第一节 过程设备设计

Heat Exchanger

1 Basic Types
2 Tubular heat exchanger structure
Heat Exchanger 3 TubeSheet Design
4 Expansion Joint Design
换 热 器
5 Vibration and Prevention of Tube Bundle

2
1

Basic Types Basic Types

依据GB151-1999《管壳式换热器》 依据GB151-1999《管壳式换热器》

管壳式换热器主要零、部件 图见表1和图1至图6。
图7 是主要部件的分类及代号。

According to GB151-1999 《Tubular Heat According to GB151-1999 《Tubular Heat

Exchangers》 Exchangers》

Nomenclatures of Exchangers Parts and

Components(shown in Table 1 and fig.1～Fig.6)

Fig.7 Types and Designations of Major Sub-units

3 4

According to GB151-1999
Basic Types Basic Types <Tubular Heat Exchangers>

According to GB151-1999
<Tubular Heat Exchangers>

5 6

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第一节 过程设备设计

According to GB151-1999
Basic Types According to GB151-1999 Basic Types <Tubular Heat Exchangers>
<Tubular Heat Exchangers>

7 8

According to GB151-1999
Basic Types According to GB151-1999
<Tubular Heat Exchangers>
Basic Types <Tubular Heat Exchangers>

9 10

Basic Types Basic Types

According to GB151-1999 According to GB151-1999

<Tubular Heat Exchangers> <Tubular Heat Exchangers>

11 12

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第一节 过程设备设计

Tubular heat exchanger

管壳式换热器

1：
Tubular heat exchanger structure。
2： Tubular heat exchanger
Tube-sheet design and bundle vibration。

13 14

Basic Types

一、Fixed Tube-sheet Type

二、Floating head type
三、U tube type
四、Packed floating head type
五、Kettle-Type Reboiler

Tubular heat exchanger 15 16

Basic Types Basic Types

一、 Fixed Tube-sheet Type
一、 Fixed Tube-sheet Type
Structure
Structure

17 18

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第一节 过程设备设计

Basic Types Basic Types

一、 Fixed Tube-sheet Type 一、 Fixed Tube-sheet Type
Structure Structure
Tubular heat exchanger

baffle
tubesheet Tube bundle

Cold flow

hot flow

The cold fluids pass through in tube, the hot

fluids pass through out of tube by baffles and
the cold and hot fluids heat transfer through the
wall. 19 20

Advantage
——The utility model has the advantages of
simple structure, compact structure, high
pressure, low cost, convenient cleaning of
pipeline, and easy plugging or replacing when
the pipeline is damaged.
优点
双管程固定管板换热器
——结构简单、紧凑、能承受较高的压力，造价
Fixed Tube-sheet Heat Exchanger with Two Tube Sides 低，管程清洗方便，管子损坏时易于堵管或更换。

21 22

Application
Shortcoming ——适用于壳侧介质清洁且不易结垢并能进行溶解清洗，管、壳
程两侧温差不大或温差较大但壳侧压力不高的场合。
——When the difference of wall temperature or It is suitable for cases where the medium on the shell side is clean
linear expansion coefficient between the tube bundle and not easy to scale and can be dissolved and cleaned. The
and the shell is large, the thermal stress in the shell temperature difference between the two sides of the tube and shell
and the tube bundle will be large. side is not big or the temperature difference between the two sides
缺点 is large, but the pressure on the shell side is not high.

——当管束与壳体的壁温或材料的线膨胀系数相 为减少热应力通常在固定管板式换热器中设置柔性元件
差较大时，壳体和管束中将产生较大的热应力。 （如膨胀节、挠性管板等），来吸收热膨胀差。
In order to reduce thermal stress, flexible elements (such as expansion
joints, flexible tube-sheet, etc.) are usually installed in fixed tube-sheet
23 heat exchangers to absorb thermal expansion difference. 24

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第一节 过程设备设计

二、浮头式 Floating Head type 二、浮头式 Floating Head type

Structure Structure

浮头端
Floating end

浮头端可自由伸缩，无热应力
25 26
Free expansion and no thermal stress at floating end Free expansion and no thermal stress at floating end

Advantage
——Cleaning between and inside the tubes is
convenient, and there is no thermal stress.

优点
——管间和管内清洗方便，不会产生热应力；

浮头式换热器
Floating Head Heat Exchanger
27 28

Shortcoming
Application
——The structure is complex, the cost is higher than
that of fixed tubesheet heat exchanger, the equipment
is bulky, the material consumption is large, and the ——适用于壳体和管束之间壁温差较大或壳程介质
floating end cap can not be inspected in operation, so 易结垢的场合。
the sealing requirement is higher in manufacture. —— Large wall temperature difference between
shell and tube bundle or easy shell-side medium
缺点
Scaling occasions.
——结构复杂，造价比固定管板式换热器高，设备笨重，
材料消耗量大，且浮头端小盖在操作中无法检查，制造
时对密封要求较高。

29 30

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第一节 过程设备设计

三、U形管式换热器
U-tube heat exchanger
U-tube
U形管

U形管式换热器
U-tube heat exchanger
31 32

缺点 受弯管曲率半径限制，布管少；
优点 结构比较简单、价格便宜，承压能力强。 管束最内层管间距大，管板利用率低；
壳程流体易短路，传热不利。
当管子泄漏损坏时，只有外层U形管可更
换，内层管只能堵死，坏一根U形管相当
于坏两根管，报废率较高。
Shortcoming
The structure is simple, the Limited by the curvature radius of the elbow, fewer
Advantage tubes are laid out; the inner tube spacing of the bundle is
price is cheap, and the large, and the utilization ratio of tube sheet is low; the fluid
pressure bearing capacity is in the shell side is easy to short circuit, and the heat
transfer is unfavorable. When the pipe leaks and damages, only
strong. the outer U-shaped tube can be replaced, and the inner tube can
only be blocked. A broken U-shaped tube is equivalent to two
broken tubes, and the scrap rate is high.

