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
basis for Experienced Based Learning when dealing with heat exchangers.

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 topic
and 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 the
indicated calculation using Excel's basic spreadsheet feature. The reader can type in the basic data
in the YELLOW-filled cells and the resultant calculated answer will be generated in BOLD RED
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
out of Tulsa, Oklahoma. Needless to say, his organization can be of great help in a heat exchanger application.
Art Montemayor - 05 April 2011
 experienced

g and positive

lso coincides

d to the topic

ratitude for his

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

6/28/2011 - Added three new tips from Gulleyassociates.com with permission. Chris Haslego
Boiling Cheresources.com Admin
Estimate - critical heat flux for propane chillers.
Calculations
Estimate - optimum flow velocity for gas inside tubes.
Construction
Longitudinal baffle heat conduction cures.

11/10/2011 - Added five new tips from Gulleyassociates.com with permission Chris Haslego
Boiling Cheresources.com Admin
Kettle Reboilers - Supports or Baffles
Construction
Design Temperatures of Carbon Steel and Low Alloy Tubes and Tubes
Design Temperatures of Nonferrous Tubes and Tubesheets
Misc.
Fouling factors for water(hr-ft2-F/Btu)
Fouling Factors for Liquid Hydrocarbons(hr-ft2-F/Btu)
4/5/2012 - Added five new tips from Gulleyassociates.com with permission Chris Haslego
Boiling Cheresources.com Admin
Vertical Thermosyphon-Calculate Pressure Drop at The Outlet Nozzle
Vertical Thermosyphon-Design for a Smaller Liquid Preheat Zone
Calculations
Estimate - Hydrocarbon Gas Heat Transfer Coefficient in Shell Side
Tube Bundle Vibration
Best Design Feature to Prevent Bundle Vibration
Misc.
Viscous Flow - Use More Pressure Drop Than Usual
Chris Haslego
Cheresources.com Admin

Chris Haslego
Cheresources.com Admin

Chris Haslego
Cheresources.com Admin

lloy Tubes and Tubesheets

ubesheets

Chris Haslego
Cheresources.com Admin
at The Outlet Nozzle
uid Preheat Zone

icient in Shell Side

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

Air Coolers:

1. Air flow accessories - don't overlook these when calculating fan HP

2. Box header design - limit of process temperature change
3. Connecting bundles of existing coolers for a new service
4. Fan drive changes that increase capacity of existing cooler
5. Fan drive noise - suggestions on how to reduce
6. Maximum motor HP for a fan
7. Maximum tube wall temperature for wrap-on fins
8. Optimum number of tube rows
9. Overall heat transfer rate estimate for hydrocarbons
10. When do bare tubes become more efficient than fin tubes?
11. When To limit number of tube passes in air coolers
12. When to use wind coolers

Boiling:

1. Avoid mist flow boiling inside tubes

2. Kettle reboiler - liquid carryover problem solutions
3. Kettle reboiler - shell nozzle arrangement problem
4. Kettle reboiler - shell vapor outlet nozzle location
5. Kettle reboiler - sizing shell vapor space
6. Kettle reboiler - undersized shell effects
7. Estimate - pool boiling heat transfer coefficient for hydrocarbons
8. Large boiling temperature difference problems
9. Lowest limit of boiling temperature difference
10. Vertical thermosyphon - choking two phase flow with small outlet nozzle
11. Vertical thermosyphon - minimum recirculation rate
12. Vertical thermosyphon - check for liquid preheat zone
13. Vertical thermosyphon - who sets recirculation rate
14. Vertical Thermosyphon-Calculate Pressure Drop at The Outlet Nozzle
 15. Vertical Thermosyphon-Design for a Smaller Liquid Preheat Zone

Calculations

1. What diameter to use to start design of a coil

2. Estimate - gas heat transfer coefficient inside tubes
3. Estimate - hydrocarbon heat transfer coefficient in tubes
4. Estimate - latent heat of hydrocarbons
5. Estimate - liquid thermal conductivity of light hydrocarbons
6. Estimate - overall heat transfer coefficient in shell & tube
7. Estimate - tube length that lowers tube pressure drop
8. How to calculate excess surface and overdesign surface
9. Use superficial velocities to calculate best heat transfer flow pattern
10. L/D equation for heat Transfer coefficient inside tubing
11. LMTD correction factor charts for TEMA G and J type shells
12. Low LMTD correction factor for divided flow
13. What is the lowest LMTD correction to use in shell & tube
14. Minimum flow area for shell side inlet nozzle
15. How to calculate performance of heat exchangers with plugged tubes
16. How to increase heat transfer for low Reynolds numbers
17. Calculate when to use seal bars on a bundle to increase heat transfer
18. Calculate S & T bundle diameter from number of tubes
19. Equation for calculating tube count in shell & tube
20. Check for hot tube wall temperature of cooling water
21. Sometimes larger tubes are better than small ones
22. Weighted MTD
23. Estimate - optimum flow velocity for gas inside tubes.
24. Estimate - Hydrocarbon Gas Heat Transfer Coefficient in Shell Side

Condensing:

1. Avoid small baffle cuts in S & T condensers

2. Estimate - Condensing heat transfer coefficient for hydrocarbons inside tubing
3. Maximum heat transfer rate inside tubes for total condensation
4. Quick estimate for reflux condenser LMTD in air cooler
5. Reflux (Knockback) condenser comments
6. Steam condenser types
 7. Sulfur condenser - design within tube velocity limits
8. Warning about small temperature pinch points in condensers
9. When to slope single tube pass tubes in condensing service
10. Zone those condensers!
11. Estimate - critical heat flux for propane chillers.

Construction:

1. Benefits of using rotated square pitch in shell & tube

2. Caution when using a longitudinal baffle in the shell side
3. Using turbulators for tube side laminar flow
4. Discussion of types of triple segmental baffles in shell & tube
5. Check entrance and exit space for shell nozzles
6. Horizontal vs vertical baffle cut in shell & tube
7. Is expansion joint required in the shell of a fixed tube sheet?
8. Increasing capacity of existing shell & tube exchangers
9. Locating vents on the shell side of vertical exchangers
10. Optimun gasket location for flanges
11. Reinforcing rods as tube inserts to increase heat transfer
12. Shell side impingement protection
13. Special shell & tube heat exchanger type (NTIW)
14. When to consider by-pass strips in shell & tube bundle
15. What is too large of temperature change in 2 tube passes ?
16. When to rotate square tube pitch in shell & tube exchanger
17. Longitudinal baffle heat conduction cures.

Heat Recovery:

1. Deciding on what fin spacing to use

2. Estimate of nozzle size for HRSG
3. Face area estimate for HRSG units
4. Maximum exhaust gas temperaure for steel fin tubes
5. When to use bare tubes in waste heat boilers

Materials:

1. Cooling water flowing inside 304SS U-tubes

Pressure Drop:

1. Allowing for fouling in pressure drop calculations

2. Allowable pressure drop suggestions
3. Allowable shell side pressure drop if a multi-leaf(a.k.a. lamaflex) long baffle is u
4. Better baffle window pressure drop equation
5. Designing for better use of tube pressure drop
6. Effect of 1st tube rows on shell nozzle pressure drop
7. Pressure drop on kettle side
8. Reducing high shell side pressure drop in fixed tube sheet exchangers
9. Use impingement rods instead of plate to lower shell press. drop
10. What design pressure drop to use for heavy liquids inside tubes
11. Maximum velocity inside tubes
12. Calculate shell nozzle pressure drop
13. Improve shell side pressure drop calculations

Tube Bundle Vibration:

1. Features of a new S & T bundle that replaces bundle that vibrated

2. Vibration cure when designing shell & tube bundles
3. Conditions likely to cause shell & tube bundle vibration
4. Cures for vibration in existing bundle
5. Best Design Feature to Prevent Bundle Vibration

Miscellaneous:

1. Allocation of streams in shell & tube

2. Articles published by Dale Gulley
3. Avoid these fluids when using lowfin tubing
4. Best heat transfer flow pattern
5. Check liquid thermal conductivity at high reduced temperatures
6. Check piping connections when there is under-performance
7. Evaluating an exchanger for a new service
8. Check heat release curve data for skipping over dewpoints and bubblepoints
9. When will exchangers with low-fins be more economical than exchangers with b
10. Problems with excess heat exchanger surface
11. Purchasing warning for shell & tube exchangers
12. What is the minimum velocity inside tubing for slurries?
13. Suggestions for low-fins and potential S & T bundle vibration
14. Choose shell & tube or multi-tube heat exchangers
15. Thermal design problem with shell side long baffle
16. Trouble shooting article in Hydrocarbon Processing
17. Under-surfaced S&T quote
18. When to add shell in Series
19. When to consider a long baffle in the shell
20. Which stream goes inside the tubes of gas/gas exchangers?
21. Weighted MTD
22. Why did performance decline in a TEMA type F,G or H type shell?
23. Zone those condensers
24. Viscous Flow - Use More Pressure Drop Than Usual
 Note: Input data into YELLOW cells and receive output in BOLD RED
Air flow accessories - don't overlook louvers and screens when calculating fan HP March, 2000
Air 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, 1998

In 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
tubesheet. If the temperature change of the tube side stream is over approximately 400 oF, then use a split header
design. This allows a hot top section to slide past a cooler bottom section.

