Custom Type Fixed Tubesheet Shell and Tube Heat Exchanger for Inter Coole
1. Equipment Overview & Configuration
A fixed tubesheet design (typically TEMA Type AEL or BEM) represents the most robust and leak-proof configuration for compressor intercooler applications. Because the tubesheets are welded directly to the shell, there are no internal gaskets or floating mechanisms, completely eliminating potential bypass leakage between high-pressure process gas and the cooling medium.
| Parameter Category | Specification Details: Shell Side | Specification Details: Tube Side |
| Fluid Allocation | Cooling Medium (e.g., Water / Glycol) | Process Gas (e.g., Air, Methanol Gas, N₂/H₂) |
| TEMA Type Components | E (One-Pass Shell) / M (Fixed Tubesheet) | A (Removable Channel & Cover) / L (Bonnet) |
| Design Pressure | 1.0 MPa (145 psi) [Customizable] | 3.5 MPa (508 psi) [Customizable] |
| Design / Test Temperature | -10°C to 80°C | -10°C to 180°C |
| Operating Temperature | Inlet: 25°C $rightarrow$ Outlet: 38°C | Inlet: 150°C $rightarrow$ Outlet: 40°C |
| Corrosion Allowance | 1.5 mm | 3.0 mm (or based on gas corrosivity) |
| Pass Count | 1-Pass | 2-Pass or 4-Pass (Optimized for gas velocity) |
| Joint Type | N/A | Strength Welded + Extended Expanded |
Materials are selected based on the specific chemistry of the process gas and the quality of the cooling water.
| Component | Standard Industrial Carbon Steel | Premium High-Corrosion / Duplex Options |
| Shell & Shell Cover | ASME SA516 Gr. 70 | ASME SA240 Type 304 / 316L Stainless Steel |
| Tubesheet | ASME SA105 / SA516 Gr. 70 | ASME SA240 S31803 (Duplex) / SS316L Clad |
| Heat Exchanger Tubes | ASME SA179 (Cold Drawn Carbon Steel) | ASME SA213 TP316L / SA789 S31803 (Duplex) |
| Tube Profile | Bare / Smooth Tube | Low-Finned (Integral) / Corrugated Tubes |
| Baffles & Spacers | ASME SA283 Gr. C / SS304 | SS316L |
| Channel / Bonnet | ASME SA106 Gr. B / SA516 Gr. 70 | ASME SA240 TP316L |
4.Typical Industrial Sector Applications
This specific ASME/NBR certificated design is built for heavy industrial environments, including:
Oil & Gas Refineries: Inter-stage cooling of hydrocarbon gases, recycle hydrogen gas, and sour gases.
Petrochemical & Methanol Plants: Cooling of synthesis gas (Syngas) and high-pressure process loops.
Air Separation Units (ASU): Multi-stage centrifugal air compressors producing bulk O2 and N2.
Large-scale Utilities: High-pressure plant air systems where NBR/NR-13 compliance is mandatory for South American/Brazilian operations.
