HEI 2623 04 Standards For Power Plant Heat Ex Changers 4th
HEI 2623 04 Standards For Power Plant Heat Ex Changers 4th
HEI 2623 04 Standards For Power Plant Heat Ex Changers 4th
INSTITUTE, INC.
STANDARDS for
POWER PLANT HEAT
EXCHANGERS
FOURTH EDITION
"Copyright December 2004 by
Heat Exchange Institute
1300 S-er Avenue
Cleveland, Ohio 44115
FIGURES
Figure 1 Cleanliness Factor-Total Fouling Comparison .........................................................
Fieurc 2 Loss Correction Factor (K.1 for Multiule Passes ..................................................
~ i & r e3 shell 1nlet ~ r e with
a ~mpingement
. . plates ...............................................................
Fibre 4 Shell Inlet Area with Impingement Rods ...............................................................
Fieurc 5 ..
Shell Inlet or Outlet Arca \virhout Imoin~ementPlate .............................................
Bundle Entrance and Exit Areas ...........................................................................
~ i & r e6
Figure 7
Figure 8
. . and Support Plates ..................................... . ................................
Typical Baffles
Pass Partition Shape Factor ....................................... .........................................
Figure 9 Packed Joint Construction Requirements ............................................................
Figure 10 Nozzle Load Nomenclature ....................................................................................
Figure 11 Methods of Support for the Unsupported Tube Span Under Consideration ..................
Figure 12 Instability constants for Critical Velocity ..............................................................
Figure 13 Bolt Tightening Sequence .......................... ...........
TABLES
Table 1 Representative Fouling Resistances ........................................................................
Table 2 Maximum Tube. Velocity
. .....................................................................................
Table 3 Nozzle Size Cnteria ...........................................................................................
Table 4 Materials of Construction ....................................................................................
Table 5 Minimum Recommended Tube Wall Thicknesses ......................................................
Table 6 Minimum Recommended Tubc Pitchcs ..................................................................
Table 7 Maximum Recommended Metal Tcmucrature of Exuandcd
Tube Joints in Carbon Steel Tubesheets .................................................................
Table 8 Tube Hole Diameters and Tolerances for Tubesheets ................................... .. .........
Table 9 Tubesheet Drilling Tolerances and Maximum Recommended Tube Gages .....................
Table 10 Cross Baffle and Support Plate Thicknesses ..........................................................
Table 11 Maximum Unsupported Tube Length ...................................................................
Table 12 Maximum Design Diametral Clearances Between Shell and Baffle ...........................
Table 13 Minimum Tie Rod Parameters ...........................................................................
Table 14 Minimum Longitudinal Baffle Thicknesses ..........................................................
Table 15 Minimum Cylinder and Formed Head Thicknesses .................................................
Table 16 Minimum Pass Partition Thicknesses ....................................................................
Table 17 Packed Joint Parameters .......................................................................................
FOREWORD
The fourth edition of these standards has been Section 4.1, General, within Section 4.0, Materials
p,. developed by the Power Plant Heat Exchanger of Constmction, has been expanded.
Section of the Heat Exchange Institute, Inc. The A new Section 5.6.9, Low Fin Tuhing, has been
technical information in these standards combines added.
present industry standards, typical Purchaser Revisions have been made to Section 6.2.1,
requirements, and Manufacturers' experience and Specification, within the heat exchanger protec-
outlines the important design criteria for power plant tion section on page 21.
heat exchangers. The calculation in Section 6.2.3 has been revised
These standards provide practical information on to show the iterative nature of the calculation.
nomenclature, dimensions, testing, and performance. Anew Section 7.9, Spare Parts, has been added to
Use of the standards will ensure a minimum of mis- expand Section 7.0, Site Installation, Inspection,
understanding between Manufacturer and Purchaser Maintenance, and Cleaning.
and will assist in the proper selection of equipment Section C2.0, Sample Problem, within Appendix
best suited to the requirements of the application. C, Procedure for Calculating Allowable Nozzle
These standards represent the collective experi- External Forces and Moments in Cylindrical
ence of the Section members and provide a guide in Vessels, has been revised.
the writing of specifications and in the selection of Minor revisions have been made to heat exchang-
heat exchangers for power plant use. er specification sheets in Appendices F-1, F-2, and
In the preparation of these standards, considera- F-3.
tion has been given to the work of other organiza-
tions, such as the American National Standards The publication of the fourth edition of the
Institute, the American Society of Mechanical Standards for Power Plant Heat Exchangers repre-
Engineers and others. Credit is hereby given to all sents another step in the Heat Exchange Institute's
those whose standards may have been helpful in this continuing program to provide standards which
work. reflect the latest technological advancements in the
To assist the user in becoming familiar with this field of heat exchange equipment. The Standards for
new fourth edition, a list of some prominent revisions Power Plant Heat Exchangers are continually
follows: reviewed by the Technical Committee a t scheduled
meetings under the direction of the Power Plant Heat
Section 3.2, Fouling Resistance and Cleanliness Exchanger Section. Suggestions for improvement of
0 Factor, has been revised.
Section 3.7 has been renamed Shell Inlet Area
these Standards are welcome and should be sent to
the Heat Exchange Institute, Inc., 1300 Sumner
with Impingement Devices. The section has also Avenue, Cleveland, Ohio 44115-2185, or via tele-
been revised to include shell inlet area with imp- phone a t 216-241-7333, via fax at 216-241-0105, or
ingment plate, shell inlet area with impingement email the Heat Exchange Institute, Inc. at hei@hea-
rods, and shell inlet area with perforated impinge-
. - texchange.org. Additional information about the
ment plate. Heat Exchange Institute, Inc, can he found a t
Fieure 3. Shell Inlet Area with Im~ineement
A - www.heatexchange.org.
plate, has been replaced with two new drawings
dealing with impingement.
1.0 SCOPE AND PURPOSE
1.1 Scope Radwaste Treatment Exchangers
These Standards are intended to apply to shell- Reactor Building Exchangers
and-tube type heat exchangers containing bare or Reboilers and Evaporators
extended surface tubes used primarily in power Residual Heat Removal Exchangers
plants. Turbine Building Exchangers
Some of the commonly used names for the heat
exchangers to which these Standards apply are list- It is not intended that these Standards be applied
ed below. It is not intended that this list be all-inclu- to heat exchange equipment covered by other
sive or that it limit the use of these Standards to HE1 Standards, such as feedwater heaters,
only those heat exchangers named. condensers, etc.
Auxiliary Steam Generators
Bearing Water Coolers 1.2 Purpose
Blowdown Exchangers These Standards have been developed to be used
Bypass Condensers by heat exchanger Purchasers and Manufacturers to
Cleanup Exchangers delineate some of the pertinent thermal, hydraulic,
Component Cooling Water Exchangers and mechanical design features and requirements
Condensate Coolers for heat exchangers used in power plants.
Fuel Oil Heaters It is intended that these Standards provide a basis
Fuel Pool Coolers for a mutual understanding and interpretation of
Fuel Reprocessing Exchangers heat exchanger requirements between the
Geothermal Units Purchaser and Manufacturer and assist in specify-
GlycoWGlycol-Water Heaters ing, designing, and fabricating heat exchangers.
HTGR Exchangers Most of the heat exchangers covered by these
Jacket Water Coolers Standards may also be required to conform to the
Liquid Metal Exchangers Design Specification and the ASME Boiler and
Lube Oil Coolers Pressure Vessel Code, Section 111, Division 1, Class
Preheaters 1,2, or 3, or Section VIII, Division 1or 2.
Figure 1
CLEANLINESS FACTOR-TOTAL FOULING COMPARISON
3.3 Heat Exchanger Approach Temperature Inside Tubes
The Purchaser, by stipulating the design point,
specifies the heat exchanger approach temperature.
(1 Generally, as the approach temperature decreases,
I the required heat exchanger surface increases.