33 34

四、填料函式 Packed floating tubesheet/head type

结构 填料函式密封
应用 管、壳壁温差较大或壳程介质易结垢需 Packing Box Seal
要清洗，又不宜采用浮头式和固定管板
式的场合。特别适用于管内走清洁而不
易结垢的高温、高压、腐蚀性大的物料。

It is not suitable to use floating head

type and fixed tube-sheet type when the
Application
temperature difference between tube and
shell wall is large or the scaling medium
on shell side is easy to form. It is
especially suitable for high temperature,
high pressure and corrosive materials which
are clean and not easy to scale.
35 36

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第一节 过程设备设计

优点 结构较浮头式简单，加工制造方便； 缺点
节省材料，造价比较低廉; 填料处易泄漏。
管束从壳体内可抽出;
管内、管间都能进行清洗，维修方便。

Advantage The structure is simpler than the

Shortcoming
floating head type, and the processing
Packing is easy to leak.
and manufacturing are convenient. The material is
saved and the cost is lower. The tube bundle can be
pulled out from the shell. Cleaning can be carried
out in and between tubes， and maintained
conveniently.
37 38

五、釜式重沸器Kettle-Type Reboiler
结构
应用 Evaporation space
4MPa 以下，且不适用于易挥发、易
燃、易爆、有毒及贵重介质，使用温度受填 蒸发空间
料的物性限制。

Under 4MPa, it is not suitable for

volatile, flammable, explosive,
Application
toxic and precious media ; its use
temperature is limited by the
physical properties of fillers.

注：填料函式换热器现在已很少采用。 (f)
Note: Packed floating head heat exchangers are seldom used now. 管束可以为浮头式、U形管式和固定管板式结构
39 40
The tube bundle can be a floating head, U-tube and fixed tube-sheet type structure.

五、釜式重沸器Kettle-Type Reboiler
与浮头式、U形管式换热器一样，
结构 特点
清洗维修方便；

可处理不清洁、易结垢介质，能

承受高温、高压（无温差应力）。
Like floating head and U-tube heat
Characteristic
exchangers, it is easy to clean and
maintain.
It can deal with unclean and scaling
medium, and can withstand high
temperature and high pressure (without
41 42

temperature difference stress).

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第一节 过程设备设计

Tubular heat exchanger structure

管壳式换热器结构 Tubular heat exchanger structure
管程——与管束中流体相通的空间
Tube side--Space Connected with Fluid in Tube Bundle 一、换热管 Heat exchange tube
壳程——换热管外面流体及相通空间
二、管板 Tube-sheet
Shell Side - Fluid and Interconnected Space outside Heat
Exchange Tube 壳程Shell Side
管程结构 三、管箱 Channel
管程Tube side
管程Tube side
Tube side structure 四、管束分程 Pass of tube bundle

五、换热管与管板连接Connection
of heat exchange tube and tube-
sheet

43 44

一、换热管Tube
Fin tube（low heating coefficient side） 单位体积传热面积增大、结构紧凑、金属耗量减少、传
热系数提高
光管Bare tube 翅片管（在给热系数低侧） Increase of heat transfer area per unit volume,
1.换热管型式 螺旋槽管Spirally grooved tube
compact structure, decrease of metal consumption
强化传热管 and increase of heat transfer coefficient
1.Type of tube Enhanced 螺纹管 Threaded tube
heat transfer 阻力大，不便清洗，易结垢堵塞High
tube 小管径
Small diameter
φ19×2、φ25×2.5 and φ38×2.5mm Seamless
resistance, inconvenient cleaning,

2.换热管尺寸 steel tube easy scaling and clogging

2. Dimensions φ25×2 and φ38×2.5mm不锈钢管 SS tube
标准管长1.5、2.0、3.0、4.5、6.0、9.0m等 用于较清洁的流体
Standard tube length 1.5、2.0、3.0、4.5、6.0、
9.0m etc. 45 For cleaner fluids 46

3.换热管材料Tube Material

carbon steel碳素钢

粘性大或污浊的流体 low alloy steel低合金钢

大管径 graphite石墨
Large diameter
A viscous or foul fluid. Stainless steel不锈钢
金属材料 copper铜 非金属材料 ceramics陶瓷
Metallic materials Nonmetallic Materials
Cu-Ni alloy铜镍合金 PTFE 聚四氟乙烯等
Polytetrafluoroethylene, etc.
Aluminium alloy铝合金

Titanium, etc.钛等
47
48

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4.换热管排列形式及中心距 4.换热管的排列方式 Tube Pattern

