Specifying Design Requirements For Heat Exchangers PDF

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
SPECIFYING DESIGN REQUIREMENTS

FOR HEAT EXCHANGERS
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramcos employees.
Any material contained in this document which is not already in the public
domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.
Chapter : Mechanical
File Reference: MEX-210.03
For additional information on this subject, contact

PEDD Coordinator on 874-6556
Evaluating Heat Exchanger Design and Installation

Specifying Design Requirements for Heat Exchangers
Section
Page
INFORMATION ............................................................................................................... 5
introduction...................................................................................................................... 5
USE OF SAUDI ARAMCO DESIGN SPECIFICATION SHEETS IN HEAT
EXCHANGER PROCUREMENT..................................................................................... 6
Use of Heat Exchanger Data Sheets ......................................................................... 6
Data Sheet for Shell-and-Tube Heat Exchangers ...................................................... 6
General Procurement Information .................................................................... 9
Section A. Process/Performance Data of One Unit ........................................ 10
Section B. Construction Data of One Shell..................................................... 10
Section C. Miscellaneous ............................................................................... 11
Data Sheet for Air-Cooled Heat Exchangers ........................................................... 12
General Procurement Information .................................................................. 14
Performance Data Section ............................................................................. 14
Design-Materials-Construction Section .......................................................... 15
EVALUATING CONTRACTOR-SPECIFIED DESIGN CONDITIONS FOR TEMATYPE AND AIR-COOLED HEAT EXCHANGER COMPONENTS ................................ 16
TEMA-Type Shell-and-Tube Heat Exchangers ........................................................ 17
Shells and Heads ........................................................................................... 18
Nozzles........................................................................................................... 18
Girth Flanges.................................................................................................. 19
Tubesheets..................................................................................................... 20
Flat Covers ..................................................................................................... 21
Internal Components ...................................................................................... 21
Air-Cooled Heat Exchangers ................................................................................... 23
Tubes ............................................................................................................. 24
Tube Fins ....................................................................................................... 24
Tube Bundles ................................................................................................. 24
Tube Supports ................................................................................................ 24
Header Boxes................................................................................................. 25
EVALUATING CONTRACTOR-SPECIFIED DIMENSIONS FOR SHELL-ANDTUBE HEAT EXCHANGER COMPONENTS ................................................................ 26
General Dimensional Verification............................................................................. 26
Typical Errors ................................................................................................. 27
Compliance with Saudi Aramco, TEMA, API, and ASME Requirements........ 27
Use of Computer Programs ..................................................................................... 27
Verifying Computer Programs ........................................................................ 28
Checking Computer Input Data ...................................................................... 28

Checking Computer Output ............................................................................ 29

Heat Exchanger Components .................................................................................. 29
Girth Flanges.................................................................................................. 30
Parameters That Affect Flange Design and In-Service Performance - ........... 33
Pass Partition Gaskets ................................................................................... 39
Flat (Channel) Cover ...................................................................................... 40
Tubesheets..................................................................................................... 42
Internal Floating Heads .................................................................................. 46
Tubes ............................................................................................................. 48
Pass Partition Plates ...................................................................................... 49
Nonpressure Containing Components............................................................ 50
EVALUATING CONTRACTOR-SPECIFIED DESIGNS FOR AIR-COOLED HEAT
EXCHANGER TUBE BUNDLES AND HEADERS ........................................................ 51
Tube Bundle Design Requirements ......................................................................... 51
Overall Bundle Design Requirements............................................................. 51
Tube Design ................................................................................................... 52
Tube Support Design...................................................................................... 53
Header Design Requirements.................................................................................. 53
Basic Design Requirements ........................................................................... 53
Header Type................................................................................................... 54
Gasket Requirements..................................................................................... 55
Nozzles and Other Connections ..................................................................... 55
Maximum Allowable Moments and Forces for Headers and Nozzles............. 55
ASME Code Requirements ............................................................................ 56
Computer Design of Header Boxes ................................................................ 58
Sample Problem 4: Evaluate Contractor-Specified Dimensions for the
Inlet/Outlet Header Box of an Air-Cooled Heat Exchanger............................. 58
COMPLETING A SAFETY INSTRUCTION SHEET FOR A SHELL-AND-TUBE
HEAT EXCHANGER ..................................................................................................... 59
Information Covered ................................................................................................ 59
Where to Find Other Information ............................................................................. 62
SUMMARY.................................................................................................................... 63
WORK AIDS.................................................................................................................. 64
WORK AID 1: PROCEDURE FOR EVALUATING CONTRACTOR-SPECIFIED
DESIGN CONDITIONS FOR TEMA-TYPE AND AIR-COOLED HEAT
EXCHANGER COMPONENTS ..................................................................................... 64
Part 1: TEMA-Type Heat Exchangers...................................................................... 64
Part 2: Air-Cooled Heat Exchangers ........................................................................ 65
DIMENSIONS FOR SHELL-AND-TUBE HEAT EXCHANGER COMPONENTS........... 67
ii

Part 1: General Requirements ................................................................................. 67

Part 2: Girth Flanges and Flat Channel Covers ...................................................... 67
Part 3: Stationary and Floating Head Tubesheets .................................................. 71
Part 4: Floating Heads With and Without Backing Rings ........................................ 74
DESIGNS FOR AIR-COOLED HEAT EXCHANGER TUBE BUNDLES AND
HEADERS..................................................................................................................... 79
Part 1: General Requirements ................................................................................. 79
Part 2: 32-SAMSS-011 and API-661 Requirements ................................................ 79
Overall Tube Bundle Design Requirements ................................................... 80
Tube Wall Minimum Thickness....................................................................... 80
Selection of Tube Fins.................................................................................... 81
Header Design Requirements ........................................................................ 82
Headers: Removable-Cover-Plate and Removable-Bonnet-Type .................. 83
Headers: Plug-Type........................................................................................ 83
Gasket Requirements..................................................................................... 84
Nozzles and Other Connections ..................................................................... 84
Part 3: ASME Code Calculations for Header Box Plate Thicknesses ...................... 84
WORK AID 4: PROCEDURE FOR COMPLETING A SHELL-AND-TUBE HEAT
EXCHANGER SAFETY INSTRUCTION SHEET .......................................................... 88
GLOSSARY .................................................................................................................. 91
LIST OF FIGURES
Figure 1. Form 2714........................................................................................................ 7
Figure 2. Form 2714(Contd) ........................................................................................... 8
Figure 3. Form 2716...................................................................................................... 13
Figure 4. Heat Exchanger Design Conditions ............................................................... 17
Figure 5. Typical Air-Cooled Heat Exchanger Tube Bundle Components..................... 23
Figure 6. Flange Loads and Moment Arms ................................................................... 32
Figure 7. Pass Partition Gasket..................................................................................... 40
Figure 8. Flat (Channel) Cover ...................................................................................... 41
Figure 9. Tubesheet Thickness ..................................................................................... 43
Figure 10. Types of Floating Heads .............................................................................. 46
Figure 11. Pass Partition Plate...................................................................................... 49
Figure 12. Typical Header Box Details .......................................................................... 57
iii

Figure 13. Ligament Efficiency in Tubesheet or Plug Sheet.......................................... 57

Figure 14. Safety Instruction Sheet Form 2713............................................................. 60
Figure 15. TEMA-Type Heat Exchanger Design Condition Evaluation.......................... 65
Figure 16. Air-Cooled Heat Exchanger Design Condition Evaluation............................ 66
Figure 17. Flange Geometry and Nomenclature ........................................................... 68
Figure 18. Tubesheet Geometry and Nomenclature ..................................................... 72
Figure 19. Floating Head Geometry and Nomenclature ................................................ 75
Figure 20. Header Box Geometry and Nomenclature ................................................... 86
Figure 21. Header Box Geometry and Nomenclature, cont'd ........................................ 87
Figure 22. Components That May Determine Shell-Side MAPNC ................................ 88
Figure 23. Components That May Determine Tube-Side MAPNC ................................ 89
Figure 24. Shell-and-Tube Heat Exchanger Safety Instruction Sheet Form 2713......... 90
LIST OF TABLES
Table 1. Design Conditions for Shell-and-Tube Heat Exchanger Components ............. 18

Table 2. ASME Code m and y Factors .......................................................................... 34
Table 3. ASME Code Gasket Widths ............................................................................ 35
Table 4. Bolting Data..................................................................................................... 36
Table 5. Minimum Required Tube Thickness ................................................................ 49
Table 6. Minimum Required Tube Thicknesses ............................................................ 81
Table 7. Limitations on Fin Types.................................................................................. 81
Table 8. Minimum Required Thickness of Header Box Components ............................ 82
Table 9. Pass Partition Plate Thickness ........................................................................ 82
Table 10. Header Box Type .......................................................................................... 83
Table 11. Header Box Calculation Verification Procedure............................................. 85
iv

INFORMATION
INTRODUCTION
This module discusses evaluation of the Contractor Design
Packages for heat exchangers in order to ensure that the
designs meet applicable Saudi Aramco requirements, industry
standards, and industry codes.
The module begins by describing the use of standard Saudi
Aramco heat exchanger specification sheets for bid inquiry,
purchase, and documentation purposes. These specification
sheets are the basis for the detailed heat exchanger mechanical
design that will follow.
The evaluation of contractor-specified design conditions using
Saudi Aramco requirements and process operating conditions is
then addressed. The design conditions are needed in the
detailed mechanical design of heat exchanger components.
The module then discusses the procedures that are used to
evaluate the contractor-specified dimensions for primary heat
exchanger components. Calculations are usually necessary to
determine these dimensions, and these calculations are now
commonly done with computer programs. Therefore, rather than
making time-consuming hand calculations to check the
contractor-specified dimensions, this module gives the
participants a general procedure that may be used to evaluate
computer-generated heat exchanger design calculations.
The module concludes with a procedure for completing a Safety
Instruction Sheet for a shell-and-tube heat exchanger, based on
Saudi Aramco requirements and information that is contained in
the Contractor Design Package. While only a shell-and-tube
heat exchanger is discussed in detail, completion of a similar
Safety Instruction Sheet is also required for air-cooled heat
exchangers.

USE OF SAUDI ARAMCO DESIGN SPECIFICATION SHEETS IN HEAT

EXCHANGER PROCUREMENT
The Saudi Aramco specification sheets that are used for design
of heat exchangers are also used in various stages of heat
exchanger procurement. These sheets are also frequently
referred to during heat exchanger operation, inspection, and
maintenance inasmuch as they are a source of reference
information. Saudi Aramco has specification sheets for shelland-tube, air-cooled, and plate-type heat exchangers. The
specification sheets for shell-and-tube and air-cooled heat
exchangers were previously introduced in
MEX 210.02 with respect to material selection requirements,
and will be discussed further in this module. The specification
sheet for plate-type heat exchangers will not be discussed.
Use of Heat Exchanger Data Sheets

Heat exchanger data sheets that are required for capital projects
are generally completed by contractors who are employed by Saudi
Aramco. The Saudi Aramco engineer will normally review the
contractor's work in order to ensure that the heat exchanger data
sheet is completed correctly. In some cases, the Saudi Aramco
engineer will complete the heat exchanger data sheet when no
contractor is involved on the project, or when an existing exchanger
must be rerated to new design conditions.
The data sheets specify the design information that is necessary
in order to request a quotation for a new exchanger and in order
to document as-built details of the exchanger. The use of data
sheets ensures that there will be a uniform bidding basis among
the competing heat exchanger manufacturers and simplifies the
bids that these manufacturers submit.
Data Sheet for Shell-and-Tube Heat Exchangers

Saudi Aramco Form 2714, Shell and Tube Heat Exchanger
Specification, is used to specify the design requirements for TEMAtype shell-and-tube heat exchangers. This form is referenced in
SAES-E-004, Basic Criteria of Shell and Tube Heat Exchangers.
This form is shown in Figure 1 and continued in Figure 2, and a
copy is contained in Course Handout 3. The form has several
sections that are filled in by process and mechanical engineers
during heat exchanger procurement. The following paragraphs
briefly describe the main sections of this form.

Equip. No.
Service
Shell I.D. D/M
mm (in) Tube Length D/M
HORIZ.
VERT.
D
mm (in) TEMA Type (Float Hd; Fixed Tube Sht.;

U Tube; Kettle) D/M*
Order No. D
Serial No. M
No. of Units D
Manufacturer M*
Mfr. Dwg. No. M
Sour Service D
YES
NO
Lethal Service D
YES
NO
Date D
Per Unit D/M*
D/M*
Shell in series
Mfr. Order No. M
Shell in parallel
Cyclic Service D
YES
NO
Total Effective Surface D/M* / No. of Shell per Unit
m2 (ft2) /
D/M*
Effective Surface Per Shell D/M* / Gross Surface Per Shell D/M*
m2 (ft2) /
m2 (ft2)
SHELL SIDE
A. PROCESS/PERFORMANCE DATA OF ONE UNIT
IN
TUBE SIDE
OUT
IN
OUT
FLUID CIRCULATED D
TOTAL FLUID ENTERING D
kg/h (Lbs/Hr)
VAPOR D
kg/h (Lbs/Hr)
LIQUID D
kg/h (Lbs/Hr)
STEAM D
kg/h (Lbs/Hr)
WATER D
kg/h (Lbs/Hr)
NONCONDENSABLE D
kg/h (Lbs/Hr)
C ( F)
TEMPERATURE D
SPECIFIC GRAVITY, LIQUID D
Cp
VISCOSITY, LIQUID/VAPOR D
MOLECULAR WEIGHT, VAPOR D
MOLECULAR WEIGHT, NONCONDENSABLE D
kJ/kg C (Btu/Lb F)
SPECIFIC HEAT, LIQUID/VAPOR D
THERMAL CONDUCTIVITY,LIQUID/VAPOR D W/m C (Btu Ft/Hr.Sq.Ft.F)

LATENT HEAT D
kJ/kg (Btu/Lb)
mN/m (Dynes/cm)
SURFACE TENSION
kPag (Psig)
INLET PRESSURE/CRITICAL PRESSURE D
m/s (Ft/S)
VELOCITY D/M*
kPa (Psi)
PRESSURE DROP, ALLOW/CALC. D/M*
m2 K/W (Sq. Ft.F Hr./Btu)

W/m2 K (Btu/h Ft2 F)
FOULING RESISTANCE (MIN) D

* FILM COEFFICIENT
C ( F )
M.T.D. (CORRECTED) D/M*

TRANSFER RATE: SERVICE D/M*
W/m2 K ( Btu/Hr. Sq. Ft. F )

W ( Btu/Hr.)
CLEAN D/M*
HEAT EXCHANGED D
rhoV2 INLET NOZZLE: D/M*
BUNDLE ENTRANCE: M*
kg/ms2 ( lb/fts2 )
BUNDLE EXIT: M*
CONDENSING/BOILING HEAT DUTY PROFILE: D

1
TEMPERATURE
C (F)
HEAT DUTY
W (Btu/h) x 106
WT. FRACTION VAPOR

VAPOR AVERAGE MOLE WEIGHT
B. CONSTRUCTION DATA OF ONE SHELL
CORROSION ALLOWANCE D
SHELL SIDE
DESIGN PRESSURE D
C ( F )
kPag ( Psig )
TEST PRESSURE D/M*
kPag ( Psig )
DESIGN TEMPERATURE D
MDMT / LPFT. D/M*
TUBE SIDE
mm ( inch )
C ( F )
NUMBER OF PASSES PER SHELL D/M*

PROCESS & ANCILLIARY CONNECTIONS
SIZE
NUMBER
RATING
FACING
SHELL - INLET D/M*

SHELL - OUTLET D/M*
TUBE - INLET D/M*
TUBE - OUTLET D/M*
VENT CONN D/M*
DRAIN CONN D/M*
CHEM CLEANING D
Figure 1. Form 2714


B. CONSTRUCTION DATA (Continued)
MATERIAL SPECIFICATION
THICKNESS
BASE METAL/
CLADDING
PWHT/RT**
TUBES D/M*: O.D. ............ mm (in.); WALL THK. ............. mm (in./BWG)

NUMBER/LENGTH D/M*: ............... /................ m (feet); WALL: avg./min.
PITCH D/M*:
mm (in.)TUBE PATTERN D/M*
30 45 60 90
STATIONARY TUBE SHEET/CLADDING D/M*
FLOATING TUBE SHEET/CLADDING D/M*
CHANNEL OR BONNET/CLADDING D/M*
CHANNEL COVER/CLADDING D/M*
SHELL/CLADDING D/M*
SHELL COVER/CLADDING D/M*
BACKING RING D/M*
FLOATING HEAD COVER/CLADDING D/M*
TYPE: D/M*
BAFFLES/SUPPORTS D/M*
"% CUT D/M*
Horiz/Vert.
PITCH (spacing c/c) D/M*
mm(in)
LONGITUDINAL BAFFLE D/M*
YES/NO
EXPANSION JOINT M*
BYPASS SEAL ARRANGEMENT D/M*
BOLTING: SHELL COVER TO SHELL D/M*
CHANNEL TO SHELL D/M*
CHANNEL COVER TO CHANNEL D/M*
FLOATING HEAD COVER TO TUBESHEET D/M*
GASKETS: SHELL COVER TO SHELL D/M*
SHELL TO STAT. TUBESHEET D/M*
CHANNEL TO STAT. TUBESHEET D/M*
CHANNEL COVERTO CHANNEL D/M*
FLOATING HEAD COVER TO TUBESHEET D/M*
YES/NO D/M*
IMPINGEMENT PROTECTION
C. MISCELLANEOUS
DIAMETER
LENGTH
WEIGHT
OVERALL DIMENSIONS M*
m (feet)
OVERALL DIMENSIONS, PACKED FOR SHIPPING M*
m (feet)
EXCHANGER, EMPTY M*
kg (Lbst)
EXCHANGER, FULL OF WATER M*
kg (Lbst)
BUNDLE (REMOVABLE) M*
kg (Lbst)
INSULATION THICKNESS D
** PWHT = POSTWELD HEAT TREATED
RT = % AGE RADIOGRAPHED
TUBE TO TUBESHEET JOINT: EXPANDED / EXPANDED & SEAL WELDED / STRENGTH WELDED
REQUIREMENTS:
CODE REQUIREMENTS: ASME BOILER AND PRESSURE VESSEL CODE SECTION VIII....... DIV. ....................... EDIT ............................. D
STANDARDS OF THE TUBULAR EXCHANGER MANUFACTURERS ASSOCIATION (TEMA) . ....................................................................... D
ARAMCO MATERIAL SYSTEMS SPECIFICATION 32-SAMSS-007
REMARKS:
D = INFORMATION SUPPLIED BY DESIGN ENGINEER WITH INQUIRY.

