t202

.479
.425
.388

.0061
.0057
.0053
.0049
.0045

.l4I

.350
.303

.407
.435
.459
.461

.495
.509

.0042
.0037
.0033

.t636

_1453

.262
.221

_555

.0028

.1963
.1963
.1953

.1262
.1335

.884
.809

.482

.0129

.510

.0122

.1393
.1466
.1529

.748

.532
.560

.t587

.520

.1623
_1660

.4t6

.0116
.0107
.0098
.0089
.0083

.367

.t963

46

.104

.1380

.1963
.1963
.1963

.9792

.t27

.1636
.1636

.1963

.00098

,0036
.0029
.0025
.0020

.14t6

.3339

.1953

.3632

.1963

.\107
.1780

.3525
.4?AE
.4536
.4803

.2618

.1754

_2618
.2618
,2618

.51t3
.5463

.666
.592

.428
.269

.521
.541

.5E4

.606
.620
.634
.652
.680

.0076

.0163
.0170
.0155
.0145
.0131
.0118
.0105
.0091

.12t3

lt4

.\227

125

.\248

134

.1649
.167r
.1864
.1903

.1938
.1971

.I993

198

227

241
232
258
283
300

.2016

3V

.2043

340

.2068
.2089

358
377

.0344
.0326
.0309
.0285

.2229

285
319
347

.0262

-23/6
.24t0

.0238

.0221

.2267

.2299
.2340
.2433
-2455

384
416
450
471

.649

.6390

.26t8

.2361

20

.035

.6793

.2618

.2435

.496
.360

tt/t

t%
t%

.6221

.3272

.2330

.32t2

_2409

.890
.920

_\425

.6648

2.057
1.921

.0E90

l0

.180
.165
.134

_0847

.1355

.t20

.7574

_25t

I.59E

.982
1.010

.0741

.u86

.8012
.8365

.0666

1.a32

.4612

1.094

.3272
.3272
.3212
_3?t2
.3272
.3272
.3212
.327?

.3089

.456

Ll80

.0579
.0521
.0426
,0334
.0247

.1100
.1027
.0926
.0833
.06E2
.0534
.0395

Ll92

_3927

1.232

.3927
.3927
.3921

.3225
.3356

1.955

1.291
1.398

l.6lE

t.2E?

.3492

1258
.996

1.334

l_370

.0755

_1008

.5079

2,410

1_760

.3144

.6660

2.201
t.934

t.182

.2904

_6697

3890

.4739

.2586

.3141
.2904
.2586

.6144

4014

_4801

1.6s9

.2300

.2300

,6784

1t/t

II

lYa

t2

tYl

ty.

l3
l4

t%

t6

t)A

t\

IE
20

.083
.065
,049
.035

t\t
tw
t\t

l0

.134

\2

.i09

tk

l4
l6

lt

z
2
2

t2

l4

.109
.095

.0E3

_8825

_9229
.9852

'\.042

.065

t.471

.120

2.433
2.494
2-513
2.642

.t09
.095
.0E3

.5236
.5236
.5236

.2644

.?t02

1,448
1.329

.2715

Ln3

.2E36

1,033
_823

1.060
1.0E4
1.120

.629

1.t52

.2932

.3587
_4606
.1665

1.810
1.834

.103

l_186
1.155

.089

L125

.065

1.556
1.410
1.339

.260
.238
.220
.196

t.284

_174

l.?3E

.153
.140

.0t7

t.411

t.2t0

.t26

0t24

_z?t8

_049

1.228

1.235
1.199

.5755
.5945

1.263

.079

.813

.125

.430
.364
.332
.305
.?10
.239

.2183
_2241

l8

.l4l
.ll4

1299

1.493
1.366
1.316

.2618
.2618
.2618

.714

.158

1.352

550

.9lE

l5

.t7l

1.43i

.3009
.3098

.2t21

I
I

.0415

.0784
.0700
.0654
.0615
.0559
.0507
.0455
.0419
.0332
.0241

_2518

l3
l4

1.126
1.536

1.103

.760
.782
.610
.634
.856
.870
.902
.930

1.241
L163

Ll50

1.037

-132

-0244
.(]EE6
_0694
.0511

521
567

.0051)

