ANETA CELAREK, JAN TALAGA

A COMPARATIVE ANALYSIS METHODOLOGY OF

CALCULATION OF STRENGTH TUBESHEETS BY
EUROPEAN STANDARDS AND GUIDELINES FOR UDT

ANALIZA PORÓWNAWCZA METODYKI OBLICZEŃ

WYTRZYMAŁOŚCIOWYCH ŚCIAN SITOWYCH WEDŁUG
NORM EUROPEJSKICH I WYTYCZNYCH UDT

Abstract
This paper presents comparison of calculation methods of the required thickness of the tube sheet in the
shell and tube heat exchanger compatible with the standards of the European standard PN - EN 13445-3,
and the guidelines of the Polish Office of Technical Inspection (UDT). Details of the methods are
illustrated by numerical examples – (calculations) for the selected design of the tubesheet.
Keywords: heat exchangers, tubes, tubesheets

Streszczenie
W artykule przedstawiono porównanie metod obliczeniowych wymaganej grubości ściany sitowej w
płaszczowo-rurkowym wymienniku ciepła zgodnych ze standardami normy europejskiej PN-EN 13445-3
i wytycznymi polskiego Urzędu Dozoru Technicznego. Szczegóły metod zilustrowano przykładami
liczbowymi dla wybranych konstrukcji dna sitowego.
Słowa kluczowe: wymienniki ciepła, rurki, dna sitowe

DOI:


MSc. Eng. Aneta Celarek, DSc. Eng. Jan Talaga, Institute of Thermal and Process Engineering,
Faculty of Mechanical Engineering, Cracow University of Technology.
44

1. Introduction

The European standard PN-EN 13445-3 shows three primary distinctions in terms of
shell and tube heat exchangers. In addition to the above standard PN-EN 13445-3 is Index
I, wherein it shows another design solution of a tubesheet. The analysis of strength
calculations for the same configurations of tubesheet differs from those described in the
Polish guidelines WUDT-UC. Polish guidelines WUDT-UC are treated as mandatory
during the design of pressure equipment.
In the norm PN-EN 13445-3: 2002, rules for different types of heat exchangers were
shown. According to the norm:
 U-tube heat exchanger (Figure 1);
 Fixed tubesheet heat exchanger (Figure 2);
 Floating head heat exchanger (Figure 3 ).
Floating head heat exchanger has three different configurations:
a) with an immersed floating head;
b) with an externally sealed floating head;
c) with an internally sealed floating tubesheet [3].

Fig. 1. U-tube heat exchanger [3] Fig. 2. Fixed tube sheet heat exchanger [3]

Fig. 3. Floating head heat exchange [3]

Table 1
The characteristic elements in the various types of heat exchangers
Characteristic U-tube tubesheet heat Fixed tubesheet heat Floating head heat
exchanger exchanger exchanger
Two – flat, circular and Two – flat, circular, and
Amount and
One –flat, circular, identical (same materials, identical connected by a
shape
uniform thickness same connection with shell bundle of straight tubes
tubesheet
and channel)
Type of Stationary attached to the
tubesheet Stationary Stationary shell and channel
(moving) Floating
Amount using 6 stationary (Fig. 4)
6 (see Fig. 4) 6 (see Fig. 4)
configurations +3 floating (Fig. 5)
Loading
3 cases 7 cases 3 cases
conditions
Tubesheet D0 D0 D0
e Ps  Pt e Ps  Pt e Pe
thickness 40.8 f  40.8 f  40.85 f 
 45

Tab. 1 shows a comparison of the information and characteristics among the types of
heat exchangers which are shown in European standards. Tab. 1 also groups the equation
on how to calculate the tubesheet thickness and which pressure we have to use in each heat
exchanger.
This article shows one of this type – U-tube heat exchanger and different uses of the
configurations of tubesheets. According the norm PN-EN 13445-3, the tubesheet may have
one of the six configurations (design solutions) shown in Fig 4.

Fig. 4. Various types of configuration tubesheets [3]

a) integral with shell and channel; b) integral with shell and gasketed with channel, extended as a
flange; c) integral with shell and gasketed with channel, not extended as a flange; d) gasketed with
shell and channel, extended as a flange or not; e) gasketed with shell and integral with channel,
extended as a flange; f) gasketed with shell and integral with channel, not extended as a flange

Configuration d covers the cases where the tubesheet is: extended as (𝑑1 as flange or not
𝑑2 )
In the floating tubesheet heat exchangers the floating tubesheet may have one of the 3
configurations shown in Fig 5.
 tubesheet integral (Fig. 5a),
 tubesheet gasketed, extended as a flange (Fig. 5b),
 tubesheet gasketed, not extended as a flange (Fig 5c).

Fig. 5. Various types of configuration floating tubesheets [3]

For each of these types configuration of tubesheet a different method of calculation is

used. All of the methods were shown in European standards PE-EN 13445-3.

