A02 APPENDIX AA
RULES FOR THE DESIGN OF TUBESHEETS
AA-1 U-TUBE TYPE TUBESHEETS
AA-1.1 Scope
These rules cover the design of tubesheets for U-
tube type heat exchangers. The tubesheets may have
one of the six configurations shown in Fig. AA-1.1
sketches (a), (b), (c), (d), (e) and (f):
AA-1.1(a) Configuration a: tubesheet integral with
shell and channel;
AA-1.1(b) Configuration b: tubesheet integral with
shell and gasketed with channel, with tubesheet extended
as a flange;
AA-1.1(c) Configuration c: tubesheet integral with
shell and gasketed with channel, with tubesheet not
extended as a flange;
AA-1.1(d) Configuration d: tubesheet gasketed with
shell and channel;
AA-1.1(e) Configuration e: tubesheet gasketed with
shell and integral with channel, with tubesheet extended
as a flange; and,
AA-1.1(f) Configuration f: tubesheet gasketed with
shell and integral with channel, with tubesheet not
extended as a flange.
Materials and methods of fabrication for tubesheets,
shells, channels, and tubes shall be in accordance with
Subsections A, B, and C. Weld sizes shall be in
accordance with Subsection B, Part UW, Figs. UW-
13.2 and UW-13.3.
AA-1.2 Conditions of Applicability
AA-1.2(a) The tubesheet shall be flat, circular and
of uniform thickness. The tubesheet shall be uniformly
perforated over a nominally circular area, in either
equilateral triangular or square patterns. However, un-
tubed lanes for pass partitions are permitted.
AA-1.2(b) The tube side and shell side pressures are
assumed to be uniform. These rules do not cover weight
loadings or pressure drop.
When these conditions of applicability are not satis-
fied, see U-2(g).
612
AA-1.3 Nomenclature
Symbols used in this Appendix are as follows.
Ap outside diameter of tubesheet, in.
Cp bolt circle diameter, in.
ctp tubesheet corrosion allowance on the tube side,
in. ct p 0 in the uncorroded condition.
Dcp inside channel diameter, in.
Dsp inside shell diameter, in.
Ep modulus of elasticity for tubesheet material at
design temperature, psi
Ecp modulus of elasticity for channel material at
design temperature, psi
Esp modulus of elasticity for shell material at design
temperature, psi
NOTE: The modulus of elasticity shall be taken from the applicable
Table TM in Section II, Part D. When a material is not listed in
the TM tables, the requirements of U-2(g) shall be applied.
Gp midpoint of contact between flange and the
tubesheet, in. [see Appendix 2, Fig. 2-4(1)]
Gcp channel gasket load reaction diameter, in. (see
Appendix 2)
Gsp shell gasket load reaction diameter, in. (see Ap-
pendix 2)
hp tubesheet thickness, in.
hgp tube side pass partition groove depth, in.
h′gp effective tube side pass partition groove
depth, in.
p MAX [(hg − ct),(0)]
MAX [(a), (b), (c), . . .] p greatest of a, b, c, . . .
Psp shell side internal design pressure (see UG-21),
psi. For shell side vacuum use a negative value
for Ps.
Ptp tube side internal design pressure (see UG-21),
psi. For tube side vacuum use a negative value
for Pt.
pp tube pitch, in.
p*p effective tube pitch, in.
rop radius to outermost tube hole center, in.
Sp allowable stress for tubesheet at tubesheet de-
sign temperature (see UG-23), psi
 APPENDIX AA — NONMANDATORY Fig. AA-1.1

tc ts
ts

A
C
A
Pt Ps
Pt Ps
Gc Ds
Dc Ds hg
h
h

(a) Configuration a: Tubesheet Integral (b) Configuration b:

With Shell and Channel Tubesheet Integral With Shell and Gasketed
With Channel, With Tubesheet Extended as a Flange

ALT
tc

C Pt Ps
A
C Dc Gs
Pt Ps Gs
h
Gc
hg
h

(e) Configuration e:
(d) Configuration d: Tubesheet Gasketed Tubesheet Gasketed With Shell and Integral
With Shell and Channel With Channel, With Tubesheet Extended as a Flange

FIG. AA-1.1 TYPICAL U-TUBE TUBESHEET TYPE CONSTRUCTION

613
AA-1.3 2001 SECTION VIII — DIVISION 1 AA-1.4

Scp allowable stress for channel material at design

temperature, psi
Ssp allowable stress for shell material at design tem-
ts perature, psi
Sy,cp yield strength for channel material at design
temperature, psi. For values of Sy,c, see Section
A
C II, Part D, Table Y-1. For materials not listed
G in Section II, Part D, Table Y-1, see UG-28.
Pt Ps Sy,sp yield strength for shell material at design tem-
Gc Ds perature, psi. For values of Sy,s, see Section II,
hg Part D, Table Y-1. For materials not listed in
h Section II, Part D, Table Y-1, see UG-28.
SPS,cp allowable primary plus secondary stress for
channel material at design temperature per UG-
23(e), psi
SPS,sp allowable primary plus secondary stress for
shell material at design temperature per UG-
23(e), psi
tcp channel thickness, in.
tsp shell thickness, in.
Wp maximum design bolt load, lb
(c) Configuration c:
p MAX [(Wc), (Ws)]
Tubesheet Integral With Shell and Gasketed
With Channel, With Tubesheet Not Extended as a Flange Wcp channel design bolt load, lb. Use Eq. 4 of 2-5(e).
Wsp shell design bolt load, lb. Use Eq. 4 of 2-5(e).
vcp Poisson’s ratio of channel material
vsp Poisson’s ratio of shell material

tc AA-1.4 Design Considerations

AA-1.4(a) The various loading conditions to be con-
A C
sidered shall include the normal operating conditions,
the startup conditions, the shutdown conditions, and
Pt Ps
G the upset conditions, which may govern the design of
Dc Gs the tubesheet. For each of these conditions, the following
loading cases shall be considered:
h
AA-1.4(a)(1) Loading Case 1. Tube side pressure
Pt acting only (Ps p 0).
AA-1.4(a)(2) Loading Case 2. Shell side pressure
Ps acting only (Pt p 0).
AA-1.4(a)(3) Loading Case 3. Tube side pressure
Pt and shell side pressure Ps acting simultaneously.
When vacuum exists, each loading case shall be
considered with and without the vacuum.
When differential design pressure is specified by the
user, the design shall be based only on loading Case
(f) Configuration f:
Tubesheet Gasketed With Shell and Integral 3, as provided by UG-21.
With Channel, With Tubesheet Not Extended as a Flange The designer should take appropriate consideration
of the stresses resulting from the pressure test required
FIG. AA-1.1 TYPICAL U-TUBE TUBESHEET TYPE by UG-99 or UG-100 [see UG-99(d)].
CONSTRUCTION (CONT’D) AA-1.4(b) As the calculation procedure is iterative,
a value h must be assumed for the tubesheet thickness
to calculate and check that the maximum stresses in

614
AA-1.4 APPENDIX AA — NONMANDATORY AA-1.5.5

tubesheet, shell, and channel are within the maximum 2 − vs D2s

permissible stress limits. Ps′ p P
8 E s ts s
AA-1.4(c) The designer shall consider the effect of
deflections in the tubesheet design, especially when the
tubesheet thickness h is less than the tube diameter.
MPs p ␳s ks ␤s (1 + h␤s) Ps′

AA-1.5 Calculation Procedure Configurations a, e and f: Calculate coefficients ␤c,

kc, ␭c, P′c, and moment MPc relative to the integral
The procedure for the design of U-tube type tube-
channel.
sheets is as follows.
AA-1.5.1 Step 1. Calculate Do and ␮ from AA-
冪12( 1 − v2c )
4
4.5.1. Calculate the tubesheet thickness for shear hsh. ␤c p
冪(Dc + tc) tc
Do 冨Ps − Pt 冨
hsh p
4␮ (0.8S)
Ec t 3c
kc p ␤c
6 (1 − v 2c )
AA-1.5.2 Step 2. Assume a value for the tubesheet
thickness h ≥ hsh. Calculate ␮* from AA-4.5.1. Deter-
mine E*/E and ␯* relative to h/p from AA-4.5.2. 2

冤 冢 冣冥
3Dc 2
␭c p k ␤2c + ␤c +
AA-1.5.3 Step 3. Calculate coefficients ␳s and ␳c 2h c h
and moment MTS due to pressures Ps and Pt acting on
the tubesheet.
Configurations a, b, and c: ␳s p Ds / Do
2 − vc D2c
Pc′ p P
8 E c tc t
Configurations d, e, and f: ␳s p Gs / Do

Configurations a, e, and f: ␳c p Dc / Do
MPc p ␳c kc ␤c ( 1 + h␤c)Pc′
Configurations b, c, and d: ␳c p Gc / Do

AA-1.5.5 Step 5. Calculate K and coefficient F.

D2o
MTS p [(␳s − 1)(␳2s + 1) Ps − (␳c − 1)(␳ 2c + 1)Pt ]
16
Configuration d: Proceed to Step 5. K p A / Do

AA-1.5.4 Step 4. Calculate the moments acting on

the tubesheet due to pressure in the integral shell and/ Configuration a:
or channel.
Configurations a, b and c: Calculate coefficients ␤s, 1 − v*
Fp ( ␭s + ␭c + E ln K )
ks, ␭s, P′s, and moment MPs relative to the integral shell. E*

冪 12 (1 − ␯ 2s )
4
Configurations b and c:
␤s p
冪(Ds + ts)ts
1 − v*
Fp ( ␭s + E ln K )
Es t3s E*
ks p ␤s
6 (1 − v2s )
Configuration d:

冤 冢 冣冥
3Ds 2 1 − v*
␭s p k ␤2 + ␤s + Fp (E ln K)
2h s s h E*

615
AA-1.5.5 2001 SECTION VIII — DIVISION 1 AA-1.5.9

Configurations e and f: AA-1.5.8 Step 8. Calculate the tubesheet bending

stress ␴.
1 − v*
Fp (␭c + E ln K)
E* 6M
␴p
␮*( h − hg′ )2

AA-1.5.6 Step 6. Calculate moment M* acting on

If ␴ < 1.5S, either use the assumed tubesheet thickness
the unperforated tubesheet rim.
h, or decrease h (h ≥ hsh) and return to Step 2.
Configuration a: M* p MTS + MPc − MPs
If ␴ > 1.5S, increase the assumed tubesheet thickness
Configuration b:
h and return to Step 2.
If ␴ p1.5S, the assumed tubesheet thickness h is
Wc (C − Gc) optimized.
M* p MTS − MPs −
2 ␲ Do
Configurations a, b, c, e, and f: Proceed to Step 9.
Configuration d: The calculation procedure is com-
Configuration c: plete

Wc (G − Gc) AA-1.5.9 Step 9. Calculate the stresses in the shell

M* p MTS − MPs − and/or channel integral with the tubesheet.
2 ␲ Do
Configurations a, b, and c: The shell shall have a
uniform thickness of ts for a minimum length of
Configuration d:
1.8冪D s t s adjacent to the tubesheet. Calculate the axial
membrane stress ␴sm, axial bending stress ␴sb, and total
W (Gc − Gs)
M* p MTS +
2 ␲ Do
axial stress ␴s, in the shell at its junction to the
tubesheet using the following equations:
Configuration e:
D2s
␴sm p P
4ts (Ds + ts) s
Ws (C − Gs)
M* p MTS + MPc +
2 ␲ Do

冤␤P 冢 冣
6 ′ 1 − v* Do 2
␴sb p ks s s +3 ␤ +
Configuration f: t2s E* h2 s h

冢 冣冥
D2o
Ws (G − Gs) ⴛ Mp + 共 P s − P t兲
M* p MTS + MPc + 32
2 ␲ Do

␴s p 冨␴sm冨 + 冨␴sb冨
AA-1.5.7 Step 7. Calculate the maximum bending
moments acting on the tubesheet at the periphery:
Configurations a, e, and f: The channel shall have
a uniform thickness of tc for a minimum length of
D2o
M* − F ( Ps − Pt ) 1.8冪D c t c adjacent to the tubesheet. Calculate the axial
32
MP p , and membrane stress ␴cm, axial bending stress ␴cb, and total
1+F
axial stress ␴c, in the channel at its junction to the
tubesheet using the following equations:
at the center:
D2c
D2 ␴cm p P
Mo p MP + o ( 3 + v* )( Ps − Pt ) 4tc (Dc + tc) t
64

冤 冢 冣
Determine the maximum bending moment M acting 6 1 − v* Do 2
␴cb p kc ␤cPc′ − 3 ␤ +
on the tubesheet: t2c E* h2 c h

冢 冣冥
D2o
ⴛ Mp + 共 P − P t兲
M p MAX [ 冨MP 冨 , 冨Mo 冨 ] 32 s

616
AA-1.5.9 APPENDIX AA — NONMANDATORY
␴c p 冨␴cm冨 + 冨␴cb冨
Configuration a: If ␴s ≤ 1.5Ss and ␴c ≤ 1.5Sc,
the shell and channel designs are acceptable and the
calculation procedure is complete.
If ␴s > 1.5Ss or ␴c > 1.5Sc, proceed to Step 10.
Configurations b and c: If ␴s ≤ 1.5Ss, the shell design
is acceptable and the calculation procedure is complete.
If ␴s > 1.5Ss, proceed to Step 10.
Configurations e and f: If ␴c ≤ 1.5Sc, the channel
design is acceptable and the calculation procedure is
complete.
If ␴c > 1.5Sc, proceed to Step 10.
AA-1.5.10 Step 10. The design shall be reconsidered
by using one or a combination of the following 3
options.
Option 1. Increase the tubesheet thickness. Increase
the assumed tubesheet thickness h and return to Step 2.
Option 2. Increase the integral shell and/or channel
thickness.
Configurations a, b, and c: If ␴s > 1.5Ss, increase
the shell thickness ts.
Configurations a, e, and f: If ␴c > 1.5Sc increase
the channel thickness tc.
If it is necessary to adjust Ds or Dc, return to Step
3; otherwise, return to Step 4.
Option 3. Elastic-plastic calculation. Perform a simpli-
fied elastic-plastic calculation by using a reduced effec-
tive modulus of the integral shell and/or channel to
reflect the anticipated load shift resulting from plastic
action at the integral shell and/or channel-to-tubesheet
junction. This may result in a higher tubesheet bending
stress ␴.
Configuration a: This option may only be used when
␴s ≤ SPS,s and ␴c ≤ SPS,c. In Step 4, if ␴s > 1.5Ss,
replace Es with Es冪1.5S s / ␴s and recalculate ks, ␭s, P′s,
and MPs.
If ␴c > 1.5Sc, replace Ec with Ec冪1.5S c / ␴c and
recalculate kc, ␭c, P′c, and MPc.
Configurations b and c: This option may only be
used when ␴s ≤ SPS,s. In Step 4, replace Es with
Es冪1.5S s / ␴s and recalculate ks, ␭s, P′s, and MPs.
Configurations e and f: This option may only be
used when ␴c ≤ SPS,c. In Step 4, replace Ec with
Ec冪1.5S c / ␴c and recalculate kc, ␭c, P′c, and MPc.
Configurations a, b, c, e, and f: Perform Steps 5
through 7, and recalculate the tubesheet bending stress
␴ given in Step 8.
If ␴ ≤ 1.5S, the assumed tubesheet thickness h is
acceptable and the design is complete.
617
AA-1.6.1
If ␴ > 1.5S, the assumed tubesheet thickness h is
not acceptable and the design shall be reconsidered by
using Option 1 or 2.
AA-1.6 EXAMPLES
Examples illustrating the use of the design rules for
tubesheets in U-tube heat exchangers are shown as
follows.
AA-1.6.1 Example 1: Tubesheet Gasketed With
Shell and Channel
AA-1.6.1(a) Given. A U-tube heat exchanger with
the tubesheet construction in accordance with configura-
tion d as shown in Fig AA-1.1 sketch (d).
AA-1.6.1(a)(1) The shell side design conditions
are −15 and 10 psi at 300°F.
AA-1.6.1(a)(2) The tube side design condition is
135 psi at 300°F.
AA-1.6.1(a)(3) The tube material is SB-111 C44300
(Admiralty). The tubes are 0.625 in. outside diameter
and 0.065 in. thick and are to be expanded for the
full thickness of the tubesheet.
AA-1.6.1(a)(4) The tubesheet material is SA-285,
Grade C (K02801) with a 0.125 in. corrosion allowance
on the tube side and no pass partition grooves. The
tubesheet outside diameter is 20.0 in. The tubesheet
has 386 tube holes on a 0.75 in. equilateral triangular
pattern. The largest center-to-center distance between
adjacent tube rows is 1.75 in., and the radius to the
outermost tube hole center is 8.094 in.
AA-1.6.1(a)(5) The shell gasket load reaction diam-
eter is 19.0 in. and the shell flange design bolt load
is 147,000 lb.
AA-1.6.1(a)(6) The channel gasket load reaction
diameter is 19.0 in. and the channel flange design bolt
load is 162,000 lb.
AA-1.6.1(b) Data Summary. The data summary con-
sists of those variables from the nomenclature (AA-
1.3 and AA-4.3) that are applicable to this configuration.
AA-1.6.1(b)(1) The data for AA-1.3 is:
Ap 20.0 in.
ctp 0.125 in.
Ep 28.3 ⴛ 106 psi from Table TM-1 of Section II,
Part D at 300°F
Gcp 19.0 in.
Gsp 19.0 in.
hgp 0 in.
h′g p 0 in.
Psp 10 psi and −15 psi
Ptp 135 psi
Sp 15,700 psi from Table 1A of Section II, Part D
at 300°F
AA-1.6.1 2001 SECTION VIII — DIVISION 1 AA-1.6.2

