Shell & Tube Cal

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
Shell And Tube Process Calculations
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramcos
employees. Any material contained in this document which is not already
in the public domain may not be copied, reproduced, sold, given, or
disclosed to third parties, or otherwise used in whole, or in part, without
the written permission of the Vice President, Engineering Services, Saudi
Aramco.
Chapter : Process
File Reference: CHE10109
For additional information on this subject, contact

R. A. Al-Husseini on 874-2792
Process
Shell and Tube Process Calculations
CONTENTS
PAGES
FLOW/EXCHANGER CONFIGURATIONS .......................................................1

Calculating Energy Balances......................................................................4
Calculating Heat Transfer Coefficients ....................................................11
Effective Temperature Difference ............................................................11
NOMENCLATURE.............................................................................................13
Change Of State (Change of Phase) Effects .............................................18
Heat Transfer Equation.............................................................................19
Heat Transfer Resistance ..........................................................................20
Calculating Surface Area..........................................................................30
Calculating Tubewall Temperature ..........................................................32
Selecting Design Pressure and Temperature ............................................39
Components of Heat Exchanger Specification Sheets..............................39
Optimizing Heat Exchanger Operations...................................................41
Troubleshooting Heat Exchangers............................................................41
Flow Optimization....................................................................................41
Exchanger Cleaning Schedules ................................................................42
Key Formulas ...........................................................................................43
Temperature Correction Factor.....................................................43
Overall Heat Duty .........................................................................43
Log Mean Temperature Difference...............................................43
Effective Temperature Difference.................................................44
Overall Heat Transfer Coefficient.................................................44
Inside Film Coefficient .................................................................44
Outside Film Coefficient...............................................................45
Tubewall Resistance .....................................................................45
Caloric Temperature .....................................................................45
Tubewall Temperature ..................................................................46
Process
WORK AID 1 - PROCEDURES FOR CALCULATING ENERGY

BALANCE...........................................................................................................51
WORK AID 2 - PROCEDURES FOR CALCULATING HEAT
TRANSFER COEFFICIENTS.............................................................................53
WORK AID 3 - PROCEDURES FOR CALCULATING
REQUIRED SURFACE AREA ...........................................................................57
WORK AID 4 - PROCEDURES FOR CALCULATING
TUBEWALL TEMPERATURE ..........................................................................58
WORK AID 5 - PROCEDURES FOR CALCULATING DESIGN
PRESSURE AND TEMPERATURE...................................................................59
Design Temperature: ................................................................................59
Design Pressure: .......................................................................................59
WORK AID 6 ......................................................................................................60
GLOSSARY ........................................................................................................62
REFERENCES.....................................................................................................63
APPENDICES .....................................................................................................64
Process
FLOW/EXCHANGER CONFIGURATIONS
The cost for a given tube or shell heat exchanger service is generally kept to a minimum by
placing the required tube surface in the minimum number of bundles. More than one shell per
service is usually specified only when the required surface exceeds that allowed for a
maximum diameter shell (maintenance considerations sets maximum shell size), a low
allowable pressure drop necessitates two shells in parallel, or the relative temperature of the
hot and cold streams makes it economical or necessary. Saudi Aramco Design Practice ADPE-001, Pg. 17, gives the maximum size shell that can be used based on Saudi Aramco
maintenance and repair capabilities. The maximums are:
Weight empty, 60,000 lb.

Tube length, 24 ft.
Shell inside diameter, 60 in.
Parallel shells are required to meet a low allowable pressure drop if a single shell exchanger
with maximum allowable baffle pitch and segmental cut or only two tube passes will not meet
the pressure drop requirement on the shellside or tubeside. To meet low allowable pressure
drop requirements, use the alternative Aramco standard tube length of 10 ft versus the usually
standard tube length of 20 ft (see ADP-E-001, Pg. 113). For a given tube surface and two
tube passes per shell, pressure drop is reduced by about a factor of 7 by placing two bundles
in parallel, each with 10-ft tubes versus one bundle with 20-ft tubes. (Both flow path and
velocity are cut in half and pressure drop varies with velocity to about the 1.8 power; 2 x
(2)1.8 @ 7.) Usually, this approach is preferred to using a single tube pass, fixed tubesheet
single shell with 20-ft tubes, which would also reduce pressure drop by about a factor of 7.
If a low allowable pressure drop is a problem only on the shellside, keeping the tube length
constant but splitting the required tube surface into two bundles will reduce the actual
shellside pressure drop. The reason for the drop is that the shell diameter, which sets the
shellside flow velocity, decreases with the square root of the change in cross-sectional area
(tube surface area). This reduces shellside velocity because the shellside flow rate decreases
linearly with tube surface.
Process
Use multiple shells in series when there is a relatively high allowable pressure drop and the
required tube surface cannot fit in one maximum size shell. Use them also when there is a
small temperature approach or a temperature crossover in the two fluid temperatures. With
multiple tube passes in one shell, the exchanger mixes the cocurrent and countercurrent flow
of hot fluid relative to cold fluid. In the more common arrangement, a single shell pass
exchanger with two or more tube passes, half of the tubeside flow path is countercurrent with
the shellside flow and half is cocurrent. An even number of tube passes is the normal
arrangement to avoid a fixed tubesheet. This mixed countercurrent and cocurrent flow limits
the relative temperatures of the hot and cold fluids that can be processed in any one shell.
Figures on Pg. 112 - 117 of the TEMA Manual are used to calculate a correction factor, FT,
which is applied to the calculated temperature difference between the two exchanger fluids.
The FT factor varies for any given set of hot and cold fluid temperatures as a function of the
number of shells in a series flow arrangement.
An example of the effect of placing a service in two bundles in series versus one bundle is as
follows:
Process
500
Temperature in F
Temperature out F
Tubeside
Cold Fluid
Shellside
Hot Fluid
120 (t1)
500 (T1)
300
300
300 (t2)
300 (T2)
120
One shell (see TEMA Manual, Pg. 112).

P = t2 - t1 = 300 - 120 = 180 = 0.474
T1 - t1
500 - 120
380
R = T1 - T2 = 500 - 300 = 200 = 1.111
t2 - t1
300 - 120
180
Refer to TEMA figures for the FT factor.
Therefore, FT = 0.8.
Two shells in series (see TEMA Manual, Pg. 113).
The values for P and R stay the same as for the one shell case.
Therefore, the FT factor = 0.955.
The foregoing calculation shows that the change from one bundle to two bundles in series,
considering only the FT factor, reduces the total required tube surface by 16%:
0.8 = 0.84
0.955
NOTE:
As a rule, do not design heat exchangers to operate with an F T less than 0.8, because the rate of
change of FT below 0.8 is too rapid to predict exchanger operation accurately.
Process
Calculating Energy Balances

Energy balance calculations around an exchanger determine the exchanger duty (Q). This can
be accomplished in three ways. Prepare a stream enthalpy summary for all streams entering
and leaving the exchanger. Calculate heat removal or addition to each exchanger stream by
the formula Q = (W) (Cp) (t), using flow rates, temperature, and specific heat
information for each stream. Calculate the heat removed or added for one of the two
exchanger streams and reconstruct the process conditions for the second stream based on the
knowledge that the heat removed from one stream must equal the heat added to the other
stream.
Working with computer-generated information means that the enthalpy for the total stream is
usually available. Doing an enthalpy balance, stream by stream, around the exchanger is the
simplest method for determining Q. If a component breakdown of the stream can be
obtained, the enthalpy of the total stream can sometimes be determined by summing the
enthalpies obtained for each component. Component enthalpy data can be found in the Data
Book on Hydrocarbons by Maxwell, Chapter 7.
The next three example problems show how to calculate the energy balance around a piece of
equipment by the methods just discussed.
Process
Example Problem 1
Calculate the exchanger duty Q by the stream enthalpy method. Refer to Figure 1, p. 11 for
typical, computer-generated stream enthalpy information, which will be used as the basis for
the first example calculation.
Calculate exchanger Q using stream enthalpy information from Figure 1.
BOTM TO PRHT - Tower bottoms to feed preheat exchanger shellside:
HTS = 0.3569 k Btu/lb
BOTM FR PRHT - Tower bottoms from feed preheat exchanger shellside:
HFS = 0.3037 k Btu/lb
FEED COLD - Tower feed to feed preheat exchanger tubeside:
HTt = 0.2829 k Btu/lb
FEED HOT - Tower feed from feed preheat exchanger tubeside:
HFt = 0.3167 k Btu/lb
From Figure 1, tubeside W is 145,812 lb/hr. Q is calculated as:
Q = (HFt - HTt) (W)
For the stream being heated.
Q = (0.3167 - 0.2829) (1000) (145,812) = 4,928,446 Btu/hr

This value for Q can be confirmed by doing the same type of calculation on the shellside of
the exchanger.
From Figure 1, shell side W is 92,482 lb/hr. Q is calculated as:
Q = (HTS - HFS) (W) for the stream being cooled
= (0.3569 - 0.3037) (1000) (92,482) = 4,920,042 Btu/hr
The minor difference (0.17%) between these two values for Q reflects the level of accuracy
built into the heat balancing calculation for each processing step calculated by the computer.
Process
HEAT EXCHANGER SPECIFICATION SHEET
(use photostat)
figure 1
Process
(use photostat)
figure 1 (cont'd)
Process
Example Problem 2
Calculate exchanger Q using stream specific heat and flow rate information in Figure 1. The
same streams are used for this example as in Example Problem 1. This calculation will use
the Q = (W) (Cp) (t) method (specific-heat method) for doing an energy balance around an
exchanger.
From Figure 1, calculate the average Cp using exchanger inlet and outlet conditions:
BOTM TO PRHT
Cp =0.8187 + 0.6314 = 0.7251

2
(Shellside)
FEED COLD
Cp =0.6019 + 0.6724 = 0.6372

2
(Tubeside)
Calculate the heat transferred:

