Aliran Fluida Pada Shell & Tube Heat Exchanger

Rangkuman Diskusi KBK Proses

24 Januari 2007 26 Januari 2007
Milis Migas Indonesia : http://groups.yahoo.com/group/Migas_Indonesia
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Editor :
Zulfan Adi Putra
Swastioko Budhi Suryanto
Moderator KBK Proses



Ahmed Syarif Jurusan Teknik Gas & Petrokimia UI

Saya mahasiswa teknik kimia. Saya masih bingung tentang penentuan fluida yang dialirkan pada
shell jika menggunakan heat exchanger jenis shell and tube. Bisa minta penjelasannya tentang
penentuan kriteria dari dua jenis fluida yang akan ditransferkan panasnya dalam heat exchanger
jenis tersebut. Yang mana yang akan dialirkan di shell dan yang mana yang akan dialirkan di tube.

Terimakasih atas tanggapannya.


Muchlis Nugroho Rekayasa Engineering

Beberapa pertimbangan fluida ditempatkan di shell atau di tube :
1. Potensi fouling, jika salah satu fluida memiliki potensi fouling/scaling (misalnya karena
punya komponen pengotor) maka sebaiknya ditempatkan di tube. Karena tube lebih mudah
dibersihkan/dirawat dengan mudah.
2. Kebutuhan jenis material, jika suatu fluida memerlukan peralatan dengan jenis material
khusus (misalnya harus alloy yang mahal) maka sebaiknya fluida itu di dalam tube. Karena
material tube itu tersedia dalam berbagai variasi, sedangkan material shell biasanya cuma
carbon steel.
3. Jenis fasa, jika dalam heat exchanger tersebut ada perubahan fasa maka sebaiknya
fluida yang berubah fasa tersebut berada di shell (misalnya evaporator chiller dan
surface condenser). Karena kalau di tube ada resiko hammering. Walaupun ada juga fluida
yang berubah fasa berada di tube dengan arrangement khusus tentunya (misalnya HP
boiler, dan air cooled condenser) karena pertimbangan perawatan, material, dsb.

Jadi pada intinya desain alat itu secara umum harus melalui pertimbangan maintainability,
operability, reliability, constructability, safety, dan economy.

Tapi ada cara lain yang lebih mudah (tapi kalau mahasiswa mungkin malah susah) untuk
menentukan fluida itu berada di shell atau di tube adalah dengan mencari tahu heat exchanger
sejenis yang sudah pernah dibuat dan beroperasi bagaimana arrangementnya, dan bagaimana
performancenya. Short cut saja lah.

Rangkuman Diskusi KBK Proses Milis Migas Indonesia Halaman 1 dari 4
Hasrat Magabe Harahap Inti Karya Persada Teknik

Disamping yang sudah diuraikan mas Muchlis di atas, sederhananya sebagai "rule of thumb" nya
dengan basis true countercurrent flow adalah : Tube side untuk fluida yang bersifat corrosive,
fouling, scaling dan bertekanan lebih tinggi, Shell Side untuk fluida yang bersifat viscous dan
condense.


Enrico Yandie Pertafenikki Engineering

I hope this rule of thumb can be useful hints for you.

Fluids to be passed through the shell :
Fluids of which pressure drop should be low
Highly viscous fluids
Fluids which exhibit a low heat transfer rate
Fluids which undergo the phase change

Fluids to be passed through the tube :
Dirty fluids
Fluids at higher pressure
Corrosive fluids
Fluids which contain solids
Cooling water


Adhi Budhiarto Pertamina Unit Pengolahan II Dumai

Beberapa hal yang perlu dipertimbangkan dalam menentukan aliran fluida dalam shell side dan
tube side untuk shell and tube exchanger adalah (urut dari yang paling penting/prioritas utama) :

Korosi
Fluida korosif sebaiknya dialirkan di tube side untuk menghindari korosi pada kedua sisi, yaitu
pada permukaan dalam shell dan pada permukaan luar tube. Jika fluida korosif dialirkan di tube,
maka hanya permukaan tube bagian dalam saja yang mengalami korosi. Jika terjadi kebocoran
pada tube, maka prop saja pada tube yang bocor, trus heat exchanger bisa difungsikan lagi.
Jumlah tube yang di-prop maksimum 10 % atau tergantung kebutuhan heat exchange-nya.