Connecting Bundles of Existing Coolers for a new Service April, 1998

When 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, 1997
If 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 Noise

The 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 Fan

Adding 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 HP

Fan Diam = 7.00 feet
This is for fan diameters greater than 3.5 ft.
Temperature Limit of Wrap-On Fins for Aircoolers June, 2000
Above 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:
Twall = Ta + (Th1 - Ta) x Ro x Uc = 459 oF
Where
Twall = temperature of tube wall
Ta = air outlet temperature = 200 oF
Th1 = temperature inside tube = 488 oF
Ro = thermal resistance of air = 0.12 hr-ft2-oF/Btu
UC = clean overall heat transfer coefficient = 7.5 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 = 200 + (488 - 200) x 0.12 x 7.5
Twall = 459 oF

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

Optimun Number of Tube Rows

The 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 Minimum temperature difference at the hot end to be 8 to 10 oF.
3 Maximum air outlet temperature to be 300 oF if tension wound fins are used.
Hydrocarbon U Estimate (Air-Coolers) February, 2002
In 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) + 0.145
U = 1/Rt
Where: viscosity is less than 3 cP
Gases 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
heavy oil coolers. If it is expected that the heat transfer coefficient is below approximately 20 Btu/hr-ft 2-oF,
investigate both bare and fin tubes.

When To Limit Tube Passes in an Aircooler November, 1999

For 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, 2000

Where 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.
March, 2000
Mist Flow Boiling Inside Tubes November, 2001
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 vap
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 a
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 Nozzles

When it is necessary to have dry vapor leaving the kettle side, the location of the nozzles is important. The inlet nozz
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 Arrangement

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
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, 2000

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
appreciable liquid carryover

Sizing the Vapor Space in Kettle Reboilers June, 1998

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
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, 1997

What effect will an undersized kettle diameter have? The effect will be a decrease in the boiling coefficient. A boilin
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 = 22 (Δt)1.25 = 2,925 Btu/(hr)(ft2)(oF)

Where
Δt = (tube wall temperature - liquid temperature 50 oF
t= temperature, oF

Large Boiling Temperature Differences March, 1999

Large temperature differences in heat exchangers where liquid is vaporized are a warning flag. When the temperatur
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
if the LMTD is over 90 oF. This is close to the critical temperature difference where film boiling will start.

Lower Limit of Boiling Film Temperature Difference February, 1997

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,
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.

Choking a Vertical Thermosyphon December, 1999

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
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:

Reduction = 3.06X -1.63X2 - 0.43 = 53.32%

Where X = area ratio= 0.40

Minimum Recirculation Rate in Thermosyphon Reboilers

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
this value.

Vertical Thermosyphon - Check for Liquid Preheat Zone February, 2001

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
preheat, there may be an input error.

Vertical Thermosyphon Recirculation Rate December, 1997

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 configurat
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 Chillers

A 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 15/1
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

Ds (0.25)

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
(41) 0.25
CHF = 12,850

Kettle Reboilers - Support or Baffles?

For kettle reboilers use segmental baffles instead of full supports if shell fouling factor is greater Than 0.002(hr-ft
Vertical Thermosyphon-Calculate Pressure Drop at The Outlet Nozzle
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 t
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 d

Ktr = ___1______ = 0.445576 (used for pressure drop calc)

Ds0.3 (If Ktr less than 0.40, use 0.40)

Kc =0.5 (1 - (No/Ds)2) = 0.28077

KT = Ktr + Kc = 0.726346
ΔPn = KT = 0.000108 x Vn2 x ρtp = 0.16944
Where:
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 Zone

At low operating pressures there will be a sensible heat liquid zone with relatively low heat transfer. This is caused by
fact that a small pressure change will cause a large increase in the boiling point. There has been a case where 90% of
tube length was in the sub-cooled phase. What can you change that will decrease the size of the liquid preheat zone a
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 pressu
at the outlet. There is on this section of the website equations to calculate the pressure drop of a nozzle that is at right
the top channel. Most vertical thermosyphons have the outlet nozzle at right angles to the top channel. There may be
change of enlarging the outlet nozzle that would be the cure. But there needs to be a check to make sure the nozzle an
connecting piping are not so large that there is liquid slip. If enlarging the right angle nozzle and piping is not the ans
there are other configerations that will use less outlet pressure drop. Next the pressure drop of using a B type channel
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.
% vapor and
ried along in a vapor
he liquid is in very
to avoid mist flow.
the velocity needs
mately 30 ft/sec.
ximum velocities are
o increase the heat

Art's Note:
ant. The inlet nozzle I agree. I have also found that locating the inlet liquid nozzle directly under the vapor outlet is not good.
er. When there is In Amine BKU reboilers I found that locating the inlet rich amine liquid as close to the U-tube bundle tube
nce away. There gave the best, consistant results in obtaining good solution stripping. This gives the heating medium
nozzle without
ng in appreciable

This arrangement
he outlet vapor. It
nless a demister

and there is a
the bundle will

ant. The inlet

carryover. When
me distance away.
vapor nozzle
e resulting in

ow the vapor
surface. The
distillation tower
kettle vapor
om two different
in quantity. A
al. One case
erence at one end
her for high heat

oefficient. A boiling
the recirculation
tion. Another

hen the temperature

of a vapor film.
rmal conductivity
iling, the vaporizer
shing the liquid.
am pressure
look at the design

convection. The
bare tubes are used,
ely 5 oF. We have
Special enhanced

exchanger. Since
on rates. A rule
as the flow area
nozzle flow
be wall is no
issible recirculation
is when the
et densities above

ures, check for the

preheat zone and
d it reduces the
e should be a
ere is no liquid

r if there will be
size and configuration
make piping

inch tubes on 15/16 inch pitch.

ar tube pitch.

han 0.002(hr-ft2­F/Btu)
 total static head.
nside flow area of the
with a side outlet
culate the pressure
the tube pressure drop.

ressure drop calc)

40, use 0.40)

er. This is caused by the

case where 90% of the
uid preheat zone and

on check the pressure drop

zzle that is at right angle to
nel. There may be a simple
e sure the nozzle and
iping is not the answer then
g a B type channel with

ally coiled.
tlet is not good.
-tube bundle tubesheet
ing medium
 Note: Input data into YELLOW cells and receive output in BOLD RED
What Coil Diameter to Use to Start Design October, 2002
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:

Size Unit Capacity flow rate

1” tube 3,000-5,000 # / tube / hr
1 ¼” pipe 5,000-10,000 # / tube / hr
1 ½” pipe 10,000-17,000 # / pipe / hr
2” pipe 17,000-35,000 # / pipe / hr
3” pipe 35,000-70,000 # / pipe / hr
4” pipe 70,000-130,000 # / pipe / hr

Estimate Gas Heat Transfer Rate for Hydrocarbons February, 1998

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

Or,
h= 1.4W0.8 = 66 Btu/hr-ft2-oF Generally understated

Operating pressure = 100.0 Psia.

W= 123.00 lb/tube/hr

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

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) = 87 Btu/Ft2-hr-oF

Where:

Viscosity = 3.0 cP.