Wcp 162,000 lb AA-1.6.1(c)(8) Step 8. Calculate ␴.

Wsp 147,000 lb ␴p 23,300 psi ≤ 1.5S p 23,600 psi
Wp 162,000 lb The assumed value for h is acceptable and the
AA-1.6.1(b)(2) The data for AA-4.3 is: calculation procedure is complete.
dtp 0.625 in.
Etp 15.4 ⴛ 106 psi from Table TM-3 of Section II, AA-1.6.2 Example 2: Tubesheet Gasketed With
Part D at 300°F Shell and Channel
pp 0.75 in. AA-1.6.2(a) Given. A U-tube heat exchanger with
rop 8.094 in. the tubesheet construction in accordance with configura-
Stp 10,000 psi from Table 1B of Section II, Part D tion d as shown in Fig AA-1.1 sketch (d).
at 300°F AA-1.6.2(a)(1) The shell side design condition is
ttp 0.065 in. 375 psi at 500°F.
ULp 1.75 in. AA-1.6.2(a)(2) The tube side design condition is
␳p 1.0 for a full length tube expansion 75 psi at 500°F.
AA-1.6.1(c) Calculation Results. The calculation re- AA-1.6.2(a)(3) The tube material is SB-111 C70600
sults are shown for loading case 3 where Ps p −15 (90 /10 copper–nickel). The tubes are 0.75 in. outside
psi and Pt p 135 psi since this case yields the greatest diameter and 0.049 in. thick and are to be expanded
value of ␴. for one-half of the tubesheet thickness.
AA-1.6.1(c)(1) Step 1. Calculate ␮ and Do from AA-1.6.2(a)(4) The tubesheet material is SA-516,
AA-4.5.1 and calculate hsh. Grade 70 (K02700) with a 0.125 in. corrosion allowance
␮p 0.167 on the tube side and a 0.1875 in. deep pass partition
Dop 16.8 in. groove. The tubesheet outside diameter is 48.88 in.
hsh p 0.301 in. The tubesheet has 1534 tube holes on a 0.9375 in.
AA-1.6.1(c)(2) Step 2. Assume a value for h. equilateral triangular pattern. The largest center-to-cen-
Calculate ␮* from AA-4.5.1. Determine E*/E and ␯* ter distance between adjacent tube rows is 2.25 in.,
from AA-4.5.2. Calculate E*. and the radius to the outermost tube hole center is
20.5 in.
hp 1.48 in.
AA-1.6.2(a)(5) The shell gasket load reaction diam-
d*p 0.580 in.
eter is 43.5 in. and the shell flange design bolt load
p* p 0.805 in.
is 675,000 lb.
␮*p 0.280
AA-1.6.2(a)(6) The channel gasket load reaction
h/pp 1.97
diameter is 44.88 in. and the channel flange design
v*p 0.368
bolt load is 584,000 lb.
E*/Ep 0.256
AA-1.6.2(a)(7) The tubesheet shall be designed for
E*p (E*/E)E p 7.24 ⴛ 106 psi
the differential design pressure.
AA-1.6.1(c)(3) Step 3. Calculate ␳s, ␳c and MTS
AA-1.6.2(b) Data Summary. The data summary con-
for configuration d. sists of those variables from the nomenclature (AA-
␳sp 1.13 1.3 and AA-4.3) that are applicable to this configuration.
␳cp 1.13 AA-1.6.2(b)(1) The data for AA-1.3 is:
MTSp −785 in.-lb/in. Ap 48.88 in.
AA-1.6.1(c)(4) Step 4. For configuration d, skip ctp 0.125 in.
Step 4 and proceed to Step 5. Ep 27.1 ⴛ 106 psi from Table TM-1 of Section II,
AA-1.6.1(c)(5) Step 5. Calculate K and F for Part D at 500°F
configuration d. Gcp 44.88 in.
Kp 1.19 Gsp 43.5 in.
Fp 0.429 hgp 0.1875 in.
AA-1.6.1(c)(6) Step 6. Calculate M* for configura- h′gp 0.0625 in.
tion d. Psp 375 psi
M*p −785 in.-lb/in. Ptp 75 psi
AA-1.6.1(c)(7) Step 7. Calculate Mp, Mo, and M. Sp 20,000 psi from Table 1A of Section II, Part D
Mp p −152 in.-lb/in. at 500°F
Mop −2380 in.-lb/in. Wcp 584,000 lb
Mp 2380 in.-lb/in. Wsp 675,000 lb

618
AA-1.6.2 APPENDIX AA — NONMANDATORY AA-1.6.3

Wp 675,000 lb The assumed value for h is acceptable and the

AA-1.6.2(b)(2) The data for AA-4.3 is: calculation procedure is complete.
dtp 0.75 in.
Etp 16.6 ⴛ 106 psi from Table TM-3 of Section II, AA-1.6.3 Example 3: Tubesheet Integral With
Part D at 500°F Shell and Channel
pp 0.9375 in. AA-1.6.3(a) Given. A U-tube heat exchanger with
rop 20.5 in. the tubesheet construction in accordance with configura-
Stp 8000 psi from Table 1B of Section II, Part D tion a as shown in Fig AA-1.1 sketch (a).
at 500°F AA-1.6.3(a)(1) The shell side design conditions
ttp 0.049 in. are −10 and 60 psi at 500°F.
ULp 2.25 in. AA-1.6.3(a)(2) The tube side design conditions are
␳p 0.5 for tubes expanded for one-half the tube- −15 and 140 psi at 500°F.
sheet thickness AA-1.6.3(a)(3) The tube material is SA-249 S31600
AA-1.6.2(c) Calculation Results. Since differential (Stainless Steel 316). The tubes are 0.75 in. outside
pressure design is specified, the calculation results are diameter and 0.065 in. thick and are to be full-strength
shown for loading case 3. welded with no credit taken for expansion.
AA-1.6.2(c)(1) Step 1. Calculate ␮ and Do from AA-1.6.3(a)(4) The tubesheet material is SA-240
AA-4.5.1 and calculate hsh. S31600 (Stainless Steel 316) with no corrosion allow-
␮p 0.2 ance on the tube side and no pass partition grooves.
Dop 41.8 in. The tubesheet outside diameter is 12.939 in. The tube-
hshp 0.979 in. sheet has 76 tube holes on a 1.0 in. square pattern.
AA-1.6.2(c)(2) Step 2. Assume a value for h. The largest center-to-center distance between adjacent
Calculate ␮* from AA-4.5.1. Determine E*/E and ␯* tube rows is 2.25 in., and the radius to the outermost
from AA-4.5.2. Calculate E*. tube hole center is 5.438 in.
hp 4.78 in. AA-1.6.3(a)(5) The shell material is SA-312
d*p 0.738 in. S31600 (Stainless Steel 316) welded pipe. The shell
inside diameter is 12.39 in. and the shell thickness is
p*p 0.971 in.
0.18 in.
␮*p 0.240
AA-1.6.3(a)(6) The channel material is SA-240
h/pp 5.10
S31600 (Stainless Steel 316). The channel inside diame-
v*p 0.407
ter is 12.313 in. and the channel thickness is 0.313 in.
E*/Ep 0.204
AA-1.6.3(b) Data Summary. The data summary con-
E*p (E*/E)E p 5.54 ⴛ 106 psi
sists of those variables from the nomenclature (AA-
AA-1.6.2(c)(3) Step 3. Calculate ␳s, ␳c and MTS
1.3 and AA-4.3) that are applicable to this configuration.
for configuration d.
AA-1.6.3(b)(1) The data for AA-1.3 is:
␳sp 1.04 Ap 12.939 in.
␳cp 1.07 ctp 0 in.
MTSp 2250 in.-lb/in. Dcp 12.313 in.
AA-1.6.2(c)(4) Step 4. For configuration d, skip Dsp 12.39 in.
Step 4 and proceed to Step 5. Ep 25.8 ⴛ 106 psi from Table TM-1 of Section II,
AA-1.6.2(c)(5) Step 5. Calculate K and F for Part D at 500°F
configuration d. Ecp 25.8 ⴛ 106 psi from Table TM-1 of Section II,
Kp 1.17 Part D at 500°F
Fp 0.458 Esp 25.8 ⴛ 106 psi from Table TM-1 of Section II,
AA-1.6.2(c)(6) Step 6. Calculate M* for configura- Part D at 500°F
tion d. hgp 0 in.
M*p 5800 in.-lb/in. h′gp 0 in.
AA-1.6.2(c)(7) Step 7. Calculate Mp, Mo, and M. Psp 60 psi and −10 psi
Mpp − 1150 in.-lb/in. Ptp 140 psi and −15 psi
Mop 26,700 in.-lb/in. Sp 18,000 psi from Table 1A of Section II, Part D
Mp 26,700 in.-lb/in. at 500°F
AA-1.6.2(c)(8) Step 8. Calculate ␴. Scp 18,000 psi from Table 1A of Section II, Part D
␴ p 29,900 psi ≤ 1.5S p 30,000 psi at 500°F

619
AA-1.6.3 2001 SECTION VIII — DIVISION 1 AA-1.6.4

Ssp 18,000 psi from Table 1A of Section II, Part D P′c p 0.559 ⴛ 10−3 in.
at 500°F (for seamless pipe, SA-312) MPcp 121 in.-lb/in.
tcp 0.313 in. AA-1.6.3(c)(5) Step 5. Calculate K and F for
tsp 0.18 in. configuration a.
␯sp 0.3 Kp 1.11
␯cp 0.3 Fp 3.90
AA-1.6.3(b)(2) The data for AA-4.3 is: AA-1.6.3(c)(6) Step 6. Calculate M* for configura-
dt p 0.75 in. tion a.
Etp 25.8 ⴛ 106 psi from Table TM-1 of Section II, M* p −33.6 in.-lb/in.
Part D at 500°F AA-1.6.3(c)(7) Step 7. Calculate Mp, Mo, and M.
pp 1.0 in. Mp p 498 in.-lb/in.
rop 5.438 in. Mo p −540 in.-lb/in.
Stp 18,000 psi from Table 1A of Section II, Part D M p 540 in.-lb/in.
at 500°F (for seamless tube, SA-213) AA-1.6.3(c)(8) Step 8. Calculate ␴.
ttp 0.065 in. ␴ p 16,500 psi ≤ 1.5S p 27,000 psi
ULp 2.25 in. AA-1.6.3(c)(9) Step 9. For configuration a, calculate
␳p 0 for no tube expansion ␴sm, ␴sb, and ␴s for the shell and ␴cm, ␴cb, and ␴c for
AA-1.6.3(c) Calculation Results. The calculation re- the channel. The shell thickness shall be 0.18 in. for
sults are shown for loading case 3 where Ps p −10 a minimum length of 2.69 in. adjacent to the tubesheet
psi and Pt p 140 psi since this case yields the greatest and the channel thickness shall be 0.313 in. for a
value of ␴. minimum length of 3.53 in. adjacent to the tubesheet.
AA-1.6.3(c)(1) Step 1. Calculate ␮ and Do from ␴sm p −170 psi
AA-4.5.1 and calculate hsh. ␴sb p −13,400 psi
␮p 0.25 ␴s p 13,600 psi ≤ 1.5Ss p 27,000 psi
Dop 11.6 in. ␴cm p 1340 psi
hshp 0.121 in. ␴cb p 19,900 psi
AA-1.6.3(c)(2) Step 2. Assume a value for h. ␴c p 21,200 psi ≤ 1.5Sc p 27,000 psi
Calculate ␮* from AA-4.5.1. Determine E*/E and v* The assumed value for h is acceptable and the shell
from AA-4.5.2 Calculate E*. and channel stresses are within the allowable stresses;
hp 0.75 in. therefore, the calculation procedure is complete.
d*p 0.75 in.
p*p 1.15 in. AA-1.6.4 Example 4: Tubesheet Gasketed With
␮*p 0.349 Shell and Integral With Channel, with Tubesheet
h/pp .75 Extended as a Flange
v*p 0.276 AA-1.6.4(a) Given. A U-tube heat exchanger with
E*/Ep 0.438 the tubesheet construction in accordance with configura-
E*p (E*/E)E p 11.3 ⴛ 106 psi tion e as shown in Fig. AA-1.1 sketch (e).
AA-1.6.3(c)(3) Step 3. Calculate ␳s, ␳c, and MTS AA-1.6.4(a)(1) The shell side design condition is
for configuration a. 650 psi at 400°F.
␳sp 1.07 AA-1.6.4(a)(2) The tube side design condition is
␳cp 1.06 650 psi at 400°F.
MTSp −160 in.-lb/in. AA-1.6.4(a)(3) The tube material is SA-179
AA-1.6.3(c)(4) Step 4. For configuration a, calculate (K10200). The tubes are 0.75 in. outside diameter and
␤s, ks, ␭s, P′s, and MPs for the shell and ␤c, kc, ␭c, 0.085 in. thick and are to be expanded for the full
P′c, and MPc for the channel. thickness of the tubesheet.
␤sp 1.21 in.−1 AA-1.6.4(a)(4) The tubesheet material is SA-516,
ksp 33,300 lb Grade 70 (K02700) with a 0.125 in. corrosion allowance
␭sp 13.6 ⴛ 106 psi on the tube side and no pass partition grooves. The
P′sp −0.702 ⴛ 10−4 in. tubesheet outside diameter is 37.25 in. The tubesheet
MPsp −5.74 in.-lb/in. has 496 tube holes on a 1.0 in. square pattern. The
␤cp 0.914 in.−1 largest center-to-center distance between adjacent tube
kcp 132,000 lb rows is 1.375 in., and the radius to the outermost tube
␭cp 44.6 ⴛ 106 psi hole center is 12.75 in.