Sediment/ Suspended Solid / Fouling
Fluida yang mengandung sediment/suspended solid atau yang menyebabkan fouling sebaiknya
dialirkan di tube sehingga dapat memudahkan waktu cleaning (jika keadaan memungkinkan, tube
bundle tidak perlu dicabut untuk cleaning, cukup dengan membuka channel cover terus tembak
deh pakai water jet/mechanical cleaning atau dibantu dengan chemical cleaning). Jika fluida yang
mengandung sediment dialirkan di shell, maka sediment/fouling tersebut akan terakumulasi pada
stagnant zone di sekitar baffles, sehingga cleaning pada sisi shell menjadi tidak mungkin
dilakukan tanpa mencabut tube bundle.

Best practice fouling factor untuk Oil Refinery streams (dalam hr.ft
2
.
o
F/Btu) :
Gas dan vapor di Crude dan Vacuum unit :
Atmospheric tower overhead vapours : 0,001
Rangkuman Diskusi KBK Proses Milis Migas Indonesia Halaman 2 dari 4
Lght naphtha : 0,001
Vacuum overhead vapours : 0,002
Crude oil (0 s/d 232
o
C)
velocity < 2 ft/s : 0,003
velocity 2 s/d 4 ft/s : 0,002
velocity > 4 ft/s : 0,002
Gasoline : 0,002
Naphtha/light distillate/kerosene/light gas oil : 0,002 - 0,003
Heavy gas oil : 0,003 - 0,005
Heavy fuel oil : 0,005 - 0,007
Kerosene : 0,002 - 0,003

Viscosity
Koefisien heat transfer yang lebih tinggi dapat diperoleh dengan menempatkan fluida yang lebih
viscous pada shell side sebagai hasil dari peningkatan turbulensi akibat aliran crossflow
(terutama karena pengaruh baffles). Biasanya fluida dengan viscosity > 2 cSt dialirkan di shell
side untuk mengurangi luas permukaan perpindahan panas yang diminta. Koefisien perpindahan
panas yang lebih tinggi terdapat pada shell side, karena aliran turbulen akan terjadi melintang
melalui sisi luar tube dan baffle.

Pressure
Kecuali dipengaruhi oleh faktor lain, maka fluida dengan pressure yang lebih tinggi sebaiknya
dialirkan di tube, sehingga shell dapat didesain untuk tekanan operasi yang lebih rendah dan heat
exchanger menjadi lebih murah. Jika fluida dengan pressure yang lebih tinggi dialirkan di shell
side, maka baik shell maupun tube bundle harus didesain untuk pressure yang tinggi. Sedangkan
jika fluida dengan pressure yang lebih tinggi ditempatkan pada tube side, maka bagian-bagian
yang harus didesain pada tekanan tinggi hanya channel, channel cover, dan tube bundle saja.
Alasan lain adalah karena tekanan kerja yang diberikan pada internal tube dua kali tekanan kerja
external tube.

Condensing vapours
Biasanya condensing vapours dialirkan di shell side untuk memfasilitasi penghilangan condensate.

Temperatur
Kecuali dipengaruhi oleh faktor lain, biasanya lebih ekonomis meletakkan fluida dengan
temperatur lebih tinggi pada tube side, karena panasnya ditransfer seluruhnya ke arah
permukaan luar tube/ke arah shell sehingga akan diserap sepenuhnya oleh fluida yang mengalir di
shell. Jika fluida dengan temperatur lebih tinggi dialirkan pada shell side, maka transfer panas
tidak hanya dilakukan ke arah tube, tapi ada kemungkinan transfer panas juga terjadi ke arah
luar shell alias ke lingkungan (yah pengaruhnya kecil sih, makanya jadi prioritas terakhir untuk
dipertimbangkan).