This is limited to a maximum viscosity of 3 cP

Estimate - Latent Heat of Hydrocarbons

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

Where:
Lat heat = The fluid's Latent Heat in Btu/lb
T = The fluid temperature in oF = 100
SG60 = The fluid's Specific gravity @ 60 oF = 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, 1999

You 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= 0.025 / (specific heat)1.5 = 0.0427
Specific Heat = 0.7000 But/lb °F

Estimate Overall Heat Transfer Rate (U) in S & T December, 2001

In the preliminary design of shell and tube heat exchangers, you need an estimate of the overall heat transfer coefficie
(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 = Fouling + Sqrt(avg. tube viscosity)/150 +((avg. shell viscosity)0.27)/140 =

Where,
Avg. tube viscosity = 2.0 cP Fouling = 0.0005 U = 1/Rt =
Avg. shell viscosity = 3.0 cP
Fouling is the total for both sides. The above is limited to a maximum viscosity of 3 cP for the tube side. There is n
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, 2001
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
following equation:
New Lg = Lg (Allowed Dp/Calc. Dp)1/3 = 15.9 feet

Where
Lg = Existing tube length = 20 feet
Allow.Dp = Allowable Tube pressure drop = 1.00 psi
Calc. Dp = Calculated 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.
How to Calculate Excess Surface and Over-design Surface

Excess surface = 100 x (Aactual –Acalculated) / Acalculated = 31.58%

Where
Aactual = actual heat transfer surface = 250.0
Acalculated = surface calculated from design overall heat transfer coefficient = 190.0

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

Use Superficial velocities to Calculate Best Heat Transfer Flow Pattern

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 gas velocity is above the following value:

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

VgMax = 72 – 148 VL +100 VL2 = 41.3 ft/sec.
where
VL = the superficial liquid velocity = 0.25 ft/sec. (less than 0.30 ft/s)

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

VgMax = 28.1 + 28 VL + 1.12 VL2 = 57.2 ft/sec.
where
VL = the superficial liquid velocity = 1.00 ft/sec. (more than 0.30 ft/s)

L/D Equation For Heat Transfer Coefficient Inside Tubing

For Reynolds numbers below 10,000 there is an L/D effect on the heat transfer coefficient inside tubing. If you use th
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.

L = Tube Length - 0.0027 Di Re 11 feet

Where
L = variable to use in L/D expression, ft
Tube Length = length of tube, ft = 20 feet
Di = tube I.D., in = 0.650 inches
Re = Reynolds number = 5,000
LMTD Correction Factor Charts for TEMA G and J Shell Types
There 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, 1996

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
difference at correction factors above 0.90. However, there is a difference at lower values. For example:

Shell-type Flow Correction Fn

Equal outlet temperatures Shell type "E" 0.805
Shell type "J" 0.775
Cold outlet 5 oF higher than hot outlet Shell type "E" 0.765
Shell type "J" 0.65
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
Gulley charts for up to 4 shells in series that are found in this Workbook.

Lowest Limit of LMTD Correction Factor

What 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 Nozzle

For single phase liquids and no impingement plate:

Minimum area = (Flow (lb/hr) x 0.04) / (38.73 Sq.Root(ρ)) = 0.261 in2

Shell Side Flow Rate = 2,000 lb/hr

 Shell Side fluid density = 62.50 lb/ft3

For boiling liquids and no impingement plate:

Minimum area = (Flow (lb/hr) x 0.04) / (22.36 Sq.Root(ρ)) = 0.453 in2

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:
Rother = 1/U -1/hio

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

3. Calculate new U
Unew = 1/(1/hio + Rother)
How to Calculate the Perfor
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 Transfer

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.
The by-pass area is normally:

FSBP = Bs (Ds - OTL) = 0.054

Bs(Ds-OTL)+Bs(OTL-Do)(P-Do)/P

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

Calculate Tube Bundle Diameter January, 2000

Following 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 inches
Where:
Tube OD = 0.750 inches
DS = Bundle diameter
Count = 250 Number of tubes
Pitch = Tube spacing = 1.000 inches

Tube Count Calculation for S & T August, 2002

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
allowance for bundle entrance and exit area.

Count = F [0.7854 x TC2 - (PLw + Do - P) (TC x Npl)] / P2 = 372 Tubes on Square Pitc
Where: = 428 Tubes on Triangular
Do = Tube O.D. = 0.750 inches
F= 1.00 for square pitch
F= 1.15 for triangle pitch
Npl = Number of tube pass lanes (1 for two pass) = 2
PLw = Tube pass lane width (typical is 0.625 inches) = 0.625 inches
P= Tube pitch = 1.000 inches
TC = (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, 1999

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
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
before it enters the water-cooled exchanger.
Sometimes Larger Tubes are Better October, 1998
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
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 MTD
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
MTD and its correction factor if one is required.

Estimate - Optimum Flow Velocity for Gas Inside Tubes

Since 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 fo
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 s
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 g
tube velocity for turbulent flow. Gases will be in turbulent flow more than 99% of the time. If your calculated tubesid
what the following equation calculates, you need more tube travel where tube travel is in the form of number of tube
length(s) for countercurrent flow. These equations can be used for two phase flow as long as the two phase viscosity

For 3/4 inch tubes with 0.06 tube wall

W = 1600(ΔPρ/L)0.555
For 1.0 inch tubes with 0.06 tube wall
W = 3500(ΔPρ/L)0.555

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.
L= 21 ft For 3/4" tubes, W = 1,497 Tube count =
ΔP = 7 psig For 1" tubes, W = 3,274 Tube count =
ρ= 2.66 lb/ft3
Mass 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 de
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 = 1600(7 x 2.66/(16+5))0.555
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:
Calculate S & T diameter from number of tubes

Estimate - Hydrocarbon Gas Heat Transfer Coefficient in Shell Side

Its difficult to estimate a gas heat transfer coefficient in the shell side because of the many variables. The following w

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
known. An example
w path rather than
diameter selection:

e, use the following:

more accurate

understated

3/4 inch tubing:

he Specific Gravity
 their specific heat.

heat transfer coefficient

have a U value.

0.020

51

tube side. There is no

ons. One option is

ength, use the

will be larger due to

 n liquid film and
will be when the

tubing. If you use the

e before laminar flow
e following for tube
type J shells.

Divided flow
e seen several
e is very little

hart for a single

the enclosed Dale

esigner use.
LMTD correction
oss of more than
 Calculate the expected performance of an exchanger that has had to have some tubes plugged

t excludes the 1. You know the original overall heat transfer coefficient for the un-plugged exchanger and th
number of tubes plugged.
2. Therefore, you know the original heat transfer area, the original hi and ho, the original tube
and 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.

 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 coefficien
1. Using the actual overall heat transfer coefficient (U). calculate the heat transfe
an 1,000, you        Rother = 1/U ­1/hio
d using shorter tubes. 2. Calculate new hio and new surface using usable number of tubes
ese factors will 3. Calculate new U
      Unew = 1/(1/hio + Rother)
4. Calculate new heat load from new surface and new U

ound the bundle.

oss flow area.
ed. The following
not a need for

Tubes on Square Pitch

Tubes on Triangular Pitch

mber of tubes

k the tube wall

ratures above
ures. As a rough
rbon liquids and
erature down
s will be cheaper
t than the outside

horter than allowed

tube length.

hen a step-wise
t exchanger area.
n TEMA in the
ublished by
ate a weighted

good starting value for this

est heat transfer for single phase fluids.

ble pressure drop.
following equation gives the optimum
our calculated tubeside velocity is below
m of number of tube passes or total tube
two phase viscosity is less than 0.015 cp,
 130
60

7 psi (after nozzle deduction) and the

bles. The following will give you a value within 25%.

e tubes plugged by doing the following:

xchanger and the

the original tubeside velocity

atures with the

nsfer coefficient.
e heat transfer resistances that exclude the tubeside resistance
Avoid Small Baffle Cuts in S & T Condensers July, 2001
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
that would hold a liquid level higher than the theoretical one.

Estimate - Condensing Heat Transfer Coefficient for Hydrocarbons Inside Tubing

Cond h = (4.15) W0.8 = 828 Btu/(hr)(ft2)(oF)

Where
Cond h = Inside condensing heat transfer coefficient
W = Condensing fluid in tubes = 750.00 lbs/hr/tube

Maximum Condensing Rate Inside Tubes August, 2001

Following is a close estimate of the maximum heat transfer rate for total condensation. It is based on the maximum
condensing rate for the average hydrocarbon to be 750 BTU/hr-ft2-F. It is good for other types of chemical compoun

Hi = 750 (Kliq / 0.07)0.9 = 3,193 Btu/hr

Where,
Kliq = liquid thermal conductivity of the condensat 0.350 Btu/hr-ft-oF

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

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

In the case of outlet process temperatures below 153.5 oF,

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

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

Reflux (“Knock back”) Condenser June, 2001

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

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

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
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
designed for 247 PSIA operating pressure and the actual pressure is 5 PSI less and the pinch point is 8 oF, there
can be a 16% drop in heat transfer.