620
AA-1.6.4 APPENDIX AA — NONMANDATORY AA-1.6.4

AA-1.6.4(a)(5) The shell gasket load reaction diam- Do p 26.3 in.

eter is 32.375 in., the shell flange bolt circle is 35 in., hsh p 1.07 in.
and the shell flange design bolt load is 656,000 lb. AA-1.6.4(c)(2) Step 2. Assume a value for h.
AA-1.6.4(a)(6) The channel material is SA-516 Calculate ␮* from AA-4.5.1. Determine E*/E and ␯*
Grade 70 (K02700). The channel inside diameter is 31 from AA-4.5.2. Calculate E*.
in. and the channel thickness is 0.625 in. hp 4.06 in.
AA-1.6.4(b) Data Summary. The data summary con- d*p 0.635 in.
sists of those variables from the nomenclature (AA- p*p 1.04 in.
1.3 and AA-4.3) that are applicable to this configuration. ␮*p 0.386
AA-1.6.4(b)(1) The data for AA-1.3 is: h/pp 4.06
A p 37.25 in. v*p 0.318
Cp 35 in. E*/Ep 0.442
ctp 0.125 in. E*p (E*/E)E p 12.2 ⴛ 106 psi
Dcp 31 in. AA-1.6.4(c)(3) Step 3. Calculate ␳s, ␳c, and MTS
Ep 27.5 ⴛ 106 psi from Table TM-1 of Section II, for configuration e.
Part D at 400°F ␳s p 1.23
Ecp 27.7 ⴛ 106 psi from Table TM-1 of Section II, ␳c p 1.18
Part D at 400°F MTS p 16,500 in.-lb/in.
Gs p 32.375 in. AA-1.6.4(c)(4) Step 4. For configuration e, calculate
hgp 0 in. ␤c, kc, ␭c, P′c, and MPc for the channel.
h′gp 0 in. ␤c p 0.409 in.−1
Psp 650 psi kcp 506,000 lb
Ptp 650 psi ␭cp 5.68 ⴛ 106 psi
Sp 20,000 psi from Table 1A of Section II, Part D P′cp 0 in.
at 400°F MPcp 0 in.-lb/in.
Scp 20,000 psi from Table 1A of Section II, Part D AA-1.6.4(c)(5) Step 5. Calculate K and F for
configuration e.
at 400°F
Kp 1.42
Sy,cp 32,500 psi from Table Y-1 of Section II, Part
Fp 0.859
D at 400°F
AA-1.6.4(c)(6) Step 6. Calculate M* for configura-
SPS,cp 65,000 psi {either 2Sy,c or 3Sc, [2(32,500) p
tion e.
65,000 or 3(20,000) p 60,000]}
M p 26,900 in.-lb/in.
tc p 0.625 in.
AA-1.6.4(c)(7) Step 7. Calculate Mp, Mo, and M.
Ws p 656,000 lb.
Mpp 8010 in.-lb/in.
␯c p 0.3
Mop 31,200 in.-lb/in.
AA-1.6.4(b)(2) The data for AA-4.3 is:
M p 31,200 in.-lb/in.
dt p 0.75 in. AA-1.6.4(c)(8) Step 8. Calculate ␴.
Et p 27.7 ⴛ 106 psi from Table TM-1 of Section II, ␴p 29,400 psi ≤ 1.5S p 30,000 psi
Part D at 400°F AA-1.6.4(c)(9) Step 9. For configuration e, calculate
p p 1.0 in. ␴cm, ␴cb and ␴c for the channel. The channel thickness
ro p 12.75 in. shall be 0.625 in. for a minimum length of 7.92 in.
St p 13,400 psi from Table 1A of Section II, Part D adjacent to the tubesheet.
at 400°F ␴cm p 0 psi
tt p 0.085 in. ␴cb p −41,400 psi
UL p 1.375 in. ␴c p 41,400 psi > 1.5Sc p 30,000 psi
␳ p 1.0 for full length tube expansion AA-1.6.4(c)(10) Step 10. Since the channel stress
AA-1.6.4(c) Calculation Results. The calculation re- exceeds the allowable stress, the design must be recon-
sults are shown for loading case 2 where Ps p 650 sidered using one of three options.
psi and Pt p 0 psi since this case yields the greatest Option 1 requires that the tubesheet thickness be
value of ␴. increased until the channel stresses calculated in Step
AA-1.6.4(c)(1) Step 1. Calculate ␮ and Do from 9 are within the allowable stress for each loading case.
AA-4.5.1 and calculate hsh. Option 2 requires that the shell and/or channel thick-
␮ p 0.25 ness be increased until their respective stresses calcu-

621
AA-1.6.4 2001 SECTION VIII — DIVISION 1
lated in Step 9 are within the allowable stress for each
loading case.
Option 3 permits one elastic-plastic calculation for
each design. If the tubesheet stress is still within the
allowable stress given is Step 8, the design is acceptable
and the calculation procedure is complete. If the tube-
sheet stress is greater than the allowable stress, the
design shall be reconsidered by using Option 1 or 2.
Choose Option 3, configuration e.
Since ␴c ≤ SPS,c p 65,000 psi for all loading cases,
this option may be used. The calculations for this
option are only required for each loading case where
␴c > 1.5Sc p 30,000 psi.
Calculate a new value of Ec for each loading case
where ␴c > 30,000 psi. For this example, the new
value of Ec and the calculations for loading case 2 are
shown.
Ec p 23.6 ⴛ 106 psi
Recalculate kc, ␭c, P′c, and MPc given in Step 4
using the applicable reduced effective modulus, Ec, for
each loading case.
kc p 431,000 lb
␭c p 4.84 ⴛ 106 psi
P′c p 0 in.
MPc p 0 in.-lb/in.
Recalculate F given in Step 5.
F p 0.811
Recalculate M* given in Step 6.
M* p 26,900 in.-lb/in.
Recalculate Mp, Mo, and M given in Step 7.
Mp p 8590 in.-lb/in.
Mo p 31,800 in.-lb/in.
M p 31,800 in.-lb/in.
Recalculate ␴ given in Step 8.
␴ p 30,000 psi ≤ 1.5S p 30,000 psi
The assumed value for h is acceptable and the
calculation procedure is complete.
AA-2 RULES FOR THE DESIGN OF
FIXED TUBESHEETS
This Appendix covers fixed circular tubesheets with
unperforated rims. Four different configurations are
applicable as shown in Fig. AA-2.0 sketches (a), (b),
(c), and (d):
AA-2(a) configuration a, which is integral on both
sides;
AA-2(b) configuration b, which is shell-side integral
and channel-side gasketed, with tubesheet extended as
a flange;
622
AA-2.1
AA-2(c) configuration c, which is shell-side integral
and channel-side gasketed, with tubesheet not extended
as a flange; and
AA-2(d) configuration d, which is gasketed on
both sides.
These design rules apply to tubesheets having tube
holes in either equilateral triangular or square patterns.
AA-2.1 Design Considerations
AA-2.1(a) It is generally not possible to determine,
by observation, the most severe condition of coincident
difference of pressure (due to Ps and Pt) and difference
of thermal expansion between tubes and shell (due to
␥). Thus, it is necessary to evaluate all the anticipated
loading conditions to ensure the worst load combination
has been considered in the design.
The various loading conditions to be considered shall
include the normal operating conditions, the start-up
conditions, the shutdown conditions, and the upset
conditions, which may govern the design of the main
components of the heat exchanger (i.e., tubesheet, tubes,
shell, channel). For each of these conditions, it is
necessary to account for the following loading cases,
which will determine the effective pressure Pe to be
used in the design formulas:
AA-2.1(a)(1) Loading Case 1. Tube side pressure
Pt acting only (Ps p 0), without thermal expansion
(␥ p 0, P s* p 0, P c* p 0).
AA-2.1(a)(2) Loading Case 2. Shell side pressure
Ps acting only (Pt p 0), without thermal expansion
(␥ p 0, P s* p 0, P c* p 0).
AA-2.1(a)(3) Loading Case 3. Tube side Pt and
shell side Ps pressures acting simultaneously, without
thermal expansion (␥ p 0, P s* p 0, P c* p 0).
AA-2.1(a)(4) Loading Case 4. Thermal expansion
␥ acting only (Pt p 0, Ps p 0).
AA-2.1(a)(5) Loading Case 5. Tube side pressure
Pt acting only (Ps p 0), with thermal expansion ␥.
AA-2.1(a)(6) Loading Case 6. Shell side pressure
Ps acting only (Pt p 0), with thermal expansion ␥.
AA-2.1(a)(7) Loading Case 7. Tube side Pt and
shell side Ps pressures acting simultaneously, together
with thermal expansion ␥.
When differential pressure design is specified by the
user, the design shall be based only on loading cases
3, 4, and 7, as provided by UG-21.
The designer should take appropriate consideration
of the stresses resulting from the pressure test required
by UG-99 or UG-100 [see UG-99(d)].
AA-2.1(b) Elastic moduli, yield strengths, and allow-
able stresses shall be taken at design temperatures.
 APPENDIX AA — NONMANDATORY Fig. AA-2.0

FIG. AA-2.0 TYPICAL FIXED TUBESHEET TYPE CONSTRUCTION

623
 Fig. AA-2.0 2001 SECTION VIII — DIVISION 1

C
2 ac Dc as A
Pt 2

G Ds
Ps
C
hg UL
h
ro

tc

Channel ts Shell

(c) Typical Shell-Side Integral and Channel-Side Gasketed Type Tubesheet

Construction With Tubesheet Not Extended as a Flange

C
2 as A
ac Dc Pt 2

Ds
Ps
C
hg UL
h
ro

tc

Channel ts Shell

(d) Typical Two-Side Gasketed Type Tubesheet Construction

01 FIG. AA-2.0 TYPICAL FIXED TUBESHEET TYPE CONSTRUCTIONS (CONT’D)

624
AA-2.1 APPENDIX AA — NONMANDATORY
However for cases involving thermal loading (loading
cases 4, 5, 6, and 7), it is permitted to use the operating
temperatures instead of the design temperatures.
AA-2.1(c) The design shall be performed for both
corroded and uncorroded conditions.
AA-2.1(d) As the calculation procedure is iterative,
a value h must be assumed for the tubesheet thickness
to calculate and check that the maximum stresses in
tubesheet, tubes, shell, and channel are within the
maximum permissible stress limits.
Because any increase of tubesheet thickness may
lead to overstresses in tubes, shell, or channel, a final
check shall be performed, using in the formulas the
nominal thicknesses of tubesheet, tubes, shell, and
channel, in both corroded and uncorroded conditions,
as specified in (c) above.
AA-2.1(e) The designer shall consider:
AA-2.1(e)(1) the loadings specified in UG-22. This
design procedure does not account for the loadings due
to weight and pressure drop across the tube-bundle.
AA-2.1(e)(2) the integrity of the tube-to-tubesheet
joint (see Appendix A).
AA-2.1(e)(3) the shell column buckling in accord-
ance with UG-23(b).
AA-2.2 Materials and Methods of Fabrication
Materials and methods of fabrication for tubesheets,
shells, channels, and tubes shall be in accordance with
Subsections A, B, and C. Weld sizes shall be in
accordance with Subsection B, Part UW, Figs. UW-
13.2 and UW-13.3.
AA-2.3 Nomenclature
Symbols used in this Appendix are as follows:
Ap outside diameter of tubesheet, in.
Cp bolt circle diameter, in. (see Appendix 2)
Dcp inside channel diameter, in.
Dsp inside shell diameter, in.
Ep modulus of elasticity for tubesheet material at
T, psi
Ecp modulus of elasticity for channel material at
Tc , psi
Esp modulus of elasticity for shell material at Ts , psi
Etp modulus of elasticity for tube material at Tt , psi
NOTE: The modulus of elasticity shall be taken from the applicable
Table TM in Section II, Part D. When a material is not listed in
the TM tables, the requirements of U-2(g) shall be applied.
Jp expansion joint factor (J p 1.0 if no joint).
Kjp axial rigidity of expansion joint, total force /
elongation, lb /in.
625
AA-2.3
Ltp tube length between outer tubesheet faces, in.
Lp Lt − 2h, tube length between inner tubesheet
faces
Psp shell side design pressure (see UG-21), psi (use
a negative value for vacuum)
Ptp tube side design pressure (see UG-21), psi (use
a negative value for vacuum)
Sp allowable stress for tubesheet material at T, psi
Scp allowable stress for channel material at Tc , psi
Ssp allowable stress for shell material at Ts , psi
Stp allowable stress for tube material at Tt , psi
SPS p allowable primary plus secondary stress for
tubesheet material at T per UG-23(e), psi
SPS,c p allowable primary plus secondary stress for
channel material at Tc per UG-23(e), psi
SPS,s p allowable primary plus secondary stress for
shell material at Ts per UG-23(e), psi
Ts,mp mean shell metal temperature along shell
length, °F
Tt,mp mean tube metal temperature along tube
length, °F
Tp tubesheet design temperature, °F (see Note)
Ttp tubes design temperature, °F (see Note)
Tsp shell design temperature, °F (see Note)
Tcp channel design temperature, °F (see Note)
NOTE: For cases involving thermal loading (loading cases 4, 5, 6,
and 7), it is permitted to use the operating temperatures instead of
the design temperatures.
Wp channel flange design bolt load, lb (see Appen-
dix 2)
aop radius of the perforated region, in.
acp radial channel dimension, in. (Fig. AA-2.0)
asp radial shell dimension, in. (Fig. AA-2.0)
dtp tube outside diameter, in.
␩p flexural efficiency
hp tubesheet thickness, in.
hgp tube-side pass partition groove depth, in.
tcp channel thickness, in.
tsp shell thickness, in.
Ntp number of tubes
ttp nominal tube wall thickness, in.
hJp height of expansion joint outside of shell enve-
lope, in. [see Fig. AA-2.0 sketch (a)]
␣ ′cp mean coefficient of thermal expansion of chan-
nel material at T ′c , in. /in. /°F
␣s,mp mean coefficient of thermal expansion of shell
material at Ts,m , in. /in. /°F
␣t,mp mean coefficient of thermal expansion of tube
material at Tt,m , in.in. /°F
␣ ′p mean coefficient of thermal expansion of tube-
sheet material at T ′, in. /in. /°F
AA-2.3 2001 SECTION VIII — DIVISION 1 AA-2.4.5