The selection of the approach temperature affects where: f = 0.0014 + 0.125(Re)-0.32
the hot and cold fluid flows which, in turn, affects
plant operating costs. Care should he taken to con-
sider capital costs versus operating costs.
When multipass arrangements are used, care
should be taken to ensure that the exchanger does Nozzle Losses
not operate in a thermally unstable region; that is,
the LMTD correction factor should not be subject
to large fluctuations with small changes in inlet
parameters.
3.4 Tube Velocity
The fluid velocity through the tubes a t the average
temperature for the design point should not exceed Tube Entrance, Exit and Turn Losses
the values contained in Table 2. These velocities are
applicable to water of boiler feed quality. Lower
velocities should be considered when erosive fluids
are present.
Total Pressure Loss
Table 2
Maximum Tube Velocity
Fluid NOTE: CONSTANTS SHOWN INCLUDE A 5%
Velocity SAFETY FACTOR.
Tube Material ftlsec
Stainless Steel, Nickel Alloys, Titanium 10.0
Copper-Nickel (70-30, 80-20, 90-10) 9.0 Definitions
(7 Admiralty, Copper, Aluminum-Brass 8.5
A P T ~ TTotal
= nozzle-to-nozzle tube side pressure
Carbon Steel 8.0
loss, psi
3.5 Pressure Loss APT = Pressure loss through tubes, psi
The allowable shell side and tube side pressure APNI = Pressure loss through channel inlet
losses shall be specified by the Purchaser. By nozzle, psi
specifying as high a shell side pressure loss as eco- APNO= Pressure loss through channel outlet
nomically justifiable, the Purchaser allows the nozzle, psi
designer to minimize the baffle pitch and thus,
minimize the unsupported tube length. By mini- APE = Tube entrance, exit, and turn losses, psi
mizing the unsupported tube length, the potential w = Tube side flow, lbm/hr
for detrimental tube vibration is reduced. Also, a p = Effective tube side density, lbm/ft3
shorter baffle pitch normally contributes to a high-
p. = Viscosity, cp
er cross-flow velocity on the shell side which
improves the heat transfer coefficient. Generally, L = Tube length per pass, ft
as the allowable shell side and tube side velocities = Flow area of tubes per pass, inz
increase, the heat exchanger surface and the poten- A,
tial for fouling decrease. d = Nominal inside diameter of tube,
see Appendix H or I
3.5.1 Tube Side Pressure Loss f = Friction factor
Below is a method of determining the tube side
pressure losses from and including the channel AN = Tube side nozzle area, in2
inlet and outlet nozzles (pressure losses are calcn- Note: For tapered nozzles use mean area.
lated for friction, nozzles, tube entrance, exit and Kt = Loss correction factor for tube
turning). This method is applicable to either configuration. For a single pass, Kt = 0.9.
straight or U-tubes. For multiple passes, see Figure 2.
This method is only applicable to clean smooth N = Number of tube passes
tubes with turbulent flow (Re>3,000) and no
r! change of phase. It is a condensed method to check
pressure losses in the evaluation of the equipment.
Re = Reynolds number
Piping configurations which produce non-uniform flow 3.7.1 Shell Inlet Area with Impingement Plate
patterns may result in accelerated wear on the internal The unrestricted flow area is the radial surface area of
components of the heat exchanger. the volume described by the projection of the nozzle into
the shell (shown as B in Figure 3).
Table 3 3.7.2 Shell Inlet Area with Impingement Rods
Nozzle Size Criteria The unrestricted flow area is the radial surface area of
the volume described by the projection of the nozzle into
Maximum Ga/p in Nozzle(l) the shell plus the open area between the first row of the
I Tube Side . Shellside impingement rods within the radial surface area (shown
as A in Figure 4). A minimum of two rows of staggered
Nozzles Nozzles
impingement rods is required as shown in Figure 4.
Liquids 3.7.3 Shell Inlet Area with Perforated
(Subcooled) Impingement Plate
Liquids
(Near Saturation
Point)
1 1 1000 2501 1MO I 250
The unrestricted flow area is the radial surface area of
the volume described by the projection of the nozzle into
the shell plus the open area in the holes on the top perfo-
Gases/DryVapors 2000 2000 2000 rated impingement plate within the radial surface area
2000 (shown as B in Figure 3). The holes between the plates
I I I I must be staggered and the area of the holes on the lower
(')G = Mass velocity, ibdsec-fti plate must equal the area of the holes on the top plate. A
p =Density, lbm/ft3
At the discretion of the designer, these values should be low- minimum gap distance of perforated hole diameter divid-
ered to account for the effectof fluids containing entrained ed by 4 must separate the plates.
droplets, bubbles, foreign matter, etc.
Figure 4
SHELL INLET AREA WITH
IMPINGEMENT RODS
least two tube diameters away from the outermost row of
tubes.
The unrestricted flow area is shown as C or D in
Figure 6, depending upon the use and placement of an
impingement plate.
, . - L LEHS
t-....
SHELL,
.......
SECTION "Y-Y"
~ ~
C
P
4
[see 3.1.1(3)1.
area calculated using the allowable value of GZ/p from
Table 3. The unrestricted flow area is the cross-sectional
-
If the desien limits are exceeded. accelerated erosion
and failure may occur. There are no definitive guidelines
area between the first full row of tubes closest to the noz- presently available that can adequately determine the
zle. This area cannot include the cross-sectional area relationship of erosion to length of time at overload or
between the portion of tubes encompassed by an impinge- abnormal operating conditions.
ment plate, unless the impingement plate is located at
4.0 MATERIALS OF CONSTRUCTION
Ll
X
X
SA-334* CS X
SA-556 CS X
SA-557 CS X
SA-688 SS X
SB-111 CU X
SB-163 NI X
SB-338 TI X
SB-395 CU X
'*Thesespecifications are suggested when impact testing is required.
Legend: CS = Carbon Steel LA = Low Alloy Steel NI = Nickel and High Nickel Alloys
SS = Stainless Steel CU = Copper and Copper Alloys TI = Titanium and Titanium Alloys
8
4.2 Gaskets and Packing 4.4 Gaskets for Internal Floating Heads
The choice of a suitable gasket material depends Flat solid material, metal jacketed, or solid metal
upon the conditions of service and, unless otherwise gaskets may be used for internal floating heads. For
f"\
i .
specified by the Purchaser, will be in accordance tube or shell side design pressures greater than 200
with the standards of the heat exchanger psig or for design temperatures greater than 300F,
Manufacturer. The Design Specification should stip- flat solid material gaskets of the compressed fiber
type should not be used.
ulate special conditions such as thermal shocks, cor-
rosive fluids, pulsating pressures, etc., since these 4.5 Halogenated Compounds
factors influence the gasket design and material Halogenated compounds are generally not accept-
\
selection. able for use with austenitic stainless steel due to the
Some of the more commonly used gasket
- materials possibility of stress corrosion cracking.
are copper, nickel-copper, stainless steel, carbon 4.6 Stainless Steel
steel, and rubber. The gasket type may be flat solid Austenitic stainless steel pressure parts used in
material, metal jacketed, spiral wound or O-rings. nuclear power plant exchangers shall meet an
Graphite or acrylic fibers may be used for flat solid acceptable criteria for preventing susceptibility to
materials and as fillers for metal jacketed gaskets. intergranular corrosion attack.
For spiral wound gaskets, graphite, ceramic, or
chlorite mineral fillers may be used. 4.7 Nonmetallic Coatings and Liners
Braided or solid packing with a variety of binders As an alternative to using materials of construc-
may also be used to perform the gasket function. tion that inhibit corrosion or erosion, consideration
may be given to using coatings and liners when han-
Graphite or organic polymer fibers may be used for dling very active fluids.
packings. Coatings such as epoxy, ceramic, coal tar, neo-
4.3 Floating Head Split Backing Rings prene, and paint can be used to protect pressure
parts.
and Bolting The maintenance and initial fabrication and
Floating head split backing rings and associated assembly must be done with care to avoid damage to
bolting shall be considered pressure parts and shall the coatings since small defects may create severe
have corrosion resistances similar to the material of failures of the coatings or liners, thus exposing the
the shell. underlying metal to corrosive attack.
