Tube to Tube Sheet

DEFINITION DEFINI TION - HEA HEAT T EXCHANG EXCHANGER  ER  

Heat exchanger is a device built for efficient heat transfer from one fluid to t o another, where the fluids are separated by a solid wall, so that they never mix. OR



Heat exchanger is defined as a device used to transfer heat from a fluids on one side of a barrier to another fluid, flowing on the other side of the barrier.

TYPES OF SHELL SHELL AND TUBE HEAT EXCHANGER  SHELL AND TUBE  TYPE HEAT EXCHANGER

FIXED TUBESHEET

FLOATING  TUBESHEET

“U” BUNDLE  WITH SINGLE  TUBE SHEET

FIXED TUBESHEET

SUMMARY 

Two tube sheets with tube bundle assembled in between, are fixed to both ends of the shell.



Tube sheets are either directly welded to shell or bolted to flanges which are welded to shell ends.



Differential expansion if any, will develop stresses in tubes & shell material.



To tae care of differential dif ferential expansion, shell may re!uire expansion bellows.

FLOATING TUBESHEET

SUMMARY 

One tubesheet is fixed to one end of the shell.



Other tubesheet is floating within the shell w ith a floating head cover.



This facilitates tube & shell to t o expand independently without inducing any stresses due to differential expansion.



"o expansion bellow is re!uired on the shell to tae t ae care of differential expansion.

“U” BUNDLE WITH SINGLE TUBESHEET

“U” TUBE BUNDLE, KETTLE TYPE EXCHANGER 

SUMMARY 

#$% bent tube bundle assembled on one tubesheet.



ssembled tube bundle is inserted into the t he shell.



Tube sheet is bolted to shell flange.



#$% tubes can expand e xpand freely inside the shell.



"o stresses due to differential expansion.



"o expansion bellow is re!uired on shell to tae care of differential expansion .

STANDARD CLASSIFICATION AS PER PER TEMA CODE 

T'( )lass #R% for severe re!uirement re!uirements s of petroleum * petroleum related application



T'( )lass #)% for moderate re!uirements of )ommercial and +eneral process application



T'( )lass #% for )hemical process service

MAJOR COMPONENTS 

SHELL



NOZZLES



CHANNEL



D’END



TUBESHEET



TUBES



BAFFLES



TIE RODS

FUNCTION OF BAFFLES 

They guide the shell side flow i !"#$ % fo&th "s well "s u' % dow di&e#tio( "#&oss the tu!e field( i#&e"sig the )elo#ity % the he"t t&"sfe& #oeffi#ie #oeffi#iet* t*



They su''o&t the tu!es "d hold the+ i '&o'e& 'ositio du&ig "sse+!ly % o'e&"tio*



,&e)et )i!&"tio of the tu!es #"used !y flow idu#ed eddies*

TYPES OF BAFFLES 

-ingle -egmental affle )uts



 (ulti  -egmental affle )uts  / Double -egment  - Triple -egment



Disc & ring type t ype

SINGLE SEGMENTAL BAFFLES 0'RT1)2 0'RT1 )2

HOR13O"T HOR13 O"T2 2

ROTT ROT T'D

($2T1  -'+('"T2 442'

DO$2' -'+('"T2 )$T-

($2T1  -'+('"T2 442'

TR152' -'+('"T2 )$T-

DISC & RING TYPE BAFFLE

 TUBE # TUBESHEET WELDING



Tu!e . tu!esheet weldig is defied "s /'&o#ess of 0oiig tu!e to tu!esheet i " he"t e1#h"ge& !y weldig2*

0R1O$- T65'- O4 T$' 7 T$'-H''T 8O1"T -trength

'xpanded / 'xp. +rooves in Tube

holes  -trength

'xpanded / 9ithout 'xp. +rooves in Tube holes  -eal

9elded & -trength 'xpanded :9ith or 9ithout 'xpansion +rooves;

 -trength

'xpanded

9elded :+roove 9eld 8oint; & 2ight

'<5"-1O" +ROO0'-

T$'

T$' -H''T

'<5"D'D 8O1"T

'<5"D'D & -'2 9'2D'D 8O1"T

9'2D +ROO0'

-TR'"TH 9'2D. (1"1($( = 5--'T$'

