International Journal of Pressure Vessels and Piping 76 (1999) 671–675

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Numerical simulation of thermal stress in tube-sheet of heat transfer

equipment
M.-S. Liu a, Q.-W. Dong a, D.-B. Wang a, X. Ling b,*
a
Zhengzhou University of Technology, Zhengzhou, People’s Republic of China
b
Nanjing University of Chemical Technology, Nanjing 210009, People’s Republic of China
Received 7 April 1999; accepted 16 April 1999

Abstract
The thermal stress induced by temperature difference in the tube-sheet of heat transfer equipment was studied in the paper. Finite element
method (FEM) was used to compute the temperature and the stress fields. The effect of the tube-sheet thickness on the thermal stress has been
discussed in terms of the results by FEM. Some measures to reduce or eliminate the thermal stress in the tube sheet are suggested. A new
design of the structure of the flexible tube sheet was proposed. q 1999 Elsevier Science Ltd. All rights reserved.
Keywords: Shell-and-tube heat exchanger; Thermal stress; Finite element method

Nomenclature MR Edge moment at the connection of the backing ring

and the flange
C Specific heat Ms Edge moment at the junction of the shell and the
[C] Matrix of specific heat tube sheet
[D] Elasticity matrix Mt Edge moment at the connection of the backing ring
{Fp }e Equivalent nodal forces due to the central force and the tube layout area
{Fq }e Equivalent nodal forces shifted from the area {Q} Node effective heat vector
force q Heat flux
{Fg }e Equivalent node forces due to body force; qB Heat source per unit volume
{FDT }e Equivalent nodal forces due to thermal loading. qs Boundary heat input per unit area
Fij Coefficient matrix Rt Limited circular diameter of the tube layout
Fip Load vector composed of the pressure and the {T} Node temperature vector
thermal expansion difference Te Convective temperature
Hs Transverse sheering force in the connection of the Tr Temperature of the outer radiant source
shell and the tube sheet _
{T} First derivative of the node temperature with
H0 Radial tension of the external edge of the tube- respect to time
sheet Vt Edge force in the connection of the backing ring
Hh Transverse sheering force at the connection of the and the tube layout area
channel and the flange Vh Header axial force
h Convective coefficient Vs Shell axial force
[K] Matrix of effective heat conduction VR Edge shearing force of the backing ring
kn Thermal conductivity k Radiation coefficient
Mf Flange moment r Material density
Mh Edge moment at the junction of the channel and the rt Ratio, rt ˆ Rt =R
flange {s } Stress vector
{e 0} Initial thermal strain vector
{e } Total strain vector
* Corresponding author. Tel.: 1 86-25-331-6755.
{s DT} the initial stress corresponding with initial stress
E-mail address: xling@httd.njuct.edu.cn (X. Ling) {e 0}
0308-0161/99/$ - see front matter q 1999 Elsevier Science Ltd. All rights reserved.
PII: S0308-016 1(99)00037-X
672 M.-S. Liu et al. / International Journal of Pressure Vessels and Piping 76 (1999) 671–675

1. Introduction

Heat transfer equipment, such as the shell-and-tube heat

exchanger and the waste heat boiler, is widely used in the
process industry to recover heat or meet the process require-
ments. They are generally subjected to the extremely
demanding conditions. The tube-sheet is the essential
component of heat transfer equipment and three major
parts of the vessel: the shell, the header and the tube bundle
are connected to it. The tube-sheet, by its very nature,
experiences both pressure stresses and thermal stresses.
Some engineering rules have been proposed to limit the
stresses in the tube-sheet in the current design codes, such
as TEAM, BS 5500, French CODAP, ASME VII-1 and
Chinese GB 151-89, etc. However, in a scientific respect,
the role of the thermal stress is not fully understood. Some-
times the thermal stress is so high that it may play an impor-
tant role and cause the failure of tube-sheet. It is thus
necessary to study further the thermal stresses in a tube-
sheet. Fig. 1. Mechanical model for the tube-sheet.
Using an analytical method to precisely calculate the
stress in the tube-sheet is very difficult due to its compli- element spatial discretization:
cated configuration and boundary conditions. Most of the
‰CŠ{T}_ 1 ‰KŠ{T} ˆ {Q} …5†
analytical procedures to design the tube-sheet are based on
R
the elastic plate theory with over-simplifying assumptions where ‰CŠ ˆ V rc{N}‰NŠ dV; ‰KŠ ˆ ‰Kk Š 1 ‰Kc Š 1 ‰Kr Š
[1,2] although a complete structure analysis of tube-sheet and {Q} ˆ {Qq } 1 {Qc } 1 {Qr }: [Kk], [Kc] and [Kr] and
can be carried out using finite element method without much [Qq], [Qc] and [Qr] can be expressed as:
simplification [3,4]. The thermal stresses in tube-sheet Z T
generally include two parts: one is due to thermal expansion ‰Kk Š ˆ ‰BŠ ‰kŠ‰BŠ dV;
difference between tubes and the shell, the other induced by V

the temperature difference in axial and radial direction. Not Z

many research papers have been published in connection ‰Kc Š ˆ h{N}‰NŠ dG;
Sc
with thermal stresses in the tube-sheet. The purpose of the
paper is to study the thermal stress in tube-sheet using finite Z
element method and present some measures for further ‰Kr Š ˆ k{N}‰NŠ dG;
Sr
design improvements.
Z
{Qq } ˆ qs {N} dV;
2. Finite element analysis for heat conduction problem V