Arrangement Form and Center Distance of Heat Exchanger Tubes
30° 60° 90° 45°

管桥强度 三角形布管多，但不易清洗；
Tube bridge 正方形及转角正方形较易清洗
strength Triangular are many tubes, but they
are not easy to clean.
清洗通道
P≥1.25d0 Squares and ratated squares are
easier to clean
Cleaning
channel 49 50

常用换热管中心距/mm
Common tube pitch

换热管外径do 12 14 19 25 32 38 45 57
Tube outside diameter

换热管中心距
Tube pitch
16 19 25 32 40 48 57 72

51 52

二、管板 二、Tube sheet

用来排布换热管；It is used to arrange tubes.
1.管板材料Tubesheet materials
作用 将管程和壳程流体分开，避免冷、热流体混合；
Function Separate the tube side and shell side fluids to
avoid mixing of cold and hot fluids.
力学性能
承受管程、壳程压力和温度的载荷作用。
mechanical property
Be born to the loads of pressure and temperature
介质腐蚀性（及tube-tubesheet间电位差对腐蚀影响）
on the tube side and shell side.
Corrosivity of medium (and effect of potential difference
between tube-tubesheet on corrosion)
贵重钢板价格
Price of precious steel plate

53 54

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第一节 过程设备设计

流体无腐蚀性或有轻微腐蚀性时， 2.管板结构Tube sheet structure

管板采用压力容器用碳素钢或低合金钢板或锻件制造；
热应力
厚度thickness—— Thermal stress
When the fluid is non-corrosive or slightly corrosive,Tube 满足强度前提下，尽量减少管板厚度
On the premise of meeting the strength, reduce the
sheets are made of carbon steel or low alloy steel sheets or
thickness of tube sheet as far as possible
forgings for pressure vessels.

腐蚀性较强时，用不锈钢、铜、铝、钛等材料，
为经济考虑，采用复合钢板或堆焊衬里。
Stainless steel, copper, aluminium, titanium and other
materials are used when the corrosion is strong.
For economic consideration, clad steel plate or surfacing
lining is used.
55 56

厚度计算标准Thickness calculation standard 薄管板 Thin Tubesheet

GB151《管壳式换热器 Tubular heat exchanger》

美国管式换热器制造商协会标准TEMA
American Association of Tube Heat Exchanger Manufacturers
西德AD标准 AD Standard in West Germany 平面形planform
椭圆形Ellipse/oval
Thick tubesheet
目前主要有 碟形Dish shape
“厚管板”——GB151《管壳式换热器》、
At present there are mainly
美国管式换热器制造商协会标准TEMA 球形spherical
厚度 挠性薄管板等
thickness
“薄管板”——西德AD标准，厚度一般 Flexible thin tube-sheet, etc.
为8-20mm
Thin Tubesheet
58
57

比较四种用于固定管板换热器的薄管板结构：
比较四种用于固定管板换热器的薄管板结构：
Four thin tube-sheet structures for fixed tube-sheet
Four thin tube-sheet structures for fixed tube-sheet
heat exchangers are compared:
heat exchangers are compared:

薄管板贴于法兰表面上， 薄管板嵌入法兰内，并将表面车
当管程通过腐蚀性介质时， 平。不论管程和壳程是否有腐蚀
密封槽开在管板上，法兰不 性介质，法兰都会与腐蚀性介质
与管程介质接触 接触，需采用耐腐蚀材料，※而
且管板受法兰力距的影响较大
The thin tube-sheet is
attached to the surface of the The thin tube-sheet is embedded in the
flange and the surface is flatted. No
flange.When the tube passes matter whether there is corrosive
（ a） through corrosive medium, medium in the pipe and shell side, the
the sealing groove is grooved flange will contact with corrosive
on the tube-sheet, and the （b） medium. Corrosion-resistant material
flange does not contact with is needed, and the tube sheet is greatly
affected by the moment of the flange.
the medium. 59 60