␣ ′sp mean coefficient of thermal expansion of shell where

material at T ′s , in. /in. /°F Ksp shell axial stiffness
T ′p tubesheet metal temperature at the rim, °F ␲ ts 共 Ds + t s 兲 E s
p
T′sp shell metal temperature at the tubesheet, °F L
T′cp channel metal temperature at the tubesheet, °F Ktp tube axial stiffness
ctp tubesheet corrosion allowance on tubeside ␲ tt 共 dt − tt 兲 Et
MAX [(a), (b), (c), . . .] p
L
p greatest of a, b, c
␯p Poisson’s ratio of tubesheet material 冪 3 (1 − ␯ 2s )
4

␯tp Poisson’s ratio of tube material ␤s p

冪
Ds + t s
␯sp Poisson’s ratio of shell material 2
ts
␯cp Poisson’s ratio of channel material
␥p axial differential thermal expansion between
冪 3 (1 − ␯ 2c)
4
tubes and shell ␤c p

冪
Dc+ tc
tc
2
AA-2.4 Design Formulas and Calculation If the shell is gasketed (configuration d), set ␤s p
Procedure 0. If the channel is gasketed (configuration b, c, or d),
The procedure for the design of a fixed tubesheet set ␤c p 0.
is as follows. Four tubesheet-shell-channel joint config- AA-2.4.3 Step 3. Calculate J by using the following
urations are covered by these procedures as shown in equation:
Fig. AA-2.0 sketches (a), (b), (c), and (d).
1
AA-2.4.1 Step 1. Determine Do, ␮, and ␮* from Jp
Ks
AA-4.5.1 and calculate ao, ␳s, ␳c, xt, and xs by using 1+
KJ
the following equations:

Do AA-2.4.4 Step 4. Calculate h/p. If ␳ changes,

ao p
2 recalculate d* and ␮* from AA-4.5.1. Determine E*/
E and ␯* relative to h/p from AA-4.5.2. Calculate
the parameters ␩, Xa , and V by using the following
as equations:
␳s p
ao
E* 1 − ␯2
␩p ⴛ
ac E 1 − ␯*2
␳c p
ao
1⁄

冤 冥
Et tt (dt − tt) a 2o 4
Xa p 24 (1 − ␯*2) Nt
2 E* L h3
冢 冣
d − 2tt
xt p 1 − Nt t
2 ao

冢 冣
2 ␤s t 3s Es as ␤ 2 h2
Vp
E h3 冤
1 − ␯s 2
1 + ␤s h + s
2
2

冢2 a 冣
dt
xs p 1 − Nt

冢1 + ␤ h + 冣冥
o ␤c t 3c Ec ac ␤ 2c h2
+ c
1− ␯ 2c 2

AA-2.4.2 Step 2. Calculate the shell and channel AA-2.4.5 Step 5. Using the calculated values of Xa , 01

parameters Ks,t , ␤s , and ␤c by using the following enter Table AA-2.4 or Fig. AA-2.4.1, to determine Zd ,
equations: Zv , and Zm . Then calculate the parameter Q1 using the
following equations:

Ks,t p
Ks ␳ s − 1 − ⌽ Zv
Q1 p
Nt K t 1 + ⌽ Zm

626
 APPENDIX AA — NONMANDATORY Table AA-2.4

TABLE AA-2.4
FORMULAS FOR DETERMINATION OF Zd , Zv , Zm , AND Fm
(1) Calculate Bessel functions of order 0 relative to x, where x varies from 0 to Xa such that 0 < x ≤ Xa:

np⬁
(x /2)4n (x /2)4 (x /2)8 (x /2)12
ber (x) p 兺 (−1)n
2
p1−
2
+
2
− +...
np0 (2n) ! (2!) (4!) (6!)2

np⬁
(x /2)4n−2 (x /2)2 (x /2)6 (x /2)10
bei (x) p 兺 (−1)n−1
2
p+
2
−
2
+ −...
np1 (2 n − 1) ! (1!) (3!) (5!)2

and their derivatives:

np⬁
(2 n) (x /2)4n−1 2 (x /2)3 4 (x /2)7 6 (x /2)11
ber′ (x) p 兺 (−1)n
2
p−
2
+
2
− +...
np1 (2 n !) (2!) (4!) (6!)2

np⬁
(2 n − 1) (x /2)4n−3 (x /2)1 3 (x /2)5 5 (x /2)9
bei′ (x) p 兺 (−1)n−1 p − + −...
np1 (2 n − 1) !2 (1!)2 (3!)2 (5!)2
NOTE: At least n p 4 + x /2 terms (rounded to the nearest integer) are required to obtain an adequate approximation of the Bessel functions
and their derivatives.

(2) Calculate functions ␺1 (x), ␺2 (x), and Z(x) relative to x:

1 − ␯*
␺1 (x) p bei (x) + · ber′ (x)
x

1 − ␯*
␺2 (x) p ber (x) − · bei′ (x)
x

(3) Calculate Za , Zd , Zv , and Zm relative to Xa:

Za p bei′ (Xa) · ␺2 (Xa) − ber′ (Xa) · ␺1 (Xa)

ber (Xa) · ␺2 (Xa) + bei (Xa) · ␺1 (Xa)

Zd p
X 3a · Za

ber′ (Xa) · ␺2 (Xa) + bei′ (Xa) · ␺1 (Xa)

Zv p
X 2a · Za
ber′2 (Xa) + bei′2 (Xa)
Zm p
Xa · Za

(4) Calculate functions Qm (x), Qv (x), and Fm (x) relative to x:

bei′ (Xa) · ␺2 (x) − ber′ (Xa) · ␺1 (x)

Qm (x) p
Za

␺1 (Xa) · ␺2 (x) − ␺2 (Xa) · ␺1 (x)

Qv (x) p
Xa · Za

(5) For each loading case, calculate Fm (x) relative to x:

Qv (x) + Q3 · Qm (x)
Fm (x) p
2

(6) Fm is the maximum of the absolute value of Fm (x) when x varies from 0 to Xa such that 0 < x ≤ Xa:

Fm p MAX |Fm (x)|

627
 AA-2.4.5 2001 SECTION VIII — DIVISION 1 AA-2.4.6

0.80

Curves giving Zd, Zv, or Zm are valid for = 0.4.

They are sufficiently accurate to be used for other
0.70 values of .

For XA 12.0, see Table AA-2.4.

0.60

0.50
Zd, Zv, or Zm

0.40

Zd

0.30

0.20
Zm

0.10
Zv

0
0 2 4 6 8 10 12

Xa

01 FIG. AA-2.4.1 Zd , Zv , and Zm VERSUS Xa

where JKs, t
Pe p
1 + JKs, t 关 QZ1 + 共 ␳s − 1 兲 QZ 2兴
冤 冢 冣 冥
1−␯ 2
A
⌽p ln +V
␩ 2 ao
ⴛ 共 Ps′ − Pt′ + P␥ + P␥* + PW + Prim 兲
01 AA-2.4.6 Step 6. Using the calculated values of Xa
and Q1 from Steps 4 and 5, calculate QZ1 and QZ2 .
where
(Zd + Q1 Zv) X 4a
N t 共 d t − t t 兲 dt
冢
QZ1 p 2␳2s ␳2 − 1
2 P s′ p x s + ␯t + ␯s − s
2a2o Ks, t JKs, t

(Zv + Q1 Zm) X 4a
冣
QZ2 p (1 − J) as hj (Ds + hj)
− Ps
2 JKs, t a2o Ds

Nt 共 dt − tt 兲 共 dt − 2tt 兲
冢 冣
Calculate the effective pressure Pe using the following 1
P t′ p x t + ␯t + P
equation: 2a2o JKs, t t

628
AA-2.4.6 APPENDIX AA — NONMANDATORY AA-2.4.7

NtKt For conservative values of P*s and P*c, use Tr p

P␥ p ␥
␲a2o T ′ , T *s p Ts′, and T *c p Tc′.

P␥* p U 共 P*s ␥*s − P*c ␥*c 兲 ␥b p 0 for configuration a

p ␳c − C / 共 2ao 兲 for configuration b

␥b
PW p − UW
2␲a2o p ␳c − G/(2ao ) for configuration c

Prim p − U 共 Ps ␥s + Pt ␥c 兲 p ␳c − ␳s for configuration d

with
共 1 + ␤s h 兲
␥*s p ␤2s t 2s ␳3s
␥ p 关 ␣ t, m 共 Tt, m − 70 兲 − ␣ s, m 共 Ts, m − 70 兲兴 L 6 共 1 − ␯ 2s 兲

共 ␳2s − 1 兲 共␳s − 1 兲
␥s p − ␥*s
NOTE: ␥ p 0 for loading cases 1, 2, and 3. 4

共 1 + ␤c h 兲
␥*c p ␤2c t 2c ␳3c
关 Zv + 共 ␳ s − 1 兲 兴
Zm X4a 6 共 1 − ␯ 2c 兲
Up
1 + ⌽ Zm
共 ␳2c − 1 兲 共␳c + 1 兲 ␳3c − ␳s
␥c p − + ␥*c
Es ts 4 2
P*s p 关 ␣s′ 共 T*s − 70 兲 − ␣′ 共 Tr − 70 兲兴
as
where
Ec tc G p the midpoint of contact between the flange and
P*c p 关 ␣c′ 共 T*c − 70 兲 − ␣′ 共 Tr − 70 兲兴 the tubesheet [similar to Fig. 2-4 sketch (1)]
ac

AA-2.4.7 Step 7. Then calculate the parameter Q3 01

using the following equation:
NOTE: For configurations b, c, and d, P*c p 0 for all cases. For
configuration d, P*s p 0 for all cases. For all configurations, P*s p
0 and P*c p 0 for loading cases 1, 2, and 3. W ␥b
2 共 Pt ␥c + P*c ␥*c + Ps ␥s − P*s ␥*s 兲 +
␲ a2o
where the average temperature of the unperforated rim Q3 p Q1 +
Pe 共 1 + ⌽Zm 兲
Tr for configuration a is

AA-2.4.7(a) Determine Fm from Table AA-2.4 or

T ′ + Ts′ + Tc′
Tr p Figs. AA-2.4.2-1 and AA-2.4.2-2, using the parameters
3
Xa and Q3 .
For configurations b and c:
Calculate the bending stress in the tubesheet using
the following equation:
T ′ + Ts′
Tr p
2 2

冢 冣 冢h − h ′ 冣
1.5 Fm 2 ao
For configuration d: ␴p Pe
␮*
g

Tr p T ′
where
h g′ p MAX [(hg − ct ), (0)] for pressure load only
Ts′ + Tr h g′ p 0 for pressure + thermal load combined, or ther-
T *s p
2 mal load only
Evaluation of tubesheet stress:
Tc′ + Tr For loading cases involving pressure loads only, i.e.,
T *c p
2 those defined by AA-2.1(a)(1), (a)(2), and (a)(3): If

629
 AA-2.4.7 2001 SECTION VIII — DIVISION 1 AA-2.4.8

0.7

0.6

0.5

Q3 = 0.8
0.4
Q3 = 0.7
Fm

Q3 = 0.6
0.3
Q3 = 0.5

Q3 = 0.4
0.2
Q3 = 0.3

Q3 = 0.2
0.1
Q3 = 0.1

Q3 = 0.0
0
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0
Xa

GENERAL NOTES:
(a) Curves giving Fm are valid for v = 0.4. They are sufficiently accurate to be used for other values of v .
(b) For values of Xa and Q3 beyond those given by the curves, see Table AA-2.4.

01 FIG. AA-2.4.2-1 Fm VERSUS Xa (0.0 ≤ Q3 ≤ 0.8)

|␴ | ≤ 1.5S, the assumed tubesheet thickness for bending AA-2.4.8 Step 8. Calculate the axial tube stress in
is acceptable; continue. If |␴ | > 1.5S, return to Step 4. the outermost tube row using the following equation:
For loading cases involving pressure and/or thermal
loadings, i.e., those defined by AA-2.1(a)(4), (a)(5), (Ps xs − Pt xt) − Pe Fq
␴t,o p
(a)(6), and (a)(7): If |␴ | ≤ SPS, the assumed tubesheet xt − x s
thickness for bending is acceptable; proceed to (b)
below. If |␴ | > SPS, return to Step 4. where
AA-2.4.7(b) Calculate the average shear stress in the Fqp (Zd + Q3 Zv) X 4a/2
tubesheet at the outer edge of the perforated region AA-2.4.8(a) If |␴t,o| ≤ ⍀t St , proceed to (b) below.
using the following equation: If |␴t,o| > ⍀t St , the tube design must be reconsidered.
⍀tp 1.0 for pressure load only
冢2 ␮ 冣 冢 h 冣 P ⍀tp 2.0 for pressure + thermal load combined or
1 ao
␶p e
thermal load only.
AA-2.4.8(b) If ␴t,o is negative, the tubes must be
If |␶| ≤ 0.8S, the assumed tubesheet thickness for checked against buckling. The maximum permissible
shear is acceptable; proceed to Step 8. If |␶ | > 0.8S, buckling stress limit St,bk for tubes is given by the
return to Step 4. following equation.

630
AA-2.4.8 APPENDIX AA — NONMANDATORY AA-2.4.8

0.4
Q3 = –0.8

Q3 = –0.7

0.3 Q3 = –0.6

Q3 = –0.5
Fm

0.2 Q3 = –0.4

Q3 = –0.3

0.1 Q3 = –0.2

Q3 = –0.1

Q3 = 0.0
0
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0
Xa

GENERAL NOTES:
(a) Curves giving Fm are valid for v = 0.4. They are sufficiently accurate to be used for other values of v .
(b) For values of Xa and Q3 beyond those given by the curves, see Table AA-2.4.

FIG. AA-2.4.2-2 Fm VERSUS Xa (−0.8 ≤ Q3 ≤ 0.0) 01

AA-2.4.8(b)(1) When Cc ≤ kᐉ/r, Sy,tp yield stress for tube material at Tt , psi.