BOTM TO PRHT
Q = (0.7251) (92,482) (234.7 - 158.2) = 5,129,990 Btu/hr
FEED COLD
Q = (0.6372) (145,812) (158.4 - 105.0) = 4,961,500 Btu/hr
NOTE: There is significantly more variation in the answer Q (3.3%) when using average Cp values than
computer-generated enthalpy values.
The last energy balance method determines how much heat is removed from one of the two
streams in the exchanger. The operating conditions for the other stream can be reconstructed
with the knowledge that the amount of heat removed from one stream in an exchanger must
equal the heat input into the second stream. This method is particularly useful for services
like recirculating thermosyphon reboilers on towers for which it is very difficult to calculate
an energy balance for the tower fluid side of the exchanger but often very easy to do an
energy balance calculation for the heating side. Example Problem 3 illustrates this method.
Process
Example Problem 3
Calculate the exchanger duty Q using the second stream reconstruction method. Calculate the
amount of heat being used to reboil the tower. The measured flow rate for the 125 psig steam
to the reboiler is 12,580 lb/hr. The steam supply conditions are 140 psia and 353F. The
steam condensate temperature is 353F.
From Figure 2, p. 14 the enthalpy of the steam is 1193.0 Btu/lb and the enthalpy for the
condensate is 324.82 Btu/lb.
Heat input to the tower Q is:
Q = (12,580) (1193.0 - 324.82) = 10,921,700 Btu/hr.
Process
PROPERTIES OF SATURATED STEAM: PRESSURE TABLE*

Internal Energy, Btu/lb
Abs. pressure
lb/in. 2
p
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10
14.696
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
110
120
130
140
150
160
170
180
190
200
250
300
350
400
450
500
550
600
650
700
750
800
850
900
950
1000
1100
1200
1300
1400
1500
2000
2500
3000
3206.2
Temp.,
F
t
101.74
126.08
141.48
152.97
162.24
170.06
176.85
182.86
188.28
193.21
212.00
213.03
227.96
240.07
250.33
259.28
267.25
274.44
281.01
287.07
292.71
297.97
302.92
307.60
312.03
316.25
320.27
324.12
327.81
334.77
341.25
347.32
353.02
358.42
363.53
368.41
373.06
377.51
381.79
400.95
417.33
431.72
444.59
456.28
467.01
476.94
486.21
494.90
503.10
510.86
518.23
525.26
531.98
538.43
544.61
556.31
567.22
577.46
587.10
596.23
635.82
668.13
695.36
705.40
Volume, ft 3/lb
Liquid
Vapor
vf
vg
0.01614
0.01623
0.01630
0.01636
0.01640
0.01645
0.01649
0.01653
0.01656
0.01659
0.01672
0.01672
0.01683
0.01692
0.01701
0.01708
0.01715
0.01721
0.01727
0.01732
0.01738
0.01743
0.01748
0.01753
0.01757
0.01761
0.01766
0.01770
0.01774
0.01782
0.01789
0.01796
0.01802
0.01809
0.01815
0.01822
0.01827
0.01833
0.01839
0.01865
0.01890
0.01913
0.0193
0.0195
0.0197
0.0199
0.0201
0.0203
0.0205
0.0207
0.0209
0.0210
0.0212
0.0214
0.0216
0.0220
0.0223
0.0227
0.0231
0.0235
0.0257
0.0287
0.0346
0.0503
333.6
173.73
118.71
90.63
73.52
61.98
53.64
47.34
42.40
38.42
26.80
26.29
20.089
16.303
13.746
11.898
10.498
9.401
8.515
7.787
7.175
6.655
6.206
5.816
5.472
5.168
4.896
4.652
4.432
4.049
3.728
3.455
3.220
3.015
2.834
2.675
2.532
2.404
2.288
1.8438
1.5433
1.3260
1.1613
1.0320
0.9278
0.8424
0.7698
0.7083
0.6554
0.6092
0.5687
0.5327
0.5006
0.4717
0.4456
0.4001
0.3619
0.3293
0.3012
0.2765
0.1878
0.1307
0.858
0.503
Enthalpy, Btu/lb
Liquid
Vapor
ht
hg
69.70
93.99
109.27
120.86
130.13
137.96
144.76
150.79
156.22
161.17
180.07
181.11
196.16
208.42
218.82
227.91
236.03
243.36
250.09
256.30
262.09
267.50
272.61
277.43
282.02
286.39
290.56
294.56
298.40
305.66
312.44
318.81
324.82
330.51
335.93
341.09
346.03
350.79
355.36
376.00
393.84
409.69
424.0
437.2
499.4
460.8
471.6
481.8
491.5
500.8
509.7
518.3
526.6
534.6
542.4
557.4
571.7
585.4
598.7
611.6
671.7
730.6
802.5
902.7
1106.0
1116.3
1122.6
1127.3
1131.1
1134.2
1136.9
1139.3
1141.4
1143.3
1150.4
1150.8
1156.3
1160.6
1164.1
1167.1
1169.7
1172.0
1174.1
1175.9
1177.6
1179.1
1180.6
1181.9
1183.1
1184.2
1185.3
1186.2
1187.2
1188.9
1190.4
1191.7
1193.0
1194.1
1195.1
1196.0
1196.9
1197.6
1198.4
1201.1
1202.8
1203.9
1204.5
1204.6
1204.4
1203.9
1203.2
1202.3
1201.2
1200.0
1198.6
1197.1
1195.4
1193.7
1191.8
1187.8
1183.4
1178.6
1173.4
1167.9
1135.1
1091.1
1020.3
902.7
Enthropy, Btu/(lb)(R)
Liquid
Vapor
sf
sg
0.1326
0.1749
0.2008
0.2198
0.2347
0.2472
0.2581
0.2674
0.2759
0.2835
0.3120
0.3135
0.3356
0.3533
0.3680
0.3807
0.3919
0.4019
0.4110
0.4193
0.4270
0.4342
0.4409
0.4472
0.4531
0.4587
0.4641
0.4692
0.4740
0.4832
0.4916
0.4995
0.5069
0.5138
0.5204
0.5266
0.5325
0.5381
0.5435
0.5675
0.5879
0.6056
0.6214
0.6356
0.6487
0.6608
0.6720
0.6826
0.6925
0.7019
0.7108
0.7194
0.7275
0.7355
0.7430
0.7575
0.7711
0.7840
0.7963
0.8082
0.8619
0.9126
0.9731
1.0580
1.9782
1.9200
1.8863
1.8625
1.8441
1.8292
1.8167
1.8057
1.7962
1.7876
1.7566
1.7549
1.7319
1.7139
1.6993
1.6870
1.6763
1.6669
1.6585
1.6509
1.6438
1.6374
1.6315
1.6529
1.6207
1.6158
1.6112
1.6068
1.6026
1.5948
1.5878
1.5812
1.5751
1.5694
1.5640
1.5590
1.5542
1.5497
1.5453
1.5263
1.5104
1.4966
1.4844
1.4734
1.4634
1.4542
1.4454
1.4374
1.4296
1.4223
1.4153
1.4085
1.4020
1.3957
1.3897
1.3780
1.3667
1.3559
1.3454
1.3351
1.2849
1.2322
1.1615
1.0580
Liquid
Uf
Vapor
Ug
69.70
93.98
109.36
120.85
130.12
137.94
144.74
150.77
156.19
161.14
180.02
181.06
196.10
208.34
218.73
227.80
235.90
243.22
249.93
256.12
261.90
267.29
272.38
277.19
281.76
286.11
290.27
294.25
298.08
305.30
312.05
318.38
324.35
330.01
335.39
340.52
345.42
350.15
354.68
375.14
392.79
408.45
422.6
435.5
447.6
458.8
469.4
479.4
488.8
598.0
506.6
515.0
523.1
530.9
538.4
552.9
566.7
580.0
592.7
605.1
662.2
717.3
783.4
872.9
1044.3
1051.9
1056.7
1060.2
1063.1
1065.4
1067.4
1069.2
1070.8
1072.2
1077.5
1077.8
1081.9
1085.1
1087.8
1090.1
1092.0
1093.7
1095.3
1096.7
1097.9
1099.1
1100.2
1101.2
1102.1
1102.9
1103.7
1104.5
1105.2
1106.5
1107.6
1108.6
1109.6
1110.5
1111.2
1111.9
1112.5
1113.1
1113.7
1115.8
1117.1
1118.0
1118.5
1118.7
1118.6
1118.2
1117.7
1117.1
1116.3
1115.4
1114.4
1113.3
1112.1
1110.8
1109.4
1106.4
1103.0
1099.4
1095.4
1091.2
1065.6
1030.6
972.7
872.9
*ABRIDGED FROM KEENAN AND KEYES, "THERMODYNAMIC PROPERTIES OF STEAM," WILEY, NEW YORK, 1936.
COPYRIGHT, 1937, BY JOSEPH H. KEENAN AND FREDERICK G. KEYES. WITH PERMISSION FROM MATTHEW A. KEENAN AND
ESTHER K. CARR.
figure 2
10
Process
Calculating Heat Transfer Coefficients

Calculating heat transfer coefficients includes calculating effective temperature differences,
recognizing change of phase effects, calculating heat transfer equations, and understanding
heat transfer resistance principles. The following section will cover each of these topics in
detail.
Effective Temperature Difference
The effective temperature difference between two fluids in an exchanger is the driving force
that transfers heat from the hot fluid to the cold fluid. The FT factor is the temperature
correction factor for the lack of a true countercurrent flow in an exchanger. The effective
temperature difference for an exchanger is calculated by multiplying the FT factor by the log
mean temperature difference (LMTD).
LMTD represents the actual temperature driving force between the fluids for true
countercurrent flow. The temperature difference between the two fluids must be measured at
numerous locations along the tubes of a true countercurrent flow exchanger. These
temperature differences are then integrated and the answer expressed in terms of the inlet and
outlet temperatures for the two fluids. Applying the following formula provides the
exchanger temperature difference.
LMTD is equal to:
T1
LMTD =
( GTTD - LTTD)
Hot Side
t2
GTTD
ln
LTTD
Cool Side
T2
TD1
where: TD1
TD2
GTTD
LTTD
TD 2
t1
= T2 - t1
=T1 - t2
= Greater temperature difference.
= Lesser temperature difference.
11
Process
Multiplying the LMTD for an exchanger by FT to obtain te accounts for nonperfect

counter-current flow and is the acceptable method for determining the true temperature
driving force for an exchanger. The heating and cooling curves for the exchanger fluids
(enthalpy versus temperature) should be close to linear (straight line) for the (FT)(LMTD)
approach to be valid. Calculation of the LMTD for exchangers with nonlinear heating and
cooling curves (condensing and/or vaporizating) will be discussed later in this module.
As shown earlier, the FT factor is affected by the number of shells in series. The effective
temperature difference [(LMTD) (FT)] is also affected by the number of shells in series. The
following example problem shows how to calculate the effect that one shell versus two shells
in series has on the effective temperature difference.
12
Process
NOMENCLATURE
Ai
Ao
as
at
Bp
C
Inside tube surface area, ft2.