21+HT '<5"D'D 4T'R 9'2D1"+

T$' -H''T

T7T- -et up for -trength 9eld

-trength 9elded & 2ight expanded

-TR'"+TH 9'2D'D 8O1"T

WELDER QUALIFI QUALIFICA CAT TION PROCEDURE SCO,E 

This '&o#edu&e #o)e&s the &e3ui&e+ets fo&

Refe&e#e do#u+ets   A&ti#le

F45 of AS6E SEC*I789:;<5('"ge4<=*

weldig % testig of

  AS6E

tu!e . tu!esheet 0oit



  3u"lifi#"tio

SEC*>III SEC*>III

Custo+e& s'e#ifi# s'e#ifi#"tio "tio

PREP PRE PARA RAT TION OF MOC MOCK K UP UP BLOCK  

The tu!esheet !lo#$ sh"ll !e '&e'"&ed o " 'l"te?fo&gig of si+il"& !"se +"te&i"l 8Thi#$ess @ o&   ++= fo& 3u"lifi#"tio of weldig '&o#edu&e*



Fo& 3u"lifi#"tio of welde& the tu!esheet !lo#$ sh"ll !e '&e'"&ed " 'l"te?fo&gig of si+il"& !"se +"te&i"l 8Thi#$ess @ o&  5 ++=*

  Afte&

+"#hiig( tu!e holes sh"ll !e d&illed "s 'e& !lo#$ !l o#$ show i fig4;*The hole sie( 'it#h % weld edges sh"ll !e ideti#"l to tu!esheet of the e3ui'+et

WELDER TRAINING & QUALIFICATION 

 At the !egiig( !egiig( welde& welde& sh"ll !e gi)e gi)e '&"#ti#e '&"#ti#e o +o#$ u' !lo#$ to "#hie)e "##e't"!le !e"d fiish "s +etioed !elow 

;=

Cot&ol of weldig "&# to ")oid +elt th&ough i tu!e w"ll*

G=

,&o'e& "&# +"i'ul"tio +"i'ul"tio 

5=

St"gge&ig of &est"&t 'oits

=

 A##e't"!le !e"d fiishes  A##e't"!le fiishes without without e1#essi)e e1#essi)e &eifo&#e+et

IMPORT IMP ORTA ANT NO NOTE TE 

Fo& '&o#edu&e 3u"lifi#"tio ; +o#$ u' welds "&e to !e '&odu#ed withi "##e't"!le st"d"&ds( "s +etioed i AS6E AS6E SEC I7( 9:4;<5*;*  Afte& "de3u"te '&"#ti#e '&"#ti#e welde&s "&e "llowed "llowed to weld i " 3u"lifi#"tio !lo#$* The u+!e& of  0oits i welde& welde& 3u"lifi#"tio !lo#$ will will !e  os "s 'e& AS6E SEC I7( 9:4;<5*G*

PRECAUTIONS BEFORE TUBE # TUBESHEET WELDING 

Uifo&+ weldig should !e #"&&ied out while weldig tu!esheet . shell *



E1#essi)e !ow will le"d to diffi#ulties while i tu!e ise&tio st"ge*

Ov!"$

%'(!) *+ ,""+)  ,"",(, !+v+!. ' !!'/ %,'' *00 * 00!+ !+ %%+,*!$1

OPERATIONAL SEQUENCES OPERAT SEQU ENCES FOR TUBE # TUBESHEET WELDING 

Iside tou#hu'



B"ffle ise&tio



Tu!e ise&tio



Setu' of tu!e . tu!esheet



:eldig of 0oits



Tu!e t&i++ig



Le"$ test

INSIDE TOUCHUP 

Iside tou#hu' of eti&e shell is to !e doe to ")oid "y &est&i#tios du&ig !"ffle ise&tio*

 All

iside se"+ should !e #he#$ed fo& +ii+u+ &eifo&#e+et* &eifo&#e+et *

BAFFLE INSERT INSERTION ION 

:hile d&illig the !"ffles( the d&ill !it usu"lly gets defle#ted f&o+ the #et&e lie of the hole th&oughout eti&e st"#$*



He#e( it is "d)is"!le to ist"ll the !"ffles i the di&e#tio of d&illig with &es'e#t to the tu!ig di&e#tio*