Heat conduction equation is given as Z

{Qc } ˆ hTe {N} dG;
2T Sc
27q 1 qB ˆ rc …1†
2t Z
Subject to the boundary conditions {Qr } ˆ kTr {N} dG:
Sr
T…x; y; z; t† ˆ Tw …x; y; z; t†; on the surface S1 …2†

2T 3. Modeling of tube sheet

2kn ˆ qs ; on the surface S2 …3†
2n 0
Based on the theory of elastic circle plate, the following
T…x; y; z; 0† ˆ T0 …x; y; z; 0† …4† main factors are taken into account:
where boundary input heat per unit area qs equals to h…Te 2 (a) The perforated tube-sheet is replaced by an elastic
Ts † for convective boundary Sc and k…Tr 2 Ts † radiant homogeneous equivalent circle plate, which is weakened
boundary Sr, respectively. by the regularly arranged tube holes and strengthened by
According to Galerkin’s law, the governing equation for the tubes simultaneously. The un-perforated rim of the
heat conduction problem can be obtained through finite tube-sheet is assumed as a circle solid sheet.
 M.-S. Liu et al. / International Journal of Pressure Vessels and Piping 76 (1999) 671–675 673

Fig. 2. The distribution of the tube sheet temperature.

Fig. 4. The distribution of the tube sheet temperature.

(b) The effect of various types of connection between the
tube-sheet, shell, and the header are considered. 4. Finite element analysis of thermal stress
(c) The flange’s moment on the tube sheet is taken into
account. Heat conduction equation for two-dimensional axial
(d) The thermal stress induced by the thermal expansion symmetric steady state problem of the tube-sheet is given as
difference between the tubes and the shell is also consid-
22 T kr 2T 22 T
ered. kr 1 1 k z 1 qB ˆ 0: …8†
2r 2 r 2r 2z2
The mechanical model for the tube-sheet is illustrated in
Similarly to the above method, the system equation of
Fig. 1. The tube-sheet is disconnected from the remainder of
finite element equation for the tube sheet’s two-dimensional
the exchanger by applying internal forces at its periphery.
axial symmetric steady state problem is given by:
Nine independent internal forces exist in the connection of
tube-sheet with shell, flange and header. In vector form, its ‰KŠ{T} ˆ {Q}: …9†
is given as follows:
The relationship between stresses and strains can be writ-
{xj } ˆ {Mh ; Hh ; Ms ; Hs ; MR ; H 0 ; rt Mt ; rt Vt ; Mf }: …6† ten as

The vector must satisfy the following algebra equation: {s} ˆ ‰DŠ…{1} 2 {10 }† ˆ ‰DŠ{1} 2 ‰DŠ{10 }: …10†

X
9 Let
Fij xj ˆ Fip i ˆ 1; 2; L; 9: …7†
jˆ1
{sDT } ˆ ‰DŠ{10 } …11†

The internal forces in the tube-sheet and correlation where {s DT} is called initial stress corresponding to initial
components can be obtained by solving the equation. It is thermal strain {ee 0}.R
very complicated that the solution is carried out using three- Using {FDT } ˆ V e ‰BŠT {sDT } dV for the nodal thermal
dimensional finite element method without any simplifica- load vector, the equilibrium equation to be satisfied can be
tion. For analysis convenience, the perforated tube-sheet is written as
treated as an equivalent solid sheet. The equivalent solid Z Z
‰BŠT ‰DŠ‰BŠ dV{U}e ˆ ‰BŠT {dDT } dV
plate has the same dimensions as the tube-sheet but the Ve Ve
modulus of elasticity E and the Poisson’s ratio V are
replaced by the equivalent modulus elasticity E p and the ˆ {Fp }e 1 {Fq }e 1 {Fg }e 1 {FDT }e : …12†
equivalent Poisson’s ratio V p to take account of the tube In matrix form, it is expressed as follows:
holes. After such simplification is adopted, the analysis of
the structure of the tube sheet can be changed into the two- ‰KŠe {U}e ˆ {Fp }e 1 {Fq }e 1 {Fg }e 1 {FDT }e : …13†
dimensional asymmetric steady state problem.