M = INFORMATION SUPPLIED BY EXCHANGER MANUFACTURER.
* = SUPPLIED AND/OR VERIFIED BY EXCHANGER MANUFACTURER WITH PROPOSAL.
REFERENCE DRAWINGS
CERTIFIED:
REVISIONS
DESCRIPTION
CHKD CERT APPD BY
DATE
APPROVED:
BY
DATE
SAUDI ARABIA
JOB ORDER/EWO NO. PLANT NO. INDEX
DRAWING NUMBER
SHEET NO. REV. NO.
DSaudi Aramco 2714-ENG (11/95)
Figure 2. Form 2714(Contd)

General Procurement
Information
The upper left portion of the form contains an area where
general information about the exchanger is specified. The
following items would probably be completed before the form is
sent out to manufacturers for bids:
Equipment No.
Service
Horiz./Vert.
No. of Units
OR No.
Date
Type (TEMA Designation)
Sour Wet Service/Lethal
Service Condition (Cyclic/Noncyclic)
The following information is typically completed either by the

manufacturer when he bids on the exchanger or by the
contractor when he specifies the purchase information:
Shell I.D.
Tube Length
Per unit (shells in series and shells in parallel)
Saudi Aramco Order No.
Manufacturer's Name
Manufacturer's Order Number
Manufacturers Drawing Number
Total Effective Surface Area and No. of Shells per Unit
Effective Surface per Shell

Section A.
Process/Performance
Data of One Unit
The contractor's process engineer typically completes the
process information that is specified in this section. The heat
exchanger manufacturer uses this information to design the
exchanger from a process standpoint. Note that this section
contains columns that are headed IN and OUT for both the
shell-side and the tube-side fluids. The purpose of these
columns is to allow the contractor's process engineer to indicate
the change in various process parameters as the fluid travels
from the inlet to the outlet on both the shell-side and tube-side
of the exchanger. In most cases, all of the information that is
necessary for the process design of the unit is provided when
the specification is sent out for bids. Any discrepancies between
the specified process information and what the manufacturer
includes in his bid must be resolved before the exchanger is
purchased, because these discrepancies could have a
significant effect on whether the heat exchanger performs its
required process function.
From a mechanical design standpoint, the values that are of
interest are the temperature, the inlet pressure, and the
pressure drop. The mechanical design temperature must be
higher than the process temperature. The mechanical design
pressure must be higher than the inlet pressure, and some
internals must be designed for the pressure drop that occurs in
the exchanger.
Section B. Construction
Data of One Shell
The mechanical design information that is necessary to
construct the heat exchanger is specified in this section. The
contractor's mechanical engineer should provided as much
information as possible in order to obtain a uniform basis for
bidding; however, in all cases, relevant requirements that are
contained in SAES-E-004 Design Criteria of Shell-and-Tube
Heat Exchangers must be completed by the contractor. Any
information that is left out should be completed by the
manufacturer when he submits his bid.
10

There are two columns in the first part of this section, one for
the shell-side data and one for the tube-side data. The following
information must be specified when the specification sheet is
sent out for bids:
Corrosion Allowance
Design Temperature
Design Pressure
Nozzle Data (Size, Number, Rating, Facing)
The following design information is normally completed by the

contractor or the manufacturer before the exchanger is
purchased:
Test Pressure
Limited By
Number of Passes per Shell
Shell I.D. and O.D.
The second part of Section B contains three columns that cover

materials and construction details for the exchanger. The first
column is for Material and Specifications, the second column is
for Thickness Base Metal/Cladding, and the last column is for
PWHT/XR (Postweld Heat Treatment/ Degree of Radiography).
Saudi Aramco material specification requirements were
discussed in MEX 210.02. In most cases, this information is
completed by the manufacturer at the time of bid; however, this
information could also be completed by the contractor when
bids are requested if the contractor has done a complete
mechanical design.
The second part of Section B also contains design information
that must be specified for the tubes and baffles.
Section C.
Miscellaneous
This section includes information (such as overall dimensions
and weights) that is normally completed by the manufacturer
when he submits his bid. The section also includes notes for the
specification sheet and an area for remarks and general
requirements, such as:
ASME Boiler and Pressure Vessel Code Section VIII, Div. (1

or 2) and Edition (i.e., year)
11

Standards of the Tubular Exchangers Manufacturer's

Association (TEMA) Type and Class
Saudi Aramco Material System Specification

32-SAMSS-007
Saudi Aramco Standard Heat Exchanger Type (Yes/No)
Reference Drawings
The lower right corner of the form contains a standard Saudi

Aramco drawing title block and revision record.
Data Sheet for Air-Cooled Heat Exchangers

Saudi Aramco Form 2716, Specifications for Air Cooled Heat
Exchanger, is referenced by SAES-E-007 Design Criteria of
Shell-and-Tube Heat Exchangers. This form is shown in
Figure 3 and a copy is contained in Course Handout 3. The form
has several sections that are completed by process and
mechanical engineers at various stages of exchanger
procurement. The following paragraphs briefly describe the
main sections of this form.
12

Saudi Aramco 2716-ENG (11/89)
NO.
DATE
BY
JO / EWO
DESCRIPTION
CHKD.
CERT.
APPD.
SAUDI ARAMCO OIL COMPANY
REVISIONS
DRAWN
BY
DATE
CHKD.
BY
OPRG. DEPT.
BY
DATE
ENG. DEPT.
BY
DATE
APPD. FOR
CONSTR.
BY
DATE
CERTIFIED
BY
DATE
THIS DRAWING IS
NOT TO BE USED
FOR CONSTRUCTION
OR FOR ORDERING
MATERIAL UNTIL
CETIFIED AND
DATED
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
Equipment No.
Service
Manufacturer
Mode / Size (length, width)
No. of Bays
Specification No. 32 - AMSS - 11

P.O. No.
Year Built
Forced or Induced
PERFORMANCE DATA - TUBE SIDE
Fluid Name
Total Fluid Entering
PERFORMANCE DATA - AIR SIDE

Altitude
Design Inlet Air Temp.
Lb/Hr
IN
Outlet Air Temp.

Min. Design Ambient
OUT
Lb/Hr
Liquid
Vapor
Lb/Hr,Mol Wt
Non-Cond.
Lb/Hr,Mol Wt
Steam
Lb/Hr
Lb/Hr
Water
Centipoises
Viscosity liq/vap.
F
Operating Temperature
Density, Liquid
Lb/Cu. Ft.
Btu/Lb F
Spec. Heat
Btu/Hr Ft. F
Conduct. liq/vap
Lethal Service
Yes
No
Pour/Freeze Point
Bubble Point
Inlet Pressure
Pressure Drop Allow/Calc
Fouling Resistance
Surface/Unit Finned Tube
Surface/Unit Bare Tube
M.T.D. Corrected
Transfer Rate -Service, Finned Tube
- Clean, Bare Tube
- Service, Bare Tube
Latent Heart
Static Pressure
Face Velocity
Air Quantity (Total)
Air Quantity / Fan
Mass Velocity (net free area)
Ft
F
F
F
In. H2O
FPM
SCFM
SCFM
Lb/h-ft2
MECHANICAL EQUIPMENT
Fans
Manufacturer
Model
No. Per Bay
F
Diameter
F
No. of Blades
RPM/Tip Speed
PSIG
Reqd. H.P. Per Fan
PSI
Blade Material
Hr Ft 2 F/Btu
Sq. Ft
Picth Angle: Adj./Auto.
Sq. Ft Speed Reducer
F
Manufacturer
Btu/Hr F Ft 2
Model
Btu/Hr F Ft 2
Type
Btu/Hr F Ft 2
No. Per Bay
Ratio
Btu/Lb
Ft
Motor (Driver)
Manufacturer
Heat Exchanged
Btu/Hr
Model
Type
No. Per Bay
Horsepower
R.P.M.
Volts / Phase / Hertz
DESIGN - MATERIALS - CONSTRUCTION

Test Pressure
psig Design Temperature
Design Pressure
TUBE BUNDLE
Size
No./ Bay
No. of Tubes/pass
Arrangement
Bundles
In Parallel
Bays
In Parallel
Bundle Frame
MISCELLANEOUS
Struct. Mount. (grade) (piperack)
Surface Preparation
Weight-Empty / Full of water
TUBE Material
HEADER Type
Material
No. Passes*
Slope
Plug Material
Gasker Material
In Seriesl Corrosion Allowance
In Seriesl No., Size Inlet Nozzle
No., Size Outlet Nozzle
Special Nozzles
c/c Rating & Facing
TI
PI
(Seamless) (Welded)
in./ft OD
in. Min. Thick

Length
No. / Bundle
Picth
in. FIN, Type
in. Material
in. Stock Thick
in. OD
in.
ft.
in.
in.
F
Fin Design Temp.
in. No. /in.
Code-ASME VIII; Div.1 Stamp(Yes) (No.)
lbs.
PSI.
Wind Load
* Give tube count of each pass when irregular

SPECIFICATION SHEET - AIR COOLED HEAT EXCHANGER
PLANT NO. INDEX
DRAWING NO.
SHT NO. REV. NO.
DE-
JO / EWO -
Figure 3. Form 2716
13

General Procurement
Information
This portion of the form contains general information about the
heat exchanger. All of this information, except for the
manufacturers name, is completed by the contractor.
Performance Data
Section
This section contains process information that is completed by
the contractor's process engineer. The heat exchanger
manufacturer uses this information to design the exchanger
from a process standpoint. Note that there is one column for
tube-side data and another column for air-side data. The tubeside column contains additional columns that are headed IN
and OUT. The purpose of these columns is to allow the
contractor's process engineer to indicate various process
parameters that may change as the tube-side fluid travels from
the inlet to the outlet of the exchanger. In most cases, all of the
information that is necessary to permit the process design of the
exchanger is provided when the specification is sent out for
bids. Any discrepancies between the specified process
information and what the manufacturer includes in his bid must
be resolved before the exchanger is purchased because these
discrepancies could have a significant effect on whether the
heat exchanger performs its required process function.
From a mechanical design standpoint, the values that are of
interest on the tube-side are the inlet temperature, the inlet
pressure, and the pressure drop. The mechanical design
temperature must be higher than the process inlet temperature.
The mechanical design pressure must be higher than the
process inlet pressure, and some internals must be designed for
the pressure drop that occurs in the exchanger. The quantities
that are of interest on the air side are the design inlet air
temperature and the minimum design temperature.
14

Design-MaterialsConstruction Section
This section includes the mechanical design information that is
necessary to construct the heat exchanger. The contractor's
mechanical engineer should provide as much information as
possible in order to obtain a uniform basis for bidding; however,
in all cases, relevant requirements that are contained in SAESE-004 and 007 must be completed by the contractor. Any
information that is left out should be provided by the
manufacturer when he submits his bid.
The following information is normally specified when the
specification sheet is sent out for bids:
Design Pressure
Wind Load
Corrosion Allowance
Nozzle Data (Size, Number, Rating, Facing)
TI and PI connections (Sizes, Number, Reference Details)
Design Temperature
ASME Code Stamping Requirements (Yes/No)
The bottom and the left margin of the form contains a standard
Saudi Aramco drawing title block and revision record.
15

EVALUATING CONTRACTOR-SPECIFIED DESIGN CONDITIONS FOR

TEMA-TYPE AND AIR-COOLED HEAT EXCHANGER COMPONENTS
SAES-E-001 specifies how to determine the heat exchanger
mechanical design conditions based on the operating conditions
that are specified on Forms 2714 and 2716 . The process
engineer always specifies the operating conditions and usually
sets the mechanical design conditions as well; however, the
mechanical engineer usually checks the design conditions as a
part of his review of the Contractor Design Package. Work Aid 1
provides a procedure that may be used to evaluate the
information that is contained in a Contractor Design Package, to
determine if the design conditions are specified correctly.
In most cases, the maximum operating pressure and
temperature can be assumed to be equal to the values that are
indicated in the process/performance section of Form 2714 or
Form 2716. However, the specified conditions may not be the
maximum operating conditions in some cases, such as when
the heat transfer surface area must be sized to transfer heat at
conditions that are lower than the maximum operating
conditions. For the purpose of this course, it will be assumed
that the operating conditions that are shown on Form 2714 and
Form 2716 are the maximum operating conditions. In actual
work, the maximum operating pressures and temperatures must
be confirmed by the process engineer in order to ensure that the
mechanical design of the heat exchanger is suitable for the
most extreme operating conditions.
Since heat exchangers transfer heat from one fluid to another,
design conditions must be specified for each fluid. Some heat
exchanger components are exposed to only one fluid, and other
components are exposed to both fluids. Therefore, some
components need only be designed for one set of design
conditions, while other components must be designed for both
sets of design conditions. From a practical standpoint, both sets
of design conditions must only be directly considered for shelland-tube heat exchangers.
16

TEMA-Type Shell-and-Tube Heat Exchangers

Figure 4 illustrates which design conditions are imposed on the
major components of a shell-and-tube heat exchanger, and
Table 1 summarizes the conditions that each major component
must be designed for. The following sections discuss the design
conditions for specific components.
Tube-Side
Design Conditions
;
;
;;
;
;
;
;;;;;
;; ;;
;
;
;
;;
;
;
;;
;
;
;
;;;;
;;;;
;;;;
;
;
;
;;;;
;
;
;
;;;;
;;
;;;
;;;;
;;
;;;;
Channel
Nozzle
Channel
Flange
;;
;;
Pass Partition
Plate
Shell
Tubes
;;;;;
;;;;;
Channel
Cover
Shell-Side
Design Conditions
Tubesheet
Flanges
Channel
Tubesheet
Shell-Side
Design Conditions
;;
;
;
;
;
Shell
Nozzle
Shell Cover
Floating Head
Cover
Tube-Side
Design Conditions
Tubesheet
Shell
Flanges
mex210.03 f03
Figure 4. Heat Exchanger Design Conditions
17