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第一节
比较四种用于固定管板换热器的薄管板结构：
Four thin tube-sheet structures for fixed tube-sheet
heat exchangers are compared:
●薄管板在法兰下面且与筒体
焊接。壳程通入腐蚀性介质
时，不必采用耐腐蚀材料；
The thin tube-sheet is under
the flange and welded to the
cylinder. It is unnecessary to
use corrosion-resistant
materials when the shell side
（c） enters the corrosive medium.
比较四种用于固定管板换热器的薄管板结构：
Four thin tube-sheet structures for fixed tube-sheet
heat exchangers are compared:
●管板离开了法兰，减小了法
兰力矩和变形对管板的影
响，降低了管板因法兰引起
的应力；
The tube sheet leaves the flange,
reduces the influence of flange
moment and deformation on the tube
sheet, and reduces the stress of the
tube sheet caused by the flange.
（c）
比较四种用于固定管板换热器的薄管板结构：
Four thin tube-sheet structures for fixed tube-sheet
heat exchangers are compared:
●过渡圆弧可减少管板边缘的
应力集中。
Transition arc can reduce the
stress concentration at the edge
of tube-sheet.
●该种管板没有法兰力矩的影
响。
（d）
This kind of tube-sheet has no
挠性薄管板结构 effect of flange moment.
Flexible thin tube-sheet
structure
111
过程设备设计
比较四种用于固定管板换热器的薄管板结构：
Four thin tube-sheet structures for fixed tube-sheet
heat exchangers are compared:
●管板与刚度较小的筒体连接，
也降低了管板的边缘应力；
The connection between the
tube-sheet and the cylinder
with smaller stiffness also
reduces the edge stress of the
tube-sheet.
●是一种较好的结构。
（c） It is a better structure.
61 62
比较四种用于固定管板换热器的薄管板结构：
Four thin tube-sheet structures for fixed tube-sheet
heat exchangers are compared:
●管板与壳体间有一个圆弧过
渡连接，并且很薄，管板具
有一定弹性，可补偿管束与
壳体间的热膨胀；
There is an arc transition
connection between the tube
sheet and the shell, and it is
（d） very thin. The tube sheet has
certain elasticity, which can
挠性薄管板结构 compensate the thermal
63 Flexible thin tube-sheet expansion between the tube 64
structure
bundle and the shell.
比较四种用于固定管板换热器的薄管板结构：
Four thin tube-sheet structures for fixed tube-sheet
heat exchangers are compared:
●壳程流体通入腐蚀性介质
时，法兰不会受到腐蚀。
The flange will not be corroded
when the shell-side fluid enters
the corrosive medium.
●挠性薄管板加工比较复杂。
（d） The processing of flexible thin
tube-sheet is complicated.
挠性薄管板结构
65 Flexible thin tube-sheet 66
structure
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第一节 过程设备设计

用于严格禁止管程
22 33
与壳程介质互相混
合的场合。 44
椭圆形管板 It is used in the case of
Elliptical strictly forbidding mixing
tube-sheet of tube side and shell
side media.
方法Method：
从短节排出
以椭圆形封头作为管板，与换热器壳体焊接在一起。
Discharge from the short
The elliptical head is used as the tube sheet and welded
together with the heat exchanger shell.
segment 11
受力情况比平管板好得多，可以做得很薄，有利于降低热应力；适 短节圆筒充入高于管程 双管板结构图
用于高压、大直径的换热器。 、壳程压力的惰性介质 Structural drawing of double tube-sheet
The stress condition is much better than that of flat The short cylinder is filled 1—空隙Gap 2—壳程管板Shell side tube-sheet
tube sheet. It can be made very thin, which is conducive with inert medium higher 3—短节Short segment 4—管程管板tube side
to reducing thermal stress. It is suitable for high 67 than the pressure on the tube-sheet 68
pressure and large diameter heat exchangers. tube and shell side.

Partition
三、管箱Channel and bonnet
特点
作用——流体送入换热管和送出换热器，在多管程结构中，还起到改变流体流向的作用。
Function--Fluid is fed into and out tube of exchanger, which
Characteristic
also plays a role in changing the flow direction of fluid in 清洗时要拆除管线；
multi-tube passes structure.
该结构适用于较清
结构形式决定因素——清洗？管束分程？Structural form
Determinants - cleaning?Tube bundle split passes? 洁的介质。
隔板
The pipeline should
隔板 be removed when
隔板 隔板 管板 隔板
（1） cleaning; the
箱盖
（2）
（2） 箱盖
structure is suitable
for cleaner media.。

(a)
(a)
(a) (b) (c) (d) 69 70

特点
Characteristic
清洗时不要拆除管线；
缺点是用材较多。

隔板 Do not remove the

pipeline when
cleaning; the
箱盖 disadvantage is that
more materials are
used.

换热器管箱Channel and Bonnet 71 (b) 72

111 12
第一节 过程设备设计

baffle

特点 特点
Characteristic Characteristic
检查、清洗不方便
Inspection and 隔板
（ 1）
管板 隔板 cleaning is 设置多层隔板
inconvenient 的管箱结构
（ 2）
Tube box
很少使用
（2） 箱盖 structure with
Rarely used
multi-layer
baffles
(c) 73
(d)
74

四、管束分程Tube Bundle Passes 管束分程布置图 Tube bundle splitting layout

管内流动的流体从管子的一端流到另一端，称为一个管程 管程数 1 2 4 6
The flow of fluid in a tube from one end to the other end is called a tube-side pass..
1 1 1 2 1
1 2 1 2 2 3
流动顺序 2 3 4 3
2 3
5 4 3 4
4 4 6 5
换热面积要变大 管数增加 流速下降 6

Enlargement of increase tubes Velocity decline

管箱隔板
exchanger area
管子加长
Tube lengthening 介质返回
侧隔板
传热系数下降
Decrease in heat 图序 a b c d e f g
transfer coefficient
多管程 流向
每程管数大致相同，温差不超过20℃左右为好
multi-tube passes The number of tubes per pass is approximately the same, flow direction
75 and the temperature difference should not exceed 20℃ or so. 76

五、换热管与管板连接 强度胀
结构Structure
Strength expanded joint
Tube-to-tubesheet Joint 强度焊
Strength welded joint
胀焊并用 300 300 300
1.强度胀
Combination of expanded and welded joint
Strength expanded joint
3638
3 63 8
3 8