1 ␲ 2 Et rp 冪 d 2t + (dt − 2 tt)2
St,bk p ⴛ
Fs 2

冢 冣
ᐉt,bk 4
r
ᐉt,bkp kᐉ
p equivalent unsupported buckling length of the
AA-2.4.8(b)(2) When Cc > kᐉ/r, tube, in. The largest value considering unsup-
ported tube spans shall be used.
冢r冣
ᐉt,bk
ᐉp unsupported tube span, in.
St,bk p
Sy,t
Fs 冤 1−
2 Cc 冥 kp 0.6 for unsupported spans between two tube-
sheets,
p 0.8 for unsupported spans between a tubesheet
and a tube support,
NOTE: St,bk shall not be greater than St .
p 1.0 for unsupported spans between two tube
supports.
where Fsp factor of safety given by
Ccp 冪 2 ␲2 Et /Sy,t Fs p MAX [(3.25 − 0.5 Fq), (1.25)]

631
 AA-2.4.8 2001 SECTION VIII — DIVISION 1 AA-2.5.1

NOTE: Fs need not be taken greater than 2.0.
If |␴t,o| ≤ St,bk, the tube design is acceptable; proceed
to (c) below. If |␴t,o| > St,bk, the tube design must be
reconsidered.
AA-2.4.8(c) For configuration d, the design procedure
is complete. For configuration a, b, or c, proceed to
next step.
01 AA-2.4.9 Step 9. The shell shall have a thickness
ts for a minimum length of 1.8 冪 Ds ts adjacent to the
tubesheets. Using the calculated values of Xa and Q3 ,
calculate QZ2*.
AA-2.4.9(b) For configurations b and c, the calculation
procedure is complete. For configuration a, proceed to
Step 10.
AA-2.4.10 Step 10. The channels shall have a thick- 01
ness tc for a minimum length of 1.8 冪 Dc tc adjacent
to the tubesheets. Calculate membrane, bending, and
total stresses in the channel due to the joint interaction,
using the following equations:
Pt ac
␴c,m p
2tc

(Zv + Q3 Zm) X 4a
QZ2* p
冢 冣 冢 E 冣 冢 ␩ 冣 冢h X 冣 P Q*
2 ␤c h Ec ␤ c tc a 3o
␴c,b p −12 1 + e z2
2 3 4
a
Then calculate membrane, bending, and total stresses
冤冢1 − 2 冣 P + P *冥 ␤
in the shell due to the joint interaction, using the 1 ␯t 2
+ t c c a 2c
following equations: 1 − ␯ 2t

a 2o Pe Pt as Ps − Pt a ␴c p |␴c,m| + |␴c,b|
␴s,m p + + ⴛ o (␳ 2s − 1)
2 a s ts 2 t s 2 ␳ s ts

For loading cases 1, 2, and 3, if ␴c ≤ 1.5Sc , and

冢 冣 冢E冣 冢 ␩ 冣 冢
␤s h Es ␤ s ts a 3o
␴s,b p 12 1 +
2 h X 4a
3
冢P − ␯ ␴ 冣
1 ts
+ s s s,m + P *s ␤ 2s a 2s
1− ␯ 2s as
␴s p |␴s,m| + |␴s,b|
AA-2.4.9(a) For loading cases 1, 2, and 3, if ␴s ≤
1.5Ss , and for loading cases 4, 5, 6 and 7, if ␴s ≤
SPS,s , the shell design is acceptable. Otherwise, the
shell design must be reconsidered by using one of the
following four options:
Option 1. Increase only the assumed tubesheet thick-
ness h, and return to Step 4.
Option 2. Increase only the shell thickness ts and
return to Step 2. It is permitted to increase the shell
thickness adjacent to the tubesheet only, as proposed
in AA-2.5.
Option 3. Increase both the assumed tubesheet thick-
ness h and the shell thickness ts , and return to Step
2. It is permitted to increase the shell thickness adjacent
to the tubesheet only, as proposed in AA-2.5.
Option 4. Perform an elastic-plastic calculation as
proposed in AA-2.6. This option may only be used
for pressure loading cases 1, 2, and 3, when ␴s ≤ SPS,s .
for loading cases 4, 5, 6 and 7, if ␴c ≤ SPS,c , the channel
冣P Q
e Z2* design is acceptable, and the calculation procedure
is complete. Otherwise, the channel design must be
reconsidered by using one of the following four options:
Option 1. Increase only the assumed tubesheet thick-
ness h, and return to Step 4.
Option 2. Increase only the channel thickness tc and
return to Step 2.
Option 3. Increase both the assumed tubesheet thick-
ness h and the channel thickness tc , and return to Step 2.
Option 4. Perform an elastic-plastic calculation as
proposed in AA-2.6. This option may only be used
for pressure loading cases 1, 2, and 3, when ␴c ≤ SPS,c .
AA-2.5 Design Formulas and Calculation
Procedure for Effect of Different
Shell Material and Thickness
Adjacent to Tubesheet
AA-2.5.1 Design Considerations. This calculation 01
procedure can only be used when the shell is integral
with tubesheet (configuration a, b, or c).
It describes how to use the rules of AA-2.4 when
the shell has a different thickness and /or a different
material adjacent to the tubesheet (see Fig. AA-2.5) in
order to reduce the bending stresses in tubesheets, shell,
or channel when these components are overstressed.
This procedure can also be used to decrease the tube-

632
 AA-2.5.1 APPENDIX AA — NONMANDATORY AA-2.6

Lt

Configuration L Configuration
a, b, or c a, b, or c
L− 1− 1
′ ′
1
1

tc ts,1 ts,1 tc

h h
α s,m,1 α s,m ts
Tubesheet

Tubesheet
Es,1 Es
Dc Ds Dc

FIG. AA-2.5 SHELL WITH INCREASED THICKNESS ADJACENT TO THE TUBESHEETS

sheet thickness, even when the shell or channel is not ␥* p 共 Tt , m − 70 兲 ␣t , m L − 共 Ts , m − 70 兲 关 ␣s , m 共 L − ᐉ1

overstressed.
The shell shall have a thickness of ts, 1 for a minimum
length of 1.8 冪 Ds ts, 1 adjacent to the tubesheets.
AA-2.5.2 Additional Notations (See Fig. AA-2.5)
aspmean radius of shell adjacent to tubes-
heets, in.
p0.5 (Ds + ts, 1)
ts,1pthickness of shell adjacent to tubesheets, in.
ᐉ1, ᐉ1′plengths of shell of thickness t s,1 adjacent
to tubesheets, in.
␣s,m,1pmean coefficient of thermal expansion of
shell material adjacent to tubesheets at Ts,m ,
in. / in. /°F
Es,1pelastic modulus of shell material adjacent
to tubesheets at Ts , psi
Ss,1pallowable stress for shell material adjacent
to the tubesheets, psi
AA-2.5.3 Calculation Procedure. The calculation
procedure of AA-2.4 shall be performed, accounting
for the following modifications.
AA-2.5.3(a) In formulas giving Ks, t (Step 2) and J
(Step 3), replace Ks by K *s, where
␲ (Ds + ts)
K *s p
L − ᐉ1 − ᐉ′1 ᐉ1 + ᐉ′1
+
E s ts Es, 1 ts, 1
01 AA-2.5.3(b) In formulas giving ␤s (Step 2), V (Step
4), ␥*s (Step 6), P*s (Step 6), and ␴s, m and ␴s, b (Step
9), replace ts by ts, 1 and Es by Es, 1.
AA-2.5.3(c) In formula giving P␥ (Step 6), replace
␥ by ␥*, where
− ᐉ′1 兲 + ␣s , m , 1 共 ᐉ1 + ᐉ′1 兲兴
AA-2.5.3(d) In step 9, replace Ss by Ss, 1. If performing 01
elastic-plastic calculation, replace Ss by Ss, 1, Sy, s by
Sy, s, 1, and Es by Es, 1 in AA-2.6, where
Sy, s, 1 p yield strength at temperature Ts′ for the shell
material adjacent to the tubesheets, psi
AA-2.6 Design Formulas and Calculation 01
Procedure for Effect of Plasticity at
Tubesheet /Channel or Shell Joint
If the loading is such that high discontinuity stresses
exist at the channel-tubesheet and /or shell-tubesheet
joint, then a decision may be made to change the
geometries of channel, shell, or tubesheet to alleviate
this condition, and meet all stress limits given in AA-
2.4 above.
However, under certain circumstances, when the tube-
sheet stress level is below the limit, but either or both
of the shell or channel bending plus membrane stresses
exceed their limits, an additional “elastic-plastic solu-
tion” iterative step may be taken as follows which
permits an adjustment of the shell and /or channel
Young’s modulus (where it affects the rotation of the
joint) to reflect the anticipated load shift resulting from
plastic action at the joint.
This elastic-plastic procedure shall only be used for
pressure loading (loading cases 1, 2, or 3), when ␴s
≤ SPS,s , and /or ␴c ≤ SPS,c .

633
 AA-2.6 2001 SECTION VIII — DIVISION 1 AA-3.1

It is not intended to be used in the creep regime
[see U-2(g)].
The introduction of a reduced effective modulus has
the effect of reducing the shell or channel stress in
the elastic-plastic iteration; however, due to load shifting
this usually leads to an increase in the tubesheet stress.
Define the bending maximum permissible stress limit
in the shell and channel as
If the results of the elastic-plastic iteration lead to
stresses in tubesheet which are within the maximum
permissible stress limits, then the design is considered
acceptable. However, if the tubesheet is now over-
stressed, the unit geometry must be reconsidered. How-
ever, in most cases, a single elastic-plastic iteration
using the appropriate reduced shell or channel Young’s
modulus results in a design which meets the require-
ments with tubesheet stress within limits.

冢 冣
SPS,s
S *s p MIN Sy,s ,
2
AA-3 FLOATING TUBESHEET HEAT
and EXCHANGERS
AA-3.1 Scope
冢 冣
SPS,c
S *c p MIN Sy,c , AA-3.1(a) This Appendix covers the design of heat
2
exchangers that have one stationary tubesheet attached
where to the shell and channel, and one floating tubesheet.
Sy,sp shell yield strength at temperature T′s , psi The tubesheets are interconnected by a bundle of straight
Sy,cp channel yield strength at temperature T′c , psi tubes. Three types of heat exchangers are covered:
For values of Sy,s and Sy,c , see Section II-D. For AA-3.1(a)(1) immersed floating head [Fig. AA-
materials not listed in Section II-D, see UG-28. 3.1.1 sketch (a)],
After Step 10 is performed for the first elastic solution AA-3.1(a)(2) externally sealed floating head [Fig.
iteration (Steps 1 to 10), calculate facts and factc as AA.3.1.1 sketch (b)], or
AA-3.1(a)(3) internally sealed floating tubesheet
[Fig. AA-3.1.1 sketch (c)].
冢 冣
|␴s,b|
facts p MIN 1.4 − 0.4 ,1 AA-3.1(b) Stationary tubesheets may have one of six
S *s configurations (Fig. AA-3.1.2):
AA-3.1(b)(1) configuration a: tubesheet integral
(for configuration d, facts p1) and with shell and channel;
AA-3.1(b)(2) configuration b: tubesheet integral

冢 冣
|␴c,b|
factc p MIN 1.4 − 0.4 ,1
S *c
(for configurations b, c, and d, factc p 1) where ␴s,b
and ␴c,b are the bending stresses computed from Steps
9 and 10. If facts and factc are both ≥ 1.0, then the
design is acceptable. However, if either facts or factc
is < 1.0, then return to steps in AA-2.4.
AA-2.6(a) Reduce Es , Ec , in Step 4 as necessary by
multiplying by facts or factc as follows:
Es p Es (facts)
Ec p Ec (factc)
and then recalculate parameter V.
01 AA-2.6(b) In Step 5, recalculate parameters ⌽ and
Q1 using the reduced values of Es and Ec.
AA-2.6(c) In Steps 6, 7, and 8, recalculate all quanti-
ties using the changed parameters.
NOTE: Value of Es in formula giving Pe is not affected by (facts).
with shell and gasketed with channel, with tubesheet
extended as a flange;
AA-3.1(b)(3) configuration c: tubesheet integral
with shell and gasketed with channel, with tubesheet
not extended as a flange;
AA-3.1(b)(4) configuration d: tubesheet gasketed
with shell and channel;
AA-3.1(b)(5) configuration e: tubesheet gasketed
with shell and integral with channel, with tubesheet
extended as a flange;
AA-3.1(b)(6) configuration f: tubesheet gasketed
with shell and integral with channel, with tubesheet
not extended as a flange.
AA-3.1(c) Floating tubesheets may have one of four
configurations (Fig. AA-3.1.3):
AA-3.1(c)(1) configuration A: tubesheet integral;
AA-3.1(c)(2) configuration B: tubesheet gasketed,
extended as a flange;
AA-3.1(c)(3) configuration C: tubesheet gasketed,
not extended as a flange;
AA-3.1(c)(4) configuration D: tubesheet internally
sealed.

634
 APPENDIX AA — NONMANDATORY Fig. AA-3.1.1

Stationary tubesheet
Floating tubesheet
configuration a, b, c, d, e, or f
configuration A, B, or C

(a) Typical Floating Tubesheet Exchanger With an Immersed Floating Head

Stationary tubesheet
configuration a, b, c, d, e, or f
Floating tubesheet
configuration A

(b) Typical Floating Tubesheet Exchanger With an Externally Sealed Floating Head

Stationary tubesheet
configuration a, b, c, d, e, or f Floating tubesheet
configuration D

(c) Typical Floating Tubesheet Exchanger With an Internally Sealed Floating Tubesheet

FIG. AA-3.1.1 TYPES OF FLOATING TUBESHEET EXCHANGERS

635
 Fig. AA-3.1.2

G
ac ac 2
ac as as as

h h h

hg hg

(a) Configuration a: (b) Configuration b: (c) Configuration c:

Tubesheet Integral With Shell and Channel Tubesheet Integral With Shell Tubesheet Integral With Shell
and Gasketed With Channel, and Gasketed With Channel,
With Tubesheet Extended as a Flange With Tubesheet Not Extended as a Flange

636
2001 SECTION VIII — DIVISION 1

G
ac as as 2 as
ac ac

h h h

hg
(e) Configuration e:
Tubesheet Gasketed With Shell
(d) Configuration d: and Integral With Channel,
Tubesheet Gasketed With Shell and Channel With Tubesheet Extended as a Flange
(f) Configuration f:
Tubesheet Gasketed With Shell
and Integral With Channel,
With Tubesheet Not Extended as a Flange

FIG. AA-3.1.2 STATIONARY TUBESHEET CONFIGURATIONS

AA-3.2 APPENDIX AA — NONMANDATORY AA-3.3

ac
ac

h h

hg

(a) Configuration A: (b) Configuration B:

Tubesheet Integral Tubesheet Gasketed,
Extended as a Flange

G A
ac ac ⫽
2 2

h h

hg

(c) Configuration C: (d) Configuration D:

Tubesheet Gasketed, Tubesheet Internally Sealed
Not Extended as a Flange

FIG. AA-3.1.3 FLOATING TUBESHEET CONFIGURATIONS

AA-3.2 Conditions of Applicability Ecp modulus of elasticity for channel material at

This Appendix covers flat fully tubed circular tubes-
heets with unperforated rims. The tubesheets shall have
tube holes in either equilateral triangular or square
patterns. Both tubesheets shall be of the same material
and thickness.
This design procedure does not account for loadings
due to weight and pressure drop across the tube bundle.
AA-3.3 Nomenclature
Symbols used in this Appendix are as follows:
Ap outside diameter of tubesheet, in.
Cp bolt circle diameter, in. (see Appendix 2)
Dcp inside channel diameter, in.
Dsp inside shell diameter, in.
Ep modulus of elasticity for tubesheet material at
T, psi
Tc, psi
Esp modulus of elasticity for shell material at Ts, psi
Etp modulus of elasticity for tube material at Tt, psi
NOTE: The modulus of elasticity shall be taken from the applicable
Table TM in Section II, Part D. When a material is not listed in
the TM tables, the requirements of U-2(g) shall be applied.
Gp midpoint of contact between flange and the
tubesheet, in. [see Appendix 2, Fig. 2-4
sketch (1)]
Gcp diameter at location of gasket load reaction for
the gasket between the channel and tubesheet,
in. (see Appendix 2)
Gsp diameter at location of gasket load reaction for
the gasket between the shell and the tubesheet,
in. (see Appendix 2)
Ltp tube length between outer tubesheet faces, in.
Lp tube length between inner tubesheet faces, in.