When to Slope Single Tube Pass Tubes in Condensing Service January, 2002
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
transfer. The benefit of sloping stops at an angle of approximately 10o. A common case of a condenser needing to
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 Condensers

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
better accuracy if the flow patterns are determined and their individualistic equations are used.
 g heat transfer
as possible.
parated flow
use a baffle cut

he maximum
mical compounds.

condensing

in one direction.
bottom section).
ontrol. The
ulations are zoned.
condensers.

120 oF. For

ure requires

n limits. The
s range sulfur

temperature

ue of fluids

ant increase in
her the heat
r needing to
An example
esigned with

that condenses
d. There is
Rotated Square Tube Pitch
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
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 Side

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

1. The largest temperature drop across the long baffle is more than 250 oF. Then the thermal efficiency
is lost due to conduction across the long baffle. Check and make sure this has been taken into consideratio
2. 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 fabrica

Using Turbulators for Tube Side Laminar Flow

If the flow inside the tubes of a heat exchanger is in laminar or viscous flow, take a look at enhancing the heat transfe
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 velocity
3 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, 1997

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 segmenta
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, 2001

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
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, 2001

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 exchange
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 horizon
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 horizonta
cut in certain boiling applications.

Is an Expansion Joint Required in the Shell? December, 1998

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
metal temperature is hotter than the shell metal temperature to require an expansion joint. Typically, an all steel
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
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, 1997

To 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, 1998

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.

Flange Gasket Location May, 1999

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
case, low pressure is considered to be below 300 psi. High pressure is considered to be approximately 750 psi
and higher.

Using Rods for Tube Inserts to Increase Heat Transfer August, 1998
Use 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 Protection

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

2. 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 rows
4. Small angle iron types setting on top of the tubes in the first 2 or 3 rows
5. Vapor belt

Special S & T Exchanger Type (NTIW) September, 1998

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
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 Bundle

Use 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, 1996

Warning! 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
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, 1999

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
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 Cures

With a longitudinal baffle and a long temperature range there can be a problem with heat conduction through the
longitudinal 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 Tubesheets
Use 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 Tubesheets

Water in the shell-side
Use the arithmetic average of the shell-side and tube-side design temperatures.
Water in the tube-side
Use the higher of the tube-side design temperature or tube-side outlet temperature + 1/3 of the LMTD.
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Choosing Fin Spacing June, 2002
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 us

HRSG Nozzle Size April, 2002

For an estimate of the nozzle size entering and leaving a HRSG unit use:

D= 0.14 x (flow)1/2 = 4.43 inches

Where:
D= diameter of nozzle
Flow = Gas flow = 1,000 lbs/hr

This is based on a total of 0.8 inches of water

Face Area for HRSG Units April, 2001

The 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) = 0.40 ft2

Where:
Flow = Exhaust Gas flow = 1,000 lbs/hr
Where face area is in square feet.

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

Maximum Exhaust Gas Temperature for Steel Fin Tubes

Here 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 o

F

Where
MaxTg = maximum gas temperature
Btemp = water boiling temperature = 300 o
F.

When to Use Bare Tubes in Waste Heat Boilers

Use bare tubes if the bundle is quite small or the gas temperature is greater than 1,350 to 1,400 oF.
f the exhaust gas.
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Cooling Water Flowing Inside 304SS U-tubes June, 1999
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
results from the flashing of steam amplifies the stress that causes stress corrosion cracking.
ubes. But if for
bration that
Calculating Fouled Pressure Drop August, 1999
There 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, 2002

If you are at a loss as to what allowable pressure drop to specify, here are some suggestions:

Fluid and Condition Allowable Pressure Drop, psi

Gas 3 to 5
Liquid 8 to 10
Change of phase
Boiling: 0.5 to 1.0 psi for greater than 10 % vapor
1.0 to 5.0 psi for less than 10 % vapor
Condensing operating pressure
Less than atmospheric 0.5
Atmospheric to 25 psi 1
25 to 50 psi 2
50 to 150 psi 3
150 psi + 3.0 to 5.0

Allowable Shell Side Pressure Drop if a Multi-leaf (a.k.a. Lamaflex) Long Baffle is Used
Four 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 Equation

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:

KP = Pressure loss coefficient for velocity head equation

fi = Friction factor for ideal tube bundle
C1 = Constant based on the type of tube layout
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.
Ncw = Effective number of tube rows crossed in baffle window
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)
Sl = Total of leakage areas (in2)
Sw = Net flow area in baffle window (in2)

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

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

Kp = 1.33

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

ΔPw = Kp x 0.000108 x Gw2/ρ

ΔPw = 1.33 x 0.000108 x (890.5)2 x 7/62.4
ΔPw = 12.78

Designing Better Use of Tube Pressure Drop October, 1999

When the calculated pressure drop inside the tubes is under-utilized, the estimated pressure drop with increased
number of tube passes is:

New tube DP = DP x (NPASS/OPASS)3 = 12.0 psi

Where
DP = Previous Pressure drop 1.5 psi
NPASS = New number of tube passes = 4
OPASS = 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.
Effect of 1st Tube Rows on Shell Nozzle Pressure Drop
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, 1999

Usually 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, 2000
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 losse

Impingement Rods January, 1997

When 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 Tubes

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 allowab
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:

Allowable tube Exchanger surface

pressure drop, psi ft2
5 4,012
25 2,104
50 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.
Maximum Velocity Inside Tubes
An estimate for maximum tube velocity inside steel tubes

Vmax = 80 / sqrt(density) = 10.2 ft/sec

Where
Vmax = maximum fluid velocity
Density = fluid density = 62.00 lb/cu ft.

Calculate Shell Nozzle Pressure Drop

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 recirculati
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
2. Calculate the slot area Aslot = 0.7854Dn2 (Pt -Dt)/(F2 x Pt)
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/As
5. Kn = 0.65 +2.14 (FR -0.4)
(minimum Kn = 0.8, maximum = 1.8)
6. ΔPn = Kn x .000108Vs2 x density
(ΔPn = total of both nozzles)
where
ΔPn = Total nozzle pressure drop (lb/ft2)
Dn = Nozzle ID in.
Ds = Shell ID in.
Dt = Tube outside diameter in.
F2 = 0.707 for 45 degree pitch, all others use 1.0
h = 0.5(Ds-OTL) in.
Kn = Pressure loss coefficient
OTL= Outer tube limit diameter in.
Pt = Tube center to center pitch in.
Vs = velocity in the entrance/exit area (ft/sec)
EXAMPLE
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
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 Sb
h = 0.50(23.25-22.375)= 0.4375
Sb = π x 13.25 x 0.4375 = 18.23

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

Calculate total area As

As = Sb + Aslot = 18.23 + 27.58 = 45.81

Calculate FR
FR = 18.23/45.81 = 0.4

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

Calculate nozzle pressure drop

Vs = (990000 x 0.04)/(45.81 x 62.4)= 13.85
ΔPn = 0.8 x 0.000108 x 13.852 x 62.4 = 1.03 psi

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

Improve Shell Side Pressure Drop Calculations

The 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”
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 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 in
fi = 0.1025 - Ideal tube bank correlation ( J. Taborek)
Nc = 13.75
Rb = 0.536
Re = 40,249
Rl = 0.615

ΔPc = 6.41 psi

ΔPshell = ΔPc + ΔPw + ΔPn

From other tips: ΔPw = 12.78
ΔPn = 1.03
ΔPshell = 6.41 +12.78 +1.03 = 20.2 psi
Experimental = 20.3 psi
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Features of a New S & T bundle to Replace Bundle That Vibrated
1. 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, 2000
The 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 b
Another cure is to use a de-resonating baffle. In a few cases, putting the problem stream inside the tubes would be be

Conditions Likely to Cause Shell & Tube Bundle Vibration May, 1997
Bundle vibration can cause leaks due to tubes being cut at the baffle holes or tubes being loosened at the tubesheet jo
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, 1997

