Process Heat Transfer Hof Master

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A Workbook Collection of Dale Gulley's Heat Exchange This workbook contains a compilation of edited, and formatted valua Exchangers that have been published and offered to the engineering and recognized authority on Heat Exchanger Design, Fabrication, and For some years , I have endeavored to collect as many of Dale's val By doing so, I have gained further insight and knowledge by reading Dale is not only an outstanding and recognized heat transfer expert member of The Tubular Exchanger Manufacturers' Association for many positive efforts this organzatn has done for the engineerng profess In the past 50 years I have arrived at many conclusions and results fabrication, and operation of heat exchangers that are identical wi with that of a lot of my past and present engineering colleagues. advice and Tips to be not only credible - but also valuable in appl I have put my effort into this compilation in order to make use of Through out this compilation, my personal notes on some of the Tips worksheet and to the right-hand side. I have used this method to r and to add empirical support and reinforcement to what Dale describ Please note that I have used the following spreadsheet and workbook ideas and recommendations expounded by Dale: The bulk of the Tips are organized in the same manner as they a have made use of Exel's Hyperlink feature to facilitate the qui the topics that are listed and grouped in the Table of Contents topic that you want to read or persue in the Table of Contents, subject and the hyperlink will take you directly to the selecte I have made every effort to convert Dale's original presentatio equations to a format that allows the reader to immediately emp indicated calculation using Excel's basic spreadsheet feature. numbers. This allows the reader to do several "what-if" calcu perceived effect on the heat exchanger. The various groups of the Tips subject matter are also hyper-li one of the groups of Tips directly from the Table of Contents. These Tips are compiled and freely distributed with Dale Gulley's p engineers who are helped and assisted by this contribution to call contribution to heat exchange. Dale is active in heat exchange de basis for Experienced Based Learning when dealing with heat exchang in the YELLOW-filled cells and the resultant calculated answer

description

Heat Transfer

Transcript of Process Heat Transfer Hof Master

Page 1: Process Heat Transfer Hof Master

A Workbook Collection of Dale Gulley's Heat Exchanger Tips

This workbook contains a compilation of edited, and formatted valuable and practical "Tips" on Heat Exchangers that have been published and offered to the engineering public by Mr. Dale Gulley, an experienced and recognized authority on Heat Exchanger Design, Fabrication, and Consulting.

For some years , I have endeavored to collect as many of Dale's valued advice and "tips" as I possibly could.By doing so, I have gained further insight and knowledge by reading and applying his tips and know-how.

Dale is not only an outstanding and recognized heat transfer expert, but he has been a contributing and positive member of The Tubular Exchanger Manufacturers' Association for many years, advocating the useful and positive efforts this organzatn has done for the engineerng profession world-wide.

In the past 50 years I have arrived at many conclusions and results in dealing with the design, specification, fabrication, and operation of heat exchangers that are identical with Dale's Tips. My experience also coincides with that of a lot of my past and present engineering colleagues. My field experience has proven Dale's advice and Tips to be not only credible - but also valuable in applying heat transfer to process operations.

I have put my effort into this compilation in order to make use of this valuable engineering know-how as a

Through out this compilation, my personal notes on some of the Tips can be seen off the printed area of the worksheet and to the right-hand side. I have used this method to record my own experience related to the topicand to add empirical support and reinforcement to what Dale describes.

Please note that I have used the following spreadsheet and workbook techniques to assist in employing the ideas and recommendations expounded by Dale:

• The bulk of the Tips are organized in the same manner as they are found in Dale's Website. I have made use of Exel's Hyperlink feature to facilitate the quick and accurate access to any of the topics that are listed and grouped in the Table of Contents. Once you locate a subject or topic that you want to read or persue in the Table of Contents, all you have to do is click on the subject and the hyperlink will take you directly to the selected Tip.

• I have made every effort to convert Dale's original presentation of recommended calculations and equations to a format that allows the reader to immediately employ his/her basic data to make theindicated calculation using Excel's basic spreadsheet feature. The reader can type in the basic data

numbers. This allows the reader to do several "what-if" calculations quickly to get an idea of the perceived effect on the heat exchanger.

• The various groups of the Tips subject matter are also hyper-linked and a reader can go directly to one of the groups of Tips directly from the Table of Contents.

These Tips are compiled and freely distributed with Dale Gulley's permission and approval. I would ask all engineers who are helped and assisted by this contribution to call or email Dale with thanks and gratitude for his contribution to heat exchange. Dale is active in heat exchange design, software, and process engineering

basis for Experienced Based Learning when dealing with heat exchangers.

in the YELLOW-filled cells and the resultant calculated answer will be generated in BOLD RED

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out of Tulsa, Oklahoma. Needless to say, his organization can be of great help in a heat exchanger application.Art Montemayor - 05 April 2011

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Exchangers that have been published and offered to the engineering public by Mr. Dale Gulley, an experienced

Dale is not only an outstanding and recognized heat transfer expert, but he has been a contributing and positive

fabrication, and operation of heat exchangers that are identical with Dale's Tips. My experience also coincides

worksheet and to the right-hand side. I have used this method to record my own experience related to the topic

These Tips are compiled and freely distributed with Dale Gulley's permission and approval. I would ask all engineers who are helped and assisted by this contribution to call or email Dale with thanks and gratitude for his

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out of Tulsa, Oklahoma. Needless to say, his organization can be of great help in a heat exchanger application.

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4/26/2011 - Added Bs factor the second term in the denominator for the equation Chris Haslegofor the seal bar calculation on sheet "Calculations". Cheresources.com Admin

6/28/2011 - Added three new tips from Gulleyassociates.com with permission. Chris HaslegoBoiling Cheresources.com Admin

Calculations

Construction

11/10/2011 - Added five new tips from Gulleyassociates.com with permission Chris HaslegoBoiling Cheresources.com Admin

Construction

Misc.

4/5/2012 - Added five new tips from Gulleyassociates.com with permission Chris HaslegoBoiling Cheresources.com Admin

Calculations

Tube Bundle Vibration

Misc.

Estimate - critical heat flux for propane chillers.

Estimate - optimum flow velocity for gas inside tubes.

Longitudinal baffle heat conduction cures.

Kettle Reboilers - Supports or Baffles

Design Temperatures of Carbon Steel and Low Alloy Tubes and TubesheetsDesign Temperatures of Nonferrous Tubes and Tubesheets

Fouling factors for water(hr-ft2-F/Btu)Fouling Factors for Liquid Hydrocarbons(hr-ft2-F/Btu)

Vertical Thermosyphon-Calculate Pressure Drop at The Outlet NozzleVertical Thermosyphon-Design for a Smaller Liquid Preheat Zone

Estimate - Hydrocarbon Gas Heat Transfer Coefficient in Shell Side

Best Design Feature to Prevent Bundle Vibration

Viscous Flow - Use More Pressure Drop Than Usual

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Chris HaslegoCheresources.com Admin

Chris HaslegoCheresources.com Admin

Chris HaslegoCheresources.com Admin

Chris HaslegoCheresources.com Admin

Design Temperatures of Carbon Steel and Low Alloy Tubes and TubesheetsDesign Temperatures of Nonferrous Tubes and Tubesheets

Vertical Thermosyphon-Calculate Pressure Drop at The Outlet NozzleVertical Thermosyphon-Design for a Smaller Liquid Preheat Zone

Estimate - Hydrocarbon Gas Heat Transfer Coefficient in Shell Side

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2911 E. 77 Pl., Tulsa, OK 74136 · P.O. Box 700295, Tulsa, OK. 74170-0295Phone: (918) 744-0100

7.

14.

Air Coolers:

1.      Air flow accessories - don't overlook these when calculating fan HP2.      Box header design - limit of process temperature change3.      Connecting bundles of existing coolers for a new service4.      Fan drive changes that increase capacity of existing cooler5.      Fan drive noise - suggestions on how to reduce6.      Maximum motor HP for a fan7.      Maximum tube wall temperature for wrap-on fins8.      Optimum number of tube rows9.      Overall heat transfer rate estimate for hydrocarbons10.  When do bare tubes become more efficient than fin tubes?11.  When To limit number of tube passes in air coolers12.  When to use wind coolers

Boiling:

1.      Avoid mist flow boiling inside tubes2.      Kettle reboiler - liquid carryover problem solutions3.      Kettle reboiler - shell nozzle arrangement problem4.      Kettle reboiler - shell vapor outlet nozzle location5.      Kettle reboiler - sizing shell vapor space6.      Kettle reboiler - undersized shell effects

Estimate - pool boiling heat transfer coefficient for hydrocarbons8.      Large boiling temperature difference problems9.      Lowest limit of boiling temperature difference10.  Vertical thermosyphon - choking two phase flow with small outlet nozzle11.  Vertical thermosyphon - minimum recirculation rate12.  Vertical thermosyphon - check for liquid preheat zone13.  Vertical thermosyphon - who sets recirculation rate

Vertical Thermosyphon-Calculate Pressure Drop at The Outlet Nozzle

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15.

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24.

Vertical Thermosyphon-Design for a Smaller Liquid Preheat Zone

Calculations

1.      What diameter to use to start design of a coil2.      Estimate - gas heat transfer coefficient inside tubes3.      Estimate - hydrocarbon heat transfer coefficient in tubes4.      Estimate - latent heat of hydrocarbons5.      Estimate - liquid thermal conductivity of light hydrocarbons6.      Estimate - overall heat transfer coefficient in shell & tube7.      Estimate - tube length that lowers tube pressure drop8.      How to calculate excess surface and overdesign surface9.      Use superficial velocities to calculate best heat transfer flow pattern10.  L/D equation for heat Transfer coefficient inside tubing11.  LMTD correction factor charts for TEMA G and J type shells12.  Low LMTD correction factor for divided flow13.  What is the lowest LMTD correction to use in shell & tube14.  Minimum flow area for shell side inlet nozzle15.  How to calculate performance of heat exchangers with plugged tubes16.  How to increase heat transfer for low Reynolds numbers17.  Calculate when to use seal bars on a bundle to increase heat transfer18.  Calculate S & T bundle diameter from number of tubes19.  Equation for calculating tube count in shell & tube20.  Check for hot tube wall temperature of cooling water21.  Sometimes larger tubes are better than small ones22.  Weighted MTD

Estimate - optimum flow velocity for gas inside tubes.Estimate - Hydrocarbon Gas Heat Transfer Coefficient in Shell Side

Condensing:

1.      Avoid small baffle cuts in S & T condensers2.      Estimate - Condensing heat transfer coefficient for hydrocarbons inside tubing3.      Maximum heat transfer rate inside tubes for total condensation4.      Quick estimate for reflux condenser LMTD in air cooler5.      Reflux (Knockback) condenser comments6.      Steam condenser types

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7.      Sulfur condenser - design within tube velocity limits8.      Warning about small temperature pinch points in condensers9.      When to slope single tube pass tubes in condensing service10.  Zone those condensers!

Estimate - critical heat flux for propane chillers.

Construction:

1.      Benefits of using rotated square pitch in shell & tube2.      Caution when using a longitudinal baffle in the shell side3.      Using turbulators for tube side laminar flow4.      Discussion of types of triple segmental baffles in shell & tube5.      Check entrance and exit space for shell nozzles6.      Horizontal vs vertical baffle cut in shell & tube7.      Is expansion joint required in the shell of a fixed tube sheet?8.      Increasing capacity of existing shell & tube exchangers9.      Locating vents on the shell side of vertical exchangers10.  Optimun gasket location for flanges11.  Reinforcing rods as tube inserts to increase heat transfer12.  Shell side impingement protection13.  Special shell & tube heat exchanger type (NTIW)14.  When to consider by-pass strips in shell & tube bundle15.  What is too large of temperature change in 2 tube passes ?16.  When to rotate square tube pitch in shell & tube exchanger

Longitudinal baffle heat conduction cures.

Heat Recovery:

1.      Deciding on what fin spacing to use2.      Estimate of nozzle size for HRSG3.      Face area estimate for HRSG units4.      Maximum exhaust gas temperaure for steel fin tubes5.      When to use bare tubes in waste heat boilers

Materials:

1.      Cooling water flowing inside 304SS U-tubes

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5.

Pressure Drop:

1.      Allowing for fouling in pressure drop calculations2.      Allowable pressure drop suggestions3.      Allowable shell side pressure drop if a multi-leaf(a.k.a. lamaflex) long baffle is used4.      Better baffle window pressure drop equation5.      Designing for better use of tube pressure drop6.      Effect of 1st tube rows on shell nozzle pressure drop7.      Pressure drop on kettle side8.      Reducing high shell side pressure drop in fixed tube sheet exchangers9.      Use impingement rods instead of plate to lower shell press. drop10.  What design pressure drop to use for heavy liquids inside tubes11.  Maximum velocity inside tubes12.  Calculate shell nozzle pressure drop13.  Improve shell side pressure drop calculations

Tube Bundle Vibration:

1.      Features of a new S & T bundle that replaces bundle that vibrated2.      Vibration cure when designing shell & tube bundles3.      Conditions likely to cause shell & tube bundle vibration4.      Cures for vibration in existing bundle

Best Design Feature to Prevent Bundle Vibration

Miscellaneous:

1.      Allocation of streams in shell & tube2.      Articles published by Dale Gulley3.      Avoid these fluids when using lowfin tubing4.      Best heat transfer flow pattern5.      Check liquid thermal conductivity at high reduced temperatures6.      Check piping connections when there is under-performance7.      Evaluating an exchanger for a new service8.      Check heat release curve data for skipping over dewpoints and bubblepoints9.      When will exchangers with low-fins be more economical than exchangers with bare tubes?10.  Problems with excess heat exchanger surface11.  Purchasing warning for shell & tube exchangers

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12.  What is the minimum velocity inside tubing for slurries?13.  Suggestions for low-fins and potential S & T bundle vibration14.  Choose shell & tube or multi-tube heat exchangers15.  Thermal design problem with shell side long baffle16.  Trouble shooting article in Hydrocarbon Processing17.  Under-surfaced S&T quote18.  When to add shell in Series19.  When to consider a long baffle in the shell20.  Which stream goes inside the tubes of gas/gas exchangers?21.  Weighted MTD22.  Why did performance decline in a TEMA type F,G or H type shell?23.  Zone those condensers

Viscous Flow - Use More Pressure Drop Than Usual

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Note:

Air flow accessories - don't overlook louvers and screens when calculating fan HP March, 2000Air static pressure loss is used to calculate the horsepower required for fans used in process air coolers. Charts and equations in the literature are usually for the tube bundle only. Frequently, air coolers have accessories like louvers and fan guards. They may also have hail, bug, or lint screens. Don't overlook the accessory pressure drop because they can increase the static pressure as much as 25%.

Box header design - limit of process temperature change March, 1998In the design of an Air cooled heat exchanger, avoid imposing too large a temperature change in the box headers. Too much temperature drop between the inlet and outlet tube passes can cause leakage where the tubes meet the

design. This allows a hot top section to slide past a cooler bottom section.

Connecting Bundles of Existing Coolers for a new Service April, 1998When re-using air cooled exchangers in a new service, don't overlook connecting the bundles in a series-parallel arrangement. New air coolers nearly always have the bundle connected in parallel. Arrange the bundles for more series type flow to increase the tube side velocity and get higher heat transfer rates. For example, an air cooler with six bundles could be arranged with four bundles in parallel, connected to two bundles in series. The two series bundles would handle the coldest part of the heat load where higher velocity is needed the most.

Increase Capacity of Existing Air Cooler with Fan Drive Changes October, 1997If you need to increase the capacity of an air cooler, don't junk it for a new one until you have exhausted the possibilities on changing the fan and the fan motor. The least expensive change is to increase the fan blade angle if it will not overload the motor. But check to make sure the blade angle is not already at the maximum. The next best change in terms of cost is to increase the fan speed by changing the drive ratio between the fan and the motor. If these changes are not enough you could increase the motor size or change the fan for one with more blades.

Suggestions to Reduce Fan Drive NoiseThe most effective solution is to reduce the fan speed by changing the drive ratio between the fan and the motor. Other suggestions are to reduce the fan blade angle or change to a fan with more blades.

Maximum Motor HP for a FanAdding more HP to a fan will only work up to a point. The fan efficiency reaches a peak. Then increasing the HP will produce no more air. An estimate for this HP is:

Max HP = 17 + 8.4 (Fan Diam - 3.5) = 46.4 HPFan Diam = 7.00 feetThis is for fan diameters greater than 3.5 ft.

Input data into YELLOW cells and receive output in BOLD RED

tubesheet. If the temperature change of the tube side stream is over approximately 400 oF, then use a split header

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Temperature Limit of Wrap-On Fins for Aircoolers June, 2000Above a certain temperature, it will be too hot for wrap-on fins. Due to thermal expansion, the aluminum fins will lose good contact with the tubing. In this case an integral type fin tube should be used. The summer time air outlet temperature is a very rough approximation. To be more exact, the tube wall temperature needs to be calculated for the hottest tube row. Then:

459Where

temperature of tube wall

Ta = air outlet temperature = 200

temperature inside tube = 488

thermal resistance of air = 0.12

clean overall heat transfer coefficient = 7.5

200 + (488 - 200) x 0.12 x 7.5

As you can see, the problem is more severe at high heat transfer rates. Not even the aircooled manufacturers agree exactly what this maximum tube wall temperature should be. The ASME code for allowable stress of aluminum has

wrap-on fins.

Optimun Number of Tube RowsThe optimum number of tube rows is a function of the maximum acceptable temperature rise of the air side. There are three limitations and the smallest air rise of the three should be used. The limitations are:

1 Limit the LMTD correction factor to a minimum of 0.9 for one tube pass - maximum air outlet temperature to be the same as the process side outlet temperature.

2

3

Twall = Ta + (Th1 - Ta) x Ro x Uc = oF

Twall = oF

Th1 = oF

Ro = hr-ft2-oF/Btu

UC = Btu/hr-ft2-oF

Example: Steam is condensing at 488 oF. Assume that the UC is 7.5 and Ro is 0.12.

If the air outlet temperature is 200 oF, then:

Twall =

Twall = 459 oF

a maximum temperature of 400 oF. I believe this is the upper limit. Then the above example is operating too hot for

Minimum temperature difference at the hot end to be 8 to 10 oF.

Maximum air outlet temperature to be 300 oF if tension wound fins are used.

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Hydrocarbon U Estimate (Air-Coolers) February, 2002In the preliminary design or checking of process air-coolers you need an estimate of the overall heat transfer coefficient (U). An estimate that is based on fin surface can be made from the following:

Fluid in Tube side Overall Heat Transfer Coefficient

Liquids Rt = 0.165 x Sqrt (avg. tube viscosity) + 0.145U = 1/Rt

Where: viscosity is less than 3 cPGases Rt = 0.29 x Sqrt (100/OP) + 0.145

U = 1/Rt

Where OP is the operating pressure in PSIA

When do Bare Tubes become More Efficient Than Fin Tubes?If the inside heat transfer coefficient beomes too low, fin tubes can become inefficient. This can be the case in

investigate both bare and fin tubes.

When To Limit Tube Passes in an Aircooler November, 1999For tube side streams that have a high heat transfer coefficient, it is probably not advantageous to use more than two tube passes. This would be for condensing streams like ammonia and steam. This could also be true for high thermal conductivity liquid streams if the LMTD is high. The velocity on these type of streams will have a minor effect on the overall heat transfer coefficient in the typical aircooler. The major thermal resistance is the air side heat transfer coefficient.

Air Cooler Using Wind December, 2000Where cooling water is not available and the outlet temperature is not critical, an air cooler can be built that depends only on the wind for cooling. It will have the best performance when the tubes have high fins and the tubes are perpendicular to the wind direction. In areas where the wind does not have a prevailing direction, arrange the tubes in a bird cage type pattern. Then there is cooling no matter which way the wind blows. If there is a prevailing wind direction, use an air cooler bundle that sets on a stand that faces the wind.

heavy oil coolers. If it is expected that the heat transfer coefficient is below approximately 20 Btu/hr-ft2-oF,

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March, 2000

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Mist Flow Boiling Inside Tubes November, 2001This is a flow pattern to avoid in heat transfer. The mist flow region is dependent upon velocity, % vapor and stratification effects. In this type of flow the tube wall is mostly dry and the liquid droplets are carried along in a vapor core. Therefore the heat transfer is much lower because the much higher thermal conductivity of the liquid is in very little contact with the tube wall. The higher the % vaporization, the lower the velocity needs to be to avoid mist flow. For example in a vertical tube where the vaporization is 50 % and the vapor density is 1.0 lb/cu ft, the velocity needs to be below approximately 80 ft/sec. If the vaporization is 75 %, the maximum velocity is approximately 30 ft/sec. This comes from the Fair equation. In a horizontal tube where there can be stratification, these maximum velocities are much lower. If the mist flow region cannot be avoided, then twisted tape turbulators can be used to increase the heat transfer. They will throw the liquid in the vapor core toward the tube wall.

Kettle Reboiler - Location of Vapor Outlet NozzlesWhen it is necessary to have dry vapor leaving the kettle side, the location of the nozzles is important. The inlet nozzle should not be located directly under the vapor outlet. This probably results in some liquid carryover. When there is a single vapor outlet, it is usually centered over the bundle with the inlet nozzle located some distance away. There have been cases where someone other than the thermal designer changed the location of this vapor nozzle without the thermal designers OK. In one case the vapor outlet was moved to the back of the kettle resulting in appreciable liquid carryover

Kettle Reboiler - Problem Shell Nozzle ArrangementSometimes you see kettle reboilers where the inlet nozzle is directly under the outlet vapor nozzle. This arrangement creates extra turbulence under the vapor nozzle which affects the amount of liquid entrainment in the outlet vapor. It is safer to use the conventional nozzle arrangement where the inlet is some lateral distance away unless a demister pad is used.

Another problem with the vertical nozzle arrangement is when the kettle bundle is relatively long and there is a single pair of nozzles. Then there is no good flow distribution. The boiling zones near the ends of the bundle will have lower fluid circulation rates and lower heat transfer.

Kettle Reboiler - Location of Vapor Outlet Nozzles October, 2000When it is necessary to have dry vapor leaving the kettle side, the location of the nozzles is important. The inlet nozzle should not be located directly under the vapor outlet. This probably results in some liquid carryover. When there is a single vapor outlet, it is usually centered over the bundle with the inlet nozzle located some distance away. There have been cases where someone other than the thermal designer changed the location of this vapor nozzle without the thermal designers OK. In one case the vapor outlet was moved to the back of the kettle resulting in appreciable liquid carryover

Sizing the Vapor Space in Kettle Reboilers June, 1998The size of the kettle is determined by several factors. One factor is to provide enough space to slow the vapor velocity down enough for nearly all the liquid droplets to fall back down by gravity to the boiling surface. The amount of entrainment separation to design for depends on the nature of the vapor destination. A distillation tower with a large disengaging space, low tower efficiency and high reflux rate does not require as much kettle vapor space as normal. Normally, the vapor outlet is centered over the bundle. Then the vapor comes from two different directions as it approaches the outlet nozzle. Only in rare cases are these two vapor streams equal in quantity. A simplification that has been extensively used is to assume the highest vapor flow is 60% of the total. One case

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where this would cause an undersized vapor space is when there is a much larger temperature difference at one end of the kettle then the other. The minimum height of the vapor space is typically 8 inches. It is higher for high heat flux kettles.

Kettle Reboiler - Effect of Undersized Kettle Diameter July, 1997What effect will an undersized kettle diameter have? The effect will be a decrease in the boiling coefficient. A boiling coefficient depends on a nucleate boiling component and a two-phase component that depends on the recirculation rate. An undersized kettle will not have enough space at the sides of the bundle for good recirculation. Another effect is high entrainment or even a two-phase mixture going back to the tower.

Estimate - Pool Boiling Heat Transfer Coefficient for Hydrocarbons

Boil h = 2,925Where

Δt = (tube wall temperature - liquid temperature 50

t =

Large Boiling Temperature Differences March, 1999Large temperature differences in heat exchangers where liquid is vaporized are a warning flag. When the temperature differences reach a certain value, the cooler liquid can no longer reach the heating surface because of a vapor film. This is called film boiling. In this condition, the heat transfer deteriorates because of the lower thermal conductivity of the vapor. If a design analysis shows that the temperature difference is close to causing film boiling, the vaporizer should be started with the boiling side full of relatively cooler liquid. This way, you don't start flashing the liquid. The liquid is slowly heated up to a more stable condition. If the vaporizer is steam heated, the steam pressure should be reduced which will reduce the temperature difference. With steam heating, take a close look at the design

Lower Limit of Boiling Film Temperature Difference February, 1997A reboiler or chiller is best designed so that it doesn't have the lower heat transfer mode of natural convection. The dividing line between natural convection and boiling depends on the type of tubing used. If steel bare tubes are used,

Choking a Vertical Thermosyphon December, 1999Choking down on the channel outlet nozzle and piping reduces the circulation rate through a heat exchanger. Since the tubeside heat transfer rate depends on velocity, the heat transfer is lower at reduced recirculation rates. A rule of thumb says that the inside flow area of the channel outlet nozzle and piping should be the same as the flow area inside the tubing. The Shell Oil Company, in an experimental study, showed that a ratio of 0.7 in nozzle flow area/tube flow area reduced the heat flux by 10%. A ratio of 0.4 cut the heat flux almost in half.An approximate equation for the amount of heat flux reduction is:

53.32%

22 (Δt)1.25 = Btu/(hr)(ft2)(oF)

oF

temperature, oF

if the LMTD is over 90 oF. This is close to the critical temperature difference where film boiling will start.

the lower limit of temperature difference between the tube wall and the boiling fluid is approximately 5 oF. We have

designed hydrocarbon chillers down to the temperature difference of 2 oF using low-finned tubes. Special enhanced

tube surfaces can be used for even lower temperature differences than 2 oF.

