These BEM heat exchangers are in the HEAT EXCHANGERS

final stages of fabrication.

Understanding TEMA Types

for Shell-and-Tube Exchangers
Shell-and-tube designs incorporate fixed or floating tubesheets, fixed
or removable tube bundles and expansion joints as needed to create an
effective heat transfer vessel. Gain a better understanding of the TEMA
types to improve your selection process.

By Bill Huffman, P.E., Ward Vessel and Heat Exchanger Corp.

A
mong the most common of tubes, which is connected on each exchanger types, the first step in
types of heat transfer side to a flat plate called a tubesheet. designing an exchanger for a specific
equipment used in The tubesheet also separates the process is thermal design. Given the
industrial applications are the various shell and tube sides of the exchanger. process conditions and heat transfer
configurations of shell-and-tube heat Baffles on the outside of the tubes requirements, the thermal design
exchangers. Suitable for a range of direct the flow of the shell-side fluid determines the exchanger’s size,
pressure and temperature conditions, back and forth across the tubes to shape, number and size of tubes,
shell-and-tube heat exchangers can be promote heat transfer. The process number of baffles and baffle pitch,
robust enough to handle corrosive or fluid can flow through either the shell etc. Other factors considered at this
even lethal fluids. or tube side, with the opposite side stage include allowable pressure drop
The shell-and-tube heat exchanger typically acting as the service side through the exchanger, any space
design allows heat transfer between (usually a heating or cooling medium). constraints on the unit, the potential
two independent, pressurized The exchanger also can have a process fouling of the unit and any resulting
chambers through the walls of the fluid on both sides. flow-induced vibration from the
tubes. The design consists of an array For most shell-and-tube heat proposed design.

May 2020 [Link] 31

TEM PERATURE SENSING

Front-End Stationary Head Types Shell Types Rear-End Head Types

A E L
Fixed Tubesheet
One-Pass Shell Like “A” Stationary Head

Channel and Removable Cover M

F Fixed Tubesheet
Two-Pass Shell with Like “B” Stationary Head
Longitudinal Baffle
B
N
G Fixed Tubesheet
Like “N” Stationary Head
Bonnet (Integral Cover) Split Flow

P
C Removable H Outside Packed Floating Head
Tube
Bundle Only Double Split Flow

Channel Integral with Tubesheet

S
and Removable Cover
Floating Head
with Backing Device
J
Divided Flow

N T
Pull-Through Floating Head

Channel Integral with Tubesheet

and Removable Cover
K
Kettle Type U
U-Tube Bundle

D
X
W
Externally Sealed
Special High Pressure Closure Crossflow Floating Tubesheet

FIGURE 1. This table, from the TEMA standard, shows the available combinations of exchanger components.
The designation types use a letter code for each of the front-end, shell and rear-end types.

32 PROCESSCOOLING May 2020

 After the exchanger size is cannot be cleaned easily. This can be
determined by the thermal design, an issue if the shell-side fluid causes
a mechanical design is performed. frequent fouling or sediment buildup.
This step determines the thickness Another disadvantage is that the
of all parts as well as welding details tubesheets are fixed, which causes
required for the temperature and stresses in the unit due to differential
pressure conditions. thermal expansion between the
Many different configurations tubes and shell. An expansion joint
of shell-and-tube heat exchangers sometimes is required to relieve this
are available. There are advantages stress, but its addition can increase the
and disadvantages to each design, overall cost.
depending on factors such as When frequent cleaning of the tube
process and thermal requirements, side is needed, NEN type exchangers
available space, financial budget and are preferred over BEM types. This is
cleaning requirements. This article because in NEN heat exchangers, the
provides information on several of This NEN-type heat exchanger is tube ends can be accessed for cleaning
ready for shipping.
the most widely used configurations by removing the end covers without
and briefly discusses some of the having to disconnect any piping to the
issues to consider when planning and rear-end types. For example, one inlet and outlet nozzles.
for and selecting a heat exchanger common type is BEM. It has a bolted
configuration. bonnet on each end, fixed tubesheets Removable U-tube
The Tubular Exchanger and a single-pass shell section. Bundle Types
Manufacturers Association, or TEMA, Another example is an AES type, Common examples of these types
publishes a standard that establishes which has a bolted front channel with of heat exchangers are BEU, BKU
design, fabrication, tolerances, removable cover, a single-pass shell and AEU. Because the bundles are
installation and maintenance of and a floating rear tubesheet. removable, the shell side can be
shell-and-tube type exchangers. This cleaned more fully than in fixed-type
standard and the ASME code are the Straight-Tube, Fixed exchangers. Another benefit with
main standards used to design and Tubesheet Type Heat the U-tube configuration is that the
fabricate exchangers along with any Exchangers tubes can expand and contract freely
applicable customer specifications. Straight-tube, fixed tubesheet heat with temperature differences without
The TEMA standard also defines the exchanger types are the most common causing stress in the shell. The
classes and main configuration styles and, generally, least expensive tubes can even expand individually
of exchangers. designs. Examples of these heat at different rates without any
Figure 1 shows the available exchanger configurations include detrimental effects. Expansion joints
combinations of exchanger BEM, AEL and NEN. are never needed with these designs.
components from the TEMA standard. One disadvantage of these designs The bundles can be replaced relatively
The designation types use a letter is that the tube bundle section is not easily if necessary.
code for each of the front-end, shell removable; therefore, the shell side One potential disadvantage to