2. Examples of calculations for U-tube heat exchangers

Below is a numerical example (examples of calculations) of the method of strength

calculations for tubesheet contained in European standards PN-EN 13445-3. The
calculations were carried out for the tubesheet of configuration b shown in Fig. 6. Tab. 2
46

presents the type of material and properties which were selected in calculations. The
assumed values of tubesheet were shown in Tab. 3 [7, 3].
Table 2
Properties of used material
Rm Rp Rpt f f20 ftest E
Tubesheet - material
[MPa] [MPa] [MPa] [MPa] [MPa] [MPa] [MPa]
P280GH (1.0426) 460 280 225 150 186.67 266.67 198610

Table 3
Input date of tubesheet
Input date Value Units Description
en 100 mm Nominal thickness of tubesheet (assume)
ct 3 mm Tubesheet corrosion allowance on the tube -side
cs 3 mm Tubesheet corrosion allowance on the shell - side
p 34 mm Tube pitch
dt 25 mm Nominal outside diameter of tubes
lt,x 80 mm Expanded length of tube in tubesheet
ea 94 mm Analysis thickness
et 2.3 mm Nominal tube wall thickness
Et 1.9861 ∙ 105 MPa Elastic modulus of tube material at design temperature
E 198610 MPa Elastic modulus of tubesheet material at design temperature
ft 111.33 MPa Nominal design stress of tube material at design temperature
Nominal design stress of tubesheet material at design
f 150 MPa
temperature
S 178000 mm2 Total unperforated area of tubesheet
D0 1163.4 mm Equivalent diameter of outer tube limit circle
GS 1255 mm Diameter of shell gasket load reaction
Gc 1255 mm Diameter of channel gasket load reaction
WS 181026 kN Shell flange design bolt load for the assembly condition
Wc 1097.94 kN Channel flange design bolt load for the assembly condition

Fig. 6. Tubesheet design for b configuration [3]

The results of calculations on the thickness of the tubesheet are shown in Tab. 4. At this
state of calculations, there are no differences in the method of calculation. Despite the
following example of the various assumed operating pressures of the tubesheet, the
calculation is carried out in the same way [3].
 47

Table 4
The method of calculations concerning size of tubesheet
Results/
Equation Units Description
value
ea  en  ct  cs Analyses thickness tubesheet
94 mm
(initial)
p*  d * The basic ligament efficiency for
 0.2647 –
p* shear
lt , x The tube expansion depth ratio (0
 0.8511 –
e ≤ 𝜌 ≤ 1)
 E   f  
d t  2  et   t    t   ; 
d  max 
*
E  f   22.09 mm The effective tube hole diameter
 

 t
d  2  e t
 
p
p* 
min S  ; 4  D0  p  36.85 mm The effective tube pitch
1 4
  D0
2

p*  d * The effective ligament efficiency

*  0.4005 – of perforated tubesheet for
p* bending
E*
  0  1  *   2  *2   3  *3 
E 0.414 – Determination of the graph
  4  *4
The effective elastic modulus of
E *  E  0414 82227.64 MPa the tubesheet at design
temperature
*  0  1  *  2  *2  3  *3 The effective Poisson’s ratio of
0.3106 – tubesheet
 4  *4 (Determination of the graph)
E *  e3 The equivalent bending rigidity of
D*  6.2993·109
12  1  *2 
Nmm
tubesheet
Gs
s  1.0787 – The shell diameter ratio
D0
Gc
c  1.0787 – The channel diameter ratio
D0
A
K 1.1174 – The tubesheet diameter ratio
D0
1  *
F  E  ln K  0.1848 – The coefficient
E*
Wmax  max Ws ;Wc  181026 kN
The maximum flange design bolt
load for the assembly condition
48

After this stage, for future calculations, pressures operating at the side shell and tube
should be selected. In this example, calculations of three types of pressures were carried out.
Values of the operating pressure were assumed.
In first load case, the analysed negative pressure operated on the shell – side. In the second
load case, the analysed negative pressure operated on the tube – side. In the third case, the
negative pressure operating on the shell or the tube side was not taken into consideration.

Table 5
Load cases used in design
ID Load Case 1 LC2 LC3 Units Description
Ps -0.1 1 1 MPa Shell – Side Pressure
Pt 0.6 -1 0.6 MPa Tube – Side Pressure

Below, Tab. 6 shows the procedure and the results of calculations carried out of the
different load cases described in Tab. 5.