637
AA-3.3 2001 SECTION VIII — DIVISION 1
p Lt − 2h
Psp shell side design pressure (see UG-21), psi (use
a negative value for vacuum)
Ptp tube side design pressure (see UG-21), psi (use
a negative value for vacuum)
Sp allowable stress for tubesheet material at T, psi
Scp allowable stress for channel material at Tc, psi
Ssp allowable stress for shell material at Ts, psi
Stp allowable stress for tube material at Tt, psi. For
a welded tube, use allowable stress for an equiv-
alent seamless tube.
Tp tubesheet design temperature, °F (see Note)
Ttp tubes design temperature, °F (see Note)
Tsp shell design temperature, °F (see Note)
Tcp channel design temperature, °F (see Note)
NOTE: For cases involving radial thermal loading (loading cases 4,
5, 6, and 7), it is permitted to use the operating temperatures instead
of the design temperatures.
Wp flange design bolt load, lb. Use W from Eq. (4)
of 2-5(e).
aop radius of the perforated region, in.
acp radial channel dimension, in. (see Fig. AA-3.1.2
and Fig. AA-3.1.3)
p (Dc + tc)/2 for configurations a, e, f, and A
p Gc/ 2 for configurations b, c, d, B, and C
p A/ 2 for configuration D
asp radial shell dimension, in. (see Fig. AA-3.1.2
and Fig. AA-3.1.3)
p (Ds + ts)/2 for configurations a, b, and c
p Gs /2 configurations d, e, and f
p ac configurations A, B, C, and D
dtp tube outside diameter, in.
␩p flexural efficiency
hp tubesheet thickness, in.
hgp tube side pass partition groove depth, in.
tcp channel thickness, in.
tsp shell thickness, in.
Ntp number of tubes
ttp nominal tube wall thickness, in.
␣′cp mean coefficient of thermal expansion of chan-
nel material at T ′c, in./in./°F
␣′p mean coefficient of thermal expansion of tube-
sheet material at T ′, in./in./°F
␣′sp mean coefficient of thermal expansion of shell
material at T ′s, in./in./°F
T ′p tubesheet metal temperature at the rim, °F
T ′sp shell metal temperature at the tubesheet, °F
T ′cp channel metal temperature at the tubesheet, °F
ctp tubesheet corrosion allowance on the tube side,
in. ct p 0 in the uncorroded condition.
MAX[(a), (b), (c),…]
p greatest of a, b, c
␯p Poisson’s ratio of tubesheet material
638
AA-3.4
␯tp Poisson’s ratio of tube material
␯cp Poisson’s ratio of channel material
␯sp Poisson’s ratio of shell material
AA-3.4 Design Considerations
AA-3.4(a) The calculation shall be performed for the
stationary end and for the floating end of the exchanger.
Since the edge configurations of the floating and station-
ary tubesheets are different, the values of A, C, Dc,
tc, Ec, G, Gc, Gs, W, and ac may be different for each
set of calculations. For the floating tubesheet calculation
as p ac. However, both tubesheets are required to
have the same thickness, and calculations shall be made
with both tubesheets having the same thickness.
AA-3.4(b) It is generally not possible to determine
by observation the most severe condition of coincident
difference of pressure (due to Ps and Pt) and difference
of radial thermal expansion between tubesheet, shell,
and channel (due to P*s and P*c). Thus, it is necessary
to evaluate all of the anticipated loading conditions to
ensure that the worst load combination has been consid-
ered in the design.
The various loading conditions to be considered shall
include the normal operating conditions, the start-up
conditions, the shutdown conditions, and the upset
conditions, which may govern the design of the main
components of the heat exchanger (i.e., tubesheet, tubes,
shell, channel). For each of these conditions, it is
necessary to account for the following loading cases:
AA-3.4(b)(1) Loading Case 1: tube side pressure
Pt acting only (Ps p 0), without radial thermal expan-
sion (P*s p 0, P*c p 0);
AA-3.4(b)(2) Loading Case 2: shell side pressure
Ps acting only (Pt p 0), without radial thermal expan-
sion (P*s p 0, P*c p 0);
AA-3.4(b)(3) Loading Case 3: tube side Pt and
shell side Ps pressures acting simultaneously, without
radial thermal expansion (P*s p 0, P*c p 0);
AA-3.4(b)(4) Loading Case 4: radial thermal expan-
sion acting only (Ps p 0, Pt p 0);
AA-3.4(b)(5) Loading Case 5: tube side pressure
Pt acting only (Ps p 0), with radial thermal expansion;
AA-3.4(b)(6) Loading Case 6: shell side pressure
Ps acting only (Pt p 0), with radial thermal expansion;
AA-3.4(b)(7) Loading Case 7: tube side Pt and
shell side Ps pressures acting simultaneously, with radial
thermal expansion.
For tubesheet configurations d, B, C, and D the
design shall be based only on loading cases 1, 2, and 3.
When differential pressure design is specified by the
user, the design shall be based only on loading cases
3 and 7 as provided by UG-21.
AA-3.4 APPENDIX AA — NONMANDATORY AA-3.5.4

AA-3.4(c) Elastic moduli, yield strengths, and allow- 2

冢 冣
dt − 2tt
able stresses shall be taken at design temperatures. xt p 1 − Nt
2ao
However, for cases involving thermal loading (loading
cases 4, 5, 6, and 7), it is permitted to use the operating
temperatures instead of the design temperatures. 2

冢 冣
AA-3.4(d) The design shall be performed for the dt
xs p 1 − Nt
corroded condition. 2ao
AA-3.4(e) As the calculation procedure is iterative,
a value h must be assumed for the tubesheet thickness
to calculate and check that the maximum stresses in
the tubesheet, tubes, shell, and channel are within the AA-3.5.2 Step 2. Calculate the shell and channel
maximum permissible stress limits. The designer should parameters ␤s and ␤c by using the following equations:
note that any increase or decrease of thickness in a
component will modify the stresses not only in this 冪 3 (1 − ␯ 2s )
4

component, but also in other components. ␤s p

冪
Ds + t s
AA-3.4(f) The designer shall consider: ts
2
AA-3.4(f)(1) the effect of deflections in a tubesheet
design, especially when the required tubesheet thickness
is less than the tube diameter; ␤s p 0 for tubesheet configurations d, e, f, A, B,
AA-3.4(f)(2) the loadings specified in UG-22. This C, and D.
design procedure does not account for loadings due to
weight and pressure drop across the tube bundle;
冪 3 (1 − ␯ 2c)
4

AA-3.4(f)(3) the integrity of the tube-to-tubesheet ␤c p

冪
Dc+ tc
joint (see Appendix A); tc
2
AA-3.4(f)(4) the stresses resulting from the pressure
test required by UG-99 or UG-100 [see UG-99(d)];
AA-3.4(g) Materials and methods of fabrication for ␤c p 0 for tubesheet configurations b, c, d, B, C,
tubesheets, shells, channels, and tubes shall be in accord- and D.
ance with Subsections A, B, and C.
AA-3.5.3 Step 3. Calculate h/p. If ␳ changes, recalcu-
AA-3.4(h) Weld sizes shall be in accordance with
late d* and ␮* from AA-4.5.1. Determine E*/E and
Subsection B, Part UW, Figs. UW-13.2 and UW-13.3.
␯* relative to h/p from AA-4.5.2. Calculate ␩, Xa, and
V by using the following equations:
AA-3.5 Design Formulas and Calculation
Procedure
E* 1 − ␯2
A set of calculations shall be performed for the ␩p ⴛ
E 1 − ␯*2
stationary tubesheet and another set shall be performed
for the floating tubesheet.
AA-3.5.1 Step 1. Determine ␮, Do, and ␮* from
1⁄

冤 冥
E t (d − t ) a 2 4

AA-4.5.1 and calculate ao, ␳s, ␳c, xt and xs from the Xa p 24 (1 − ␯* ) Nt t t t 3t o

2
E* L h
following equations:

冢 冣
2 ␤s t 3s Es as ␤ 2s h2
ao p
Do
2
Vp
Eh 3 冤
1 − ␯ 2s
1 + ␤s h +
2

冢 冣冥
␤c t 3c Ec ac ␤ 2c h2
a + 1 + ␤c h +
␳s p s 1 − ␯ 2c 2
ao

ac AA-3.5.4 Step 4. Using the calculated value of Xa,

␳c p
ao enter Table AA-2.4, or Fig. AA-2.4.1 to determine Zd,

639
AA-3.5.4 2001 SECTION VIII — DIVISION 1 AA-3.5.6

Zv, and Zm. Then calculate the parameter Q1 using the 0 for all loading cases. For all configurations P*s p 0 and P*c p
0 for loading cases 1, 2, and 3.
following equation:
For conservative values of P*s and P*c use Tr p
␳ − 1 − ⌽ Zv T′; otherwise:
Q1 p s
1 + ⌽ Zm for configuration a:

where T ′ + Ts′ + Tc′

Tr p
3

冤 冢 冣 冥
1 − ␯2 A
⌽p ln +V
␩ 2ao for configurations b and c:

T ′ + T s′
AA-3.5.5 Step 5. Calculate the effective pressure Pe Tr p
2
using the following equations.
AA-3.5.5(a) If the exchanger has an immersed floating for configurations e, f, and A:
head [Fig. AA-3.1.1 sketch (a)]:
T ′ + Tc′
Pe p Ps − Pt Tr p
2

AA-3.5.5(b) If the exchanger has an externally sealed For conservative values of P*s and P*c use T*s p T′s
floating head [Fig. AA-3.1.1 sketch (b)]: and T*c p T′c; otherwise for all configurations:

Pe p Ps (1 − ␳2s ) − Pt Ts′ + Tr
Ts* p
2
AA-3.5.5(c) if the exchanger has an internally sealed
floating tubesheet [Fig. AA-3.1.1 sketch (c)]:
Tc′ + Tr
Tc* p
Pe p (Ps − Pt)(1 − ␳2s ) 2

AA-3.5.6(c) Calculate Q2 using the following equa-

AA-3.5.6 Step 6. Calculate the parameters ␥b, P*s, tions:
P*c, Q2, and Q3.
AA-3.5.6(a) Calculate the parameter ␥b using the W ␥b
following equations: a2o 共 Pt ␥c + P*c ␥*c + Ps ␥s − P*s ␥*s 兲 +
2␲
␥bp 0 for tubesheet configurations a, A, and D Q2 p
1 + ⌽Zm
p ␳c − C/ 2ao for tubesheet configurations b and B
p ␳c − G/ 2ao for tubesheet configurations c and C where
p ␳c − ␳s for tubesheet configuration d
p C/ 2ao − ␳s for tubesheet configuration e 共 1 + ␤s h 兲
p G/ 2ao − ␳s for tubesheet configuration f ␥*s p ␤2s t 2s ␳3s
6 共 1 − ␯ 2s 兲
AA-3.5.6(b) Calculate P*s and P*c using the following
equations:
共 ␳2s − 1 兲 共␳s − 1 兲
␥s p − ␥*s
E t 4
P*s p s s 关 ␣s′ 共 T*s − 70 兲 − ␣′ 共 Tr − 70 兲兴
as
共 1 + ␤c h 兲
␥*c p ␤2c t 2c ␳3c
Ec tc 6 共 1 − ␯ 2c 兲
P*c p 关 ␣c′ 共 T*c − 70 兲 − ␣′ 共 Tr − 70 兲兴
ac
共 ␳2c − 1 兲 共␳c + 1 兲 ␳3c − ␳s
where Tr is the average temperature of the unperfora- ␥c p − + ␥*c
4 2
ted rim.
NOTE: For configurations b, c, d, B, C, and D, P*c p 0 for all AA-3.5.6(d) Calculate the bending stress in the tube-
loading cases. For configurations d, e, f, A, B, C, and D, P*s p sheet ␴.

640
AA-3.5.6 APPENDIX AA — NONMANDATORY AA-3.5.7

AA-3.5.6(d)(1) If Pe p 0, calculate ␴ using the AA-3.5.7 Step 7. Calculate the tube axial stress in
following equation: the outermost tube row using the following equation:

冢 冣
2Q2Zv
6Q2 2(Ps x s − Pt xt ) − X4a Pe (Zd + ZvQ1) +
␴p a 2o
␮*(h − hg′ ) 2 ␴t, o p
2(xt − xs)

AA-3.5.6(d)(2) If Pe ≠ 0, determine Fm from the AA-3.5.7(a) If |␴t,o| ≤ ΩtSt, proceed to (b) below. If
Table AA-2.4 or Figs. AA-2.4.2-1 and AA-2.4.2-2, |␴t,o| > ΩtSt, the tube design must be reconsidered.
using the parameters Xa and Q3 where Ωtp 1.0 for pressure load only
p 2.0 for pressure + thermal load combined or
2Q2 thermal load only.
Q3 p Q1 + AA-3.5.7(b) If ␴t,o is negative, the tubes must be
Pe a 2o
checked against buckling. The maximum permissible
buckling stress limit St,bk for tubes is given by the
Then calculate ␴ using the following equation: following equation.
AA-3.5.7(b)(1) When Cc ≤ kᐉ/r,
2

冢 冣 冢h − h ′ 冣
1.5 Fm 2 ao
␴p Pe 1 ␲ 2Et
␮* St,bk p ⴛ
Fs 2

冢 冣
g
ᐉt,bk
r
where
h′gp MAX [(hg − ct), 0] for pressure load only AA-3.5.7(b)(2) When Cc > kᐉ/r,
h′gp 0 for pressure + thermal load combined, or

冢 冣
thermal load only ᐉt,bk

冤 冥
AA-3.5.6(e) Evaluation of tubesheet bending stress: Sy,t r
AA-3.5.6(e)(1) for loading cases involving pressure St,bk p 1−
Fs 2Cc
load only, i.e., those defined in AA-3.4(b) as loading
case 1, 2, or 3:
If |␴| ≤ 1.5S, the assumed tubesheet thickness for
bending is acceptable; continue. If |␴| > 1.5S, return NOTE: St,bk shall not be greater than St .
to Step 3. where
AA-3.5.6(e)(2) for loading cases involving pressure Ccp 冪 2 ␲2 Et /Sy,t
and/or thermal loadings, i.e., those defined in AA- Sy,tp yield stress for tube material at design tempera-
3.4(b) as loading cases 4, 5, 6, or 7: ture Tt , psi.
If |␴| ≤ 3S, the assumed tubesheet thickness for rp 冪 d 2t + (dt − 2 tt)2/4
bending is acceptable; proceed to (f). If |␴| > 3S, return ᐉt,bkp kᐉ
to Step 3. p equivalent unsupported buckling length of the
AA-3.5.6(f) For tubesheet configuration B, C, or tube, in. The largest value considering unsup-
D the design procedure is complete. For tubesheet ported tube spans shall be used.
configuration a, b, c, d, e, or f proceed to (g) below. ᐉp unsupported tube span, in.
For tubesheet configuration A, proceed to Step 9. kp 0.6 for unsupported spans between two tubes-
AA-3.5.6(g) Calculate the average shear stress in the heets,
tubesheet at the outer edge of the perforated region p 0.8 for unsupported spans between a tubesheet
using the following equation: and a tube support,
p 1.0 for unsupported spans between two tube

冢2␮冣 冢 h 冣 P supports.
1 ao
␶p e
Fsp factor of safety given by
FspMAX [(3.25 − 0.25(Zd + Q3Zv)Xa4), 1.25]
for Pe ≠ 0
If |␶| ≤ 0.8S, the assumed tubesheet thickness for
Fsp1.25 for Pe p 0
shear is acceptable; proceed to Step 7. If |␶| > 0.8S,
return to Step 3. NOTE: Fs need not be taken greater than 2.0.