5.1 Code Requirements test medium should be high enough to preclude the
- are
The shell and tube sides of the heat exchanger possibility of damage due to brittle fracture.
considered separate pressure vessels and may be 5.5 CorrosionAllowances
constructed to separate Code Sections, Divisions and
Classes, as specified by the Purchaser. The applica- Corrosion allowances shall be specified by the
ble Code edition and addenda shall be determined in Purchaser and should apply to all surfaces of the
accordance with current Code rules. Code Cases may pressure retaining parts which contact the corrosive
also be used. fluid(s), except as follows:
(1)Flange faces
5.2 Design Pressures (2) Floating head backing rings
The Purchaser shall specify separate design pres- (3) Internal bolting
sures for the shell and tube sides. This shall include (4) Tubes, unless otherwise specified by the
any vacuum or external pressure conditions which Design Specification
may be applicable.
On parts which are grooved for pass partitions,
5.3 Design Temperatures the depth of the groove may be considered available
The Purchaser shall specify separate design tem- for corrosion allowance.
peratures for the shell and tube sides. Particular
attention should be given to both minimum and max- 5.6 Tubes
imum design temperatures. The most severe design The useful life of a tube is normally affected by the
temperature, whether shell or tube side, should be conditions Of service, such as fluid chemistry, oper-
used to design parts (tubesheets, tubes, floating ating temperatures, and fluid velocities, as well as
heads) which come into contact with both fluids, the effects of short and long term shutdowns. These
unless a less severe temperature can be justified. factors should be taken into consideration hy the
The shell and tube sides are to be hydrostatically 5.6.1 Tube Diameters
r' tested in accordance with the Code. The test should
be so conducted as to facilitate visual inspection for
The minimum outside tube diameter should be 3/8
inch nominal. These Standards cover outside tube
tube joint leakage from a t least one side, refera ably diameters up to 2 inches nominal; however, larger
the tube side. The temperature of the hydrostatic diameters may be used.
5.6.2 Tube Wall Thickness 5.6.5 U-Tubes
Average wall or minimum wall tubes are equally The following formula should be used to determine
acceptable providing that, in the case of average the minimum required thickness of the tube wall
wall tubes, the calculated thickness for pressure before bending: ;
takes into consideration the tolerance in wall thick-
ness. The minimum recommended tube wall thick-
nesses are shown in Table 5.
where
Table 5
Minimum Recommended Tube Wall Thicknesses t = Minimum required tube wall thickness
before bending, in /
Tube Material Wall Thickness t. = The greater of the following, in:
Austenitic Stainless Steel (1)The minimum required tube wall
1
(Straight Tubes) 22 BWG Avg. Wall thickness of a straight tube calculated
Anstenitic Stainless Steel for internal pressure:
(U-tubes) 20 BWG Avg. Wall
Nickel Alloy 18 BWG Avg. Wall
Copper and Copper Alloy 18 BWG Avg. Wall
(2) The minimum required tube wall
Titanium (Straight Tubes) 22 BWG Avg. Wall thickness of a straight tube calculated "I
Carbon Steel 0.050 in Ava. Wall for external pressure in accordance I
with the Code
5.6.3 Tube Pitch and Layout do = Outside diameter of tube, in
The tubes may be laid out in any one of the P = Design pressure, psig
following patterns: R = Radius of bend a t centerline of tube, in
(1) Triangular S = Allowable design stress, psi
(2) Rotated triangular
(3) Square All U-tubes shall be pressure tested after bending,
(4) Rotated square but prior to assembly.
Tubes should have a nominal center-to-center 5.6.6 H e a t Treatment of U-Bends . ,\
spacing which is no less than that shown in Table 6. Cold work in forming U-bends may increase sus-
When square or rotated square pitch is necessary to ceptibility to stress corrosion cracking in certain
ij
provide a cleaning lane, the nominal distance materials and environments. The Purchaser shall
between tubes should be no less than Y4 inch. specify if heat treatment of the U-bends is required.
Table 6 5.6.7 Tube Joint Temperature
Minimum Recommended Tube Pitches When tubes are to be installed in carbon steel
tubesheets, Table 7 should be used to determine
Nominal Nominal whether the maximum operating metal temperature
Tube Outside Diameter Tube P i t c h for the specified tube material is in a range low
enough to permit a tube joint which is expanded only.
Welded tube joints should he used when tempera-
tures range from the values in Table 7 to the maxi-
mum metal temperatures permitted by the Code.
'I" Nominal
Heaviest "'
1
Minimum Standard l-
1
i g.
a-m....e-n.t..Width,
Tubesheet Thickness, in.
/2'/2/ 3 1
. .
4 /
in.
5 1 6
Minimum
Ligament
in.
~
Permissible
~
"' Heavier gages may be used for full strength welded and partial strength welded tube-to-tubesheet joints.
'2' The above Table of Minimum Standard Ligament Width is based on a ligament tolerance not exceeding the sum of twice
the drill drift tolerance plus 0.020" for tubes less than 5/s" O.D. and 0.030" for tubes 5/s" O.D. and larger. Drill drift
tolerance = 0.0016 x (thickness of tubesheet in tube diameters), in.
5.7.6 Removable Tube Bundles welds. These welds shall be defined and sized in
In exchangers where the tube bundle is removable accordance with UW-20 of ASME Section VIII,
and the tubesheet is bolted between two flanees - Division 1.
:
n
\ ,
(three element bolted joint), it is recommended that
provisions be made such that the shell side or tube
5.7.7.4 Welded and Expanded
side joint can be independently disassembled from A welded and expanded tube joint is typically con-
the tubesheet without breaking the other joint. structed and tested as follows:
(1) Groove tube holes, if required
5.7.7 Tube Joints (2) Clean tubes, tube holes, and face of
5.7.7.1 Expanded tubesheet
(3) Insert tubes and fit up as required
Tubes should be expanded into the tubesheet for a (4) Weld tubes to tubesheet
distance of a t least 2 inches or within '/s inch of the (5) Perform leak test
shell side face, whichever is less. Caution should be (6)Expand tubes
taken to ensure that the expansion does not extend (7) Liquid penetrant examine tube-to-
beyond the shell side face of the tubesheet. The tubesheet welds
tubes may protrude beyond the tubesheet surface by
no more than 'A inch or be recessed bv no more than 5.8 Tube Bundles
'/16 inch. ~ u b e sshould not extend "above the top All baffles and support plates in the tube bundle
tubesheet in vertical exchangers. should be securely held in place by tie rods and
spacers or a n equivalent construction.
5.7.7.2 Grooved
When required, each tube hole should be grooved 5.8.1 Cross Baffles and Support Plates
(rectangular or curved) with two 1/8 inch wide by 1/64 Cross baffles and support plates (baffles) should
inch deep grooves. be designed with consideration given to both ther-
mal and mechanical requirements. This relationship
5.7.7.3 Welded is especially important in limiting tube vibration.
Welded tube-to-tubesheet joints should be used Support plates are primarily designed for support-
where additional tube joint sealing or strength is ing tubes. Cross baffles provide flow direction for
required. heat transfer in addition to supporting tubes. See
Tube-to-tubesheet welds are classified as full Figure 7 for a representation of typical baffles and
strength welds, partial strength welds, and seal support plates. Other types may be considered.
BAFFLE TYPES
SUPPORT PLATE TYPES
. -
SEGMENTAL I I
-I I
No 'lbbes -, I I I
.l-L-L{L-fL
I I I
10
DOUBLE SEGMENTAL
.L-+-"-#
0 0
n 0 OF OG I I I
TRIPLE SEGMENTAL SEMI-SUPPORT PLATE
J (optional)
for use on removable
bundles.