Best practice penempatan fluida di shell atau di tube :
Fluida yang mengalir pada shell :
Condensing vapours
Allowable pressure drop yang lebih rendah
Jumlah aliran yang lebih besar dengan sifat fisis yang sama dengan fluida di tube
Fluida viscous yang clean
Vaporizing

Rangkuman Diskusi KBK Proses Milis Migas Indonesia Halaman 3 dari 4
Fluida yang mengalir pada tube :
Cooling water
Fluida tekanan tinggi
Fluida korosif/alloy construction

Khusus untuk cooling water, pertimbangkan penggunaannya jika temperatur proses tinggi, karena
temperatur proses yang tinggi dalam water-cooled exchanger dapat menyebabkan :
Overheating cooling water pada tube wall (akan menyebabkan mineral scaling)
Perbedaan temperatur yang tinggi antara shell dan tube (mechanical problem)

Best practice-nya, jangan gunakan cooling water jika fluida panas > 200
o
C untuk mencegah
terjadinya fouling yang disebabkan oleh hardness salts dalam air. Selain itu, temperatur air
keluar dibatasi maksimum 50
o
C.

Semoga bermanfaat.

Rangkuman Diskusi KBK Proses Milis Migas Indonesia Halaman 4 dari 4
How to Select Shell and Tube Heat Exchanger Classes and Types


Drajad Agus Widodo (drajad_aw@yahoo.com)

Fundamentals of Shell and Tube Heat
Exchangers
A shell and tube heat exchanger is a cylindrical vessel
housing a set of tubes (called the tube bundle) containing
a fluid at some temperature and immersed in another
fluid at a different temperature. The transfer of heat
occurs between the fluid flowing over the tubes and the
fluid flowing inside the tubes. The fluid flow inside the
tubes is said to be tube side and the fluid flow external
to the tube bundle is said to be shell side

Basic Components of Shell and Tube Heat
Exchangers

Fig. 1 Shell and Tube Exchanger Components
While there is an enormous variety of specific design
features that can be used in shell and tube exchangers,
the number of basic components is relatively small.
Tubes
The tubes are the basic component of the shell and tube
exchanger, providing the heat transfer surface between
one fluid flowing inside the tube and the other fluid
flowing across the outside of the tubes. The tubes may be
seamless or welded and most commonly made of copper
or steel alloys. Other alloys of nickel, titanium, or
aluminum may also be required for specific applications.
The tubes may be either bare or with extended or
enhanced surfaces on the outside. Extended or enhanced
surface tubes are used when one fluid has a substantially
lower heat transfer coefficient than the other fluid.
Extended surfaces, (finned tubes) provide two or four
times as much heat transfer area on the outside as the
corresponding bare tube, and this area ratio helps to
outside heat transfer coefficient.


Fig. 2 Finned Tube
More recent developments are: a corrugated tube which
has both inside and outside heat transfer enhancement, a
finned tube which integral inside turbulators as well as
extended outside surface, and tubing which has outside
surfaces designed to promote nucleate boiling.
Tube Sheets
The tubes are held in place by being inserted into holes in
the tube sheet and there either expanded into grooves cut
into the holes or welded to be tube sheet where the tube
protrudes from the surface. The tube sheet is usually a
single round plate of metal that has been suitably drilled
and grooved to take the tubes (in the desired pattern), the
gaskets, the spacer rods, and the bolt circle where it is
fastened to the shell. However, where mixing between
the two fluids (in the event of leaks where the tube is
sealed into the tube sheet) must be avoided, a double tube
sheet may be provided.
Fig. 3 Tube Sheet
The space between the tube
sheets is open to the
atmosphere so any leakage of
either fluid should be quickly
detected. Triple tube sheets
(to allow each fluid to leak separately to the atmosphere
without mixing) and even more exotic designs with inert
gas shrouds and/or leakage recycling systems are used in
cases of extreme hazard or high value of the fluid.
The tube sheet, in addition to its mechanical
requirements, must withstand corrosive attach by both
fluids in the heat exchanger and must be
electrochemically compatible with the tube and all tube-
side material. Tube sheets are sometimes made from low
carbon steel with a thin layer of corrosion-resisting alloy
metallurgically bonded to one side.
Shell and Shell-side Nozzles
The shell is simply the container for the shell-side fluid,
and the nozzles are the inlet and exit ports. The shall
normally has a circular cross section and is commonly
made by rolling a metal plate of the appropriate
dimensions into a cylinder and welding the longitudinal
joint (rolled shells). Small diameter shells (up to
around 24 inches in diameter) can be made by cutting
pipe of the desired diameter to the correct length (pipe
shells). The roundness of the shell is important in fixing
the maximum diameter of the baffles that can be inserted
and therefore the effect of shell-to-shell baffle leakage.
Pipe shells are more nearly round than rolled shells
unless particular care is taken in rolling.
In large exchangers, the shall is made out of low carbon
steel wherever possible for reasons of economy, though
other alloys can be and are used when corrosion or high
temperature strength demands must be met.
Tube-Side Channel and Nozzles
Tube-side channels and nozzles control the flow of the
tube-side fluid into and out of the tubes of the exchanger.
Since the tube-side fluid is generally the more corrosive,
these channels and clan instead of solid alloy.