Total outside surface area of bare tubes, ft2.
Free cross-sectional area for flow across tube bundle, ft2.
Internal cross-sectional area of tubes per pass, ft2.
Baffle spacing, in. (baffle pitch).
Clearance between adjacent tubes, in. = P - do
Cp
Des
des
Di
di
Dm
dm
Do
do
Ds
ds
Fc
fs
ft
FT
g
g
Gs
Gs
Gt
hi
ho
jH
Specific heat, Btu/lb F.

Equivalent diameter shell and tube exchanger on shellside, ft.
Equivalent diameter shell and tube exchanger on shellside, in.
Inside diameter of tube, ft.
Inside diameter of tube, in.
Logarithmic mean diameter of tube, ft.
Logarithmic mean diameter of tube, in.
Outside diameter of tube, ft.
Outside diameter of tube, in.
Inside diameter of shell, ft.
Inside diameter of shell, in.
Caloric fraction.
Friction factor on shellside, ft2/in.2.
Friction factor on tubeside, ft2/in.2.
Correction factor for LMTD for no true countercurrent flow in
shell and tube heat exchanger.
Acceleration of gravity, 4.18 x 108 ft/hr2.
Acceleration of gravity, ft/s2.
Mass velocity of fluid on shellside, lb/hr ft2.
Mass velocity of water on shellside, lb/hr ft2.
Mass velocity of fluid on tubeside, lb/hr ft2.
Heat transfer coefficient of fluid inside tubes, Btu/hr ft2 F.
Heat transfer coefficient of fluid outside tubes, Btu/hr ft2 F.
Heat transfer factor.
k
km
Kc
Thermal conductivity of fluid, Btu/hr ft F.

Thermal conductivity of tube metal, Btu/hr ft F.
Caloric factor.
13
Process
lm
L
M
Tubewall thickness, ft.
n
nb
nt
Length of one tube, ft.

(T1 - T2) / (t2 - t1).
Number of tube passes per shell.
Number of baffles.
Number of tubes per shell.
P
Pr
Tube pitch, in.

Return pressure drop for fluid flow from one tube pass to the
Ps
Pt
PT
next one, psi.

Total pressure drop one shellside, psi.
Friction pressure drop for fluid flow through tubes, psi.
Total pressure drop on tubeside, psi.
Q
R
Res
Ret
rdi
rdo
ri
rm
ro
s
t
T1
t1
T2
t2
(t)1
Heat transferred, Btu/hr.

Overall resistance to heat flow, hr ft2 F/Btu.
Reynold's number on shellside of shell and tube exchanger.
Reynold's number on tubeside of shell and tube exchanger.
Fouling resistance to heat flow on tubeside, hr ft2 F/Btu.
Fouling resistance to heat flow on shellside, hr ft2 F/Btu.
Resistance to heat flow on the inside of the tube, hr ft2 F/Btu.
Resistance to heat flow of tubewall, hr ft2 F/Btu.
Resistance to heat flow on the outside of the tube, hr ft2 F/Btu.
Specific gravity (sp. gr.), dimensionless.
Thickness of tubewall, ft.
Inlet temperature of hot fluid, F.
Inlet temperature of cold fluid, F.
Outlet temperature of hot fluid, F.
Outlet temperature of cold fluid, F.
Temperature difference of fluid at one end of heat exchanger
(t)2
(larger value), F.
Temperature difference of fluid at one end of heat exchanger
Tc
tc
tc
te
(smaller value), F.
Caloric temperature, hot fluid, F.
Caloric temperature, cold fluid, F.
Cold terminal difference, F.
Effective temperature difference, F.
14
Process
th
tm
tw
Uc
Uo
Vs
Vt
Ws
Wt
Z
Hot terminal difference, F.

Logarithmic mean temperature difference (LMTD), F.
Tubewall temperature, F.
Clean overall heat transfer coefficient, Btu/hr ft2 F.
Overall heat transfer coefficient, Btu/hr ft2 F.
Linear velocity of fluid on shellside, ft/s.
Linear velocity of fluid on tubeside, ft/s.
Flow rate of fluid on shellside, lb/hr.
Flow rate of fluid on tubeside, lb/hr.
(t2 - t1) / (T1 - t1).
mu or
mu or
muw or w
r
Viscosity at average fluid temperature, lb/hr ft (mu = 2.42 mu).

Viscosity at average fluid temperature, centipoises.
Viscosity at tubewall temperature, lb/hr ft.
Fluid density, lb/ft3.
x = 0.25 for Ret < 2100

phit = (tubeside), where
x = 0.14 for Ret > 2100
w
phis
TEMA
0.14
(shellside)
Standards of Tubular Exchanger Manufacturers Association.
Figure 3
15
Process
Example Problem 4
In this example problem, te will be calculated for a service using one shell and then two
shells in series.
Calculate the effective temperature difference for the given set of temperature conditions with
one shell and with two shells in series. It has been assumed that both the heating and cooling
curves are linear. The temperature conditions for this example are as follows:
400
Tubeside
Cold Fluid
Shellside
Hot Fluid
Temperature in F
100 (t1)
400 (T1)
Temperature out
F
350 (t2)
300 (T2)
350
300
100
Refer to TEMA figures for FT factor.

One shell (see TEMA Manual, Pg. 112).
P = t2 - t1 = 350 - 100 = 250 = 0.633
T1 - t1
400 - 100
300
R = T1 - T2 = 400 - 300 = 100 = 0.40
t2 - t1
350 - 100
250
Therefore, FT factor = 0.898. (CAUTION: never use an FT factor less than 0.8 in a design,
because at values less than 0.8 the R curve cannot be accurately read.) Note that an
exchanger with an FT of 0.8 is transferring the maximum amount of heat possible for one
shell.
Two shells in series (see TEMA Manual, Pg. 113).
Values for P and R stay the same as for the one shell case.
Therefore, FT factor = 0.975.
Next, calculate the LMTD for this problem using TEMA Manual, Pg. 111, for the LMTD
formula solving chart.
16
Process
The greater terminal temperature difference = (300 - 100) = 200F.

The lesser terminal temperature difference
= (400 - 300) = 50F.
17
Process
LMTD = 200 - 50 = 150 = 108.2F

1.386
ln 200
50
97.2F
te = (FT) (LMTD) = (0.898)

For one shell case.
(108.2) = 105.5F
te = (FT) (LMTD) = (0.975)

For two shell case.
(108.2) =
For a given Q and heat transfer coefficient, the surface requirement (tube surface) for a heat
exchanger to transfer the given Q varies inversely and linearly with te. Therefore, by going
to two shells, you reduce the surface requirement for this example by 8%:
97.2 = 0.92
105.5
Change Of State (Change of Phase) Effects
When two or more of vapor desuperheating, condensing, and liquid sub-cooling take place in
one exchanger service, the cooling/heating curves become very nonlinear (bent), as shown in
Figure 4 (lower picture). When condensing is present, this characteristic is highlighted by
comparing the two heat release curves shown in Figure 4. For a very nonlinear heat release
curve, a weighted MTD must be calculated. The LMTD for each major zone (shown as 1, 2,
and 3 in Figure 4) must be calculated and weighted to reflect the heat transferred in that
particular zone prior to combining all zone LMTDs. In this case, the formula for overall
LMTD (MTD weighted) becomes:
MTD (weighted) =
Q Total
Qzone 1
Q
Q
+ zone 2 + zone 3 + . . .
LMTD1 LMTD2 LMTD3
The effect of cocurrent/countercurrent flow in the exchanger (FT factor) is treated the same
for a phase change service (condensing or vaporizing) as for a no-phase-change service.
Exchanger service terminal conditions are still used to determine a value for FT. However, all
other aspects of the design calculations, determination of hi, ho, rdi, rdo, Tc, tc, tw, PT, and
Ps, are done by zone. All liquid and gas properties have to be calculated at each zone inlet
and outlet in the cyclic trial-and-error hand calculations required to fully define the equipment
configuration needed for a heat exchange service involving a phase change. Because this
procedure is so time consuming, this work is almost always done by very complex,
sophisticated, computer programs.
18
Process
TYPICAL HEAT RELEASE (T-Q) CURVES
Temperature
Gas or Liquid Cooling