LONG BAFFLE
Figure 7
TYPICAL BAFFLES AND SUPPORT PLATES
5.8.1.1 Tube Hole Diameters Table 11
For unsupported tube lengths up to and including Maximum Unsupported Tube Length
30 inches, tube hole diameters should be the nomi-
nal tube OD plus 1/32 inch. When the unsupported Nominal Tube Maximum Unsupported , ',
tube length is greater than 30 inches and the nom- Outside Diameter Tube Length U
inal tube OD is less than or equal to lV4 inches, in in
tube hole diameters should be the nominal tube OD 3/s 28
plus Y64inch. All tube holes shall have a maximum
over-tolerance of 0.010 inch. The tube holes shall be
smooth, and burrs shall be removed to prevent
damage to the tubes.
5.8.1.2 Baffle Thickness
Thc nominal thickness ol'bamcs should he no less
than that civen in Table 10. Whcn thc float in^ head
end of a t;be bundle is to be supported by a71111 or
partial support plate, the nominal thickness of the
plate should not be less than that given in the
column for unsupported tube lengths over 60 inches.
'1
Table 15
Minimum Cylinder and Formed Head
5.8.2.2 Spacers Thicknesses
Spacers should be cut in a manner that provides
proper baffle alignment. Spacer wall thickness shall Nominal Shell Nominal Thickness
be adequate to withstand buckling loads caused by Inside Diameter Carbqn Steel Al!oys
tie rod nut torque and, in the case of vertical heat in m ln
exchangers, additional dead weight baffle load. 4-7 y411, 0.120
>7-9 0.120
,P>
,
5.8.3 Longitudinal Baffles 1/4(2>
Table 14
Minimum Longitudinal Baffle Thicknesses
Nominal Shell (l)If pipe is used, the nominal wall thickness should be
Inside Diameter Nominal Thickness Standard Weight.
in in c2)If pipe is used, the nominal wall thickness should be
4-25 '/4 Schedule 30.
>25-39 3/s
5.9.3 Expansion Joints
>39-59 '/z
The purchaser shall specify all the operating con-
>59-79 5/8 ditions required by 3.1.1 to enable the Manufacturer
Over 79 3/4 to assess the need for an expansion joint. Under
some conditions, excessive longitudinal stresses in
either the shell or tubes of a heat exchanger having
The preferred method of sealing longitudinal baf- fixed tubesheets and straight tubes can arise. These
fles is to weld them to the shell. When longitudinal stresses result from a combination of loads generat-
baffles are not welded, flexible seals may be used to ed by fluid pressure and those due to differential
prevent leakage between the shell and the longitu- thermal expansion. They are generated by the inter-
dinal baffle. Special design consideration should be action between the shell, tubes, and tubesheets, all
given to cases where there is a large differential acting as stmctural members.
pressure across the longitudinal baffle, and the use A shell expansion joint should be considered if, in
of flexible seals may be undesirable. its absence, the shell or tube longitudinal stress
exceeds the allowable value; the tube joint load is
5.8.4 Impingement Plates
17 When a n impingement plate is used, the nominal
excessive; or the tube buckling load is excessive. The
likelihood of any of these conditions is increased
thickness should be no less than 1/4 inch for alloys when there is an extreme temperature differential
and Y8inch for carbon steel (see 3.7). or high pressure on either the shell side or tube side.
Shell expansion joints shall be constructed in Table 16
accordance with the Code and analyzed for each Minimum Pass Partition Thicknesses
operating condition. The data for each operating
condition shall consist of the shell side design con- Nominal Channel Nominal Thickness
ditions, the total design axial movement of the Inside Diameter Carbqn Steel Alloys
expansion joint (+ for joint extension, - for joint in m in
compression), and the required cycle life, as a min- 4-12 y4 v4
imum. To ensure that the expansion joint is
designed for its intended function, it is important >12-25 3/s y4
that the required cycle life be a realistic indication >25-39 1/2 3/s
of the cycles that the heat exchanger is expected to >39-59 5/s 1/2
experience over its design life. Over 59 3/4 Vs
Bellows expansion joints should be supplied with
shipping brackets which shall be removed or discon-
nected after the heat exchanger is installed. In addi-
tion, removable covers shall be supplied on bellows
expansion joints which are to be insdated and where
it is necessary to protect the bellows element. The Curve A -Short Edges (W) Fixed and
Manufacturer shall advise the bellows expansion Long Edges (L) Supported
joint manufacturer of the required weld end materi-
al and the acceptable flexible element materials.
When expansion joints are used, the tubes may no
longer act as stays for the tubesheets; hence, the
tubesheet thicknesses may have to be increased to
reduce the stresses to allowable values.
5.10 Channels, Bonnets, and Floating Heads
5.10.1 Thickness
The nominal channel, bonnet, and floating head
thicknesses should be no less than that shown in
Table 15.
5.10.2 Interpass Flow Velocity
The length of channels, bonnets, and floating
heads should be designed such that the nominal
interpass flow velocity will be no greater than 0.7
times the mean velocity in one tube pass.
5.10.3 Pass Partition Plates
The thickness of pass partition plates should be
calculated in accordance with the equation below,
but in no case should the nominal thickness be less
than that given in Table 16. Figure 8
PASS PARTITION SHAPE FACTOR
r' Nominal
Shell
Inside
Nominal
Packing
Packed Tubesheet"'
Packed Tubesheet with Lantern Ring
Minimum
Minimum Maximum Maximum Number of Maximum Maximum
Diameter Ring Size Number of Pressure Temp. Rings Pressure Temp.
in in Rings psig "F Each Side ~sig "F
4-19 3/8 2 300 600 1 300 400
>19-39 ?z 2 300 600 1 150 400
>39-59 I
% I
2 300 600 I
1 75 400
Over 59 I Pucked Joints Sot Recornrnendcd In These Sizes
(') Can be applied to a packed nozzle with diameters equivalent to the respective shell diameters.
-
r, cl) Local Stresses in Spherical and Cylindrical Shells due t o
External Loadings, K.R. Wichman, A.G. Hopper and
J.L. Mershon-Welding Research Council, Bulletin
107/Angust, 1965-Revised Printing-March, 1979
5.14.3 Design Criteria f, = Calculated natural frequency of the
The tube bundle should be designed so that the unsupported tube span under consideration
velocity a t the tube span under consideration satis- using the applicable end fixity conditions
fies the following relationship: - *. , llsec
(C..).
,d ;
~
g = Gravitational constant =
386 lbm-idlbf-sec2
I = Moment of inertia, in4 (see Appendix H or I)
= ddn4-di4)/64
where K = 1.0 for straight portion of tubes
VaCt= Maximum cross flow gap velocity a t the = 0.866 for U-bend portion of tubes
tube row under consideration, ftJsec L = Unsupported tube span under considera-
VCrit=Critical velocity, ft/sec tion, in (for U-bends, L = the full developed
length)
m = Effective weight of the tube per unit length,
5.14.4 Method of Calculation Ibndin
= We+Wt+Ws
5.14.4.1 Calculate V,,t W: = l b d i n of tube metal
Wt = l b d i n of fluid inside tube
5.14.4.2 Calculate [f,, fi] Ws = l b d i n of shell side fluid displaced by
the tube i.,
,
\
where
C, = Constant applicable to the method of sup-
port for the unsupported tube span under where
consideration as follows (see Figure 11): p = Instability Constant from Figure 12
= 3.56 for both ends fixed
p = Tube pitch, in (see Figure 12)
= 2.45 for one end fixed, one end simply
supported 6 = Logarithmic decrement of damping is a
= 1.57 for both ends simply supported measure of the decay of vibration amplitude ,1 .
d, = Outside diameter of the tube, in with time of a tube vibrating in a still fluid. \J
di = Inside diameter of the tube, in (see Estimated values of 6 in still fluids are:
Appendix H or I) 6 = 0.10 for water and other liquids
E = Modulus of elasticity, psi (see Appendix J) 6 = 0.03 for air and vapors
F =Axial force in tubes, tensile (+), p = Density of the shell side fluid, lbm/ft3
compressive (-1, lbf
Flow
A
30'
-
Flow
60'
.-
Triangular Rotated Triangular
-
Flow 450 Flow
Square
Rotated Square
Figure 12
INSTABILITY CONSTANTS FOR CRITICAL VELOCITY
6.0 HEAT EXCHANGER PROTECTION
6.1 Safety Requirements
, r-\, . The Code specifies a variety of measures for the
protection uf'htat exchanger.<against over-pressu~.c.