Lt29

.109
.095
.083
.072
.065

l133

.2484
.2532

.0067

.1990
2041

.t20
t2

1.176

1.183

.19t6

l0

.0!t7

{92

.0203
.0178
.0134

.670

I
I

1.289

1.351

L46?
1.2t1

5q. Inch

t.D.
_066

.00068
.00055

.1259
.1296
.1333

o.D.

.0392
.0350
.0321

.0307
.0280
.0253
.0227
.0210
.0166

.1354
.1159
.0931

.3140

.3V4
.3211
.3255
.3291

555
708
749
E04

852
898

.l0E

1.279
t.167

_210

.3314

921

1.149

.191

.3366

997

1.t09

.146

.341{

1060

1.075

_106

.3836
.3880
.3974
.4018

970

1.404
1.359

.565

.4052

1037

ll82

.605

'\.273

1250
1305

1.238

I440
I537

I.153

t.2t

_470
_426
.391

.4097
.1136
.4196
_4250
.4291

I31l

1.0E5

.185

t707

L059

_134

.1806
,1546

_4853
.4933

1860

.t241

.50tE

.575
.476
.370

2299

1.218
1-170
1.121
1.095

3795

1.136

.709
.647

l5?6

2014

2l6l

4t2l

Ll79

.315
.304
.212

t.ll6

.293

l.\22
Ll05

.559
.500

t.090

l.0i
1.09

t3

l.I4

The Mechanical Design of Shell-and-Tube Heat Exchangers

109

Table 7-4
Minimum Tube Bend Radii l4l
Tube Outside Dia. (in.)

Duplex, all sizes

*Plain:5/s

Bend Radius (in.)

3 times Tube O.D.

Center-to-Center Oistance (in.)

6 times Tube OD

t3/te

15/s

131t6

2z/s

*For bends this sharp, the tube wall on the outer circumference of the tube ma\ thin down lt/z to 2 gauge rhicknesses. dependin| on condition and specific
tube materiaL Morc genercus ndii \9ill reduce this thinning. TEMA presents a formula for calculating the minimum wall thickness.

VAPOR IN LET

FLUID

IN

LET

FLUIO OUTLET
CONDENSATE OUTLET

Figure 7-7. Baffles can divert flow horizontally. (Courtesy of

Howell Training Company.)

Figure 7-6. Although complex, this design eliminates tube vi-

bration. To use this configuration, one must be cognizant of

pressure data [5]. (Courtesy of Heat Transfer Engineering,
Hemisphere Publishing Corporation, New York, Washington,

D.C.)

Figure 7-8. Longitudinal baffles direct flow in the axial direction. (Courtesy of Howell Training Company.)

10

Mechanical Design of Process Systems

flow area decreases, that is, the velocity

increases with an increase in the number of oasses.
The control of flow in exchangers is accomplished as
increases as the

well with orifice baffles. Figure 7-9 shows an annular

orifice baffle. To utilize this type of design a very clean
shell-side fluid is required, since the fluid must flow in
the annular space between the tube outside diameter and
the hole in the baffle forming the orifice. The flow at the
orifice is very turbulent and the pressure drop through an
orifice-baffle arrangement is very high. Consequently,
these baffles are not used often in industry. Also, since
the orifice baffle requires a very clean fluid, non-Newtonian fluids are completely ruled out. We will see later
in the chapter that the plate fin type of exchanger is superior to the shell and tube design for many clean services.
The reason for the shell and tube desisn to be dominant
is because of the wider variery of fliids it can handle
versus any other design.
Other baffle arrangements are possible with varying
baffle shapes and orientations. Figure 7-10 shows baffles in disc and doughnut shapes, which disperse the
flow in a radial direction. Baffles can be cut to allow for
horizontal or vertical flow in varying amounts as shown
in Figure 7-11.