641
AA-3.5.7 2001 SECTION VIII — DIVISION 1 AA-3.6.1

If |␴t, o| ≤ St,bk, the tube design is acceptable; proceed

冤冢1 − 2 冣P + P 冥 ␤ a
1 ␯c * 2 2
+ t c c c
to (c) below. If |␴t, o| > St,bk, the tube design must be 1 − ␯2c
reconsidered.
AA-3.5.7(c) For tubesheet configuration d, the design ␴c p 冨␴c,m冨 + 冨␴c,b冨
procedure is complete. For tubesheet configuration a,
b, or c, proceed to Step 8. For tubesheet configuration
e or f, proceed to Step 9.
For loading cases 1, 2, and 3, if |␴c| ≤ 1.5Sc,
AA-3.5.8 Step 8. The shell shall have a thickness the channel design is acceptable, and the calculation
of ts for minimum length of 1.8冪D s t s adjacent to the procedure is complete. For loading cases 4, 5, 6, and
tubesheets. Calculate membrane, bending, and total 7, if |␴c| ≤ 3Sc, the channel design is acceptable, and
stresses in the shell due to the joint interaction, using the calculation procedure is complete. Otherwise, the
the following equations: channel design must be reconsidered by using one of
the following three options:

冢 冣 冢␳ t 冣冢␳ − 1冣
a2o Pe Pa P − Pt ao Option 1. Increase only the assumed tubesheet thick-
␴s, m p + t s + s 2
s
2as ts 2ts 2 s s ness h and return to Step 3.
Option 2. Increase only the channel thickness tc and
return to Step 1.
Option 3. Increase both the assumed tubesheet thick-
冢 冣冢 冣冢 冣冢 冣冢 冣
␤sh Es ␤s ts a3o 2Q2Zm
␴s,b p 12 1 + P (Z + ZmQ1兲 + ness h and the channel thickness tc, and return to Step 1.
2 E ␩ 2h3 e v a2o

冢 冣
1 t
+ Ps − ␯s␴s, m s + P*s ␤2s a2s
1 − v2s as
AA-3.6 Examples
AA-3.6.1 Example 1: Floating Tubesheet Ex-
␴s p 冨␴s,m冨 + 冨␴s,b冨 changer With an Immersed Floating Head
AA-3.6.1(a) Given. A floating tubesheet exchanger
AA-3.5.8(a) For loading cases 1, 2, and 3, if |␴s| ≤ with an immersed floating head [Fig. AA-3.1.1 sketch
1.5Ss, the shell design is acceptable. For loading cases (a)]. The stationary tubesheet is gasketed with the shell
4, 5, 6, and 7, if |␴s| ≤ 3Ss, the shell design is acceptable. and channel (Fig. AA-3.1.2 configuration d), and the
Otherwise, the shell design must be reconsidered by floating tubesheet is not extended as a flange (Fig.
using one of the following three options: AA-3.1.3 configuration B).
Option 1. Increase only the assumed tubesheet thick- AA-3.6.1(b) Summary of Data Common to Both Tube-
ness h and return to Step 3. sheets
Option 2. Increase only the shell thickness ts and AA-3.6.1(b)(1) Loads
return to Step 1. Psp shell side design pressure p 250 psi
Option 3. Increase both the assumed tubesheet thick- Ptp tube side design pressure p 150 psi
ness h and the shell thickness ts, and return to Step 1. AA-3.6.1(b)(2) Tubesheets. Triangular pitch.
AA-3.5.8(b) For configurations b and c, the calculation Ntp 466
procedure is complete. For configuration a, proceed to pp 1.0 in.
Step 9. rop 12.5 in.
␳p 0.8
AA-3.5.9 Step 9. The channels shall have a thickness ULp 2.5 in.
of tc for a minimum length of 1.8冪D s t s adjacent to ctp 0 in.
the tubesheets. Calculate membrane, bending, and total ␯p 0.31
stresses in the channel due to the joint interaction, Ep 27 ⴛ 106 psi
using the following equations: Sp 19,000 psi
AA-3.6.1(b)(3) Tubes
Pt ac dtp 0.75 in.
␴c,m p
2tc ttp 0.083 in.
Ltp 256 in.
kᐉp 15.375 in.

冢 冣冢 冣冢 冣冢 冣冢 冣
␤ch Ec ␤c tc a3o 2Q2Zm ␯tp 0.31
␴c,b p −12 1 + P (Z + ZmQ1兲 +
2 E ␩ 2h3 e v a2o Etp 27 ⴛ 106 psi

642
AA-3.6.1 APPENDIX AA — NONMANDATORY AA-3.6.1

Stp 13,350 psi TABLE AA-3.6.1-1

Sytp 20,550 psi Symbol Loading Case 1 Loading Case 2 Loading Case 3
AA-3.6.1(c) Data for the Stationary Tubesheet
AA-3.6.1(c)(1) Loads Q2, in.-lb/in. −213 355 142
Q3 0.0952 0.0952 0.0952
Wp 211,426 lb
Fm 0.102 0.102 0.102
AA-3.6.1(c)(2) Tubesheet ␴, psi −16,400 27,400 11,000
hp 1.75 in. ␶, psi −2210 3680 1470
Ap 33.071 in. ␴to, psi 2570 −4530 −1960
Gsp 29.375 in. St,bk, psi ... 10,700 10,700
Gcp 29.375 in.
Cp 31.417 in.
hgp 0.197 in.
AA-3.6.1(d) Stationary Tubesheet Calculation Results
AA-3.6.1(d)(1) Step 1 ␥cp −0.0106
asp 14.7 in. h′gp 0.197 in.
acp 14.7 in. For each loading case the absolute value of the
Lp 253 in. tubesheet bending stress 冨␴冨 is below 1.5S (28,500 psi)
␮p 0.250 and is acceptable. For each loading case the absolute
Dop 25.8 in. value of the tubesheet shear stress 冨␶冨 is below 0.8S
d*p 0.657 in. (15,200 psi) and is acceptable. For loading cases 2 and
p*p 1.07 in. 3 the absolute value of the tube stress 冨␴to冨 is less than
␮*p 0.384 the maximum permissible buckling stress limit, St,bk.
aop 12.9 in. For loading case 1, the tube stress is tensile, and
␳sp 1.14 therefore, the tubes do not need to be checked for
␳cp 1.14 buckling. For each loading case the tube stress is less
xtp 0.760 than St (13,350 psi) and is therefore acceptable.
xsp 0.605 AA-3.6.1(e) Data for the Floating Head:
AA-3.6.1(d)(2) Step 2 AA-3.6.1(e)(1) Loads
␤sp 0 in.−1 Wp 26,225 lb
␤cp 0 in.−1 AA-3.6.1(e)(2) Tubesheet. Both tubesheets must be
AA-3.6.1(d)(3) Step 3 the same thickness.
h/pp 1.75 hp 1.75 in.
E*/Ep 0.402 Ap 26.89 in.
␯*p 0.309 Gp 26.496 in.
␩p 0.402 Gcp 26.496 in.
Xap 3.61 Cp 27.992 in.
Vp 0 hgp 0 in.
AA-3.6.1(d)(4) Step 4 AA-3.6.1(f) Floating Head Calculation Results
Zdp 0.0327 AA-3.6.1(f)(1) Step 1
Zvp 0.0786 asp 13.2 in.
Zmp 0.421 acp 13.2 in.
⌽p 0.563 Lp 253 in.
Q1p 0.0781 ␮p 0.250
AA-3.6.1(d)(5) Step 5 Dop 25.8 in.
Pep −150 psi, 250 psi, and 100 psi for loading cases d*p 0.657 in.
1, 2, and 3, respectively p*p 1.07 in.
AA-3.6.1(d)(6) Steps 6 and 7 (Table AA-3.6.1-1) ␮*p 0.384
␥bp 0 aop 12.9 in.
P*sp 0 psi ␳sp 1.03
P*cp 0 psi ␳cp 1.03
␥*sp 0 xtp 0.760
␥sp 0.0106 xsp 0.605
␥*cp 0 AA-3.6.1(f)(2) Step 2

643
AA-3.6.1 2001 SECTION VIII — DIVISION 1 AA-3.6.2

TABLE AA-3.6.1-2 Ptp tube side design pressure p 30 psi

Symbol Loading Case 1 Loading Case 2 Loading Case 3 AA-3.6.2(b)(2) Tubesheets. Triangular pitch.
Ntp 1189
Q2, in.-lb/in. −10.2 16.9 6.78 pp 1.25 in.
Q3 0.0213 0.0213 0.0213
rop 22.605 in.
Fm 0.0750 0.0750 0.0750
␴, psi −9520 15,900 6340 ␳p 0.958
hgp 0 in.
ULp 0 in.
ctp 0 in.
␯p 0.32
Ep 14.8 ⴛ 106 psi
␤sp 0 in.−1
Sp 11,300 psi
␤cp 0 in.−1
AA-3.6.2(b)(3) Tubes
AA-3.6.1(f)(3) Step 3
dtp 1.0 in.
h/pp 1.75
ttp 0.049 in.
E*/Ep 0.402
Ltp 144 in.
␯*p 0.309
kᐉp 16 in.
␩p 0.402
␯tp 0.32
Xap 3.61
Etp 14.8 ⴛ 106 psi
Vp 0
Stp 11,300 psi
AA-3.6.1.(f)(4) Step 4
Sytp 31,600 psi
Zdp 0.0327
AA-3.6.2(b)(4) Shell
Zvp 0.0786
Dsp 48 in.
Zmp 0.421
tsp 0.375 in.
⌽p 0.0974
␯sp 0.31
Q1p 0.0205
Esp 28.55 ⴛ 106 psi
AA-3.6.1(f)(5) Step 5
Ssp 20,000 psi
Pep −150 psi, 250 psi, and 100 psi for loading cases
AA-3.6.2(c) Data for the Stationary Tubesheet
1, 2, and 3, respectively.
AA-3.6.2(c)(1) Loads
AA-3.6.1(f)(6) Step 6 (Table AA-3.6.1-2)
Wp 288,910 lb
␥bp 0
AA-3.6.2(c)(2) Tubesheet
P*sp 0 psi
hp 1.375 in.
P*cp 0 psi
Ap 51 in.
␥*sp 0
Gsp 49.71 in.
␥sp 4.26 ⴛ 10−4
Gcp 49.616 in.
␥*cp 0
Cp 49.5 in.
␥cp −4.26 ⴛ 10−4
AA-3.6.2(d) Stationary Tubesheet Calculation Results
h′gp 0 in.
AA-3.6.2(d)(1) Step 1
For each loading case the absolute value of the
asp 24.9 in.
tubesheet bending stress 冨␴冨 is below 1.5S (28,500) psi
acp 24.8 in.
and is acceptable.
Lp 141 in.
AA-3.6.2 Example 2: Floating Tubesheet Ex- ␮p 0.200
changer With an Externally Sealed Floating Head Dop 46.2 in.
AA-3.6.2(a) Given. A floating tubesheet exchanger d*p 0.906 in.
with an externally sealed (packed) floating head [Fig. p*p 1.25 in.
AA-3.1.1 sketch (b)]. The stationary tubesheet is gas- ␮*p 0.275
keted with the shell and channel (Fig. AA-3.1.2 configu- aop 23.1 in.
ration d), and the floating tubesheet is integral with ␳sp 1.08
the head (Fig. AA-3.1.3 configuration A). ␳cp 1.07
AA-3.6.2(b) Summary of Data Common to Both Tube- xtp 0.547
sheets xsp 0.443
AA-3.6.2(b)(1) Loads AA-3.6.2(d)(2) Step 2
Psp shell side design pressure p 150 psi ␤sp 0 in.−1

643.1
AA-3.6.2 APPENDIX AA — NONMANDATORY AA-3.6.2

TABLE AA-3.6.2-1 AA-3.6.2(e)(2) Tubesheet. Both tubesheets must be

Symbol Loading Case 1 Loading Case 2 Loading Case 3 the same thickness.
hp 1.375 in.
Q2, in.-lb/in. −116 138 110 Ap 47.625 in.
Q3 0.0828 0.0463 0.0605
Fm 0.0594 0.0442 0.0499
␣′p 4.8 ⴛ 10−6 in./in./°F
␴, psi −11,000 −6420 −16,500 AA-3.6.2(e)(3) Channel
␶, psi −1260 −991 −2250 Dcp 47 in.
␴to, psi 2680 2550 5100 tcp 0.3125 in.
␯cp 0.32
Ecp 14.8 ⴛ 106 psi
Scp 11,300 psi
␣′cp 4.8 ⴛ 10−6 in./in./°F
AA-3.6.2(f) Floating Head Calculation Results
␤cp 0 in.−1 AA-3.6.2(f)(1) Step 1
AA-3.6.2(d)(3) Step 3 asp 23.7 in.
h/pp 1.10 acp 23.7 in.
E*/Ep 0.280 Lp 141 in.
␯*p 0.337 ␮p 0.200
␩p 0.284 Dop 46.2 in.
Xap 8.84 d*p 0.906 in.
Vp 0 p*p 1.25 in.
AA-3.6.2(d)(4) Step 4 ␮*p 0.275
Zdp 0.00214 aop 23.1 in.
Zvp 0.0130 ␳sp 1.02
Zmp 0.163 ␳cp 1.02
⌽p 0.312 xtp 0.547
Q1p 0.0682 xsp 0.443
AA-3.6.2(d)(5) Step 5. Pe p −30.0 psi, −23.6 psi, AA-3.6.2(f)(2) Step 2
and −53.6 psi for loading cases 1, 2, and 3, respectively. ␤sp 0 in.−1
AA-3.6.2(d)(6) Steps 6 and 7 (Table AA-3.6.2-1) ␤cp 0.471 in.−1
␥bp −0.00203 AA-3.6.2(f)(3) Step 3
P*sp 0 psi h/pp 1.1
P*cp 0 psi E*/Ep 0.280
␥*sp 0 ␯*p 0.337
␥sp 0.00298 ␩p 0.284
␥*cp 0 Xap 8.84
␥cp −0.00180 Vp 0.542
h′gp 0 in. AA-3.6.2(f)(4) Step 4
For each loading case the absolute value of the Zdp 0.00214
tubesheet bending stress 冨␴冨 is below 1.5S (16,950 psi) Zvp 0.0130
and is acceptable. For each loading case the absolute Zmp 0.163
value of the tubesheet shear stress 冨␶冨 is below 0.8S ⌽p 1.81
(9,040 psi) and is acceptable. For each loading case Q1p 2.85 ⴛ 10−4
the tube stress ␴to is tensile, and, therefore, the tubes AA-3.6.2(f)(5) Step 5. Pe p −30.0 psi, −7.24 psi,
do not need to be checked for buckling. For each −37.2 psi, 0 psi, −30.0 psi, −7.24 psi, and −37.2 psi
loading case the tube stress is less than St (11,300 psi) for loading cases 1 through 7, respectively.
and is therefore acceptable. AA-3.6.2(f)(6) Steps 6 and 9 (Table AA-3.6.2-2)
AA-3.6.2(e) Data for the Floating Head ␥bp 0
AA-3.6.2(e)(1) Loads Trp 218 °F
Wp 0 1b T*cp 226 °F
T ′p 200 °F P*sp 0 psi
T′cp 235 °F P*cp 8.21 psi

643.2
AA-3.6.2 2001 SECTION VIII — DIVISION 1 AA-3.6.3

TABLE AA-3.6.2-2
Loading Case

Symbol 1 2 3 4 5 6 7

Q2, in.-lb/in. 84.5 17.8 102 24.1 109 41.9 126

Q3 −0.0103 −0.00892 −0.0100 ... −0.0133 −0.0214 −0.0214
Fm 0.0239 0.0243 0.0239 ... 0.0229 0.0206 0.0232
␴, psi −4410 −1080 −5490 278 −4230 −917 −5310
␴c,m, psi 1140 0 1140 0 1140 0 1140
␴c,b, psi 10,100 1630 11,800 848 11,000 2480 12,600
␴c, psi 11,300 1630 12,900 848 12,100 2480 13,700

␥*sp 0 dtp 0.75 in.