Thc Purchaser shall install orutrotive dev~ct!sin the
system to prevent thermaf and mechanical tran- where
sients from exceeding those conditions for which the
heat exchanger is designed. V = Rupture flow velocity, Wsec
g = Gravitational Constant = 32.2 lbm-Wbf-sec2
6.2 Relief Valves Ap = Net difference in the design pressures
between the shell and tube sides, psi
6.2.1 Specification p = Density of the discharging fluid. lbm/ft3
Relief valves are normally beyond the scope of the k = Resistance coefficient
-
heat exchanger Manufacturer's res~onsibilitv.
Pressure and temperature relief requirements are In the case where the shell side design pressure is
most appropriately specified for the entire piping less than the tube side design pressure, the resis-
loop including the heat exchanger. However, should tance coefficient is constant at 1.2 and proceed to the
the Purchaser require independent relief valves last step. When the shell side design pressure is
specifically for the heat exchanger, it shall be so stat- greater than the tube side design pressure, use a
ed in the Design Specification including any special resistance coefficient of 0.44 as a first guess and pro-
requirements. ceed.
6.2.2 Installation Criteria
The following recommendations are offered to (ii) Using the calculated value of V from step (i),
assist in the proper location and installation of relief determine the following:
valves:
(1)Valves should be installed vertically.
(2) If two or more relief valves are attached
to the same nozzle, the flow area of the
nozzle should be at least equal to the
combined flow area of the relief valve
inlet connections.
(3) The discharge piping connected to the
relief valve exit should he equal or larger
in diameter than the valve exit opening. where
There should be no intervening valves or Re = Reynolds number associated with the
obstructions in this line. discharging stream
(4) The discharge piping should be designed ".Wsec
V = R u ~ t u r eflow velocitv.
to minimize the stress of the valve body p = gamic viscosity of discharging fluid, cP
and the heat exchanger. f = Friction Factor
d = Nominal inside diameter of tube. in
6.2.3 Design Criteria (see Appendix H or I)
Conditions that should be considered in sizing the
orifice area of the relief valves are given below: (iii) Using the above calculated value of k, recalcu-
late the flow velocity. Repeat the above procedure
(1)Thermal Expansion Relief: The relief valve until the calculated value of k matches the assumed
should be designed to relieve the pressure caused value.
by thermal expansion of the entrapped fluid
when the isolation valves are closed. (iv) Using the calculated flow velocity, calculate the
(2) Tube Rupture: Relief valve flow shall be based on required relief valve flow rate.
the clean rupture of one exchanger tube resulting
in two flow conduits.
Figure 13
BOLT TIGHTENING SEQUENCE
7.9 S p a r e Parts a n d Special Tools
The following list of typical spare parts and special tools should be considered by the purchaser of heater
exchangers. The specific parts and quantities should be listed in the specifications. In the preparation of the spec-
ification the purchaser should consider pre-operational and post-operational spares.
' 1 ,
'> ,
7.9.1 S p a r e Parts
The recommended spare parts for heat exchangers are listed below:
Typical
S p a r e Parts Quantity Comments
Tube Plugs 10% of tube holes To include special welding supplies if welded
plugs are used.
Bolting:
Manway Cover, Channel 10% of sets A set implies a bolt and nut.
Cover. or Pass Partition
cover' (if required)
I,
Gaskets 2 Sets This set should include gaskets for pass par-
1,
tition cover (if required). NOTE: Proper
storage procedures must be observed since
,',
some gasket materials can deteriorate in a
short time if improperly stored.
where
Q = Heat exchanger duty, Btu/hr
U = Overall heat transfer coefficient, Btu/hr-ft2-OF (external surface)
A, = Effective external surface, ft2
MTD = Mean temperature difference, OF
where
u = Overall heat transfer coefficient (fouled), Btu/hr-ft2-OF (external surface)
ha = Film coefficient of fluid outside of tubes, Btu/hr-ft2-"F (external surface)
hi = Film coefficient of fluid inside of tubes, Btu/hr-ft2-OF (internal surface)
lo = Fouling resistance on outside of tubes, hr-ft2-'FBtu (external surface)
ri = Fouling resistance on inside of tubes, hr-ft2-"FBtu (internal surface)
rw = Resistance of tube wall referred to outside surface, including extended surface, if
present, hr-ft2-'F/Btu (external surface)
= Effective external surface, ft2
= Effective internal surface, ft2
= Fin efficiency (equals one for bare tubes and less than one for finned tubes)
where
do = O.D. of bare tube or root diameter of fin, in
z = Fin height, in
t = Tube wall thickness, in
N = Number of fins per inch
k = Tube wall thermal conductivity, Btu-ft/hr-ft2-"F
A3.0 Heat Balance
where
Q = Total heat exchanger duty, Btulhr
TI, Tz = Hot fluid inlet, outlet temperature, OF
tl, tz = Cold fluid inlet, outlet temperature, "F
Ts,t s = Hot fluid, cold fluid saturation temperature, F
Wh, Wc = Hot fluid, cold fluid mass flow rate, lbmhr
Cphv,Cpev = Hot fluid, cold fluid vapor mean heat capacity, Btdbm-"F
Cphl, Cpcl = Hot fluid, cold fluid liquid mean capacity, Btdbm-'F
Ah, A, = Hot fluid, cold fluid latent heat of vaporization, B t d b m
For partial condensation or vaporization, the appropriate latent heat is multiplied by the fluid
fraction which changes state.
APPENDIX B
P r
I LMTD CORRECTION FACTORS AND TEMPERATURE EFFICIENCIES
where
LMTD = Logarithmic mean temperature difference, OF
TI, Tz = Hot fluid inlet, outlet temperature, OF
tl, tz = Cold fluid inlet, outlet temperature, OF
?
( B2.0 LMTD Correction Factors
[MTD] = [LMTDI F
F, the correction factor to adjust for deviation from true counterflow, is a function of
R and P and can be obtained from Figures B-1 thru B-9, as applicable.
MTD = Mean temperature difference, "F
LMTD = Logarithmic mean temperature difference for true counterflow, OF
When R is greater than 1.0, it may be difficult reading F values off of Figures B-l thru B-5. If this
is the case, R and P may be recalculated using T1 and Tz interchanged with tl and tz, respectively.
P, the temperature efficiency, is a function of R and NTU and can be obtained from Figures B-10
thru B-12, as applicable.
UA,
NTU = -
wccpc
where
When R is greater than 1.0, it may be difficult reading NTU values off of Figures B-10 thru B-12.
If this is the case, R, NTU, t2, and T2 may be recalculated using Wh, Cph,and T1 interchanged
with W,, C,,, and tl, respectively.
