MECHANICAL DESIGN ENGINEERING
Shell & Tube Heat Exchanger
Mechanical Design Capabilities
Heat Exchanger Mechanical Design
MECHANICAL ENGINEERING DESIGN EXPERTISE
Our seasoned in-house mechanical design engineers perform expert design of all shell and tube heat exchanger structural components such as the shell, tubes, baffles, and headers to ensure they can withstand the mechanical stresses, pressures, and environmental conditions they will encounter during operation.
At Metalforms, we are committed to ensuring the structural integrity, durability, efficiency, and safety of your heat exchanger under the specific operating conditions of your process—including advising on the materials, optimal dimensions, and layout configuration of tubes, shell, and baffles.
Once the design is complete, our teams develop detailed manufacturing plans to guide the fabrication process and ensure the unit meets all performance specifications and safety standards.
After fabrication, the heat exchanger undergoes rigorous testing, such as pressure tests and inspections, to verify that it meets all performance specifications and safety standards to support performance, reliability—and maximum uptime
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MECHANICAL ENGINEERING EXPERTISE
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Design StandardsMetalforms is committed to designing the highest quality shell & tube heat exchangers and ASME pressure vessels—in full accordance with individual customer specifications and the following industry standards:
• ASME U, U2, U3, and S certifications
• TEMA Class R, C, & B
• NBIC certification
• API (American Petroleum Institute) 620, 650, & 660
• AWS-certified welders
Throughout the design process, we rigorously apply the ASME and NBIC codes to ensure the structural integrity and safety of our pressure vessels. For heat exchangers, we adhere to TEMA and API 660 standards, which are critical for achieving reliability, efficiency, and long service life in demanding environments. -
Mechanical Design Software
We leverage the latest versions of AspenTech Exchanger Design and Rating software to perform mechanical design calculations for heat exchangers, ensuring compliance with the most current ASME code—as well as related customer design requirements.
For pressure vessel design, we utilize Codeware Compress software, which is specifically tailored for ASME-compliant pressure vessel calculations. Additionally, we use MathCad Prime 3 software to verify ASME design code calculations and to validate the results generated by both licensed and in-house software tools.
Nozzle loads are evaluated through finite element analysis (FEA) using Nozzle Pro software ensuring accurate assessment of stress and strain.
We also employ code calculation software to design vertical supports, erection lugs, and trunnions, adhering to WRC guidelines to ensure structural integrity and safety. -
Applications
We design shell and tube heat exchangers and asme pressure vessels tailored to meet our customers’ diverse needs and facilitating efficient heat transfer, precise temperature control, and enhanced process performance across a range of applications, including:
• Cooling water systems
• Distillation and gas treating units
• Fuel gas conditioning systems
• Heat recovery systems
• Heat treatment systems
• Heat/oil transfer systems• Lube oil systems
• Power generation systems
• Product storage systems
• Selective catalytic reduction (SCR) units
• Steam systems
• Tank heating systems
• More -
Heat Exchanger ConfigurationsWe manufacture an extensive variety of shell & tube heat exchanger configurations with options and characteristics to serve virtually any purpose, including the following:
• Double-Pipe• Floating & Fixed Head Options• Multitube• Parallel-Flow, Counter-Flow• Regenerative & Non-regenerative Configurations• Single & Double Tubesheet• Single Pass, Multi Pass• Standalone Units- U-tube
- Hairpin
- Parallel Units
- Expansion Joints
- Insulation Jackets
- Lined & Unlined Flanges
- With & Without Phase Change
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Example Heat Exchanger Projects
Our heat exchangers are meticulously designed to optimize thermal efficiency and reliability and ensure seamless integration—and superior performance—within your operations.
Example heat exchanger designs include:• Chillers / coolers
• Condensers
• Evaporators
• Fuel heaters
• Gas cooling
• Heaters
• Intercoolers
• Kettle reboilers• Preheaters
• Re-boilers
• Steam generators
• Super heaters
• Vaporizers
• Vacuum condensers -
Example ASME Pressure Vessel Projects
Our ASME pressure vessels are built to the highest standards, to your exact specifications and in adherence with all applicable industry standards for optimal performance, longevity—and uptime.
Example ASME pressure vessel projects include:• ASME Storage Vessels
• Process Reactors
• Separators
• Heat Exchangers
• Distillation Columns
• Boilers• Pressure Filters
• Storage Bullets
• Absorbers
• Catalytic Converters
• Pressure Vacuum Vessels
•Blowdown Drums
HEAT EXCHANGER SERVICES
FREE Seminar: Heat Exchanger
Design & Fabrication Principals
Join us in Beaumont, Texas!
This on-site course for new engineers and others combines classroom discussion with a tour of our active shop to provide a complete, understanding of the shell & tube heat exchanger specification, design and fabrication process!
Open to qualified owners/operators and EPC participants only