Channel Covers
The channel covers are round plates that bolt to the
channel flanges and can be removed for tube inspection
without disturbing the tube-side piping. In smaller heat
exchangers, bonnets with flanged nozzles or threaded
connections for the tube-side piping or often used instead
of channels and channel covers
Pass Divider
A pass divider is needed in one channel or bonnet for an
exchanger having two tube-side passes, and they are
needed in both channels or bonnets for an exchanger
having more than two passes.
The arrangement of the dividers in multiple-pass
exchangers is somewhat arbitrary, the usual intent being
to provide nearly the same number of tubes in each pass,
to minimize the number of tubes lost from the tube count,
to minimize the pressure difference across any pass
divider (to minimize leakage and therefore the violation
of the MTD derivation), to provide adequate bearing
surface for the gasket and to minimize fabrication
complexity and cost.
Baffles
Baffles serve two functions; Most importantly, they
support the tubes in the proper position during assembly
and operation and prevent vibration of the tubes caused
by flow-induced eddies, and secondly, they guide the
shell-side flow back and forth across the tube field,
increasing the velocity and the heat transfer coefficient.


Fig. 4 Baffle cuts (a) Baffle cuts for single segmental
baffles. (b) Baffle cuts for double segmental baffles. (c)
Baffle cuts for triple segmental baffles.
Selection of Shell and Tube Heat Exchanger
Classes
TEMA Standards provide a Recommended Good
Practice for the designers consideration in areas outside
of the limits of the specified standards. Guidance and
references are noted for seismic design, large diameter
exchangers, tube vibration, tube-to-tube sheet stress
analysis, nozzle loading analysis, and numerous other
design-limiting features.
Shell and tube heat exchanger technology for gas,
chemical, and petroleum plants has developed a broad.
exchangers, tube vibration, tube-to-tube sheet stress
analysis, nozzle loading analysis, and numerous other
design-limiting features. basis of common understanding
through the Standards of Tubular Exchangers
Manufacturers Association (TEMA). These TEMA
Standards provide nomenclature, dimensional
tolerances, manufacturers and purchasers
responsibilities, general installation and operating
guidelines, and specific design and fabrication practices.
The design and fabrication practices of TEMA are in
three classifications, called Class R, C, or B.
Class R includes heat exchangers specified for the
most severe service in the petroleum-
chemical processing industry. Safety and
durability are required for exchangers
designed for such rigorous condition.
Class C includes heat exchangers designed for the
generally moderate services and
requirements. Economy and overall
compactness are the two essential features
of this class.
Class B are heat exchangers specified for general
process service. Maximum economy and
optimum compactness are the main criteria
of design.