P = TEMPERATURE EFFICIENCY
I ,
LMTD CORRECTION FACTOR
I
I I 1
i 1 SHELL PASS 2 OR MULTIPLE OF 2 TUIIEPASSES
P = TEMPERATURE EFFICIENCY
4
LMTD CORRECTION FACTOR
c
3 SHELL PASSES 1 1
6 OR MULTIPLE OF 6 TUBE PASSES (
( I -;
I
k
0.4 016 0.7
P = TEMPERATURE EFFICIENCY
4 SHELL PASSES
6 SHELL PASSES
TEMPERATURE EFFICIENCY
PARALLEL FLOW
0.2
0.4
>-
0.6
0.8
1.o
1.2
1.4
1.6
1.8
2.0
2.2
2.4
2.6
2.8
3.0
3.5
4.0
4.5
5.0
5.5
6.0
7.0
8.0
9.0
10.0
NTU
~-
--~
~ ~
~~ - ~ - -
c:
--
TEMPERATURE EFFICIENCY
TRUE COUNTERFLOW
TEMPERATURE EFFICIENCY
0.2
1 SHELL PASS
0.4
0.6
0.8
1.o
1.2
1.4
1.6
1.8
2.0
2.2
2.4
2.6
2.8
3.0
3.5
4.0
4.5
5.0
6.0
7.0
8.0
9.0
10.0
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.91 2 3 4 5 6 7 8 9-")
C::
~~ ~
NTU
. .--~
i-~
~ --
.- -
~. ~~ -~
APPENDIX C
PROCEDURE FOR CALCULATING ALLOWABLE NOZZLE
EXTERNAL FORCES AND MOMENTS IN CYLINDRICAL VESSELS "'
r'
\
! C1.O Nomenclature
P = Design Pressure, psi
ro = Nozzle Outside Radius, inches (see Figure C-1)
R, = Mean Radius of Shell, inches (see Figure C-1)
T = Shell Thickness, inches (see Figure C-1)
6 S, = Maximum Code allowable stress due to design pressure and nozzle loads a t
design temperature, psi
Section VIII, Division 1:Value of yield strength associated with the applicable
load combination or stress combination.
I Section VIII, Division 2: Allowable stress intensity associated with the applicable
load combination or stress combination.
Section 111, Division 1: Allowable stress intensity associated with the applicable
service limit or stress combination.
u = Calculated Stress Due to Design Pressure, psi
S, = Maximum Code allowable stress due to design pressure a t design temperature, psi
'\
Section VIII, Division 1:Maximum Allowable Stress Value, S
I,
Section VIII, Division 2: Design Stress Intensity Value, S,
Section 111, Division 1: Design Stress Intensity Value, S, or Allowable Stress
Value, S, as applicable.
I
p = Dimensionless Numbers
1 Y =Dimensionless Numbers
OL =Dimensionless Numbers
II Z = Dimensionless Numbers
Figure C-1
NOMENCLATURE
C2.0 External Forces and Moments Calculate Pressure Stress
To calculate the maximum force and moment, first
evaluate p and y. Then determine or, Z and 4 from i
Figures C-2, C-3 and C-4 for the specified p and y, ,..
"
Calculate Mowable Forces and Moments
I
FmF =
or
(sY- u) = l
3 1
MRCM=
"' ro SY =
(37.5)' (15) (31,500) = 604,048 in-lbf
1,100
Plot the value of FRRFas FRF and the smaller of (37'5)2 (15)(31,500 - 14,850 I
MRCMand MRLMas MRM.The allowable nozzle loads 340
i
are bounded by the area FRF,0, M m .
1,032,973 in-lbf
. .i
I I
Plot the value of FRRFas Fw and the smaller of Li
M R Cand~ MRLMas MRM.The allowable nozzle loads !
are bounded by the area of FRF,0, and MRM.
Heavy Hex
Thread Data Nut Dimensions Minimum Dimensions
Nominal No. of Root Area Pitch Across Across Bolt Radial Edge
Bolt Size Threads (inz) Diameter Flats Corners Spacing Distance Distance
per xn (in) (in) (in) (in)
(in) n As Di Do (in) (in) R E
1h 13 0.126 0.4485 0.875 0.969 1v4 '%o %
% 11 0.202 0.5644 1.062 1.175 I?/2 '%6 34
% 10 0.302 0.6832 1.250 1.382 I%, 1% '%G
% 9 0.419 0.8009 1.438 1.589 2x0 'KG
1 8 0.551 0.9168 1.625 1.796 2%. 1%
1% 8 0.728 1.0417 1.812 2.002 21,$ 1% 1%
1%. 8 0.929 1.1667 2.000 2.209 21x0 1% 1%.
1% 8 1.155 1.2916 2.188 2.416 3x6 1y3 1%
1% 8 1.405 1.4166 2.375 2.622 3M. 2 1%
1yx 8 1.680 1.5416 2.562 2.828 3% 2% 1%
1% 8 1.980 1.6665 2.750 3.035 33/,, 2% 1%
1yn 8 2.304 1.7915 2.938 3.242 4 2% 1I/H
2 8 2.652 1.9165 3.125 3.449 4%. 2% 2
2% 8 3.423 2.1664 3.500 3.862 4% 2% 2%.
2 ?h 8 4.292 2.4164 3.875 4.275 5lh 3x0 2%
2 3 ~ 8 5.259 2.6663 4.250 4.688 53A. 33h ZVQ
The following equation may be used to calculate the applied torque on the nut to develop the stress in
the bolts:
T = Torque = T,ft-lbf
where
S = Bolt stress, psi
Other variables in the equations above are found in the preceding Bolting Data Table,
APPENDIX F-1
HEAT EXCHANGE INSTITUTE INC.
HEAT EXCHANGER SPECIFICATION SHEET
English Units
53 NOTES:
54
55
APPENDM F-2
HEAT EXCHANGE INSTITUTE INC.
HEAT EXCHANGER SPECIFICATION SHEET
SI Units
JOB NO.
24
25 TEMPERATURE IN -C
26 TEMPERATURE OUT -C
27 OPERATING PRESSURE labs) kPa
28 NUMBER OF PASSES PER SHELL
29 VELOCITY rnls
30
31
32
PRESSURE LOSS
FOULING RESISTANCE
HEAT EXCHANGER DUTY- MW
.kPa
rnZ 'CIW
MTD-'C
33 SERVICE RATE - Wlrn2 'K EFF. SURFACE - rn2
41 -
CORRn9rnh~A N I mnr&urc
42 - --
rnrn
I
43 CODE ncuuinc#v~c#uIa
MKH Units
31 FOULING RESISTANCE 1
32
33 - ..
HEAT EXCHANGER DUTY - kcam
SERVICE RATE kcallh rnZ "K
MTD-'C
-
EFF SURFACE rn2
1-3
0
, REF. "0" g
I OPTIONAL
RlTY
D < 40", t 118"
D < 40", i- 1/8" D = 40"-60" * 3/16"
D = 40"-60",t 3/16" D > 60". ? 114"
D = 61"-80"; 1/4"
D > 80", ? 5/16" d > 24". 5/16"
Aluminum Brass-B 16.9 16.6 16.5 16.0 15.6 15.4 15.0 14.7 14.2 13.7 - - -
(Alloy 687)
90-10 Copper Nickel 19.0 18.7 18.5 18.0 17.6 17.3 16.9 16.6 16.0 15.4 - - -
(Alloy 706)
80-20 Copper-Nickel 21.2 20.8 20.6 20.0 19.5 19.2 18.8 lb.4 17.8 17.1 - - -
(Alloy 710)
70-30 Copper Nickel 23.3 22.9 22.7 22.0 21.5 21.1 20.7 20.2 19.6 18.8 - - -
(Alloy 715)
Unalloyed Titanium - - - 15.5 15.0 14.6 14.0 13.3 12.6 11.9 11.2 - -
Grades 1 , 2 , 3 , & 7
Stainless Steel 304 12.2 12.5 12.7 12.9 13.2 13.4 13.6 13.8 14.0 14.3 14.5 14.7 14.9 15.1 15.3
(UNS
- - S304XX) pppppppppp---
Stainless Steel 3161317 11.5 11.7 12.0 12.2 12.4 12.7 12.9 13.1 13.3 13.6 13.8 14.0 14.2 14.4 14.6
(UNS S316XWS317XX)
Stainless Steel 439 - - - - - - - - - - - - - - -
(UNS S430351
Stainless Steel 29-4 - - - - - - - - - - - - - - -
(LINS S44735)
Carbon Steel 23.5 23.0 22.5 21.9 21.4 20.8 20.2 19.6 19.0 18.3 17.6 16.8 16.2 15.7 15.6
Nickel Allov
Alloy 4001405
(UNS N04400N04405)
*n,
?