Figure 7-9. Annular orifices between tube outside surface and

hole in baffle plate [6].

Tie Rods
These are structural rods that run oarallel to the exchanger tubes through the outer perimeter of the baffles.
fastened to the tubesheets such that they space and support the baffles. Tie rods, being attached to the baffle
plates, also prevent them from vibrating and damaging
the tubes. Table 7-5 lists what TEMA recommends as a
minimum number of tie rods and rod diameters for a set
of shell diameters.

Figure 7-10. Doughnut and disc type baffles [6].

Tubesheets
These are the structured plates in which the tubes are
connected at each end ofthe exchanger. Tubesheets come

in two basic types-single and double. Double

tube-

sheets consist of two tubesheets mounted together at each

end of the tubes with a clearance between the two sheets.
The reason for using two tubesheets at each end is to reduce the possibility of a leak of the tube-side fluid. Dou-

ble tubesheets are quite common with highly toxic services, where a leak cannot be tolerated.
Single tubesheets are much more common than double
tubesheets because ofprocess applications and economy.
Typical tube-tubesheet connections are shown in Figure

1a

Of great immediate concern in tubesheet design is the

loading induced by the tubes thermal movement, which

Table 7-5

TEMA Tie Rod Standards (in.)

Nominal

"R" Exchanger

ShellDiameter
8-15
r6-27
28-33
34-48
49-60

"c"

"R"

Exchanger
Tie Rod
Dlameter

& "8"
Exchanger
Tie Rod

irinlmum

Dlameter

of Tie Rods

3/z

3/t

4
3/a

tlz
tlz
tlz

Number

rlz

tlz

o
o
8
10

The Mechanical Design of Shell-and-Tube Heat

Exchangers

is a definite problem in fixed

% Cul Bd!.d on Diomehr

tubesheet exchangers.
TEMA gives two equations for determining the compressive stress induced on tubesheets for all three types of
exchangers-Classes R, C, and B:

Ihis Areo Cll Ool to Arlor Vopor Passog..

Siz of Cul Set by Combiiolions ol Heol
Troisfr Collicint oid Pressure Drop.

: ::
when Cc < ktlr
z\Ku r
_ | ,,-,,-,1
o. = : ll - llllJ I when C" > k#r
t I
lLc I
o,

This Areo Reooead lron Soiil lo Allo* lor

Liquid D,oinoqa,Sire Sel to Slil Erpcl.d Fkr

Soltb

{iidor,

Voror Possoq. Areo

where

rl Bollh Cll
or lor 0.oininq olrer lfoshout.sir. ro Suil
Flor.Ihis b l'lol Becohriended tor

Should be Rrhoved

coidensed liquid

oy

Tubes)

rh.n

rhr

C"

:
:
tr :
ki =
:

Mun be Horironlor,

Ihe. Sdionlind0ding

(7

is High.

tloriron16l Condenseri.

I8) tlorkonlol C!l 8!ftle

Figure 7-11. Baffle details [4].

(7-2)

[rf,:i"
minimum yield stress oftube material ofdesign
remperalure
radius of gyration of tube
0.25[d3 + (d" - 2t,)2]0 50, in.
tube wall thickness, in.
equivalent effective unsupported length of the

tube. in.
unsupported tube span, in.

Applied Process Design for Chemicol ond Petrochemicol Plonts

Flush lo

Tube Shee

Clod
Tobe Sheet

Ferrule,some

l/l6"to l/4'
nne

0s tnner

Tube Woll
8= l5'Avirose

Beoded or Belled

Flored

We ld ed

Dupler Tube

Beoded or Eelled
This Tube Moy olso be Inslolled
Ploin End (No Ferrule)or Flqred
With or Withoul Ferrule,

l/8"

5/16' Minimu m

Minimum

p-tre'' Uinirr.,Usuolly l/4"

ssq+
$\

-r)

lA) VeflicolCul Eoltle

Ploin

111

usn"

Typicol Grooved Detoil

Figure 7-12. Typical tubesheet-tube connections [4].