(No Phase Change)
T1
T2
t2
t1
Q
Temperature
Gas or Liquid Cooling

(Two-Phase Change)
T1
1
2
t 2
T 2
3
t1
Gas Cooling
Condensing
Liquid Subcooling
Figure 4
Heat Transfer Equation
The rate of transfer Q (Btu/hr) from one fluid to another through a metal wall is proportional
to the overall heat transfer coefficient Uo (Btu/hr ft2 F), the area of the tube surface Ao (ft2),
and the temperature difference between the hot and cold fluid te (F).
Q = (Uo) (Ao) (te)
19
Process
Q is the difference between the heat content (enthalpy) of the exchanger inlet and outlet
streams. Uo is calculated from correlations for different fluids as a function of their properties
(such as density, viscosity). The te term is the effective temperature difference between the
hot and cold fluid, which is calculated from the exchanger inlet/outlet temperatures combined
with certain correction factors like the FT factor. Each term (Q, Uo, and te) will be
discussed in more detail later in this module.
One additional equation should be mentioned at this point; namely, the heat capacity
equation:
Q = (W) (Cp) (t)
in which Q is the heat flow of the stream over a temperature rate t, W is the flow rate
(lb/hr), Cp is the heat content of the fluid, generally referred to as the specific heat (Btu/lb F)
because it is on a per pound and degree basis. In most liquid and vapor streams that are fed to
an exchanger in the refinery, the specific heat (Cp) is defined by curves as a function of
stream properties and temperatures. A typical family of specific heat curves for liquids and
vapors of various densities can be found in the TEMA Manual, Pg. 137-144 and in Chapter 7
of the Data Book on Hydrocarbons by Maxwell. Sometimes the enthalpy level of the
exchanger inlet and outlet streams is not readily available. In these situations, use the formula
Q = (W) (Cp) (t) to determine the Q added to or removed from a stream in the heat
exchanger. This formula is based on a measured flow rate, measured inlet and outlet
temperatures, and a specific heat selected from the appropriate curve.
Heat Transfer Resistance
Heat is transferred from one fluid to the other fluid in a shell and tube heat exchanger through
the tube metal wall. The tubewall and adjacent film layers limit the transfer rate from the
tubeside fluid to the shellside fluid. Without these limits, the rate of heat transfer would be
very high, as when two fluids are mixed together. Therefore, we refer to these heat transfer
limits as heat transfer resistances. Resistances are the inverse of heat transfer coefficients:
Uo = 1
R
1
Overall coefficient =
total resistance
The total resistance (R) for a clean exchanger is made up of the film resistance on the inside
of the tube (ri), the metal tubewall resistance (rm), and the film resistance on the outside of
the tube (ro). Earlier in this course, we discussed the importance of having fluid velocities
which kept fluid flow in the turbulent flow region versus the laminar or transition flow
regions. Even when the bulk fluid is in the turbulent flow region, a laminar flow area (film)
exists next to the tubewall. Generally, lower film resistances are associated with higher
velocities, lower viscosities, and thinner laminar-flow films.
20
Process
Clean exchangers become dirty (fouled) after they have been in service. Some services foul
the exchanger much more quickly than other services. Therefore, to obtain acceptable heat
transfer in an exchanger at the end of its cycle run length, the exchanger designer must
consider the fouled condition. Two more resistances must be factored in: (rdi) fouling
resistance on the inside of the tube and (rdo) fouling resistance on the outside of the tube.
Both rdi and rdo are selected based on operating experience. A listing of typical fouling
factors for some different services is given in the TEMA Manual, Pg. 211 to 215. Local
refinery experience should prevail over these typical TEMA values, however, where a
disagreement develops.
Heat Transfer Resistance
ri
rdi
rm
Bulk Fluid
Shellside
Liquid
Temperature
Temperature
rdo
ro
Tubeside
Liquid
Bulk Fluid
Temperature
Tube Wall
Outside Film
Outside Fouling (Scale)
Inside Fouling (Scale)

Inside Film
FIGURE 5
The overall coefficient for an exchanger including the effect of fouling then becomes:
1
Uo =
R
A
A
R = ro + r do + r m + r i o + r di o
Ai
Ai
A o Do d o
=
=
Ai
di
Di
The term Ao/Ai appears in the formula because the resistance on the inside of the tube must
be corrected for the difference between the area of the inside and outside tubewalls. All
resistances are on a per-sq.-ft. basis and must be consistent when added together.
21
Process
The fouling resistances rdo and rdi are selected based on operating experience. However, the
film resistances ro and ri are calculated from formulas based on flow velocities and fluid
properties, factors which determine the type of laminar flow layer next to the tube wall. To
calculate the exchanger shellside and tubeside heat transfer coefficient, use these formulas:
(Cp)( ) 1/3 x k
1
= h i = J H
w Di
ri
k
1 = h = J (Cp) ()
o
H
ro
k
where: Cp
Des
Di
hi
ho
JH
k
ri
ro
m
mw
m'
x
1/3
0.14 k
w
Des
= Specific heat, Btu/lb F.

= Equivalent diameter shell and tube exchanger on shellside, ft.
= Inside diameter of tube, ft.
= Heat transfer coefficient of fluid inside tubes, Btu/hr ft2 F.
= Heat transfer coefficient of fluid outside of tubes, Btu/hr ft2 F.
= Heat transfer factor. (Figure 6 for tube, Figure 7 for shell).
= Thermal conductivity of fluid, Btu/hr/ft F.
= Resistance to heat flow on the inside of the tube, hr ft2 F/Btu.
= Resistance to heat flow on the outside of the tube, hr ft2 F/Btu.
= Viscosity at average fluid temperature, lb/hr ft (u = 2.42 u').
= Viscosity at tubewall temperature, lb/hr ft.
= Viscosity at average fluid temperature, centipoise.
= 0.14 for Re > 2,100; 0.25 for Re < 2,100
To find JH for tube side, use Figure 6.

Re t =
Gt
Di G t
= wt / at
Di 2 nt
at =
4 n
where: at
Di =
Gt =
n =
nt =
Ret =
Wt =
=
=
Internal cross sectional area per pass, ft2.
Inside tube diameter, ft.
Fluid mass velocity on tubeside, lb/hr ft2.
Number of tube passes per shell.
Number of tubes per shell.
Tubeside Reynolds number.
Weight flow tubeside, lb/hr.
Viscosity at average tubeside temperature, lb/hr ft.
22
Process
To find JH for shell side, use Figure 7.

DesGs
Res =
Gs = Ws / as
as =
c' d sBp
p 144
pitch Des =
4 P2 do2 4
do
)
)
2 3 P2 do2 2
pitch Des =
do
c' = P - do
where: as
BP
c'
ds
Des
Gs
P
Res
Ws
=
=
=
=
=
=
=
=
=
=
Free cross sectional area for flow across tube bundle, ft2.
Baffle spacing (pitch), in.
Clearance between adjacent tubes, in.
Inside diameter of shell, in.
Equivalent diameter of shell, ft. (Figure 7).
Fluid mass velocity on shellside, lb/hr ft2.
Tube pitch, in.
Reynold's number shell side.
Weight flow, shell side, lb/hr.
Viscosity at average shell side temperature, lb/hr ft.
23
Process
Example Problem 5
In this example problem, the tubeside and shellside film coefficients hi and ho will be
calculated.
Calculate the tubeside and shellside film coefficients for the exchanger service defined in
Figure 1. This exchanger has 0.75-in. O.D. tubes on 1-in.-square pitch. The tubes are 20 ft
long, have a wall thickness of 0.109, are arranged as two tube passes/shell.
Calculate the tubeside coefficient first.
Di = 0.532 = 0.0443 ft
12
Calculate the tubeside flow cross-sectional area at.
at = (cross-sectional area/tube)(number of tubes/pass/shell)
at =
0.2223 298
x
= 0.2300 ft 2
144
2
Next, calculate the mass velocity Gt and Reynold's number:

D G
Ret = i t
To determine the heat transfer correlation factor JH (see Figure 6):
Gt =
W t 145,812
2
=
= 633,913 lb / hr ft
at
0.2300
( 0.0443)(633,913)
= 128,550
0.1036+ 0.0764
( 2.42 )
2
JH = 330
0.14
1/ 3
(Cp)( ) k
h i = JH

k w Di
Re t =
24
Process
hi
(0.6019 + 0.6724)
(0.09) (2.42)
2
= (330)
0.0556 + 0.0485
2
( 0.6372)( 0.09)(2.42 )
= 330
0.0521
hi
1/3
1/3
0.09 2.42
0.08 2.42
0.14
0.0556 + 0.0485
2
0.0443
(1.02)
0.0521
= (330)(1.387)(1.017)(1.175)
0.0443
= 546.95 Btu/hr ft2 F
(For this sample calculation, and w were obtained from a computer printout for this
exchanger service. Average bulk and tubewall temperature calculations will be covered later
in this module.)
25
Process
TUBESIDE HEAT TRANSFER
See Page 26A
figure 6
26
Process
For the shellside coefficient (ho), this exchanger has P = 1 in. 90 square, Bp = 5.25 in., ds =
22 in., and from Figure 7, C = 0.250 in. and des = 0.95 in.:
as
= ds C
Bp
= (22) (0.25) 5.25
= 0.2005 ft2
(144) (P)
(144) (1)
92,482
W
= 461,257 lb/hr ft2
Gs = a s =
0.2005
s
0.95 (461,257)
(0.0792) (461,257)
D
es Gs
12
Res =
=
=
= 190,280
0.0613 + 0.0972 (2.42)
(0.0793) (242)
2
From Figure 7, JH = 340 for a baffle cut of 17.4% (from Figure 1):
ho = JH
(Cp) ()
k
1/3
0.14 k
w
Des
0.8187 + 0.6314 (0.0793) (2.42)

2
= (340)
0.0399 + 0.0484
2
= (340)
1/3
0.0793 2.42
0.0873 2.42
0.14
0.0399 + 0.0484
2
0.95
12
(0.7251) (0.1919) 1/3

(0.9866) 0.0442
0.0442
0.0792
= (340) (1.4654) (0.9866) (0.5581) = 274.4 Btu/hr ft F
27
Process
SHELLSIDE HEAT TRANSFER CURVE
See Page 28A
figure 7
28
Process
(See Figure 1.) A value of 0.002 has been selected for rdo and rdi fouling factors. The value
for rm (tubewall resistance) is so small relative to the other resistances that it is usually
ignored except in exchanger heat transfer coefficients higher than about 125 Btu/ft2/F/hr. A
value for rm can be calculated from the equation:
rm =
l m (tubewall thickness)
k m (at average wall temperature
Average tubewall temperature is the average of the shellside and tubeside wall temperatures
obtained from the computer printout for this example problem. (Tubeside, 150F; shellside,
178F.):
150F + 178 F
= 164F and km = 29.5 Btu / hr F ft
2
For carbon steel tubes (see the TEMA Manual, Pg. 185 ).
rm =
0.109
12
29.5
= 0.0003
The overall coefficient Uo is now calculated from the following equation:

Uo =
1
R
A
A
R = ro + r do + r m + r i o + rdi o
Ai
Ai
R=
1
1 0.1963
0.1963
+ 0.002 + 0.0003+
+ (0.002)
0.1393
274.4
548.6 0.1393
R = 0.0036 + 0.002 + 0.0003 + 0.0026 + 0.0028 = 0.0113

Uo =
1
= 88.4 Btu/hr ft2 F
0.0113
29
Process
Calculating Surface Area

Calculation of shell and tube exchanger surface area (tube O.D. surface) for a new exchanger
is usually by trial and error. A value is first estimated for the overall coefficient (Uo),
combined with the calculated LMTD (te) and divided into the calculated exchanger duty
(Q). The resulting value is an estimate of the required exchanger surface:
Ao =
Q
Uo (te)
Based on estimates of tubeside and shellside velocities and Reynold's numbers, a first trial
estimate is made for such things as number of tube passes, baffle pitch, and so on. The
standardized shell and tube exchanger configurations given in Saudi Aramco Design Practice
ADP-E-001 should greatly influence the selection of an exchanger configuration.
The first trial exchanger configuration is used as the basis for detailed calculation of the
tubeside and shellside pressure drop and film coefficients (hi and ho). Rarely do the detailed
calculations on the first trial result in a final exchanger design. Usually, the calculated values
for hi or ho show that the original estimated Uo was incorrect or the allowable pressure drop
for one or both sides (shell/tube) of the exchangers is exceeded by the calculated pressure
drop. A new exchanger configuration is estimated for the second trial calculation. The
procedure for determining exchanger surface is repeated until the calculated values for a trial
calculation are consistent with the selected exchanger configuration.
The exchanger surface area Ao (tube outside wall) is transformed into an exchanger
configuration by selecting a standard tube length (10 ft or 20 ft for Saudi Aramco), a tube
diameter, and wall thickness (set by type of service and Saudi Aramco standards). These
selections define the total number of tubes to be used in the number of shells selected based
on the FT factor and the required number of tube passes as set by the allowable tubeside
pressure drop.
30
Process
Example Problem 6
In this example problem, calculate the number of tubes associated with a given surface area.
Assume the value for Ao is 1170 ft2, and the exchanger has 20-ft-long tubes, 3/4-in. O.D.
with a 0.109-in. wall thickness.
nt = Number of tubes =
Ao
1170
=
(Do )(20ft) (0.1963)(20)
= 298 tubes
For existing exchangers, the surface Ao is calculated from the data on the exchanger data
sheets which often are kept in mechanical catalogs in the refinery. The detailed mechanical
catalog provides the engineer with considerable information about the exchanger. Usually the
value for Ao is available in the mechanical catalog information. If not, Ao can be calculated
from the mechanical catalog information on tube size, length, and so on. The actual surface
in the exchanger is usually in excess to varying degrees of what the engineering specification
requires.
31
Process
Calculating Tubewall Temperature

The tubewall temperature for shell and tube exchangers is usually calculated for one or both
of two reasons. First, calculations to determine values for ho and hi (shellside and tubeside
film coefficients) contain the term:
0.14
w
as part of the formula. w is the viscosity of either the tubeside or shellside fluid at the tubewall temperature. For light hydrocarbons, (/w)0.14 usually is in the range of 0.9 to 1.1.
However, for heavier hydrocarbons the term can become significant, and the metal wall temperature should be calculated using the caloric temperatures for that heat exchange service.
The caloric temperature for the tubeside (tc) and for the shellside (Tc) is a weighted average
temperature. For most exchanger designs involving light hydrocarbons, the shellside and
tubeside fluid properties are determined at the arithmetic mean fluid temperature for the
tubeside or shellside (Fc = 0.5). Because the arithmetic mean is not a weighted average, it
assumes that Uo for the exchanger is close to being constant over the entire exchanger. The
Uo is usually constant for light hydrocarbon services but changes appreciably for heavy
hydrocarbon services. This change is taken into account by using the caloric temperature
instead of the arithmetic mean fluid temperature. An approximation of the caloric
temperature can be obtained by setting Fc to 0.4 in the following formulas.
For the fluid being heated: (Cold Fluid)
tc = Fc(t2 - t1) + t1
For the fluid being cooled: (Hot Fluid)
Fc = 0.4
Tc = Fc(T1 - T2) + T2
32
Process
For heat exchange services where heavy hydrocarbons or special design considerations (to be
covered later) are involved, Tc or tc can be more accurately determined from Figure 8.
Figure 8 takes into account the API (gravity) of the hydrocarbon being processed by the
exchanger which in turn reflects the expected change in Uo over the length of the exchanger.
From Figure 8 you can also observe that the 0.4 factor used in our shortcut formula is an
average value for Fc. Using Figure 8 information, you will find that the formulas for tc and
Tc remain the same as the shortcut formula except that the Fc term replaces the 0.4 term.
Calculate driving temperature difference at hot and cold end of exchanger. Using API for
each fluid and temperature change (T1 - T2) and (t2 - t1) find Kc for each fluid. Find Fc for
each fluid. The caloric temperature for both streams should be calculated using the lowest Fc.
T1 t h
t2
T2
t c
t1
th = T1 _ t 2
tc = T2 _ t1
33
Process
Average Fluid Temperature
See Page 33A
Figure 8
34
Process
The second reason for calculating the tubewall temperature is that for some exchanger
services special process conditions must be considered. For example, in pipestill overhead
condensers, a very corrosive, contaminated water can condense on the tubewall before the
bulk fluid dew point is reached, rapidly corroding through the tubes. If a special condition is
realized as a result of doing tubewall temperature calculations based on caloric temperatures,
then the exchanger tube material can be upgraded at considerable expense or other processing
conditions can be changed to avoid the problem. The tubewall temperature tw is calculated
from the following formulas.
For hot fluid on shellside:
tw = Tc - (Uo) (ro + rdo) (Tc - tc)
For hot fluid on tube side:
tw = Tc - (Uo) (ri + rdi) Ao (Tc - t c )
Ai
The terms (Uo) (ro + rdo) give the portion (fraction) of the total resistance 1/Uo that exists
between the bulk fluid (shellside in this case) and the tubewall on the shellside. Temperature
change from the bulk fluid temperature on one side of the exchanger through the tubewall to
the other bulk fluid temperature varies linearly with resistance. In both of the formulas for tw,
the resistance across the tubewall (rm) is ignored. When tw is calculated using the shellside
or tubeside conditions, tw on both sides of the tube is considered to be the same since rm is
very small.
The following example problem shows how to calculate an exchanger tubewall temperature
using caloric temperatures.
35
Process
Example Problem 7
Calculate the tube metal temperature for the exchanger service defined below. Use caloric
temperatures for this example.
Fluid
Density (API)
Temperature in/out (F)
Film resistance (ri and ro)(hr F ft2/Btu)
Fouling resistance (rdi and rdo) (hr F
ft2/Btu)
Tubeside O.D. (in.)/B.W.G.
Tubeside
Crude
20
300/200
0.015
0.003
1.0/12
T1 300
Because the tubeside has the hot fluid use

formula:
tw = Tc - (Uo) (ri + rdi)
Ao ( - )
T t
Ai c c
Shellside
Gasoline
60
80/120
0.004
0.001
120
t2
T2
200
80 t
1
From Figure 8 calculate Tc and tc
t cold end = T2 - t1 = 200 - 80
= 120F
t hot end = T1 - t2 = 300 - 120 = 180F

t cold end = 120 = 0.6667
180
t hot end
36
Process
Temperature change:
T1 T 2 = 300 100 = 100
t 2 t 1 = 120 80 = 40
For shellside 60API gasoline, light hydrocarbon can use average temperature.
Kc is very low and off-chart.
For tubeside 20 API crude and change 100F, Kc = 0.7 (see Figure 8). (Hot fluid.)
Using Kc = 0.7 (maximum Kc)
Fc = 0.435
Use this Fc for calculation of caloric temperature for both fluids.
Tc = Fc (inlet temperature - outlet temperature) + outlet temperature
= Fc (T1 - T2) + T2
= (0.435) (300 - 200) + 200 = 243.5 F
Tc = (0.435)(120 - 80) + 80 = 97.4
37
Process
From TEMA Manual, Table D-7, Pg. 178:

1 in. 12 B.W.G.
O.D. = 1.279
I.D.
This is the same as: Ao

Ai
A
R = (r i + r di ) o + r o + r do = (0.015 + 0.003)(1.279) + 0.004 + 0.001
Ai
R = 0.023 + 0.004 + 0.001 = 0.028
1
1
=
= 35.7
R 0.028
For hot fluid on tube side
Uo =
A
t w = T c Uo (r i + r di ) o (T c t c )
Ai
t w = 243.5 (35.7)(0.015 + 0.003)(1.279)(243.5 97.4) =
t w = 243.5 (35.7)(0.023)146.1 = 243.5 120 = 123.5 F
38
Process
Selecting Design Pressure and Temperature

Selection of the design pressure and design temperature for the exchanger defined on the
specification sheet generally follows a set of guidelines like those listed in Work Aid 5 for use
in this course. Local standard practices should be referred to for all D.T. and D.P.
determinations.
Components of Heat Exchanger Specification Sheets
This module has covered the major design points associated with the calculation of a shell and
tube heat exchanger. Now the results of these calculations have to be assembled and placed
in a standardized exchanger specification sheet. The information placed on this specification
sheet will be used by the manufacturer to make the exchanger in accordance with the process
requirements.
Several computer programs can be used to perform the required calculations. A sample
computer input and related output for a liquid/liquid shell and tube heat exchanger is provided
in Appendix A. Review the material so that the forms are familiar when the job requires
using the computer for rating or reviewing an exchanger service.
Example Problem 8
In this example problem, complete the following heat exchanger specification sheet.
39
Process
EXAMPLE SPECIFICATION
4572
Aramco 2714 M-ENG (3/89)