Reduction = 3.06X -1.63X2 - 0.43 =

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Where X = area ratio 0.40

Minimum Recirculation Rate in Thermosyphon ReboilersWhen does a recirculation rate become too low (high % vaporization)? When this happens, the tube wall is no longer wet and the heat transfer diminishes. The guidelines in the literature show the lowest permissible recirculation rates give from 25 to 40% vaporization for hydrocarbons. It has been observed that this threshold is when the outlet two-phase density (volume basis) is below 1.0 lb/cu-ft. Nearly all thermosyphons have outlet densities above this value.

Vertical Thermosyphon - Check for Liquid Preheat Zone February, 2001When designing vertical thermosyphon reboilers with boiling at low operating process fluid pressures, check for the presence of a liquid preheat zone. Back pressure raises the boiling point at the interface of liquid preheat zone and subcooled boiling. This boiling point rise creates a liquid zone with relatively low heat transfer and it reduces the temperature driving force (MTD). If the operating pressure is below approximately 25 PSIA, there should be a liquid preheat zone. The lower the operating pressure, the more likely there is liquid preheat. If there is no liquid preheat, there may be an input error.

Vertical Thermosyphon Recirculation Rate December, 1997In the design of vertical thermosyphons, the recirculation rate should be set by the process engineer if there will be anything unusual about the connecting piping. The recirculation rate is especially sensitive to the size and configuration of the outlet piping. If the recirculation rate is left for the thermal designer to set, they will have to make piping assumptions that may be violated later in the actual installation.

Estimate - Critical Heat Flux For Propane ChillersA simple equation is presented for a kettle reboiler. It is conservative for very small bundles. The crital heat flux depends on the geometry of the bundle. The following estimate is based on 3/4 inch tubes on 15/16 inch pitch. It is actually good for any tube diameter with a tube pitch/tube diameter ratio of 1.25 and triangular tube pitch. A boiling temperature of -30 F. is assumed for the propane.

CHF = 32500 = 12844 Btu/h ft2

CHF = crital heat flux in Btu/(hr)(ft)2 Ds = shell bundle diameter in inches 41

Example

What is the critical heat flux for a 41 inch diameter bundle?

CHF = 32500

CHF = 12,850

Kettle Reboilers - Support or Baffles?

Ds(0.25)

(41) 0.25

For kettle reboilers use segmental baffles instead of full supports if shell fouling factor is greater Than 0.002(hr-ft2-F/Btu)

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Vertical Thermosyphon-Calculate Pressure Drop at The Outlet NozzleA rule of thumb is that the pressure drop at the outlet nozzle should not be greater than 30% of the total static head. There is another tip in this boiling section about choking the flow with a small outlet nozzle. The inside flow area of the outlet nozzle should be the same or greater than the total flow area inside the tubing. For a channel with a side outlet the pressure drop is composed of a turning loss and a contraction loss The following equations calculate the pressure drop at the outlet. The pressure drop for expansion into the channel is not included here but is with the tube pressure drop.

= 0.445576 (used for pressure drop calc)

(If Ktr less than 0.40, use 0.40)

Kc =0.5 (1 - (No/Ds)2) = 0.28077 KT = Ktr + Kc = 0.726346

= 0.16944Where: Ds = Top channel ID (inches) = 14.8 Ktr = pressure loss coefficient for turning loss = 0.445576 (calculated) Kc = pressure loss coefficient for contraction into nozzle = 0.28077 KT = total pressure loss coefficient = 0.726346 No = Outlet nozzle ID (inches) = 9.8 Vn = velocity thru nozzle (ft/sec) = 120 ρtp = two-phase density (lb/ft3) = 0.15

ΔPn = pressure drop thru channel and outlet nozzle (Psi) = 0.17

Vertical Thermosyphon-Design for a Smaller Liquid Preheat ZoneAt low operating pressures there will be a sensible heat liquid zone with relatively low heat transfer. This is caused by the fact that a small pressure change will cause a large increase in the boiling point. There has been a case where 90% of the tube length was in the sub-cooled phase. What can you change that will decrease the size of the liquid preheat zone and increase the overall heat transfer?

One answer is to evaluate the piping system above the top tubesheet. In order to make an evaluation check the pressure drop at the outlet. There is on this section of the website equations to calculate the pressure drop of a nozzle that is at right angle to the top channel. Most vertical thermosyphons have the outlet nozzle at right angles to the top channel. There may be a simple change of enlarging the outlet nozzle that would be the cure. But there needs to be a check to make sure the nozzle and connecting piping are not so large that there is liquid slip. If enlarging the right angle nozzle and piping is not the answer then there are other configerations that will use less outlet pressure drop. Next the pressure drop of using a B type channel with a long radius ell could be tried. If this doesn't do it, try a mitered channel design.

Another solution to the problem is to investigate inserts such as swisted tape, wire matrix , or helically coiled.

Ktr = ___1______

Ds0.3

ΔPn = KT = 0.000108 x Vn2 x ρtp

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This is a flow pattern to avoid in heat transfer. The mist flow region is dependent upon velocity, % vapor and stratification effects. In this type of flow the tube wall is mostly dry and the liquid droplets are carried along in a vapor core. Therefore the heat transfer is much lower because the much higher thermal conductivity of the liquid is in very little contact with the tube wall. The higher the % vaporization, the lower the velocity needs to be to avoid mist flow. For example in a vertical tube where the vaporization is 50 % and the vapor density is 1.0 lb/cu ft, the velocity needs to be below approximately 80 ft/sec. If the vaporization is 75 %, the maximum velocity is approximately 30 ft/sec. This comes from the Fair equation. In a horizontal tube where there can be stratification, these maximum velocities are much lower. If the mist flow region cannot be avoided, then twisted tape turbulators can be used to increase the heat

Art's Note:When it is necessary to have dry vapor leaving the kettle side, the location of the nozzles is important. The inlet nozzle I agree. I have also found that locating the inlet liquid nozzle directly under the vapor outlet is not good. should not be located directly under the vapor outlet. This probably results in some liquid carryover. When there is In Amine BKU reboilers I found that locating the inlet rich amine liquid as close to the U-tube bundle tubesheet a single vapor outlet, it is usually centered over the bundle with the inlet nozzle located some distance away. There gave the best, consistant results in obtaining good solution stripping. This gives the heating medium have been cases where someone other than the thermal designer changed the location of this vapor nozzle without the thermal designers OK. In one case the vapor outlet was moved to the back of the kettle resulting in appreciable

Sometimes you see kettle reboilers where the inlet nozzle is directly under the outlet vapor nozzle. This arrangement creates extra turbulence under the vapor nozzle which affects the amount of liquid entrainment in the outlet vapor. It is safer to use the conventional nozzle arrangement where the inlet is some lateral distance away unless a demister

Another problem with the vertical nozzle arrangement is when the kettle bundle is relatively long and there is a single pair of nozzles. Then there is no good flow distribution. The boiling zones near the ends of the bundle will

When it is necessary to have dry vapor leaving the kettle side, the location of the nozzles is important. The inlet nozzle should not be located directly under the vapor outlet. This probably results in some liquid carryover. When there is a single vapor outlet, it is usually centered over the bundle with the inlet nozzle located some distance away. There have been cases where someone other than the thermal designer changed the location of this vapor nozzle without the thermal designers OK. In one case the vapor outlet was moved to the back of the kettle resulting in

The size of the kettle is determined by several factors. One factor is to provide enough space to slow the vapor velocity down enough for nearly all the liquid droplets to fall back down by gravity to the boiling surface. The amount of entrainment separation to design for depends on the nature of the vapor destination. A distillation tower with a large disengaging space, low tower efficiency and high reflux rate does not require as much kettle vapor space as normal. Normally, the vapor outlet is centered over the bundle. Then the vapor comes from two different directions as it approaches the outlet nozzle. Only in rare cases are these two vapor streams equal in quantity. A simplification that has been extensively used is to assume the highest vapor flow is 60% of the total. One case

Page 21: Process Heat Transfer Hof Master

where this would cause an undersized vapor space is when there is a much larger temperature difference at one end of the kettle then the other. The minimum height of the vapor space is typically 8 inches. It is higher for high heat

What effect will an undersized kettle diameter have? The effect will be a decrease in the boiling coefficient. A boiling coefficient depends on a nucleate boiling component and a two-phase component that depends on the recirculation rate. An undersized kettle will not have enough space at the sides of the bundle for good recirculation. Another

Large temperature differences in heat exchangers where liquid is vaporized are a warning flag. When the temperature differences reach a certain value, the cooler liquid can no longer reach the heating surface because of a vapor film. This is called film boiling. In this condition, the heat transfer deteriorates because of the lower thermal conductivity of the vapor. If a design analysis shows that the temperature difference is close to causing film boiling, the vaporizer should be started with the boiling side full of relatively cooler liquid. This way, you don't start flashing the liquid. The liquid is slowly heated up to a more stable condition. If the vaporizer is steam heated, the steam pressure should be reduced which will reduce the temperature difference. With steam heating, take a close look at the design

A reboiler or chiller is best designed so that it doesn't have the lower heat transfer mode of natural convection. The dividing line between natural convection and boiling depends on the type of tubing used. If steel bare tubes are used,

Choking down on the channel outlet nozzle and piping reduces the circulation rate through a heat exchanger. Since the tubeside heat transfer rate depends on velocity, the heat transfer is lower at reduced recirculation rates. A rule of thumb says that the inside flow area of the channel outlet nozzle and piping should be the same as the flow area inside the tubing. The Shell Oil Company, in an experimental study, showed that a ratio of 0.7 in nozzle flow

the lower limit of temperature difference between the tube wall and the boiling fluid is approximately 5 oF. We have

F using low-finned tubes. Special enhanced

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When does a recirculation rate become too low (high % vaporization)? When this happens, the tube wall is no longer wet and the heat transfer diminishes. The guidelines in the literature show the lowest permissible recirculation rates give from 25 to 40% vaporization for hydrocarbons. It has been observed that this threshold is when the outlet two-phase density (volume basis) is below 1.0 lb/cu-ft. Nearly all thermosyphons have outlet densities above

When designing vertical thermosyphon reboilers with boiling at low operating process fluid pressures, check for the presence of a liquid preheat zone. Back pressure raises the boiling point at the interface of liquid preheat zone and subcooled boiling. This boiling point rise creates a liquid zone with relatively low heat transfer and it reduces the temperature driving force (MTD). If the operating pressure is below approximately 25 PSIA, there should be a liquid preheat zone. The lower the operating pressure, the more likely there is liquid preheat. If there is no liquid

In the design of vertical thermosyphons, the recirculation rate should be set by the process engineer if there will be anything unusual about the connecting piping. The recirculation rate is especially sensitive to the size and configuration of the outlet piping. If the recirculation rate is left for the thermal designer to set, they will have to make piping

The crital heat flux depends on the geometry of the bundle. The following estimate is based on 3/4 inch tubes on 15/16 inch pitch. It is actually good for any tube diameter with a tube pitch/tube diameter ratio of 1.25 and triangular tube pitch.

For kettle reboilers use segmental baffles instead of full supports if shell fouling factor is greater Than 0.002(hr-ft2-F/Btu)

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A rule of thumb is that the pressure drop at the outlet nozzle should not be greater than 30% of the total static head. There is another tip in this boiling section about choking the flow with a small outlet nozzle. The inside flow area of the outlet nozzle should be the same or greater than the total flow area inside the tubing. For a channel with a side outlet the pressure drop is composed of a turning loss and a contraction loss The following equations calculate the pressure drop at the outlet. The pressure drop for expansion into the channel is not included here but is with the tube pressure drop.

(used for pressure drop calc)

(If Ktr less than 0.40, use 0.40)

At low operating pressures there will be a sensible heat liquid zone with relatively low heat transfer. This is caused by the fact that a small pressure change will cause a large increase in the boiling point. There has been a case where 90% of the tube length was in the sub-cooled phase. What can you change that will decrease the size of the liquid preheat zone and

One answer is to evaluate the piping system above the top tubesheet. In order to make an evaluation check the pressure drop at the outlet. There is on this section of the website equations to calculate the pressure drop of a nozzle that is at right angle to the top channel. Most vertical thermosyphons have the outlet nozzle at right angles to the top channel. There may be a simple change of enlarging the outlet nozzle that would be the cure. But there needs to be a check to make sure the nozzle and connecting piping are not so large that there is liquid slip. If enlarging the right angle nozzle and piping is not the answer then there are other configerations that will use less outlet pressure drop. Next the pressure drop of using a B type channel with

Another solution to the problem is to investigate inserts such as swisted tape, wire matrix , or helically coiled.

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I agree. I have also found that locating the inlet liquid nozzle directly under the vapor outlet is not good. In Amine BKU reboilers I found that locating the inlet rich amine liquid as close to the U-tube bundle tubesheet gave the best, consistant results in obtaining good solution stripping. This gives the heating medium

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Note:

What Coil Diameter to Use to Start Design October, 2002When starting to design a coil or other single continuous tube heat exchanger, the diameter is unknown. An example of this is an economizer in a heat recovery system. In this case it is desirable to have a single flow path rather than using parallel paths where headers are required. The following gives guidelines for liquids on a diameter selection:

Size Unit Capacity flow rate

1” tube 3,000-5,000 # / tube / hr1 ¼” pipe 5,000-10,000 # / tube / hr1 ½” pipe 10,000-17,000 # / pipe / hr2” pipe 17,000-35,000 # / pipe / hr3” pipe 35,000-70,000 # / pipe / hr4” pipe 70,000-130,000 # / pipe / hr

Estimate Gas Heat Transfer Rate for Hydrocarbons February, 1998If you need to estimate a gas heat transfer rate or see if a program is getting a reasonable gas rate, use the following:

h = 75 Generally more accurate

Or,

h = 66 Generally understated

Operating pressure = 100.0 Psia.W = 123.00 lb/tube/hr

Estimate Hydrocarbon Heat Transfer Coefficient In Tubes Use the following equation to estimate the heat transfer coefficient when liquid is flowing inside 3/4 inch tubing:

Hio = 150 / sqrt(avg. viscosity) = 87Where:

Viscosity = 3.0 cP.

Estimate - Latent Heat of HydrocarbonsAn equation from the Bureau of Standards Miscellaneous Publication No. 97 can be used when the Specific Gravity is greater than 0.67 and less than 0.934. It is:

Input data into YELLOW cells and receive output in BOLD RED

75 x (Op. pressure/100)1/2 = Btu/hr-ft2-oF

1.4W0.8 = Btu/hr-ft2-oF

This is for inside the tubes. The rate will be lower for the shell side or if there is more than one exchanger.

Btu/Ft2-hr-oF

This is limited to a maximum viscosity of 3 cP

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Lat heat = (111 - 0.09T)/SG60 = 113 Btu/lb

Where:Lat heat = The fluid's Latent Heat in Btu/lb

100

= 0.9000 (0.67<SG<0.934)

For hydrocarbons below a Specific Gravity of 0.67 and pressures below 50 psia, use:

Lat heat = 172 - 0.195 T

Liquid Thermal Conductivity for Light Hydrocarbons July, 1999You can make an estimate for the liquid thermal conductivity of light hydrocarbons if you know their specific heat. It is good for propane and heavier.

K = 0.0427Specific Heat = 0.7000 But/lb °F

Estimate Overall Heat Transfer Rate (U) in S & T December, 2001In the preliminary design of shell and tube heat exchangers, you need an estimate of the overall heat transfer coefficient (U). Process simulator programs give you a UA from which you can estimate the surface if you have a U value. An estimate for a hydrocarbon U value can be made from the following:

Rt =

Where,

Avg. tube viscosity = 2.0 cP Fouling = 0.0005 U = 1/Rt =Avg. shell viscosity = 3.0 cP

limit on the shell viscosity. This is also limited to bare tube surface with no internal turbulation devices.

Estimated Tube Length That Lowers Tube Pressure Drop September, 2001When the calculated tube side pressure drop exceeds the allowable, there are several design options. One option is to design with shorter tubing when the number of tube passes is one. To estimate the new tube length, use the following equation:

New Lg = 15.9 feet

WhereLg = Existing tube length = 20 feet

Allowable Tube pressure drop = 1.00 psiCalculated Tube pressure drop = 2.00 psi

The final tube length needs to be slightly longer than calculated because the calculated surface will be larger due to a lower tube velocity that gives a lower heat transfer.

T = The fluid temperature in oF =

SG60 = The fluid's Specific gravity @ 60 oF

0.025 / (specific heat)1.5 =

Fouling + Sqrt(avg. tube viscosity)/150 +((avg. shell viscosity)0.27)/140 =

Fouling is the total for both sides. The above is limited to a maximum viscosity of 3 cP for the tube side. There is no

Lg (Allowed Dp/Calc. Dp)1/3 =

Allow.Dp =Calc. Dp =

G43
Dale: There is a maximum sp. Gravity of 0.934.
Page 27: Process Heat Transfer Hof Master

How to Calculate Excess Surface and Over-design Surface

Excess surface = 31.58%Where

actual heat transfer surface = 250.0

surface calculated from design overall heat transfer coefficient = 190.0

Use Superficial velocities to Calculate Best Heat Transfer Flow PatternThe best heat transfer occurs when there is an annular flow pattern. Then there is a relatively thin liquid film and little vapor in contact with the heat transfer surface. How do you tell if the flow is annular? It will be when the superficial gas velocity is above the following value:

If the superficial liquid velocity is below 0.30 ft/s:

41.3 ft/sec.where

VL = the superficial liquid velocity = 0.25

If the superficial liquid velocity is above 0.30 ft/s:

57.2 ft/sec.where

VL = the superficial liquid velocity = 1.00

L/D Equation For Heat Transfer Coefficient Inside TubingFor Reynolds numbers below 10,000 there is an L/D effect on the heat transfer coefficient inside tubing. If you use the full tube length for L, you may be too conservative. There will be turbulation at the tube entrance before laminar flow is fully developed. The turbulent length needs to be subtracted from the full tube length. Use the following for tube sizes 1.0 inch or less.

11 feet

WhereL = variable to use in L/D expression, ftTube Length = length of tube, ft = 20 feet

0.650 inchesRe = Reynolds number = 5,000

100 x (Aactual –Acalculated) / Acalculated =

Aactual =

Acalculated =

To calculate over-design surface use the clean overall heat transfer coefficient for Acalculated.

VgMax = 72 – 148 VL +100 VL2 =

ft/sec. (less than 0.30 ft/s)

VgMax = 28.1 + 28 VL + 1.12 VL2 =

ft/sec. (more than 0.30 ft/s)

L = Tube Length - 0.0027 Di Re

Di = tube I.D., in =

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LMTD Correction Factor Charts for TEMA G and J Shell TypesThere are LMTD correction factor charts in TEMA for a single type G shell and two in series of type J shells. For charts of more shells in series, refer to the enclosed Dale Gulley-generated charts in this Workbook.

Divided Flow LMTD Correction November, 1996Something to watch out for is the LMTD correction for Divided Flow Shell & Tube Exchangers. Divided flow (shell type J) does not have the same correction as the usual flow pattern (shell type E). We have seen several instances lately where a thermal design program made this correction factor mistake. True, there is very little difference at correction factors above 0.90. However, there is a difference at lower values. For example:

Shell-type Flow

Equal outlet temperatures Shell type "E" 0.805Shell type "J" 0.775

0.765

Shell type "J" 0.65Contact us if you do not have LMTD correction factor charts for divided flow. TEMA has one chart for a single shell but it gives high values for the above examples and it is hard to read in this range. Refer to the enclosed Dale Gulley charts for up to 4 shells in series that are found in this Workbook.

Lowest Limit of LMTD Correction FactorWhat is the lowest LMTD correction factor to be used? Here is what several literature sources say:

Heat Exchanger Design Handbook (HEDH):“F should be kept above 0.75 to 0.80”

Perry's Chemical Engineers' Handbook:“Values of F less than 0.80 (0.75 at the very lowest) are generally unacceptable because the exchanger configuration chosen is inefficient ...”

In over 50 years of experience, a correction factor of 0.75 is the lowest we have seen a thermal designer use. Although there was one case where an operating shell-and-tube heat exchanger reflected a lower LMTD correction factor than 0.75. Another way of looking at the correction factor is to never use a temperature cross of more than 5 degrees F in a single multi-tube pass shell.

Minimum Flow Area For Shell Side Inlet NozzleFor single phase liquids and no impingement plate:

Minimum area = (Flow (lb/hr) x 0.04) / (38.73 Sq.Root(ρ)) = 0.261

Shell Side Flow Rate = 2,000 lb/hr

Correction Fn

Cold outlet 5 oF higher than hot outlet Shell type "E"

in2

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Shell Side fluid density = 62.50

For boiling liquids and no impingement plate:

Minimum area = (Flow (lb/hr) x 0.04) / (22.36 Sq.Root(ρ)) = 0.453

How to Calculate the Performance of Heat Exchangers with Plugged Tubes

1. Using the actual overall heat transfer coefficient (U), calculate the heat transfer resistances that excludes the tube side resistance:

3. Calculate new U

How to Calculate the Performance of Heat Exchangers With Plugged Tubes 4. Calculate a new heat load from new surface and a new U

How to Increase Heat Transfer for Low Reynolds Numbers September, 1999

If pressure drop is available and if the tube side Reynolds number is less than 5,000 and more than 1,000, you

can probably increase the heat transfer considerably by increasing the number of tube passes and using shorter tubes. This will not only increase the tube velocity but there will be a lower L/D correction. Both of these factors will

increase the heat transfer.

Calculate When to Use Seal Bars on a Bundle to Increase Heat TransferOne of the fluid by-pass streams that lower the shell-side heat transfer is the stream that flows around the bundle. To evaluate, calculate a heat transfer variable named FSBP. It is the ratio of the by-pass to the cross flow area. The by-pass area is normally:

FSBP = Bs (Ds - OTL) = 0.054Bs(Ds-OTL)+Bs(OTL-Do)(P-Do)/P

WhereDs = inside diameter of shell = 23.00 in.

OTL = The Outer Tube Limit, or outer diameter of the tube bundle = 22.75 in.Bs = Baffle Spacing = 18.00 in.Do = tube OD = 1.00 in.P = tube spacing = 1.25 in. Typical value is 1.25 x tube OD

lb/ft3

in2

Rother = 1/U -1/hio

2. Calculate new hio and new surface using usable number of tubes

Unew = 1/(1/hio + Rother)

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Calculate Tube Bundle Diameter January, 2000Following are equations for one tube pass bundle diameter when the tube count is known or desired:

For tubes with 30 Deg. Pitch:

DS = 1.052 x pitch x SQRT(count) + tube O.D. = 17.384 inches

For tubes with 90 Deg. Pitch:

DS = 1.13 x pitch x SQRT(count) + tube O.D. = 18.617 inchesWhere:Tube OD = 0.750 inches

DS = Bundle diameterCount = 250 Number of tubesPitch = Tube spacing = 1.000 inches

Tube Count Calculation for S & T August, 2002If you don't have a tube count table for a shell and tube exchanger, the tube count can be calculated. The following equation is good for any size tube on any tube pitch. It is primarily for situations where there is not a need for allowance for bundle entrance and exit area.

Count = 372 Tubes on Square Pitch

Where: = 428 Tubes on Triangular PitchDo = Tube O.D. = 0.750 inches

F = 1.00 for square pitchF = 1.15 for triangle pitch

Npl = Number of tube pass lanes (1 for two pass) = 2PLw = Tube pass lane width (typical is 0.625 inches) = 0.625 inches

P = Tube pitch = 1.000 inchesTC = (Bundle diameter - tube O.D.) = 22.250 inches

For tube pass lane width for square rotated tube pitch use (1.414P – Do). The decrease in the number of tubes due to bundle entrance and exit area could be allowed for by using a larger PLw.

Tube Wall Temperature for Cooling Water January, 1999When designing heat exchangers where hot process streams are cooled with cooling water, check the tube wall temperature. Hewitt says that where calcium carbonate may deposit, heat transfer surface temperatures above

before it enters the water-cooled exchanger.

If FSBP is more that 0.15, then seal bars are needed.

F [0.7854 x TC2 - (PLw + Do - P) (TC x Npl)] / P2 =

140 oF should be avoided. Corrosion effects should also be considered at hot tube wall temperatures. As a rough

rule of thumb, make this check if the inlet process temperature is above 200 oF for light hydrocarbon liquids and

300 - 400 oF for heavy hydrocarbons. Consider using Air coolers to bring the process fluid temperature down

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Sometimes Larger Tubes are Better October, 1998There is an exception to the rule that a shell and tube heat exchanger service using 3/4 inch tubes will be cheaper than one using 1-inch tubes. This is when the tubeside has a much lower heat transfer coefficient than the outside of the tubes and the following conditions are present:

The flow will be in laminar flow if two (2) tube passes are used.

If four (4) tube passes are used, the tubes in the 3/4 inch selection will have to be significantly shorter than allowed in order to meet pressure drop. On the other hand, the 1-inch tube design uses the full allowable tube length.

Weighted MTDIf there is more than a slight curvature in the heat release curve, things get more complicated. Then a step-wise method using local temperatures and local heat transfer coefficients are used to calculate the heat exchanger area. The question is what do you report as the MTD and the correction factor? There is a reference in TEMA in the temperature relations section T-3.2 that refers to a weighted MTD. The article mentioned was published by Dale Gulley in the June 1966 issue of Hydrocarbon Processing. The article shows how to calculate a weighted MTD and its correction factor if one is required.

Estimate - Optimum Flow Velocity for Gas Inside TubesSince the design of heat exchangers is a trial and error solution, a good starting point is desired. Usually the design starts with an estimated overall heat transfer coefficient. If you don't know a good starting value for this coefficient the equations presented here give this starting point with simple equations.

In the design of heat exchangers using up the maximum allowable pressure drops gives the highest heat transfer for single phase fluids. The equations below estimates the tube velocity(W)for a gas that will meet the maximum allowable pressure drop. From W you can calculate the tube count or heat transfer coefficient. For a given tube length the following equation gives the optimum tube velocity for turbulent flow. Gases will be in turbulent flow more than 99% of the time. If your calculated tubeside velocity is below what the following equation calculates, you need more tube travel where tube travel is in the form of number of tube passes or total tube length(s) for countercurrent flow. These equations can be used for two phase flow as long as the two phase viscosity is less than 0.015 cp,

For 3/4 inch tubes with 0.06 tube wall

For 1.0 inch tubes with 0.06 tube wall

Where: L = total tube lengths in ft. (Add [8 x tube ID in inches] ft for turning losses for each tube pass) W = lb/hr/tube ΔP = allowable pressure drop inside tubes in psi (deduct 15% for nozzle pressure drops) ρ = density in lb/cu.ft.