保证换热管与管板连接的密封性能及抗拉脱强度的胀接
l

K
the expanded joint of ensuring sealing performance and tensile debonding K K
3

strength of tube-to-tubesheet joint

300
贴胀

设计压力Design pressure≤4.0MPa；
300
3

应用 设计温度Design temperature≤300℃；
300

操作中无剧烈振动、无过大温度波动，No violent
vibration,no excess temperature gradient 用于δ≤25mm 用于δ＞25mm 用于厚管板及避免
Application 的场合 的场合 晶间腐蚀的场合
及无明显应力腐蚀等场合。And no evident stress
corrosion in operation
77 强度胀接管孔结构Strength expansion nozzle hole structure 78

111 13
第一节 过程设备设计

胀接机理Mechanism of strength expanded joint

非均匀胀接Non-uniform expanded joint

方法
Method 液压胀
均匀胀接Uniform expanded joint 管器

Hydraulic
管子硬度一般须低于管板硬度， expander
若达不到，可进行管头退火处理

79 80

液压胀接hydraulically expanded
81 82
机械胀接Mechanical expanded

保证换热管与管板连接的密封性能及抗拉脱强度的焊接。
2.强度焊 the welded joint of ensuring sealing performance and
Strength welded joint tensile debonding strength of tube-to-tubesheet joint
优点 焊接结构强度高，抗拉脱力强度高。
高温下也能保证连接处的密封性能和抗拉脱能力。
泄露处可补焊和更换。

Advantage The welding structure has high strength and

high tensile debonding strength.
The sealing performance and pull-off
resistance of the joint can also be
guaranteed at high temperature.
The leak port can be repaired and replaced.

用于整体管板 图6-20 强度焊接管孔结构 用于复合管板 83 84

111 14
第一节 过程设备设计

焊后，管子与管板中存在残余热应力和应力集中，
缺点 应用 除较大振动和缝隙腐蚀场合外，该方法应用广泛;
运行时可能引起应力腐蚀与疲劳破坏；
薄管板不能胀，只能焊。
缝隙腐蚀。

Application 除较大振动和缝隙腐蚀场合外，该方法应用广泛;
After welding, there are residual
thermal stress and stress concentration In addition to large vibration and crevice
Shortcoming in tube-to-tubesheet.Stress corrosion corrosion, this method is widely used.
and fatigue damage may occur during
operation. 薄管板不能胀，只能焊。

Crevice corrosion. Thin tubesheet can not expand, can only be welded.
85 86

3.胀焊并用 3.胀焊并用
Combination of expanded and welded joint Combination of expanded and welded joint

主要有强度胀+密封焊、强度焊+贴胀、强度焊+强度胀等 密封性能要求较高；
There are mainly strength expanded + sealing welded, 承受振动和疲劳载荷；
strength welded + light expanded, strength welded 应用：
有缝隙腐蚀；
+ strength expanded and so on.
需使用复合管板等的场合

不仅能提高连接处的抗疲劳性能，
The requirement of sealing
而且还可消除应力腐蚀和缝隙腐蚀，
提高使用寿命
Application: performance is high ；
Bearing vibration and fatigue load;
It can not only improve the fatigue resistance of the joints, Crevice corrosion;
but also eliminate stress corrosion and crevice corrosion
Occasions requiring the use of clad
and prolong service life.
tubesheets, etc.
87 88

讨论discuss
关于先焊还是先胀的讨论
Discussion on Welded Firstly or Expanded Firstly

机械胀接——先焊后胀
Mechanical expanded--First weld and then expand.

液压胀接——先胀后焊
hydraulically expanded--First expand and then weld.
89 90
切除管子端部Cut off the end of the tube

111 15
第一节 过程设备设计

一、壳体Shell
壳程结构Shell-side structure
1. 接管Shell Nozzle

一、壳体Shell

二、折流板Baffle
焊在壳体上，供壳程流体进、出。
三、折流杆Baffle rod Welded on the shell for the flow in
and out of the shell-side.
四、防短路结构Anti-short pass construction

五、壳程分程shell-side divided two passes

91 92

一、壳体Shell 一、壳体Shell
2. 防冲挡板Impingement plate
3.导流筒Flow-diversion sleeve
防止进口流体直接冲击管束造成管子的侵蚀和振动，在壳
程进口接管处安装，也叫缓冲板。 减少流体滞留区，改善两端流体的分布，
To prevent the erosion and vibration of the tube caused by 增加换热管的有效换热长度，提高传热效率；
the direct impact of the inlet fluid on the tube bundle, it is Reduce the fluid retention zone, improve the
installed at the inlet nozzle of the shell side, also known as distribution of fluid at both ends, increase the
the buffer plate. effective heat transfer length of tube, and improve the
heat transfer efficiency;
焊接在拉杆、定距管、折流板上Welded on tie
固定形式 rod, pitch pipe and baffle plate
起防冲挡板的作用。
Fixed form 焊接在圆筒上Welding on cylinder
用U型螺栓固定在换热管上Fixed on heat Play the role of anti-impact baffle.
exchanger tube with U-bolt
93 94

二、折流板 Baffle
1.作用 Role

提高壳程流体流速，增加湍动程度；
使壳程流体垂直冲刷管束，提高壳程传热系数；
Increase the velocity and turbulence of fluid
in the shell side.The heat transfer
coefficient of the shell side is increased by
making the shell side fluid wash the tube
bundle vertically.
减少结垢。
Reduce scaling.