Equip. No.
Service
E - 1B/C
VGO
Feed Preheat
Double Pipe)
Order No.
Mfr. Dwg. No.
Mfr. Order No.
Sour Wet Serv/Lethal
#Serv. Condition (#Cyclic/Non-cyclic)
SQ. FT.
SQ. FT.
TOTAL FLUID ENTERING

VAPOR
lb/hr
LIQUID
lb/hr
lb/hr
375,941
375,941
0
0
0
0
WATER
lb/hr
lb/hr
F
NONCONDENSABLE
TEMPERATURE
SPECIFIC GRAVITY
......................
MOLECULAR WEIGHT, VAPOR
......................
MOLECULAR WEIGHT, NONCONDENSABLE
cP
Btu/lb F
Btu/hr ft F
SPECIFIC HEAT
DEPT.
THERMAL CONDUCTIVITY
INLET PRESSURE
......................
VELOCITY
ft/min
psi
PRESSURE DROP, ALLOW/CALC.
TRANSFER RATE SERVICE
......................
HEAT EXCHANGED
1,310,751
0
0
1,310,751
1,310,751
0
0
0
0
0
120
0
191
0
233
0
215
0.91
39.97
---
0.89
9.41
---
0.71
0.28
---
0.72
0.31
----0.541
---
---
---
0.469
0.508
0.550
0.0649
0.0627
0.0678
---
275
---
100
--10.00
17.921
20.00
0.002
0.004
F 64.3
Btu/hr F ft 2
CLEAN
0.0634
---
6.81
M.T.D. (CORRECTED) & CORRECTION FACTOR
......................
OUT
1,310,751
375,941
hr ft F/Btu
FOULING RESISTANCE (MIN.)
IN
375,941
Btu/lb
psig
LATENT HEAT
......................
PR'G. DEPT.
OUT
lb/hr
lb/hr
STEAM
......................
TUBE SIDE
IN
FLUID CIRCULATED
VISCOSITY, LIQUID/VAPOR
5,168
2,584
SHELL SIDE
A. PROCESS/PERFORMANCE DATA OF ONE UNIT
APPROVALS
1
SHELLS IN PARALLE
Manufacturer
Effective Surface Per Shell*
......................
Date
SHELLS IN SERIES
Total Effective Surface * and No. of Shells per Unit
REVISIONS
QR No.
Per Unit
Shell and Tube

TEMA - AES
16 ft
Serial No.
No. of Units
Type (Float Hd. Fix. T. Sh: U. Tube; Kettle;
Tube Length
Shell I.D.
HORZ.
VERT.
and
mm Btu/hr
0.99
52.98
13.01
......................
SCALE
......................
DATE
......................
......................
......................
GR. ............
B. CONSTRUCTION DATA OF ONE SHELL
SHELL SIDE
TUBE SIDE
CORROSION ALLOWANCE
DESIGN TEMPERATURE
DESIGN PRESSURE
TEST PRESSURE
LIMITED BY:
NUMBER OF PASSES PER SHELL
SIZE
NOZZLES
NUMBER
RATING
FACING
SHELL - INLET
SHELL - OUTLET
CHANNEL - INLET
CHANNEL - OUTLET
SHELL: I.D. .........................
O.D. .........................
figure 9
40
Process
Optimizing Heat Exchanger Operations

Optimizing heat exchanger operation is essential to maintaining the lowest cost, highest
efficiency operation possible. The following sections outline several components to consider
when optimizing exchanger operations.
Troubleshooting Heat Exchangers
Troubleshooting heat exchangers involves comparing operating data with the process design
basis and manufacturer configuration information. Differences between them indicate why
the exchanger is not functioning properly. A data comparison may show a problem with the
exchanger (fouled, improperly manufactured, or improperly designed) or with the service
conditions (actual/design rates considerably different, or actual/design temperatures different).
If an initial comparison does not explain the problem, more elaborate comparisons must be
made, such as analyzing fluid samples to obtain physical properties information. Some of the
first comparisons that should be made are an energy balance around the exchanger, a material
balance around the exchanger, a determination of te and overall Uo, and calculation of the
quantity of heat transferred (Q) under existing operating conditions. As discussed earlier, one
very important source of information in this effort is the exchanger manufacturer mechanical
configuration data sheets in which the actual manufactured configuration sometimes differs
significantly from the design specified.
Flow Optimization
One of the major expenses in operating a refinery is the cost of utilities, particularly the cost
of the fuel consumed by furnaces. Therefore, it is usually economical to use most of the heat
generated in the product streams from each processing step to preheat feed streams to
processing steps. Provide low-temperature-level preheat with product streams that contain
intermediate-level heat and high-temperature-level preheat with those that contain hightemperature-level heat. Heat should be interchanged between product and feed streams with
the drop in temperature level defined by economic considerations.
The hot-end terminal temperature selected for complicated heat integration schemes, such as
for a crude preheat train, is based on the economic comparison of heat exchange surface
(that needed to get to a higher preheat temperature) versus a savings in crude preheat furnace
fuel consumption. The magnitude of the heat exchanger surface on the hot end per unit of
fuel savings is affected by the extent to which other product streams are heat integrated with
the crude at lower temperature levels. Therefore, with so many interacting variables, an
elaborate computer program is often used to achieve the optimum heat integration
arrangement based on capital investment cost (equipment cost) versus operating cost (furnace
fuel and product cooling water costs).
41
Process
The foregoing discussion concerns the design of a new grassroots preheat train of exchangers.
In an existing preheat train, because of significant changes in the processing operation, it is
often economical to re-analyze each heat exchanger in the train to get the maximum possible
furnace preheat temperature, thereby minimizing fuel operating costs. This is a complicated
trial-and-error calculation if done by hand. Again there are computer programs that take
existing preheat trains and find the optimum new operating conditions for the latest new
processing scheme.
When an existing heat exchanger is considered for use in a significantly different service, the
exchanger's performance in the new service can be estimated by the formulas in Work Aid 6.
Limit use of these formulas to heat exchanger services where only sensible heat is transferred
(no condensing or vaporizing) and all are in the turbulent flow region. Subscript 1 is for
present service; subscript 2 is for new service.
Exchanger Cleaning Schedules
A cleaning schedule should be established for heat exchange services that foul at a rate which
requires cleaning in between major turnarounds. Exchangers that mildly foul are generally
cleaned in the major turnaround effort.
To establish a meaningful cleaning schedule, gather base data for the clean exchanger when
the exchanger is put into service. Energy and mass balances are done for the clean exchanger
so that an actual operating clean coefficient (Uc) and clean shellside and tubeside pressure
drop can be calculated. The calculated clean coefficient and pressure drop may be
significantly different from the corresponding design values. The calculated clean coefficient
and pressure drop along with pertinent data (flow rates, temperatures, and fluid properties) are
recorded as base data which will be compared with future calculations to determine the degree
of fouling. The calculated data for the partially fouled exchanger is compared with the clean
exchanger base data and design fully fouled condition to arrive at the date for the next
cleaning of the exchanger. If significant fouling is taking place on both sides, only the change
in pressure drop on the shellsides and tubesides will give an indication as to how much of the
fouling is on which side. Calculation of the fouled Uo will only indicate the total amount of
exchanger fouling.
To track the amount of fouling in an exchanger one can calculate Uo frequently (weekly) and
plot Uo versus time. The pattern of the fouling curve will usually repeat itself after each
cleaning. One can also calculate the resistance due to dirt using the following relationships:
d
1
= R = o ri + rm + ro
di
Uo
42
Process
Key Formulas
The following are the more important formulas in this module. Note that many of these items
can be easily programmed for personal computer use.
Temperature Correction Factor
P = t2 - t1
T1 - t1
where: P
R
T1
t1
T2
t2
R = T1 - T2
t2 - t1
Tema factor.
Tema factor.
Inlet temperature of hot fluid, F.
Inlet temperature of cold fluid, F.
Outlet temperature of hot fluid, F.
Outlet temperature of cold fluid, F.
Overall Heat Duty

Q = (Uo) (Ao) (te)
Q = (W) (Cp) (t)
where: Ao =Total outside surface area of bare tubes, ft2.
Cp
= Specific heat, Btu/lb F.
Q
= Heat transferred, Btu/hr.
t
= Temperature difference, F.
te
= Effective temperature difference, F.
Uo
= Overall heat transfer coefficient, Btu/hr ft2 F.
W
= Rate, lb/hr.
Log Mean Temperature Difference
LMTD =
GTTD - LTTD
ln GTTD
LTTD
where: GTTD = Greater temperature difference.

LTTD
= Lesser temperature difference.
43
Process
Effective Temperature Difference

te = (FT) (LMTD)
where: Ft
= Correction factor for LMTD for no true countercurrent flow in shell and
tube heat exchanger.
LMTD
= Log mean temperature difference.
te = Effective temperature difference, F.
Overall Heat Transfer Coefficient
Uo =
1
R
A
A
R = ro + r do + r m + r m o + r di o
Ai
Ai
where: Ai = Inside tube surface area, ft2.
Ao
= Total outside surface area of bare tubes, ft2.
R= Overall resistance to heat flow, hr ft2 F/Btu.
rdi
= Fouling resistance to heat flow on tubeside, hr ft2 f/Btu.
rdo
= Fouling resistance to heat flow on shellside, hr ft2 F/Btu.
ri = Resistance to heat flow on the inside of the tube, hr ft2 F/Btu.
rm
= Resistance to heat flow of tubewall, hr ft2 F/Btu.
Uo
Inside Film Coefficient
1 = hi = JH Cp
ri
k
1/3
0.14 k
w
Di
where: Cp = Specific heat, Btu/lb F.