Table 1 Comparison of TEMA Classes R, C and B Exchangers

Para. Topic R C B
1.12 Definition For the generally severe
requirement of petroleum
and related processing
application
For the generally moderate
requirements of commercial
and general process
application
For chemical process
service
1.51 Corrosion allowance on
carbon steel
1/8 inch 1/16 inch 1/16 inch
2.5 Tube pitch and minimum
cleaning lane
1.25 x tube OD. 1/4 inch
lane.
1.25 x tube OD. Tube OD =
5/8 or less, may be located
1.2 x tube OD
1.25 x tube OD. Lane may
be 3/16 inch in 12 inch and
smaller shells. Minimum
cleaning lanes 1/4" for shell
diameter greater 12
4.42 Longitudinal baffle
thickness
1/4 inch minimum 1/8 inch alloy, 1/4 inch CS 1/8 inch alloy, 1/4 inch
carbon steel
4.71 Minimum tie rod diameter 3/8 inch in 6 15 inch Shells
Diameter
1/4 inch in 6-15 inch Shells
Diameter
1/4 inch in 6-15 inch Shells
Diameter
5.11 Floating head cover cross-
over area
1.3 times tube flow area Same as tube flow area Same as tube flow area
5.31 Lantern ring construction 375
o
F maxi. 300 psi up to
24 inch diam. Shell
150 psi for 25-42 inch shells
75 psi for 43-60 inch shells
600 psi maximum (same as TEMA R)
6.2 Gasket materials Metal jacketed or solid metal
for
(a) internal floating head
cover
(b) 300 psi and up.
(c) All hydrocarbons
Metal jacketed or solid metal
(a) internal floating head
(b) 300 psi and up.
(Same as TEMA C)
6.32 Peripheral gasket contact
surface
Flatness tolerance specified No tolerance specified No tolerance specified
7.131 Minimum tube sheet
thickness with expanded
tube joints
Outside diameter of the tube 0.75 x tube OD for 1 inch
and smaller.
7/8 inch for 1 1/4 OD
1 inch for 1 1/2 OD
1.25 inch for 2 OD
(Same as TEMA C) +
In no case shall the total
tube sheet thickness,
including corrosion
allowance, be less than 3/4"
7.44 Tube Hole Grooving Two grooves Above 300 psi design
pressure and/or above 350
o
F
design temp: 2 grooves
(Same as TEMA R)
7.51 Length of expansion Smaller of 2 inch or tube
sheet thickness 1/8
Smaller of 2 x tube OD or
tube sheet thickness 1/8
(Same as TEMA R)
7.6 Tube sheet pass partition
grooves
3/16 inch deep grooves
required
Over 300 psi 3/16 inch deep
grooves required or other
suitable means for retaining
gaskets in place
(Same as TEMA C)
10.3 Pipe Tap Connections 6000 psi coupling with bar
stock plug
3000 psi coupling 3000 psi coupling with bar
stock plug
10.32 Pressure Gauge connections Required in nozzle 2 inch &
up with one connection of
3/4 minimum NPS
(shall be specified by
purchaser)
Required in nozzle 2 inch &
up with one connection of
1/2 minimum NPS
10.33 Thermometer Connections Required in nozzles 4 inch &
up with one connection of 1
minimum NPS
(shall be specified by
purchaser)
(Same as TEMA R)
11.1 Minimum bolt size 3/4 inch 1/2 inch recommended,
smaller bolting may be used
5/8 inch



Selection of Shell and Tube Heat Exchanger
Types
Nomenclature
Fig 5 summarizes the major shell-and-tube exchanger
components other than tubes and baffles. The letters are
used for a standard nomenclature in the industry. A three-
letter type designation in the order of front head type,
shell type, and rear head is used. For example, an AJS
would have a front head that is removable with a
removable cover, a shell that is arranged for divided
flow, and a rear floating head with a backing device
(usually a split-ring).















Fig. 5 TEMA-type designations for shell and tube heat
exchangers.
Principal Type of Construction

Fig. 5 shown details of the construction of the TEMA
types of shell-and-tube heat exchangers. These and other
types are discussed in the following paragraphs.

Fixed-Tube-Sheet Heat Exchanger
Fixed-tube-sheet exchanger Fig. 6b are used more often
than any other type, and the frequency of use has been
increasing in recent years. The tube sheets are welded to
the shell. Usually these extend beyond the shell and serve
as flanges to which to tube-side header are bolted. This
construction requires that the shell and tube-sheet
materials be weldable to each other.

When such welding is not possible, a blind gasket type
of construction is utilized. The blind gasket is not
accessible for maintenance or replacement once the unit
has been constructed. This construction is used for steam
surface condensers, which operate under vacuum.

The tube-side header (or channel) may be welded to the
tube sheet, as shown in Fig 5 for type C and N heads.
This type of construction is less costly than types B and
M or A and L and still offers the advantage that tubes
may be examined and replaced without disturbing the
tube-side piping connections.

There is no limitation on the number of tube-side passes.
Shell-side passes can be one or more, although shells
with more than two shell-side passes are rarely used.