Components Designed for

Shell-Side Conditions

Tube-Side Conditions

Both Shell-Side and TubeSide Conditions
Shell
Channel
Tubes
Shell Cover
Channel Cover
Tubesheet(s)
Shell Flanges
Channel Flange
Tubesheet Flanges
Shell Nozzles
Channel Nozzles
Floating Head
Pass Partition Plate
Table 1. Design Conditions for Shell-and-Tube Heat Exchanger Components

Shells and Heads
The shell and shell cover must be designed for the shell-side
conditions and the channel and channel cover must be designed
for the tube-side conditions. These components are made of
cylindrical shells, conical shells, or formed heads, and they are
designed for the design pressure at the design temperature
using the ASME Code Section VIII. Design procedures that are
used for these components were discussed in MEX 202.
Nozzles
Shell-side nozzles are designed for the shell-side conditions and
tube-side nozzles are designed for the tube-side conditions. The
nozzles necks are cylindrical shells and are designed in
accordance with the ASME Code for their respective design
conditions. Because there are cut-outs in the shell due to the
nozzle penetration, nozzle reinforcement requirements must be
evaluated in accordance with the ASME Code.
Nozzles typically have standard flanges in order to permit
attachment to the connected pipe. These flanges are designed
in accordance with ASME/ANSI B16.5 for up to 600 mm (24 in.)
size and must meet other design standards for larger sizes. The
flange Class (e.g., Class 150, 300, or 600) is specified based on
the required design pressure and design temperature.
18

External forces and moments may be exerted on the nozzles by

piping that is attached to them, and the nozzles should be
designed for these loads in addition to the design pressure. If
the piping loads are high, they should be specified to the heat
exchanger manufacturer so that he can determine if additional
nozzle reinforcement is required.
All these aspects of nozzle design were discussed in
MEX 202.
Girth Flanges
Figure 4 shows that a typical shell-and-tube heat exchanger has
several girth flanges. On the rear or floating head end of the
exchanger, a flange may be used to bolt the shell cover to the
shell. This shell cover flange is designed for shell-side
conditions. On the front or stationary end of the exchanger, a
girth flange may be used to bolt a flat cover onto the channel.
This channel flange is designed for the tube-side conditions. A
girth flange may also be used to bolt the channel to the shell.
In many cases, the tubesheet at the stationary end of the
exchanger may be clamped between a pair of girth flanges. In
these clamped tubesheet designs, one of the girth flanges is
attached to the channel and the other girth flange is attached to
the shell. The shell-side flange at the stationary-end tubesheet
must be designed for the shell-side conditions, and the tubeside flange at the tubesheet must be designed for the tube-side
conditions. In addition, since both flanges are connected by the
same set of bolts, the flanges must be designed for a common
bolt load. This bolt load may be governed by either the shellside or tube-side flange design, whichever results in the larger
bolt load. The actual design of such flanges will be discussed in
more detail in a later section.
Girth flanges are normally of nonstandard sizes, and are
designed using procedures that are contained in the ASME
Code. These flange design procedures are discussed in a later
section of this module.
19

Tubesheets
Tubesheets are exposed to both the shell-side and the tubeside design conditions. In actual operation, the tubesheets are
normally exposed only to a differential pressure (i.e., the
difference between the tube-side pressure and the shell-side
pressure) and are at a temperature that is between the shellside and the tube-side temperatures. While the tubesheets
could be designed on this basis, tubesheets are major
components of the exchanger and are typically designed for the
more severe of either the shell-side or the tube-side conditions.
While conservative, this design approach is realistic inasmuch
as it is often possible for one side of the exchanger or the other
side to be exposed to its operating conditions while the other
side is not.
There are some services where it is impossible for only one side
of the exchanger to be at its operating conditions while the other
side is not (e.g., for a reactor feed-effluent exchanger where
both sides are automatically either in operation or not). In other
cases, it may be very expensive to design the tubesheet for the
worst design conditions. In these special situations, the
tubesheet may be designed for only the differential pressure
between the tube-side and the shell-side.
An additional factor is that hydrotest of the heat exchanger is
normally done on each side separately. Thus, one side will have
the full hydrotest pressure while the opposite side has no
pressure.
Tubesheets typically operate at a temperature that is between the
shell-side and the tube-side temperatures. The TEMA standard
allows tubesheets to be designed for the mean metal temperature
unless the owner specifies otherwise. If a mean temperature is
used, it should be based on heat transfer calculations that account
for the heat transfer coefficients and various modes of operation.
Except for fixed tubesheet heat exchangers, tubesheets are usually
designed for the higher of either the tube-side or the shell-side
temperatures unless it is impossible for the exchanger to be
exposed to the higher temperature (e.g., if a refractory lining is
installed on the tubesheet to reduce its metal temperature). In the
case of fixed tubesheet exchangers, it may not be practical to
design the fixed tubesheet if the design conditions are too
conservative. Therefore, the tubesheets of fixed tubesheet
exchangers are usually designed for a calculated mean
temperature.
20

Flat Covers
Flat covers are typically used on the channel side of TEMA
Type A and Type C exchangers and are designed for the tubeside pressure and temperature conditions. Covers for
exchangers that have internal pass partition plates must also be
designed to limit the deflection of the cover in order to minimize
leakage across the pass partition plate. Deflection limits are
specified in TEMA and are discussed in a later section.
Internal Components
Internal components of a heat exchanger may be subjected to
pressure from both sides or may not be subjected to any
significant pressure. In general, the design temperature of the
component is taken as the higher design temperature of the
fluids with which it is in contact. The TEMA standard also
permits internal components to be designed for a mean metal
temperature unless the owner specifies otherwise. In most
cases, internal components are designed for the more severe
set of conditions.
Floating Heads - The tube-side conditions impose an internal
pressure on the floating head, and the shell-side conditions

impose an external pressure on the floating head. Both sets of
conditions must be checked separately in order to determine
which one governs the design of the floating head and its
associated flange and backing ring. As with tubesheets, floating
heads are usually designed for the more severe of either the
shell-side or the tube-side conditions. Recall from MEX 202 that
the design of heads and cylinders for external pressure
conditions is done using a different procedure than is used for
internal pressure conditions. Therefore, the governing condition
for the head thickness may not necessarily be the higher
pressure side of the exchanger.
21

Tubes - Tubes of shell-and-tube heat exchangers are typically
designed independently for internal pressure at the tube-side

conditions and for external pressure at the shell-side conditions.
The tube design is governed by the set of conditions that
requires the larger tube thickness. The longitudinal stress due to
weight and pressure may govern the design in some cases;
however, it is usually more economical to reduce the baffle or
tube support spacing rather than to increase the tube wall
thickness.
In fixed tubesheet exchangers, consideration must also be given
to designing the tubes for forces that are due to the differential
temperature between the tubes and the shell. If the tube loads
are too high, normal practice is to use a shell expansion joint
rather than to increase the tube wall thickness. Tube vibration
may also be a consideration in the design of tubes. Tube
vibration is discussed in MEX 210.05.
Pass Partition Plates and Longitudinal Baffles Pass partition
plates are located in the channel and the floating heads of some
exchangers. Typically, these plates are designed for the
maximum normal pressure drop across the tube side. Some
exchanger configurations include shell-side longitudinal baffles,
and these baffles must be designed for the shell-side pressure
drop.
Nonpressure Containing Components include tie-rods,
spacers, impingement plates, baffles, and support plates. The

design of these components is typically based on minimum
sizes that are specified in TEMA based on nominal shell
diameter. Tube support plates that are thicker than the TEMA
minimum values may be required in some cases where there is
a large shell-side corrosion allowance or if flow pulsation or tube
vibration is a special design consideration.
22

Air-Cooled Heat Exchangers

As described in MEX 210.01, air-cooled heat exchangers are
composed of a tube bundle, one or more header boxes, a steel
frame, steel ductwork, and machinery for the fan. Several of
these primary components are illustrated in Figure 5. The basic
minimum thicknesses for many of the components are given in
the SAMSS or API standards, and the tubes and the header
boxes are designed for internal pressure in accordance with the
ASME Code. The design of the machinery and structural steel
parts is outside the scope of this course. The design conditions
that are used for the tubes, tube fins, tube bundle, tube
supports, and header boxes are briefly discussed below.
Figure 5. Typical Air-Cooled Heat Exchanger Tube Bundle Components
23

Tubes
The tubes of an air-cooled heat exchanger are typically
designed with respect to strength, based on the process-side
design pressure and design temperature. Design of the tubes
must also take into consideration the additional longitudinal
stress that is caused by the weight loads from the tubes, tube
fins, and tube contents. Note that it is usually more economical
to shorten the tube support spacing, rather than increase the
tube wall thickness in cases where excessive longitudinal stress
or tube sagging are a problem. The needed tube surface area of
the exchanger is usually determined based on the air-side
design temperature conditions.
Tube Fins
Several different designs are available that may be used to
attach fins to the tubes. The tube metal temperature typically
governs which fin attachment option is used for a specific heat
exchanger. The fin attachment design is typically selected
based on the maximum process-side design temperature,
because it is usually possible to stop the air flow while the
process fluid continues to flow.
Tube Bundles
The tube bundle must be designed for the process-side design
temperature in case the air flow is stopped. The bundle must be
designed for differential thermal expansion between it and the
supporting frame and structure. The tube bundle must be
designed to be rigid in order to permit handling it as a complete
assembly both in the shop and in the field. The tube bundle and
side frame assemblies must also be designed to withstand the
required wind loads and earthquake loads.
Tube Supports
The tubes are supported at intervals that are short enough to
prevent excessive sagging due to the imposed weight loads.
Excessive sagging could cause flow distribution problems, or
cause meshing or crushing of the fins. The fluid property
information, design temperature, and tube design details that
are specified on Form 2716 are used to help determine the
required tube support spacing.
24

Header Boxes
The header boxes are designed for internal pressure at the
process-side design conditions. The specific heat exchanger
service and design conditions may affect design details of the
header box. Header box design details are discussed later in
this module.
API-661 limits the loads that may be imposed by connected
piping on heat exchanger nozzles in order to avoid
overstressing the nozzles and the header boxes. The maximum
permitted nozzle loads are a function of nozzle diameter. The
header boxes must also be designed to transmit piping loads
from the nozzles to the exchanger-side frame and support
structure.
25

EVALUATING CONTRACTOR-SPECIFIED DIMENSIONS FOR SHELLAND-TUBE HEAT EXCHANGER COMPONENTS

A shell-and-tube heat exchanger is composed of many
components, such as cylindrical or conical shells, flat plates,
and formed heads. Although minimum thicknesses for these
components are given in 32-SAMSS-007, API-660, TEMA, or
the ASME Code, these components must normally be designed
and dimensioned for the specific heat exchanger design
requirements. The design of components such as cylindrical
shells and formed heads was covered in MEX 202 and will not
be discussed. Components that are unique to shell-and-tube
heat exchangers (e.g., girth flanges, flat [channel] covers,
internal floating heads, tubesheets, tubes, and pass partition
plates) will be discussed.
To evaluate the dimensions that a contractor or manufacturer
specifies for shell-and-tube heat exchanger components, the
Saudi Aramco engineer typically checks that all dimensions are:
Consistent on all drawings and in all specifications and

calculations that are made by the manufacturer and that are
included in the Contractor Design Package.
In accordance with the design and calculation requirements

that are specified in Form 2714, 32-SAMSS-007, API-660,
TEMA, and the ASME Code.
Work Aid 2 provides an overall procedure that may be used to

evaluate the dimensions that are specified for the major
components of shell-and-tube heat exchangers. The sections
that follow elaborate on several aspects of this procedure and
discuss several of the design requirements for specific heat
exchanger components.
General Dimensional Verification

The dimensions that are specified for heat exchanger
components must be checked to ensure that they are consistent
and that they comply with Saudi Aramco and industry
requirements. Fundamental and simple errors are often made
that are not related to design calculations.
26

Typical Errors
Many mistakes are made when copying dimensions from
calculation sheets to fabrication drawings or from one drawing
to another. Corrosion allowance is sometimes left out or may be
counted twice when component thicknesses are indicated on
the drawing. In some cases, details may not be consistent
between the overall heat exchanger assembly drawing and
other drawings that specify individual component details.
Another typical mistake occurs when a detail on one drawing is
revised, but other details in the Contractor Design Package are
not revised to be consistent with the change.
Compliance with Saudi
Aramco, TEMA, API,
and ASME
Requirements
While manufacturers are all familiar with TEMA, API-660, and
ASME Code requirements, the manufacturer may not be familiar
with Saudi Aramco's specific requirements. In some cases,
dimensional requirements or dimensional limits that are given on
Form 2714 or in 32-SAMSS-007 may be neglected. In other
cases, the manufacturer may misinterpret a Saudi Aramco
requirement. Therefore, several problems can usually be
identified if a review for compliance is made with respect to
specific Saudi Aramco requirements.
Use of Computer Programs

The required mechanical design calculations for heat exchanger
components are normally done using computer programs.
Therefore, the Saudi Aramco engineer will normally have to
check computer-generated calculations, in addition to checking
the fabrication exchanger drawings, in order to confirm that the
heat exchanger design is acceptable.
27

Verifying Computer
Programs
The required design calculations must be done in accordance
with the appropriate TEMA and ASME Code requirements. In
order to check a manufacturer's computer program, it is usually
sufficient to review a verification example problem that was
made for the program. If no verification problem is available,
another approach is to select a typical exchanger and
thoroughly check the calculations for the selected exchanger.
This check can be done by redoing the calculations by hand or
by using another, commercially-available computer program for
heat exchanger design that has already been independently
verified. Commercial programs that are widely used are usually
updated frequently and corrected quickly when errors are found.
All of the heat exchanger calculations that are used in this
module were made using the CODECALC computer program by
Coade, Inc. This program is available within Saudi Aramco. It
may be assumed that the CODECALC program has been
thoroughly tested and verified. All computer programs require
the same input, use the same TEMA or ASME Code equations,
and give similar output. The purpose of this course is not to
instruct participants in how to run a specific computer program,
but in how to evaluate whether the contractor or exchanger
manufacturer has done his job properly. Therefore, the Work
Aids were developed to facilitate the process of checking the
input and output of a typical computer program. However, the
terminology that is used in the input and output of the
CODECALC program is explained where necessary.
Checking Computer
Input Data
Checking for consistency between the computer program input
data and the information that is included in various parts of the
Contractor Design Package is tedious but is necessary. The
necessary input includes design conditions, some dimensional
information, material properties, and other Code design
information.
Some computer programs require that necessary design factors
be manually entered from tables or figures that are in the
standard or Code, whereas other programs have internal data
bases that contain the needed information. A small mistake in
28

the computer program input can result in completely incorrect

calculations.
Checking Computer
Output
Checking that the contractor or manufacturer has correctly
interpreted the computer program output is tedious, but this
checking is still necessary because errors can still be made at
this stage. Examples of errors that can be made at this stage
include overlooking corrosion allowances or specifying
information on the fabrication drawings that does not coincide
with the program output (e.g., an incorrect thickness).
Heat exchanger programs can also calculate the Maximum
Allowable Working Pressure (MAWP) of exchanger components
based on a specified component thickness and other as-built
dimensions. The basic approach that is used to solve for MAWP
was discussed in MEX 202. For heat exchangers, the MAWP is
determined by solving the appropriate TEMA or ASME Code
equations for pressure in terms of the as-built thickness and
other dimensions. The MAWP is then shown in the program
output. Knowing the MAWP is useful if it is required to rerate an
exchanger. Rerating a heat exchanger is discussed in MEX
210.05.
Heat Exchanger Components

This section will review the design requirements for the following
components of shell-and-tube heat exchangers and air-cooled
heat exchanger.
Girth flanges
Pass partition gaskets
Flat (channel) cover
Tubesheets
Internal floating heads
Tubes
Pass partition plates
Nonpressure containing parts
29