W = 1600(ΔPρ/L)0.555

W = 3500(ΔPρ/L)0.555

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L = 21 ft For 3/4" tubes, W = 1,497 Tube count =

ΔP = 7 psig For 1" tubes, W = 3,274 Tube count =

ρ = 2.66Mass flow = 195000 lb/h

Example

Use 3/4 inch tubes and 16 foot tubes. The maximum allowable pressure drop inside the tubes is 7 psi (after nozzle deduction) and the gas density is 2.66 lb/cu.ft. The tube side flow is 195,000 lb/hr. What should be the starting tube count?Solution

W = 1497 lb/hr/tube

Tube count = 195,000/1497 = 130

For a shell-and-tube heat exchanger, calculate the shell diameter when given the tube count here:

Estimate - Hydrocarbon Gas Heat Transfer Coefficient in Shell SideIts difficult to estimate a gas heat transfer coefficient in the shell side because of the many variables. The following will give you a value within 25%.

Ho = 430.Cp(ΔP/L x ρ)1/3 = 17 Btu/h ft2 °F

where Cp = specific heat (Btu/lb-F) = 0.15 L = tube length (ft) = 10 ΔP = shell side pressure drop (Ps= 2 (subtract nozzle losses) ρ = density of gas (lb/ft3) = 0.085

lb/ft3

W = 1600(7 x 2.66/(16+5))0.555

Calculate S & T diameter from number of tubes

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When starting to design a coil or other single continuous tube heat exchanger, the diameter is unknown. An example of this is an economizer in a heat recovery system. In this case it is desirable to have a single flow path rather than using parallel paths where headers are required. The following gives guidelines for liquids on a diameter selection:

If you need to estimate a gas heat transfer rate or see if a program is getting a reasonable gas rate, use the following:

Generally more accurate

Generally understated

Use the following equation to estimate the heat transfer coefficient when liquid is flowing inside 3/4 inch tubing:

An equation from the Bureau of Standards Miscellaneous Publication No. 97 can be used when the Specific Gravity

. The rate will be lower for the shell side or if there is more than one exchanger.

Page 34: Process Heat Transfer Hof Master

You can make an estimate for the liquid thermal conductivity of light hydrocarbons if you know their specific heat.

In the preliminary design of shell and tube heat exchangers, you need an estimate of the overall heat transfer coefficient (U). Process simulator programs give you a UA from which you can estimate the surface if you have a U value.

0.020

51

When the calculated tube side pressure drop exceeds the allowable, there are several design options. One option is to design with shorter tubing when the number of tube passes is one. To estimate the new tube length, use the

The final tube length needs to be slightly longer than calculated because the calculated surface will be larger due to

for the tube side. There is no

Page 35: Process Heat Transfer Hof Master

The best heat transfer occurs when there is an annular flow pattern. Then there is a relatively thin liquid film and little vapor in contact with the heat transfer surface. How do you tell if the flow is annular? It will be when the

For Reynolds numbers below 10,000 there is an L/D effect on the heat transfer coefficient inside tubing. If you use the full tube length for L, you may be too conservative. There will be turbulation at the tube entrance before laminar flow is fully developed. The turbulent length needs to be subtracted from the full tube length. Use the following for tube

Page 36: Process Heat Transfer Hof Master

There are LMTD correction factor charts in TEMA for a single type G shell and two in series of type J shells.

Something to watch out for is the LMTD correction for Divided Flow Shell & Tube Exchangers. Divided flow (shell type J) does not have the same correction as the usual flow pattern (shell type E). We have seen several instances lately where a thermal design program made this correction factor mistake. True, there is very little

Contact us if you do not have LMTD correction factor charts for divided flow. TEMA has one chart for a single shell but it gives high values for the above examples and it is hard to read in this range. Refer to the enclosed Dale

In over 50 years of experience, a correction factor of 0.75 is the lowest we have seen a thermal designer use. Although there was one case where an operating shell-and-tube heat exchanger reflected a lower LMTD correction factor than 0.75. Another way of looking at the correction factor is to never use a temperature cross of more than

Page 37: Process Heat Transfer Hof Master

Calculate the expected performance of an exchanger that has had to have some tubes plugged by doing the following:

1. Using the actual overall heat transfer coefficient (U), calculate the heat transfer resistances that excludes the 1. You know the original overall heat transfer coefficient for the un-plugged exchanger and the number of tubes plugged.

2. Therefore, you know the original heat transfer area, the original hi and ho, the original tubeside velocityand the original duty and terminal temperatures.

3. You want to know what will be the new duty capacity and terminal temperatures with the unit operating with plugged tubes.

How to Calculate the Performance of Heat Exchangers With Plugged Tubes

After a heat exchanger goes into operation it may develope leaks in the tube walls. The following procedure calculates the new heat load and new overall heat transfer coefficient.

1. Using the actual overall heat transfer coefficient (U). calculate the heat transfer resistances that exclude the tubeside resistance

If pressure drop is available and if the tube side Reynolds number is less than 5,000 and more than 1,000, you

can probably increase the heat transfer considerably by increasing the number of tube passes and using shorter tubes. This will not only increase the tube velocity but there will be a lower L/D correction. Both of these factors will 3. Calculate new U

4. Calculate new heat load from new surface and new U

One of the fluid by-pass streams that lower the shell-side heat transfer is the stream that flows around the bundle. To evaluate, calculate a heat transfer variable named FSBP. It is the ratio of the by-pass to the cross flow area.

       Rother = 1/U -1/hio

2. Calculate new hio and new surface using usable number of tubes

      Unew = 1/(1/hio + Rother)

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If you don't have a tube count table for a shell and tube exchanger, the tube count can be calculated. The following equation is good for any size tube on any tube pitch. It is primarily for situations where there is not a need for

Tubes on Square Pitch

Tubes on Triangular Pitch

For tube pass lane width for square rotated tube pitch use (1.414P – Do). The decrease in the number of tubes

When designing heat exchangers where hot process streams are cooled with cooling water, check the tube wall temperature. Hewitt says that where calcium carbonate may deposit, heat transfer surface temperatures above

F should be avoided. Corrosion effects should also be considered at hot tube wall temperatures. As a rough

F for light hydrocarbon liquids and

F for heavy hydrocarbons. Consider using Air coolers to bring the process fluid temperature down

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There is an exception to the rule that a shell and tube heat exchanger service using 3/4 inch tubes will be cheaper than one using 1-inch tubes. This is when the tubeside has a much lower heat transfer coefficient than the outside

If four (4) tube passes are used, the tubes in the 3/4 inch selection will have to be significantly shorter than allowed in order to meet pressure drop. On the other hand, the 1-inch tube design uses the full allowable tube length.

If there is more than a slight curvature in the heat release curve, things get more complicated. Then a step-wise method using local temperatures and local heat transfer coefficients are used to calculate the heat exchanger area. The question is what do you report as the MTD and the correction factor? There is a reference in TEMA in the temperature relations section T-3.2 that refers to a weighted MTD. The article mentioned was published by Dale Gulley in the June 1966 issue of Hydrocarbon Processing. The article shows how to calculate a weighted

Usually the design starts with an estimated overall heat transfer coefficient. If you don't know a good starting value for this

In the design of heat exchangers using up the maximum allowable pressure drops gives the highest heat transfer for single phase fluids. The equations below estimates the tube velocity(W)for a gas that will meet the maximum allowable pressure drop. From W you can calculate the tube count or heat transfer coefficient. For a given tube length the following equation gives the optimum tube velocity for turbulent flow. Gases will be in turbulent flow more than 99% of the time. If your calculated tubeside velocity is below what the following equation calculates, you need more tube travel where tube travel is in the form of number of tube passes or total tube length(s) for countercurrent flow. These equations can be used for two phase flow as long as the two phase viscosity is less than 0.015 cp,

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130

60

Use 3/4 inch tubes and 16 foot tubes. The maximum allowable pressure drop inside the tubes is 7 psi (after nozzle deduction) and the

Its difficult to estimate a gas heat transfer coefficient in the shell side because of the many variables. The following will give you a value within 25%.

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Calculate the expected performance of an exchanger that has had to have some tubes plugged by doing the following:

1. You know the original overall heat transfer coefficient for the un-plugged exchanger and the

2. Therefore, you know the original heat transfer area, the original hi and ho, the original tubeside velocity

3. You want to know what will be the new duty capacity and terminal temperatures with the

The following procedure calculates the new heat load and new overall heat transfer coefficient.

1. Using the actual overall heat transfer coefficient (U). calculate the heat transfer resistances that exclude the tubeside resistance

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Avoid Small Baffle Cuts in S & T Condensers July, 2001There will be a theoretical liquid level when there is condensation in a heat exchanger. The condensing heat transfer coefficient decreases as its' liquid film increases. For best heat transfer the liquid level should be low as possible. Small baffle cuts in a shell and tube exchanger will hold a higher liquid level than large cuts. Use a separated flow model equation system to determine the theoretical liquid level. Unless you want subcooling, do not use a baffle cut that would hold a liquid level higher than the theoretical one.

Estimate - Condensing Heat Transfer Coefficient for Hydrocarbons Inside Tubing

Cond h = 828WhereCond h = Inside condensing heat transfer coefficient

W = Condensing fluid in tubes = 750.00 lbs/hr/tube

Maximum Condensing Rate Inside Tubes August, 2001Following is a close estimate of the maximum heat transfer rate for total condensation. It is based on the maximum

Hi = 3,193 Btu/hrWhere,

liquid thermal conductivity of the condensat 0.350

For example this equation yields a maximum heat transfer rate for steam to be 3,600.

Quick Estimate for Reflux Condenser LMTD in Air-cooler

curve has a hump which will give a LMTD higher than one calculated from a straight line condensing plot. An equation that makes a quick estimate for the LMTD is:

Standard LMTD x Factor

Then LMTD Factor = 1.4 -0.0092 (T -110)

Reflux (“Knock back”) Condenser June, 2001Do not design this like the usual vertically condensing heat exchanger where both gas and liquid flow in one direction. In this type of condenser, the coldest condensate will be in contact with the entering hot vapor (in the bottom section). Nearly everything about this type condenser is different. It is both difficult to design and difficult to control. The flow patterns, pressure drop and heat transfer calculations are different. Be sure the heat transfer calculations are zoned.

(4.15) W0.8 = Btu/(hr)(ft2)(oF)

condensing rate for the average hydrocarbon to be 750 BTU/hr-ft2-F. It is good for other types of chemical compounds.

750 (Kliq / 0.07)0.9 =

Kliq = Btu/hr-ft-oF

This type of service has steam condensing out from a non-condensable gas which is mostly CO2. The condensing

In the case of outlet process temperatures below 153.5 oF,

Where T = outlet temperature and air inlet temperature is 100 oF.

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Types of Steam CondensersSmall steam condensers use shell-and-tube heat exchangers while large steam condensers use surface condensers.

lower temperatures, a “X” type shell can be used. A point is reached where the size or operating pressure requires a surface condenser.

Sulfur Condenser - Tube Velocity LimitsFor good operation of a sulfur condenser the design velocities inside the tubes should be within certain limits. The velocity range is between 1.5 and 6.0 lb/sq ft-sec. Below this range there will be slugging. Above this range sulfur fogging will occur..

Small Temperature Pinch Points in Condensers November, 1998 Be extra careful when condensers are designed with a small pinch point. A pinch point is the smallest temperature difference on a temperature vs. heat content plot that shows both streams. If the actual pressure is less than the process design operating pressure, there can be a significant loss of heat transfer. This is especially true of fluids that have a relative flat vapor pressure plot like ammonia or propane. For example: If an ammonia condenser is

can be a 16% drop in heat transfer.

When to Slope Single Tube Pass Tubes in Condensing Service January, 2002At low vapor velocities, it has been proven that even a slight downward slope of tubes gives a significant increase in heat transfer in the case of tube-side condensation. But this does not mean the larger the slope the higher the heat

have the tubes sloped is when they are operating near atmospheric pressure and there is one tube pass. An example of this is a sulfur condenser. It has a low pressure drop usually less than 0.5 psi. They typically are designed with a slope of 1/8 inch per foot of tubing.

Zone Those CondensersThe heat transfer and pressure drop of a condenser usually should be zoned. A typical heat exchanger that condenses 100% of the vapor will go through 2 or 3 different flow pattern zones before the flow becomes a liquid. There is better accuracy if the flow patterns are determined and their individualistic equations are used.

A conventional “E” type shell is used when the steam condensing temperature is above approximately 120 oF. For

designed for 247 PSIA operating pressure and the actual pressure is 5 PSI less and the pinch point is 8 oF, there

transfer. The benefit of sloping stops at an angle of approximately 10o. A common case of a condenser needing to

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There will be a theoretical liquid level when there is condensation in a heat exchanger. The condensing heat transfer coefficient decreases as its' liquid film increases. For best heat transfer the liquid level should be low as possible. Small baffle cuts in a shell and tube exchanger will hold a higher liquid level than large cuts. Use a separated flow model equation system to determine the theoretical liquid level. Unless you want subcooling, do not use a baffle cut

Following is a close estimate of the maximum heat transfer rate for total condensation. It is based on the maximum

Do not design this like the usual vertically condensing heat exchanger where both gas and liquid flow in one direction. In this type of condenser, the coldest condensate will be in contact with the entering hot vapor (in the bottom section). Nearly everything about this type condenser is different. It is both difficult to design and difficult to control. The flow patterns, pressure drop and heat transfer calculations are different. Be sure the heat transfer calculations are zoned.

-F. It is good for other types of chemical compounds.

. The condensing

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Small steam condensers use shell-and-tube heat exchangers while large steam condensers use surface condensers.

lower temperatures, a “X” type shell can be used. A point is reached where the size or operating pressure requires

For good operation of a sulfur condenser the design velocities inside the tubes should be within certain limits. The velocity range is between 1.5 and 6.0 lb/sq ft-sec. Below this range there will be slugging. Above this range sulfur

Be extra careful when condensers are designed with a small pinch point. A pinch point is the smallest temperature

process design operating pressure, there can be a significant loss of heat transfer. This is especially true of fluids

At low vapor velocities, it has been proven that even a slight downward slope of tubes gives a significant increase in heat transfer in the case of tube-side condensation. But this does not mean the larger the slope the higher the heat

have the tubes sloped is when they are operating near atmospheric pressure and there is one tube pass. An example of this is a sulfur condenser. It has a low pressure drop usually less than 0.5 psi. They typically are designed with

The heat transfer and pressure drop of a condenser usually should be zoned. A typical heat exchanger that condenses 100% of the vapor will go through 2 or 3 different flow pattern zones before the flow becomes a liquid. There is

A conventional “E” type shell is used when the steam condensing temperature is above approximately 120 oF. For

. A common case of a condenser needing to

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Rotated Square Tube PitchSome heat exchanger specifications for shell and tube heat exchangers mention square pitch but do not specifically mention rotated square pitch. Engineers with little thermal design experience who are trying to strictly adhere to the specifications may reject this type of tube pitch. The benefits for this type of tube pitch sometimes get lost because of this. Rotated square pitch gives better mixing of the shell fluid and better heat transfer for the heavier fluids. Frequently the shell size can be reduced when there will be heavier liquids on the shell side and the designer uses rotated square pitch.

Caution When Using a Longitudinal Baffle in the Shell SideThe following are potential problems when considering the use of a longitudinal baffle in a new S & T heat exchanger:

is lost due to conduction across the long baffle. Check and make sure this has been taken into consideration;If the long baffle is not welded to the shell, the pressure drop across the long baffle is more than 7 to 8 psi. This will also lose thermal efficiency. The seal on the long baffle should be tested in the shop after fabrication.

Using Turbulators for Tube Side Laminar FlowIf the flow inside the tubes of a heat exchanger is in laminar or viscous flow, take a look at enhancing the heat transfer. One simple and inexpensive device is the twisted-tape insert. Using twisted-tape inserts for laminar flow in new heat exchangers results in cost savings and smaller heat exchangers. Twisted-tape inserts can be used in existing heat exchangers to make a significant increase in capacity. The amount of increase in heat exchanged depends on whether the increase in pressure drop can be tolerated. If there is no pressure drop limitation, there can be as much as a 50% increase in capacity.

Here are the recommended guide lines for using twisted tape inserts:

1 Pressure drop in the tube side without inserts is less than 3 to 4 PSI.2 Minimum fluid viscosity of 2 centipoise unless there is a very low velocity3 Use a minimum tube diameter of 5/8” for .001 fouling. Use a minimum of 1” diameter for

0.0015 fouling. It is not recommendable to use turbulators in a service that has a fouling factor greater than 0.0015.

These guidelines for tube diameter are due to fouling being more of a problem with turbulators in small tubes.

Triple Segmental Baffles November, 1997There is more than one kind of triple segmental baffles in the shell side of heat exchangers. Be sure you know which kind if you are checking a design that uses them. There is the kind you see in TEMA where there are three different groups in a set. The total number of baffle pieces is six. There is the kind that is like producing two double segmental streams in parallel. There are two groups in a set and a total of five baffle pieces. Another kind has only three pieces in a group and each piece has a different shape.

Entrance and Exit Space for Shell Nozzles January, 2001There have been cases where not enough space was under the shell nozzles. This can be critical for applications like a horizontal thermosyphon or other pressure drop sensitive applications. Check the distance from the nozzle I.D. to the nearest tube row or impingement plate. If there is an impingement plate this distance should be ¼ or more of the

1.      The largest temperature drop across the long baffle is more than 250 oF. Then the thermal efficiency

2.     

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nozzle I.D. If there is no impingement plate this distance should be 1/6 or more of the nozzle I.D. If pressure drop is not a consideration and TEMA requirements are met and vibration is not a problem then the above calculated distance could be reduced. This criterion naturally doesn't apply to shells with distributor belts or where the nozzle is beyond the back of a U-tube bundle.

For information on calculating shell nozzle pressure drops, refer to “Calculate Shell Nozzle Pressure Drop” in the calculation Tab of this Workbook.

Horizontal vs. Vertical Baffle Cut in S & T Exchangers May, 2001In shell and tube heat exchangers it is safer from a thermal design standpoint to use vertical baffle cuts but horizontal cuts have an advantage in certain situations. Horizontal cuts are best if the shell side stream is clean and single phase. There will be less of the shell side stream bypassing through the tube pass lanes. Since in a multi-tube pass exchanger there will be more horizontal tube pass lanes than vertical pass lanes, you need to flow perpendicular to these pass lanes for minimum by-passing of the shell stream. This means horizontal cut. Where you do not want to use horizontal cut is when there is either condensing or where there is the possibility of foreign material being in the flowing stream. It is suggested to use a maximum fouling factor of 0.002 for horizontal baffle cut. It may be possible to use horizontal cut in certain boiling applications.

Is an Expansion Joint Required in the Shell? December, 1998A fixed tube sheet exchanger does not have provision for expansion of the tubing when there is a difference in metal temperature between the shell and tubing. When this temperature difference reaches a certain point, an expansion joint in the shell is required to relieve the stress. It takes a much lower metal temperature difference when the tube metal temperature is hotter than the shell metal temperature to require an expansion joint. Typically, an all steel

because the maximum allowable tube Compressive stress has been exceeded. According to the TEMA procedure for evaluating this stress, the compressive stress is a strong function of the unsupported tube span. This is normally twice the baffle spacing.

Increasing Capacity of Existing Shell & Tube Exchangers March, 1997To increase heat transfer check out using low fins or other special tubing. When an increase in capacity will cause excessive pressure drop, you may not have to junk the heat exchangers. Investigate the relatively inexpensive modification of reducing the number of tube passes. Other possibilities are arranging multiple exchangers in parallel.

Locating Vents on the Shell Side of Vertical Exchangers July, 1998Proper venting of equipment is not always given the consideration it deserves. One place where venting is especially a problem is underneath the tubesheet of a vertical exchanger. The problem is that there will always be a space above the vent connection to trap gases or vapors. Besides the poor heat transfer in this region, this can cause corrosion problems. It is important to get the vent connection as close to the tubesheet as possible. Using multiple connections that are smaller is one solution. Another solution is to fabricate the upper tubesheet with a small vent tunnel inside.

Flange Gasket Location May, 1999There is an optimum diameter of the gasket for flanges. It is when the total Operating moment of the flange under pressure is equal to the gasket seating moment. For low-pressure flanges, the diameter should be as close to the bolt circle as possible. For high-pressure flanges, the diameter should be as close to the flange I.D. as possible. In this case, low pressure is considered to be below 300 psi. High pressure is considered to be approximately 750 psi

exchanger can take a maximum of approximately 40 oF metal temperature difference when the tube side is the hottest.

When the shell side is the hottest, the maximum is typically 150 oF. Usually if an expansion joint is required, it is

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and higher.

Using Rods for Tube Inserts to Increase Heat Transfer August, 1998Use concrete reinforcing rods inserted inside the tubes to increase the heat transfer and tube velocity. It is a quick and economical solution. This is usually done only in clean services. A typical case is using 3/8" rods inside a 3/4" x 14 BWG tube. The tube side heat transfer coefficient is increased by a factor of 1.7. However, you have to be able to stand the increase in pressure drop. It goes up by a factor of 9.5. Another example is a 1.0" x 16 BWG avg. wall tube where the heat transfer goes up by a factor of 1.17 and the pressure drop by a factor of 3.5.

Shell Side Impingement ProtectionThere may be tube vibration or erosion if the shell-side fluid velocity is above a maximum value. These values can be found in TEMA section RCB-4.61 & 4.62. In the eighth edition the maximum values can be found on page 35.

The most common impingement protection is a plate baffle that is slightly above the tube bundle. But this type of protection has some drawbacks. It has a relatively higher pressure drop than most other methods and the tubes on the first several rows tend to vibrate. Other types of impingement protection are:

1. Plate within a nozzle enlarger2. Solid rods instead of tubes for the first 2 or 3 rows.3. Snap-on tube protectors on top of the tubes in the first 2 or 3 rows4. Small angle iron types setting on top of the tubes in the first 2 or 3 rows5. Vapor belt

Special S & T Exchanger Type (NTIW) September, 1998A shell & tube heat exchanger with normal segmental baffles has tubes that miss every other baffle. This can lead to long unsupported tube lengths for some applications. A long tube span has a low natural frequency and is prone to vibration. One solution is to design a “no tubes in window” (NTIW) exchanger. This design has no tubes in the baffle cut out. By using intermediate supports between baffles, the natural frequency of the tubes can be raised considerably to resist vibration.

When to Consider By-pass Strips in S & T BundleUse a by-pass strip if tubes are removed under a nozzle. Removing tubes leaves an open area where the shell fluid can flow either over or under the bundle.

Consider by-pass strips if the bundle to shell clearance is more than 3/4 inches and the shell fluid is mostly sensible heat transfer.

Especially consider by-pass strips if the shell liquid is a hydrocarbon with an average viscosity greater than 1 centipoise and the tube fluid has a high heat transfer coefficient (example water). In this case, a 5 to 10% increase in heat duty can be achieved by installing by-pass strips.

What is too Large a Temperature Change in 2 Tube Passes? December, 1996Warning! Large tube side temperature change. A big difference between the inlet and outlet temperature of the tube side causes leakage and bypass problems. The worst case is a shell and tube exchanger with two (2) tube passes where a gasket is used to seal between the passes. A careful analysis should be made if the temperature

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difference across the pass plate is more than 300 oF. For a channel type that has a welded in pass plate, make an analysis if the temperature difference is more than 450 oF. If this temperature difference causes an over stressed condition, possible cures are:

Add a unit in series so each unit has a smaller temperature difference; Use one tube pass if the penalty isn't too great;For air coolers, use a split headers design.

Rotated Square Tube Pitch February, 1999Some heat exchanger specifications for shell and tube heat exchangers mention square pitch but do not specifically mention rotated square pitch. Engineers with little thermal design experience who are trying to strictly adhere to the specifications may reject this type of tube pitch. The benefits for this type of tube pitch sometimes get lost because of this. Rotated square pitch gives better mixing of the shell fluid and better heat transfer for the heavier fluids. Frequently the shell size can be reduced when there will be heavier liquids on the shell side and the designer uses rotated square pitch.

Longitudinal Baffle Heat Conduction CuresWith a longitudinal baffle and a long temperature range there can be a problem with heat conduction through thelongitudinal baffle. There will be a loss of thermal efficiency due to the heat conduction. The longitudinal baffle can be fabricated in one of two ways.1. Leaving an small enclosed air gap between two longitudinal baffles.2. Spray an insulating material like Ryton on the longitudinal baffle.

Design Temperatures of Carbon Steel and Low Alloy Tubes and TubesheetsUse the higher of the shell-side and tube-side design temperatures up to 650 F. At higher design temperatures use the arithmetic average of the 2 design temperatures.

Design Temperatures of Nonferrous Tubes and TubesheetsWater in the shell-side

Water in the tube-side

·       

·       

·       

     Use the arithmetic average of the shell-side and tube-side design temperatures.

    Use the higher of the tube-side design temperature or tube-side outlet temperature + 1/3 of the LMTD.

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Some heat exchanger specifications for shell and tube heat exchangers mention square pitch but do not specifically mention rotated square pitch. Engineers with little thermal design experience who are trying to strictly adhere to the specifications may reject this type of tube pitch. The benefits for this type of tube pitch sometimes get lost because

Frequently the shell size can be reduced when there will be heavier liquids on the shell side and the designer uses

The following are potential problems when considering the use of a longitudinal baffle in a new S & T heat exchanger:

is lost due to conduction across the long baffle. Check and make sure this has been taken into consideration;If the long baffle is not welded to the shell, the pressure drop across the long baffle is more than 7 to 8 psi. This will also lose thermal efficiency. The seal on the long baffle should be tested in the shop after fabrication.