导流筒Flow-diversion sleeve 95 96

111 16
第一节 过程设备设计

二、折流板 Baffle 二、折流板 Baffle

2.结构形式(见图）structural style(see fig.)

水平 竖直 转角
(a)单弓形Single
（a）segmental
单弓形 baffle (c)三弓形 Triple segmental baffle
（C）三弓形
Baffle form
弓形 Segment type
圆盘-圆环形 Disk-ring type
堰形折流板 Weir baffle type
（d）四弓形
(b)双弓形Double segmental baffle (d)圆盘-圆环形Disk-ring baffle
(b)双弓形

折流板形式 Baffle form

97 98

3.弓形缺口及通液口设置Arc cut and liquid flow path

二、折流板 Baffle
壳程为单相清洁液体时，折流板缺口上下布置with clean fluid
（A） of single phase in shell-side ,the baffle cut shall be horizontally
arranged at top or bottom location.
弓形缺口高度/h Height of segmental baffle cut/h

通气口gas flow path

应使流体流过缺口时与横向流过管束时的流速相近
Ensure that the flow velocity passing through cut should be
nearly equal to the flow velocity across the tube bundle.
缺口大小用弓形弦高占壳体内直径的百分比来表示，
如单弓形折流板，h一般取0.20～0.45Di，最常用0.25Di。
The baffle cut is defined as the segment opening height
expressed as a percentage of the shell inside diameter .For
single segmental baffle ,the opening height h of baffle cut is 通液口liquid flow path
0.2-0.45 Di in general and the h is 0.25Di at the most common.
99 100
折流板缺口布置 baffle cut layout

(B) 卧式换热器的壳程介质为气液相共存或液体中含有固体颗粒时，折流板
缺口应垂直左右布置，并在折流板最低处开通液口。
For horizontal exchanger with medium containing both gas and liquid
phases or with liquid medium containing a few solid particles in shell
side,the baffle cut shall be arranged at sidewise(left or right),and a liquid
flow path shall be provided at baffle bottom .

通液口liquid flow path

折流板缺口垂直左右布置
折流板缺口布置
baffle cut layout Vertical left and right layout of baffle cut
101 102

111 17
第一节 过程设备设计

Segment type

Disk-ring type

103 104
折流板 Baffle

4.折流板布置Arrangement of baffle
位置：管束两端的折流板尽量靠近进出口接管
Location:The baffles at both ends of the bundle are as close as possible
Segment type
to the inlet and outlet nozzles.
间距： Lmin不小于0.2Di，且不小于50mm；Lmax不大于Di；
Space: Lmin is not less than 1/5 the shell inside diameter , and not less than 50mm;
Lmax is large than the shell inside diameter.

Disk-ring type

105 106

折流板上管孔与换热管的间隙以及折流板与壳体内壁之间的间隙
The clearance between tube hole and heat exchange tube on
baffle plate and the clearance between baffle plate and
inner wall of shell
过大——泄露严重，不利传热；易引起振动。
Too large -- serious leakage, unfavorable heat transfer; 当换热管的无支撑跨距超过了标准中规定值时，
easy to cause vibration. 必须设置一定数量的支撑板，按照折流板处理。
过小——安装困难。 When the unsupported tube length exceeds the
Too small -- difficult to install. specified value in the standard ,An certain number of
supporting plates must be set up and treated as the
baffle plate.
107 108

111 18
第一节 过程设备设计

5.折流板的固定Fixation of baffles 5.折流板的固定Fixation of baffles

A、换热管外径 ＞14mm时——拉杆--定距管结构 B、换热管外径 ≤ 14mm时——点焊结构
When tube outside diameter ＞14mm—Tie Rod-Spacer Construction When tube outside diameter ≤ 14mm—Tack Welding Construction

点焊 Tack Welding Construction

dn
dn dn
dn
d+1 d

点焊

拉杆结构 Rod-Spacer Construction

拉杆结构 Tack Welding Construction
109 110

三、折流杆Baffle Rod 三、折流杆Baffle Rod

作用——管束支撑结构
Function——Tube Bundle Supporting Structure
（1）支撑杆
Supporting rod
特点——减轻折流板对换热管的剪切破坏和流体诱导振动；
（2）折流杆
避免折流板导致的传热死区，减小流体阻力， 2 3
Rod baffle
提高传热效率。
（3）滑轨
Features——Reduce the shear damage and fluid-induced
vibration of heat exchanger tube caused by baffle；avoid heat 1
Slide rail
transfer dead zone caused by baffle, reduce fluid resistance and
improve heat transfer efficiency.
折流杆结构 Baffle rod structure
111 112

四、防短路结构Anti-Short Pass Construction

旁路挡板可用钢板或扁钢制成，其厚度一般与折流板相同。
旁路挡板 挡管（或称假管） 中间挡板 Bypass seal can be made of steel plate or flat steel, its thickness is generally
Bypass seal Dummy tube（False tube） Intermediate seal
the same as baffle.
旁路挡板嵌入折流板槽内，并与折流板焊接。
旁路挡板
1.旁路挡板 The bypass seal is embedded in the baffle groove and welded with the
旁路挡板
Bypass seal Bypass seal baffle.
壳体公称直径DN≤500mm时，增设一对旁路挡板；
为了防止 When the nominal diameter of the shell is less than 500 mm, a pair of
壳程边缘 折流板
折流板
bypass seals are added.
介质短路 Baffle
DN = 500mm时，增设二对挡板；
In order to prevent short When DN = 500mm, added two pairs of bypass seals.
circuit of shell side edge DN≥1000mm时，增设三对旁路挡板。
medium
When DN≥1000mm, added three pairs of bypass seals.
挡管结构
Dummy tube structure 113 114