112

Mechanical Design of Process Systems

r
{o'
['o
:
4 :
oc :
Et

for unsupported tube lengths between two

tubesheets

for unsupported tube lengths between

where f" :
C:

mode constant from Thble 7-6

span length, in.

I:
E=
I =
W:
Wt :
Wq :
W6o :

tubesheet and a baffle

for unsupported tube lengths between two

baffles

modulus of elasticity of tube material at mean

tube metal temperature, psi
outside diameter of tubes, in.
allowable tube compressive stress, psi, for the
tubes at the outer periphery of the tube bundle

Equation 7-1 is based on Euler's columl equation and

Equation 7-2 is based on the short column formula developed by Professor J. B. Johnson during the nineteenth
century.
Other TEMA formulations are summarized in the following sections. The reader is urged to be familiar with
the TEMA standard and follow its guidelines in designing a shell and tube heat exchanger.

tube natural frequency, Hz

modulus of elasricity. psi

moment of inertia, in.a (Table 7-3)

Wr

Wn

MWr", lbs/ft

weight of empty tube (Table 7-3)

weight of fluid inside tube 0.00545
p"d"'?

M : added mass coefficient from

p : fluid density, lbs/ft3
d : diameter of tube, in

Table 7-6

subscripts:

i :

o:

inside
outside

Allowable Tube Compressive Stress-Periphery of

Bundle. The allowable tube compressive stress, psi, for
the tubes at the periphery of the bundle is given by:

TEMA Formulations

a,:ffi-28

Baffles and Support Plates

Natural Frequencies ot Straight Tubes on Multiple
Equal Spans

-r

s"=\l
- 21r -

when C.

-. I
(kur)l
2C"l

kf/ror

whenc >kur

/:*

3.36C

where

C"'Vsr
= l/

Table 7-o

Mode Constant-C
Extreme Ends Supported
No.

of
Spans

lst

2
3

Mode

31.73
31.73

3r.73

5
6
7

31.73

31,73
31.73

to

2nd Mode
126.94

[21

Extreme Ends ClamDed

,l-r+r

Fr-l-'-l*,.1
|--___l
/T-7\--lzf-R
lst

Mode

2nd Mode

49.59

49.59

37.O2

37.O2

198.34
72.36
59.56
49.59

34.99
34.32
33.67

34.99
34.32
33.67

40.52
38.40

&.52

33.O2

33.02

72.36
40,52

33.02
33.02
33.02

p1d1,

weight of fluid displaced by tube 0.00545

Extreme Ends Clamped-Supported

r-fr-fr

lst

Mode

49.59
37.O2

34.32

44.r9

37.O2

34.99

znd

Mode

160.66
63.99
49.59
42.70

39.10
37.O2

32.37
31.73
31.73

35.66
34.99
34.32
33.67

The Mechanical Desien of Shell-and-T[be Heat Exchansers

yield stress, psi, oftube material at design metal
temperature used.
radius of gyration of tube

0.25

KT:

.vu +la" -

2tJ1,

only, may be calculated as follows:

2.74C"
R2

where

fnu

:
:

U-tube natural frequency, Hz

mode constant for U-bend
bend radius, in.

spans between two tube-

Note: For other than simple support conditions the calculated

frequency may be estimated by multiplying the above

spans between a tubesheet

value for f,, by the appropriate ratio of mode constants

from Thble 7-6 using single span values.

sheets.

0,8 for unsupported

quency, assuming simple supports and for the first mode

in. (Table 7-3)

equivalent unsupported buckling length of the

tube, inches. Use the largest value considering
unsupported tube spans.
unsupported tube span, in.