If the flow inside the tubes of a heat exchanger is in laminar or viscous flow, take a look at enhancing the heat transfer. One simple and inexpensive device is the twisted-tape insert. Using twisted-tape inserts for laminar flow in new heat exchangers results in cost savings and smaller heat exchangers. Twisted-tape inserts can be used in existing heat exchangers to make a significant increase in capacity. The amount of increase in heat exchanged depends on whether the increase in pressure drop can be tolerated. If there is no pressure drop limitation, there can be as much as a 50%

There is more than one kind of triple segmental baffles in the shell side of heat exchangers. Be sure you know which kind if you are checking a design that uses them. There is the kind you see in TEMA where there are three different groups in a set. The total number of baffle pieces is six. There is the kind that is like producing two double segmental streams in parallel. There are two groups in a set and a total of five baffle pieces. Another kind has only three pieces

There have been cases where not enough space was under the shell nozzles. This can be critical for applications like a horizontal thermosyphon or other pressure drop sensitive applications. Check the distance from the nozzle I.D. to the nearest tube row or impingement plate. If there is an impingement plate this distance should be ¼ or more of the

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nozzle I.D. If there is no impingement plate this distance should be 1/6 or more of the nozzle I.D. If pressure drop is not a consideration and TEMA requirements are met and vibration is not a problem then the above calculated distance could be reduced. This criterion naturally doesn't apply to shells with distributor belts or where the nozzle is beyond

In shell and tube heat exchangers it is safer from a thermal design standpoint to use vertical baffle cuts but horizontal cuts have an advantage in certain situations. Horizontal cuts are best if the shell side stream is clean and single phase. There will be less of the shell side stream bypassing through the tube pass lanes. Since in a multi-tube pass exchanger there will be more horizontal tube pass lanes than vertical pass lanes, you need to flow perpendicular to these pass lanes for minimum by-passing of the shell stream. This means horizontal cut. Where you do not want to use horizontal cut is when there is either condensing or where there is the possibility of foreign material being in the flowing stream. It is suggested to use a maximum fouling factor of 0.002 for horizontal baffle cut. It may be possible to use horizontal

A fixed tube sheet exchanger does not have provision for expansion of the tubing when there is a difference in metal temperature between the shell and tubing. When this temperature difference reaches a certain point, an expansion joint in the shell is required to relieve the stress. It takes a much lower metal temperature difference when the tube

because the maximum allowable tube Compressive stress has been exceeded. According to the TEMA procedure for evaluating this stress, the compressive stress is a strong function of the unsupported tube span. This is normally

To increase heat transfer check out using low fins or other special tubing. When an increase in capacity will cause

modification of reducing the number of tube passes. Other possibilities are arranging multiple exchangers in parallel.

Proper venting of equipment is not always given the consideration it deserves. One place where venting is especially a problem is underneath the tubesheet of a vertical exchanger. The problem is that there will always be a space above the vent connection to trap gases or vapors. Besides the poor heat transfer in this region, this can cause corrosion problems. It is important to get the vent connection as close to the tubesheet as possible. Using multiple connections that are smaller is one solution. Another solution is to fabricate the upper tubesheet with a small vent tunnel inside.

There is an optimum diameter of the gasket for flanges. It is when the total Operating moment of the flange under pressure is equal to the gasket seating moment. For low-pressure flanges, the diameter should be as close to the bolt circle as possible. For high-pressure flanges, the diameter should be as close to the flange I.D. as possible. In this

F metal temperature difference when the tube side is the hottest.

F. Usually if an expansion joint is required, it is

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Use concrete reinforcing rods inserted inside the tubes to increase the heat transfer and tube velocity. It is a quick

3/4" x 14 BWG tube. The tube side heat transfer coefficient is increased by a factor of 1.7. However, you have to be able to stand the increase in pressure drop. It goes up by a factor of 9.5. Another example is a 1.0" x 16 BWG

There may be tube vibration or erosion if the shell-side fluid velocity is above a maximum value. These values can be

The most common impingement protection is a plate baffle that is slightly above the tube bundle. But this type of protection has some drawbacks. It has a relatively higher pressure drop than most other methods and the tubes on

A shell & tube heat exchanger with normal segmental baffles has tubes that miss every other baffle. This can lead to long unsupported tube lengths for some applications. A long tube span has a low natural frequency and is prone to vibration. One solution is to design a “no tubes in window” (NTIW) exchanger. This design has no tubes in the

Use a by-pass strip if tubes are removed under a nozzle. Removing tubes leaves an open area where the shell fluid

Consider by-pass strips if the bundle to shell clearance is more than 3/4 inches and the shell fluid is mostly sensible

centipoise and the tube fluid has a high heat transfer coefficient (example water). In this case, a 5 to 10% increase

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difference across the pass plate is more than 300 oF. For a channel type that has a welded in pass plate, make an analysis if the temperature difference is more than 450 oF. If this temperature difference causes an over stressed

Some heat exchanger specifications for shell and tube heat exchangers mention square pitch but do not specifically mention rotated square pitch. Engineers with little thermal design experience who are trying to strictly adhere to the specifications may reject this type of tube pitch. The benefits for this type of tube pitch sometimes get lost because

Frequently the shell size can be reduced when there will be heavier liquids on the shell side and the designer uses

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Choosing Fin Spacing June, 2002In waste heat applications, the fin spacing depends not only on the heat transfer but the cleanliness of the exhaust gas. If the gas is fouled from soot or other fine particulates, use a maximum of 5 fins per inch. For very dirty gases the fin spacing can be as low as 2 fins per inch. Usually there will be soot if fuels heavier than diesel fuel are fired. The designer needs to know the source of the waste heat gas so that he can make a decision on what fin spacing to use.

HRSG Nozzle Size April, 2002For an estimate of the nozzle size entering and leaving a HRSG unit use:

D = 4.43 inchesWhere:

D = diameter of nozzleFlow = Gas flow = 1,000 lbs/hr

This is based on a total of 0.8 inches of water

Face Area for HRSG Units April, 2001The starting point in the design of a heat-recovery steam generator (HRSG) is the face area. This will determine the preliminary duct dimensions and starting face areas of any economizers and superheaters.

Face area = (Flow / 2,500) = 0.40Where:Flow = Exhaust Gas flow = 1,000 lbs/hr

Where face area is in square feet.

Maximum Exhaust Gas Temperature for Steel Fin TubesHere is an approximation of the maximum exhaust temperature for steel fin tubes when generating steam. Otherwise, the fins would need to be the more expensive 409 SS material. This is based on the typical 2 inch O.D. tubing with 1 inch fins and 6 to 7 fins/inch.

MaxTg = 1,090 - 0.23 Btemp = 1,021

WhereMaxTg = maximum gas temperature

Btemp = water boiling temperature = 300

When to Use Bare Tubes in Waste Heat Boilers

0.14 x (flow)1/2 =

ft2

This is based on using 2 inch O.D. tubing with 1 inch high fins. The tubing is arranged on 4 1/8 inch triangular pitch.

oF

oF.

Use bare tubes if the bundle is quite small or the gas temperature is greater than 1,350 to 1,400 oF.

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In waste heat applications, the fin spacing depends not only on the heat transfer but the cleanliness of the exhaust gas. If the gas is fouled from soot or other fine particulates, use a maximum of 5 fins per inch. For very dirty gases the fin spacing can be as low as 2 fins per inch. Usually there will be soot if fuels heavier than diesel fuel are fired. The designer needs to know the source of the waste heat gas so that he can make a decision on what fin spacing to use.

The starting point in the design of a heat-recovery steam generator (HRSG) is the face area. This will determine

Otherwise, the fins would need to be the more expensive 409 SS material. This is based on the typical 2 inch O.D.

1/8 inch triangular pitch.

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Cooling Water Flowing Inside 304SS U-tubes June, 1999Normally it is OK to use 304SS when cooling water with low chloride content is flowing inside U-tubes. But if for some reason the operating pressure drops to saturation there can be corrosion problems. The tube vibration that results from the flashing of steam amplifies the stress that causes stress corrosion cracking.

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Normally it is OK to use 304SS when cooling water with low chloride content is flowing inside U-tubes. But if for some reason the operating pressure drops to saturation there can be corrosion problems. The tube vibration that

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Calculating Fouled Pressure Drop August, 1999There are various ways to account for fouling when calculating pressure drop.

One way would be to add a small amount to the tube diameter. This has a complex effect that is not linear in nature.

A simpler method is to add 10% for each 0.001 increase in fouling factor. Then multiply this factor by the clean pressure drop. You would use a pressure drop factor of 1.2 for a fouling factor of 0.002.

Allowable Pressure Drop Suggestions March, 2002If you are at a loss as to what allowable pressure drop to specify, here are some suggestions:

Fluid and Condition Allowable Pressure Drop, psiGas 3 to 5 Liquid 8 to 10Change of phase

Boiling: 0.5 to 1.0 psi for greater than 10 % vapor1.0 to 5.0 psi for less than 10 % vapor

Condensing operating pressureLess than atmospheric 0.5Atmospheric to 25 psi 125 to 50 psi 250 to 150 psi 3150 psi + 3.0 to 5.0

Allowable Shell Side Pressure Drop if a Multi-leaf (a.k.a. Lamaflex) Long Baffle is UsedFour thin (0.008”) stainless strips are normally used to seal the sides of the long baffle. Because of their flexibility, they are not able to withstand large shell side pressure drops. It is best to limit the pressure drop to 5 psi with 7.5 psi being the maximum.

Better Baffle Window Pressure Drop EquationA new baffle window pressure drop equation has been published in the June 2004 issue of Hydrocarbon Processing. The name of the article is “More Accurate Exchanger Shell-Side Pressure Drop Calculations”. The article can be found on this page with the subject “Heat Exchanger Articles Published by Dale Gulley”. The equation improves the accuracy of the shell side pressure drop. Refer to the article for more detail. The equation has the following form:

fi = Friction factor for ideal tube bundle

For 30 deg. Triangular, 2.2;For 90 deg. Square, 3.64;For 45 deg. sq. rotated, 2.29;For 60 deg. Triangular, 1.79 estimated.

KP = Pressure loss coefficient for velocity head equation

C1 = Constant based on the type of tube layout

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D = Distortion factor for ideal fluid stream. It varies with baffle cut. Refer article elsewhere on this site for equation. (Baffle cuts from 24% to 29% (fractional) have a distortion factor of 1.0)

EXAMPLE:This is taken from the first experimental case in “A Reappraisal of Shellside Flow in Heat Exchangers HTD-Vol. 36”. Average flow of 990,000 lb/hr with a density of 62.4 lb/ft3 is flowing through a 13.25 ID nozzle. The shell ID is 23.25 in. and the OTL is 22.375 in. The tube OD is 0.75 in. on a tube pitch of 0.9375 in. with 30 degree layout. There are 7 baffles and 26% baffle cut.

The following are taken from a tip in this section named “Improve Shell Side Pressure Drop Calculations”

fi = 0.1025Ncw = 5.96Sl = 11.0Sw = 44.47C1 for a 30 degree layout is 2.2D = 1 since the fractional baffle cut is 26%

Kp = 1.33

Gw = (990000 x 0.04)/44.47 = 890.5 (#/sqft-sec)

ΔPw = 12.78

Designing Better Use of Tube Pressure Drop October, 1999When the calculated pressure drop inside the tubes is under-utilized, the estimated pressure drop with increased number of tube passes is:

12.0 psiWhere

Previous Pressure drop 1.5 psiNPASS = New number of tube passes = 4OPASS = Old number of tube passes = 2

This would be a good estimate if advantage is not taken of the increase in heat transfer. Since the increased number of tube passes gives a higher velocity and increases the calculated heat transfer coefficient, the number of tubes to be used will decrease. The use of fewer tubes increases the new pressure drop. For a better estimate of the new pressure drop, add 25% if the heat transfer is all sensible heat.

Ncw = Effective number of tube rows crossed in baffle window

Sl = Total of leakage areas (in2)

Sw = Net flow area in baffle window (in2)

Kp = 0.1025 ( (2.2 x5.96) -2(11/44.47)2) )

ΔPw = Kp x 0.000108 x Gw2/ρ

ΔPw = 1.33 x 0.000108 x (890.5)2 x 7/62.4

New tube DP = DP x (NPASS/OPASS)3 =

DP =

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Usually when shell-and-tube heat exchangers are designed, the tube layout is made so that the shell entrance area is approximately equal to the shell nozzle flow area. The average distance to the 1st tube row is Dn/4 where Dn is the inside diameter of the shell nozzle. In this case the pressure loss coefficient is 1.0 for the pressure drop calculation for the shell nozzle entrance.

If the shell nozzles are greater than 2” and some tubes are not omitted from the tube layout, the nozzle entrance pressure drop can be significantly higher than the normal calculation based on the nozzle flow area. In a case of a 6” shell nozzle and where no tubes were omitted in a BEM type heat exchanger, the pressure drop was 3 times higher than that calculated with just the nozzle flow area. For more information, you can refer to the tip “Calculate Shell Nozzle Pressure Drop” in this Workbook.

Kettle Pressure Drop April, 1999Usually you will see the allowable pressure drop on the specification sheet for the shell side of a kettle reboiler to be stated as “nil”. This is close to being true only for the bundle. The inlet and outlet kettle nozzles will have a definite pressure drop. It is best to locate the inlet nozzle on the side of the kettle and above the bundle. This keeps the pressure drop down because there are no tubes in the vicinity to provide a restriction.

Fixed Tube Sheet Exchanger and High Shell Side Pressure Drop July, 2000When there is a design problem meeting the allowable shell side pressure drop, reverse the stream sides. Since it is a fixed tube sheet exchanger, the unit can be designed with one (1) tube pass. Other types of heat exchangers can be designed with a single tube pass but they can have more operating problems. The pressure drop can be further reduced by using axial nozzles that are on the exchanger centerline. This eliminates large turning pressure drop losses.

Impingement Rods January, 1997When shell pressure drop is critical and impingement protection is required, use rods or tube protectors in top rows instead of a plate. These create less pressure drop and better distribution than an impingement plate. An impingement plate causes an abrupt 90 degree turn of the shell stream which causes extra pressure drop.

Specifying Pressure Drop for Heavy Liquids Inside TubesFrequently process engineers specify 5 or 10 psi for allowable pressure drop inside heat exchanger tubing. For heavy liquids that have fouling characteristics, this is usually not enough. There are cases where the fouling excludes using turbulators and using more than the customary tube pressure drop is cost effective. This is especially true if there is a relatively higher heat transfer coefficient on the outside of the tubing. The following example illustrates how allowable pressure drop can have a big effect on the surface calculation. A propane chiller was cooling a gas treating liquid that had an average viscosity of 7.5 cP. The effect on the calculated surface was as follows:

5 4,01225 2,10450 1,419

You can see that using 25 psi pressure drop reduced the surface by nearly one-half. This would result in a price reduction for the heat exchanger of approximately 40%. This savings offset the cost of the pumping power.

Effect of 1st Tube Rows on Shell Nozzle Pressure Drop

Allowable tube pressure drop, psi

Exchanger surface ft2

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Maximum Velocity Inside TubesAn estimate for maximum tube velocity inside steel tubes

80 / sqrt(density) = 10.2 ft/secWhere

maximum fluid velocityDensity = fluid density = 62.00 lb/cu ft.

Calculate Shell Nozzle Pressure DropShell nozzle pressure drop calculation methods are difficult to find in the open literature. The nozzle pressure drops are difficult to predict accurately. There is a complex flow pattern of a tube matrix, bundle bypassing, and recirculation. Because of this, it is possible to have pressure loss coefficients greater than the customary 1.5 velocity heads for sharp edge expansion/contraction edges.

If the bundle entrance area is equal to or greater than the inlet nozzle flow area, use a pressure loss coefficient of 1.0. If the bundle exit area is equal to or greater than the exit nozzle area, us a pressure loss coefficient of 0.58. There are indications that it should be larger. The following procedure is for the situation where the nozzle flow area is greater than the entrance or exit area and the bundles do not have an impingement plate. If there is an impingement plate, there will have to be added a turning loss to the calculation below. If the two shell side nozzles are not the same size, calculate the inlet pressure drop and take 2/3 of it and make a separate calculated pressure drop for the outlet and take 1/3 of it.

Shell Entrance or Exit Area:1. Calculate the bundle bypass area Sb = π x Dn x h

3. Calculate the shell entrance and exit area.(As)As = Sb + Aslot(refer TEMA RGP-RCB-4.621 & 4.622)4. Calculate ratio of Sb to total area FR = Sb/As5. Kn = 0.65 +2.14 (FR -0.4)(minimum Kn = 0.8, maximum = 1.8)

(ΔPn = total of both nozzles)where

Dn = Nozzle ID in.Ds = Shell ID in.Dt = Tube outside diameter in.F2 = 0.707 for 45 degree pitch, all others use 1.0h = 0.5(Ds-OTL) in.Kn = Pressure loss coefficientOTL= Outer tube limit diameter in.Pt = Tube center to center pitch in.Vs = velocity in the entrance/exit area (ft/sec)

Vmax =

Vmax =

2. Calculate the slot area Aslot = 0.7854Dn2 (Pt -Dt)/(F2 x Pt)

6. ΔPn = Kn x .000108Vs2 x density

ΔPn = Total nozzle pressure drop (lb/ft2)

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EXAMPLE

the OTL is 22.375 in. The tube OD is 0.75 in. on a tube pitch of 0.9375 in. with 30 degree layout.

Calculate Sbh = 0.50(23.25-22.375)= 0.4375Sb = π x 13.25 x 0.4375 = 18.23

Calculate Aslot

Calculate total area AsAs = Sb + Aslot = 18.23 + 27.58 = 45.81

Calculate FRFR = 18.23/45.81 = 0.4

Calculate KnKn = 0.65 +2.14(0.4 -0.4) = 0.65 (use minimum 0.8)

Calculate nozzle pressure dropVs = (990000 x 0.04)/(45.81 x 62.4)= 13.85

Comment - Using 1.5 total pressure loss coefficient and the nozzle flow area gives only 0.21 PSI

Improve Shell Side Pressure Drop CalculationsThe shell side pressure drop calculation can be improved by better equations for the baffle window and the nozzle pressure drops. Both of these methods can be found elsewhere on this web page.

The baffle window pressure drop in the open literature is a function only of the number of tubes crossed and the velocity in the window. It does not take into account a friction factor, type of tube pattern or fluid eddies.

When there are no tubes removed under the shell nozzles and the nozzles are large, using the nozzle flow area can result in wrong pressure drop calculations.

This is taken from the first experimental case in “A Reappraisal of Shell side Flow in Heat Exchangers HTD-Vol. 36”.

23.25 in. and the OTL is 22.375 in. The effective tube length is 11.729 ft. The tube OD is 0.75 in. on a tube pitch of 0.9375 in. with 30 degree layout. There are 7 baffles and 26% baffle cut

From the following the cross flow pressure drop is calculated:

Bs = 17.6 infi = 0.1025 - Ideal tube bank correlation ( J. Taborek)

990,000 lb/hr with a density of 62.4 lb/ft3 is flowing through a 13.25 in. ID nozzle. The shell ID is 23.25 in. and

Aslot = 0.7854(13.252) (0.9375-0.75)/(1.00 x .9375)= 27.58

ΔPn = 0.8 x 0.000108 x 13.852 x 62.4 = 1.03 psi

Average flow of 990,000 lb/hr with a density of 62.4 lb/ft3 is flowing through a 13.25 ID nozzle. The shell ID is

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Nc = 13.75Rb = 0.536Re = 40,249Rl = 0.615

ΔPc = 6.41 psi

ΔPshell = ΔPc + ΔPw + ΔPnFrom other tips: ΔPw = 12.78ΔPn = 1.03ΔPshell = 6.41 +12.78 +1.03 = 20.2 psiExperimental = 20.3 psi

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One way would be to add a small amount to the tube diameter. This has a complex effect that is not linear in nature.

A simpler method is to add 10% for each 0.001 increase in fouling factor. Then multiply this factor by the clean

Four thin (0.008”) stainless strips are normally used to seal the sides of the long baffle. Because of their flexibility,

A new baffle window pressure drop equation has been published in the June 2004 issue of Hydrocarbon Processing. The name of the article is “More Accurate Exchanger Shell-Side Pressure Drop Calculations”. The article can be found on this page with the subject “Heat Exchanger Articles Published by Dale Gulley”. The equation improves the accuracy of the shell side pressure drop. Refer to the article for more detail. The equation has the following form:

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Distortion factor for ideal fluid stream. It varies with baffle cut. Refer article elsewhere on this site for

This is taken from the first experimental case in “A Reappraisal of Shellside Flow in Heat Exchangers HTD-Vol. 36”. Average flow of 990,000 lb/hr with a density of 62.4 lb/ft3 is flowing through a 13.25 ID nozzle. The shell ID is 23.25 in. and the OTL is 22.375 in. The tube OD is 0.75 in. on a tube pitch of 0.9375 in. with 30 degree layout.

This would be a good estimate if advantage is not taken of the increase in heat transfer. Since the increased number of tube passes gives a higher velocity and increases the calculated heat transfer coefficient, the number of tubes to be used will decrease. The use of fewer tubes increases the new pressure drop. For a better estimate of the new

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Usually when shell-and-tube heat exchangers are designed, the tube layout is made so that the shell entrance area is approximately equal to the shell nozzle flow area. The average distance to the 1st tube row is Dn/4 where Dn is the inside diameter of the shell nozzle. In this case the pressure loss coefficient is 1.0 for the pressure drop calculation

pressure drop can be significantly higher than the normal calculation based on the nozzle flow area. In a case of a

higher than that calculated with just the nozzle flow area. For more information, you can refer to the tip “Calculate

Usually you will see the allowable pressure drop on the specification sheet for the shell side of a kettle reboiler to

When there is a design problem meeting the allowable shell side pressure drop, reverse the stream sides. Since it is a fixed tube sheet exchanger, the unit can be designed with one (1) tube pass. Other types of heat exchangers can be designed with a single tube pass but they can have more operating problems. The pressure drop can be further reduced by using axial nozzles that are on the exchanger centerline. This eliminates large turning pressure drop losses.

Frequently process engineers specify 5 or 10 psi for allowable pressure drop inside heat exchanger tubing. For heavy liquids that have fouling characteristics, this is usually not enough. There are cases where the fouling excludes using turbulators and using more than the customary tube pressure drop is cost effective. This is especially true if there is a relatively higher heat transfer coefficient on the outside of the tubing. The following example illustrates how allowable pressure drop can have a big effect on the surface calculation. A propane chiller was cooling a gas treating liquid

You can see that using 25 psi pressure drop reduced the surface by nearly one-half. This would result in a price

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Shell nozzle pressure drop calculation methods are difficult to find in the open literature. The nozzle pressure drops are difficult to predict accurately. There is a complex flow pattern of a tube matrix, bundle bypassing, and recirculation. Because of this, it is possible to have pressure loss coefficients greater than the customary 1.5 velocity heads for

If the bundle entrance area is equal to or greater than the inlet nozzle flow area, use a pressure loss coefficient of 1.0. If the bundle exit area is equal to or greater than the exit nozzle area, us a pressure loss coefficient of 0.58. There are indications that it should be larger. The following procedure is for the situation where the nozzle flow area is greater than the entrance or exit area and the bundles do not have an impingement plate. If there is an impingement plate, there will have to be added a turning loss to the calculation below. If the two shell side nozzles are not the same size, calculate the inlet pressure drop and take 2/3 of it and make a separate calculated pressure drop for the outlet and

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The shell side pressure drop calculation can be improved by better equations for the baffle window and the nozzle

The baffle window pressure drop in the open literature is a function only of the number of tubes crossed and the

When there are no tubes removed under the shell nozzles and the nozzles are large, using the nozzle flow area can

This is taken from the first experimental case in “A Reappraisal of Shell side Flow in Heat Exchangers HTD-Vol. 36”.

23.25 in. and the OTL is 22.375 in. The effective tube length is 11.729 ft. The tube OD is 0.75 in. on a tube pitch

is flowing through a 13.25 in. ID nozzle. The shell ID is 23.25 in. and

is flowing through a 13.25 ID nozzle. The shell ID is

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Features of a New S & T bundle to Replace Bundle That Vibrated1. If possible, design for lower cross flow velocity with special baffles.2. Make sure that impingement plate is very secure.3. Use a tube/baffle clearance of 1/64.4. Use thicker baffles.5. Use closer baffle/shell clearance.6. Use thicker tubes.7. If tubes are low fins, have the tubing bare where it goes through the baffles.

Vibration Cure When Designing Shell & Tube Bundles May, 2000The cure depends upon whether it is flow induced or acoustical type vibration. Both types can be cured by using a lower cross flow velocity across the bundle. To do this, use double or triple segmental baffles. This not only lowers the velocity but the closer resulting baffle spacing increases the natural frequency of the bundle. Another possibility is to use a “No Tubes in Baffle Window” design. Then you can use as many baffle supports as necessary with very little effect on shell pressure drop.

If the vibration is the acoustical type, use either 30 degree triangular pitch or square rotated pitch. The former is the best. Another cure is to use a de-resonating baffle. In a few cases, putting the problem stream inside the tubes would be better.

Conditions Likely to Cause Shell & Tube Bundle Vibration May, 1997Bundle vibration can cause leaks due to tubes being cut at the baffle holes or tubes being loosened at the tubesheet joint. There are services that are more likely to cause bundle vibration than others are. The most likely service to cause vibration is a single-phase gas operating at a pressure of 100 to 300 PSI. This is especially true if the baffle spacing is greater than 18 inches and single segmental type. Another service that sometimes causes bundle vibration is water in the shell side. Water has a relatively higher momentum than other most fluids. Therefore, if extra precautions on bundle design are not taken, a vibration problem can develop later when the exchanger goes into operation.