Most 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 Vibration

In designing a shell-and-tube heat exchanger, use a 30o triangular tube pitch if possible. This will lower the vortex sh
frequency which is a direct function of something called a Strouhal number. The Strouhal number is a constant comp
of the vortex shedding frequency, shell side velocity and tube OD.
The 30° triangular tube pitch has a significantly lower Strouhal number than other tube pitch types. Using Barrington
for 3/4 inch tubes on 30o triangular tube pitch the Strouhal number is 0.21. But for 60o rotated triangular tube pitch t
Strouhal number is 0.81.
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Allocation of Streams in Shell & Tube May, 1998
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 problem
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

1. "More Accurate Exchanger Shell-and-Tube Pressure Drop Calculations", Hydrocarbon Processing, June 2004
2. "Troubleshooting Shell-and-Tube Heat Exchangers", Hydrocarbon Processing, September 1996
3. "Computers help Design Tubesheets", The Oil & Gas Journal, May 20,1974
4. "Computer Programs aid Design Work", The Oil & Gas Journal, Jan. 13,1969
5. "How to Calculate Weighted MTD's", Petroleum Refiner, July 1966
6. "How to Figure True Temperature Difference in Shell-and-Tube Exchangers", The Oil & Gas Journal, Sept. 14,
1964
7. "Make This Correction Factor Chart to Find Divided Flow Exchanger MTD", Petro/Chem Engineer, July 1962
8. "Use Computers to Select Exchangers", Petroleum Refiner, July 1960

Copies of the articles are available in .pdf format

Avoid These Fluids When Using Low fin Tubing

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,
amines and glycols.

Use Superficial velocities to Calculate Best Heat Transfer Flow Pattern

The best heat transfer occurs when there is an annular flow pattern. Then there is a relatively thin liquid film and littl
vapor in contact with the heat transfer surface. How do you tell if the flow is annular? It will be when the superficia
gas velocity is above the following value:

VgMax = 72 -148VL +100 VL2 = 1,832.0

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

Check Liquid Thermal Conductivity at High Reduced Temperatures November, 2000

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
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 coefficien
by using an independent and reliable correlation for the calculation.
Check Piping Connections When There is Under-performance July, 2002
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
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, 2000
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 specificatio
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, 1998
Frequently 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-fins
4. When (total shell resistance/total tube resistance) is greater than 0.4

Excess Heat Exchanger Surface Problems September, 2002

Excess surface does not always mean being safe. It can lead to control problems, pulsations, or freezing of condensa
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, 2001

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”.

Minimum Velocity inside Tubing for Slurries

The minimum velocity for slurries inside tubes for shell-and-tube is 4 ft/sec. This is for a fine material like a catalyst
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, 2002
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
software shows that the bundle may vibrate are:

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.

Shell & Tube or Multi-Tube? June, 1997

It 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, 1997

The 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, 1996

To 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 Quote

When a vendor’s heat exchanger quote is under-surfaced, the following should be asked:
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, 2000

Usually 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, 2001

The 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:

Factor = (flow)2 / density

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

Factor = (flow)2 / pressure

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)

0.0005 steam,steam condensate,engine jacket water
0.0010 boiler feed water
0.0015 clean water,moutain water,etc.
0.0020 normal cooling tower water

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

Fouling = 0.025/V1.67
Where V =ft/sec

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

0.0010 If sp. gravity At 60F less than 0.80, lube oil and heating oils
0.0020 If sp. gravity At 60F 0.80 -0.87
0.0030 If sp. gravity At 60F 0.87 -1.00
0.0050 Heavy fuel oils

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 sho
tubes than normal. Also the fluid could be placed in the shell side if cleanig isn't a problem.
y best put in
aterial problems.
as streams on
ubes with the

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passes and shorter
Art Montemayor September 30, 2005
Rev: 0

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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WorkSheet: TEMA Designations
Art Montemayor September 30, 2005
Rev: 0

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

Conventional Front End Heads:

A
or,
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

FileName: 378802750.xls
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WorkSheet: TEMA Designations
Art Montemayor September 30, 2005
Rev: 0
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, then
this 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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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,
including the backing device, must be disassembled. If pulling from the front head is required a type AET
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 a
common 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 Reynolds
number (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 area
and more tubes) in order to do a heat transfer operation.

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Rev: 0

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 permit
the 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 pressure
drop. 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. There
are, 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 shell
wall in order to ensure that there will be no internal, by-pass leakage. This positive step negates the possibility
of 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 techniques
and 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, 2003
Rev: 0
Heat Exchanger Tube Sheet Layout Count Table
Source: "Applied Process Design for Chemical and Petrochemical Plants"; Vol. 3; p.24
Ernest E. Ludwig; Gulf Publishing Co.; Houston, TX (1965)
Shell I. D., inches
Tube 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
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
Fixed Tubes
One-Pass

3/4" on 1" Triang. 33 57 91 117 157 217 277 343 423 493 577 667 765 889 1,007 1,127
3/4" on 1" Square 33 53 85 101 139 183 235 287 355 419 495 587 665 765 865 965
1" on 1-1/4" Triang. 15 33 57 73 103 133 163 205 247 307 361 427 481 551 633 699
1" on 1-1/4" Square 17 33 45 65 83 111 139 179 215 255 303 359 413 477 545 595
3/4" on 15/16" Triang. 32 58 94 124 166 228 300 370 452 528 626 734 846 964 1,088 1,242
Fixed Tubes

3/4" on 1" Triang. 28 56 90 110 154 208 264 326 398 468 556 646 746 858 972 1,088
3/4" on 1" Square 26 48 78 94 126 172 222 280 346 408 486 560 644 746 840 946
1" on 1-1/4" Triang. 16 32 52 62 92 126 162 204 244 292 346 410 462 530 608 688
Two-Pass

1" on 1-1/4" Square 12 26 40 56 76 106 136 172 218 248 298 348 402 460 522 584
3/4" on 15/16" Triang. 8 34 64 94 134 180 234 304 398 460 558 648 768 882 1,008 1,126
3/4" on 1" Triang. 8 26 60 72 108 158 212 270 336 406 484 566 674 772 882 1,000
U Tubes

3/4" on 1" Square 12 30 52 72 100 142 188 242 304 362 436 506 586 688 778 884
1" on 1-1/4" Triang. XX 8 26 42 58 84 120 154 192 234 284 340 396 466 532 610
1" on 1-1/4" Square XX 12 22 38 58 76 100 134 180 214 256 304 356 406 464 526
3/4" on 15/16" Triang. XX 48 84 108 154 196 266 332 412 484 576 680 788 904 1,024 1,172
Fixed Tubes

3/4" on 1" Triang. XX 44 72 96 134 180 232 292 360 424 508 596 692 802 912 1,024
3/4" on 1" Square XX 48 72 88 126 142 192 242 308 366 440 510 590 688 778 880
1" on 1-1/4" Triang. XX 24 44 60 78 104 138 176 212 258 308 368 422 486 560 638
Four-Pass

1" on 1-1/4" Square XX 24 40 48 74 84 110 142 188 214 260 310 360 414 476 534
3/4" on 15/16" Triang. XX 28 56 84 122 166 218 286 378 438 534 622 740 852 976 1,092
3/4" on 1" Triang. XX 20 52 64 98 146 198 254 318 386 462 542 648 744 852 968
U Tubes

3/4" on 1" Square XX 24 44 64 90 130 174 226 286 342 414 482 560 660 748 852
1" on 1-1/4" Triang. XX 20 36 50 74 110 142 178 218 266 322 376 444 508 584
1" on 1-1/4" Square XX 16 32 50 66 90 122 166 198 238 286 336 384 440 500
3/4" on 15/16" Triang. XX 80 116 174 230 294 372 440 532 632 732 844 964 1,106
Fixed Tubes

3/4" on 1" Triang. XX 66 104 156 202 258 322 388 464 548 640 744 852 964
3/4" on 1" Square XX 54 78 116 158 212 266 324 394 460 536 634 224 818
1" on 1-1/4" Triang. XX 34 56 82 112 150 182 226 274 338 382 442 514 586
Six-Pass

1" on 1-1/4" Square XX 44 66 88 116 154 184 226 268 318 368 430 484
3/4" on 15/16" Triang. XX 74 110 156 206 272 358 416 510 596 716 826 944 1,058
3/4" on 1" Triang. XX 56 88 134 184 268 300 366 440 518 626 720 826 940
U Tubes

3/4" on 1" Square XX 56 80 118 160 210 268 322 392 458 534 632 718 820
1" on 1-1/4" Triang. XX 30 42 68 100 130 168 206 252 304 356 426 488 562
1" on 1-1/4" Square XX 42 60 80 110 152 182 224 268 316 362 420 478
3/4" on 15/16" Triang. XX 94 140 198 258 332 398 484 576 682 790 902 1,040
Fixed Tubes