0.6 for unsupported

113

and a baffle.
1.0 for unsupported spans between two baf-

fles.

Note: The value of S" shall not exceed the Code allowable
tensile stress of the tube material at desisn metal temperature used.

Effect ot Longitudinal Tube Stress

ASME Tube Joint Load Grlteria

The ASME Secrion VItr Division Dressure vessel

code lists formularions in evaluating tube forces exerted
on tubesheets. Referring to Figure 7-13 and Table 7-7
the formulas for the maximum tube force are as follows:

Dt2

'Er.,j
where fnp

tube natural frequency in stressed condition, Hz

tensile, negative
for compressive)

P = axial force, lbs (positive for

Natural Frequencies of Straight Tubes on Unequal

Multiple Spans

f" :

For

F, :

joint types a, b, c, d,

(7-3)

A,o,11f,

For joint types

F,

e:

f, g, h, i, j,

k:
(7-4)

A,o"11f,f"f,

where

maximum tube joint force, lb1

cross-sectional metal area of tube, in.2
oall : ASME maximum allowable stress. psi
f= joint reliability factor

Ft

10.83 t'z

f. (no tesg = maximum value without test given

For a tube on multiple unequal spans with the extreme
ends fixed and simply supported at the intermediate supports, ki can be obtained by solving the following characteristic determinant for an n span system.

Natural Frequencies of U-Tubes. It must be recognized that each tube is a continuous beam that has a single fundamental frequency. This frequency may be
largely governed by the lowest "stand alone" frequency
of either the longest straight span or the U-bend. It is
suggested that both be calculated and that the lower value
be used, keeping in mind the approximate and somewhat
conservative nature of the result. The straight span frequency may be determined from Thble 7-6 using the appropriate mode constant. The U-bend out-of-plane fre-

f, (teso

in

Table 7-'7

maximum value with test as specified in

the ASME Section

VIII Division

code, per section UA-002

Figre 7-14 shows how the tube joint load varies for
various tube gauges of various process conditions. Naturally, as the tube wall increases, the tube stiffens and,
consequently, the force exerted by the tube on the tubesheet joint increases. The engineer should evaluate the
tube loads with the various process conditions possible
and use the worst for determining the maximum tube
joint force, as shown in Figure 7-14. The TEMA standard gives the formulations to determine the tube ioint
lorces and the user is referred to this standard for these
expressrons.

The buckling of exchanger tubes can be a problem if

thermal expansion is not properly accounted for in de-

Mechanical Design of Process Systems

114

Table 7-7
Reliability Factors, f,

Joint

Type

Notes

Descriptions
Welded only, a> 1.4r
Welded only, tsa<L.4t

(1)(7X8)
(1X2)
(1X3)
(1X6)
(1X7X8)

Brazed, examined
Brazed, not fully examinable
Rolled, welded, a> l.4t
Rolled, two or more grooves,
and welded, a< l.4r
Rolled, single-groove, and
welded, a < 1.4r
Rolled, no grooves, and
and welded, a < 1.4r
Rolled, two or more grooves
Rolled, single groove
Rolled, no grooves

f
c
h
I

[71

l. (tesr)

f, (no test)

1.00

0.50
1.00

0.80
0.55
0.80
0.40
0.80

0.95

o.75

0.85

0.65

0.70
0.90
0.80
0.60

0.50
0.70
0.65
0.50

0.70
1.00

(1X4)(s)
(7)
(l

)(4)(s)
(7)

(l)(4)(5)
(7)

(l)(4xs)
(l)(4x5)
(l)(4)(5)