Cures for Vibration in Existing Bundle September, 1997Most flow-induced vibration occurs with the tubes that pass through the baffle window of the inlet zone. The unsupported lengths in the end zones are normally longer than those in the rest of the bundle. For 3/4 inch tubes, the unsupported length can be 4 to 5 feet. The cure for removable bundles, where the vibration is not severe, is to stiffen the bundle. This can be done by inserting metal slats or rods between the tubes under the nozzles. Normally this only needs to be done with the first few tube rows. Another solution is to add a shell nozzle opposite the inlet so as to cut the inlet fluid velocity in half. For non-removable bundles, this is the best solution. Adding a distributor belt on the shell would be a very good solution but it is expensive.

If a U-tube bundle has a vibration problem in the bend area, metal slates or rods can be inserted between the tubes. If a slight decrease in heat transfer is not a problem, encircle the U-bends with a band or heavy wire and squeeze the tubes together.

Best Design Feature to Prevent Bundle VibrationIn designing a shell-and-tube heat exchanger, use a 30o triangular tube pitch if possible. This will lower the vortex shedding frequency which is a direct function of something called a Strouhal number. The Strouhal number is a constant composed of the vortex shedding frequency, shell side velocity and tube OD.

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The 30° triangular tube pitch has a significantly lower Strouhal number than other tube pitch types. Using Barrington as a source, for 3/4 inch tubes on 30o triangular tube pitch the Strouhal number is 0.21. But for 60o rotated triangular tube pitch the Strouhal number is 0.81.

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The cure depends upon whether it is flow induced or acoustical type vibration. Both types can be cured by using

lowers the velocity but the closer resulting baffle spacing increases the natural frequency of the bundle. Another possibility is to use a “No Tubes in Baffle Window” design. Then you can use as many baffle supports as necessary

If the vibration is the acoustical type, use either 30 degree triangular pitch or square rotated pitch. The former is the best. Another cure is to use a de-resonating baffle. In a few cases, putting the problem stream inside the tubes would be better.

Bundle vibration can cause leaks due to tubes being cut at the baffle holes or tubes being loosened at the tubesheet joint. There are services that are more likely to cause bundle vibration than others are. The most likely service to cause vibration is a single-phase gas operating at a pressure of 100 to 300 PSI. This is especially true if the baffle spacing is greater than 18 inches and single segmental type. Another service that sometimes causes bundle vibration is water in the shell side. Water has a relatively higher momentum than other most fluids. Therefore, if extra precautions on

unsupported lengths in the end zones are normally longer than those in the rest of the bundle. For 3/4 inch tubes, the unsupported length can be 4 to 5 feet. The cure for removable bundles, where the vibration is not severe, is to stiffen the bundle. This can be done by inserting metal slats or rods between the tubes under the nozzles. Normally this only needs to be done with the first few tube rows. Another solution is to add a shell nozzle opposite the inlet so as to cut the inlet fluid velocity in half. For non-removable bundles, this is the best solution. Adding a distributor belt

If a U-tube bundle has a vibration problem in the bend area, metal slates or rods can be inserted between the tubes. If a slight decrease in heat transfer is not a problem, encircle the U-bends with a band or heavy wire and squeeze

In designing a shell-and-tube heat exchanger, use a 30o triangular tube pitch if possible. This will lower the vortex shedding frequency which is a direct function of something called a Strouhal number. The Strouhal number is a constant composed

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The 30° triangular tube pitch has a significantly lower Strouhal number than other tube pitch types. Using Barrington as a source, for 3/4 inch tubes on 30o triangular tube pitch the Strouhal number is 0.21. But for 60o rotated triangular tube pitch the

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Allocation of Streams in Shell & Tube May, 1998For those exchangers that need countercurrent flow, the stream with the highest pressure drop is usually best put in the tube side. This is true unless the design pressure is so high for the shell side that there would be material problems. High pressure drop instead of high design pressure is opposite of conventional thinking. If there are gas streams on both sides with mol. weights about the same and a small temperature difference, put the stream in the tubes with the highest value of the following:

(#//hr)(#/hr)/op. pressure

Otherwise, calculate the little more difficult term Vel x Vel x Density term for each side and put the stream with the highest value in the tubes.

Heat Exchanger Articles Published by Dale Gulley

Copies of the articles are available in .pdf format

Avoid These Fluids When Using Low fin TubingWhen a fluid has a high surface tension, the fluid doesn't readily flow from the gap between the tube fins. This adds resistance and lowers the heat transfer. The types of fluids that are to be avoided are those whose surface tension is above 30 to 40 dynes/cm. This includes such fluids as condensing steam, aqueous solutions with a high % of water, amines and glycols.

Use Superficial velocities to Calculate Best Heat Transfer Flow PatternThe best heat transfer occurs when there is an annular flow pattern. Then there is a relatively thin liquid film and little vapor in contact with the heat transfer surface. How do you tell if the flow is annular? It will be when the superficial gas velocity is above the following value:

VgMax = 1,832.0where

VL = the superficial liquid velocity = 5.0 ft/sec.

Check Liquid Thermal Conductivity at High Reduced Temperatures November, 2000There have been instances where process simulators have given results where the liquid thermal conductivity was nearly the same as the vapor thermal conductivity when the reduced temperature was still significantly lower than the critical temperature. Examine carefully the liquid thermal conductivity when its reduced temperature is above approximately 0.70. You may be able to justify a higher conductivity value and thus a higher heat transfer coefficient by using an independent and reliable correlation for the calculation.

1.  "More Accurate Exchanger Shell-and-Tube Pressure Drop Calculations", Hydrocarbon Processing, June 20042.  "Troubleshooting Shell-and-Tube Heat Exchangers", Hydrocarbon Processing, September 19963.  "Computers help Design Tubesheets", The Oil & Gas Journal, May 20,19744.  "Computer Programs aid Design Work", The Oil & Gas Journal, Jan. 13,19695.  "How to Calculate Weighted MTD's", Petroleum Refiner, July 19666.  "How to Figure True Temperature Difference in Shell-and-Tube Exchangers", The Oil & Gas Journal, Sept. 14,     19647.  "Make This Correction Factor Chart to Find Divided Flow Exchanger MTD", Petro/Chem Engineer, July 19628.  "Use Computers to Select Exchangers", Petroleum Refiner, July 1960

72 -148VL +100 VL2 =

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Check Piping Connections When There is Under-performance July, 2002When a heat exchanger is installed and it is not achieving the desired heat duty, the first thing to check is the piping. Is the piping connected to the correct sides? It may be piped-up backwards. The worst case is when the shell side has a viscosity more than approximately 3 cP and there is no extra heat transfer enhancement inside the tubing. This could cause the fluid, when piped to the tube side, to be in laminar flow with its low heat transfer coefficient.

Evaluating a Shell & Tube Exchanger For a New Service September, 2000The best information to have for a shell and tube heat exchanger is a specification sheet and a full set of drawings. If both are not available, it is better to have the drawings. This is because they are more accurate on the mechanical details and they have tube layout details and seal bar information that the specification sheet does not have. What are most often missing on older heat exchangers are the bundle drawings. In this case, you need the original specification sheet. Then you can use its data and simulate the shell side heat transfer and pressure drop by running a thermal design Program to get a baffle configuration. Then this is used with the new process data to evaluate the new service. This procedure will not be as accurate as having the exact baffling but it is the best you can do if this is all you have to work with.

Check Heat Release Curves for Skipping Over Dewpoints & Bubblepoints January, 1998Frequently process engineers specify tabular heat release data that skips over dew points and bubble points. If equal increments of heat load or temperatures are used, chances are that the dew points and bubble points will be missed. It is important that the heat content at dew points or bubble points be shown.

When Will Exchangers With Low-fins be More Economical Than Exchangers With Bare Tubes?1. If the shell size is a least 2 sizes smaller (pipe size).2. If the shell size is at least 14" O.D.3. If there are fewer exchangers. when using low-fins4. When (total shell resistance/total tube resistance) is greater than 0.4

Excess Heat Exchanger Surface Problems September, 2002Excess surface does not always mean being safe. It can lead to control problems, pulsations, or freezing of condensate. Vaporization services and reboilers can particularly be a problem. Provide a way to control the flow of the heat medium in a new plant. In an existing installation without control, the boiling temperature difference may be so high that there is complete flashing of the liquid into vapor. Then the liquid feed rushes in to replace it which results in pulsations that may give downstream problems. The quickest solution is to either plug the tubes or put an orifice in the outlet vapor line to restrict the flow.

Purchasing Shell & Tube Exchangers March, 2001It is to the benefit of purchasers of shell and tube heat exchangers to not insist on applying their design. If the heat exchanger is to be built to TEMA requirements, it will void the guarantee. The last line of paragraph G5.2 says, “The thermal guarantee shall not be applicable to exchangers where the thermal performance was made by the purchaser”.

Minimum Velocity inside Tubing for SlurriesThe minimum velocity for slurries inside tubes for shell-and-tube is 4 ft/sec. This is for a fine material like a catalyst.

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For slurries there is a special Reynolds number used for calculating the settling velocity. For more information on slurries, refer to chapter C11 in the piping handbook.

Suggestions for Low-Fins and Potential S & T Bundle Vibration May, 2002Tube bundles are more likely to vibrate if there is not a close clearance between the tubes and baffles. Low-fins are more susceptible to vibration because of the valleys between the fins. Another factor that makes them susceptible is that some low-fins are manufactured with the fin O.D. smaller than the bare ends. Some suggestions if the design software shows that the bundle may vibrate are:

Shell & Tube or Multi-Tube? June, 1997It is best to use Multi-tube (Hairpin) Exchangers instead of Shell & Tube when:

1. You require a small surface (less than 400 square feet);2. There is a temperature cross in the heat transferred in a Shell & Tube;3. The liquid flows are less than 150,000 lbs/hr;4. Natural gas flows less than 1,200 X Sq. root(oper. pressure)

Thermal Evaluation of Long Baffles August, 1997The two thermal design problems associated with using two shell passes and a longitudinal baffle in Shell and Tube heat exchangers are:

1 Heat conduction through the baffle. There is a calculation method by Whistler. It is a correction applied to the LMTD.

2 Fluid by-pass around the long baffle. If possible, use an exchanger type where the long baffle is seal welded to the shell in order to avoid bypassing of the shell fluid. This should be done with a full penetration weld. The exchanger types, where the long baffles can be welded in, are Fixed Tube Sheets or U-Tubes. If U-tubes, the number of tube passes must be a multiple of four. Then the bundles can be removed. Other designs use multi-leaf long baffles for two shell passes. Since these cannot make a perfect seal, the amount of shell fluid bypassing the bundle must be calculated.

Trouble-Shooting Article October, 1996To find out more about heat exchangers, see Dale Gulley's article in the 1996 September issue of Hydrocarbon Processing. The title is “Troubleshooting Shell-and-Tube Heat Exchangers”. It gives helpful information on diagnosing problems.

Undersurfaced S&T QuoteWhen a vendor’s heat exchanger quote is under-surfaced, the following should be asked:

1.      Specify the low-fin tubing be bare where it passes through baffling.2.      Specify a tight tube hole tolerance.3.      Purchase tubing that has a fin O.D. the same as the bare ends.

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1. Are there seal strips? If so, how many?2. What tube hole clearance was used in the baffles

When to Add Shells in Series August, 2000Usually you should design for the least number of shells for an item. However, there are times when it is more economical to add a shell in series to the minimum configuration. This will be when there is a relatively low flow in the shell side and the shell stream has the lowest heat transfer coefficient. This happens when the baffle spacing is close to the minimum. The minimum for TEMA is (Shell I.D./5). Then adding a shell in series gives a higher velocity and a much better heat transfer because of the smaller flow area in the smaller required exchangers.

When to Consider a Long Baffle in the Shell October, 2001The cost curve for a shell and tube heat exchanger decreases with increasing surface. The curve flattens at about 6,000 square feet of bare surface. If the first selection has multiple shells that are not countercurrent flow and each shell has less than 6,000 square feet, consider using a long baffle for cost savings. This is especially true if the exchanger is of a type where the long baffle can be welded to the shell (less likely to bypass fluid).

Which Stream Goes Inside Tubes for Gas/Gas Exchangers?In a counter-current flow heat exchanger, the steam with the highest factor as calculated below goes inside the tubes:

You can also use the following factor if both gases’ molecular weight and temperature are about the same on both sides:

Why Did the Performance Decline in a TEMA F, G, or H Type Shell?Has performance declined after the bundle has been pulled and later installed back in the shell? If the longitudinal long baffle is sealed on the sides with leaf seals, they are probably the problem. These thin flexible strips should be positioned so that they form a concave pattern and flex upward. Then, when the shell fluid puts pressure on the leaves, they will press harder against the sides of the shell. If there is too much pressure - or if the bundle is installed upside down - the leaves will flex downward, and the shell fluid will bypass the bundle. Another possibility is that the leaf seals were damaged when the bundle was out of the shell.

Fouling factors for water(hr-ft2-F/Btu)

For cooling water when velocity is 3 -8 ft/sec

Fouling Factors for Liquid Hydrocarbons(hr-ft2-F/Btu)

Factor = (flow)2 / density

Factor = (flow)2 / pressure

0.0005  steam,steam condensate,engine jacket water0.0010  boiler feed water0.0015  clean water,moutain water,etc.0.0020  normal cooling tower water

Fouling = 0.025/V1.67

    Where V =ft/sec

0.0010  If sp. gravity At 60F less than 0.80, lube oil and heating oils

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Viscous Flow - Use More Pressure Drop Than Usual High viscosity fluids can have a problem achieving the design heat transfer. The fluids are usually petroleum based and have an API of 20 or less.

Low pressure drops can cause maldistribution of the tubeside flow which in turn reduces the heat transfer. That is why you can see allowable pressure drops 2 or 3 times higher than usual. There is a method by A.C. Mueller for calculating this minimum allowable pressure drop. Another thing that can help is to use more tube passes and shorter tubes than normal. Also the fluid could be placed in the shell side if cleanig isn't a problem.

0.0020  If sp. gravity At 60F  0.80 -0.870.0030  If sp. gravity At 60F  0.87 -1.000.0050  Heavy fuel oils

Page 79: Process Heat Transfer Hof Master

For those exchangers that need countercurrent flow, the stream with the highest pressure drop is usually best put in the tube side. This is true unless the design pressure is so high for the shell side that there would be material problems. High pressure drop instead of high design pressure is opposite of conventional thinking. If there are gas streams on both sides with mol. weights about the same and a small temperature difference, put the stream in the tubes with the

Otherwise, calculate the little more difficult term Vel x Vel x Density term for each side and put the stream with the

When a fluid has a high surface tension, the fluid doesn't readily flow from the gap between the tube fins. This adds resistance and lowers the heat transfer. The types of fluids that are to be avoided are those whose surface tension is above 30 to 40 dynes/cm. This includes such fluids as condensing steam, aqueous solutions with a high % of water,

The best heat transfer occurs when there is an annular flow pattern. Then there is a relatively thin liquid film and little vapor in contact with the heat transfer surface. How do you tell if the flow is annular? It will be when the superficial

There have been instances where process simulators have given results where the liquid thermal conductivity was nearly the same as the vapor thermal conductivity when the reduced temperature was still significantly lower than the

approximately 0.70. You may be able to justify a higher conductivity value and thus a higher heat transfer coefficient

1.  "More Accurate Exchanger Shell-and-Tube Pressure Drop Calculations", Hydrocarbon Processing, June 2004

6.  "How to Figure True Temperature Difference in Shell-and-Tube Exchangers", The Oil & Gas Journal, Sept. 14,

7.  "Make This Correction Factor Chart to Find Divided Flow Exchanger MTD", Petro/Chem Engineer, July 1962

Page 80: Process Heat Transfer Hof Master

When a heat exchanger is installed and it is not achieving the desired heat duty, the first thing to check is the piping. Is the piping connected to the correct sides? It may be piped-up backwards. The worst case is when the shell side has a viscosity more than approximately 3 cP and there is no extra heat transfer enhancement inside the tubing. This

The best information to have for a shell and tube heat exchanger is a specification sheet and a full set of drawings. If both are not available, it is better to have the drawings. This is because they are more accurate on the mechanical details and they have tube layout details and seal bar information that the specification sheet does not have. What are most often missing on older heat exchangers are the bundle drawings. In this case, you need the original specification sheet. Then you can use its data and simulate the shell side heat transfer and pressure drop by running a thermal design Program to get a baffle configuration. Then this is used with the new process data to evaluate the new service. This procedure will not be as accurate as having the exact baffling but it is the best you can do if this is all you have

January, 1998Frequently process engineers specify tabular heat release data that skips over dew points and bubble points. If equal increments of heat load or temperatures are used, chances are that the dew points and bubble points will be missed.

Excess surface does not always mean being safe. It can lead to control problems, pulsations, or freezing of condensate.

medium in a new plant. In an existing installation without control, the boiling temperature difference may be so high that there is complete flashing of the liquid into vapor. Then the liquid feed rushes in to replace it which results in pulsations that may give downstream problems. The quickest solution is to either plug the tubes or put an orifice in

It is to the benefit of purchasers of shell and tube heat exchangers to not insist on applying their design. If the heat exchanger is to be built to TEMA requirements, it will void the guarantee. The last line of paragraph G5.2 says, “The thermal guarantee shall not be applicable to exchangers where the thermal performance was made by the purchaser”.

The minimum velocity for slurries inside tubes for shell-and-tube is 4 ft/sec. This is for a fine material like a catalyst.

Page 81: Process Heat Transfer Hof Master

For slurries there is a special Reynolds number used for calculating the settling velocity. For more information on

Tube bundles are more likely to vibrate if there is not a close clearance between the tubes and baffles. Low-fins are more susceptible to vibration because of the valleys between the fins. Another factor that makes them susceptible is that some low-fins are manufactured with the fin O.D. smaller than the bare ends. Some suggestions if the design

The two thermal design problems associated with using two shell passes and a longitudinal baffle in Shell and Tube

Page 82: Process Heat Transfer Hof Master

economical to add a shell in series to the minimum configuration. This will be when there is a relatively low flow in the shell side and the shell stream has the lowest heat transfer coefficient. This happens when the baffle spacing is

The cost curve for a shell and tube heat exchanger decreases with increasing surface. The curve flattens at about

each shell has less than 6,000 square feet, consider using a long baffle for cost savings. This is especially true if

In a counter-current flow heat exchanger, the steam with the highest factor as calculated below goes inside the tubes:

You can also use the following factor if both gases’ molecular weight and temperature are about the same on both sides:

Has performance declined after the bundle has been pulled and later installed back in the shell? If the longitudinal long baffle is sealed on the sides with leaf seals, they are probably the problem. These thin flexible strips should be

leaves, they will press harder against the sides of the shell. If there is too much pressure - or if the bundle is installed upside down - the leaves will flex downward, and the shell fluid will bypass the bundle. Another possibility is that

Page 83: Process Heat Transfer Hof Master

High viscosity fluids can have a problem achieving the design heat transfer. The fluids are usually petroleum based

That is why you can see allowable pressure drops 2 or 3 times higher than usual. There is a method by A.C. Mueller for calculating this minimum allowable pressure drop. Another thing that can help is to use more tube passes and shorter

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Art Montemayor September 30, 2005Rev: 0

Page 96 of 140FileName: document.xls

WorkSheet: TEMA Designations

TEMA DESIGNATIONS

Front End Stationary Head Shell Type Rear End Stationary Head

A Channel and removable cover E One-pass shell L Fixed tubesheet; like "A" Stationary head.

B Bonnet (Integral Cover) F 2-pass shell with longitudinal M Fixed tubesheet; like "B"baffle stationary head.

C Channel integral with tubesheet G Split Flow Shell N Fixed tubesheet; like "C" & removable cover. stationary head.

Shown: Removable Tube Bundle

N Channel integral with tubesheet H Double split flow P Outside, packed floating head& removable cover.

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Art Montemayor September 30, 2005Rev: 0

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WorkSheet: TEMA Designations

D Special, high-pressure closure J Divided shell flow S Floating head with backingdevice (split-ring)

Conventional Front End Heads:

Aor,

B

K Kettle type of reboiler T Pull-through floating head

Other popular rear end head types employed:

U U-tube bundle design(No Rear Head Required)

W Packed floating tubesheet with lantern ring

Page 98: Process Heat Transfer Hof Master

Art Montemayor September 30, 2005Rev: 0

Page 98 of 140FileName: document.xls

WorkSheet: TEMA Designations

Some examples of the TEMA designation for Heat Exchangers are shown below:

BEM Front bonnet (Intergral Cover), with one-Pass Shell and a Fixed Tubesheet rear Bonnet

Fixed tubesheet heat exchanger. This is a very popular version as the heads can be removed to clean the inside of the tubes. The front head piping must be unbolted to allow front head removal; if this is undesirable, thenthis can be avoided by applying a type A front head. In that case only the cover needs to be removed. It is not possible to mechanically clean the outside surface of the tubes as these are fixed inside the shell. Chemical cleaning can be used in the shell side. Shown is a version with one shell pass and two tube passes. This is probably the least expensive of the shell-and-tube designs.

BEM This is the same type of heat exchanger as shown above, except it has only one tube pass

AEM Channel with Removable Cover, One Pass Shell, Fixed Tubesheet Bonnet

This is almost the same type of heat exchanger as the first BEM. The removable cover allows the inside of the tubes to be inspected and cleaned without unbolting the piping. However, as can be expected, the tradeoff is that this convenient feature makes it more expensive.

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Art Montemayor September 30, 2005Rev: 0

Page 99 of 140FileName: document.xls

WorkSheet: TEMA Designations

The maintenance feature of having a removable tube bundles requires an exchanger as the following:

AES Channel and Removable Cover, One Pass Shell, Floating Head with Backing Device

A floating head heat exchanger is excellent for applications where the difference in temperature between the hot and cold fluid causes unacceptable stresses in the axial direction, between the shell and tubes. The floating head can move, i.e. it provides the ability to allow tube expansion in the axial direction.

Note that the bundle can not be pulled from the front end. For maintenance both the front and rear end head,

should be selected.

However, it is wise and prudent to be aware of the inherent trade-offs in this design. Note that the tube-side fluid can leak through the internal floating head cover gasket and mix (or contaminate) the shell-side fluid.It is very difficult -and sometimes impossible to mitigate or compensate for the internal bolts tightening the internal bonnet to remain under constant, steady torque. Hot fluid temperatures make the bolts expand and the result is a reduction in bolt torque and subsequent leaks through the bonnet gasket. Additionally, it is acommon and expected occurance for maintenance crews to find the internal bolts badly rusted or corroded to the point where they have to be burned or sawed off in order to extract the "removable" tube bundle.

The chemical engineer has other options to apply when requiring mechanical expansion of a heat exchanger tube bundle. Various rear head design also exist that allow for tube bundle expansion. Among these are the popular (and inexpensive) "U" tube bundle design. A "P" and "W" rear head design will also contribute this feature without the hazard of internal mixing (or contamination) of the two fluids.

Also, be aware that any TEMA shell and tube design with a removable tube bundle feature has - by nature - a larger shell diameter (& increased cost) due to the need to be able to pull the rear tubesheet the length of the exchanger's shell. A larger diameter shell can sometimes also present problems in a lower Reynoldsnumber (yielding a lower heat transfer) and internal by-passing of the shell fluid around the baffles (this also reduces the effective heat transferred. All these effects eventually lead to a bigger heat exchanger (more areaand more tubes) in order to do a heat transfer operation.

including the backing device, must be disassembled. If pulling from the front head is required a type AET

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Art Montemayor September 30, 2005Rev: 0

Page 100 of 140FileName: document.xls

WorkSheet: TEMA Designations

Longitudinal Baffles - their application and inherent problems

The employment of longitudinal baffles in heat exchangers - such as the "F", "G", and "H" shell types - can often resolve both heat transfer and fluid flow problems within the shell and tube exchanger used.

Their application can significantly increase the shell-side Reynolds Number and lead to more efficient shell-side heat transfer coefficients with a subsequent increase in heat transfer. Additionally, these type of baffles permitthe engineer to incorporate counter-flow heat transfer. True counter-current heat transfer is as efficient a heat transfer configuration as an engineer can obtain. In some heat recovery applications, this is highly sought.By splitting the shell-side flow, some applications can actually have a significant reduction in shell-side pressuredrop. This is especially true in partial vacuum process operations where a minimum of pressure drop can be tolerated.

However, the application of longitudinal baffles should be always carefully scrutinized and used sparingly. Thereare, as would be expected, some very important trade-offs involved in the application of longitudinal baffles.Firstly, if a longitudinal baffle is a process necessity, the baffle should be seal-welded against the inner shellwall in order to ensure that there will be no internal, by-pass leakage. This positive step negates the possibilityof having a removable tube bundle. Additionally, the welding necessity requires a minimum shell diameter and this winds up being applicable only to relatively large streams.

By the basic need to establish effective shell-side flow around a longitudinal baffle, one has to accept the obvious fact that a minimum of shell-side clearances can be tolerated. Once having said and applied these facts,one then has to also accept that the required, small baffle clearances mean extraordinary fabrication techniquesand resultant super-human maintenance efforts to extract a removable tube bundle. In far too many actual field cases, it has been found that the removable tube bundle with a longitudinal baffle is a non-practical device.Field results have shown that in most cases the tube bundle has resulted in being destroyed in order to remove it.This extraordinary and desperate maintenance act labels such a design as non-practical.