3/4" on 1" Triang. XX 82 124 170 224 286 344 422 496 588 694 798 902
3/4" on 1" Square XX 94 132 174 228 286 352 414 490 576 662 760
1" on 1-1/4" Triang. XX 66 90 120 154 190 240 298 342 400 466 542
Eight-Pass

1" on 1-1/4" Square XX 74 94 128 150 192 230 280 334 388 438
3/4" on 15/16" Triang. XX 68 102 142 190 254 342 398 490 578 688 796 916 1,032
3/4" on 1" Triang. XX 52 82 122 170 226 286 350 422 498 600 692 796 908
U Tubes

3/4" on 1" Square XX 48 70 106 146 194 254 306 374 438 512 608 692 792
1" on 1-1/4" Triang. XX 24 38 58 90 118 154 190 238 290 340 404 464 540
1" 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 101 of 140 FileName: 378802750.xls

WorkSheet: Tube Counts
 March 12, 2001
Art Montemayor
Rev: 0

HEAT EXCHANGER SUMMARY

T in, Cold Side (t1) 69 F

o

T out, Cold Side (t2) 83 F

o

T in, Hot Side (T1) 169 F

o

T out, Hot Side (T2) 128 F o

Exchanger Heat Duty 3,950 M Btu/hr

Overall U, estimated 100 Btu/hr - Ft2 - oF
Number of shell passes 1
Number of tube passes 2
Log Mean Temperature Difference, LMTD 72 oF
F Factor (see below) 0.98
Adjusted LMTD 70 oF
Heat Transfer Area calculated 562 Ft2
Design contingency factor 1.25
Over-design allowance 1.00
Heat Transfer Area required 702 Ft2

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 [(RP-1)/(P-1)](1/N)
Px 0.14
Term 2 1.60 (R^2+1)0.5/(R-1)
Term 3 0.38 1.46
Term 4A 13.45
Term 4B 7.26
Term 4 0.62
F 0.98

W, Cp, T2

w, cp, t1 q, U, A, DTm w, cp, t2

W, Cp, T1

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WorkSheet: HX Design
 SHELL & TUBE HEAT EXCHANGER SPECIFICATION Sheet 1 of 1
Montemayor (English Units)
Corporation Project No.

Rev. 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 * ft
2
Gross Eff. Shells/Unit One Surface/Shell * ft
2
Gross Eff.
6 P&ID No. Plot Plan No. Other Ref. Dwg No.
7 PERFORMANCE OF ONE UNIT
8 Fluid Allocation SHELL SIDE TUBE SIDE
9 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 Gravity
19 Viscosity cP
20 Vapor Molecular Weight
21 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 Resistance ft2·h·ºF/Btu .
28 Heat Exchanged Btu/h Log MTD (Uncorrected) ºF Log MTD (Corrected) * ºF
29 Transfer Rate, Service * Btu/ft2·h·ºF . Transfer Rate, Clean * Btu/ft2·h·ºF .
30 CONSTRUCTION AND MATERIALS
31 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 Shell
36 Connections In
37 Size & Out
38 Rating Intermediate
39 Tubes: Type Number * OD 0.75 in. 16 BWG or 30° in.
45°
X Min.
60° 90°
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 Welded
42 Baffles - Cross: Type * Spacing * in. * % Cut on X Diam. Area
43 Baffles - Long: Perm. Removable Seal Type: Bypass Seal:
44 rv2: 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 MATERIAL§ THK, in. C.A., in. PART MATERIAL§ THK, in. C.A., in.
47 Tubes Stainless Stl 16 BWG min. Floating Tubesheet Carbon Steel * ----
48 Shell Fixed Tubesheet Carbon Steel * 0.125
49 Shell Cover Tube Supports Carbon Steel * 0.125
50 Channel Cross Baffles Carbon Steel * 0.125
51 Channel Cover Long Baffle Carbon Steel * 0.125
52 Fltg Head Cover Gaskets Stainless Stl ----
53 §
Stress Relieved (Mark "SR') and/or Radiographed (Mark 'XR') Parts User Spec.:
54 Code Requirements: ASME Sec. VIII, Para. 1 (1992) Stamp? Yes TEMA Class:
55 Weights: Shell * lb Filled with Water * lb Bundle * lb
56 Remarks 1. Items marked with an asterisk (*) to be completed by Vendor.
57
58
Rev Date Description By Chk. Appr. Rev Date Description By Chk. Appr.
0 For Purchase
 PLATE & FRAME HEAT EXCHANGER SPECIFICATION Sheet 1 of 1
Montemayor (English Units)
Corporation Project No. 1234567

Rev. No.
1 Service Cooling Water Exchanger Equipment No.
2 Location Unit P.O. No.
3 Manufacturer * Model * Mfr Ref. No. * No. Req'd One
4 Size, Type *-* Frames/Unit One Connected in Single
5 Surface/Unit * ft2 Effective Surface/Frame * ft2 Gross
6 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 90 105
18 Density, Specific Gravity 0.907 0.929 0.995 0.992
19 Viscosity cP 0.54 13.7 0.76 0.65
20 Vapor Molecular Weight ---- ---- ---- ----
21 Specific Heat Btu/lb·ºF 0.867 0.843 1.0 1.0
22 Thermal Conductivity Btu/h·ft·ºF 0.178 0.160 0.358 0.365
23 Latent Heat Btu/lb ---- ----
24 Operating Pressure, Inlet psig 75 60
25 Velocity X Max. Min. fps 8.0 8.0
26 Pressure Drop, Clean (Allow./Calc.) psi 10 * 10 *
27 Fouling Resistance ft2·h·ºF/Btu 0.001 0.003
28 Heat Exchanged 3,097,238 Btu/h Log MTD (Uncorrected) 157.0 ºF Log MTD (Corrected) * ºF
29 Transfer Rate, Service * Btu/ft2·h·ºF Transfer Rate, Clean * Btu/ft2·h·ºF
30 CONSTRUCTION AND MATERIALS
31 Allocation HOT SIDE COLD SIDE Sketch (Frame, Nozzle Orientation)
32 Design Pressure psig 150 125
33 Test Pressure psig Code Code
34 Design Temperature ºF 300 300
35 Number of Passes per Frame Two *
36 Corrosion Allowance in. 0.0625 None
37 Connections In 3" 150# RF 6" 125# FF
38 Size & Out 3" 150# RF 6" 125# FF
39 Rating Intermediate ---- ----
40 rv2, Inlet/Outlet lb/ft·s
41 Impingement Protection? Yes
42 No. of Plates Frame Capacity (Max. No. of Plates)
43 PART MATERIAL§ THK, in. C.A., in. PART MATERIAL§ THK, in. C.A., in.
44 Plates Stnless Steel 16 BWG min. 0.03125 Connections Stnless Steel 0.03125
45 Plate Gaskets Carbon Steel * 0.03125 Frame Carbon Steel 0.03125
46 End Cover Carbon Steel * 0.03125 Carrying Bar Carbon Steel 0.03125
47 Carbon Steel 0.03125 Carbon Steel 0.03125
48 § Stress Relieved (Mark "SR') and/or Radiographed (Mark 'XR') Parts
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? Yes
52 Client Spec.: Weights: Empty Frame * lb Filled with Water * lb
53 Remarks 1. Items marked with an asterisk (*) to be completed by Vendor.
54
55
Rev Date Description By Chk. Appr. Rev Date Description By Chk. Appr.
0 9-Dec-96 For Inquiry ABC DEF XYZ
 October 02, 2003
Art Montemayor Overall Heat Transfer Coefficient
Rev: 0
Typical Overall Heat Transfer Coefficients
Source: http://www.the-engineering-page.com/forms/he/typU.html

Shell and Tube Heat Exchangers Overall “U”

Hot Fluid Cold Fluid
W/m2-C Btu/hr-ft2-oF
Heat Exchangers
Water Water 800 – 1,500 140 - 264
Organic solvents Organic Solvents 100 - 300 17 – 52
Light oils Light oils 100 - 400 17 – 70
Heavy oils Heavy oils 50 - 300 9 – 53
Reduced crude Flashed crude 35 - 150 6 – 26
Regenerated DEA Fouled DEA 450 - 650 79 – 114
Gases (p = atm) Gases (p = atm) 5 - 35 1.0 – 6
Gases (p = 200 bar) Gases (p = 200 bar) 100 - 300 17 – 53

