Mechanical

Module from the Heat Exchanger Engineering Curriculum curriculum.

Module 4 - Mechanical Design · Learning Objectives · 1. Size tubesheet per TEMA tubesheet formulas (thickness vs pressure) · 2. Select tube-to-tubesheet joint: strength-welded or expanded+seal-welded · 3. Design impingement protection when rho*V^2 > 4000 lb/ft-s2 (TEMA) · 4. Set shell/channel pressure-design per ASME VIII Div 1 · 5. Control tube length vs vibration (Owen plot, HTRI TEMA RGP-RCB-4.6) · Tube-to-Tubesheet Joint Types

Joint	Leak Integrity	Pressure Rating	Sour Service	Cost	Use
Expanded only	Acceptable for low P	< 300 psig	Not preferred	Low	Utility
Expanded + light seal weld	Good	<600 psig	OK if PWHT	Medium	Most common
Expanded + full strength weld	Excellent	Any	Yes (PWHT)	High	Hydrogen, tough services
Welded only (no expansion)	Depends on weld	Any	Yes	High	Special services
Hydro-expanded	Good	<900 psig	Careful	Medium	High tube count

Source: Heat_Exchanger_Engineering_Curriculum_v1.xlsx · Sheet: Mechanical

© 2026 Inflection Point Engineering, LLC. All rights reserved. The content of this page — including calculation methods, reference data, written analysis, interactive tools, and source code — is the intellectual property of Inflection Point Engineering, LLC and is protected under applicable copyright, trademark, and trade secret laws. Unauthorized reproduction, redistribution, modification, or derivative use in whole or in part is prohibited without prior written consent.

Disclaimer. This material is provided for informational and educational purposes only and does not constitute professional engineering advice. Calculations, reference data, and methodologies are based on published standards and accepted engineering practice but are not a substitute for engineering judgment, site-specific analysis, or review by a licensed Professional Engineer. Inflection Point Engineering, LLC makes no warranties, express or implied, regarding the accuracy, completeness, or fitness for a particular purpose of any content presented here, and shall not be liable for any direct, indirect, incidental, or consequential damages arising from its use. Users assume all risk associated with applying this content to real-world design, operations, or decisions.