111 19
第一节 过程设备设计

2、挡管 Dummy tube 2、挡管 Dummy tube

防止管间短路；Prevent short circuit between tubes.
分程隔板槽背面两管板之间设置两端堵死的管子，即挡管；
Dummy tube is a tube blinded at both ends,and is installed at Dummy tube
back of pass partition groove between two tubesheets.
挡管一般与换热管规格相同，可与折流板点焊固定，也可用拉
杆（带定距管或不带定距管）代替。
The size of dummy tube is the same as tube,thedummy tube
tube may be tack welded to baffle,and also be replaced by tie
rod (with or without spacer). Dummy tube

挡管每隔3～4排换热管设置一根，但不设置在折流板缺口处
挡管结构 Dummy tube structure
One dummy tube shall be provided for each 3～4 rows of
tubes,but shall not be installed at the baffle cut location.
115 116

3.中间挡板
Intermediate seal Intermediate seal
中间挡板

隔板与挡管
Baffle and Dummy tube 中间挡板
117 Intermediate seal 118

3.中间挡板 五、壳程分程 Shell Psses

Intermediate seal
U形管束中心部分存在较大间隙 ，防止管间短路；
Large gap exists in the center part of U-tube bundle to prevent short circuit
between tubes. 根据工艺设计要求，

中间挡板一般与折流板点焊固定； 或为增大壳程流体传热系数，
The intermediate seal is usually fixed by tack welded with baffle. 也可将换热器壳程分为多程的结构。
中间挡板的数量 :DN≤500mm时，设置1块挡板；500mm<DN<1000mm时，
设置2块挡板；DN≥1000mm时，设置不少于3块挡板。 According to the requirements of process design;
The number of intermediate seals are recommended below:
Or to increase the heat transfer coefficient of fluid in the shell side;
for nominal diameter DN≤500mm,one intermediate seal ;
for nominal diameter 500mm<DN<1000mm,two intermediate seals ; The shell side can also be divided into multi-pass structures.
for nominal diameter DN ≥10 00mm,not less than three intermediate seals .

119 120

111 20
第一节 过程设备设计

换热设备
以下内容不讲解，略
p.121-147
管板设计
1 基本类型 Tube sheet design
2 管壳式换热器结构
只管使用，不考虑设计，在这里不做讨论
3 管板设计 Just use it, not consider the design, not discuss it here.
4 膨胀节设计
5 管束振动和防止
一、管板设计的基本考虑

二、管板设计思路

121
三、薄管板设计 122

一、管板设计的基本考虑 GB151《管壳式换热器》
各国的管板设计公式尽管形式各异，但其大体上
是分别在以下三种基本假设的前提下得出的：
（1）将管板看成周边支承条件下承受均布载荷的圆平板， 假设：
应用平板理论得出计算公式。考虑到管孔的削弱，再引入
经验性的修正公式。 把实际的管板简
化为承受均布载
（2）将管子当作管板的固定支撑而管板是受管子支撑着的 荷、放置在弹性
圆平板。管板的厚度取决于管板上不布管区的范围。实践
证明，这种公式适用于各种薄管板的计算。 基础上且受管孔
均匀削弱的当量
（3）将管板视为在广义弹性基础上承受均布载荷的多孔圆 圆平板。
平板，既把圆平板简化为受到规则排列的管孔削弱、同时
又被管子加强的等效弹性基础上的均质等效圆平板。
123 124

a.管束对管板挠度的约束作用，但忽略管束对管板转角的约束作用 b.管板周边不布管区对管板应力的影响
按其面积简化为
靠近中央部分的布管区
管板 圆环形实心板
靠近周边处较窄的不布管区

布管区

不布管区

管板边缘的应力下降

125 126

111 21
第一节 过程设备设计

c.不同结构形式的换热器, 管板边缘有不同形式的连接结构，根 d.管板兼作法兰时，法兰力矩的作用对管板应力的影响

据具体情况，考虑壳体、管箱、法兰、封头、垫片等元件对管
板边缘转角的约束作用； (不同连接结构，设计步骤有所不同)

a型 b型 c型

e型 f型
127 128
d型 e型 f型

假设：
二、管板设计思路
把实际的管板简化为承受均布载荷、放置在弹性基础上且受管孔
均匀削弱的当量圆平板。 1. 管板弹性分析 简化管板为弹性基础
上的等效均质圆平板
a. 管束对管板挠度的约束作用，但忽略管束对管板转角的约束作用 综合考虑Ps、Pt；ΔT；
预紧法兰力矩等载荷
b. 管板周边不布管区对管板应力的影响：将管板划分为两个区，即 建立每个单独元件位移与转角
靠近中央部分的布管区和靠近周边处较窄的不布管区。通常管板 u、ω---N 与其上的内力的关系式
周边部分较窄的不布管区按其面积简化为圆环形实心板。由于不
布管区的存在，管板边缘的应力下降；
以内力为未知量的变形协调方程组
Ε---u、ω
c. 不同结构形式的换热器，管板边缘有不同形式的连接结构，根
据具体情况，考虑壳体、管箱、法兰、封头、垫片等元件对管板 Ε---N 求得内力后，计算危险截面上应力
边缘转角的约束作用；
Ε---σ
d. 管板兼作法兰时，法兰力矩的作用对管板应力的影响。 129 应力校核 130