␥sp 0.000288 ttp 0.065 in.
␥*cp 0.00712 Ltp 155.875 in.
␥cp 0.00683 kᐉp 20.75 in.
h′gp 0 in. ␯tp 0.31
For each loading case the absolute value of the Etp 26.5 ⴛ 106 psi
tubesheet bending stress 冨␴冨 is below 1.5S (16,950 psi) Stp 15,800 psi
and is acceptable. Sytp 17,500 psi
For loading cases 1, 2, and 3 the absolute value of AA-3.6.3(c) Data for the Stationary Tubesheet
the channel stress 冨␴c冨 is below 1.5Sc (16,950 psi) and AA-3.6.3(c)(1) Loads
is therefore acceptable. For loading cases 4, 5, 6, and Wp 290,720 lb
7 the absolute value of the channel stress is below 3Sc AA-3.6.3(c)(2) Tubesheet
(33,900 psi) and is therefore acceptable. hp 1.188 in.
AA-3.6.3 Example 3: Floating Tubesheet Ex- Ap 39.875 in.
changer With an Internally Sealed Floating Head Gsp 39.441 in.
AA-3.6.3(a) Given. A floating tubesheet exchanger Gcp 39.441 in.
with an internally sealed floating head [Fig. AA-3.1.1 Cp 41.625 in.
sketch (c)]. The stationary tubesheet is gasketed with AA-3.6.3(d) Stationary Tubesheet Calculation Results
the shell and channel (Fig. AA-3.1.2 configuration d), AA-3.6.3(d)(1) Step 1
and the floating tubesheet is packed and sealed on its asp 19.7 in.
edge (Fig. AA-3.1.3 configuration D). acp 19.7 in.
AA-3.6.3(b) Summary of Data Common to Both Tube- Lp 153 in.
sheets ␮p 0.200
AA-3.6.3(b)(1) Loads Dop 31.9 in.
Psp shell side design pressure p 150 psi d*p 0.636 in.
Ptp tube side design pressure p 175 psi p*p 0.938 in.
AA-3.6.3(b)(2) Tubesheets. Triangular pitch. ␮*p 0.322
Ntp 1066 aop 15.9 in.
pp 0.9375 in. ␳sp 1.24
rop 15.563 in. ␳cp 1.24
␳p 0.88 xtp 0.597
hgp 0 in. xsp 0.410
ULp 0 in. AA-3.6.3(d)(2) Step 2
ctp 0 in. ␤sp 0 in.−1
␯p 0.31 ␤cp 0 in.−1
Ep 26.5 ⴛ 106 psi AA-3.6.3(d)(3) Step 3
Sp 15,800 psi h/pp 1.27
AA-3.6.3(b)(3) Tubes E*/Ep 0.338

643.3
AA-3.6.3 APPENDIX AA — NONMANDATORY AA-3.6.3

TABLE AA-3.6.3-1 TABLE AA-3.6.3-2

Symbol Loading Case 1 Loading Case 2 Loading Case 3 Symbol Loading Case 1 Loading Case 2 Loading Case 3

Q2, in.-lb/in. −1250 1070 −179 Q2, in.-lb/in. −548 469 −78.2
Q3 0.0962 0.0962 0.0962 Q3 0.0661 0.0661 0.0661
Fm 0.0702 0.0702 0.0702 Fm 0.0575 0.0575 0.0575
␴, psi 21,900 −18,800 3130 ␴, psi 11,400 −9780 1630
␶, psi 3120 −2670 445
␴to, psi −4650 3830 −814
St,bk, psi 10,550 ... 10,550

AA-3.6.3(f) Floating Head Calculation Results

AA-3.6.3(f)(1) Step 1
asp 18.4 in.
␯*p 0.316 acp 18.4 in.
␩p 0.339 Lp 153 in.
Xap 7.40 ␮p 0.200
Vp 0 Dop 31.9 in.
AA-3.6.3(d)(4) Step 4 d*p 0.636 in.
Zdp 0.00369 p*p 0.938 in.
Zvp 0.0186 ␮*p 0.322
Zmp 0.197 aop 15.9 in.
⌽p 0.597 ␳sp 1.16
Q1p 0.202 ␳cp 1.16
AA-3.6.3(d)(5) Step 5. Pe p 92.9 psi, −79.6 psi, xtp 0.597
and 13.3 psi for loading cases 1, 2, and 3, respectively. xsp 0.410
AA-3.6.3(d)(6) Steps 6 and 7 (Table AA-3.6.3-1) AA-3.6.3(f)(2) Step 2
␥bp 0 ␤sp 0 in.−1
P*sp 0 psi ␤cp 0 in.−1
P*cp 0 psi AA-3.6.3(f)(3) Step 3
␥*sp 0 h/pp 1.27
␥sp 0.0315 E*/Ep 0.338
␥*cp 0 ␯*p 0.316
␥cp −0.0315 ␩p 0.339
h′gp 0 in. Xap 7.40
For each loading case the absolute value of the Vp 0
tubesheet bending stress 冨␴冨 is below 1.5S (23,700 psi) AA-3.6.3(f)(4) Step 4
and is acceptable. For each loading case the absolute Zdp 0.00369
value of the tubesheet shear stress 冨␶冨 is below 0.8S Zvp 0.0186
(12,640 psi) and is acceptable. For loading cases 1 and Zmp 0.197
3, the absolute value of the tube stress 冨␴to冨 is less ⌽p 0.388
than the maximum permissible buckling stress limit Q1p 0.139
St,bk. For loading case 2, the tube stress is tensile, and AA-3.6.3(f)(5) Step 5. Pe p 59.2 psi, −50.7 psi,
therefore, the tubes do not need to be checked for and 8.46 psi for loading cases 1, 2, and 3, respectively.
buckling. For each loading case the tube stress is less AA-3.6.3(f)(6) Step 6 (Table AA-3.6.3-2)
than St (15,800 psi) and is therefore acceptable. ␥bp 0
AA-3.6.3(e) Data for the Floating Head P*sp 0 psi
AA-3.6.3(e)(1) Loads P*cp 0 psi
Wp 0 lb ␥*sp 0
AA-3.6.3(e)(2) Tubesheet. Both tubesheets must be ␥sp 0.0133
the same thickness. ␥*cp 0
hp 1.188 in. ␥cp −0.0133
Ap 36.875 in. h′gp 0 in.

643.4
AA-3.6.3 2001 SECTION VIII — DIVISION 1 AA-4.3

Do

t, x

ro
UL
p

tt

dt

FIG. AA-4.1 TUBESHEET GEOMETRY FIG. AA-4.2 TUBE EXPANSION GEOMETRY

For each loading case the absolute value of the
tubesheet bending stress 冨␴冨 is below 1.5S (23,700 psi)
and is acceptable.
AA-4 EFFECTIVE ELASTIC CONSTANTS
AA-4.1 Scope
The ligament efficiences and effective elastic con-
stants to be used in the calculation of U-tube, fixed,
and floating tubesheets are determined herein.
AA-4.2 Conditions of Applicability
AA-4.2(a) These rules apply to flat fully tubed circular
tubesheets of constant thickness having tube holes in
either an equilateral triangular or a square pattern.
AA-4.2(b) Unperforated diametral lanes are permitted
for pass partitions provided that the distance between
adjacent tube rows, UL (see Fig. AA-4.1), does not
exceed 4p(UL ≤ 4p).
AA-4.3 Nomenclature
The symbols described below are used for determin-
ing the effective elastic constants.
Dop equivalent diameter of outer tube limit circle, in.
dtp nominal outside diameter of tube, in.
d*p effective tube hole diameter, in.
Ep modulus of elasticity for tubesheet material at
design temperature, psi
Etp modulus of elasticity for tube material at tube-
sheet design temperature, psi
NOTE: The modulus of elasticity shall be taken from the applicable
Table TM in Section II, Part D. When a material is not listed in
the TM tables, the requirements of U-2(g) shall be applied.
E*p effective modulus of elasticity of tubesheet in
perforated region, psi
hp tubesheet thickness, in.
ᐉtxp expanded length of tube in tubesheet (0 ≤ ᐉtx ≤
h), in. (see Fig. AA-4.2)
NOTE: An expanded tube-to-tubesheet joint is produced by applying
pressure inside the tube such that contact is established between the
tube and tubesheet. In selecting an appropriate value of expanded
length, the designer shall consider the degree of initial expansion,
differences in thermal expansion, or other factors that could result
in loosening of the tube within the tubesheet.
MAX [(a), (b), (c), . . .] p greatest of a, b, c, . . .
pp tube pitch, in.
p*p effective tube pitch, in.
rop radius to outermost tube hole center, in.
Sp allowable stress for tubesheet material at tube-
sheet design temperature (see UG-23), psi
Stp allowable stress for tube material at tubesheet
design temperature (see UG-23), psi. For a

643.5
AA-4.3 APPENDIX AA — NONMANDATORY AA-4.5.2

welded tube, use the allowable stress for an AA-4.5 Calculation Procedure
equivalent seamless tube.
AA-4.5.1 Determination of Effective Dimensions
ttp nominal tube wall thickness, in.
and Ligament Efficiencies. From the geometry and
ULp largest center-to-center distance between adja-
material properties of the exchanger, calculate Do , ␮,
cent tube rows, in. d*, p*, and ␮*. See Figs. AA-4.1 and AA-4.2.
␮p basic ligament efficiency
␮*p effective ligament efficiency
␯*p effective Poisson’s ratio in perforated region of Do p 2ro + dt
tubesheet
p − dt
␳p tube expansion depth ratio p ᐉtx /h, (0 ≤ ␳ ≤ 1) ␮p
p

冦冤d − 2t 冢 E 冣冢 S 冣 ␳ 冥, 关d − 2t 兴冧
Et St
d* p MAX t t t t

AA-4.4 Design Considerations

p
AA-4.4(a) Elastic moduli and allowable stresses shall p* p 1⁄

冢 冣
2
4UL
be taken at the design temperatures. However, for cases 1−
␲Do
involving thermal loading, it is permitted to use the
operating temperatures instead of the design tempera-
p* − d*
tures. ␮* p
p*
AA-4.4(b) When the values calculated in this section
are to be used for fixed tubesheets, they shall be
determined in both the corroded and uncorroded condi- AA-4.5.2 Determination of Effective Elastic Prop-
tions. erites. Determine the values for E*/E and ␯* relative
AA-4.4(c) ␳ may be either calculated or chosen as to h/p using either Fig AA-4.3 (equilateral triangular
a constant. pattern) or Fig. AA-4.4 (square pattern).

643.6
Fig. AA-4.3 2001 SECTION VIII — DIVISION 1

0.8 0.7
h /p
2.00

0.7 1.00
0.6

0.50
0.6
0.5

0.5
0.4 0.25
E /E

0.4

0.3 0.15
0.3

0.2
0.2 h /p
0.10
0.25 0.1
0.1
0.50
2.00
0.10
0 0
0 0.1 0.2 0.3 0.4 0.5 0.6 0 0.1 0.2 0.3 0.4 0.5 0.6
µ µ
(a) E /E (Equilateral Triangular Pattern) (b) (Equilateral Triangular Pattern)

(a) Equilateral Triangular Pattern E*/E p ␣0 + ␣1␮* + ␣2␮*2 + ␣3␮*3 + ␣4␮*4

h/p ␣0 ␣1 ␣2 ␣3 ␣4
0.10 0.0353 1.2502 −0.0491 0.3604 −0.6100
0.25 0.0135 0.9910 1.0080 −1.0498 0.0184
0.50 0.0054 0.5279 3.0461 −4.3657 1.9435
2.00 −0.0029 0.2126 3.9906 −6.1730 3.4307

(b) Equilateral Triangular Pattern ␯* p ␤0 + ␤1␮* + ␤2␮*2 + ␤3␮*3 + ␤4␮*4

h/p ␤0 ␤1 ␤2 ␤3 ␤4
0.10 −0.0958 0.6209 −0.8683 2.1099 −1.6831
0.15 0.8897 −9.0855 36.1435 −59.5425 35.8223
0.25 0.7439 −4.4989 12.5779 −14.2092 5.7822
0.50 0.9100 −4.8901 12.4325 −12.7039 4.4298
1.00 0.9923 −4.8759 12.3572 −13.7214 5.7629
2.0 0.9966 −4.1978 9.0478 −7.9955 2.2398

GENERAL NOTES:
(a) The polynomial equations given in the tabular part of this Figure can be used in lieu of the curves.
(b) For both parts (a) and (b) in the tabular part of this Figure, these coefficients are only valid for 0.1 ≤
␮* ≤ 0.6.
(c) For both parts (a) and (b) in the tabular part of this Figure: for values of h/p lower than 0.1, use h/p
p 0.1; for values of h/p higher than 2.0, use h/p p 2.0.

FIG. AA-4.3 CURVES FOR THE DETERMINATION OF E* /E AND ␯* (EQUILATERAL TRIANGULAR PATTERN)

643.7
 APPENDIX AA — NONMANDATORY Fig. AA-4.4

(a) Square Pattern E*/E p ␣0 + ␣1␮* + ␣2␮*2 + ␣3␮*3 + ␣4␮*4

h/p ␣0 ␣1 ␣2 ␣3 ␣4
0.10 0.0676 1.5756 −1.2119 1.7715 −1.2628
0.25 0.0250 1.9251 −3.5230 6.9830 −5.0017
0.50 0.0394 1.3024 −1.1041 2.8714 −2.3994
2.00 0.0372 1.0314 −0.6402 2.6201 −2.1929

(b) Square Pattern ␯* p ␤0 + ␤1␮* + ␤2␮*2 +␤3␮*3 + ␤4␮*4

h/p ␤0 ␤1 ␤2 ␤3 ␤4
0.10 −0.0791 0.6008 −0.3468 0.4858 −0.3606
0.15 0.3345 −2.8420 10.9709 −15.8994 8.3516
0.25 0.4296 −2.6350 8.6864 −11.5227 5.8544
0.50 0.3636 −0.8057 2.0463 −2.2902 1.1862
1.00 0.3527 −0.2842 0.4354 −0.0901 −0.1590
2.00 0.3341 0.1260 −0.6920 0.6877 −0.0600

GENERAL NOTES:
(a) The polynomial equations given in the tabular part of this Figure can be used in lieu of the curves.
(b) For both parts (a) and (b) in the tabular part of this Figure, these coefficients are only valid for 0.1 ≤
␮* ≤ 0.6.
(c) For both parts (a) and (b) in the tabular part of this Figure: for values of h/p lower than 0.1, use h/p
p 0.1; for values of h/p higher than 2.0, use h/p p 2.0.

FIG. AA-4.4 CURVES OF THE DETERMINATION OF E* /E AND ␯* (SQUARE PATTERN)

643.8