Factors to Consider When Deciding on a Heat Exchanger Configuration

1. Does the bundle need to be removable for regular cleaning?

2. Do the tubes need to be straight for regular cleaning, or can they have U-bends?
3. Is there a need to access the tube ends without removing any inlet/outlet piping?
4. Is there a large difference in operating temperatures of the shell and tube sides?
5. Will the unit be horizontal or vertical?
6. What budget is available for the exchanger?

May 2020 [Link] 33

TEM PERATURE SENSING

A 3D model of a baffle cage is compared to the actual baffle cage.

34 PROCESSCOOLING May 2020

selecting this type of heat exchanger
is that it can be hard to clean the
inside of the tubes, especially in the
bent portion. Removable bundles are
not recommended over about 36”
diameter because these tube bundles
are heavy and difficult to remove and
install.

Removable-Bundle,
Floating Tubesheet Types
Rear-end head, shell-and-tube
heat exchanger types P, S, T and W
incorporate a floating rear tubesheet.
While each type offers a slightly
different design, any floating tubesheet
design generally will be more costly
than the removable U-tube or straight- Common examples of removable U-type bundle type heat exchangers are BEU,
tube, fixed tubesheet designs. BKU and AEU. A BEU is shown here.
Removable-bundle, floating
tubesheet designs provide advantages, a secondary tubesheet and seal to and-flued joints can be connected in
however. Because they include further separate the shell and tube series to relieve additional thermal
removable bundles, cleaning and sides of the exchanger. Any leaks at the stress and allow more expansion.
maintenance are easier. The tube tube-to-tubesheet joint are contained in When the amount of expansion
bundles do not have hard-to-clean a secondary chamber before reaching between the tubes and shell is higher,
U-bends, and the shell side of the the other side. This option can add a bellows-type joint is needed. This
bundle can be accessed as needed. significant cost to the unit price is a thin-wall design, with several
Bundle replacement also is easier. In because tubesheets are one of the most convolutions to allow expansion.
addition, like U-tube bundles, these expensive components of an exchanger. Due to the thin wall, any minor
types allow free expansion of the tube mechanical damage can cause a leak
bundle based on thermal differences, Expansion Joint that is expensive to repair. For this
and they do not cause stresses in other Considerations reason, bellows-type joints usually are
parts of the exchanger. In heat exchangers with fixed supplied with a protective shroud.
A disadvantage of the P and W tubesheet designs, differential thermal
type exchangers is that they require expansion can cause excessive stresses In conclusion, despite the variety
a packing seal. This can lead to in the tubes, tubesheets or the shell. of sizes, shapes and configurations
reliability problems because these seals Often, this is the case when there is available in shell-and-tube
are less robust than gasket-type seals. a large difference in the operating exchangers, a cost-effective design
The S and T types include a hidden temperatures of the shell and tube can be produced for nearly any heat
internal gasket that can be difficult to sides. For this reason, it is important transfer requirement. While these
change. for the designer to know the expected are the most common shell-and-tube
operating temperatures of the fluids on exchanger types, others exist. With
Double Tubesheet Types each side for any expected operating careful consideration of the exchanger
One of the common failure points case (including temperatures during requirements and constraints, an
for any heat exchanger is a leak at the startup, shutdown or cleaning informed decision can be made for
tube-to-tubesheet joint. A failure in operations). specifying or purchasing any heat
this joint can cause the fluid in the The two main types of expansion exchanger. PC
shell side to leak into the tube side, or joints are flanged-and-flued, and
vice versa. In applications where cross- bellows. The flanged-and-flued type Bill Huffman is the director of engineering
contamination must be avoided (for is a thick-wall expansion joint design. at Ward Vessel and Exchanger. The
process or safety reasons), a double- Although it allows less expansion, it Charlotte, N.C.-based company can be
tubesheet design can be used. is much more durable than a bellows reached at 704-568-3001 or visit
A double-tubesheet design adds type and unlikely to leak. Flanged- [Link].

May 2020 [Link] 35