Girth Flanges
Girth flanges are custom-designed for most shell-and-tube heat
exchangers, although some manufacturers attempt to
standardize some aspect of their girth flange designs. All girth
flanges should be checked for compliance with the ASME Code,
Section VIII Div. 1, Appendix 2. The procedure is quite involved
and is best done by using a computer program. Work Aid 2
contains an overall procedure that may be used to check design
calculations that are provided by a contractor or manufacturer
for exchanger girth flanges. The following sections briefly
describe:
The steps in the overall ASME flange design procedure.
The parameters that affect flange design and in-service

performance.
The tubesheet girth flange design requirements for TEMA

Type A and Type B exchangers.
Overall ASME Flange Design Procedure The flange design
procedure consists of the following steps:
Determining bolting requirements.
Determining flange design loads and moments.
Determining stresses in two flange ring and flange hub.
The first main step in flange design is usually to determine the

number and size of bolts that are required for the flange. Bolting
requirements are determined by calculating the loads on the
bolts during both normal operation (i.e., based on the design
conditions), Wm1, and during the initial flange boltup (i.e., the
gasket seating conditions), Wm2. The bolt area that is required
for each of these loads is then calculated by dividing each bolt
load by the allowable stress of the bolts at design temperature
and room temperature, respectively. Either the operating case
or the gasket seating case may yield the minimum required bolt
area, Am. Inasmuch as bolts come in standard sizes, and
inasmuch as there are limitations on the spacing between bolts,
the actual bolt area, Ab, is usually greater than the maximum
required bolt area.
\The next step is to determine the design loads and moments on
the flange. These loads include the design bolt load on the
flange (W), the hydrostatic pressure loads that act on the flange
(HD and HT), and the gasket sealing force (HG). Because these
30

loads do not all act at the same location on the flange, effective
moment arms (hD, hT, and hG) are calculated based on the
locations of the bolts and gasket and on the flange geometry
(SeeFigure 6). The appropriate loads are then multiplied by the
effective lever arms in order to determine flange design
moments for the operating case and the gasket seating case.
31

Figure 6. Flange Loads and Moment Arms
Finally, the stresses in the flange ring and the flange hub are
calculated using stress factors that are in the ASME Code (which
are based on the flange geometry), the applied moments, and the
flange geometry. These stresses are calculated for both the
operating case and the gasket seating case and are then compared
to the appropriate Code allowable stress. If the flange is properly
designed, all of the flange stresses will be lower than the
appropriate allowable stresses. It may be necessary to increase the
flange thickness, change the hub dimensions, or make other
changes to the flange design parameters in order to keep the
flange stresses within their allowable limits. The computer
programs that are used for flange design use iterative calculation
procedures in order to optimize flange design.
32

Parameters That Affect

Flange Design and InService Performance The following additionally significant parameters are discussed
below:
ASME Code m and y parameters.
Specified widths for peripheral ring gaskets and pass

partition gaskets.
Flange facing and nubbin width w.
Bolt size, number, and spacing.
The gasket factor, m, is a parameter that determines the

amount of force that is required to keep the gasketed joint tight.
The minimum design seating stress, y, is a parameter that
determines how much gasket stress is required to initially seat
or deform the gasket. Both of these parameters are used in the
flange design calculations.
The ASME Code specifies m and y based on gasket type in
Table 2-5.1 (excerpted in Table 2). Higher values of m and y
typically indicate that a gasket is harder to seal or seat. While
this is a consideration in gasket selection, gasket type and
gasket material are usually selected based on historical service
experience and corrosion resistance. For example, both TEMA
and 32-SAMSS-007 specify gasket requirements based on
service conditions as discussed in MEX 210.02. In addition, m
and y are only two of many parameters in the flange design
calculations.
33

Gasket Material
Gasket
Factor
m
Min.
Design
Seating
Stress
y, psi
Facing Sketch and

Column in Table
2-5.2
Flat metal, jacketed asbestos filled:

Soft aluminum
3.25
5 500
Soft copper or brass
3.50
6 500
Iron or soft steel
3.75
7 600
Monel
3.50
8 000
4-6% chrome
3.75
9 000
Stainless steels and nickel-base alloys
3.75
9 000
Soft aluminum
4.00
8 800
Soft copper or brass
4.75
13 000
Iron or soft steel
5.50
18 000
Monel or 4-6% chrome
6.00
21 800
Stainless steels and nickel-base alloys
6.50
26 000
(1a), (1b), (1c), (1d);

(2); Column II
Solid flat metal:
(1a), (1b), (1c), (1d);

(2), (3), (4), (5);
Column I
Table 2. ASME Code m and y Factors

TEMA specifies a minimum required width for the peripheral ring
gaskets at external joints and for pass partition gaskets.
Although TEMA exchangers operate over a very wide range of
service conditions, these minimum gasket widths have been
used for many years and are typically specified.
The gasket widths that are referred to in TEMA are actual
minimum widths. In addition to the actual minimum width, N, two
other gasket widths are referred to in the ASME Code: the basic
seating width, bo, and the effective seating width, b. The
effective seating width is a function of the basic seating width,
and the basic seating width is a function of the actual width and
the type of flange face. See Table 2-5.2 in the ASME Code
(Excerpted in Table 3). In general, wider gaskets provide better
sealing, but a wider gasket also requires more bolting to seat
and seal the gasket. The required flange thickness increases as
the amount of bolting increases.
34

Table 3. ASME Code Gasket Widths
35

Effective Gasket Seating Width, b
b = bo when bo 1/ 4 in.; b = bo when bo > 1/ 4 in.

The effective seating width, b, discussed above is also a
function of the flange facing type and the nubbin width, w, for
flat metal gaskets. Table 2-5.1 (excerpted in Table 2) in the
Code indicates which facing sketch is applicable for a given
gasket type and material, and Table 2-5.2 (Table 3) shows the
equations for determining b based on w, N, and the type of
flange facing. Note that b is the factor used in the subsequent
Code equations to determine the load required for sealing the
gasket during operation, WM1, and the load required for seating
the gasket initially, WM2. Once a gasket type, material, width,
and facing are selected, the required bolting area can be
determined.
The bolt size, number and spacing that are used to clamp the
flanges together are interrelated parameters that affect the
overall design of the flanges. Bolting is typically selected per
TEMA Table D-5 (See Table 4), with the added restrictions in
TEMA Par. R-11.1 that the minimum bolt size is 19 mm (3/4 in.).
Bolt
Size
Threads
Nut Dimensions
Bolt
Spacing
Radial
Distance
Radial
Distance
Edge
Distance
Wrench
Diameter
Bolt
Size
dB
No. of
Threads
Root
Area,
in.2
Across
Flats
Across
Corners
Rh
Rr
dB
1/2
13
0.126
7/8
0.969
1 1/4
13/16
5/8
5/8
1 1/2
1/2
5/8
11
0.202
1 1/16
1.175
1 1/2
15/16
3/4
3/4
1 3/4
5/8
3/4
10
0.302
1 1/4
1.383
1 3/4
1 1/8
13/16
13/16
2 1/16
3/4
7/8
0.419
1 7/16
1.589
2 1/16
1 1/4
15/16
15/16
2 3/8
7/8
0.551
1 5/8
1.796
2 1/4
1 3/8
1 1/16
1 1/16
2 5/8
Table 4. Bolting Data
TEMA Table D-5 indicates the number of threads per inch and
the tensile stress area at the root of the threads. The number of
bolts multiplied by the bolt root area of a single bolt must be
greater than the minimum required bolt area, Am. The bolts must
be far enough away from the shell or hub of the flange and be
far enough apart circumferentially so that there is adequate
clearance to permit access for a wrench to tighten and loosen
36

the bolts. TEMA Table D-5 also indicates minimum dimensions

to ensure adequate access for standard wrenches.
While it may appear that maintaining these minimum
dimensions can easily be achieved if a few large bolts are used,
the bolts should also be spaced as close together as practical
for several reasons.
Having fewer bolts increases the bolt load moment arms.

Larger moment arms increase the bending moments for
which the flange must be designed and thus increase the
required flange thickness.
TEMA also requires in Par. 11.2 that the flange design

moment be increased if the bolts are widely spaced. Here
again, this results in a thicker flange.
Excessive bolt spacing could make the flange more prone to

leakage since the portions of the gasket that are located
between the bolts might not be compressed sufficiently by
the bolts to maintain a tight seal.
A final TEMA requirement in Par. 11.24 is that the total number

of bolts be an integral multiple of four.
A manufacturer's computer program will typically design the
bolting and the flange subject to all the above conditions. The
responsibilities of the Saudi Aramco engineer would then be to
check the computer program input, to determine that the
appropriate TEMA and ASME Code factors and allowable
stresses were used, and to confirm that the computer program
output has been correctly interpreted and incorporated into the
design.
Tubesheet Girth Flange Design Requirements for TEMA Type A
and Type B Exchangers TEMA Type A and Type B
exchangers have the fixed tubesheet compressed between two

girth flanges. These girth flanges require special design
consideration. Each flange must be designed for the appropriate
design conditions on each side of the tubesheet, and for the
common bolt load that is imposed on each flange. The common
bolt load may be based on the operating or gasket seating
loads, and these loads may be different on each side of the
tubesheet.
The proper design of these girth flanges typically requires that at
least three separate flange calculations be made.
37

The first calculation is done to design the flange on the

channel side of the tubesheet for the tube-side design
conditions.
The second calculation is done to design the flange on the

shell-side for the shell-side design conditions.
After reviewing the first two calculations, one flange will

typically be found to require more bolting than the other. In
this case, the flange that requires less bolting must be
redesigned for the larger amount of bolting.
Sample Problem 1 covers how to evaluate the design of this

type of tubesheet girth flange.
Sample Problem 1: Evaluate Contractor-Specified Dimensions
for the Mating Girth Flanges at the Tubesheet of a TEMA-Type
AET Heat Exchanger You must evaluate the contractor-
specified dimensions for the mating girth flanges at the fixed

tubesheet end of a Type AET heat exchanger. All the
information that is needed to solve this problem is in Contractor
Design Package 4 in Course Handout 4. This information
includes the heat exchanger specification sheet, flange
dimensions, and the CODECALC computer program output for
the shell girth flange and the mating channel girth flange. Part 2
of Work Aid 2 is used to solve this problem.
The first step in evaluating a design is to compare the common
dimensions between the two mating flanges and the number
and size of bolts that are shown in the detail drawings for the
flanges. Flange dimensions are also checked for consistency
between the drawing details and the computer program input
and output.
Note that additional design information is included in the
computer program input, such as ASME Code gasket factors
and the allowable stresses for the flange material and the
bolting. This additional design information must be checked
against the ASME Code requirements. All of the computer input
appears to be correct in this problem.
The next step is to evaluate the overall design. The tube side
and shell side of the exchanger have different design conditions;
therefore, calculations were first made for the shell flange for the
shell-side conditions, and then made for the channel flange for
the tube-side conditions. By comparing the computer output for
the required bolt area, Am, between the two computer runs, it is
seen that the shell flange governs the bolting requirement for
38

these mating flanges because it requires a larger value for Am.

Therefore, a second analysis was made for the channel flange
to account for the bolt load that is required by the shell flange.
In reviewing the input for the second channel flange design
case, it can be seen that the appropriate values for the
operating bolt load, gasket seating bolt load, and the flange
design bolt load have been entered for the mating flange bolt
loads. These bolt loads were taken from the previous
calculations that were done for the shell flange.
Because the computer program input and output have been
checked and the program has been verified, it is concluded that
the dimensions specified by the manufacturer for the girth
flanges are correct inasmuch as the dimensions are in
accordance with the computer program output.
Pass Partition Gaskets
Most exchangers have at least two tube-side passes. A pass

partition gasket is used in the channel for these exchangers in
order to provide internal sealing between the tube passes at the
pass partition plate (see Figure 7). A pass partition gasket is
also required at the floating head end for exchangers that have
more than two tube-side passes. The pass partition gasket has
more surface area that must be compressed when compared to
a conventional gasket that only has material at its periphery.
Therefore, the flange bolting must be sufficient to compress the
gasket enough at both its periphery and at the pass partition
plate. If the exchanger has more than two tube passes, the pass
partition gasket has even more surface area that must be
compressed.
39

Figure 7. Pass Partition Gasket
Although not specifically referred to in the ASME Code

calculations or in TEMA, girth flanges should be designed to
provide additional bolting in order to adequately compress pass
partition gaskets and achieve a tight seal. Properly designed
bolting should be able to compress the gasket at both its
periphery and at the pass partition.
Bolting design can be handled in several ways. In the
CODECALC program, the length of the pass partition gasket
may be entered as a separate parameter. If the width of the
pass partition gasket (Npp) differs from the width of the
peripheral gasket (N), the length that is input (Lpp) is adjusted as
follows:
Npp
Lpp = (Gasket Inside Diameter)
N
The bolt area that is required is then increased to account for

the additional gasket area.
Flat (Channel) Cover
Flat covers are used on the channels of TEMA Type A and Type
C exchangers in order to close the end of the channel (Refer to
Figure 8).
40

Figure 8. Flat (Channel) Cover
41

The ASME Code design procedure for flat covers is specified in

Par. UG-34 and is based on determining the minimum cover
thickness that is required to limit the stress in the cover plate to
the material allowable stress. In the ASME procedure, the
thickness of the flat cover, t, is determined as a function of the
pressure, P, the cover plate allowable stress, S, the flange
design bolt load, W, the diameter of the gasket, d, and the
gasket moment arm, hG.
In addition, TEMA also restricts the maximum deflection that
can occur at the center of the cover if the exchanger has pass
partition baffles. The limit on cover deflection is specified in
order to minimize leakage that can occur across the pass
partition baffle. TEMA Par. RCB-9.21 limits the maximum cover
deflection to the following limits:
0.76 mm (0.03 in.) for nominal cover diameters through 600

mm (24 in.).
0.125% of the nominal cover diameter for larger sizes.
An equation for calculating the deflection at the center of the

cover is provided in TEMA Par. RCB-9.21. Computer programs
are often used to make the calculations for a flat channel cover
even though the calculations are not highly complicated. The
cover deflection limit, rather than the ASME Code allowable
stress, will generally govern the channel cover thickness for
heat exchangers that have a pass partition plate.
The procedure that is in Work Aid 2 for girth flanges also may
be used to check design calculations that are provided by a
contractor or manufacturer for exchanger flat (channel) covers.
Tubesheets
Different types of tubesheets may be used in heat exchangers.

The most frequently used and simplest types of tubesheets to
design are those associated with TEMA Type S, Type T, and Utube type exchangers. The procedures that are most often used
for the design of tubesheets in these exchangers is in
accordance with TEMA Paras. RCB-7-1 through RCB-7-13.
42

The ASME Code also has a tubesheet design procedure in

nonmandatory Appendix AA. The ASME procedure is applicable
for U-tube type and fixed tubesheet types of exchangers. Note
that the ASME Code procedure is more complicated than the
TEMA procedure, and that the TEMA procedure is used to
design most heat exchanger tubesheets. Work Aid 2 covers
only the TEMA procedure. The following paragraphs discuss
several considerations for tubesheet design.
- TEMA Par. RCB-7.12 requires that the
tubesheet thickness be measured at the bottom of the pass
partition baffle groove or the shell-side longitudinal baffle
groove, if so equipped. This is the thinnest portion of the
tubesheet, as illustrated in Figure 9.
Tubesheet Thickness
Figure 9. Tubesheet Thickness
43

The effective thickness must also exclude any corrosion

allowance that is required that is in excess of the partition
groove depths. The effective thickness should be exclusive of
any applied facings, but the thickness of cladding or weld
overlay that is in excess of the specified corrosion allowance
may be considered as effective in accordance with TEMA and
ASME procedures.
Basic Minimum Thicknesses TEMA specifies basic minimum
thicknesses for the tubesheet based on overall fabrication and

handling requirements when the tubes are expanded into the
tubesheet. Par. RCB-7.13 requires that the tubesheet thickness,
exclusive of corrosion allowance, should be at least equal to the
nominal tube diameter but that the tubesheet thickness
including corrosion allowance cannot be less than 19 mm
(3/4 in.).
Effective Thickness The required effective thickness of the
tubesheet is determined based on limiting the bending and

shear stresses in the tubesheet to the appropriate ASME Code
allowable stress. The appropriate TEMA paragraph references
are as follows:
Par. RCB-7.132 determines tubesheet thickness based on

limiting the bending stress in the center of the tubesheet.
Par. RCB-7.133 determines the tubesheet thickness based

on limiting the shear stress in the tubesheet at the periphery
of the tube bundle.
Some tubesheets may be extended as a flange, as in a Ttype floating end tubesheet. Par. RCB-7.134 determines the
thickness of the flanged extension portion of the tubesheet.
Fixed Tubesheet Exchangers A significant design issue in fixed

tubesheet type exchangers is differential thermal expansion
between the shell and the tubes. Fixed tubesheet exchangers
are exchangers where both the front (i.e., channel) end
tubesheet and the rear (i.e., shell) end tubesheet on the
exchanger are rigidly attached to the shell. These exchangers,
designated as L-, M-, or N-types, are much more complicated to
design than S-, T-, or U- type exchangers because the tubes
and shell interact with the tubesheets.
44