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Art Montemayor September 30, 2003Rev: 0

Page 101 of 140 FileName: document.xlsWorkSheet: Tube Counts

Heat Exchanger Tube Sheet Layout Count TableSource: "Applied Process Design for Chemical and Petrochemical Plants"; Vol. 3; p.24

Ernest E. Ludwig; Gulf Publishing Co.; Houston, TX (1965)

Shell I. D., inchesTube O. D. & Pitch 8 10 12 13-1/4 15-1/4 17-1/4 19-1/4 21-1/4 23-1/4 25 27 29 31 33 35 37

On

e-P

ass

Fix

ed

T

ub

es 3/4" on 15/16" Triang. 33 69 105 135 193 247 307 391 481 553 663 763 881 1,019 1,143 1,269

3/4" on 1" Triang. 33 57 91 117 157 217 277 343 423 493 577 667 765 889 1,007 1,1273/4" on 1" Square 33 53 85 101 139 183 235 287 355 419 495 587 665 765 865 9651" on 1-1/4" Triang. 15 33 57 73 103 133 163 205 247 307 361 427 481 551 633 6991" on 1-1/4" Square 17 33 45 65 83 111 139 179 215 255 303 359 413 477 545 595

Tw

o-P

ass

Fix

ed

T

ub

es 3/4" on 15/16" Triang. 32 58 94 124 166 228 300 370 452 528 626 734 846 964 1,088 1,242

3/4" on 1" Triang. 28 56 90 110 154 208 264 326 398 468 556 646 746 858 972 1,0883/4" on 1" Square 26 48 78 94 126 172 222 280 346 408 486 560 644 746 840 9461" on 1-1/4" Triang. 16 32 52 62 92 126 162 204 244 292 346 410 462 530 608 6881" on 1-1/4" Square 12 26 40 56 76 106 136 172 218 248 298 348 402 460 522 584

U T

ub

es

3/4" on 15/16" Triang. 8 34 64 94 134 180 234 304 398 460 558 648 768 882 1,008 1,1263/4" on 1" Triang. 8 26 60 72 108 158 212 270 336 406 484 566 674 772 882 1,0003/4" on 1" Square 12 30 52 72 100 142 188 242 304 362 436 506 586 688 778 8841" on 1-1/4" Triang. XX 8 26 42 58 84 120 154 192 234 284 340 396 466 532 6101" on 1-1/4" Square XX 12 22 38 58 76 100 134 180 214 256 304 356 406 464 526

Fo

ur-

Pa

ss

Fix

ed

T

ub

es 3/4" on 15/16" Triang. XX 48 84 108 154 196 266 332 412 484 576 680 788 904 1,024 1,172

3/4" on 1" Triang. XX 44 72 96 134 180 232 292 360 424 508 596 692 802 912 1,0243/4" on 1" Square XX 48 72 88 126 142 192 242 308 366 440 510 590 688 778 8801" on 1-1/4" Triang. XX 24 44 60 78 104 138 176 212 258 308 368 422 486 560 6381" on 1-1/4" Square XX 24 40 48 74 84 110 142 188 214 260 310 360 414 476 534

U T

ub

es

3/4" on 15/16" Triang. XX 28 56 84 122 166 218 286 378 438 534 622 740 852 976 1,0923/4" on 1" Triang. XX 20 52 64 98 146 198 254 318 386 462 542 648 744 852 9683/4" on 1" Square XX 24 44 64 90 130 174 226 286 342 414 482 560 660 748 8521" on 1-1/4" Triang. XX 20 36 50 74 110 142 178 218 266 322 376 444 508 5841" on 1-1/4" Square XX 16 32 50 66 90 122 166 198 238 286 336 384 440 500

Six

-Pa

ss

Fix

ed

T

ub

es 3/4" on 15/16" Triang. XX 80 116 174 230 294 372 440 532 632 732 844 964 1,106

3/4" on 1" Triang. XX 66 104 156 202 258 322 388 464 548 640 744 852 9643/4" on 1" Square XX 54 78 116 158 212 266 324 394 460 536 634 224 8181" on 1-1/4" Triang. XX 34 56 82 112 150 182 226 274 338 382 442 514 5861" on 1-1/4" Square XX 44 66 88 116 154 184 226 268 318 368 430 484

U T

ub

es

3/4" on 15/16" Triang. XX 74 110 156 206 272 358 416 510 596 716 826 944 1,0583/4" on 1" Triang. XX 56 88 134 184 268 300 366 440 518 626 720 826 9403/4" on 1" Square XX 56 80 118 160 210 268 322 392 458 534 632 718 8201" on 1-1/4" Triang. XX 30 42 68 100 130 168 206 252 304 356 426 488 5621" on 1-1/4" Square XX 42 60 80 110 152 182 224 268 316 362 420 478

Eig

ht-

Pa

ss

Fix

ed

T

ub

es 3/4" on 15/16" Triang. XX 94 140 198 258 332 398 484 576 682 790 902 1,040

3/4" on 1" Triang. XX 82 124 170 224 286 344 422 496 588 694 798 9023/4" on 1" Square XX 94 132 174 228 286 352 414 490 576 662 7601" on 1-1/4" Triang. XX 66 90 120 154 190 240 298 342 400 466 5421" on 1-1/4" Square XX 74 94 128 150 192 230 280 334 388 438

U T

ub

es

3/4" on 15/16" Triang. XX 68 102 142 190 254 342 398 490 578 688 796 916 1,0323/4" on 1" Triang. XX 52 82 122 170 226 286 350 422 498 600 692 796 9083/4" on 1" Square XX 48 70 106 146 194 254 306 374 438 512 608 692 7921" on 1-1/4" Triang. XX 24 38 58 90 118 154 190 238 290 340 404 464 5401" on 1-1/4" Square XX 34 50 70 98 142 170 206 254 300 344 396 456

Notes: 1) The above tube counts have an allowance made for Tie Rods.2) The Radius of Bend for the U-Tube bundles is equal to (2.5) (Tube O.D.); The actual number of U-tubes is 1/2 of the above figures.

Page 102: Process Heat Transfer Hof Master

Art MontemayorMarch 12, 2001

Rev: 0

Page 102 of 140FileName: document.xlsWorkSheet: HX Design

HEAT EXCHANGER SUMMARY

69

83

169

128 Exchanger Heat Duty 3,950 M Btu/hr

Overall U, estimated 100 Number of shell passes 1 Number of tube passes 2

Log Mean Temperature Difference, LMTD 72 F Factor (see below) 0.98

Adjusted LMTD 70

Heat Transfer Area calculated 562 Design contingency factor 1.25 Over-design allowance 1.00

Heat Transfer Area required 702

450 psig, Saturated Steam Req'd, 5,163 lbs/hr

CW Req'd @ 14 deg rise, gpm 564 gpm

Calculation of F Factor: P (or S) 0.14 R 2.93

Term 1 0.69 Px 0.14

Term 2 1.60 Term 3 0.38 1.46 Term 4A 13.45 Term 4B 7.26 Term 4 0.62

F 0.98

T in, Cold Side (t1) oF

T out, Cold Side (t2) oF

T in, Hot Side (T1) oF

T out, Hot Side (T2) oF

Btu/hr - Ft2 - oF

oF

oF

Ft2

Ft2

[(RP-1)/(P-1)](1/N)

(R^2+1)0.5/(R-1)

q, U, A, DTmw, cp, t1

W, Cp, T2

W, Cp, T1

w, cp, t2

Page 103: Process Heat Transfer Hof Master

SHELL & TUBE HEAT EXCHANGER SPECIFICATION Sheet 1 of 1

(English Units)

Corporation Project No.

1 Service Lean MEA Solution Cooler Equipment No.

2 Location Unit P.O. No.

3 Manufacturer * Model * Mfr Ref. No. * No. Req'd

4 TEMA Size, Type Horiz. Vert. Connected in Series Parallel

5 Surface/Unit * Gross Eff. Shells/Unit One Surface/Shell * Gross Eff.

6 P&ID No. Plot Plan No. Other Ref. Dwg No.

7 PERFORMANCE OF ONE UNIT8 Fluid Allocation SHELL SIDE TUBE SIDE9 Fluid Circulated

10 Total Fluid Entering lb/h 11 Vapor (In/Out) lb/h 12 Liquid lb/h 13 Steam lb/h 14 Non-Condensables lb/h 15 Fluid Vaporized or Condensed lb/h 16 Steam Condensed lb/h 17 Temperature ºF 18 Density, Specific Gravity19 Viscosity cP 20 Vapor Molecular Weight21 Specific Heat Btu/lb·ºF 22 Thermal Conductivity Btu/h·ft·ºF 23 Latent Heat Btu/lb 24 Operating Pressure, Inlet psig 25 Velocity Max. Min. fps 26 Pressure Drop, Clean (Allow./Calc.) psi 27 Fouling Resistance28 Heat Exchanged Btu/h Log MTD (Uncorrected) ºF Log MTD (Corrected) * ºF 29 Transfer Rate, Service * Transfer Rate, Clean *30 CONSTRUCTION AND MATERIALS31 SHELL SIDE TUBE SIDE Sketch (Bundle, Nozzle Orientation)32 Design Pressure psig 33 Test Pressure psig 34 Design Temperature ºF 35 Number of Passes per Shell36 In37 Out38 Intermediate39 Tubes: Type Number * OD 0.75 in. 16 BWG or in. X Min. Av. Wall

40 Tube Length in. Tube Pitch 0.9375 in. Flow Pattern (circle one)

41 Shell: ID * in. OD * in. Tube-to-Tubesheet Joint Rolled and Seal Welded42 Baffles - Cross: Type * Spacing * in. * % Cut on X Diam. Area43 Baffles - Long: Perm. Removable Seal Type: Bypass Seal:44 Inlet Nozzle * lb/ft·sec Bundle Entrance * lb/ft·sec Bundle Exit * lb/ft·sec

45 Expansion Joint? Yes X No Type: Impingement Protection? X Yes No

46 PART THK, in. C.A., in. PART THK, in. C.A., in.47 Tubes Stainless Stl 16 BWG min. Floating Tubesheet Carbon Steel * ----48 Shell Fixed Tubesheet Carbon Steel * 0.12549 Shell Cover Tube Supports Carbon Steel * 0.12550 Channel Cross Baffles Carbon Steel * 0.12551 Channel Cover Long Baffle Carbon Steel * 0.12552 Fltg Head Cover Gaskets Stainless Stl ----53 User Spec.:54 Code Requirements: ASME Sec. VIII, Para. 1 (1992) Stamp? Yes TEMA Class:55 Weights: Shell * lb Filled with Water * lb Bundle * lb56 Remarks5758

Rev Date Description By Chk. Appr. Rev Date Description By Chk. Appr.

0 For Purchase

ft2 ft2

ft2·h·ºF/Btu .

Btu/ft2·h·ºF . Btu/ft2·h·ºF .

rv2:

MATERIAL§ MATERIAL§

§ Stress Relieved (Mark "SR') and/or Radiographed (Mark 'XR') Parts

1. Items marked with an asterisk (*) to be completed by Vendor.

ConnectionsSize & Rating

60° 90°45°30°

Rev

. No

.

Montemayor

Page 104: Process Heat Transfer Hof Master

PLATE & FRAME HEAT EXCHANGER SPECIFICATION Sheet 1 of 1(English Units)

Corporation Project No. 1234567

1 Service Cooling Water Exchanger Equipment No.

2 Location Unit P.O. No.

3 Manufacturer * Model * Mfr Ref. No. * No. Req'd One4 Size, Type * - * Frames/Unit One Connected in Single

5 Surface/Unit * Effective Surface/Frame * Gross6 P&ID No. Plot Plan No. Other Ref. Dwg No.

7 PERFORMANCE OF ONE UNIT

8 Fluid Allocation HOT SIDE COLD SIDE

9 Fluid Circulated Cooling Water

10 Total Fluid Entering lb/h 31,500 206,483 11 Vapor (In/Out) lb/h ---- ---- ---- ---- 12 Liquid lb/h 31,500 31,500 206,483 206,483 13 Steam lb/h ---- ---- ---- ---- 14 Non-Condensables lb/h ---- ---- ---- ---- 15 Fluid Vaporized or Condensed lb/h ---- ---- ---- ---- 16 Steam Condensed lb/h ---- ---- ---- ---- 17 Temperature ºF 235 120 90 10518 Density, Specific Gravity 0.907 0.929 0.995 0.99219 Viscosity cP 0.54 13.7 0.76 0.6520 Vapor Molecular Weight ---- ---- ---- ---- 21 Specific Heat Btu/lb·ºF 0.867 0.843 1.0 1.022 Thermal Conductivity Btu/h·ft·ºF 0.178 0.160 0.358 0.36523 Latent Heat Btu/lb ---- ---- 24 Operating Pressure, Inlet psig 75 6025 Velocity X Max. Min. fps 8.0 8.026 Pressure Drop, Clean (Allow./Calc.) psi 10 * 10 *27 Fouling Resistance 0.001 0.00328 Heat Exchanged 3,097,238 Btu/h Log MTD (Uncorrected) 157.0 ºF Log MTD (Corrected) * ºF

29 Transfer Rate, Service * Transfer Rate, Clean *30 CONSTRUCTION AND MATERIALS

31 Allocation HOT SIDE COLD SIDE Sketch (Frame, Nozzle Orientation)

32 Design Pressure psig 150 12533 Test Pressure psig Code Code34 Design Temperature ºF 300 30035 Number of Passes per Frame Two *36 Corrosion Allowance in. 0.0625 None37 In 3" 150# RF 6" 125# FF38 Out 3" 150# RF 6" 125# FF39 Intermediate ---- ----40 lb/ft·s

41 Impingement Protection? Yes42 No. of Plates Frame Capacity (Max. No. of Plates)

43 PART THK, in. C.A., in. PART THK, in. C.A., in.

44 Plates Stnless Steel16 BWG min. 0.03125 Connections Stnless Steel 0.0312545 Plate Gaskets Carbon Steel * 0.03125 Frame Carbon Steel 0.0312546 End Cover Carbon Steel * 0.03125 Carrying Bar Carbon Steel 0.0312547 Carbon Steel 0.03125 Carbon Steel 0.0312548

49 OSHA Type Protective Shroud? Yes Material: Carbon Steel Insulation: Heat Conservation

50 Cleaning: Painting:

51 Code Requirements: ASME Sec. VIII, Para. 1 (1992) Stamp? Yes52 Client Spec.: Weights: Empty Frame * lb Filled with Water * lb

53 Remarks

54

55

Rev Date Description By Chk. Appr. Rev Date Description By Chk. Appr.

0 9-Dec-96 For Inquiry ABC DEF XYZ

ft2 ft2

ft2·h·ºF/Btu

Btu/ft2·h·ºF Btu/ft2·h·ºF

rv2, Inlet/Outlet

MATERIAL§ MATERIAL§

§ Stress Relieved (Mark "SR') and/or Radiographed (Mark 'XR') Parts

1. Items marked with an asterisk (*) to be completed by Vendor.

ConnectionsSize & Rating

Rev

. No

.

Montemayor

Page 105: Process Heat Transfer Hof Master

Art Montemayor Overall Heat Transfer CoefficientOctober 02, 2003

Rev: 0

Page 105 of 140FileName: document.xlsWorkSheet: Typical "U"

Typical Overall Heat Transfer CoefficientsSource: http://www.the-engineering-page.com/forms/he/typU.html

Shell and Tube Heat Exchangers Overall “U”Hot Fluid Cold Fluid

Heat ExchangersWater Water 800 – 1,500 140 - 264Organic solvents Organic Solvents 100 - 300 17 – 52Light oils Light oils 100 - 400 17 – 70Heavy oils Heavy oils 50 - 300 9 – 53Reduced crude Flashed crude 35 - 150 6 – 26Regenerated DEA Fouled DEA 450 - 650 79 – 114Gases (p = atm) Gases (p = atm) 5 - 35 1.0 – 6Gases (p = 200 bar) Gases (p = 200 bar) 100 - 300 17 – 53

CoolersOrganic solvents Water 250 - 750 44 – 132Light oils Water 350 - 700 62 - 123Heavy oils Water 60 - 300 11 - 53Reduced crude Water 75 - 200 13 – 35Gases (p = atm) Water 5 - 35 1.0 – 6Gases (p = 200 bar) Water 150 - 400 26 – 70Gases Water 20 - 300 4 – 53Organic solvents Brine 150 - 500 26 – 88Water Brine 600 – 1,200 106 – 211Gases Brine 15 - 250 3 - 44

HeatersSteam Water 1,500 – 4,000 264 - 700Steam Organic solvents 500 – 1,000 88 - 176Steam Light oils 300 - 900 53 – 159Steam Heavy oils 60 - 450 11 – 79Steam Gases 30 - 300 5 – 53Heat Transfer (hot) Oil Heavy oils 50 - 300 9 – 53Heat Transfer (hot) Oil Gases 20 - 200 4 - 35Flue gases Steam 30 - 100 5 - 18Flue gases Hydrocarbon vapors 30 -100 5 - 18

CondensersAqueous vapors Water 1,000 – 1,500 176 – 264Organic vapors Water 700 – 1,000 123 – 176Refinery hydrocarbons Water 400 - 550 70 - 97

W/m2-C Btu/hr-ft2-oF

Page 106: Process Heat Transfer Hof Master

Art Montemayor Overall Heat Transfer CoefficientOctober 02, 2003

Rev: 0

Page 106 of 140FileName: document.xlsWorkSheet: Typical "U"

Water 500 - 700 88 – 123Vacuum condensers Water 200 - 500 35 – 88

VaporizersSteam Aqueouos solutions 1,000 – 1,500 176 – 264Steam Light organics 900 – 1,200 159 – 211Steam Heavy organics 600 - 900 106 – 159Heat Transfer (hot) oil Refinery hydrocarbons 250 - 550 44 – 97

Air Cooled ExchangersProcess Fluid (tube side)Water 300 - 450 53 - 79Light organics 300 - 700 53 - 123Heavy organics 50 - 150 9 - 26Gases 50 - 300 9 - 53Condensing hydrocarbons 300 - 600 53 - 106

Immersed coilsCoil Fluid Pool Fluid

Natural circulationSteam 500 – 1,000 88 – 176

Steam Light oils 200 - 300 35 – 53Steam Heavy oils 70 - 150 12 – 26Aqueous solutions Water 200 - 500 35 – 88Light oils Water 100 - 150 18 – 26

AgitatedSteam 800 – 1,500 140 – 264

Steam Light oils 300 - 500 53 – 88Steam Heavy oils 200 - 400 35 – 70Aqueous solutions Water 400 - 700 70 - 123Light oils Water 200 - 300 35 - 53

Jacketed vesselsJacket Fluid Vessel Fluid

Steam 500 - 700 88 - 123Steam Light organics 250 - 500 44 - 88Water 200 - 500 35 - 88Water Light organics 200 - 300 35 - 53

Art’s Note: Above U’s were originally given in metric units and the conversion to good, old fashioned US engineering units is based on:

Vapors with some non condensables

Dilute aqueous solutions

Dilute aqueous solutions

Dilute aqueous solutions

Dilute aqueous solutions

1.0 Btu/hr-ft2-oF = 5.678263 Watts/m2-oK

Page 107: Process Heat Transfer Hof Master

Art Montemayor G KETTLES RECIRCULATION COOLERE-G-43

October 24, 1997

Page 107 of 140 Electronic FileName: document.xlsWorkSheet: Shell-Side Pressure drop

ID = Shell Internal diameter, in. = 23

Tube external diameter, in. = 0.75

Tubes' Pitch, in. = 0.9375C' = Clearance between tubes = 0.1875B = Baffle spacing, in. = 15N = Number of Shell-side baffles = 11

0.4792W = Shell-side mass flowrate,lb/h = 325500

Shell-side unit mass flowrate,lb/h-ft2 = 679,304

Equivalent shell diameter, ft = 0.0458333

Shell-side Reynolds Number = 643.3

f = 0.00352

0.52

20

Fluid's Viscosity, lb/ft-h 48.4

k = 0.086

Fluid's Prandtl Number = 292.7

1s = Shell fluid's specific gravity = 0.9303721

Shell-side pressure drop, psi = 16.8

ODT =PT =

aS = Shell-side crossflow area, ft2 =

GS =De =

NRe =Friction factor for pressure drop, ft2/in2 =

cP = Fluid's Heat Capacity, Btu/lb-oF = m = Fluid's Viscosity, cP =

m' =Fluid's therm. cond., Btu/ft-h-oF =

NPr =Fs = Viscosity ratio, (m/mw)0.14 =

DP =

From "Process Heat Transfer"; D. Kern; McGraw-Hill; 1950; pages 147-148

DP = f G2sDs(N+1)/(5.22 x 1010)Des Fs

Page 108: Process Heat Transfer Hof Master

Quick & Dirty Tubular Heat Exchanger Rating Sheet

Project Reactor Warm Water System Upgrade Project No. Item No. E-G-XX Service By Date/Time 13-Mar-97 15:12

Input flows, conditions and properties data for shellside and

tubeside. transfer coefficients to this point (i.e., not including shellside h):

Tube Side Shell 235

CW Fluid Name Warm Water 195

418,000 Flow (M), lb/h 195,000 Then the required transfer A = 2,139

88 130 Number of tubes required = 545

102 100 Reset tubes/pass (Step 3), then no. of passes = 4

Av. Density 62.05 61.9 Total tube count = 584

Av. Viscosity 0.723 0.590 8.1

Av. Heat Capacity 1 1 Actual effective transfer area, A = 2,293

Heat Exchanged 5,850,014 Q, Btu/h 5,850,000 OK?

Av. Thermal Conductivity 0.360 0.368

Fouling Resistance 0.002 0.0015 Tube Pitch 0.9375 in.

Prandtl No. 4.86 3.88 and estimate shell diameter Pattern Tri

Uncorrected MTD 18.9 Shell ID from Tube Count Tables 27 in.

Corrected MTD 14.0 Select Baffle Spacing 16 in.

Number of Baffles = 14

0.600

Tube OD 0.7500 in. 0.55 in.

length (can be trial and error). BWG 16 325,000

Tube ID, d = 0.620 in. 25,258

Tube Length, L = 20 ft. Shellside Friction Factor = 0.00178

0.302 2.7

Effective transfer area per tube = 3.927 90.4

1,140

195.1

Tubes/pass = 146 0.0% OK?

tubes per tube pass. lb/h per tube = 2,863 614.9

Av. velocity, fps = 6.11 OK?

40,324

Tubeside Friction Factor, f = 0.010

1.01 OK? adjust tube length, number of tubes per pass, number of passes, and/or shell

113.7 baffle spacing. Remember to reset shell diameter from tube count tables, as

1,335 required.

Step 1. Step 4. Start configuring the exchanger. Begin with the total calculated

Ustart = Btu/h·ft2·oF On that basis, assumed Uo = Btu/h·ft2·oF

ft2

Temp. in, oFTemp. out, oF

r, lb/ft3

m, cP Tubeside DP (incl. returns) = psi OK?cp, Btu/lb·oF ft2

k, Btu/h·ft·oF R, ft2·h·oF/Btu Step 5. Select tube arrangement

cpm/koFoF

Flow Area across Bundle, as = ft2

Step 2. Input tubing OD, BWG and Equivalent Diameter, de (see table) =Mass Velocity, Gs = lb/h·ft2

Shellside Reynolds No., NRe =

Flow area per tube, at = in.2 Shellside DP = psi OK?

ft2 Outside Transfer Factor, jh =Outside Film Coefficient, ho =

Calculated Uo =Step 3. Estimate the number of Check: % difference, Ucalc. vs Uassum. =

Uclean =

Tubeside Reynolds No., NRe =Step 6. Check tubeside velocity and DP, shellside DP. If too high or too low,

DP per pass, psi =Inside Transfer Factor, jh =Inside Film Coefficient, hi =

Page 109: Process Heat Transfer Hof Master

CALCULATION SHEET

Signature Art Montemayor Date 18-Feb-04 Checked Date Proj No.

Project D. Q. Kern, "Process Heat Transfer"; Mc-Graw Hill; 1950; p. 274 File

Subject Horizontal n-Propanol Total Condenser Sheet 1 of 10

1

2 A horizontal, 1-2 condenser is required for condensing pure propyl alcohol emanating from the top of a distillation

3 column. Side-to-side, 25% cut segmental baffles will be used. Basic data is as follows:

4

5 Propanol flowrate 60,000 lb/hr

6 Propanol vapors' inlet pressure 15.0 psig

7 Propanol vapors' inlet temperature 244

8 Cooling Water inlet temperature 85

9 Propanol allowable pressure drop 2.00 psi

10 CWS allowable pressure drop 10.00 psi

11 Dirt factor 0.003

12 Condenser tubes' length 8.00 feet

13 Tubes' OD 0.7500 inches

14 Tubes' length 8.00 feet

15 Tubes' gauge 16 BWG

16 Tubes' ID 0.6200 inches

17 Tubes' pitch 0.9375 Triangular, inches

18 Clearance between tubes 0.1875 inches

19 Propanol Latent Heat at 15 psig 285 Btu/lb

20 Propanol Molecular Weight 60.1

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

A B C D E F G H I J K L

oFoF

Tem

pera

ture

, oF

85

244

Distance along tubes

Vapor inlet

Condensate outlet

Cooling water out

Cooling water in

Page 110: Process Heat Transfer Hof Master

CALCULATION SHEET

Signature Art Montemayor Date 18-Feb-04 Checked Date Proj No.

Project D. Q. Kern, "Process Heat Transfer"; Mc-Graw Hill; 1950; p. 274 File

Subject Horizontal n-Propanol Total Condenser Sheet 2 of 10

45

46 First, make a heat and material balance to establish the heat load and the cooling water required:

47

48 Propanol latent heat for condensation = 17,100,000 Btu/hr

49 Cooling water terminal temperature = 120

50 Cooling water required = 488,571 lb/hr = 976 gpm

51 Propanol Water Differ.

52 244 Higher Temperature 120 124

53 244 Lower Temperature 85 159

54 0 Difference 35 35

55

56 Log Mean Temperature Difference = LMTD = 141

57

58 Since the shell side Propanol vapor is essentially isothermal, the exchanger is in true counterflow.

59

60 The caloric temperature of the hot fluid

61 The caloric temperature of the cold fluid

62 The average temperature of the cold fluid

63 The influence of the tube-wall temperature is included in the condensing film coefficient.

64

65 102.5

66

67 Execute a trial calculation:

68 a) 100

69 Condensing film coefficients will generally range from 150 to 300. Assuming a film coefficient of 1,000

70

71

72 Heat transfer area = A = 1,215

73 Quantity of 3/4" OD tubes = 773

74

75 b)

76 large number of tubes, making a 2-pass assumption inadvisable.