Tubes can completely fill the heat-exchanger shell.
Clearance between the outermost tubes and the shell is
only the minimum necessary for fabrication. Between the
inside of the shell and the baffles some clearance must be
provided so that baffles can slide into the shell.
Fabrication tolerances then require some additional
clearance between the outside of the baffles and the
outermost tubes. The edge distance between the outer of
the baffles and the outer tube limit (OTL) and the baffle
diameter must be sufficient to prevent vibration of the
tube from breaking through the baffle holes. The
outermost tube must be contained within the OTL.

Tubes can replaced. Tube-side headers, channel covers,
gaskets etc., are accessible for maintenance and
replacement. Neither the shell-side baffle structure nor
the blind gasket is accessible. During tube removal, a
tube may break within the shell. When this occurs, it is
most difficult to remove or to replace the tube. The usual
is to plug the appropriate holes in the tube sheets.

U-Tube Heat Exchanger (Fig. 6d)
The tube bundle consists of the stationary tube sheet, U
tubes (or hairpin tubes), baffles or support plates, and
appropriate tie rods and spacers. The tube bundle can be
removed from the heat-exchanger shell. A tube-side
header (stationary head) and a shell with integral shell
cover, which is welded to the shell, are provided. Each
tube is free to expand or contract without any limitation
being placed upon it by the other tubes.

The U-tube bundle has the advantage of providing
minimum clearance between the outer tube limit and the
inside of the shell for any of the removable-tube-bundle
constructions. Clearances are of the same magnitude as
for fixed-tube-sheet heat exchangers.

The number of tube holes in a given shell is less than that
for a fixed-tube-sheet exchanger because of limitation of
bending tubes of a very short radius.

The U-tube design offers the advantage of reducing the
number of joints. In high-pressure construction this
feature becomes of considerable importance in reducing
both initial and maintenance costs. The use of U-tube
construction has increased significantly with the
development of hydraulic tube cleaners, which can
remove fouling residues from both the straight and the U-
bend portions of the tubes.

Kettle-type reboilers, evaporators, etc., are often U-tube
exchangers with enlarged shell sections for vapor-liquid
separation. The U-tube bundle replaces the floating-heat
bundle of Fig.6e.

The U-tube exchanger with copper tubes, cast-iron
header, and other parts of carbon steel is used for water
and steam services in office buildings, schools, hospitals,
hotel, etc. Nonferrous tube sheets and admiralty or 90-10
copper-nickel tubes are the most frequently used
substitute materials. These standard exchangers are
available from a number of manufacturers at costs far
below those of custom-built process-industry equipment.

Packed-Lantern-Ring Exchanger (Fig. 6f)

This construction is the least costly of the straight-tube
removable bundle types. The shell-and tube-side fluids
are each contained by separate rings of packing separated
by a lantern ring and are installed at the floating tube
sheet. The lantern ring is provided with weep holes. Any
leakage passing the packing goes through the weep holes
and then drops to the ground. Leakage at the packing will
not result in mixing within the exchanger of two fluids.

The width of the floating tube sheet must be great enough
to allow for the packings, the lantern ring, and
differential expansion. Sometimes a small skirt is
attached to a thin tube sheet to provide the required
bearing surface for packings and lantern ring.
The clearance between the outer tube limit and the inside
of the shell is slightly larger than that for fixed-tube-sheet
and U-tube exchangers. The use of a floating-tube-sheet
skirt increases this clearance. Without the skirt the
clearance must make allowance for tubeholes distortion
during tube rolling near the outside edge of the tube-
sheet or tube-end welding at the floating tube sheet.

The packed-lantern-ring construction is generally limited
to design temperatures below 191
o
C (375
o
F)and to the
mild services of water, steam, air, lubricating oil, etc.
Design gauge pressure does not exceed 2068 kPa (300
lbf/in2) for pipe shell exchangers and is limited to 1034
kPa (150 lbf/in2) for 610 to 1067 mm (24 to 42 in.)
diameter shells.

Outside-Packed Floating-Head Exchanger
(Fig. 6c)

The shell-side fluid is contained by rings of packing,
which are compressed within a stuffing box by a packing
follower ring. This construction was frequently used in
the chemical industry, but in recent years usage has
decreased. The removable-bundle construction
accommodates differential expansion between shell and
tubes and is used for shell-side service up to 4137 kPa
gauge pressure (600 lbf/in2) at 316
o
C (600
o
F). There
are no limitations upon the number of tube-side passes or
upon the tube-side design pressure and temperature. The
outside-packed floating-head exchanger was the most
commonly used type of removable-bundle construction
in chemical-plant service.