Table 6
Calculation the moment acting at different part of tubesheet [3]
Equation LC 1 LC 2 LC 3 Units Description
The moment due
D0
2
to pressures
M TS   [(s  1)  (2s  1)  Ps  Ps and
16 -10087.73 28822.08 5764.42 Nmm
Pt acting on the
 (c  1)  (c  1)  Pc ]
2
unperforated
tubesheet rim
The moment
Wmax Gc  Gs  acting on the
M *  M TS  -10087.73 28822.08 5764.42 Nmm
2    D0 unperforated
tubesheet rim
2 the moment
 F  Ps  Pt 
D0
M*  acting at
32 -3894.83 11128.08 2225.62 Nmm
MP  periphery of
1 F tubesheet
2 The moment
 3  *  Ps  Pt 
D0
M0  MP  -52905.35 151160 30231.63 Nmm acting at centre
64 of tubesheet
The maximum

M  max M P ; M 0  52905.35 151160 30231.63 Nmm moment acting
of tubesheet
6 M The calculated

*  ea  hg '
2 97.86 279.59 55.92 MPa stress in a
component
 1   D0  The calculated
        Ps  Pt -8.18 23.28 4.6756 MPa shear stress in a
 4   e  component
 49

Depending on the applied pressure, different torques were obtained. In any case, the
strength conditions of the maximum radial bending stress in the tubesheet and the maximum
shear stress in the tubesheet have been fulfilled. The designed tubesheet fulfilled strength
conditions for pressures assumed in Tab. 5. The material and size of the tubesheet were well
selected.

3. Example of calculation for U-tube heat exchanger tubesheet extended as a flange

This section shows a comparison of the results of calculations performed in accordance

with the WUDT-UC [2, 4, 8] and European standards. Tab. 7. shows input dates of
strength parameters for the material used in the calculations [7, 6]. Tables 9, 10 and 11 were
shown the selected results of these calculations. The calculations were carried out for
tubesheet extended as a flange [4, 8].

Table 7
Properties of used material
Tubesheet – Rm Rp Rpt E
material [MPa] [MPa] [MPa] [MPa]
S235JRG2
410 235 210 205000
(1.0038)

Tab. 8 contains basic information about the value assumed during the design of
tubesheet. The input dates of tubesheet were selected from the Polish standards for this
project [1, 5].

Table 8
The dimensions and the results of the calculated thickness of the tubesheets
depending on the area
WUDT-UC PN-EN 13445-3 Units Description
dz = 25 dt = 25 mm The nominal outer diameter of the pipe
t = 32 p = 32 mm The tube pitch
g = 12 – mm Initial thickness
l0 = 12 lt,x = 12 mm The expanded length of tube in tubesheet
The large centre- to- centre distance between adjust
– UL = 32 mm
tube rows
f = 533.126 S = 533.126 mm2 The total unperforated area of tubesheet

Tab. 9 and 10 show the results of calculating assembly and operating the bolts loads,
necessary for the appropriate operation of the flange connection.
50

Table 9
The results of calculations for the assembly in the event of a tubesheet used in connection flange
-screw
PN-EN
WUDT-UC Units Description
13445-3
D1 = 1400 d1 = 1400 mm The nominal diameter of the tubesheet
The inside diameter of the contact face between
Dw = 1426 B = 1426 mm
loose and stub flanges in a lap joint
Du = 1481 G = 1504.3 mm The diameter of gasket load reaction
– b0 = 26 mm The basic gasket or joint seating width
The contact width of gasket or joint seating
U = 54.5 w = 52 mm
pressure
Ucz= 25.61 b = 12.85 mm The effective gasket or joint seating width
The minimum required gasket or joint seating
σm = 18.3 y = 26.20 MPa
pressure
The minimum required bolt load for assembly
Nm1 = 2502000 WA = 104694 N
condition
C = 1.4 – – The correction coefficient use in WUDT-UC
The minimum required bolt load for assembly
Nm2 = 5618000 – N
condition – used correction coefficient

Table 10
The results of calculations for operating in the event of a tubesheet used in connection flange –
screw

WUDT-UC PN-EN 13445-3 Units Description

The inside diameter of the contact face between
Du = 1481 G = 1504.3 mm
loose and stub flanges in a lap joint
p0 = 1.6 P = 1.6 MPa Design pressure
The coefficient of hedging against a decline in
b = 1.5 – –
the strength S as a result of creep
The pressure on the gasket to guarantee
σr = 4.8 mP = 2.4 MPa
tightness of the joint in the operating conditions
Ucz = 26.61 b = 12.85 mm The effective gasket or joint seating width
P = 2754000 H = 2843667 N The total hydrostatic end force
The compression load on gasket to ensure tight
S = 953200 HG = 22684 N
joint
The minimum required bolt load for operating
Nr = 4013000 Wop = 2866351 N
condition

Tab. 11 shows the final results for the calculation of the bottom sieve according to
WUDT-UC and European standards.
 51