Excessively high differential temperatures between the shell

side and tube side of the exchanger can result in the following:
High thermal stresses in the tubesheet or shell that can and

cause a fatigue failure.
High longitudinal loads in the tubes that could buckle the

tubes and/or cause leakage at the tube-to-tubesheet joints.
Because of these concerns, some fixed tubesheet exchangers

may be equipped with an expansion joint in the shell. The
expansion joint permits differential thermal expansion between
the shell side and the tube side without causing excessive loads
or stresses. An expansion joint is normally necessary if the
temperature differential between the tube wall temperature of
any one tube pass and the average shell side temperature
exceeds approximately 28C (50F). However, when the shell
and tube materials have different thermal expansion
coefficients, a stress analysis is required even when the
temperature differential is less than 28C (50F).
Fixed tubesheet exchangers are usually designed using a
computer program that determines the interactions between the
tubes, the shell, and the tubesheet. These programs typically
make the calculations in accordance with TEMA Par. RCB-7.16
and with Nonmandatory Appendix AA of the ASME Code.
Tubesheets that have a nonuniform thickness, or that
incorporate flexible knuckles at their periphery, may be used on
some exchangers. These tubesheets are considered as special
cases in TEMA Par. RCB-7.3 and should be designed in
accordance with Div. 1 or Div. 2 of the ASME Code.
for the Floating End Tubesheet of a TEMA-Type AET Heat
Exchanger You must evaluate the contractor-specified
dimensions for the floating end tubesheet of a Type AET

exchanger. All the information that is needed to solve this
problem is in Contractor Design Package 4 in Course
Handout 4. This information includes the heat exchanger
specification sheet, dimensions, and the CODECALC computer
program output for the floating end tubesheet. Part 3 of Work
Aid 2 is used to solve this problem.
45

The first step in evaluating the design is to compare the

dimensions that are specified in the drawing of the tubesheet to
the computer program input. This comparison includes items
such as the facing ID, tubesheet OD, and bolt circle diameter.
Additional design information that is included in the computer
program input, such as the gasket m and y factors and the
tubesheet allowable stress, is also checked with the ASME
Code. All of the computer input appears to be correct in this
problem.
Inasmuch as the computer program input has been checked
and the program has been verified, it is concluded that the
thickness specified for the floating end tubesheet is correct
because the CODECALC output shows no overstress, and the
dimensions that are shown in the tubesheet drawing coincide
with the program output.
Internal Floating Heads
Internal floating heads are used on TEMA-Type AES and Type

AET exchangers. The S-type floating head requires a split
backing ring to clamp the floating head to the tubesheet. The Ttype floating head is bolted directly to the tubesheet. These
head types are illustrated in Figure 10. The required thicknesses
of the flange ring and of the dished head for both types of
floating heads may be determined using Appendix 1-6 of the
ASME Code.
Figure 10. Types of Floating Heads

46

If the floating head is subjected to a high external (i.e., shell

side) pressure, the head must also be checked for buckling in
accordance with the ASME Code Section UG-33.
The Appendix 1-6 method is relatively simple and can be done
on a calculator, but computer programs are normally used to
design floating heads. Although acceptable to the ASME Code,
this method is approximate in that it does not consider the
continuity between the flange ring and the dished head. The
ASME Code indicates that a more exact method of analysis
which considers the continuity between the flange ring and the
head may be used if it meets the requirements of Section U-2 of
the Code. A procedure that was published by Soehren in ASME
paper ASME 57-A-7-47, The Design of Floating Heads for Heat
Exchangers, is one such method that is acceptable to the Code.
In many cases the Soehren method yields a thinner, more
economical flange ring and floating head design than does the
Appendix 1-6 method. However, the Soehren method is more
complicated, requires the solution of simultaneous equations,
and is best calculated using a computer program.
47


for Floating Head Cover of a TEMA-Type AET Heat Exchanger
You must evaluate the contractor-specified dimensions for the

floating head of a Type AET exchanger. All the information that
is needed to solve this problem is in Contractor Design Package
4 in Course Handout 4. This information includes the heat
exchanger specification sheet, the dimensions of the floating
head, and the CODECALC computer program output for the
floating head. Part 4 of Work Aid 2 may be used to solve this
problem.
The first step in evaluating the design is to compare the
dimensions on the tubesheet and the floating head, such as
facing ID, OD, and bolt circle diameter. Dimensions are also
checked for consistency between the dimensions that are
shown in the detail drawings and the dimensions in the
computer program input. Additional design information is
included in the computer program input, such as the gasket m
and y factors and the allowable stresses for the ring and the
dished head materials. This additional information should be
checked against the ASME Code. All of the computer input
appears to be correct in this problem.
Since the computer program input and output have been
checked and the program has been verified, it is concluded that
the specified dimensions for the floating head are correct
because the dimensions shown on the drawing are in
accordance with the computer program output.
Tubes
The tubes in TEMA P-, U-, S-, T-, and W-types of exchangers
are typically designed in accordance with the ASME Code Par.
UG 31. Par. UG 31 references Par. UG 27 for internal pressure
and Par. UG 28 for external pressure. TEMA Par. 7.2 provides
requirements for determining the axial tensile and compressive
loads in the tubes for TEMA L-, M-, and N-type fixed tubesheet
exchangers.
Wall Thickness and Corrosion Allowance 32-SAMSS-007
requires tubes to be 19 mm (3/4 in.) outside diameter with

minimum thicknesses as shown in Table 5.
48

Tube Material
Minimum Required Thickness, mm (in.)
Carbon or Alloy Steel
14 BWG [2.1 mm (0.083 in.)]
Nonferrous Material
16 BWG [1.65 mm (0.065 in.)]

Table 5. Minimum Required Tube Thickness
Although tubes are also subject to corrosion, corrosion

allowances are not explicitly applied to tubes per TEMA Par.
RCB 1.517. The tube thickness that is required for internal or
external pressure is small, and the difference between the
minimum supplied wall thickness of the tube and the minimum
required thickness is available for corrosion allowance. Tubes
are also considered to be replaceable parts, and therefore do
not need as large a corrosion allowance as other exchanger
components. Consideration should be given to using a thicker
tube gage or using a higher alloy tube material in services
where high corrosion rates are expected where the design
conditions require an unusually large tube wall thickness.
Pass Partition Plates
The required thickness of a pass partition plate is typically

determined in accordance with TEMA Par. RCB-9.132. The
thickness of the plate is a function of the dimensions of the
plate, a and b, the pressure drop across the plate, q, the ASME
Code allowable stress for the plate material, S, and a factor that
is based on the conditions of the plate edges, B (see Figure 11).
Figure 11. Pass Partition Plate

49

Note that pass partition plates do not require a corrosion

allowance per TEMA Par. RCB-1.518. If a corrosion allowance
is desired, it should be applied to both sides of the pass partition
plate because both sides are exposed to the process fluid.
Nonpressure
Containing
Components
Nonpressure containing components include tie-rods, spacers,

impingement plates, baffles, and support plates. These
components are typically supplied with the minimum
thicknesses that are specified in TEMA Paras. RCB-4.4 through
4.7, based on the nominal shell diameter.
API-660 requires that the thickness of transverse baffles and
support plates not be less than the shell-side corrosion
allowance and that the thickness of impingement baffles should
not be less than 6.5 mm (1/4 in.). Thicker tube support plates
may be required in some cases, per RCB-4.43, for services that
are prone to flow pulsation or tube vibration. Nonpressure
containing parts also do not require a corrosion allowance per
TEMA RCB-1.516. If a corrosion allowance or a more robust
design is required for a particular application, this requirement
should be specifically stated in the purchase order.
50

EVALUATING CONTRACTOR-SPECIFIED DESIGNS FOR AIR-COOLED

HEAT EXCHANGER TUBE BUNDLES AND HEADERS
The general approach that is used to evaluate contractorspecified designs for air-cooled heat exchanger tube bundles
and headers is the same as is used for shell-and-tube heat
exchangers. Dimensional consistency must be verified, and all
calculations and design procedures must be done in accordance
with the applicable Saudi Aramco and industry engineering
documents. These engineering documents include 32-SAMSS011, API-661, and the ASME Code.
Work Aid 3 provides an overall procedure that may be used to
evaluate the designs that are specified for air-cooled heat
exchanger tube bundles and headers. The sections that follow
elaborate on several aspects of this procedure and discuss
several of the design requirements.
Tube Bundle Design Requirements

Tube bundle design requirements are specified in Section 5 of
API-661 and in 32-SAMSS-011. As previously noted, the
sections and paragraph numbers in the SAMSS correspond to
the same locations in API-661.
Overall Bundle Design
Requirements
The tube bundle should be designed to be rigid so that it may be

handled as a complete assembly without distorting and being
damaged. The tube bundle grows in both length and width due
to thermal expansion of the metal when the exchanger is in
operation. Provision must be made in the design to permit the
thermal expansion of the bundle because restrained thermal
expansion could cause excessive stresses in the bundle that
might eventually result in a failure. 32-SAMSS-011, Par. 6.1.1.4,
requires that one header (usually the return header) be free to
move due to thermal expansion and that the bundle and the
structural mounting must have Teflon slide plates. Teflon has a
much lower friction coefficient than steel, and its use permits the
bundle to slide more easily.
51

Tube Design
The tubes are typically designed in accordance with the ASME

Code Par. UG 31. Par. UG 31 references Par. UG 27 for
internal pressure design and Par. UG 28 for external pressure
design. The tubes must also be designed for the combination of
the longitudinal stress due to internal pressure and bending
stress due to the tube weight. It is usually more economical to
change tube support spacing rather than to increase tube wall
thickness in cases where longitudinal overstress or sagging are
a problem.
Tube Diameter Wall Thickness, and Corrosion Allowance
API-661 recommends a minimum prime tube diameter of

25.4 mm (1 in.) in order to provide basic mechanical integrity to
the bundle. API-661 specifies minimum required nominal tube
wall thicknesses in order to provide basic mechanical strength,
corrosion allowance, and for standardization purposes. These
minimum thicknesses are summarized in Work Aid 3.
Note that the required tube thickness varies with the tube
material. This variation is due to differences in both the
corrosion resistance and the strength of the different tube
materials. As with shell-and-tube heat exchangers, corrosion
allowances are not explicitly applied to the tubes of air-cooled
heat exchangers because the thickness that is required for
pressure is small, and the tubes are considered to be
replaceable parts.
Selection of Tube Fins The tubes of air-cooled heat
exchangers normally have external fins in order to increase their

external heat transfer area. API-661 describes the various types
of tube fins that are available. 32-SAMSS-011 specifies
temperature limits and restrictions on the use of the various fin
types and attachment methods based on Saudi Aramco
experience. These limits and restrictions are summarized in
Work Aid 3.
52

Tube Support Design
The tubes are supported in the bundle in order to prevent

sagging of the tubes and meshing of the fins. Meshing of the
fins limits their effectiveness from a heat transfer standpoint and
could also result in mechanical damage to the tubes. API-661
specifies a maximum center-to-center distance between tube
supports in order to minimize the possibility that these problems
will occur. API-661 requires that structural hold-downs be
provided at each tube support in order to prevent the tubes from
lifting due to high winds or abnormal flow conditions.
API-661 requires that tube spacers be designed so that they do
not rely on the outer periphery of the fin for bearing in order to
not damage the fins. The spacers must also prevent the fins
from meshing together.
Header Design Requirements

Header design requirements are specified in 32-SAMSS-011,
API-661, and the ASME Code. These requirements consist of
design details for the type of header and its individual
components and procedures to calculate the required wall
thicknesses of the flat plates that are used to fabricate the
header.
Basic Design
Requirements
API-661 and 32-SAMSS-011 cover basic design requirements

for the design of headers. API-661 requires that, if the
temperature differential between any adjacent tube passes is
greater than 200F (111C), split headers, U-tubes, or other
means must be used to accommodate the differential thermal
expansion that will occur between the tube passes. This
accommodation is required in order to avoid excessive stress in
the tubes that could cause the tubes to fail and to avoid
excessive forces at the tube-to-tubesheet joints that could result
in leakage.
53

API-661 specifies basic minimum thicknesses for header

components based on their material, as summarized in
Work Aid 3. Note that these thicknesses already include a
nominal corrosion allowance of 3.2 mm (1/8 in.) for carbon and
low-alloy steel components. SAMSS-011 increases the required
thickness of the tubesheet beyond what is required by API-661.
These basic minimum thickness requirements are specified in
order to ensure basic strength and rigidity of the header box
structure, to accommodate typical tube-to-tubesheet and plugto-plug sheet design details, and to better resist the loads that
are applied by the connected piping system.
Header Type
32-SAMSS-011 requires that plug-type headers be used for

process-type coolers and that removable cover plate-type
headers be used for lube oil and seal oil coolers below
1 725 kPa (250 psig). Plug-type headers are used for process
applications and for the higher pressure oil cooler applications
because plug-type headers are less prone to leakage and are
preferred for more severe process applications.
Plug-Type Header -
Requirements for plug-type headers are

specified in API-661. The tube plug holes are specified to be
slightly larger than the tube diameter in order to provide
sufficient clearance to enter the inside of the tube with
inspection or cleaning tools.
API-661 specifies design requirements for removable cover
plate-type and removable bonnet-type headers. An important
consideration in the design of the flat cover or bonnet cover of
these header types is the spacing of the bolts that attach the
cover or bonnet to the header. If the bolts are spaced too far
apart, insufficient compressive load may be exerted on the
portion of the gasket that is between the bolts. Insufficient
gasket compression will make the cover prone to leakage. API661 provides an equation to determine the maximum permitted
bolt spacing. Because the bolts must be tightened with a
wrench, the bolts must also be spaced a minimum distance
apart in order to provide sufficient space for the wrench. API661 also specifies minimum bolt spacing requirements in
Table 1.
Removable Cover Plate-Type and Removable Bonnet-Type Headers
54

Gasket Requirements
The gasket surface of the tubesheet plug hole must be spotfaced in order to provide a smooth and confined seating surface
for the gasket. Gaskets that are used for tube plugs should be
either the solid metal or double-metal-jacketed type and be of
the same material classification as the plug. The use of these
gasket types ensures that the gasket is of relatively strong
construction and will have the same corrosion resistance as the
plug.
Gaskets that are used for flat covers and bonnets must also be
the double-jacketed, non-asbestos filled type, except that
synthetic fiber gaskets can be used in water, lube oil, and seal
oil service if the pressure does not exceed 2 100 kPa
(300 psig) and a parting agent is used on both sides of the
gasket. The minimum width of cover plate gaskets must be
9 mm (3/8 in.) in order to provide enough sealing surface area,
and gaskets must be of one-piece construction.
Nozzles and Other
Connections
API-661 specifies flange and fabrication requirements for

nozzles and other connections. 32-SAMSS-011 specifies
additional requirements that relate to nozzle strength, type of
connection, material selection, and fabrication details.
Maximum Allowable
Moments and Forces for
Headers and Nozzles
API-661 specifies maximum allowable forces and moments that

may be imposed on nozzles by the attached piping. Each nozzle
must be designed by the manufacturer to withstand a certain
amount of force and moment that generally increases with
nozzle size.
Since more than one nozzle is usually attached to a header, the
manufacturer must also design the header itself to withstand a
certain amount of total load from all the nozzles. If there is more
than one bundle per heat exchanger bay, the total of all nozzle
loads should not exceed three times the loading for one header.
The piping designer uses these permissible loads as additional
design criteria when he is designing the associated piping
systems. The manufacturer must ensure that the nozzle is not
overstressed when these permitted loads are applied.
55