Notes:
(l) The use of f. Ceso factor requires qualification in accordance with UA-003 and UA-004.
(2) For welds where a is less than t, fi (no test) 0. Tubes with Type (b) joints where a<t may be considered as acting as stays and contributing to the
strength of the tubesheet only when the joint is tested in accordance with UA 003 and UA-o(X.
(3) A value of 1 00 for f, (test) or .80 for f, (no test) can be applied only to joints in which visual examination assures that the brazing filler metal has
penetrated the entire joint [see UB-14(a)] and the depth of penetration is not less than three times the nominal thickness of the tube wall.
(4) When the ralio of OD. to LD., using nominal tube dimensioos, is less than 1.05 or geater than l-410, qualification in accordance with UA403 and
UA-oO1 is required.
(5) The nominal pitch used in the desigo of tubesheets for roller expanded joints shall not be less than the following:

P=

d" + 0.165 (d" + 2r)

= nominal pitch (center-to-center distance of adjacent tube holes),

= tube o.D_, in.
I = nominal thickness of average wall tube, in.

in.

except that:

(a) nominal pitch shalt not be less than 4 + 2t unless the joint is qualified in accordance with UA-003 and UA-004; and
(b) 96% of the ligaments between tube holes throughout the thickrcss of the rnachined tubesheet shall not be less than 0.85

(P-4). Ligaments which

do not meet this requirement shall be evaluated and orrections made as may be necessary.
(6) A value of .50 for f, (test) or .40 for f, (no tso shall be used for joinls in which visual examination will not provide proof that the brazing filler metal
has penetrated the entire joint Isee US-14(b)1.
(7) The value of f. (no test) applies only to material combinations as provided for under Section IX. For material combinations not provided for under
Section IX, f. must be determined by test in accordance with UA-003 and LIA-0O4.
(8) For joint types involving more than one fastening method, the sequence used in the joint descriptions does not necessarily indicate the order in which

the

oDerations are Derformed.

sign. One such formulation to predict the critical buckling load is as follows:

P.,

q'' t0.5216r
- , "
,,
I L** l'
\Ns + t/

where L,u6"

NB :

t7-51

total length of tubei between tubesheets

number of baffles

Equation 7-5 is based on the Euler column formula. In

situations where there are several baffles, such that the
effective length, L", divided by the radius of gyration, k,
is between 30 and 120, exclusive, then the Johnson short

column equation is more accurate. For a tube to be considered as a series of short columns constrained by fixed
ends, one must be certain that the baffles constraining
the tubes allow practically no translational or rotational
movement. The stiffness of the baffle plate should be

analyzed, as small translational and rotational tube

movement allowed by the baffle plate could considerably alter the buckling characteristics of the tube. The
evaluation of a baffle plate containing several tubes can
be a somewhat detailed analysis, and it may be faster to
consider the tube as a continuous beam in determining
buckling characteristics.
For further details on the mechanical design of exchangers, the reader is referred to TEMA. We will discuss tube vibrations shortly.

The Mechanical Desien of Shell-and-Tube Heat

PBOCESS EVALUATION OF SHELL AND

TUBE EXCHAI{GERS

mechanical engineering coincide. Thus, the mechanical

engineer must be cognizant of process evaluation of heat
exchangers in order to design these units.
A thermal evaluation of shell and tube heat exchansers
concerns primarily two modes of heat transfer-conJuction and convection.
In Chapter 3 we considered heat transfer through piping and vessel components as well as jacketed systems.
As described in Chapter 3, the basic expressions used in
conveetion are as follows:

We are concerned here only with any particular heat

exchanger and determining whether it can transfer heat
energy as required. How the unit affects process conditions of the entire system is not our concern here, because we are interested only in the proper performance
of the unit. Evaluating the exchanger in relation to the
process system is the primary concern of the chemical
engineer. The thermal evaluation of the exchanger is one
area where chemical and mechanical engineering overlap; just as in Chapters 2 and 4 we saw how civil and

:
q:
q

rhcpat

(3-24)

UA(LMTD)

(3-26)

t2l

{1t
Some ecceptable weld geometriea where

is not less

(61

lhan

Exchansers t15

l.4t

l7l

(81

Figure 7-13. Joint types [7]. (Courtesy of ASME.)