作用在封头(管箱)与管箱法兰连接处的——
边缘弯矩 Mh、横剪力 Hh，轴向力 Vh

内力共
14个

管板与其相关
131 132
管板与其相关元件的内力分析图
元件的内力分析图

111 22
第一节 过程设备设计

作用在环形的不布管区
作用在垫片上的
轴向内力 VG 与壳体法兰之间即半径
与作用在螺栓圆上的 为R处的:
Vb
螺栓力 Vb
VG
VG
Vb VR
MR 弯矩 MR
HR
HR
VR
径向力 HR
轴向剪力 VR
管板与其相关 管板与其相关
元件的内力分析图 元件的内力分析图
133 134

2. 危险工况
作用在管板布管区
与边缘环板连接处 确定危险工况的基本原则：
即半径为Rt处的:
如果不能保证换热器壳程压力ps与管程压力pt在任何情况
下都能同时作用，则不允许以壳程压力和管程压力的压差
进行管板设计。
Mf
Mf 边缘弯矩Mf
Hf
径向剪力Hf 如果ps和pt之一为负压时，则应考虑压差的危险组合。
Vf
边缘剪力Vf
管板是否兼作法兰等不同结构，危险工况组合也不同。
管板与其相关
元件的内力分析图
135 136

3. 管板应力校核

对于固定管板换热器，管板分析时应考虑下列危险工况: 需计算出的进行校核的应力：

在不同的危险工况组合下，计算出相应的：
只有壳程压力ps ，而管程压力pt=0，不计热膨胀差；
管板布管区应力值、
只有壳程压力ps ，而管程压力pt=0，同时考虑热膨胀差； 环形板的应力值、
壳体法兰应力、
只有管程压力pt ，而壳程压力ps =0，不计热膨胀差；
换热管轴向应力、
换热管与管板连接拉脱力q
只有管程压力pt ，而壳程压力ps =0，同时考虑热膨胀差。

应力分类、校核
137 138

111 23
第一节 过程设备设计

4. 管板应力的调整 5. 管板设计计算软件

调整方法
减少繁重劳动，利用计算软件，如SW6等。
※增加管板厚度 提高管板的抗弯截面模量

※降低壳体轴向刚度，如设置膨胀节
（降低由温差引起的膨胀差导致的管板应力增加）

139 140

三、薄管板设计 换热设备
主要载荷由管壁与壳壁的温度差决定，
流体压力引起的应力与挠度相对说来是不大的。
6.2.1 基本类型
表6-3 薄管板的厚度 mm 6.2.2 管壳式换热器结构

公称 300~ 500~ 700~ 900~ 1400~ 6.2.3 管板设计

直径 400 600 800 1200 1800 6.2.4 膨胀节设计
管板 6.2.5 管束振动和防止
8 10 12 14 16
厚度

管子的稳定性验算
141 142

一、膨胀节的作用

膨胀节设计 1.膨胀节的作用

Expansion Joint Design 降低由于管束和

壳体间热膨胀差
一、膨胀节的作用
所引起的管板应
力、换热管与壳
二、是否设置膨胀节的判断 体上的轴向应力
以及管板与换热
管间的拉脱力。

143
U形膨胀节 144

111 24
第一节 过程设备设计

a. U膨胀节
2.膨胀节的结构形式 b. Ω膨胀节
c. 平板膨胀节

二、是否设置膨胀节的判断

别忽视其他有效方法

标准：GB16749《压力容器波形膨胀节》

145 146
膨胀节

换热设备
5 管束振动和防止
1 基本类型 Vibration and Prevention of Tube Bundle
2 管壳式换热器结构
3 管板设计 一、振动原因
4 膨胀节设计 Vibrating cause
5 管束振动和防止

二、振动防止
147
Vibration prevention 148

一、振动原因 1.外激振力External exciting force 二、振动防止 Vibration prevention

Vibrating cause
2.流体诱导振动 Fluid-induced vibration
a.纵向流体诱导振动
1. Change the velocity of flow
Longitudinal fluid-induced vibration 1.改变流速
2. Change the natural
b.横向流体诱导振动 现象 2.改变管子固有频率 frequency of tube
Transverse fluid-induced vibration
3.增设消声板 3. Adding muffler plate
4. Suppression of periodic vortex
4.抑制周期性旋涡
Jet switching

射
Acoustic vibration

声
Turbulent flutter

湍
vortex shedding

disturbance
Fluid elastic

旋 流
涡 体 流 振 流 5. Installing impingement
脱 弹 颤 动 转 5.设置防冲板或导流筒 plate or flow-diversion sleeve
落 性 振 换
扰
动 149 150

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