Note that neither API-661 nor the ASME Code specifies how the
manufacturer must design the nozzles and headers for these
loads. These load limits were set by a consensus agreement
between the manufacturers and the users, and these limits have
historically proven to be acceptable. Therefore, the use of
standard nozzle and header design details is usually considered
to be sufficient.
ASME Code
Requirements
Tubesheets, plug sheets, and covers must also be designed in

accordance with the ASME Code Section VIII, Div. 1,
Par. UG-34 and Appendix 13. The rules of Par. UG-34 can be
applied to the design of the flat rectangular plates that make up
the header box, a bonnet-type cover, and a removable flat
cover. The equations in UG-34 are explicit and can be used to
calculate the component thicknesses directly based on overall
dimensions, design pressure, and allowable stress.
Design of Rectangular Header Boxes Appendix 13 of the
ASME Code applies to the design of rectangular vessels in

general. This Appendix specifically treats the design of
tubesheets, plug sheets, and the top, bottom, and end plates of
the rectangular header boxes or bonnet covers of air-cooled
heat exchangers. The design procedures that are in Appendix
13 usually yield a thinner, more economical design than would
result from using the UG-34 procedures; however, the equations
are not explicit (i.e., the equations cannot be directly solved for
the thickness of a single component in terms of other
quantities).
Appendix 13 treats the header box as a complete structure, and
the internal pressure load causes membrane stresses and
bending stresses in each of the plates that form the box (i.e., the
tubesheet, plug sheet, end plates, top and bottom plates, [see
Figure 12]). The bending stresses in the plates are a function of
the moment distribution factors that are in turn a function of the
thickness and the dimensions of all of the plates that make up
the box. This is a relatively complicated design procedure to
apply.
56

Figure 12. Typical Header Box Details
The design procedure in Appendix 13 also requires that the

stiffness and stresses in the tubesheet and plug sheet be
adjusted to account for the tube holes and plug holes. These
holes weaken the tubesheet and plug sheet. A ligament efficiency
is used to adjust the stiffness and stresses that are calculated,
and the ligament efficiency is based on the tube hole or plug hole
dimensions and the pitch between the holes. (See Figure 13).
p d
Ligament Efficiency =
p
Figure 13. Ligament Efficiency in Tubesheet or Plug Sheet
57

Computer Design of
Header Boxes
Whereas the required thicknesses of header box components

can be readily checked once a design has been developed, a
trial-and-error method must be used for the initial design. In the
trial-and-error method, an initial estimate of the component
thicknesses is made based on assuming that the end of each
side of the box is rigidly supported. The thickness of the plates
is then incremented until all of the components that make up the
box are below the allowable stress. The design of such
components is therefore easily programmed into a computer.
Sample Problem 4: Evaluate Contractor-Specified
Dimensions for the Inlet/Outlet Header Box of an
Air-Cooled Heat Exchanger
You must evaluate the contractor-specified dimensions for the

inlet/outlet header box of an air-cooled heat exchanger. All the
information that is needed to solve this problem is in Contractor Design
Package 5 in Course Handout 4. This information includes the
specification sheet for the air-cooled heat exchanger, the dimensions
of the inlet/outlet header box, and the CODECALC computer program
output. Work Aid 3 is used to solve this problem.
The first step in evaluating the manufacturer's design is to compare the
dimensions that are specified in the drawings of the inlet/outlet header
with the computer program input. These dimensions include the length,
width, and depth of the header box, the component thicknesses, and
the tube hole and plug hole dimensions. Additional design information
that may be required, such as the allowable stress, should also be
verified against the ASME Code. All of the computer input appears to
be correct in this example.
Inasmuch as the computer program input has been checked and the
program has been verified, it is concluded that the dimensions
specified by the manufacturer for the header box plates are correct
based on stress analysis considerations because the CODECALC
output shows that the header box components are not overstressed.
However, note that the 0.375 in. thickness specified for the stay plate
is less than the 0.5 in. minimum thickness that is required by
API-661. Therefore, the stay plate thickness must be increased to
0.5 in. Because the stresses are acceptable and the component
dimensions are consistent between the program and the detailed
drawings, the header box design is acceptable once the stay plate
thickness is increased.
58

COMPLETING A SAFETY INSTRUCTION SHEET FOR A SHELL-ANDTUBE HEAT EXCHANGER

As discussed in MEX 202, the purpose of a Safety Instruction
Sheet is to ensure that operations, maintenance, and inspection
personnel have adequate information in a consistent format.
This information concerns safe operating limits, protective
devices, and any special safety precautions that may be
required.
SAES-E-004 and 007 requires that a Safety Instruction Sheet
be completed for every new process heat exchanger. In most
cases, a contractor who is working for Saudi Aramco is
responsible for completing the Safety Instruction Sheet. The
Saudi Aramco Engineer is then responsible for checking the
contractor's work. In all cases, the Safety Instruction Sheet is
completed based on the final, certified, as-built, manufacturers
data for the heat exchanger, not the data that is on the heat
exchanger specification sheet.
The Safety Instruction Sheet must also be revised whenever the
heat exchanger is rerated or modified. The Saudi Aramco
engineer may be responsible for revising the Safety Instruction
Sheet when heat exchangers are rerated or modified.
Saudi Aramco has Safety Instruction Sheets for both shell-andtube and air-cooled heat exchangers. This module only
discusses the Safety Instruction Sheet for shell-and-tube heat
exchangers. SAES-A-005, Preparation of Safety Instruction
Sheets, outlines the procedures for preparing Safety Instruction
Sheets. These procedures are referenced in
Work Aid 4. A copy of SAES-A-005 is contained in Course
Handout 2.
Information Covered
A copy of the Safety Instruction Sheet for shell-and-tube heat
exchangers, Form 2713, is shown in Figure 14, and additional
copies are provided in Course Handout 3. Form 2713 includes
general information, basic process design information,
mechanical design information, and operating limits. The
following paragraphs highlight several of the primary types of
information that are required on Form 2713. Refer to Figure 14
or Course Handout 3.
59

Figure 14. Safety Instruction Sheet Form 2713
60

The top part of Form 2713 contains basic equipment

information such as service, manufacturer, serial number,
applicable construction Code and edition, and reference
drawings.
Shell-side, tube-side, and tube-bundle details are provided in

the next sections of the form. These sections contain
mechanical design information and summarize information
on pressure testing of the exchanger, such as the following:
Shell diameter, thickness, and material
Tube material, diameter, and thickness
Initial test pressure
Limiting component in the test
Basis for the calculated test pressure
The lower part of the form contains information on the

operating limits of the shell side and tube side of the
exchanger, such as the following:
Design pressure and design temperature
Basis for the design pressure
Pressure relief valve location
Relief valve set pressure
Routine test pressure
Minimum required thicknesses of the components, "tm"
Actual available corrosion allowances of the
components, C
Reference drawing numbers
The next section is used to specify any special hazards,

recommendations, inspections, or tests that are important for
the safe operation of the exchanger.
The bottom part of the form contains standard Saudi Aramco

drawing information, and the left side contains revision
record and approval information.
61

Form 2713 provides much information about a shell-and-tube

heat exchanger. It makes it possible for operations,
maintenance, and inspection personnel to get needed
information from one source without reviewing many drawings.
There will be situations when the detailed exchanger fabrication
drawings must be checked to resolve questions. However,
having the information on this one form reduces the need to
refer to the drawings and focuses the research on the
necessary items.
Where to Find Other Information

Almost all of the information that is required on the Safety
Instruction Sheet is obtained from the final version of the heat
exchanger specification sheet, the as-built exchanger drawings,
and the mechanical design calculations. The paragraphs that
follow highlight other items that might have to be obtained from
other sources:
Any special design considerations or unusual construction

features that should be highlighted would have been
developed either during the initial specification of the
exchanger or during its detailed engineering. Pertinent
information could be obtained from the process and
mechanical engineers who were assigned to the work.
Information as to the locations of the relief valves that protect

the shell side and the tube side of the exchanger is available
from the contractor. The Process and Instrument Diagram (P
& ID) for the system will typically show the relief valve
locations.
Information and guidance with regard to any special safety

hazards, recommendations, inspections, and tests can be
obtained from General Safety Instructions, Saudi Aramco GI
No. 2608, and discussions with process, safety,
maintenance, and inspection personnel who are assigned to
the project and are familiar with the heat exchanger and its
application.
62

SUMMARY
This module has described the evaluation of contractorspecified heat exchanger designs based on applicable
specification data, Saudi Aramco requirements, and industry
requirements. Procedures that may be used to evaluate heat
exchanger design conditions and mechanical design details,
based on process information and information that is contained
in a Contractor Design Package, were discussed. Inasmuch as
heat exchangers are now normally designed using computer
programs, the design evaluation procedures concentrated on
checking computer program-generated information rather than
on reviewing or performing hand calculations. Finally, the
procedure for completing the Safety Instruction Sheet for a
shell-and-tube heat exchanger was discussed. participants are
now able to evaluate contractor-specified heat exchanger
designs.
After a heat exchanger is designed, it is then fabricated,
inspected, and tested. These subjects are discussed in
MEX 210.04.
63

WORK AIDS
WORK AID 1:
PROCEDURE FOR EVALUATING CONTRACTORSPECIFIED DESIGN CONDITIONS FOR TEMA-TYPE

AND AIR-COOLED HEAT EXCHANGER
COMPONENTS
The procedures in this Work Aid may be used to evaluate whether design conditions
that are specified in a Contractor Design Package for a heat exchanger meet the Saudi
Aramco requirements that are specified in SAES-E-007. A copy of SAES-E-001 is
included in Course Handout 2. Part 1 of this Work Aid is used for TEMA-type heat
exchangers, and Part 2 is used for air-cooled heat exchangers.
Part 1: TEMA-Type Heat Exchangers

1.
Determine the process operating conditions for the shell side and tube side. List
the process operating conditions in Figure 15 under Operating Conditions.
Operating conditions are specified in Section A of Form 2714.
2.
Determine the mechanical design conditions specified by the contractor for the
shell side and tube side. List the design conditions in Figure 15 under Design
Conditions. Mechanical design conditions are specified in Section B of Form 2714.
3.
Determine if the design conditions meet the requirements that are specified in
SAES-E-007 paragraph 7.2.2. These requirements are summarized as follows:
The design pressure must be at least the greater of the maximum operating
pressure plus 104 kPa(ga) (15 psig), or 110 percent of the maximum operating
pressure.
The design temperature must be at least the maximum operating temperature

plus 28C (50F). Metal design temperatures shall be based on "steaming out"
conditions if applicable.
The minimum design temperature must be the minimum metal temperature that
is coincident with any pressure greater than 25 percent of the design pressure.
The possibility of auto-refrigeration during start-up, shutdown, or upset must be
considered in determining the minimum design temperature.
64

4.
Indicate the results of your evaluation in the last column of Figure 15.
DESCRIPTION
Operating
Conditions
Design
Conditions
Acceptable
(Yes/No)
Shell Side Max. Temperature, C (F)

Shell Side Min. Temperature, C (F)
Shell Side Pressure, kPa (psig)
Tube Side Max. Temperature, C (F)
Tube Side Min. Temperature, C (F)
Tube Side Pressure, kPa (psig)
Figure 15. TEMA-Type Heat Exchanger Design Condition Evaluation
Part 2: Air-Cooled Heat Exchangers

1.
Determine the operating conditions for the process side. List these in Figure 16
under Operating Conditions. Process operating conditions are indicated on Lines
16 and 23 of Form 2716.
2.
Determine the design air inlet, outlet, and ambient temperatures. List these in
Figure 16 under Design Conditions. Air temperatures are indicated in the column
headed Performance Data - Air Side of Form 2716.
3.
Determine the process-side design conditions specified by the contractor and list
these in Figure 16 under Design Conditions. Process-side design conditions are
indicated on Line 42 of Form 2716.
4.
Determine if the process-side design conditions meet the requirements that are
specified in SAES-E-007. Refer to Step 3 of Part 1.
5.
Determine if the air-side design inlet, outlet, and ambient temperatures meet the
requirements that are specified in Para. 6.4 and 6.5 of SAES-E-007.
65

6.
Indicate the results of your evaluation in the last column of Figure 16.
Operating
Conditions
Description
Design
Conditions
Acceptable
(Yes/No)
Process Max. Temperature, C (F)

Process Min. Temperature, C (F)
Process Inlet Pressure, kPa (psig)
Inlet Air Temperature, C (F)
Outlet Air Temperature, C (F)
Min. Ambient Temperature, C (F)
Figure 16. Air-Cooled Heat Exchanger Design Condition Evaluation
66

WORK AID 2:
PROCEDURE FOR EVALUATING CONTRACTORSPECIFIED DIMENSIONS FOR SHELL-AND-TUBE

HEAT EXCHANGER COMPONENTS
The procedures in this Work Aid may be used to evaluate whether the dimensions that
are specified in a Contractor Design Package for a shell-and-tube heat exchanger meet
Saudi Aramco, TEMA, API-660, and ASME requirements. This Work Aid is divided into
four major parts as follows:
Part 1 provides a general procedural-type checklist that should be used in all

cases.
Part 2 is used for girth flanges and flat channel covers.
Part 3 is used for stationary and floating end tubesheets.
Part 4 is used for floating heads.
Part 1: General Requirements

The following procedural items should be checked in all cases:
1.
Confirm that the specified dimensions are consistent in all drawings, specifications,
and calculations that are provided in the Contractor Design Package. This will be
done while checking the design details and dimensions in accordance with Parts 2
through 4 of this Work Aid.
2.
Confirm that the dimensions and design details are in accordance with
requirements specified in 32-SAMSS-007, API-660, and the ASME Code. Further
details on this check are provided in Parts 2 through 4 of this Work Aid.
3.
Confirm that all calculations are done in accordance with ASME Code procedures.
This may involve verification of the computer program that is used by the
exchanger manufacturer. For the purposes of this course, it may be assumed that
the CODECALC computer program that is being used has been verified.
Part 2: Girth Flanges and Flat Channel Covers

Use the following procedure to check computer calculations that have been made to
verify the design of a girth flange or a channel cover. This procedure is generic in that it
may be applied to calculations that have been done using most computer programs.
However, because the CODECALC program is used for all calculations that are done in
this course, the parameter names that are used in the CODECALC program are
identified in parentheses where appropriate.
67

The program input must be checked to ensure that it conforms to the flange design
requirements. The program output must be checked to ensure that it verifies the design
that has been used for the girth flange or cover plate.
In using this procedure, refer to Figure 17 for flange geometry and nomenclature.
Figure 17. Flange Geometry and Nomenclature
1.
Verify that the correct flange type is specified. Heat exchanger girth flanges are
typically the integral weld neck flange. Permissible flange types are specified in
Appendix 2 of the ASME Code.
2.
Verify that the specified design pressure (P) is equal to the pressure that is listed
on the specification sheet.
3.
Verify that the specified design temperature is equal to the temperature listed on
the specification sheet.
4.
For the girth flange, verify that the corrosion allowance (FCOR) is equal to the
corrosion allowance that is listed on the specification sheet.
68

For the flat channel cover, verify that the corrosion allowance is equal to the depth
of the pass partition groove in the channel cover.
5.
Verify that the flange material is the same as the material listed on the specification
sheet.
6.
Verify that the allowable stress for the flange or flat cover material conforms to the
allowable stress specified in the ASME Code. Note that many programs such as
CODECALC have the ASME allowable stress tables built into them and
automatically use the correct allowable stress.
7.
Verify that the bolt material is the same as the material listed on the specification
sheet.
8.
Verify that the allowable stress for the bolt material conforms to the allowable
stress specified in the ASME Code. Note that many programs such as
CODECALC have the ASME allowable stress tables built into them and
9.
Verify that the flange inside diameter (B) is equal to the uncorroded (new) diameter
shown on the detailed drawing. This is not applicable for the flat channel cover.
10. Verify that the flange outside diameter (A) is equal to the uncorroded (new)
diameter shown on the detailed drawing.
11. Verify that the hub thickness at the small end of the flange (shell end, G0) is equal
to the uncorroded (new) thickness shown on the detailed drawing. This is not
applicable for the flat channel cover.
12. Verify that the hub thickness at the back of the flange (large end, G1) is equal to
the uncorroded (new) thickness shown on the detailed drawing. This is not
applicable for the flat channel cover.
13. Verify that the flange thickness (T) is equal to the uncorroded (new) thickness
shown on the detailed drawing.
14. Verify that the hub length (HL) is equal to the length shown on the detailed
drawing. This is not applicable for the flat channel cover.
15. Verify that the diameter of the bolt circle (C) is equal to the diameter shown on the
detailed drawing.
16. Verify that the bolt diameter (DB) is equal to the diameter shown on the detailed
drawing.
17. Verify that the thread series (SERIES) is identified as "TEMA."
18. Verify that the number of bolts is equal to the number shown on the detailed
drawing.
69