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

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

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

FileName: 378802750.xls
Page 105 of 140
WorkSheet: Typical "U"
 October 02, 2003
Art Montemayor Overall Heat Transfer Coefficient
Rev: 0
Vapors with some non condensables Water 500 - 700 88 – 123
Vacuum condensers Water 200 - 500 35 – 88

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

Air Cooled Exchangers

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

Immersed coils
Coil Fluid Pool Fluid
Natural circulation
Steam Dilute aqueous 500 – 1,000 88 – 176
Steam solutions
Light oils 200 - 300 35 – 53
Steam Heavy oils 70 - 150 12 – 26
Aqueous solutions Water 200 - 500 35 – 88
Light oils Water 100 - 150 18 – 26

Agitated
Steam Dilute aqueous 800 – 1,500 140 – 264
Steam solutions
Light oils 300 - 500 53 – 88
Steam Heavy oils 200 - 400 35 – 70
Aqueous solutions Water 400 - 700 70 - 123
Light oils Water 200 - 300 35 - 53

Jacketed vessels
Jacket Fluid Vessel Fluid
Steam Dilute aqueous 500 - 700 88 - 123
Steam solutions
Light organics 250 - 500 44 - 88
Water Dilute aqueous 200 - 500 35 - 88
Water solutions
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:
1.0 Btu/hr-ft2-oF = 5.678263 Watts/m2-oK

FileName: 378802750.xls
Page 106 of 140
WorkSheet: Typical "U"
Art Montemayor G KETTLES RECIRCULATION COOLER October 24, 1997
E-G-43

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

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

ID = Shell Internal diameter, in. = 23

ODT = Tube external diameter, in. = 0.75
PT = Tubes' Pitch, in. = 0.9375
C' = Clearance between tubes = 0.1875
B= Baffle spacing, in. = 15
N= Number of Shell-side baffles = 11
aS = Shell-side crossflow area, ft2 = 0.4792
W = Shell-side mass flowrate,lb/h = 325500
GS = Shell-side unit mass flowrate,lb/h-ft2 = 679,304
De = Equivalent shell diameter, ft = 0.0458333
NRe = Shell-side Reynolds Number = 643.3
f = Friction factor for pressure drop, ft /in =
2 2
0.00352
cP = Fluid's Heat Capacity, Btu/lb- F = o
0.52
m = Fluid's Viscosity, cP = 20
m' = Fluid's Viscosity, lb/ft-h 48.4
k = Fluid's therm. cond., Btu/ft-h-oF = 0.086
NPr = Fluid's Prandtl Number = 292.7
Fs = Viscosity ratio, (m/mw) =
0.14
1
s = Shell fluid's specific gravity = 0.9303721

DP = Shell-side pressure drop, psi = 16.8

Page 107 of 140 Electronic FileName: 378802750.xls

WorkSheet: Shell-Side Pressure drop
 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

Step 1. Input flows, conditions and properties data for shellside and Step 4. Start configuring the exchanger. Begin with the total calculated
tubeside. transfer coefficients to this point (i.e., not including shellside h):
Tube Side Shell Ustart = 235 Btu/h·ft2·oF
CW Fluid Name Warm Water On that basis, assumed Uo = 195 Btu/h·ft2·oF
418,000 Flow (M), lb/h 195,000 Then the required transfer A = 2,139 ft2
88 Temp. in, oF 130 Number of tubes required = 545
102 Temp. out, oF 100 Reset tubes/pass (Step 3), then no. of passes = 4
Av. Density 62.05 r, lb/ft 3
61.9 Total tube count = 584
Av. Viscosity 0.723 m, cP 0.590 Tubeside DP (incl. returns) = 8.1 psi OK?
Av. Heat Capacity 1 c p
, Btu/lb· o
F 1 Actual effective transfer area, A = 2,293 ft2
Heat Exchanged 5,850,015 Q, Btu/h 5,850,000 OK?
Av. Thermal Conductivity 0.360 k, Btu/h·ft· F o
0.368
Fouling Resistance 0.002 R, ft2·h·oF/Btu 0.0015 Step 5. Select tube arrangement Tube Pitch 0.9375 in.
Prandtl No. 4.86 c p
m /k 3.88 and estimate shell diameter Pattern Tri
Uncorrected MTD 18.9 o
F Shell ID from Tube Count Tables 27 in.
Corrected MTD 14.0 o
F Select Baffle Spacing 16 in.
Number of Baffles = 14
Flow Area across Bundle, as = 0.600 ft2
Step 2. Input tubing OD, BWG and Tube OD 0.7500 in. Equivalent Diameter, de (see table) = 0.55 in.
length (can be trial and error). BWG 16 Mass Velocity, Gs = 325,000 lb/h·ft2
Tube ID, d = 0.620 in. Shellside Reynolds No., NRe = 25,258
Tube Length, L = 20 ft. Shellside Friction Factor = 0.00178
Flow area per tube, at = 0.302 in. 2 Shellside DP = 2.7 psi OK?
Effective transfer area per tube = 3.927 ft2 Outside Transfer Factor, jh = 90.4
Outside Film Coefficient, ho = 1,140
Calculated Uo = 195.1
Step 3. Estimate the number of Tubes/pass = 146 Check: % difference, U calc.
vs U assum.
= 0.0% OK?
tubes per tube pass. lb/h per tube = 2,863 Uclean = 614.9
Av. velocity, fps = 6.11 OK?
Tubeside Reynolds No., NRe = 40,324
Tubeside Friction Factor, f = 0.010 Step 6. Check tubeside velocity and DP, shellside DP. If too high or too low,
DP per pass, psi = 1.01 OK? adjust tube length, number of tubes per pass, number of passes, and/or shell
Inside Transfer Factor, jh = 113.7 baffle spacing. Remember to reset shell diameter from tube count tables, as
Inside Film Coefficient, hi = 1,335 required.
 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 oF
8 Cooling Water inlet temperature 85 oF
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
Vapor
23 inlet
24 Cooling water
25 out
26
27
28
29
30
31
32
Cooling water in
33 Condensate
34 outlet
35
36
244
Temperature,o F

37
38
39
40
41
85
42
43 Distance along tubes
44

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

57
58 Since the shell side Propanol vapor is essentially isothermal, the exchanger is in true counterflow.
59
60 Tc = The caloric temperature of the hot fluid
61 tc = The caloric temperature of the cold fluid
62 ta = The average temperature of the cold fluid
63 The influence of the tube-wall temperature is included in the condensing film coefficient.
64
65 The mean ta = 102.5 oF can be used as the caloric temperaure of the cold fluid
66
67 Execute a trial calculation:
68 a) Assume that UD = 100 Btu/hr-oF-ft2
69 Condensing film coefficients will generally range from 150 to 300. Assuming a film coefficient of 1,000
70 for water, UC will range from 130 to 230 Btu/hr-oF-ft2.
71
72 Heat transfer area = A = Q/UD DT = 1,215 ft2
73 Quantity of 3/4" OD tubes = 773
74
75 b) Assume that 4 tube passes are used. The quantity of water is large, but the condenser will have a
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 count of 766 tubes in a 31 inch ID shell.
79 c) The corrected UD coefficient, using the 31" shell, is now calculated:
80 Corrected area, A = 1,203 ft2
81 Corrected UD = Q/A DT = 101 Btu/hr-oF-ft2
82
83
84
85
86
87
88

A B C D E F G H I J K L
 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-Propanol
91
92 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
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 The shell-side or bundle crossflow area = a S =(ID) (C') (B)/(PT * 144) = 1.33 ft2 (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 PT = Tube pitch, inches
102
103 The shell-side mass velocity = G s = W / aS = 44,953 lb/hr-ft2
104
105 The condensate loading on the horizontal tubes = G'' = W/L*Nt2/3 = 89.6 lb/hr-linear ft
106 where,
107 L = Tube length, feet
108 Nt = Tube quantity effective for condensation
109
110 Assume the value of the average condensing film coefficient = h O = 200 Btu/hr-ft2-oF
111
112 hiO = hi (ID/OD) = 1,075 Btu/hr-ft2-oF (Refer to line # 165)
113 where,
114 hiO = The inside film (water) heat transfer coefficient refered to the tube OD, Btu/hr-ft 2-oF
115 hi = The inside (water) film heat transfer coefficient = 1,300 Btu/hr-ft2-oF (From fig. 25 )
116
117 Tube wall temperature = tW = ta + [hO/(hiO + hO)] (Tv - ta) = 125 F
o
(Eq. 5.31; p. 98)
118 where,
119 Tv = Average temperature of hot fluid (vapor), oF
120
121 Shell side film temperature = tf = (Tv + tw)/2 = 184 F
o