B"ffles "&e ise&ted ito the shell with the hel' of fi1tu&e*

FIXTURE FOR BAFFLE INSERTION

TUBE INSERT INSERTION ION 

Cle"ig of tu!e % tu!e sheet is the +ost '&i+"&y &e3ui&e+et !efo&e tu!e ise&tio* Ut+ost #"&e is to !e gi)e fo& the #le"ig '&o#ess "##o&dig to the st"d"&d '&"#ti#es* '&"#ti#es *



Tu!e ise&tio is doe with the hel' of 'ilots whi#h '&o)ides e"se i tu!e ise&tio*

STA ST ANDARD L&T PRACTICES PRACT ICES 

The tu!e holes "d out side su&f"#e of tu!e sh"ll !e #le"ed tho&oughly to &e+o)e "y oil( g&e"se( &ust( dust f&o+ su&f"#es*



Tu!e eds should !e #le"ed +ii+u+ u'to Tu!e G ++ of legth "t !oth eds !y wi&e wheelig*

SETUP OF TUBE # TUBESHEET 

Setu' is to !e doe i "##o&d"#e to the '&o0e#tio +etioed i the d&"wig*



,&o0e#tio &igs "&e utilied to esu&e the '&o0e#tio of tu!es with &es'e#t to tu!e sheet*

PREPARA PREPA RAT TORY ARRA ARRANG NGEM EMEN ENT T BEFORE WELDING 

 Afte& ise&tio of tu!es t u!es i tu!e holes( hol es( the tu!e eds ed s sh"ll !e 'ulled outside fo& #le"ig of tu!e OD* The #o&&es'odig hole ID o o''osite ed sh"ll !e #le"ed 85++( +ii+u+=* I " &ow( oe tu!e sh"ll !e 'ulled fo&w"&d "d "d0oiig tu!e sh"ll !e 'ushed !"#$w"&d fo& #le"ig of tu!e OD "d hole ID "lte&"ti)ely*



 A)"il"!ility of high 'u&ity "&go #ylide& #ylide & duly #le"&ed !y weldig egg* Fo& 'u&ity #he#$( !e"d4o4'l"te de'osit sh"ll !e #"&&ied out* Afte& g&idig the !e"d to &e+o)e the h"lf thi#$ess( ,T #he#$ sh"ll !e 'e&fo&+ed* E"#h tested "d #le"&ed #ylide& sh"ll !e"& sig"tu&e of weldig egiee&*

   

   

Tho&i"ted Tu Tugste gste 85* di"*= High f&e3ue#y uit i weldig +?# is wo&$ig* ,&e "d 'ost flow of shieldig g"s is '&o'e&ly "d0usted* :elde&s "&e 3u"lified to weld th"t '"&ti#ul"& 0oit "d #le"&ed RT of 0oit o +o#$ 4u' 'ie#e !efo&e st"&t of weldig* "s #u' with g"s leses* Le"$"ge of shieldig g"s i #oe#tios :"te& #oolig syste+ "d w"te& #i&#ul"tio is i o&de&* Joit sh"ll !e #le"ed with "#etoe 0ust !efo&e st"&t of t"#$ weldig

PRECAUTIONS WHILE WELDING     

 

Follow the weldig '"&"+ete&s "s s'e#ified i :,S* :eldig to !e 'e&fo&+ed with sho&test 'ossi!le "&#* Oly )e&ti#"l u' '&og&essio is to the used* ,&o0e#tio of tugste ele#t&ode f&o+ g"s #u' sh"ll !e $e't +"1 K* ++* Tugste i#lusio to the ")oided* I #"se of "y dou!t the 'oit sh"ll the d&essed !efo&e '&o#eedig fo& fu&the& weldig*  A&# iiti"tio iiti"tio sh"ll !e usig high high f&e3ue#y f&e3ue#y li+it* Rest"&t 'oit i " '"ss sh"ll !e $e't "t le"st ++ !efo&e the #&"te& 'oit of the !e"d* The &est"&t of su##essi)e '"sses sh"ll !e st"gge&ed w*&*t '&e)ious '"sses*





  

