Tema Designations

The popularity of shell and tube exchangers has resulted in a standard nomenclature being
developed for their designation and use by the Tubular Exchanger Manufactures Association
(TEMA). This nomenclature is defined in terms letters and diagrams. The first letter describes the
front header type, the second letter the shell type and the third letter the rear header type. Figure 2
shows examples of a BEM, CFU, and AES exchangers while Figure 3 illustrates the full TEMA
nomenclature.

Figure 3. TEMA nomenclature. 1988 by Tubulare Exchanger Manufacturers Association.

Many combinations of front header, shell and rear header can be made. The most common
combinations for an E-Type Shell are given in Table 2 but other combinations are also used.

Table 2. Shell and tube geometric terminology

Fixed tubesheet exchangers U-tube exchangers Floating head exchangers

AEL AEU AES
AEM CEU BES
AEN DEU
BEL
BEM
BEN

Essentially there are three main combinations

Fixed tubesheet exchangers

U-tube exchangers
Floating header exchangers

Fixed Tubesheet Exchanger (L, M, and N Type Rear Headers)

In a fixed tubesheet exchanger, the tubesheet is welded to the shell. This results in a simple and
economical construction and the tube bores can be cleaned mechanically or chemically. However,
the outside surfaces of the tubes are inaccessible except to chemical cleaning.

If large temperature differences exist between the shell and tube materials, it may be necessary to
incorporate an expansion bellows in the shell, to eliminate excessive stresses caused by expansion.
Such bellows are often a source of weakness and failure in operation. In circumstances where the
consequences of failure are particularly grave U-Tube or Floating Header units are normally used.

This is the cheapest of all removable bundle designs, but is generally slightly more expensive than a
fixed tubesheet design at low pressures.

U-Tube Exchangers

In a U-Tube exchanger any of the front header types may be used and the rear header is normally a
M-Type. The U-tubes permit unlimited thermal expansion, the tube bundle can be removed for
cleaning and small bundle to shell clearances can be achieved. However, since internal cleaning of
the tubes by mechanical means is difficult, it is normal only to use this type where the tube side
fluids are clean.

Floating Head Exchanger (P, S, T and W Type Rear Headers)

In this type of exchanger the tubesheet at the Rear Header end is not welded to the shell but
allowed to move or float. The tubesheet at the Front Header (tube side fluid inlet end) is of a larger
diameter than the shell and is sealed in a similar manner to that used in the fixed tubesheet design.
The tubesheet at the rear header end of the shell is of slightly smaller diameter than the shell,
allowing the bundle to be pulled through the shell. The use of a floating head means that thermal
expansion can be allowed for and the tube bundle can be removed for cleaning. There are several
rear header types that can be used but the S-Type Rear Head is the most popular. A floating head
exchanger is suitable for the rigorous duties associated with high temperatures and pressures but
is more expensive (typically of order of 25% for carbon steel construction) than the equivalent
fixed tubesheet exchanger.

Considering each header and shell type in turn:

A-Type front header

This type of header is easy to repair and replace. It also gives access to the tubes for cleaning or
repair without having to disturb the pipe work. It does however have two seals (one between the
tube sheet and header and the other between the header and the end plate). This increases the risk
of leakage and the cost of the header over a B-Type Front Header.

B-Type front header

This is the cheapest type of front header. It also is more suitable than the A-Type Front Header for
high pressure duties because the header has only one seal. A disadvantage is that to gain access to
the tubes requires disturbance to the pipe work in order to remove the header.

C-Type front header

This type of header is for high pressure applications (>100 bar). It does allow access to the tube
without disturbing the pipe work but is difficult to repair and replace because the tube bundle is an
integral part of the header.

D-Type front header

This is the most expensive type of front header. It is for very high pressures (> 150 bar). It does
allow access to the tubes without disturbing the pipe work but is difficult to repair and replace
because the tube bundle is an integral part of the header.

N-Type front header

The advantage of this type of header is that the tubes can be accessed without disturbing the pipe
work and it is cheaper than an A-Type Front Header. However, they are difficult to maintain and
replace as the header and tube sheet are an integral part of the shell.

Y-Type front header

Strictly speaking this is not a TEMA designated type but is generally recognized. It can be used as a
front or rear header and is used when the exchanger is to be used in a pipe line. It is cheaper than
other types of headers as it reduces piping costs. It is mainly used with single tube pass units
although with suitable partitioning any odd number of passes can be allowed.
E-Type shell

This is most commonly used shell type, suitable for most duties and applications. Other shell types
only tend to be used for special duties or applications.

F-Type shell

This is generally used when pure countercurrent flow is required in a two tube side pass unit. This
is achieved by having two shells side passesthe two passes being separated by a longitudinal
baffle. The main problem with this type of unit is thermal and hydraulic leakage across this
longitudinal baffle unless special precautions are taken.

G-Type shell

This is used for horizontal thermosyphon reboilers and applications where the shellside pressure
drop needs to be kept small. This is achieved by splitting the shellside flow.

H-Type shell

This is used for similar applications to G-Type Shell but tends to be used when larger units are
required.

J-Type shell

This tends to be used when the maximum allowable pressure drop is exceeded in an E-Type Shell
even when double segmental baffles are used. It is also used when tube vibration is a problem. The
divided flow on the shellside reduces the flow velocities over the tubes and hence reduces the
pressure drop and the likelihood of tube vibration. When there are two inlet nozzles and one outlet
nozzle this is sometimes referred to as an I-Type Shell.