The floating-tube-sheet skirt, where in contact with the
rings of packing, has fine machine finish. A split shear
ring is inserted into a groove in the floating-tube-sheet
skirt. A slip-on backing flange, which in service is held
in place by the shear ring, bolts to the external floating-
head cover.

The floating-head cover is usually a circular disk. With
an odd number of tube-side passes, an axial nozzle can
be installed in such a floating-head cover. If a side nozzle
is required, the circular disk is replaced by either a disked
head or a channel barrel (similar to Fig. 6f) bolted
between floating-head cover and floating-tube-sheet
skirt.

Internal Floating-Head Exchanger (Fig. 6a)

The internal floating-head design is used extensively in
petroleum-refinery service, but in recent years there has
been a decline in usage.

A split backing ring and bolting usually hold the floating-
head cover at the floating tube sheet. These are located
beyond the end of the shell and within the larger-
diameter shell cover. Shell cover, split backing ring, and
floating-head cover must be removed before the tube
bundle can pass through the exchanger shell.

With an even number of tube-side passes the floating-
head cover serves as return cover for the tube-side fluid.
With an odd number of passes a nozzle pipe must extend
from the floating-head cover through the shell cover.
Provision for both differential expansion and tube-bundle
removal must be made.

Pull-Through Floating-Head Exchanger
(Fig. 6e)

Construction is similar to that of the internal-floating-
head split-backing-ring exchanger except that the
floating-head cover bolts directly to the floating tube
sheet. The tube bundle can be withdrawn from the shell
without removing either shell cover or floating-head
cover. This feature reduces maintenance time during
inspection and repair.

The large clearance between the tubes and the shell must
provide for both the gasket and the bolting at the
floating-head cover. This clearance is about 2 to 2
times that required by the split-ring design. Sealing strips
or dummy tubes are often installed to reduce bypassing
of the tube bundle.



































1. Stationary Head Channel 20. Slip-On Backing Flange
2. Stationary Head Bonnet 21. Floating Head Cover - External
3. Stationary Head Flange Channel or Bonnet 22. Floating Tube sheet Skirt
4. Channel Cover 23. Packing Box Flange
5. Stationary Head Nozzle 24. Packing
6. Stationary Tube sheet 25. Packing Gland
7. Tubes 26. Lantern Ring
8. Shell 27. Tie-Rods and Spacers
9. Shell Cover 28. Transverse Baffles or Support Plates
10. Shell Flange Stationary Head End 29. Impingement Plate
11. Shell Flange Rear Head End 30. Longitudinal Baffle
12. Shell Nozzle 31. Pass Partition
13. Shell Cover Flange 32. Vent Connection
14. Expansion Joint 33. Drain Connection
15. Floating Tube sheet 34. Instrument Connection
16. Floating Head Cover 35. Support Saddle
17. Floating Head Flange 36. Lifting Lug
18. Floating Head Backing Device 37. Support Bracket
19. Split Shear Ring 38. Weir
39. Liquid Level Connection

Fig. 6 Heat-Exchanger-Component nomenclature. (a) Internal-floating-heat exchanger (with floating-head backing device).
Type AES. (b) Fixed-tube-sheet exchanger. Type BEM. (c) Outside-packed floating-head exchanger. Type AEP. (d) U-tube
heat exchanger. Type CFU. (e) Kettle-type floating-head reboiler. Type AKT. (f) Exchanger with packed floating tube sheet
and lantern ring. Type AJW. (Standard of Tubular Exchanger Manufacturers Association)

Table 2 Features of TEMA Shell and Tube Type Exchangers
Type of design Fixed
tubesheet
U-tube Packed
lantern-ring
floating head
Internal
floating head
(split backing
ring)
Outside-
packed
floating
head
Pull-
through
floating
head
TEMA rear-head
type
L or M or N U W S P T
Relative cost
increases from A
(least expensive)
through E (most
expensive)
B A C E D E
Provision for
differential
expansion
Expansion
joint in shell
Individual tubes
free to expand
Floating head Floating head Floating
head
Floating
head
Removable
bundle
No Yes Yes Yes Yes Yes
Replacement
bundle possible
No Yes Yes Yes Yes Yes
Individual tubes
replaceable
Yes Only those in
outside row
Yes Yes Yes Yes
Tube cleaning by
chemicals inside
and outside
Yes Yes Yes Yes Yes Yes
Interior tube
cleaning
mechanically
Yes Special tools
required
Yes Yes Yes Yes
Exterior tube
cleaning
mechanically:

