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Procedural TEMA AES Parametric Mesh Pipeline
Shell Barrel
TEMA Type AES • Heat Exchanger
1. Complete Assembly Overview
Floating head split-backing-ring exchanger (AES Configuration)
Shell Side Duty
4.85 MW
Tube Count
148 Tubes
Shell Press.
24.5 barg
Baffle Cut
25% Horiz.
Overview Channel Head (Type A) Stationary Tubesheet Tube Bundle & Passes Segmental Baffles Floating Head (Type S) Shell & Impingement Plate TEMA Standards Spec
Exchanger Component
Front Channel Head
Removable cover channel head with pass partition plate configured for 2-pass tube-side fluid routing.
Material:
SA-516 Gr. 70
Design Code:
ASME VIII Div 1
Design Temp:
280 °C
Corrosion Allow:
3.2 mm
Phase 01 // Industrial Architecture

TEMA Type AES Heat Exchanger

The TEMA AES is an industry-standard floating head heat exchanger with a removable channel cover (A), one-pass cylindrical shell (E), and a split-backing-ring floating head (S). It is built for severe thermal stress, differential thermal expansion, and mechanical cleanability.

Removable Tube Bundle Differential Expansion Absorbed 2-Pass Tube / 1-Pass Shell

💡 Pro Tip: Click on any 3D component directly, or toggle Cutaway & Exploded views in the bottom dock!

Phase 02 // Stationary End

Type 'A' Channel & Cover

The stationary front channel head permits servicing and tube inspection without disconnecting the external process piping. A central horizontal pass partition plate seals against the stationary tubesheet gasket, directing fluid into the lower tube bundle and receiving it back from the upper bundle.

Forged Bolted Flanges Pass Partition Lane DN150 300# RF Nozzles
Phase 03 // Pressure Boundary

Stationary Tubesheet (Fixed End)

The stationary tubesheet is clamped tightly between the shell flange and channel head flange. Tubes are roller-expanded and seal-welded into double grooved holes to eliminate cross-contamination between shell-side and tube-side fluids under 25 barg pressure.

Triangular Pitch (30°) Double-Grooved Serrations SA-350 LF2 Forging
Phase 04 // Core Heat Transfer Surface

148-Tube Bundle Core (2-Pass)

High-velocity cold process fluid travels across 148 seamless titanium/stainless tubes (3/4" OD x 14 BWG). With two tube passes, velocity is doubled, maximizing the tube-side heat transfer coefficient ($h_i$) and scouring boundary layer fouling deposits.

Seamless 3/4" (19.05 mm) OD Total Area: 112.5 m² Fouling Resistance: 0.0003 m²·K/W
Phase 05 // Shell Dynamics

Segmental Baffles & Spacer Tie-Rods

25% cut horizontal segmental baffles induce turbulent cross-flow across the tube bank, multiplying the shell-side Nusselt number. Six longitudinal tie-rods and machined spacer collars prevent tube vibration and flow-induced acoustic resonance.

25% Cut Segmental Plate Baffle Spacing: 350 mm Vibration Damping Support
Phase 06 // Thermal Expansion Release

Floating Head with Split Backing Ring

The floating head cover bolts to the rear floating tubesheet with an internal split backing ring (TEMA Type S). Because the rear head floats completely free inside the enlarged shell cover, thermal expansion between shell and tubes causes zero tensile stress.

Split Backing Ring Bolting Zero Thermal Stress Anchor Removable Without Shell Cut
Phase 07 // Vessel Containment

Shell Barrel & Impingement Plate

The carbon steel outer shell barrel (DN600) features saddle supports, lifting lugs, and an internal curved impingement baffle plate positioned right beneath the shell inlet nozzle. This plate deflects high-velocity two-phase inlet fluids, preventing tube erosion and mechanical wear.

Erosion Impingement Shield Dual Saddle Supports ASME Section VIII Div 1 Design

TEMA AES Engineering Specifications

Rigorous mechanical design criteria and thermal performance parameters verified against ASME Section VIII Div. 1 and TEMA Class R standards.

Design Parameter Shell Side (Hot Medium) Tube Side (Cold Medium) Unit / Design Code
Operating Fluid Heavy Naphtha / Gasoil Treated Demin Water / Crude Feed API Service
Design Pressure 24.5 32.0 barg
Operating Temperature (In / Out) 215.0 / 142.0 45.0 / 118.5 °C
Mass Flow Rate 42,500 68,200 kg/h
Heat Duty (Q) 4,850 kW (4.85 MW) TEMA Calculated
Total Effective Heat Transfer Area 112.5 m² (1,211 sq ft) OD Basis
Tube Geometry 148 Tubes × 19.05 mm (3/4") OD × 2.11 mm wall × 4,500 mm length Triangular 30° Pitch (25.4 mm)
Baffle Configuration 11 Segmental Baffles (25% cut, 350 mm spacing) 2 Passes (Single Partition Plate) TEMA R Compliant
Pressure Drop (ΔP Allow / Calc) 0.45 / 0.38 bar 0.70 / 0.52 bar Hydraulic Verification Pass