Di
= Inside diameter of tube, ft.
hi
= Heat transfer coefficient of fluid inside tubes, But/hr ft2 F.
JH
= Heat transfer factor.
k = Thermal conductivity of fluid, Btu/hr ft F.
m
= Viscosity at average fluid temperature, lb/hr ft (mu = 2.42 mu').
mw
44
Process
Outside Film Coefficient

1 = ho = JH Cp
ro
k
1/3
0.14 k
w
Des
where: Cp = Specific heat, Btu/lb F.

Des
= Equivalent diameter shell and tube exchanger on shellside, ft.
ho
= Heat transfer coefficient of fluid outside tubes, Btu/hr ft2 F.
JH
= Heat transfer factor.
k = Thermal conductivity of fluid, Btu/hr ft F.
ro
m
= Viscosity at average fluid temperature, lb/hr ft (mu = 2.42 mu').
mw
Tubewall Resistance
rm =
lm
km
where: km = Thermal conductivity, Btu/hr ft F.

rm
= Resistance to heat flow of tubewall, hr ft2 F/Btu.
lm
= Tubewall thickness, ft.
Caloric Temperature
tc = 0.4 (t2 - t1) + t1 (fluid being heated) (Cold fluid)
Tc = 0.4 (T1 -T2) + T2 (fluid being cooled) hot fluid)
For Fc
t h = T1 t 2
t c = T 2 t1
45
Process
Tubewall Temperature
Shellside with hot fluid:
tw = Tc - (Uo) (ro + rdo) (Tc - tc)
where: rdo = Fouling resistance to heat flow on shellside, hr ft2 F/Btu.
ro
Tc
= Caloric temperature, hot fluid, F.
tc
= Caloric temperature, cold fluid, F.
tw
= Tubewall temperature, F.
Uo
Tubeside with hot fluid:
tw = Tc - (Uo) (ri + rdi)
Ao
(Tc - t c)
Ai
where: Ai = Inside tube surface area, ft2.

Ao
= Total outside surface area of bare tubes, ft2.
rdi
= Fouling resistance to heat flow on tubeside, hr ft2 F/Btu.
Tc
= Caloric temperature, hot fluid, F.
tc
= Caloric temperature, cold fluid, F.
tw
= Tubewall temperature, F.
Uo
46
Process
Flow Optimization
Tubeside film coefficient:
h1 = R2 = 2
1
h2
R1
0.47
k1
k2
0.67
Cp1
Cp2
0.33
G1
G2
0.8
D2
D1
0.2
where: Cp1 = Heat capacity at condition 1.

Cp2
= Heat capacity at condition 2.
D1
= Tube diameter at condition 1.
D2
= Tube diameter at condition 2.
G1
= Mass velocity at condition 1.
G2
h1
= Heat transfer coefficient at condition 1.
h2
k1
= Thermal conductivity at condition 1.
k2
m1
= Viscosity at condition 1.
m2
R1
= Overall resistance at condition 1.
R2
With permisssion from the Gas Processors Suppliers Association. Source: Engineering Data
Book.
47
Process
Tubeside pressure drop:

P2 = 2
1
P1
where: D1
0.2
G2
G1
1.8
1 D1
2 D2
1.2
n2
n1
= Diameter at condition 1.
D2
G1
G2
n1
= Number of tube passes at condition 1.
n2
= Number of tube passes at condition 2.
P1 = Pressure drop at condition 1.
P2 = Pressure drop at condition 2.
m1
m2
r1
= Density at condition 1.
r2
= Density at condition 2.
48
Process
Book.
Shellside film coefficient:
h1 = R2 = 2
h2
R1
1
0.27
k1
k2
0.67
Cp1
Cp2
0.33
G1
G2
0.6
D2
D1
0.4
where: Cp1 = Heat capacity at condition 1.

Cp2
= Heat capacity at condition 2.
D1
D2
G1
G2
h1
h2
k1
k2
m1
m2
R1
R2
Book.
49
Process
Shellside pressure drop:

P2 = 2
1
P1
where: D1
0.15
G2
G1
1.85
1 D1
2 D2
0.15
tube
nb + 1 2 rows crossed2
nb + 1 1
tube
rows crossed1
D2 = Diameter at condition 2.
G1 = Mass velocity at condition 1.
G2 = Mass velocity at condition 2.
(nb + 1)1 = Number of baffles plus 1 at condition 1.
(nb + 1)2 = Number of baffles plus 1 at condition 2.
P1
= Pressure drop at condition 1.
P2
= Pressure drop at condition 2.
m1 = Viscosity at condition 1.
m2 = Viscosity at condition 2.
r1 = Density at condition 1.
r2 = Density at condition 2.
Book.
50
Process
WORK AID 1 - PROCEDURES FOR CALCULATING ENERGY BALANCE

This work aid is designed to assist the participants in Exercise 1 - Calculating Energy
Balance.
Part 1
To calculate the energy balance for a water cooled cooler:
A.
Tubeside (water):
Q = (W) (Cp) (t)
where: Q
Cp
t
W
B.
=
=
=
=
Heat transferred, (Btu/hr).

Specific heat of water, (Btu/lb F).
Temperature difference, (water side) F
Flow of water, (lb/hr).
Shellside fluid:
Q = (W) (Cp) (t)
where: Cp = Average specific heat of shellside fluid, (Btu/lb F).
W = Shellside flow rate, (lb/hr).
t = Shellside temperature difference, (F).
51
Process
C.
Shellside fluid (enthalpy method):

Q = (Hin - Hout) (W)
where: Hin = Shellside inlet enthalpy, (Btu/lb F).
Hout = Shellside outlet enthalpy, (Btu/lb).
W = Shellside flow rate, (lb/hr).
Part 2
To calculate the heat input to the tower in Part 1, use the formula:
Q = W (Hin - Hout)
Step 1: Determine the value for W in lb/hr.
Step 2: Using Figure 2, determine the steam enthalpy, Btu/lb.
Step 3: Using Figure 2, determine condensate enthalpy, Btu/lb.
Step 4: Substitute the values in the equation to obtain Q in Btu/hr.
52
Process
WORK AID 2 - PROCEDURES FOR CALCULATING HEAT TRANSFER

COEFFICIENTS
This work aid is designed to assist the participant in Exercise 2 - Calculate Heat Transfer
Coefficients.
Part 1: To calculate heat transfer coefficients in existing exchangers, use the formula:
U =
Q
Q
=
A LMTD FT
A te
Step 1: Calculate A, ft2:

A = (no. of tubes/shell) (no. of shells) (length of tube) (tube circumference in ft)
Step 2: Calculate tubeside API, where:
API =
141.5
sp. gr.
- 131.5
Step 3: Calculate shellside API, where:

API =
141.5
sp. gr.
- 131.5
Step 4: Determine tubeside specific heat, Cp:

-
Use average temperature.

Use chart in Maxwell, Pg. 93.
Step 5: Determine shellside specific heat, Cp.

-
Use average temperature.

Use chart in Maxwell, Pg. 93.
Step 6: Calculate Q on the shellside, using:

Q = (W) (Cp) (t)
Step 7: Calculate Q on the tubeside, using:
Q = (W) (Cp) (t)
53
Process
Step 8: Determine FT, using the formulas:

P = t2 - t1
T1 - t1
and
R = T1 - T2
t2 - t1
Use TEMA Manual, Pg. 113 to determine FT.

Step 9: Determine LMTD, using TEMA chart.
Step 10: Calculate LMTD, using the formula:
LMTD = G.T.D. - L.T.D.
lnG.T.D.
L.T.D.
Where: G.T.D. = Greater temperature difference.
L.T.D. = Lesser temperature difference.
Step 11: Substitute values in the formula:
U =
Q
A LMTD FT
Part 2: To calculate heat transfer coefficients for a new exchanger, several calculations are
required:
A.
First, calculate the tubeside film coefficient, using the formula:

hi = JH
Cp
k
1/3
0.14 k
w
Di
Step 1: Determine the internal area of one tube, using the TEMA Manual, Pg. 178.
Step 2: Calculate at (in ft2), where:
at = (cross-sectional area/tube) (number of tubes/pass/shell)
Step 3: Calculate Gt, where:
t
Gt = W
at
54
Process
Step 4: Calculate Ret, where:

Ret = Di Gt
Step 5: Determine JH, using Figure 6.

Step 6: Substitute the values into the equation:
hi = JH
B.
Cp
k
1/3
0.14 k
w
Di
Calculate the shellside film coefficient, using the formula:

ho = JH
Cp
k
1/3
0.14 k
w
Des
Step 1: Using Figure 7, determine C.

Step 2: Using Figure 7, determine des.
Step 3: Calculate as, using the formula:
as = ds C
Bp
144 P
Step 4: Calculate Gs, using the formula:

s
Gs = W
as
Step 5: Calculate Res, using the formula:

D G
Res = es s
Step 6: Determine JH, using Figure 7.

Step 7: Substitute the values into the equation:
ho = JH
Cp
k
1/3
0.14 k
w
Des
55
Process
C.
Calculate the overall coefficient:
Step 1: From the computer printout, determine rm and rdo (Figure 11).
Step 2: Calculate rm, using the formula:
rm = lm
km
Use TEMA Manual, Pg. 185 for km and Pg. 178 for Ao/Ai.
Ao do
=
Ai
di
Step 3: Calculate the overall heat transfer coefficient (Uo), using the formula:
Uo =
1
R
A
A
R = r o + r do + r m + ri o + rdi o
Ai
Ai
56
Process
WORK AID 3 - PROCEDURES FOR CALCULATING REQUIRED SURFACE AREA

This work aid is designed to assist the participant in Exercise 3 - Calculate Surface Area.
Part 1: To calculate the exchanger surface required for a new heat exchanger, use the
formula:
Ao =
Q
te Uo
Step 1: Determine the FT factor, using the TEMA Manual, Pg. 113 and the formulas:
P = t2 - t1
T1 - t1
and
R = T1 - T2
t2 - t1
Step 2: Determine LMTD, using the formula:

LMTD =
GTTD - LTTD
ln GTTD
LTTD
Step 3: Calculate te, where:

te = (LMTD) (FT)
Step 4: Use the computer printout (Figure 11) for the defined Q.
Step 5: Substitute the values into the formula:
Ao =
Q
te Uo
Part 2: To calculate the surface area for an existing exchanger, use the formula:
Ao = (number of tubes/shells) (number of shells) (tube length) (tube O.D. surface/ft length)
57
Process
WORK AID 4 - PROCEDURES FOR CALCULATING TUBEWALL TEMPERATURE

This work aid is designed to assist the participant in Exercise 4 - Calculate Tubewall
Temperature.
To calculate the tube metal temperature for Exercise 7, use the formula:
t w = T c (Uo )(r1 + r di )
Ao
(T t )
Ai c c
Step 1: Calculate the cold end t.