Triangular
pitch
No No No No No No
Square pitch Yes Yes Yes Yes Yes Yes
Hydraulic-jet
cleaning:

Tube interior Yes Special tools
required
Yes Yes Yes Yes
Tube exterior No Yes Yes Yes Yes Yes
Double tubesheet
feasible
Yes Yes No No Yes No
Number of tube
passes
No practical
limitations
Any even
number possible
Limited to one
or two passes
No practical
limitations
No practical
limitations
No practical
limitations
Internal gaskets
eliminated
Yes Yes Yes No Yes No

NOTE : Relative costs A and B are not significantly different and interchange for long lengths of tubing.
U-tube bundles have been built with tube supports which permit the U-bends to be spread apart and tubes inside of the bundle replaced.
Normal triangular pitch does not permit mechanical cleaning. With a wide triangular pitch, which is equal to 2 (tube diameter plus
cleaning lane)/ 3, mechanical cleaning is possible on removable bundles. This wide spacing is infrequently used.
For odd number of tube side passes, floating head requires packed joint or expansion joint.

Table 3 Application Shell and Tube Types
Type
Designation
Significant Feature Applications Best Suited Limitation Relative Cost in
Carbon Steel
Construction
Fixed Tube
sheet
Both tube sheets fixed to
shell
Condensers; liquid-liquid;
gas-gas; cooling and
heating, horizontal or
vertical, reboiling
Temperature difference
at extremes of about
200
o
F. Due to
differential expansion
1.0
Floating
Head or
Tube sheet
(removable
and non-
removable
bundles)
One tube sheet floats in
shell or with shell, tube
bundle may or may not be
removable from shell, but
back cover can be removed
to expose tube ends
High temperature
differentials, above about
200
o
F. Extremes; dirty
fluids requiring cleaning
of inside as well as
outside of shell,
horizontal or vertical.
Internal gaskets offer
danger of leaking.
Corrosiveness of fluids
on shell side floating
parts. Usually confined
to horizontal units
1.28
U-Tube; U-
Bundle
Only one tube sheet
required. Tubes bent in U-
shape. Bundle is removable
High temperature
differentials which might
require provision for
expansion in fixed tube
units. Clean service or
easily cleaned conditions
on both tube side and
shell side. Horizontal or
vertical.
Bends must be
carefully made or
mechanical damage and
danger of rupture can
result. Tube side
velocities can cause
erosion of inside of
bends. Fluid should be
free of suspended
particles
1.08
Kettle Tube bundle removable as
U-type or floating head.
Shell enlarged to allow
boiling and vapor
disengaging
Boiling fluid on shell
side, as refrigerant, or
process fluid being
vaporized. Chilling or
cooling of tube side fluid
in refrigerant evaporation
on shell side
For horizontal
installation. Physically
large for other
applications
1.2 1.4

References
1. Standard of Tubular Exchanger Manufacturers
Association, Eight Edition 1999
2. Perrys Chemical Engineers Handbook, Copyright
1999 by The McGraw-Hill Company, Inc.
3. A. Keith Escoe, Mechanical Design of Process
Systems Volume 2, 1986
4. Wolverine Engineering Data Book II by Wolverine
Tube, Inc Research and Development Team, 2001
Please send your thought and suggest to
drajad_aw@yahoo.com

THE AUTHOR
Drajad AW is a Mechanical
Engineer with PT Technip
Indonesia responsible for Package
Equipments. After graduating from
Sepuluh Nopember Institute of
Technology (ITS) with a B.Sc
degree in Marine Engineering, he
joined PT. Mafhindo Utama, PT
Indo-Laval, PT. Erraenersi
Konstruksindo, PT. Rekayasa
Industri, PT. Istana Karang Laut, Malaysia Marine and
Heavy Engineering SDN BHD. He was for eight years the
Static Engineer (Pressure Vessels, Tanks, Filters, etc) and
Package Equipments Engineer.