K-Type shell

This is used only for reboilers to provide a large disengagement space in order to minimize
shellside liquid carry over. Alternatively a K-Type Shell may be used as a chiller. In this case the
main process is to cool the tube side fluid by boiling a fluid on the shellside.

X-Type shell

This is used if the maximum shellside pressure drop is exceeded by all other shell and baffle type
combinations. The main applications are shellside condensers and gas coolers.

L-Type rear header

This type of header is for use with fixed tubesheets only, since the tubesheet is welded to the shell
and access to the outside of the tubes is not possible. The main advantages of this type of header are
that access can be gained to the inside of the tubes without having to remove any pipework and the
bundle to shell clearances are small. The main disadvantage is that a bellows or an expansion roll
are required to allow for large thermal expansions and this limits the permitted operating
temperature and pressure.

M-Type rear header

This type of header is similar to the L-Type Rear Header but it is slightly cheaper. However, the
header has to be removed to gain access to the inside of the tubes. Again, special measures have to
be taken to cope with large thermal expansions and this limits the permitted operating temperature
and pressure.

N-Type rear header

The advantage of this type of header is that the tubes can be accessed without disturbing the pipe
work. However, they are difficult to maintain and replace since the header and tube sheet are an
integral part of the shell.

P-Type rear header

This is an outside packed floating rear header. It is, in theory, a low cost floating head design which
allows access to the inside of the tubes for cleaning and also allows the bundle to be removed for
cleaning. The main problems with this type of header are:

large bundle to shell clearances required in order to pull the bundle;

it is limited to low pressure nonhazardous fluids, because it is possible for the shellside fluid
to leak via the packing rings;
only small thermal expansions are permitted.

In practice it is not a low cost design, because the shell has to be rolled to small tolerances for the
packing to be effective.

S-Type rear header

This is a floating rear header with backing device. It is the most expensive of the floating head types
but does allow the bundle to be removed and unlimited thermal expansion is possible. It also has
smaller shell to bundle clearances than the other floating head types. However, it is difficult to
dismantle for bundle pulling and the shell diameter and bundle to shell clearances are larger than
for fixed head type exchangers.

T-Type rear header

This is a pull through floating head. It is cheaper and easier to remove the bundle than with the S-
Type Rear Header, but still allows for unlimited thermal expansion. It does, however, have the
largest bundle to shell clearance of all the floating head types and is more expensive than fixed
header and U-tube types.

U-tube

This is the cheapest of all removable bundle designs, but is generally slightly more expensive than a
fixed tubesheet design at low pressures. However, it permits unlimited thermal expansion, allows
the bundle to be removed to clean the outside of the tubes, has the tightest bundle to shell
clearances and is the simplest design. A disadvantage of the U-tube design is that it cannot normally
have pure counterflow unless an F-Type Shell is used. Also, U-tube designs are limited to even
numbers of tube passes.

W-Type rear header

This is a packed floating tubesheet with lantern ring. It is the cheapest of the floating head designs,
allows for unlimited thermal expansion and allows the tube bundle to be removed for cleaning. The
main problems with this type of head are:

the large bundle to shell clearances required to pull the bundle and;
the limitation to low pressure nonhazardous fluids (because it is possible for both the fluids
to leak via the packing rings).

It is also possible for the shell and tube side fluids to become mixed if leakage occurs.

Shell selection

E-type shells are the most common. If a single tube pass is used and provided there are
more than three baffles, then near counter-current flow is achieved. If two or more tube
passes are used, then it is not possible to obtain pure countercurrent flow and the log mean
temperature difference must be corrected to allow for combined cocurrent and
countercurrent flow using an F-factor.

G-type shells and H shells are normally specified only for horizontal thermosyphon
reboilers. J shells and X-type shells should be selected if the allowable DP cannot be
accommodated in a reasonable E-type design. For services requiring multiple shells with
removable bundles, F-type shells can offer significant savings and should always be
considered provided they are not prohibited by customer specifications

Front header selection

The A-type front header is the standard for dirty tubeside fluids and the B-type is the
standard for clean tubeside fluids. The A-type is also preferred by many operators
regardless of the cleanliness of the tubeside fluid in case access to the tubes is required. Do
not use other types unless the following considerations apply.

A C-type head with removable shell should be considered for hazardous tubeside fluids,
heavy bundles or services requiring frequent shellside cleaning. The N-type head is used
when hazardous fluids are on the tubeside. A D-type head or a B-type head welded to the
tubesheet is used for high pressure applications. Y-type heads are only normally used for
single tube-pass exchangers when they are installed in line with a pipeline.

Rear header selection

For normal service a Fixed Header (L, M, N-types) can be used provided that there is no
overstressing due to differential expansion and the shellside will not require mechanical
cleaning. If thermal expansion is likely a fixed header with a bellows can be used provided
that the shellside fluid is not hazardous, the shellside pressure does not exceed 35 bar (500
psia) and the shellside will not require mechanical cleaning.

A U-tube unit can be used to overcome thermal expansion problems and allow the bundle
to be removed for cleaning. However, countercurrent flow can only be achieved by using an
F-type shell and mechanical cleaning of the tubeside can be difficult.

An S-type floating head should be used when thermal expansion needs to be allowed for
and access to both sides of the exchanger is required from cleaning. Other rear head types
would not normally be considered except for the special cases.