19. For mating girth flanges that have a fixed tubesheet in between them, verify that
the following bolt loads have been specified based on calculations that have been
made for the opposite flange:
Operating Bolt Load
Gasket Seating Bolt Load
Flange Design Bolt Load
These values are found from output information that is found in preliminary
calculations that are done for the flanges.
20. Verify that the gasket outside diameter is equal to the diameter shown on the
detailed drawing.
21. Verify that the flange face outside diameter (FOD) is equal to the diameter shown
on the detailed drawing.
22. Verify that the gasket inside diameter is equal to the diameter shown on the
detailed drawing.
23. Verify that the flange face inside diameter (FID) is equal to the diameter shown on
the detailed drawing.
24. Verify that the gasket factor, m, is equal to the factor that is specified indicated in
the ASME Code, Section VIII, Division 1, Appendix 2, Table 2-5.1, for the specified
gasket type.
25. Verify that the gasket design seating stress, y, is equal to the stress indicated in
the ASME Code, Section VIII, Division 1, Appendix 2, Table 2-5.1 for the specified
gasket type.
26. Verify that the sketch number that is specified for the flange facing agrees with the
sketch number listed in ASME Code, Section VIII, Division 1, Table 2-5.2 for the
type of flange facing that is shown on the detailed drawing.
27. Verify that the column number (I or II) for the facing sketch agrees with the column
number listed in ASME Code, Section VIII, Division 1, Table 2-5.2 for the specified
gasket type.
28. Verify that the gasket thickness is equal to the dimension shown on the detailed
drawing.
29. Verify that the nubbin width (when a nubbin flange face is specified) is equal to the
dimension shown on the detailed drawing.
30. Verify that the length of the pass partition gasket is equal to the gasket inner
diameter, multiplied by the fraction Npp/Ng, where Npp is the width of the pass
70

partition gasket and Ng is the width of the girth flange gasket. This only applies for
channel covers when there is a pass partition plate in the channel.
31. Verify that the required bolt area (AM) is less than the actual total bolt area.
32. Verify that the actual bolt spacing lies between the minimum and maximum
permitted bolt spacings. The permitted spacings should have been determined
based on TEMA requirements.
33. Flange Stresses. Calculated and allowable stresses are output for the operating
case and for the gasket seating case. Confirm that the calculated stresses are all
less than the allowable stresses for each case. The following stresses must be
checked:
Longitudinal Hub Stress
Radial Flange Stress
Tangential Flange Stress
Maximum Average Stress
Bolt Stress
34. Verify that the Maximum Allowable Working Pressure for the corroded flange
(MAWP) is at least equal to the design pressure.
35. Verify that the required flange thickness, including corrosion allowance, is less than
or equal to the specified thickness (T) and the thickness that is shown on the
detailed drawing.
36. For channel covers, verify that the actual cover deflection is no more than the
deflection that is permitted by TEMA.
Part 3: Stationary and Floating Head Tubesheets

Use the following procedure to check computer calculations that
have been made to verify the design of a tubesheet that is either
stationary or at a floating head. This procedure is generic in that
it may be applied to calculations that have been done using
most computer programs. However, because the CODECALC
program is used for all calculations that are done in this course,
the parameter names that are used in the CODECALC program
are identified in parentheses where appropriate.
The program input must be checked to ensure that it conforms
to the tubesheet design requirements. The program output must
71

be checked to ensure that it verifies the design that has been

used for the tubesheet.
In using this procedure, refer to Figure 18 for tubesheet
geometry and nomenclature.
Figure 18. Tubesheet Geometry and Nomenclature
1.
Verify that the correct tubesheet type is specified and is consistent with information
that is contained in the detailed drawing. Several common tubesheets options are
as follows:
Stationary, gasketed on both sides
Stationary, integral with the shell
Stationary, integral with the channel
U-tube, gasketed on both sides
U-tube, integral with the shell
U-tube, integral with the channel
Pull-through floating head
Floating head with backing device
2.
Verify that the specified design pressures for the shell side (PS) and channel sides
(PC) are each equal to the applicable pressures that are listed on the specification
sheet.
3.
Verify that the specified design temperature (TEMPTS) is equal to the temperature
listed on the specification sheet.
72

4.
Verify that the materials for the shell, tubesheet, and channel are the same as the
materials listed on the specification sheet.
5.
Verify that the allowable stresses for the shell, tubesheet, and channel conform to
the allowable stresses specified in the ASME Code. Note that many programs
such as CODECALC have the ASME allowable stress tables built into them and
6.
Verify that the tubesheet thickness (TTS) is equal to the uncorroded (new)
thickness shown on the detailed drawing.
7.
Verify that the shell-side and tube-side corrosion allowances (CAS and CAC) are
equal to the corrosion allowances listed on the specification sheet.
8.
For gasketed tubesheets:

a.
Verify that the gasket inside diameter and outside diameter equal the
diameters indicated in the detail drawing.
b.
Verify that the flange face inside diameter (FID) and outside diameter (FOD)
equal the diameters indicated in the detail drawing.
c.
Verify that the gasket factor, m, is equal to the factor that is specified
indicated in the ASME Code, Section VIII, Division 1, Appendix 2, Table 2-5.1,
for the specified gasket type.
d.
Verify that the gasket design seating stress, y, is equal to the stress indicated
in the ASME Code, Section VIII, Division 1, Appendix 2, Table 2-5.1 for the
specified gasket type.
e.
Verify that the sketch number that is specified for the flange facing agrees
with the sketch number listed in ASME Code, Section VIII, Division 1, Table
2-5.2 for the type of flange facing that is shown on the detailed drawing.
f.
Verify that the column number (I or II) for the facing sketch agrees with the
column number listed in ASME Code, Section VIII, Division 1, Table 2-5.2 for
the specified gasket type.
g.
Verify that the gasket thickness is equal to the dimension shown on the
detailed drawing.
h.
Verify that the nubbin width (when a nubbin flange face is specified) is equal
to the dimension shown on the detailed drawing.
I.
Verify that the length of the pass partition gasket is equal to the gasket inner
partition gasket and Ng is the width of the girth flange gasket. This
73

requirement only applies for channel covers when there is a pass partition
plate in the channel.
9.
Verify that the tube outside diameter (DT) is equal to the diameter shown on the
detailed drawing.
10. Verify that the tube thickness (TT) is equal to the diameter thickness shown on the
detailed drawing.
11. Verify that the tube pitch (PT) matches the pitch shown on the detailed drawing.
12. Verify that the tube pattern (i.e., square or triangular) matches the pattern shown
13. Verify that the depth of the pass partition groove (GROOVE) is equal to the depth
14. If the tubesheet is extended as a flange, verify that the outside diameter of the
flanged portion (DF) is consistent with what is shown on the detailed drawing.
15. If the tubesheet is extended as a flange, verify that the thickness of the flanged
portion (TF) is consistent with what is shown on the detailed drawing.
16. Verify that the diameter of the bolt circle (DB) is equal to the diameter shown on
17. Verify that the bolt diameter (DBOLT) is equal to the diameter shown on the
detailed drawing.
18. Verify that the thread series is identified as "TEMA."
19. Verify that the number of bolts (NUMBER) is equal to the number shown on the
detailed drawing.
20. Verify that the actual tubesheet thickness is at least equal to the required thickness
and is consistent with what is shown on the detailed drawing.
Part 4: Floating Heads With and Without Backing Rings

Use the following procedure to check computer calculations that
have been made to verify the design of a floating head. This
procedure is generic in that it may be applied to calculations that
have been done using most computer programs. However,
because the CODECALC program is used for all calculations
that are done in this course, the parameter names that are used
74

in the CODECALC program are identified in parentheses where

appropriate.
The program input must be checked to ensure that it conforms
to the floating head design requirements. The program output
must be checked to ensure that it verifies the design that has
been used for the floating head.
In using this procedure, refer to Figure 19 for floating head
geometry and nomenclature.
Figure 19. Floating Head Geometry and Nomenclature
1.
Verify that the specified floating head type is consistent with what is shown in the
detailed drawing. The most common type is Type (d) as described in Appendix 1-6
in the ASME Code.
2.
Verify that the specified design temperature (TEMP) is equal to the temperature
3.
Verify that the specified tube-side design pressure (P.S.) is equal to the pressure
4.
Verify that the specified shell-side design pressures (PSS) is equal to the pressure
5.
Verify that the specified tube-side corrosion allowance (CATS) is equal to the
corrosion allowance listed on the specification sheet.
75

6.
Verify that the shell-side corrosion allowance (CASS) is equal to the corrosion
allowance listed on the specification sheet.
7.
Verify that the materials for the head, flange, bolts, and backing ring are the same
as the materials listed on the specification sheet.
8.
Verify that the allowable stresses for the head, flange, bolts, and backing ring
conform to the allowable stresses specified in the ASME Code. Note that many
programs such as CODECALC have the ASME allowable stress tables built into
them and automatically use the correct allowable stress.
9.
Verify that the crown radius of the head (CR) is consistent with what is specified on
10. Verify that the inside diameter of the flange (FID) is consistent with what is
specified on the detailed drawing.
11. Verify that the outside diameter of the flange (FOD) is consistent with what is
12. Verify that the inside diameter of the backing ring (DR) is consistent with what is
13. Verify that the actual thickness of the head (TH) is consistent with what is specified
14. Verify that the actual thickness of the flange (TC) is consistent with what is
15. Verify that the actual thickness of the backing ring (TR) is consistent with what is
16. Verify that the number of splits in the backing ring (NSPLIT) is consistent with what
is specified on the detailed drawing.
17. Verify that the distance between the centroid of the flange and the attachment
point at the head centerline is consistent with what is specified on the detailed
drawing.
18. Refer to the detailed drawing to determine whether the flange is or is not slotted
and verify that the appropriate detail is specified in the calculations. The flange will
normally not be slotted.
19. Verify that the diameter of the bolt circle (DB) is equal to the diameter shown on
20. Verify that the bolt diameter (DBOLT) is equal to the diameter shown on the
detailed drawing.
76

21. Verify that the thread series is identified as "TEMA."

22. Verify that the number of bolts is equal to the number shown on the detailed
drawing.
23. Verify that the gasket type and material that is used is consistent with what is
24. Verify that the gasket outside diameter is equal to the diameter shown on the
detailed drawing.
25. Verify that the flange face outside diameter (FOD) is equal to the diameter shown
26. Verify that the gasket inside diameter is equal to the diameter shown on the
detailed drawing.
27. Verify that the flange face inside diameter (FID) is equal to the diameter shown on
28. Verify that the gasket factor, m, is equal to the factor that is specified indicated in
the ASME Code, Section VIII, Division 1, Appendix 2, Table 2-5.1, for the specified
gasket type.
29. Verify that the gasket design seating stress, y, is equal to the stress indicated in
the ASME Code, Section VIII, Division 1, Appendix 2, Table 2-5.1 for the specified
gasket type.
30. Verify that the sketch number that is specified for the flange facing agrees with the
sketch number listed in ASME Code, Section VIII, Division 1, Table 2-5.2 for the
type of flange facing that is shown on the detailed drawing.
31. Verify that the column number (I or II) for the facing sketch agrees with the column
number listed in ASME Code, Section VIII, Division 1, Table 2-5.2 for the specified
gasket type.
32. Verify that the gasket thickness is equal to the dimension shown on the detailed
drawing.
33. Verify that the nubbin width (when a nubbin flange face is specified) is equal to the
dimension shown on the detailed drawing.
34. Verify that the length of the pass partition gasket is equal to the gasket inner
partition gasket and Ng is the width of the girth flange gasket. This only applies for
channel covers when there is a pass partition plate in the channel.
77

35. Verify that the actual thickness of the head is at least equal to the minimum
required thickness (considering the corrosion allowances) and is consistent with
what is shown on the detailed drawing.
36. Verify that the actual thickness of the flange is at least equal to the minimum
37. Verify that the actual thickness of the backing ring is at least equal to the minimum
78

WORK AID 3:
PROCEDURE FOR EVALUATING CONTRACTORSPECIFIED DESIGNS FOR AIR-COOLED HEAT

EXCHANGER TUBE BUNDLES AND HEADERS
The procedures in this Work Aid may be used to evaluate whether the tube bundle and
header designs that are specified in a Contractor Design Package for an air-cooled heat
exchanger meet Saudi Aramco, API-661, and ASME requirements. This Work Aid is
divided into three major parts as follows:
Part 1 provides a general procedural-type checklist that should be used in all

cases.
Part 2 provides a procedure for checking compliance with the requirements that
are contained in 32-SAMSS-011 and API-661.
Part 3 provides a procedure for evaluating whether the mechanical design

calculations are in accordance with the ASME Code. It is assumed that a
computer program has been used for these calculations.
Part 1: General Requirements

The following procedural items should be checked in all cases.
1.
Confirm that the specified dimensions are consistent in all drawings, specifications,
and calculations that are provided in the Contractor Design Package. This will be
done while checking the design details and dimensions in accordance with Parts 2
and 3 of this Work Aid.
2.
Confirm that the dimensions and design details are in accordance with
requirements specified in 32-SAMSS-011, API-661, and the ASME Code. Further
details on this check are provided in Part 2 of this Work Aid.
3.
Confirm that all calculations are done in accordance with ASME Code procedures.
This may involve verification of the computer program that is used by the
exchanger manufacturer. For the purposes of this course, it may be assumed that
the CODECALC computer program that is being used has been verified.
Part 2: 32-SAMSS-011 and API-661 Requirements

Use the procedure that follows to determine whether the requirements that are specified
in 32-SAMSS-011 and API-661 have been met. The paragraph references that are
indicated are in API-661 unless otherwise noted. For each requirement, circle Yes or
No depending on whether the requirement has been met or not.
79

Overall Tube Bundle

Design Requirements
1.
Par. 5.1.1.1. Is the tube bundle designed to be rigid for handling as a complete
assembly? Yes/No.
2.
Par. 5.1.1.3. Has provision for at least 6 mm (1/4 in.) of lateral movement in both
directions and 13 mm ( 1/2 in.) of lateral movement in one direction been
provided? Yes/No.
3.
Par. 5.1.1.4. Has provision been made in the design to accommodate the thermal
expansion of the tubes? Yes/No.
4.
32-SAMSS-011, Par. 5.1.1.4. Do the bundle and the structural mounting have
Teflon slide plates at the moving end? Yes/No.
5.
Par. 5.1.1.5. Are the tube supports no more than 1.83 m (6 ft.) from center to
center? Yes/No.
6.
Par. 5.1.1.6. Are structural hold-downs provided at each tube support? Yes/No.
7.
Par. 5.1.1.7. Are tubes of single-pass condensers and all heating coils sloped
downward at 10 mm per meter (1/8 in. per ft.) toward the outlet header? Yes/No.
8.
Par. 5.1.1.8. Are air seals provided throughout the bundle to minimize air leakage?
Yes/No. Any air gap that is more than 10 mm (3/8 in.) wide is excessive.
9.
Par. 5.1.1.9. Is 12 gage (2.8 mm [0.105 in.]) minimum thickness used for air seal
construction? Yes/No.
10. Par. 5.1.1.10. Are bolts for removable air seals at least 10 mm (3/8 in.) nominal
diameter? Yes/No.
11. 32-SAMSS-011, Par. 5.1.1.11. Do the tube ends extend beyond the tubesheet 3
mm 1.5 mm (1/8 in. 1/16 in.)? Yes/No.
12. 32-SAMSS-011, Par. 5.1.1.12. Are tube spacers designed so that they do not rely
on the outer periphery of the fins for bearing, and do the spacers prevent the fins
from meshing? Yes/No.
Tube Wall Minimum
Thickness
13. Par. 5.1.12.1. Does the diameter of the prime tube equal the recommended
minimum of 25.4 mm (1 in.)? Yes/No.
80

14. Par. 5.1.12.3. Does the minimum tube wall thickness meet the requirements
shown in Table 6? Yes/No.
Minimum Required
Thickness, mm (in.)
Tube Material
Carbon and Low-Alloy Steels (Through 9%

Chrome)
2.74 (0.108)
High-Alloys Steels (Austenitic and Ferritic)
1.65 (0.065)
Copper or Aluminum Alloy
2.11 (0.083)
Titanium
1.24 (0.049)
Table 6. Minimum Required Tube Thicknesses
Selection of Tube Fins
15. 32-SAMSS-011, Par. 5.1.12.7. Do the type of tube fins meet the requirements
specified in Table 7? Yes/No.
Fin Type
Use Limitations
Tension
wound
Auxiliary coolers and lube oil coolers at temperatures less than

95C (200F)
Extruded
Temperatures less than 260C (500F)
Embedded
Temperatures less than 400C (750F)
Other types
Must be approved by the buyer. Consult CSD as required.