19.820.420.9
20.420.9 21.522.0 - - - - - - - - - -
References: ASME Section 11, Part D, except for tho following materials:
Admiralty and all Copper-Nickels: @ 70 % Scovill; 63 maximum temperature, HTRI .
-Aluminum Brass-B:Copper Development Association
SS439, SS29-4, andAL6XTAllegheny Ludlum
APPENDIX L
METRIC CONVERSION FACTORS
NOMENCLATURE
NAME SYMBOL OTHER UNITS
inchfinches in
footlfeet ft
meter (SI) m
millimeter mm
square inch in2
square foot ft2
square meter (SI) m2
square centimeter cm2
square millimeter mm2
cubic inch in3
cubic foot ft3
gallon (US liquid) gal
cubic meter (SI) m3
liter L
pound mass (avoirdupois) lbm
kilogram (SI) kg
pound force (avoirdupois) lbf
kilogram force kgf
newton (SI) N
degree Fahrenheit "F
kelvin (SI) K Note 5.
degree Celsius (SI) "C Note 5.
British thermal unit
(International Table) Btu
kilocalorie
(International Table) kcal
joule (SI) J
kilojoule kJ
second (customary) see
second (SI) s
minute min
hour (customary) hr
hour (metric) h
watt (SI) W
megawatt MW
pound foreelsquare inch psi
inches of mercury in Hg
feet of water ft H20
pascal (SI) Pa
kilopascal kPa
bar bar
millimeter of mercury mmHg
tom torr
centipoise CP
Notes:
1. (SI) Denotes an "International System of Units" unit.
2. Pressure should always be designated as gage or absolute.
3. The acceleration of gravity, g, is taken as 9.80665 m/s2.
4. One gallon (U S liquid) equals 231 in3.
5 . For temperature interval, 1K = 1C exactly.
APPENDIX L - Continued
PREFIXES DENOTING DECIMAL MULTIPLES OR SUBMULTIPLES
PREFIX SYMBOL MULTIPLICATION FACTOR
micro I*. 0.000 001 =
milli m 0.001 = 10"
centi C 0.01 = 10-2
deci d 0.1 = 10-I
deca da 10 = 10'
hecto h 100 = lo2
kilo k 1000 = 103
mega M 1000 000 = lo6
gigs G 1000 000 000 = lo9
CONVERSION FACTORS
LENGTH
MULTIPLY BY TO OBTAIN
in 2.540 x m
in 2.540 X 10' mm
ft 3.048 x 10-I m
ft 3.048 x 10% mm
AREA
MULTIPLY BY TO OBTAIN
in2 6.451600 X 10" mZ
in2 6.451600 X 10' mmz
ft2 9.290304 x mZ
ft2 9.290304 X 10' mm2
VOLUME
MULTIPLY BY TO OBTAIN
in3 1.638706 X lo-" m8
in3 1.638706 X 1D2 L
ft3 2.831685 X 1D2 m3
ft3 2.831685 X 10' L
gal 3.785412 x 10" m3
gal 3.785412 L
MASS
MULTIPLY BY TO OBTAIN
lbm 4.535924 X 10.' kg
FORCE
MULTIPLY BY TO OBTAIN
lbf 4.448222 N
lbf 4.535924 X 10.' kgf
kgf 9.806650 N
TEMPERATURE
K = (OF + 459.67)ll.S K = ("C + 273.15)
"C = ("F - 32)ll.S 'C = ( K - 273.15)
OF = 1.8 'C + 32 "F = 1.8 K - 459.67
ENERGY, WORK OR QUANTITY OF HEAT
MULTIPLY BY TO OBTAIN
Btu J
Btu kcal
Rdbf J
ftlbf kcal
APPENDIX L - Continued
POWER (ENERGYiTIME)
MULTIPLY BY TO OBTAIN
Btuihr 2.930711 x 10.' W
Btuihr 2.930711 x 10" MW
Btulhr 2.519958 x lo-' kcalh
PRESSURE OR STRESS (FORCEIAREA)
MULTIPLY BY TO OBTAIN
psi 6.894757 X lo8 Pa
psi 6.894757 kPa
psi 6.894757 x bar
psi 7.030696 x 10" kgWcmZ
1bVft2 4.788026 x 10' Pa
1bWftZ 4.788026 X 1w2 kPa
1bVft2 4.882428 kgVm'
inHg (32'F) 3.38638 X lo3 Pa
inHg (32'F) 3.38638 kPa
inHg (32F) 3.38638 x lo-= bar
inHg (32F) 3.45315 x 10" kgVcm2
inHg (32F) 2.540 X 10' mmHg
torr (OC) 1.33322 X 10" Pa
tom (OC) 1.0 mmHg
ftH,O (39.2"F) 2.98898 x lo3 Pa
ftH,O (39.2"F) 2.98898 kPa
ftH,O (39.2'F) 3.047915 X loZ kgVm2
VELOCITY ( L E N G r n I M E )
MULTIPLY BY TO OBTAIN
ftlsec 3.048000 X lo-' d s
ftlmin 5.080000 X m/s
MASS FLOW RATE (MASS/TIME)
MULTIPLY BY TO OBTAIN
lbmhr 1.259979 x lo4 kgls
lbmhr 4.535924 X 10.' kgk
VOLUME FLOW RATE WLUMEiTIME)
MULTIPLY BY TO OBTAIN
ft3/min 4.719474 X lo4 m3/s
ft3/min 1.699011 ms/h
gaWmin 6.309020 X lo5 m3/s
gaWmin 2.271247 X 10.' m3/h
gaVmin 3.785412 Llmin
M3.0 PARAMETERS
M3.1 V (See Figure M-1)
V = C for a channel with a bolted Cover
= B for a channel with an integral (welded) cover (Bonnet)
= R for a channel with a Reducer
CHANNEL REDUCER
Figure M-1
Tube Side Closures
INTEGRAL TUBE SIDE,
GASKETED SHELL SIDE
Figure M-2
Stationary Tubesheet Arrangements
ONE-PASS SHELL
TWO-PASS SHELL
-FLOW SHELL
Figure M-3
Shell Side Arrangements
CROSS-FLOW SHELL
X
KETTLE-TYPE SHELL
K
KETTLE-TYPE SHELL
K
70
PULLTHROUGH
FLOATING TUBESHEET
WITH SPLIT BACKING RING
Figure M-4
Floating and Packed Tubesheet Arrangements (Rear Only)
FLOATING HEAD
F
U-TUBE
U
Figure M-5
Tube Side Closures (Rear Only)
Exchanger with a one-pass shell, channel cover, pull-through floating tubesheet, and
floating head.
C Exchanger with a one-pass shell, channel cover on front end, packed tubesheet, and
packed channel cover on rear end.
Exchanger with a twopass shell, channel cover on front end, packed tubesheet with
lantern ring, and bonnet on rear end.
Figure M-6
Typical Arrangements
C4S3B
Exchanger with a splibflow shell, bellows expansion joint, channel cover on front end,
and bonnet on rear end.
C2E6F
Exchanger with a one-pass shell, channel cover, floating tubesheet with split backing
ring, and floating head.
BlDU
Exchanger with a divided-flow shell, bonnet, and U-tubes.
74
BlKU
Kettle with bonnet and 1J-tubes.