Step 2: Calculate the hot end t.
Step 3: Calculate t cold end/t hot end.
Step 4: Determine Kc, using Figure 8. Use largest Kc.
Step 5: Determine Fc, using Figure 8.
Step 6: Calculate Tc, using the formula:
Tc = Fc(T1 T2) + T2
Step 7: Calculate tc, using the formula:
tc = Fc(t2 t1) + t1
Step 8: Substitute the values into the formula.
58
Process
WORK AID 5 - PROCEDURES FOR CALCULATING DESIGN PRESSURE AND

TEMPERATURE
This work aid is designed to assist the participant in Exercise 5 - Calculate Design Pressure
and Temperature.
Design Temperature:
For operating temperatures up to 750F, use maximum operating temperature plus 50F.
For operating temperatures above 750F, evaluate each individual case for the most
economical solution because the decrease in allowable stress for carbon steel is significant
for a small temperature increase in this temperature range.
Develop design temperature for each tubeside and shellside based on their circuit
conditions, respectively.
Design Pressure:
For pressures up to 250 psig, use maximum operating pressure plus 10% or 15 psi (the
greater of the two).
For pressures above 250 psig, use maximum operating pressure plus 10% or 25 psi (the
greater of the two).
If the exchanger is fed by a pump, the design pressure is the greater of either pump normal
pressure plus the maximum suction pressure or 120% of pump normal pressure plus
normal suction pressure.
A design pressure is developed for each tubeside and shellside based on their circuit
conditions, respectively.
For services where the high pressure side design pressure greatly exceeds the low pressure
side design pressure (say 1.5 times), special requirements are needed to protect the low
pressure side against a tube or tube sheet rupture.
59
Process
WORK AID 6
PART I
1.
Q = m cp t
QNEW = QOLD
t NEW
t OLD
2.
Determine FT.
3.
Determine LMTD and te.
4.
Q
Find Uo = (A t e )
A is effective and for two shells.
5.
If Uo indicates normal fouling, then lower heat transfer is probably due to temperature
upstream.
PART III
1.
Since Q = m cp, and m e cp are constant, then QNEW = QOLD
2.
Find new FT, LMTD and te.
3.
Find new Uo.
t NEW
t OLD
60
Process
1
4.
RCLEAN =
U oCLEAN
RTOTAL = RCLEAN + RDIRT

1
RCURRENT
= U CURRENT
1
RDESIGN = U DESIGN
61
Process
GLOSSARY
baffle pitch
The distance between adjacent baffles.
bundle
The tubes in a shell and tube exchanger are held together to

form a bundle of tubes, which is slid into the shell of the
exchanger as a single unit.
caloric temperature
The temperature which is used instead of the mean temperature

in an exchanger as the basis for fluid properties. It reflects the
fact that the overall coefficient in the exchanger does not stay
consistent over the length of the exchanger.
cocurrent flow
Both fluids are flowing in the same direction.
condensing
When a vapor is cooled and reaches the dew point, part of it

becomes liquid. This is condensing.
countercurrent flow
Both fluids are flowing in opposite directions.
effective
temperature
difference
The driving force behind the transfer of heat between the

shellsides and tubesides of the exchanger. The value for
E.T.D. is the log mean temperature difference corrected for the
exchanger flow arrangement.
liquid subcooling
Cooling a liquid to temperatures below the bubble point

temperature.
LMTD
Logarithmic-mean temperature difference.
segment cut
The part of the bundle circular cross section not covered by a

baffle.
temperature cross
over
The temperature at which the temperature of the fluid being

cooled falls below the outlet temperature of the fluid being
heated.
vapor
desuperheating
Removing heat until a vapor reaches the dew point.
62
Process
REFERENCES
1. Chemical Engineer's Handbook, 6th Edition, R. H. Perry and D. Green (Physical
properties, general information, calc equations).
2. Data Book on Hydrocarbons, J. B. Maxwell (Hydrocarbon physical properties).
3. Engineering Data Book, Gas Processors Suppliers Association, 10th Edition, 1987.
4. Process Heat Transfer, D. Q. Kern, 1950.
5. Standards of the Tubular Exchanger Manufacturers Association (TEMA) (Properties, heat
exchanger information).
6. AES-E-001, Basic Design Criteria for Unfired Heat Transfer Equipment.
7. ADP-E-001, Exchangers.
63
Process
APPENDICES
In order to optimize exchanger operations, various computer programs can be utilized.
A sample computer input related output for a liquid/liquid shell and tube heat exchanger has
been provided in the appendix. Review this material so that the forms are familiar when the
job requires use of the computer for rating or reviewing an exchanger service.
64
Process
(use photostat)
figure 13
65
Process
(use photostat)
figure 13 (cont'd)
66
Process
(use photostat)
figure 13 (cont'd)
67
Process
(use photostat)
figure 13 (cont'd)
68
Process
(use photostat)
figure 13 (cont'd)
69
Process
For a clean exchanger:

d
do
1
rdi + rdo
= R CLEAN = o ri + rm + ro
Uo
d
di
and i
is zero.
For a dirty exchanger:
1
= R = RCLEAN + RDIRT
Uo
do

d
where RDIRT = i rdi + rdo
If conditions have changed significantly from design condition, hi and ho can be adjusted to
current conditions using the equations from the Natural Gasoline Processing Handbook
summarized in Key Formulas. RCLEAN can then be recalculated. The current RDIRT can
be compared to the design RDIRT.
Many heat exchange services are regulated by instrumentation to provide a stream to a
downstream process at a consistent temperature. This temperature is accomplished by
bypassing part of the exchanger feed around the exchanger and mixing this bypassed material
with the exchanger effluent. The degree of bypassing is regulated by a temperature controller
which senses the downstream mixture temperature. When the exchanger is clean, the
maximum amount of feed is bypassed; and when the exchanger is fouled to the maximum, no
feed is bypassing the exchanger. By recording the clean bypassing condition (percent of feed
bypassed), you can easily estimate the amount of exchanger fouling by observing the amount
of feed bypassed with the partially fouled exchanger.
70
Process
Some terms are in both equations; the value for the term , for example, is the bulk fluid
viscosity for the tubeside fluid at the average tubeside temperature in the hi equation and for
the shellside fluid at the average shellside temperature in the ho equation.
All terms in the hi and ho equations represent a physical property for the exchanger fluid or
an exchanger configuration except the term JH. JH is a correlation of data (some field and
lab) presented as a function of Reynold's number. The JH correlation represents the mean of
the data, not the extent to which the raw data are scattered. Most data-based correlations are
considered to have an acceptable accuracy with a + 30% scatter. Such a data point scatter is
shown in Figure 5 for measured shell and tube exchanger Uo versus calculated Uo correlated
as a function of Reynold's number.
ERROR RATIO, HEAT DUTY CALCULATED/MEASURED
Figure 5A
This means that a correction factor must be applied to the hand-calculated value for hi or ho
to give a 90% probability that the exchangers calculated will be adequate for the service.
Values for this correction factor as a function of Reynold's number are considered to be
proprietary but are usually included in sophisticated, computerized, heat exchanger sizing
programs. This discussion illustrates the importance of using modern computer programs
instead of hand calculations to determine the adequacy of a specified heat exchanger for a
particular service.
71
Process
The following example problem shows how to determine values for hi and ho.
72

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Shell And Tube Process Calculations

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FLOW/EXCHANGER CONFIGURATIONS .......................................................1

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WORK AID 1 - PROCEDURES FOR CALCULATING ENERGY

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Weight empty, 60,000 lb.

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One shell (see TEMA Manual, Pg. 112).

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Calculating Energy Balances

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For the stream being heated.

Q = (0.3167 - 0.2829) (1000) (145,812) = 4,928,446 Btu/hr

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HEAT EXCHANGER SPECIFICATION SHEET

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Cp =0.8187 + 0.6314 = 0.7251

Cp =0.6019 + 0.6724 = 0.6372

Calculate the heat transferred:

Q = (0.7251) (92,482) (234.7 - 158.2) = 5,129,990 Btu/hr

Q = (0.6372) (145,812) (158.4 - 105.0) = 4,961,500 Btu/hr

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PROPERTIES OF SATURATED STEAM: PRESSURE TABLE*

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Calculating Heat Transfer Coefficients

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Multiplying the LMTD for an exchanger by FT to obtain te accounts for nonperfect

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Inside tube surface area, ft2.

Specific heat, Btu/lb F.

Thermal conductivity of fluid, Btu/hr ft F.

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Tubewall thickness, ft.

Length of one tube, ft.

Tube pitch, in.

next one, psi.

Heat transferred, Btu/hr.

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Hot terminal difference, F.

Viscosity at average fluid temperature, lb/hr ft (mu = 2.42 mu).

x = 0.25 for Ret < 2100

Standards of Tubular Exchanger Manufacturers Association.

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Refer to TEMA figures for FT factor.

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The greater terminal temperature difference = (300 - 100) = 200F.

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= (400 - 300) = 50F.

LMTD = 200 - 50 = 150 = 108.2F

te = (FT) (LMTD) = (0.898)

te = (FT) (LMTD) = (0.975)

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TYPICAL HEAT RELEASE (T-Q) CURVES

Gas or Liquid Cooling

Gas or Liquid Cooling

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Inside Fouling (Scale)

Shell & Tube Cal

Shell & Tube Cal