77 From the tube counts table, 4 tube passes using 3/4" OD tubes on 15/16" triangular pitch , yields a

78 766 tubes in a 31 inch ID shell.

79 c)

80 Corrected area, A = 1,203

81 101

82

83

84

85

86

87

88

A B C D E F G H I J K L

oF

oF

Tc =tc =ta =

The mean ta = oF can be used as the caloric temperaure of the cold fluid

Assume that UD = Btu/hr-oF-ft2

for water, UC will range from 130 to 230 Btu/hr-oF-ft2.

Q/UD DT = ft2

Assume that 4 tube passes are used. The quantity of water is large, but the condenser will have a

count of

The corrected UD coefficient, using the 31" shell, is now calculated:

ft2

Corrected UD = Q/A DT = Btu/hr-oF-ft2

Page 111: Process Heat Transfer Hof Master

CALCULATION SHEET

Signature Art Montemayor Date 18-Feb-04 Checked Date Proj No.

Project D. Q. Kern, "Process Heat Transfer"; Mc-Graw Hill; 1950; p. 274 File

Subject Horizontal n-Propanol Total Condenser Sheet 3 of 10

89

90 Calculations for shell side hot fluid, n-Propanol91

92

93 3 crosses for the proposed side-to-side flow. Since these are the minimum baffles that can be used, this should

94 yield the lowest attainable shell-side pressure drop in this configuration.

95

96 1.33 (Eq. 7.1; p.138)

97 where,

98 ID = Shell inside diameter, inches

99 C' = Clearance between tubes, inches

100 B = Baffle spacing, inches

101 Tube pitch, inches

102

103 44,953

104

105 The condensate loading on the horizontal tubes = G'' = 89.6 lb/hr-linear ft

106 where,

107 L = Tube length, feet

108 Tube quantity effective for condensation

109

110 200

111

112 1,075 (Refer to line # 165)

113 where,

114

115 The inside (water) film heat transfer coefficient = 1,300 (From fig. 25 )

116

117 125 (Eq. 5.31; p. 98)

118 where,

119

120

121 184

122

123 0.095 (From Table 4)

124

125 0.80 (From Table 6)

126

127 0.62 cP (From Fig. 14)

128

129

130

131

132

133

A B C D E F G H I J K L

Assume a maximum baffle spacing. This will be 32-1/2", 31", and 32-1/2" which is equal to 96" or 2 baffles and

The shell-side or bundle crossflow area = aS =(ID) (C') (B)/(PT * 144) = ft2

PT =

The shell-side mass velocity = Gs = W / aS = lb/hr-ft2

W/L*Nt2/3 =

Nt =

Assume the value of the average condensing film coefficient = hO = Btu/hr-ft2-oF

hiO = hi (ID/OD) = Btu/hr-ft2-oF

hiO = The inside film (water) heat transfer coefficient refered to the tube OD, Btu/hr-ft2-oFhi = Btu/hr-ft2-oF

Tube wall temperature = tW = ta + [hO/(hiO + hO)] (Tv - ta) = oF

Tv = Average temperature of hot fluid (vapor), oF

Shell side film temperature = tf = (Tv + tw)/2 = oF

Shell side film thermal conductivity = kf = Btu/hr-ft2-oF/ft

Specific Gravity of shell side film = sf =

Viscosity of shell side film = mf =

Page 112: Process Heat Transfer Hof Master

CALCULATION SHEET

Signature Art Montemayor Date 18-Feb-04 Checked Date Proj No.

Project D. Q. Kern, "Process Heat Transfer"; Mc-Graw Hill; 1950; p. 274 File

Subject Horizontal n-Propanol Total Condenser Sheet 4 of 10

134

135 (Equation 12.42; p. 266)

136 where,

137 h' =

138 film coefficient absolute viscosity = 1.5004 lb/ft-hr

139

140 = 49.92

141 g = = 4.18E+08

142 G'' = Condensate loading for horizontal tubes, lb/hr-ft

143

144 Average shell side condensing film coefficient = 178

145

146 Calculations for tube side cold fluid, Water147

148 Flow area of a 3/4" OD x 16 BWG tube = 0.3020 (From condenser tube table)

149

150 Flow area per tube = 0.402

151 where,

152 Number of tubes effective for condensation

153

154 n = Number of tube passes

155

156 1,216,508

157

158 Average water velocity in the tube side = V = 5.41 ft/sec

159

160 102.5

161

162 0.72 cP = 1.74 lb/ft-hr

163 Tubes' ID = 0.0517 ft

164

165 Reynolds Number (for pressure drop only) = 36,073

166

167 1,300 (From Fig. 25)

168

169 1,075

170 where,

171

172

173 Based on h' = 172 instead of the assumed 200, a new value of tw and tf could be obtained to give a more exact value

174 of h' based on the fluid properties at a value of tf more nearly correct. However, it is not necessary in this example

175 because the condensate properties will not change materially.

176

177

178

A B C D E F G H I J K L

h' ( mf2 / kf

3 rf2 g)1/3 = 1.5 (4 G''/mf)-1/3

Average condensing film coefficient, Btu/hr-ft2-oFmf =kf = film coefficient thermal conductivity, Btu/hr-ft2-oF/ftrf = film coefficient density, lb/ft3

Acceleration of gravity, ft/hr2

Btu/hr-ft2-oF

in2

NT a't / 144 n = ft2

NT =a't = Flow area per tube, in2

Water mass velocity in the tube side = Gt = w / at = lb/hr-ft2

Gt / (3,600*r) =

At the average water temperature, ta, of oF:

Water viscosity = m =

D Gt/m =

Tube side water heat transfer film coefficient = hi = Btu/hr-ft2-oF

hiO = hi (ID/OD) = Btu/hr-ft2-oF

hiO = The inside film (water) heat transfer coefficient refered to the tube OD, Btu/hr-ft2-oF

Page 113: Process Heat Transfer Hof Master

CALCULATION SHEET

Signature Art Montemayor Date 18-Feb-04 Checked Date Proj No.

Project D. Q. Kern, "Process Heat Transfer"; Mc-Graw Hill; 1950; p. 274 File

Subject Horizontal n-Propanol Total Condenser Sheet 5 of 10

179

180 Calculations for shell side pressure drop181

182 The propanol vapor temperature = 244

183 Propanol vapor viscosity = 0.010 cP = 0.0242 lb/ft-hr (From fig. 15)

184

185

186 The hydraulic radius employed for correlating shell-side coefficients for bundles having baffles is not the true hydraulic

187 radius. The direction of flow in the shell is partly along an d partly at right angles to the long axes of the bundle's tubes.

188 The flow area at right angles to the long axes is variable from tube row to tube row. A hydraulic radius based upon

189 the flow area across any one row could not distinguish between square and triangular pitch. In order to obtain a simple

190 correlation combining both the size and closeness of the tubes and their type of pitch, excellent agreement is

191 obtained if the hydraulic radius is calculated along (instead of across) the long axes of the tubes.

192

193 (4 * free area)/(wetted area) =

194 = 0.55 inches = 0.0458 ft (From fig. 28)

195

196 Shell-side Reynolds Number = 85,139

197

198 Shell-side friction factor for 25% cut segmental baffles = f = 0.00141 (From fig. 29)

199

200 Number of shell-side crosses = (N+1) = 3

201

202 Assume that the propanol vapor follows the ideal gas law at the low pressure.

203

204 Propanol vapor density = 0.236

205

206 Propanol vapor specific gravity = s = 0.00378

207

208 2.58 ft

209

210 Shell-side pressure drop = 1.2 psi (Eq. 12.47; p.273)

211

212

213 Calculations for tube side pressure drop214

215 For the tube side Reynolds Number = 36,073 the corresponding tube-side friction factor

216

217 f = 0.00019 (From fig. 26)

218

219 Tube-side pressure drop = Straight tube pressure drop + Return Loss pressure drop

220

221 3.3 psf = 0.02 psi

222 (Eq. 7.45; p. 148)

223

A B C D E F G H I J K L

oF

Shell-side equivalent diameter (De):

De = [(4) (0.5 *PT * 0.86 * PT - 0.5 * p * d2 /40] / (0.5 * p *d)

De Gs /m =

ft2/in2

MW / (V1) (T2/T1) (P1/P2) = lb/ft3

Shell Inside Diameter = Ds =

(1/2) [ f *Gs2 Ds (N+1) /(5.22 * 1010 *De * s)] =

ft2/in2

Straight tube pressure drop = DPt = f * Gt2 * Ln/(5.22*1010 *De * s *Ft) =

Page 114: Process Heat Transfer Hof Master

CALCULATION SHEET

Signature Art Montemayor Date 18-Feb-04 Checked Date Proj No.

Project D. Q. Kern, "Process Heat Transfer"; Mc-Graw Hill; 1950; p. 274 File

Subject Horizontal n-Propanol Total Condenser Sheet 6 of 10

224

225 7.3 psi (Eq. 7.46; p.148)

226

227 Total tube-side pressure drop = 7.29 psi

228 where,

229 L = tube length, feet

230 n = Number of tube passes

231

232 g' =

233

234

235

236

237 152.4

238

239

240

241

242 101 (From line 81)

243

244 0.0033

245 (Note: In condensation calculations the omission of the tube metal resistance may introduce a significant error and

246 should be checked.)

247

248

249 178 h (outside) 1,075

250 152.4

251 101

252 0.0033

253 0.003

254 1.2 7.29

255 2.00 10.00

256

257 Conclusion:258 The first trial calculated is satisfactory and yields the following exchanger:

259 Shell side Tube side

260 ID = 31 inches Quantity and length = 766; 8' - 0"

261 Baffle spacing = 31 inches (approx. OD, BWG, & pitch = 3/4"; 16 BWG; 15/16", triangular

262 Passes = 1 Passes = 4

263

264 It is interesting at this point to compare a vertical condenser with this horizontal model. The horizontal and vertical

265

266 number of tubes in both models is the same. To this end a vertical condenser will be assumed which uses the same

267 tube count as the above except that the tube length may be 12 or 16 ft (as needed) to account for the lower

268 coefficients obtained in the vertical orientation.A B C D E F G H I J K L

Return Loss pressure drop = DPr = (4*n/s) (V2/2 g') =

Ft = The viscosity ratio (m/mw)0.14 in the tubesAcceleration of gravity, 32.2 ft/sec2

Calculation of clean overall coefficient UC:

UC = (hio * ho )/(hio + ho) = Btu/hr-ft2-oF

Calculation of dirt factor R d:

Corrected UD = Btu/hr-oF-ft2

Rd = (UC - UD)/(UC * UD) = hr-ft2-oF/Btu

Shell side

Summary of Results

Tube side

UC =

UD =

Rd calculated =

Rd required =

Calculated DPAllowable DP

condensing film coefficients are both affected by W and Nt, and the best basis fof comparison is otained when the

Page 115: Process Heat Transfer Hof Master

CALCULATION SHEET

Signature Art Montemayor Date 18-Feb-04 Checked Date Proj No.

Project D. Q. Kern, "Process Heat Transfer"; Mc-Graw Hill; 1950; p. 274 File

Subject Vertical n-Propanol Total Condenser Sheet 7 of 10

269

270 The vertical condenser to be rated will be oriented as seen in the sketch below. The process conditions will be

271 identical to those of the previous horizontal model rated. In order to prevent water corrosion in the carbon steel shell,

272 the water will also be introduced in the tube side.

273

274

275

276

277

278

279

280

281

282

283

284

285

286

287

288

289

290

291

292

293 Total heat transferred = 17,100,000 Btu/hr

294

295 Log Mean Temperature Difference = LMTD = 141

296

297

298 102.5

299

300 Trial Calculation:301

302 a) 70

303 The equation for the condensing film coefficient gives greater values for horizontal tubes than for vertical tubes.

304

305

306 Heat transfer area = A = 1,735

307

308 The nearest common, available tube length (using the same 766 tubes) is:

309

### Tube length = 11.5 feet

311

312

313

A B C D E F G H I J K L

oF

Caloric temperature of the Propanol vapor = TC

Caloric temperature of the water = tC = oF

Assume that the overall dirty heat transfer coefficient, UD = Btu/hr-ft2-oF

It will, consequently, be necessary to reduce the value of UD.

Q/UD * DT = ft2

( use 12 foot length tubes )

Vapor inlet

Condensate outlet

Cooling water outCooling water in

Page 116: Process Heat Transfer Hof Master

CALCULATION SHEET

Signature Art Montemayor Date 18-Feb-04 Checked Date Proj No.

Project D. Q. Kern, "Process Heat Transfer"; Mc-Graw Hill; 1950; p. 274 File

Subject Vertical n-Propanol Total Condenser Sheet 8 of 10

314

315 b) The same tube layout, using 3/4" OD x 16 BWG tubes on 15/16" triangular pitch and 4 passes will also be

316 used.

317

318 c)

319 1,804

320 67

321

322

323 Calculations for shell side hot fluid, n-Propanol324

325 Tubes' outside diameter, Do = 0.0625 ft

326

327 399 lb/hr-lin. ft (Eq. 12.36; p. 265)

328

329 100

330

331 1,075 (Refer to line # 165)

332 where,

333

334 The inside (water) film heat transfer coefficient = 1,300 (From fig. 25 )

335

336 114.5 (Eq. 5.31; p. 98)

337 where,

338

339

340 179

341

342 0.095 (From Table 4)

343

344 0.80 (From Table 6)

345

346 0.65 cP

347

348 (Equation 12.39; p. 266)

349 where,

350 h' =

351 film coefficient absolute viscosity = 1.573 lb/ft-hr

352

353 = 49.92

354 g = = 4.18E+08

355 G' = Condensate loading for vertical tubes, lb/hr-ft

356

357 Average shell side condensing film coefficient = 104

358

A B C D E F G H I J K L

The corrected UD coefficient, using the 31" shell, is now calculated:

Corrected area, A = Q/UD*Dt = ft2

Corrected UD = Q/A DT = Btu/hr-oF-ft2

Condensate loading for vertical tubes = W/Nt * p * Do =

Assume the value of the average condensing film coefficient = hO = Btu/hr-ft2-oF

hiO = hi (ID/OD) = Btu/hr-ft2-oF

hiO = The inside film (water) heat transfer coefficient refered to the tube OD, Btu/hr-ft2-oFhi = Btu/hr-ft2-oF

Tube wall temperature = tW = ta + [hO/(hiO + hO)] (Tv - ta) = oF

Tv = Average temperature of hot fluid (vapor), oF

Shell side film temperature = tf = (Tv + tw)/2 = oF

Shell side film thermal conductivity = kf = Btu/hr-ft2-oF/ft

Specific Gravity of shell side film = sf =

Viscosity of shell side film = mf = (From Fig. 14; also, 4*G'/m = 1,025)

h' ( mf2 / kf

3 rf2 g)1/3 = 1.47 (4 G'/mf)-1/3

Average condensing film coefficient, Btu/hr-ft2-oFmf =kf = film coefficient thermal conductivity, Btu/hr-ft2-oF/ftrf = film coefficient density, lb/ft3

Acceleration of gravity, ft/hr2

Btu/hr-ft2-oF

Page 117: Process Heat Transfer Hof Master

CALCULATION SHEET

Signature Art Montemayor Date 18-Feb-04 Checked Date Proj No.

Project D. Q. Kern, "Process Heat Transfer"; Mc-Graw Hill; 1950; p. 274 File

Subject Vertical n-Propanol Total Condenser Sheet 9 of 10

359

360 Calculations for tube side cold fluid, Water361

362 The tube-side water conditions and configuration is the same as the horizontal configuration.

363

364 1,075

365 where,

366

367

368

369 Calculations for shell side pressure drop370

371 It is necessary to arrange the 12-foot tube bundle into a minimum number of bundle crosses, or (N + 1) = 5.

372 The spacing between baffles will be:

373 B = 29 inches

374

375 1.24 (Eq. 7.1; p.138)

376 where,

377 ID = Shell inside diameter, in.

378 C' = Clearance between tubes, in.

379 B = Baffle spacing, in.

380 Tube pitch, in.

381

382 48,387

383

384 The propanol vapor temperature = 244

385 Propanol vapor viscosity = 0.010 cP = 0.0242 lb/ft-hr (From fig. 15)

386

387 0.0458 ft (From table in fig. 28)

388

389 91,642

390

391 Shell-side friction factor for 25% cut segmental baffles = f = 0.00140 (From fig. 29)

392

393 Number of shell-side crosses = (N+1) = 5

394

395 Propanol vapor specific gravity = s = 0.00378 (Same as line 206)

396

397 2.58 ft

398

399 Shell-side pressure drop = 2.3 psi (Eq. 12.47; p.273)

400

401 This pressure drop prediction is high, and if it cannot be compensated for by elevating the condenser, it will be

402 necessary to use the half-circle (50% cut) support baffles as shown in Example 7-8.

403

A B C D E F G H I J K L

hiO = hi (ID/OD) = Btu/hr-ft2-oF

hiO = The inside film (water) heat transfer coefficient refered to the tube OD, Btu/hr-ft2-oF

Shell-side (bundle) crossflow area = as = (ID * C' * B)/(PT * 144) = ft2

PT =

The shell-side mass velocity = Gs = W / aS = lb/hr-ft2

oF

Equivalent diameter for pressure drop = De =

Shell-side Reynolds Number = ReS = De * GS / m =

ft2/in2

Shell Inside Diameter = Ds =

(1/2) [ f *Gs2 Ds (N+1) /(5.22 * 1010 *De * s)] =

Page 118: Process Heat Transfer Hof Master

CALCULATION SHEET

Signature Art Montemayor Date 18-Feb-04 Checked Date Proj No.

Project D. Q. Kern, "Process Heat Transfer"; Mc-Graw Hill; 1950; p. 274 File

Subject Vertical n-Propanol Total Condenser Sheet 10 of 10

404

405 Calculations for tube side pressure drop406

407 The basic data is the same as in the horizontal model example, except for the tube length.

408

409 5.0 psf = 0.03 psi

410 (Eq. 7.45; p. 148)

411

412 7.3 psi (Eq. 7.46; p.148)

413

414 Total tube-side pressure drop = 7.30 psi

415

416

417

418

419 95.0

420

421

422

423

424 67 (From line 81)

425

426 0.0043

427

428

429

430 104 h (outside) 1,075

431 95.0

432 67

433 0.0043

434 0.003

435 2.3 7.30

436 2.00 10.00

437

438 Conclusion:439 Shell side Tube side

440 ID = 31 inches Quantity and length = 766; 12' - 0"

441 Baffle spacing = 29 inches (approx. OD, BWG, & pitch = 3/4"; 16 BWG; 15/16", triangular

442 Passes = 1 Passes = 4

443

444 This vertical condenser is somewhat secure in performing the specified heat transfer duty but it exceeds the

445 allowable pressure drop, although not seriously. The advantage of horizontal condensation may be observed

446

447 The vertical unit has an inherent advantage, however, when the condensate is to be subcooled.

448

A B C D E F G H I J K L

Straight tube pressure drop = DPt = f * Gt2 * Ln/(5.22*1010 *De * s *Ft) =

Return Loss pressure drop = DPr = (4*n/s) (V2/2 g') =

Calculation of clean overall coefficient UC:

UC = (hio * ho )/(hio + ho) = Btu/hr-ft2-oF

Calculation of dirt factor R d:

Corrected UD = Btu/hr-oF-ft2

Rd = (UC - UD)/(UC * UD) = hr-ft2-oF/Btu

Shell side

Summary of Results

Tube side

UC =

UD =

Rd calculated =

Rd required =

Calculated DPAllowable DP

from the UC of 148.5 in the horizontal condenser as compared with the 93.2 in the vertical unit in identical service.

Page 119: Process Heat Transfer Hof Master

Some of this data was taken from Standards of the Tubular Exchanger Manufacturers Association (TEMA); 7th Edition (1988); page 178. Note: some of the tabular TEMA data contained ERRATA, but this was corrected with this spreadsheet's formulas.

BWG

1/2" O. D. Condenser tube 3/4" O. D. Condenser tube

Outside Inside78 0.1659 0.148

10 0.134 0.48211 0.120 0.51012 0.109 0.282 0.0625 0.1309 0.0738 0.456 0.53213 0.095 0.56014 0.083 0.334 0.0876 0.1309 0.0874 0.370 0.58415 0.072 0.60616 0.065 0.370 0.1075 0.1309 0.0969 0.302 168 0.62017 0.058 0.63418 0.049 0.402 0.1269 0.1309 0.1052 0.236 198 0.65220 0.035 0.430 0.1452 0.1309 0.1126 0.174 227 0.68022 0.028 0.444 0.1548 0.1309 0.1162 0.141 241

NOTES:

Material FactorAluminum 0.35Titanium 0.58

A.I.S.I. 300 Series Stainless Steels 0.99A.I.S.I. 400 Series Stainless Steels 1.02

Aluminum Bronze 1.04Aluminum Brass 1.06

Nickel-Chrome-Iron 1.07Admiralty 1.09

Nickel 1.13Nickel-Copper 1.12

Copper and Cupro-Nickels 1.14

Wall thickness

inchesTube I. D.

inchesTube flow area in2

Surface area per linear foot, ft2

Tube weight per linear foot, lb of

steel*

Constant C **

Tube I. D. inches

* The weight of the condenser tubes is based on low carbon steel with a density of 0.2836 lbs/in3

** Liquid Velocity within the tubes = (Lbs Per Tube Hour) / (C * Liquid Specific Gravity) in feet per sec. (Specific gravity of Water @ 60

Page 120: Process Heat Transfer Hof Master

Some of this data was taken from Standards of the Tubular Exchanger Manufacturers Association (TEMA); 7th Edition (1988); page 178. Note: some of the tabular TEMA data contained ERRATA, but this was corrected with this spreadsheet's formulas.

3/4" O. D. Condenser tube 1" O. D. Condenser tube

Outside Inside Outside

0.670 0.3526 0.26180.704 0.3893 0.2618

0.1825 0.1963 0.1262 0.883 285 0.732 0.4208 0.26180.2043 0.1963 0.1335 0.808 319 0.760 0.4536 0.26180.2223 0.1963 0.1393 0.747 347 0.782 0.4803 0.26180.2463 0.1963 0.1466 0.665 384 0.810 0.5153 0.26180.2679 0.1963 0.1529 0.592 418 0.834 0.5463 0.26180.2884 0.1963 0.1587 0.522 450 0.856 0.5755 0.26180.3019 0.1963 0.1623 0.476 471 0.870 0.5945 0.26180.3157 0.1963 0.1660 0.429 492 0.884 0.6138 0.26180.3339 0.1963 0.1707 0.367 521 0.902 0.6390 0.26180.3632 0.1963 0.1780 0.268 567 0.930 0.6793 0.2618

Tube flow area in2

Surface area per linear foot, ft2

Tube weight per linear foot,

lb of steel

Constant C **

Tube I. D. inches

Tube flow area in2

Surface area per linear foot, ft2

* The weight of the condenser tubes is based on low carbon steel with a density of 0.2836 lbs/in3. For other metal materials multiply by the following factors:

** Liquid Velocity within the tubes = (Lbs Per Tube Hour) / (C * Liquid Specific Gravity) in feet per sec. (Specific gravity of Water @ 60 oF = 1.00)

Page 121: Process Heat Transfer Hof Master

Some of this data was taken from Standards of the Tubular Exchanger Manufacturers Association (TEMA); 7th Edition (1988); page 178. Note: some of the tabular TEMA data contained ERRATA, but this was corrected with this spreadsheet's formulas.

1" O. D. Condenser tube 1-1/4" O. D. Condenser tube

Inside Outside Inside0.890 0.6221 0.3272 0.2330 2.059

0.1754 1.473 550 0.920 0.6648 0.3272 0.2409 1.9140.1843 1.348 0.954 0.7148 0.3272 0.2498 1.7440.1916 1.241 656 0.982 0.7574 0.3272 0.2571 1.5990.1990 1.129 708 1.010 0.8012 0.3272 0.2644 1.4500.2047 1.038 749 1.030 0.8332 0.3272 0.2697 1.3410.2121 0.919 804 1.060 0.8825 0.3272 0.2775 1.1730.2183 0.814 852 1.080 0.9161 0.3272 0.2827 1.0590.2241 0.714 898 1.110 0.9677 0.3272 0.2906 0.8830.2278 0.650 927 1.120 0.9852 0.3272 0.2932 0.8240.2314 0.584 1.130 1.0029 0.3272 0.2958 0.7630.2361 0.498 997 1.150 1.0387 0.3272 0.3011 0.6410.2435 0.361 1,060 1.180 1.0936 0.3272 0.3089 0.455

Surface area per linear foot, ft2

Tube weight per linear foot, lb of

steel

Constant C **

Tube I. D. inches

Tube flow area in2

Surface area per linear foot, ft2

Tube weight per linear foot, lb of

steel

Page 122: Process Heat Transfer Hof Master

1-1/4" O. D. Condenser tube 1-1/2" O. D. Condenser tube 2" O. D. Condenser tube

Outside Inside970

1,037 1.170 1.0751 0.3927 0.3063 2.3551.200 1.1310 0.3927 0.3142 2.165

1,182 1.230 1.1882 0.3927 0.3220 1.970 1,8601,250 1.260 1.2469 0.3927 0.3299 1.771 1.760 2.43281,305 1.280 1.2868 0.3927 0.3351 1.635 2,014 1.782 2.49411,377 1.310 1.3478 0.3927 0.3430 1.427 1.810 2.57301,440 1.330 1.3893 0.3927 0.3482 1.286 2,180 1.834 2.6417

1.360 1.4527 0.3927 0.3560 1.0701,537 1.370 1.4741 0.3927 0.3587 0.997 2,300

1.380 1.4957 0.3927 0.3613 0.9241,626 1.400 1.5394 0.3927 0.3665 0.7751,706

Constant C **

Tube I. D. inches

Tube flow area in2

Surface area per linear foot, ft2

Tube weight per linear foot,

lb of steel

Constant C **

Tube I. D. inches

Tube flow area in3

Page 123: Process Heat Transfer Hof Master

2" O. D. Condenser tube

Outside Inside

0.5236 0.4608 2.412 3,7950.5236 0.4665 2.204 3,8910.5236 0.4739 1.935 4,0140.5236 0.4801 1.701 4,121

Surface area per linear foot, ft3

Tube weight per linear foot, lb of steel

Constant C **

Page 124: Process Heat Transfer Hof Master

Art MontemayorHeat Exchanger Tubesheets

Tubesheet ThicknessOctober 09, 1991

Rev: 0

Page 124 of 140FileName: document.xls

WorkSheet: TubeSheet

The thickness of heat exchanger tubesheets is an important consideration in cost-estimating and selecting design alternatives for process heat systems. According to the Tubular Exchanger Manufactureres Assn. (TEMA) standards, the tubesheet thickness for shell-and-tube exchangers is given by the formula:

F = 1.25G = 12 inchesP = 350 psigS = 17,500 psi

T = 1.06 inches

TEMA gives precise rules for determining the variables F, G, P, and S for exchanger design. For estimating purposes, however, these terms can be taken as:

T = Tubesheet thickness, inchesF = a factor

= 1.0 for stationary and floating-head tubesheets = 1.25 for U-tube tubesheets

G = shell internal diameter, as calculated from transfer surface and tube dimensions, inchesP = design pressure, psigS = tubesheets' material allowable stress, psi

Values of S for some common materials are shown in the following table. With this table and the other terms,tubesheet thickness can be calculated in this spreadsheet.