Exchanger with a one-pass shell, flanged and flued expansion joint, and channel
reducers on both sides.
Gasket Leaks Improper bolt torque sequence a t Replace gasket and consult operating
installation manual for proper sequence of bolt
tightening
Replacement gasket is not compatible Replace gasket with compatible gasket
with original design shown in operating manual
Gasket surface has been eroded due to Remove cover, repair gasket surface by
previous leaks welding and/or machining and replace
gasket
Bolting has galled due to improper Replace gasket and bolting
tightening and/or lubrication
Corrosion High fluid velocities sweep away Reduce velocity, reduce turbulence
protective oxide layer or coating
n
Dissimilar metals in the presence of an Provide epoxy lining, or coating, provide
electrolytic solution cathodic protection (Reference section 6.3
in the HE1 Standards for Power Plant
Heat Exchangers.)
Damage to the oxide layer or to the Consult plant chemist
protective coating
Cavitation Eliminiate or reduce cavitation
Acidity or oxygen building up in cracks Remove crevice, consult plant chemist
and crevices
Tube Leak(s) Tube to tubesheet joint failures Inspect overlaid tubesheets for cracking
(Exhibited by increased or separation. Inspect tube to tubesheet
flow, pressure losses, joint for damage. If damaged, contact
and contamination on supplier for repair procedure
the lower pressure side.
In severe cases, tube Check operations to prevent any possible
leaks will result in temperature shocks
relief valve or rupture
disk activation.) Damage from corrosion andlor erosion Inspect tubes for corrosion and/or erosion
damage. Consult the plant chemist and
the supplier for possible repairs which
may include retubing, replacement,
sleaving, or linings
Mechanical damage Inspect the tube and shell sides for for-
eign or loose internal parts. Remove any
foreign parts and repair damage.
Consult with the supplier if any loose
internal parts are found
APPENDM N I
TROUBLESHOOTING GUIDE
)
&
'
Symptoms Possible Causes Possible Solutions
I
Tube Leak(s) continued Vibration Identify all tube leak locations on the I
tube layout drawing. An effort should be I
made to determine the location of the
leak from the front tubesheet.
The supplier of the equipment should be
notified and provided all pertinent oper-
ating conditions along with the plug
map identifying leak locations
Possible solutions mav involve the
following:
Tube plugging (after first using cap-
ture rods to stabilize loose tube ends.)
Insurance plugging
Staking of tube bundles where
possible
Limiting certain modes of operation
Pass Partition Leaks Pass partition gasket failure Consult supplier for appropriate
(Exhibited by reduced replacement
tubeside temperature
rise and higher TTD.) Pass partition nut failure due to Consult supplier over stud and nut
cycling operation material selections, and consider tack
welding replacement nuts, self locking
nuts, or tension controlled washers 3
Pass partition cracking due to cycling Consult supplier over possible repairs
Water hammer or abnormal operating Make repairs as required and review
conditions operating procedures
Erosion damage from tubeside inlet Consult supplier and review pass
nozzle partition plate material
I
Standards for Power Plant Heat Exchangers Index
Alterations ................................................ 23 Fouling Resistance ...................................... .1.3. 4
Approach Temperature ................................ . l ,5 Gaskets ........................................................ 9
Baffles ...................................................
13.14. 15 Gross Surface ................................................... 1
Cuts ...................................................... 14 Halogenated Compounds ................................. 9
Diameters .................................... .. ........14 Hydrostatic Tests ............................................9
Spacing ..................................................14 Impingement ...............................................6. 7
Thicknesses ......................................... .14,15 Inlet Area ............................................... .6.7
Tube Hole Diameters ................................ 14 Plates (Impact) .................................... 6.7. 15
Blanketing ................................................... 22 Inert Gas Blanket .......................................... 22
Bonnets ..................................... ....................16 Inspection ............................................. .22.23
Thicknesses ............................................. 16 Installation ............................................... .21.23
Boundaries ...................................................... 1 Intergranular Corrosion .................................... 9
Bundle Entrance Areas ................................... 7 Liners ............................................................ 9
Bundle Exit Areas ............................................. 7 Logarithmic Mean Temperature Difference
'. Channels ................................................... 16,22 (LMTD) ................................................... 1
I.
Thicknesses .......................................... 16 Longitudinal Bafles ..................................... 15
i Cleaning .................................................. .22,23 Maintenance .............................................. 23
Shop ...................................................... 22 Materials of Construction ............................... ..8
!
\ Site ........................................................23 Mean Temperature Difference (MTD) ..................2
Mechanical Design Standards ....................... 9-20
Cleanliness Factor .......................................
1
1,3
Nozzles ................................................
\.
6.18. 19
i Coatings ....................................................... 9
Code ........................................................... 1,9 Sizing .................................................... 6
Requirements ............................................. 9 Loads ...............................................18.19
Corrosion .................................................. .9,22 Operating Modes ............................................ 7
: p,. Allowances ................................................ 9 Operating Pressures ....................................... 2
Protection ................................................ 22 Operating Temperatures .................................... 2
Covers .....................................................15,16 Operation .................................................. .7.23
I Thicknesses .......................................... 15,16 Overall Heat Transfer Coefficient....................... 2
Design Point ................................................... 1 Packed Joints .............................................. 17
Design Pressures .......................................... 1,9 Packing .................................... ..................... 9
..
Design Temperatures ................................... 1,9 Pass Partitions ....................................... 11.16.17
Diameter ...................................... .10,11,12,14, 15 Grooves ............................................... .11.17
Baffles .................................... .. ...........14 Plates .....................................................16
Shells .................................................... 15 Painting ......................................................... 22
Tubes .....................................................10 Performance ................................................ 2
Tube Holes ................................... .11,12,14 Plugging ...................................................... 11
Drains ............................................................ 7 Pressure Loss .......................................... 2.5. 6
!
Drying Procedures ....................................... 22 Relief Valves................................................... 21
Duty ..........................................................1,2 Repairs ........................................................23
..
Effective Surface ............................................. 1 Rust Inhibitors ............................................ 22
I
Expansion Joints ....................................... 15 Safety Valves ................................................ 21
Floating Heads ............................................. 9, 16 Sealing Devices (By-Pass) ........................... 2 5
Thicknesses ............................................. 16 Service Rate (See Ovorall Heat Transfer
Coefficient) ............................................. 2
Shells .....................................................6.7. 15 Tie Rods .....................................................15
Diameter ...............................................15 Tube Bundles .............................................. 13
Inlet Area ............................................... .6.7 Tubes ....................................
5.8.9.10.11.13.19. 20
Outlet Area ............................................ .6.7 Bundles ..................................................13
Thicknesses ........................................... 15 Diameters ................................................ 10
Shell Covers ................................................... 15 Joints (Tube-to-Tubesheet)..................10.11. 13
Thicknesses ........................................... 15 Materials .............................................. .8. 9
Shipment .....................................................22 Thicknesses .......................................... 10
Shutdown ......................................................23 Velocity ............................................. .5.20
Spacers ........................................................15 Vibration ............................................19.20
Startup ................................... .. ..................23 Tubesheets .............................................. 11.12
Storage ........................................................22 Clad .....................................................11
Supports ................................................18,19,20 Ligaments .........................................ll.12
Support Plates .................................... ......13,14 Thicknesses ........................................... 11
Thicknesses ................................. 10,11.14,15, 16 Tube Holes .......................................... 11.12
Baffles .............................................. 14,15 U-Tubes .........................................................
10
Bonnets ................................................... 16 Thickness .............................................. 10
Channels ................................................ 16 Heat Treatment ......................................10
Covers ................................................. 16 Vents ............................................................
7
Floating Heads .......................................16 Vibration ...................................................
19.20
Tubes .................................................... 10
Tubesheets ........................................... 11
Shells .................................................... 15
Shell Covers ........................................... 15