Fig. 3. The distribution of the tube sheet thermal stress (Mises). Fig. 5. The distribution of the tube sheet thermal stress (Mises).
674 M.-S. Liu et al. / International Journal of Pressure Vessels and Piping 76 (1999) 671–675
Fig. 6. Type of thin tube-sheet.
When neglecting the terms {Fp }e , {Fq }e and {Fg }e , (12)
becomes
‰KŠe {U}e ˆ {FDT }e : …
As a result of the assembly of the element stiffness, the
governing system of equation is obtained in the form
‰KŠ{U} ˆ {FDT }: …
The nodal displacement under the equivalent temperature
difference load can be obtained by solving Eq. (15). Then
the thermal stress can also be obtained from Eq. (10).
5. Numerical examples
Example one: A waste heat boiler at conversion section of
methanol is used to produce steam in a factory. The pressure
of tube side is 2.06 MPa. The stream of tube side is the
reforming gas at 8308C. The stream of its shell side is
the cooled water. The heat-insulating layer is stuck to the
surface of tube-sheet to prevent tube-sheet from overheat-
ing. According to our on-site measurements and theoretical
calibration, the wall temperature of the shell and the tube is
taken to be at 227 and 2708C, respectively. The thickness of
the tube sheet is 80 mm.
The numerical distributions of temperature and thermal
stress in the tube sheet by FEM are shown in Figs. 2 and 3,
respectively.
Example two: The inlet temperature of the tube is 58C, the
outlet temperature is 308C and the design pressure is
1.57 MPa. The steam in the shell side is superheated
steam. Its inlet temperature is about 300–3508C. Its working
pressure is 0.3 MPa, and its design pressure is 0.6 MPa. The
Fig. 7. Configuration of flexible thin tube-sheet.
material of the shell and the tubes is chosen to be 16MnR
and stainless steel, respectively. Through the calculation of
process and strength, the diameter of the shell is 600 mm,
14†
the thickness of the shell and the tube sheet is 10 and
50 mm, respectively. The outside diameter of the tube is
25 mm and the inside diameter is 21 mm. The total number
15† of the tubes is 284.
The results are obtained by use of the finite element
method. The distribution of the tube sheet temperature is
shown in Fig. 4. The distribution of stress in the tube sheet is
illustrated in Fig. 5. It is obvious that the thermal stress of
the tube sheet is fairly large from Figs. 3 and 5.
6. Application of thin tube-sheet
It can be seen from the above analysis that the thermal
stress is rather significant due to the temperature difference
between the upper and lower surfaces and thickness of tube-
sheet. It is thus necessary to take measures to decrease the
thickness of tube sheet.
The measures are as follows [5]:
(a) The surface of the tube sheet is welded on the flange,
as shown in Fig. 6(a);
(b) The tube sheet is inserted into the internal surface of
the flange and cut into smooth surface, as shown in Fig.
6(b);
(c) The tube sheet is under the flange and welded on the
shell, as shown in Fig. 6(c);
(d) The structure of the flexible thin tube-sheet is shown
in Fig. 6(d). It has been widely used in the water tube
boiler.
In order to reduce the stress in the tube sheet of
Example one, a new design has been proposed. The
Fig. 8. Distribution of thermal stress in tube sheet of waste heat boiler
(Mises).
 M.-S. Liu et al. / International Journal of Pressure Vessels and Piping 76 (1999) 671–675
Fig. 9. Distribution of thermal stress in tube-sheet of water heater (Mises).
improved configuration of tube-sheet and the thermal stress
distribution are shown in Figs. 7 and 8, respectively.
If the tube-sheet in example two is replaced with welding
thin tube-sheet structure, the thickness of tube sheet by finite
element method is 17 mm. In this case, the thermal stress
distribution of tube sheet is shown in Fig. 9.
Comparing Figs. 3 and 5 with Figs. 8 and 9, it is obvious
that the present designs decrease the thermal stresses in the
tube sheets.
7. Concluding remarks
In this paper, the finite element method has been used to
analyze the temperature field and thermal stress in tube-
sheet in order to obtain an optimized design of tube-sheets
in heat exchangers. It has been seen that the temperature
difference across the tube sheet thickness can be very
675
considerable causing high thermal stress if the tube sheet
is thick. When the flexible thin tube-sheet is adopted, the
thermal stress can be decreased significantly. The exchanger
with the improved structure has many other advantages such
as; light in weight, laborsaving, easy to manufacture and
cost-effective. Especially, a considerable saving of material
can be achieved when the stainless steel or noble metal is
used.
Acknowledgements
The authors would like to thank Professor S.-T. Tu for
helpful discussions.
References
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reinforced by tubes and their effective constance. ASME, PVP
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[2] Fan QS. The stress analysis and strength design of the pressure vessel.
Atomic energy publishing house, 1989, in Chinese.
[3] Bathe KJ. Finite element procedures in the engineering analysis,
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[4] Wilson EL, Bathe KJ, Peterson F. Finite element analysis of linear and
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[5] GB151-89, Steel tubular heat exchanger, 1989, in Chinese.