Material100 200 300 400 500

SA-516 Grade 70 17,500 17,500 17,500 17,500 17,500Stainless Steel -- 17,700 16,100 15,900 --1.25Cr - 0.5Mo - Si Steel 15,000 15,000 15,000 15,000 15,000Monel 17,500 16,500 15,500 14,800 14,700SB-171 Naval Brass -- 12,500 10,500 2,000 --SB-402 Copper Nickel 12,500 10,500 10,400 10,400 10,400SB-11 Copper 6,600 5,700 5,000 -- --

From: Chemical Engineering Magazine; Plant Notebook; May 12, 1975

Temperature, oF

T= F G2 √ PS

Page 125: Process Heat Transfer Hof Master

SHELL AND TUBE HEAT EXCHANGER TUBESHEET LAYOUTS (TUBE COUNTS)Source: "Process Heat Transfer"; Donald Q. Kern, McGraw-Hill Book Co. (1950); page 841

3/4" O. D. tubes on 1-inch square pitch 1" O. D. tubes on 1-1/4 inch square pitch 1-1/4" O. D. tubes on 1-9/16 inch square pitch

8 32 26 20 20 21 16 1410 52 52 40 36 32 32 26 24 16 12 1012 81 76 68 68 60 48 45 40 38 36 30 24 22

13-1/4 97 90 82 76 70 61 56 52 48 44 32 30 3015-1/4 137 124 116 108 108 81 76 68 68 64 44 40 3717-1/4 177 166 158 150 142 112 112 96 90 82 56 53 5119-1/4 224 220 204 192 188 138 132 128 122 116 78 73 7121-1/4 277 270 246 240 234 177 166 158 152 148 96 90 8623-1/4 341 324 308 302 292 213 208 192 184 184 127 112 106

25 413 394 370 356 346 260 252 238 226 222 140 135 12727 481 460 432 420 408 300 288 278 268 260 166 160 15129 553 526 480 468 456 341 326 300 294 286 193 188 17831 657 640 600 580 560 406 398 380 368 358 226 220 20933 749 718 688 676 648 465 460 432 420 414 258 252 24435 845 824 780 766 748 522 518 488 484 472 293 287 27537 934 914 886 866 838 596 574 562 544 532 334 322 31139 1049 1024 982 968 948 665 644 624 612 600 370 362 348

Note: These tube counts can be taken only as an estimate. For accurate tube counts, an actual scaled layout should be done. Kern does not reveal where he obtained this information and he is not specific in giving details to what TEMA type, orientation, and Outer Tube Limits (OTL) this data applies.Consequently, the user is advised to scrutinize this information before using it.

Another estimating method for tube counts is found in "Petroleum Refinery Engineering"; Nelson; McGraw-Hill; Page 544:

The number of heat exchanger tubes can be estimated from the equation

where,C = 0.75 (a constant for Square pitch)P = the tube spacing, in inches

Shell I. D. Inches 1

TubePass2

TubePass4

TubePass6

TubePass8

TubePass1

TubePass2

TubePass4

TubePass6

TubePass8

TubePass1

TubePass2

TubePass4

TubePass

N = C * (L/P)2

Page 126: Process Heat Transfer Hof Master

L = the Outer Tube Limit, in inches

The OTL is about 1-1/2" less than the inside diameter of the shell in floating head exchangers.It is about 5/8" less than the shell inside diameter of fixed-head or U-tube construction.

Tube Spacing = 1.5 inchesOuter Tube Limit = 13.5 inches

Number of Tubes = 61

Page 127: Process Heat Transfer Hof Master

SHELL AND TUBE HEAT EXCHANGER TUBESHEET LAYOUTS (TUBE COUNTS)Source: "Process Heat Transfer"; Donald Q. Kern, McGraw-Hill Book Co. (1950); page 841

1-1/4" O. D. tubes on 1-9/16 inch square pitch 1-1/2" O. D. tubes on 1-7/8 inch square pitch

16 16 16 16 12 1222 22 22 22 16 1635 31 29 29 25 24 2248 44 39 39 34 32 2964 56 50 48 45 43 3982 78 62 60 57 54 50

102 96 78 74 70 66 62123 115 94 90 86 84 78146 140 112 108 102 98 94174 166 131 127 120 116 112202 193 151 146 141 138 131238 226 176 170 164 160 151268 258 202 196 188 182 176304 293 224 220 217 210 202342 336 252 246 267 230 224

Kern does not reveal where he obtained this information and he is not specific in giving details to what TEMA type, orientation, and Outer Tube Limits (OTL) this data applies.

6 TubePass

8 TubePass

1 TubePass

2 TubePass

4 TubePass

6 TubePass

8 TubePass

Page 128: Process Heat Transfer Hof Master

SHELL AND TUBE HEAT EXCHANGER TUBESHEET LAYOUTS (TUBE COUNTS)Source: "Process Heat Transfer"; Donald Q. Kern, McGraw-Hill Book Co. (1950); page 842

3/4" O. D. tubes on 15/16-inch triangular pitch 3/4" O. D. tubes on 1-inch triangular pitch

8 36 32 26 24 18 37 30 2410 62 56 47 42 36 61 52 4012 109 98 86 82 78 92 82 76

13-1/4 127 114 96 90 86 109 106 8615-1/4 170 160 140 136 128 151 138 12217-1/4 239 224 194 188 178 203 196 17819-1/4 301 282 252 244 234 262 250 22621-1/4 361 342 314 306 290 316 302 27823-1/4 442 420 386 378 364 384 376 352

25 532 506 468 446 434 470 452 42227 637 602 550 536 524 559 534 48829 721 692 640 620 594 630 604 55631 847 822 766 722 720 745 728 67833 974 938 878 852 826 856 830 77435 1102 1068 1004 988 958 970 938 88237 1240 1200 1144 1104 1072 1074 1044 101239 1377 1330 1258 1248 1212 1206 1176 1128

Note: These tube counts can be taken only as an estimate. For accurate tube counts, an actual scaled layout should be done. Kern does not reveal where he obtained this information and he is not specific in giving details to what TEMA type, orientation, and Outer Tube Limits (OTL) this data applies.As an example of a discrepancy, refer to the 8" shell with 3/4" tubes on 15/16" triangular pitch and 2-passes. An actual layout yields 48 tubes with 3/16" OTL, as compared with the listed 32 tubes.Consequently, the user is advised to scrutinize this information before using it.Triangular pitch should never be used with a dirty or fouling fluid on the shellside of an exchanger. This configuration is impossible to clean mechanically.

Another estimating method for tube counts is found in "Petroleum Refinery Engineering"; Nelson; McGraw-Hill; Page 544:

The number of heat exchanger tubes can be estimated from the equation

where,C = 0.86 (a constant for Triangular pitch)P = the tube spacing, in inchesL = the Outer Tube Limit, in inches

The OTL is about 1-1/2" less than the inside diameter of the shell in floating head exchangers.It is about 5/8" less than the shell inside diameter of fixed-head or U-tube construction.

Tube Spacing = 1.5 inchesOuter Tube Limit = 13.5 inches

Number of Tubes = 70

Shell I. D. Inches 1

TubePass2

TubePass4

TubePass6

TubePass8

TubePass1

TubePass2

TubePass4

TubePass

N = C * (L/P)2

Page 129: Process Heat Transfer Hof Master

SHELL AND TUBE HEAT EXCHANGER TUBESHEET LAYOUTS (TUBE COUNTS)Source: "Process Heat Transfer"; Donald Q. Kern, McGraw-Hill Book Co. (1950); page 842

3/4" O. D. tubes on 1-inch triangular pitch 1" O. D. tubes on 1-1/4 inch triangular pitch 1-1/4" O. D. tubes on 1-9/16 inch triangular pitch

24 21 16 16 1436 32 32 26 24 20 1874 70 55 52 48 46 4 32 3082 74 68 66 58 54 50 38 36

118 110 91 86 80 74 72 54 51172 166 131 118 106 104 94 69 66216 210 163 152 140 136 128 95 91272 260 199 188 170 164 160 117 112342 328 241 232 212 212 202 140 136394 382 294 282 256 252 242 170 164474 464 349 334 302 296 286 202 196538 508 397 376 338 334 316 235 228666 640 472 454 430 424 400 275 270760 732 538 522 486 470 454 315 305864 848 608 592 562 546 532 357 348986 870 674 664 632 614 598 407 390

1100 1078 766 736 700 688 672 449 436

These tube counts can be taken only as an estimate. For accurate tube counts, an actual scaled layout should be done. Kern does not reveal where he obtained this information and he is not specific in giving details to what TEMA type, orientation, and Outer Tube Limits (OTL) this data applies.As an example of a discrepancy, refer to the 8" shell with 3/4" tubes on 15/16" triangular pitch and 2-passes. An actual layout yields 48 tubes with 3/16" OTL, as compared with the listed 32 tubes.

Triangular pitch should never be used with a dirty or fouling fluid on the shellside of an exchanger. This configuration is impossible to clean mechanically.

Another estimating method for tube counts is found in "Petroleum Refinery Engineering"; Nelson; McGraw-Hill; Page 544:

The OTL is about 1-1/2" less than the inside diameter of the shell in floating head exchangers.It is about 5/8" less than the shell inside diameter of fixed-head or U-tube construction.

6 TubePass

8 TubePass

1 TubePass

2 TubePass

4 TubePass

6 TubePass

8 TubePass

1 TubePass

2 TubePass

Page 130: Process Heat Transfer Hof Master

1-1/4" O. D. tubes on 1-9/16 inch triangular pitch 1-1/2" O. D. tubes on 1-7/8 inch triangular pitch

1426 22 20 18 14 14 12 1232 28 26 27 22 18 16 1445 42 38 36 34 32 30 2762 58 54 48 44 42 38 3686 78 69 61 58 55 51 48

105 101 95 76 72 70 66 61130 123 117 95 91 86 80 76155 150 140 115 110 105 98 95185 179 170 136 131 125 118 115217 212 202 160 154 147 141 136255 245 235 184 177 172 165 160297 288 275 215 206 200 190 184335 327 315 246 238 230 220 215380 374 357 275 268 260 252 246425 419 407 307 299 290 284 275

4 TubePass

6 TubePass

8 TubePass

1 TubePass

2 TubePass

4 TubePass

6 TubePass

8 TubePass

Page 131: Process Heat Transfer Hof Master

Art Montemayor November 03, 1997

Page 131 of 140FileName: document.xlsWorkSheet: Total Tubes

greater than that shown for a fixed tube sheet design and smaller for a pull-through floating head. In any case,

tubes that can be fitted into a given tubesheet depends upon the pass partition pattern, the thickness of the pass dividers and exactly where the drilling pattern is started relative to the dividers and the outer tube limit. Additional tubes will be lost from the bundle for a U-tube design because the minimum bending radius prevents tubes from being inserted in some, or all, of the possible drilling positions near the centerline of the U-tube pattern. Tubes will also be lost if an impingement plate is inserted underneath the nozzle. For a no-tubes-in-the-window design,

Number of Tube Passes

1 2 4 6

6.82

0.75 0.9375 Triang. 38 32 26 240.75 1.0000 Square 32 26 20 200.75 1.0000 Triang. 37 30 24 241.00 1.2500 Square 21 16 16 14

1.00 1.2500 Triang. 22 18 16 14

8.77

0.75 0.9375 Triang. 62 56 47 420.75 1.0000 Square 52 52 40 36

0.75 1.0000 Triang. 61 52 48 481.00 1.2500 Square 32 32 26 241.00 1.2500 Triang. 37 32 28 28

12.00 10.75

0.75 0.9375 Triang. 109 98 86 820.75 1.0000 Square 80 72 68 680.75 1.0000 Triang. 90 84 72 701.00 1.2500 Square 48 44 40 381.00 1.2500 Triang. 57 52 44 42

13.25 12.00

0.75 0.9375 Triang. 127 114 96 900.75 1.0000 Square 95 90 81 770.75 1.0000 Triang. 110 101 90 881.00 1.2500 Square 60 56 51 461.00 1.2500 Triang. 67 63 56 54

15.25 14.00

0.75 0.9375 Triang. 170 160 140 1360.75 1.0000 Square 138 132 116 1120.75 1.0000 Triang. 163 152 136 1331.00 1.2500 Square 88 82 75 701.00 1.2500 Triang. 96 92 86 84

17.25 16.00

0.75 0.9375 Triang. 239 224 194 1880.75 1.0000 Square 188 178 168 1640.75 1.0000 Triang. 211 201 181 1761.00 1.2500 Square 112 110 102 981.00 1.2500 Triang. 130 124 116 110

19.25 18.00

0.75 0.9375 Triang. 301 282 252 2440.75 1.0000 Square 236 224 216 2080.75 1.0000 Triang. 273 256 242 2361.00 1.2500 Square 148 142 136 129

TOTAL NUMBER OF TUBES IN AN EXCHANGER, Nt:

If not known by direct count, find the tube quantity in the tube count table as a function of Dotl, the tube

pitch, p, and the layout. The shell diameter Di and outer tube limit Dotl given in the table are those for a

conventional split-ring floating head design, fully tubed out. For a given shell diameter, the value of Dotl will be

the tube count can be reasonably interpolated from the Table using the known or specified Dotl, asuming that

the tube count is proportional to (Dotl)2. All tube count tables are only approximate since the actual number of

the actual number of tubes in the bundle is FcNt. Fc is the fraction of total tubes in crossflow.

Shell ID in.

Outer Tube Limit

Diameter, in.

Tube OD in

Tube Pitch, in.

Tube Layout

8.071 (Sch. 30)

10.02 (Sch. 40)

Page 132: Process Heat Transfer Hof Master

Art Montemayor November 03, 1997

Page 132 of 140FileName: document.xlsWorkSheet: Total Tubes

19.25 18.00

1.00 1.2500 Triang. 172 162 152 148

21.00 19.25

0.75 0.9375 Triang. 361 342 314 3060.75 1.0000 Square 276 264 246 2400.75 1.0000 Triang. 318 308 279 2691.00 1.2500 Square 170 168 157 1501.00 1.2500 Triang. 199 188 170 164

23.25 21.50

0.75 0.9375 Triang.0.75 1.0000 Square0.75 1.0000 Triang.1.00 1.2500 Square1.00 1.2500 Triang.

25.00 23.25

0.75 0.9375 Triang.0.75 1.0000 Square0.75 1.0000 Triang.1.00 1.2500 Square1.00 1.2500 Triang.

27.00 25.25

0.75 0.9375 Triang.0.75 1.0000 Square0.75 1.0000 Triang.1.00 1.2500 Square1.00 1.2500 Triang.

29.00 27.25

0.75 0.9375 Triang.0.75 1.0000 Square0.75 1.0000 Triang.1.00 1.2500 Square1.00 1.2500 Triang.

31.00 29.25

0.75 0.9375 Triang.0.75 1.0000 Square0.75 1.0000 Triang.1.00 1.2500 Square1.00 1.2500 Triang.

33.00 31.25

0.75 0.9375 Triang.0.75 1.0000 Square0.75 1.0000 Triang.1.00 1.2500 Square1.00 1.2500 Triang.

35.00 33.25

0.75 0.9375 Triang.0.75 1.0000 Square0.75 1.0000 Triang.1.00 1.2500 Square1.00 1.2500 Triang.

37.00 35.25

0.75 0.9375 Triang.0.75 1.0000 Square0.75 1.0000 Triang.1.00 1.2500 Square1.00 1.2500 Triang.

39.00 37.25

0.75 0.9375 Triang.0.75 1.0000 Square0.75 1.0000 Triang.1.00 1.2500 Square1.00 1.2500 Triang.

42.00 40.25

0.75 0.9375 Triang.0.75 1.0000 Square0.75 1.0000 Triang.1.00 1.2500 Square

Page 133: Process Heat Transfer Hof Master

Art Montemayor November 03, 1997

Page 133 of 140FileName: document.xlsWorkSheet: Total Tubes

42.00 40.25

1.00 1.2500 Triang.

44.00 42.25

0.75 0.9375 Triang.0.75 1.0000 Square0.75 1.0000 Triang.1.00 1.2500 Square1.00 1.2500 Triang.

48.00 46.00

0.75 0.9375 Triang.0.75 1.0000 Square0.75 1.0000 Triang.1.00 1.2500 Square1.00 1.2500 Triang.

52.00 50.00

0.75 0.9375 Triang.0.75 1.0000 Square0.75 1.0000 Triang.1.00 1.2500 Square1.00 1.2500 Triang.

56.00 54.00

0.75 0.9375 Triang.0.75 1.0000 Square0.75 1.0000 Triang.1.00 1.2500 Square1.00 1.2500 Triang.

60.00 58.00

0.75 0.9375 Triang.0.75 1.0000 Square0.75 1.0000 Triang.1.00 1.2500 Square1.00 1.2500 Triang.

Page 134: Process Heat Transfer Hof Master

Art Montemayor November 03, 1997

Page 134 of 140FileName: document.xlsWorkSheet: Total Tubes

greater than that shown for a fixed tube sheet design and smaller for a pull-through floating head. In any case,

tubes that can be fitted into a given tubesheet depends upon the pass partition pattern, the thickness of the pass dividers and exactly where the drilling pattern is started relative to the dividers and the outer tube limit. Additional tubes will be lost from the bundle for a U-tube design because the minimum bending radius prevents tubes from being inserted in some, or all, of the possible drilling positions near the centerline of the U-tube pattern. Tubes will also be lost if an impingement plate is inserted underneath the nozzle. For a no-tubes-in-the-window design,

Number of Tube Passes

8

18

36

606836408670744450

128108110

6472

178142166

8294

234188210116

, fully tubed out. For a given shell diameter, the value of Dotl will be

since the actual number of

Page 135: Process Heat Transfer Hof Master

Art Montemayor November 03, 1997

Page 135 of 140FileName: document.xlsWorkSheet: Total Tubes

128290234260148160

Page 136: Process Heat Transfer Hof Master

Art Montemayor November 03, 1997

Page 136 of 140FileName: document.xlsWorkSheet: Total Tubes

Page 137: Process Heat Transfer Hof Master

Art Montemayor November 03, 1997

Tube OD, in. Tube Pitch, in. Layout

0.625 0.8125 0.704 0.406

0.750 0.9375 0.814 0.469

0.750 1.0000 1.000 1.000

0.750 1.0000 0.707 0.707

0.750 1.0000 0.866 0.500

1.000 1.2500 1.250 1.250

1.000 1.2500 0.884 0.884

1.000 1.2500 1.082 0.625

Tube Pitch Types:

Note: Flow arrows are perpendicular to the baffle cut edge

Pp, in. Pn, in.

TUBE PITCH PARALLEL TO FLOW, PP, AND NORMAL TO FLOW, PN

These quantities are needed only for the purpose of estimating other parameters. If a detailed drawing of the exchanger is available, or if the exchanger itself can be conveniently examined, it is better to obtain these other parameters by direct count or calculation. The quantities are described by Figure 5.2-1 and

read from Table IV for the most common tube layouts.

30o Triangular 60o Rotated Triangular

Flow

Flow

SquareRotated Square

Page 138: Process Heat Transfer Hof Master

Art Montemayor Heat Exchanger TemperaturesAugust 21, 2004

Rev: 0

Page 138 of 140FileName: document.xls

Worksheet: Ht Exchanger Temperatures

Source: Chemical Engineering Magazine; Plant Notebook Section; Unknown dateJ. T. Petrosky; Vulcan Materical Co. Wichita, Kansas

Direct Calculation of Exchanger Exit Temperatures

In specifying heat exchanger sevices for process design, it is frequently necessary to arive at optimum condtions through trial and error. However, the determination of each set of condtions within this trial-and-error also involves

calculation of interrelated variables, such as inlet and outlet temperatures and area; and this can result in

trial-and-error calculations within the trial-and -error for the optimum. It is, thus, convenient to be able to calculate exchanger outlet conditions directly, based on known or assumed values of inlet temperatures, specific heats, flowing quantities, overall transfer rate, and surface. Such a direct calculation is developed as follows and shown in the sketch.

Nomenclature:q = Heat duty, Btu/hr or kcal/hr = 1,000,000

Constant or average specific heat on the shell side, Btu/lb or kcal/kg = 0.5000

Constant or average specific heat on the tube side, Btu/lb or kcal/kg = 1.0000W = Fluid mass flow rate in shell side, lb/hr or kg/hr = 100,000w = Fluid mass flow rate in tube side, lb/hr or kg/hr = 45,000

U = 125

A = 300.0

250

85

Subscript denoting inlet conditions

Subscript denoting outlet conditions

From the derived equations, let: Z = 50,000B = 45,000

C = 0.9200444

Therefore,

152

Cp =cp =

Overall heat transfer coefficient, Btu/hr-ft2-oF or kcal/hr-m2-oC =Total exchanger heat transfer area, ft2 or m2 =

T1 = Shell-side fluid temperature, oF or oC =t1 = Tube-side fluid temperature, oF or oC =

DTm = Log mean temperature difference, oF or oC=

1 =

2 =

T2 = B t1 (1 - C) - T1(B - Z)/(Z - BC) = oF or oC

q, U, A, DTmw, cp, t1

W, Cp, T2

W, Cp, T1

w, cp, t2

C=eUA( 1

Z− 1B )

Page 139: Process Heat Transfer Hof Master

Art Montemayor Heat Exchanger TemperaturesAugust 21, 2004

Rev: 0

Page 139 of 140FileName: document.xls

Worksheet: Ht Exchanger Temperatures

Equations and their derivations:

In specifying heat exchanger sevices for process design, it is frequently necessary to arive at optimum condtions through trial and error. However, the determination of each set of condtions within this trial-and-error also involves Let:

calculation of interrelated variables, such as inlet and outlet temperatures and area; and this can result in B =

trial-and-error calculations within the trial-and -error for the optimum. It is, thus, convenient to be able to calculate Z =exchanger outlet conditions directly, based on known or assumed values of inlet temperatures, specific heats, flowing quantities, overall transfer rate, and surface. Such a direct calculation is developed as follows and shown Combining both above equations,

The heat transferred to the tube-side fluid = q = (w) (cp) (t2 - t1)

The heat transferred to the shell-side fluid = q = (W) (Cp) (T1 -T2)

(w) (cp)(W) (Cp)

The heat transferred is also=UA ΔTm=UA [ (T 1−t2)−(T 2−t1)

ln(T1−t2)(T2−t1) ]

t2=( ZB )(T1−T 2 )+t1

Z (T 1−T 2)=UA [ (T 1−t2 )−(T2−t1)

ln(T 1−t2 )(T 2−t1 ) ]

ln [T 1−(ZB )(T1−T 2)−t1

(T 2−t1) ]=UA [T 1−( ZB )(T1−T 2 )+t1−(T2−t1)

Z (T 1−T2 ) ]ln [T 1−T 1 (ZB )+T2 (ZB )−t1

(T 2−t1) ]=UA [T 1−T 1 ( ZB )+T 2 ( ZB )+t1−T2+t1

Z (T1−T 2 ) ]

ln [T 1 (1−ZB )+T2 (ZB )−t1(T2−t1 ) ]=UA [T 1− ( ZB ) (T 1−T2 )−T2

Z (T 1−T 2) ]=UA (T 1−T 2 )−(ZB )(T 1−T 2)

Z (T 1−T 2)

ln [T 1 (1−ZB )+T2 (ZB )−t1(T2−t1 ) ]=UA [ 1− ( ZB )

Z ]=UA ( 1Z− 1B )

Page 140: Process Heat Transfer Hof Master

Art Montemayor Heat Exchanger TemperaturesAugust 21, 2004

Rev: 0

Page 140 of 140FileName: document.xls

Worksheet: Ht Exchanger Temperatures

The heat transferred is also=UA ΔTm=UA [ (T 1−t2)−(T 2−t1)

ln(T1−t2)(T2−t1) ]

ln [T 1−(ZB )(T1−T 2)−t1

(T 2−t1) ]=UA [T 1−( ZB )(T1−T 2 )+t1−(T2−t1)

Z (T 1−T2 ) ]ln [T 1−T 1 (ZB )+T2 (ZB )−t1

(T 2−t1) ]=UA [T 1−T 1 ( ZB )+T 2 ( ZB )+t1−T2+t1

Z (T1−T 2 ) ]

ln [T 1 (1−ZB )+T2 (ZB )−t1(T2−t1 ) ]=UA [T 1− ( ZB ) (T 1−T2 )−T2

Z (T 1−T 2) ]=UA (T 1−T 2 )−(ZB )(T 1−T 2)

Z (T 1−T 2)

ln [T 1 (1−ZB )+T2 (ZB )−t1(T2−t1 ) ]=UA [ 1− ( ZB )

Z ]=UA ( 1Z− 1B )