Du&ig ,T "fte& &oot '"ss it sh"ll !e esu&ed th"t the 'eet&"t 8dye= is ot ete&ig the u4welded 0oits* If the dye h"s ete&ed the i welded 0oits( the 0oit sh"ll !e #le"ed tho&oughly !y 'ullig the tu!es fo&w"&d "d !"#$w"&d* :eld sh"'e % sie sh"ll !e #ot&olled to +eet the &e3ui&e+et of )isu"l is'e#tio* Fo& weld sie #o&&e#t fillet g"uge sh"ll !e used* Oly oe welde& sh"ll the "llowed to #o+'lete "  0oit* 6i1 u' i " 0oit sh"ll sh "ll !e ")oided* :eldig &e#o&d of e"#h T.TS 0oits sh"ll !e +"it"ied with d"t" "d welde& st"+'* The "&go #ylide& sh"ll !e &e'l"#ed whe the&e is 'ositi)e '&essu&e* 8 ; $g 'e& s3*#+=



Fille& wi&e sh"ll !e #le"ed with e+e&y '"'e& followed !y "#etoe #le"ig* Afte& #le"ig( it sh"ll !e h"dled usig #le"ed #otto h"d glo)e



:hile usig i#oel fille& wi&e( the "&# sh"ll !e $e't o CS tu!es to ")oid e1#essi)e +eltig of SS #l"ddig*



Joits sh"ll !e tho&oughly #le"ed "fte& ,T !efo&e de'ositig e1t '"sses*



O1idied eds of fille& wi&e sh"ll !e #ut !efo&e &eusig it*

WELDING DEFECTS

TUBE TRIMMING 

Tu!e t&i++ig is &e3ui&ed to !e doe "fte& Tu!e weldig &oot '"ss of "ll tu!es i oe tu!esheet*



It is doe to &e+o)e e1#essi)e tu!e legth !y +"#hiig o 0o!*



Su'e&)iso& should o!se&)e th"t +ii+u+ tu!e legth t&i++ig 8  ;++ = is &e3ui&ed*

LEAK TEST  Ai&

"d so"' solutio solutio le"$ test* test*

 Heliu+

le"$ test*

 Me&osee  Hot

le"$ test*

oil test*

 H"loge

le"$ test*

USEFUL USE FUL CALCUL CALCULA ATION IONS S 

:elde& out'ut*



Coute&weight #"l#ul"tio*



Shell t&i++ig*

WELDER OUTPUT 

 



 

C"l#ul"te welde& out'ut fo& " 0o! with ; os of tu!e with G++ di" 'e& shift  Assu+e th"t effi#ie#y of ")e&"ge welde& fo& tu!e tu !e . tu!esheet tu!e sheet weldig is G+t&?;Gh&s* Ci&#u+fe&e#e of tu!e @ G'ie&  @ G5*;;<; @ KG*5++ @ K5++ "''&o1* :elde& out'ut?shift @ A)e&"ge effi#ie#y?#i&#u+fe&e#e @ G; ? K5 @ 5

COUNTER WEIGHT CLACULATION

   

Coute& weight @ 1 7  RHS s'" @ :eight of !"ffle  LHS s'" 7   @ ; He#e( #oute&weight 7 @ ; to

SHELL TRIMMING Shell t&i++ig fo& A4ty A4ty'e 'e weld #ofigu&"tio* 

7 @ L4G,4T;4TG4B;4BGQS

SHELL TRIMMING Shell t&i++ig fo& B4ty'e weld #ofigu&"tio 

7 @ L4G,4T;4TG4B;4BG4GH4GRQS

ABBRE2ATIONS          

7 @ Dist"#e f&o+ the edge of tu!esheet to shell edge 8"#tu"l=* T; @ Thi#$e Thi#$ess ss of tie&od t ie&od tu!esheet 8"#tu"l=* TG @ Thi#$e Thi#$ess ss of se#od tu!esheet 8"#tu"l=* , @ Re3ui&ed tu!e '&o0e#tio L @ Legth of tu!es 8"#tu"l= H @ Height of li' o se#od tu!esheet R @ Root g"' !etwee tu!esheet % shell B; @ Bulge o tie &od tu!esheet "fte& weldig 8"#tu"l= BG @ E1'e#ted !ulge o se#od tu!esheet S @ Sh&i$"ge of tu!esheet