Table 7. Limitations on Fin Types
81

Header Design
Requirements
16. Par. 5.1.5.2. If the differential design temperature of any adjacent tube pass is over
111C (200F), is a split header design, U-tube design, or other means used to
accommodate differential thermal expansion between the adjacent tube passes?
Yes/No.
17. Par. 5.1.5.5. Are the minimum thicknesses of header box components in
accordance with Table 8? Yes/No.
Carbon or Low-Alloy
Steel
Component
High-Alloy Steel or
Other Materials
Tubesheet
20 mm (3/4 in.)*
16 mm (5/8 in. )*
Plug sheet
20 mm (3/4 in.)
16 mm (5/8 in.)
Top, bottom, and end plates
12 mm (1/2 in.)
10 mm (3/8 in.)
Removable cover plates
25 mm (1 in.)
25 mm (1 in.)
* 25.4 mm (1 in.) minimum thickness including corrosion allowance per Par. 5.1.5.5
of 32-SAMSS-011.
Table 8. Minimum Required Thickness of Header Box Components
18. Par 5.1.5.6. Does the minimum pass partition plate thickness meet the
requirements in Table 9? Yes/No.
Pass Partition Plate

Material
Minimum Required
Thickness, mm (in.)
Carbon and Low-Alloy

Steels
12 (1/2) *
Nonferrous High-Alloy Steel
6 (1/4)
* Includes up to 3 mm (1/8 in.) corrosion allowance on

each side.
Table 9. Pass Partition Plate Thickness
82

19. 32-SAMSS-011, Par 5.1.5.7. Does the header box type meet the requirements in
Table 10? Yes/No.
Exchanger Service
Header Box Type
Process Cooler
Plug Type Header
Lube Oil Cooler or Seal Oil Cooler
Removable Cover or Cover Plate if less

than 1 750 kPa (250 psig)
Table 10. Header Box Type

Headers: Removable-CoverPlate and Removable-BonnetType
20. Par 5.1.6.5. Are jackscrews or a 5 mm (3/16 in.) clearance provided at the cover
periphery to facilitate dismantling? Yes/No.
21. Par 5.1.6.8. Is the minimum diameter of stud bolts 20 mm
(3/4 in.)? Yes/No. Is the minimum diameter of through bolts 16 mm (5/8 in.)?
Yes/No.
22. Par 5.1.6.9. Does the bolt spacing exceed the maximum spacing requirements
(refer to API-661 directly)? Yes/No.
23. Par 5.1.6.10. Is the bolt spacing less than the minimum spacing that is specified in
Table 1 of API-661? Yes/No.
24. Par 5.1.6.11. For bolts that straddle the corners, does the diagonal distance meet
the maximum bolt spacing criteria? Yes/No.
Headers: Plug-Type
25. Par 5.1.7.2. Does the diameter of the tube plug holes equal the nominal outside
diameter of the tube plus 0.8 mm (1/32 in.) minimum? Yes/No.
26. Par 5.1.7.3. Is the gasket surface of the tubesheet plug hole spot faced? Yes/No.
27. Par 5.1.8.7. Are threaded plugs that are 40 mm (1-1/2 in.) and less in diameter
Unified Fine Thread in accordance with ANSI B1.1? Yes/No.
28. Par 5.1.8.8. Are threaded plugs that are greater than 40 mm
(1-1/2 in.) in diameter 12 thread series per ANSI B1.1? Yes/No.
83

Gasket Requirements
29. Par 5.1.9.1. Are gaskets for tube access plugs solid metal or double-metaljacketed type and of the same material classification as the plug? Yes/No.
30. Par 5.1.9.2. Are cover plate gaskets for flat covers and bonnets double-jacketed,
non-asbestos filled type? Yes/No. Per
32-SAMSS-011, if the pressure does not exceed 2 100 kPa (300 psig), a synthetic
gasket with parting agent on both sides of the gasket may be used in water, lube
oil, and seal oil services.
31. Par 5.1.9.3 and Par 5.1.9.4. Are cover plate gaskets a minimum width of 9 mm (3/8
in.), and are the gaskets of one piece construction? Yes/No.
Nozzles and Other
Connections
32. 32-SAMSS-011, Par. 5.1.10.4. If nozzles are made from pipe, is only seamless
pipe used? Yes/No.
If the connections are 50 mm (2 in.) or smaller, is the thickness Schedule 80
minimum? Yes/No.
33. 32-SAMSS-011, Par 5.1.10.15. For small diameter connections, are bosses used
per Saudi Aramco Standard Drawings AE-036175 or AE-036367? Yes/No.
34. 32-SAMSS-011, Par. 5.1.10.18. Do nozzles protrude beyond the inside surface of
the header? Yes/No. If Yes, they are in violation of this requirement.
35. 32-SAMSS-011, Par. 5.1.10.19. If the header is lined with a corrosion resistant
material, are the nozzles also lined in the same manner? Yes/No.
Part 3: ASME Code Calculations for Header Box Plate Thicknesses

Use the procedure that is summarized in Table 11 to check computer calculations that
have been made to verify the design of a header box for an air-cooled heat exchanger.
This procedure is generic in that it may be applied to calculations that have been done
using most computer programs. However, because the CODECALC program is used
for all calculations that are done in this course, the parameter names that are used in
the CODECALC program are identified in parentheses where appropriate.
The program input must be checked to ensure that it conforms to the header box design
requirements. The program output must be checked to ensure that it verifies the design
that has been used for the header box.
In using this procedure, refer to Figure 20 and Figure 21 for header box geometry and
nomenclature.
84

Step
1
2
3
4
5
6
7
Item to Verify
Correct Header Box Type Has Been Selected for Analysis. Several
common options are as follows:
Equal or unequal thicknesses of the long-side plates.
One or two internal stay plates.
External reinforcement.
Design Pressure (P)
Design Temperature (TEMP)
Material Specifications for the Header Box Components and Stay Plates
Allowable Stresses and Minimum Yield Stresses for Header Box
Components and Stay Plates Conform to ASME Code.
Note: Many programs such as CODECALC have the ASME allowable
stress tables built into them and automatically use the correct allowable
stress.
Short-Side Length Dimension (H). The new, uncorroded length should be
input.
Minimum Thickness of the Short-Side Plates (t1). The new, uncorroded
thickness should be input.
Information Source
Detailed Drawing
Form 2716
Form 2716
Form 2716
ASME Code
Detailed Drawing
Detailed Drawing
Mid-side joint efficiency on the short side (E) in accordance with the
ASME Code and consistent with the radiographic inspection specified on
If no long seam, then E = 1.0.
If 100% RT, then E = 1.0.
If Spot RT, then E = 0.85.
If no RT, then E = 0.70.
ASME Code
Detailed Drawing
Corner joint efficiency on the short side (EC) in accordance with the
the detailed drawing. See Step 8.
ASME Code
Detailed Drawing
10
Long-Side Length Dimension (h).
Detailed Drawing
11
Minimum Thickness of the Long-Side Plates (t2). The new, uncorroded

Detailed Drawing
12
Mid-side joint efficiency on the long side (E) is in accordance with the
the detailed drawing. See Step 8.
Minimum Thickness of the End Plates (t5). The new, uncorroded
Corrosion Allowance of the Shell
Tube Hole Pitch Distance (p)
Tube Hole Diameter. Each hole may have multiple diameters (i.e., d0, d1,
d2).
Depth of the Holes. Each hole diameter will have a specific depth (i.e.,
T0, T1, T2).
Plug Hole Pitch Distance (p)
Plug Hole Dimensions
Minimum Thickness of Stay Plate (t3, t4)
Corrosion Allowance of Stay Plate
Membrane Stress, Bending Stress, and Total Stress in the Short-Side
Plates, Long-Side Plates, End Plates, and at the Corner Sections. Check
that actual stresses are below the corresponding allowable stresses.
MAWP based on Membrane Stress, Bending Stress, and Total Stress.
MAWP for the exchanger is the lowest of the calculated values, and
should be above the design pressure.
ASME Code
Detailed Drawing
13
14
15
16
17
18
19
20
21
22
23
Detailed Drawing
Form 2716
Detailed Drawing
Detailed Drawing
Detailed Drawing
Detailed Drawing
Detailed Drawing
Detailed Drawing
Form 2716
Computer Output
Computer Output
Table 11. Header Box Calculation Verification Procedure
85

Figure 20. Header Box Geometry and Nomenclature
86

PLATE WITH MULTIDIAMETER HOLES
Figure 21. Header Box Geometry and Nomenclature, cont'd
87

WORK AID 4:
PROCEDURE FOR COMPLETING A SHELL-ANDTUBE HEAT EXCHANGER SAFETY INSTRUCTION

SHEET
Use the procedural steps that are contained in SAES-A-005, Preparation of Safety
Instruction Sheets, to complete Safety Instruction Sheets for shell-and-tube heat
exchangers, Form 2713. The key numbers that are indicated in the procedure are
shown on the edited Form 2713 in Figure 24. A copy of SAES-A-005 is contained in
Course Handout 2.
Most of the procedural steps that are contained in SAES-A-005 are straightforward and
do not require further explanation. The following additional procedural information is
provided to assist in completing several of the key number items.
1.
Key Number 22 - Determine the Basis for Calculated Test Pressure on the Shell
Side
Review the manufacturer's calculations and determine the Maximum Allowable
Pressure New and Cold ( MAPNC) for the components that are listed in Figure 22.
List these values in the column headed MAPNC:
Component
MAPNC
Shell
Shell Cover
Shell Cover Flange
Shell Flange Mating to Cover Flange
Shell Girth Flange at Tubesheet
Fixed Tubesheet (maximum shell-side pressure)
Tubes (maximum external pressure)
Floating Tubesheet (maximum shell-side pressure)
Floating Head (maximum shell-side pressure)
Floating Head Flange (maximum shell-side pressure)
Figure 22. Components That May Determine Shell-Side MAPNC
88

1.
The basis for calculated test pressure on the shell side is the minimum of the
MAPNCs listed above. Use the shell-side design pressure if the MAPNCs for the
components are not provided in the contractor calculations.
2.
Key Number 34 - Determine the Basis for Calculated Test Pressure on the Tube
Side
Review the manufacturer's calculations and determine the MAPNC for the components
in Figure 23. List these values under the Column headed MAPNC:
Component
MAPNC
Channel
Channel Cover
Channel Cover Flange
Channel Girth Flange at Tubesheet
Fixed Tubesheet (maximum tube-side pressure)
Tubes (maximum internal pressure)
Floating Tubesheet ( maximum tube-side pressure)
Floating Head (maximum tube-side pressure)
Floating Head Flange (maximum tube-side pressure)
Figure 23. Components That May Determine Tube-Side MAPNC
The basis for calculated test pressure on the tube side is the minimum of the MAPNCs
listed above. Use the tube-side design pressure if the MAPNCs for the components are
not provided in the contractor calculations.
3.
Key Numbers 62 and 72 - Determine the tm's for Each Component.
Review the contractor's calculations and look for the minimum required thickness, tm, of
each component.
If the minimum required thickness is indicated exclusive of the nominal

corrosion allowance, this is the tm for the component.
If the minimum required thickness includes a corrosion allowance, subtract the

nominal corrosion allowance from the minimum thickness that was determined
by the manufacturer. This is the tm.
If the minimum required thickness of the part is not known, subtract the nominal
corrosion allowance from the nominal thickness and assume that this is the tm
for the component.
89

Saudi Aramco 2713-ENG (2/90)
SAUDI ARAMCO OIL COMPANY

DATA AND OPERATION LIMITS - HEAT EXCHANGERS
EQUIPMENT DATA
SERVICE:
ITEM NO.:
MFR.:
SIZE:
PLANT EQUIPM. NO.:
MFR. SERIAL NO.:
ORDER NO.:
TYPE:
APPLICABLE CODE & EDITION:
YEAR BUILT:
EQUIPMENT DRAWINGS:
WEIGHT
COMPLETE:
WEIGHT
BUNDLE:
SHELL SIDE
DIA.:
FLUID:
LG.:
IN. THICK:
IN.
X - RAT:
SR.:
TYPE LONG SEAM:
MAT'L.:
D.
%
BASIS FOR CALCULATED TEST PRESSURE
PSIG.
TEST APPLIED NEW:
COVER
LIMITED BY:
PSIG
MAT'L.:
FORM:
RING MAT'L.:
IN. THICK:
TUBE SIDE
FLUID:
TUBES
LAYOUT & SPACING:
BASIS FOR CALCULATED TEST PRESSURE
TEST APPLIED NEW:
IN. O.D.
BWG.
IN. LG.
F
PSIG.
LIMITED BY:
PSIG
COVER MAT'L.:
CHANNEL MAT'L:
FLT. HD. MAT'L.:
IN. THICK
IN. THICK
IN. THICK
TUBE BUNDLE DETAILS

BUNDLE NO.:
TUBE MAT'L:
NO. PER UNIT:
EXT. AREA:
FT2
TUBE SHEET MAT'L:
NO. PASS:
NO. PER UNIT:
IN. THICK:
TUBE SHEET MAT'L:
EXT. AREA:
FT2
NO. PASS:
IN. THICK
LININGS:
OPERATING LIMITS
( OPERATING LIMITS REQUIRE OPERATIONS ENGINEERING APPROVAL )
SHELL
DESIGN PRESS.:
TUBES
PSI
BASED ON:
PROTECTED BY RELIEF VALVE ON:
RV. SET AT:
PSI
ROUTINE TEST PRESSURE:
PSI
RV. SET AT:
DRAWN
BY
MIN. THICK. AT:
DATE
SHELL
CHANNEL
CHKD.
BY
SHELL COVER
CHANNEL COVER
SHELL COVER RING
FLOATING HEAD
SHELL NOZZLE SECTION
BAFFLE
OPRG. DEPT.
PSI
BASED ON:
PROTECTED BY RELIEF VALVE ON:
REVISIONS
DESIGN PRESS.:
PSI
NOTE ANY OTHER BASIS

tM
C
MIN. THICK. AT:
PSI
PSI
ROUTINE TEST PRESSURE:

F
PSI
NOTE ANY OTHER BASIS

tM
C
FLT. TUBE SHEET
BY
FIXED TUBE SHEET
DATE
DESIGN DATA SHEET
ENG. DEPT.
BOLT & GASKET DWG.

SAFETY PRECAUTIONS
NOTE BELOW ANY SPECIAL HAZARDS, RECOMMENDATIONS, INSPECTIONS OR TESTS THAT ARE IMPORTANT FOR THE EQUIPMENT.
BY
DATE
APPD. FOR
CONSTR.
BY
DATE
CERTIFIED
BY
DATE
THIS DRAWING IS
NOT TO BE USED
FOR CONSTRUCTION
OR FOR ORDERING
MATERIAL UNTIL
CETIFIED AND
DATED
SAFETY INSTRUCTION SHEET - SHELL AND TUBE EXCHANGER
PLANT NO. INDEX
DRAWING NO.
SHT NO. REV. NO.
DESAUDI ARABIA
JO / EWO -
Figure 24. Shell-and-Tube Heat Exchanger Safety Instruction Sheet Form 2713
90

GLOSSARY
BWG
Birmingham Wire Gauge. A standard measure of plate

thickness as designated by a specific BWG number.
Each BWG number corresponds to a specific thickness
in inches.
embedded fin
A rectangular cross section, aluminum fin that is

wrapped under tension and mechanically embedded in a
groove that is spirally cut into the surface of the tube.
footed fin
An L-shaped aluminum fin that is wrapped under tension

over the outside surface of a tube with the tube fully
covered by the feet between the fins. The fin ends are
secured to prevent loosening or unraveling of the fins
under the design conditions.
integral fin
An aluminum outer tube from which fins have been

formed by extrusion and then mechanically bonded to
an inner tube.
overlapped footed fin
An L-shaped aluminum fin that is wrapped under tension

over the outside surface of a tube, with the tube fully
covered by the overlapped feet that are under and
between the fins. The fin ends are secured to prevent
loosening or unraveling of the fins under the design
conditions.
91

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