Table 11
Comparison of the results of calculated thickness of the tubesheet

WUDT-UC PN-EN 13445-3

The calculated thickness of the
go e
tubesheet
mm mm

1. Precinct flange connection 26 32

2. Precinct bundle of tubes 20 12

3. Outside the bundle of tubes 34 12

The thickness of whole tubesheet * 34 32

* Industry seeks to standardise the thickness of the tube sheet for each of its area

4. Conclusion

The European standard PN-EN 13445-3 has procedures for the calculation of tubesheet
for more structural solutions than Polish guidelines WUDT-UC. The calculations are
dependent on the heat exchanger and the type of tubesheets.
In the case of guidelines WUDT-UC, the amount of these solutions is very limited and
reduced to a few cases. However, this greatly facilitates carrying out the calculations. All
the values in the design are known.
Large difference were noted when comparing the two methods of calculating
algorithms. For calculation algorithm strength WUDT-UC as the minimum thickness of the
tube sheet assumes a value equal to 12 mm, regardless of the material from which the tube
sheet and the diameter of the heat exchanger and the load applied pressure.
In the European standard PN-EN 13445-3, there is no requirement specifying the
minimum size of the tubesheet. The calculation is carried out for the assumed thickness of
the tubesheet. It is important only for the thickness to fulfil strength requirements. If these
conditions are not fulfilled, the calculations must be repeated by increasing the thickness of
the tubesheet.
When comparing the results of calculation for tubesheet extended as a flange, conducted
for both of these documents, large differences are noted. The same situation occurs in the
event of comparing the dimensions of sealing solutions for the flange connection. They
relate to the average diameter of the seal 𝐷𝑢 and the inside diameter of the contact face
between loose and stub flanges in a lap joint G.
According to the algorithm calculations WUDT-UC thickness of the tubesheet meets
the conditions adopted in the project in the precinct flange connection and it is 26 mm.
However, according to European standard PN-EN 13445-3, this value is higher, at 32 mm.
In the precinct bundle of tubes, higher values in the calculation were obtained for the
guidance WUDT-UC equal 20 mm. In the case of the European standard, this value was
12 mm. For the region outside the bundle of tubes, a similar situation was noted. For the
European standard PN-EN 13445-3 there was a higher value – 32 mm than for the
guidelines WUDT-UC – 12 mm.
52

Finally, the thickness of tubesheet for European standard PN-EN 13345-3 was equal to
34 mm. The calculations that were carried out for guidelines WUDT-UC amounted to
32 mm.
It was found that the calculations performed according to the European standards PN-
EN 13445-3 are more accurate and increase the strength of the structure. Due to the greater
thickness of the tubesheet heat exchanger, it meets the requirements of safety and allows
safe operation of the device.
In the analysed examples, an analogy on the section of the tubesheet into different areas
was noted. Equation determination of tubesheet thickness have been summarised in below
Tab. 12.

Table 12
Comparison of formulas used to determine the thickness of the tube sheet in each of its region
Region Precinct
Outside the
Precinct flange connection bundle of
bundle of tubes
Standards tubes
WUDT-UC Dz = Dw + 2·gs:
- assembly conditions:
D0  Dw  2  g s
 km  2  N m 
  Dzk  2  d 0   h 2 g 0  0.45   
p0
g
qmin
- operating conditions: k m
D0  Dw  2  g s
 kr  2  N r 
  Dzk  2  d 0   h 2
PN-EN - assembly conditions: Assumed in the Assumed in
13445-3 12 M project, checked the project,
e fl ,a   A under the checked
 D 
2
 fA
  Dex  1    1     ex   strength under the
  A   conditions and strength
corrected when conditions
- operating conditions: are not and
12 M op complied. corrected
e fl ,op  
 D  
2
f when are
  Dex  1    1     ex   not
  A   complied.

References

[1] Pikoń J, Podstawy konstrukcji aparatury chemicznej. Cz II. Elementy aparatury

chemicznej, PWN, Warszawa 1979.
[2] Warunki Urzędu Dozoru Technicznego, Urządzenia Ciśnieniowe, Wydanie 10.2003.
[3] Norma PN-EN 13445-3:2002.
 53

[4] Talaga J, Felkowski Ł, Obliczenia połączeń kołnierzowych w świetle norm PN-EN

13445 i specyfikacji technicznej WUDT-UC, Inżynieria i Aparatura Chemiczna, 50, nr
6, 2011, 5-8.
[5] Pikoń J, Podstawy konstrukcji aparatury chemicznej. Cz I. Tworzywa konstrukcyjne,
PWN, Warszawa 1979.
[6] Materiały firmy Spetech (15.05.2016): http://www.spetech.com.pl.
[7] Norma PN-EN 13445-2:2002.
[8] Celarek A, Analiza porównawcza metodyki obliczeń wytrzymałościowych ścian
sitowych według Norm Europejskich i wytycznych UDT, Praca magisterska,
Politechnika Krakowska, Kraków 2015.