122
123 Shell side film thermal conductivity = k f = 0.095 Btu/hr-ft2-oF/ft (From Table 4)
124
125 Specific Gravity of shell side film = sf = 0.80 (From Table 6)
126
127 Viscosity of shell side film = mf = 0.62 cP (From Fig. 14)
128
129
130
131
132
133

A B C D E F G H I J K L
 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 h' ( mf2 / kf3 rf2 g)1/3 = 1.5 (4 G''/mf)-1/3 (Equation 12.42; p. 266)
136 where,
137 h' = Average condensing film coefficient, Btu/hr-ft 2-oF
138 mf = film coefficient absolute viscosity = 1.5004 lb/ft-hr
139 kf = film coefficient thermal conductivity, Btu/hr-ft - F/ft
2 o

140 rf = film coefficient density, lb/ft 3 = 49.92

141 g = Acceleration of gravity, ft/hr2 = 4.18E+08
142 G'' = Condensate loading for horizontal tubes, lb/hr-ft
143
144 Average shell side condensing film coefficient = 178 Btu/hr-ft2-oF
145
146 Calculations for tube side cold fluid, Water
147
148 Flow area of a 3/4" OD x 16 BWG tube = 0.3020 in2 (From condenser tube table)
149
150 Flow area per tube = NT a't / 144 n = 0.402 ft2
151 where,
152 NT = Number of tubes effective for condensation
153 a't = Flow area per tube, in2
154 n = Number of tube passes
155
156 Water mass velocity in the tube side = G t = w / at = 1,216,508 lb/hr-ft2
157
158 Average water velocity in the tube side = V = Gt / (3,600*r) = 5.41 ft/sec
159
160 At the average water temperature, t a, of 102.5 o
F:
161
162 Water viscosity = m = 0.72 cP = 1.74 lb/ft-hr
163 Tubes' ID = 0.0517 ft
164
165 Reynolds Number (for pressure drop only) = D Gt/m = 36,073
166
167 Tube side water heat transfer film coefficient = h i = 1,300 Btu/hr-ft2-oF (From Fig. 25)
168
169 hiO = hi (ID/OD) = 1,075 Btu/hr-ft2-oF
170 where,
171 hiO = The inside film (water) heat transfer coefficient refered to the tube OD, Btu/hr-ft 2-oF
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
 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 drop
181
182 The propanol vapor temperature = 244 o
F
183 Propanol vapor viscosity = 0.010 cP = 0.0242 lb/ft-hr (From fig. 15)
184
185 Shell-side equivalent diameter (De):
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 De = (4 * free area)/(wetted area) = [(4) (0.5 *PT * 0.86 * PT - 0.5 * p * d2 /40] / (0.5 * p *d)
194 = 0.55 inches = 0.0458 ft (From fig. 28)
195
196 Shell-side Reynolds Number = De Gs /m = 85,139
197
198 Shell-side friction factor for 25% cut segmental baffles = f = 0.00141 ft2/in2 (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 = MW / (V1) (T2/T1) (P1/P2) = 0.236 lb/ft3
205
206 Propanol vapor specific gravity = s = 0.00378
207
208 Shell Inside Diameter = Ds = 2.58 ft
209
210 Shell-side pressure drop = (1/2) [ f *Gs2 Ds (N+1) /(5.22 * 1010 *De * s)] = 1.2 psi (Eq. 12.47; p.273)
211
212
213 Calculations for tube side pressure drop
214
215 For the tube side Reynolds Number = 36,073 the corresponding tube-side friction factor
216
217 f = 0.00019 ft2/in2 (From fig. 26)
218
219 Tube-side pressure drop = Straight tube pressure drop + Return Loss pressure drop
220
221 Straight tube pressure drop = DPt = f * Gt2 * Ln/(5.22*1010 *De * s *Ft) = 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
 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 Return Loss pressure drop = DPr = (4*n/s) (V2/2 g') = 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 Ft = The viscosity ratio (m/mw)0.14 in the tubes
232 g' = Acceleration of gravity, 32.2 ft/sec2
233
234
235 Calculation of clean overall coefficient UC:
236
237 UC = (hio * ho )/(hio + ho) = 152.4 Btu/hr-ft2-oF
238
239
240 Calculation of dirt factor Rd:
241
242 Corrected UD = 101 Btu/hr-oF-ft2 (From line 81)
243
244 Rd = (UC - UD)/(UC * UD) = 0.0033 hr-ft2-oF/Btu
245 (Note: In condensation calculations the omission of the tube metal resistance may introduce a significant error and
246 should be checked.)
247 Shell Summary of Tube
248 side Results side
249 178 h (outside) 1,075
250 UC = 152.4
251 UD = 101
252 Rd calculated = 0.0033
253 Rd required = 0.003
254 1.2 Calculated DP 7.29
255 2.00 Allowable DP 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 condensing film coefficients are both affected by W and N t, and the best basis fof comparison is otained when the
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
 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
Cooling water
274 Cooling water in out
275
276
277 Vapor
278
inlet
279
280
281
282
283
284
285
286
287
288
Condensate
289 outlet
290
291
292
293 Total heat transferred = 17,100,000 Btu/hr
294
295 Log Mean Temperature Difference = LMTD = 141 o
F
296
297 Caloric temperature of the Propanol vapor = T C
298 Caloric temperature of the water = tC = 102.5 o
F
299
300 Trial Calculation:
301
302 a) Assume that the overall dirty heat transfer coefficient, U D = Btu/hr-ft2-oF
70
303 The equation for the condensing film coefficient gives greater values for horizontal tubes than for vertical tubes.
304 It will, consequently, be necessary to reduce the value of U D.
305
306 Heat transfer area = A = Q/UD * DT = 1,735 ft2
307
308 The nearest common, available tube length (using the same 766 tubes) is:
309
### Tube length = 11.5 feet ( use 12 foot length tubes )
311
312
313
A B C D E F G H I J K L
 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) The corrected UD coefficient, using the 31" shell, is now calculated:
319 Corrected area, A = Q/UD*Dt = 1,804 ft2
320 Corrected UD = Q/A DT = 67 Btu/hr-oF-ft2
321
322
323 Calculations for shell side hot fluid, n-Propanol
324
325 Tubes' outside diameter, Do = 0.0625 ft
326
327 Condensate loading for vertical tubes = W/N t * p * Do = 399 lb/hr-lin. ft (Eq. 12.36; p. 265)
328
329 Assume the value of the average condensing film coefficient = h O = 100 Btu/hr-ft2-oF
330
331 hiO = hi (ID/OD) = 1,075 (Refer to line # 165)
Btu/hr-ft2-oF
332 where,
333 hiO = The inside film (water) heat transfer coefficient refered to the tube OD, Btu/hr-ft 2-oF
334 hi = The inside (water) film heat transfer coefficient = 1,300 Btu/hr-ft2-oF (From fig. 25 )
335
336 Tube wall temperature = tW = ta + [hO/(hiO + hO)] (Tv - ta) = 114.5 F
o
(Eq. 5.31; p. 98)
337 where,
338 Tv = Average temperature of hot fluid (vapor), oF
339
340 Shell side film temperature = tf = (Tv + tw)/2 = 179 F
o

341
342 Shell side film thermal conductivity = k f = 0.095 Btu/hr-ft2-oF/ft (From Table 4)
343
344 Specific Gravity of shell side film = sf = 0.80 (From Table 6)
345
346 Viscosity of shell side film = mf = 0.65 cP (From Fig. 14; also, 4*G'/m = 1,025)
347
348 h' ( mf2 / kf3 rf2 g)1/3 = 1.47 (4 G'/mf)-1/3 (Equation 12.39; p. 266)
349 where,
350 h' = Average condensing film coefficient, Btu/hr-ft 2-oF
351 mf = film coefficient absolute viscosity = 1.573 lb/ft-hr
352 kf = film coefficient thermal conductivity, Btu/hr-ft - F/ft
2 o

353 rf = film coefficient density, lb/ft 3 = 49.92

354 g = Acceleration of gravity, ft/hr2 = 4.18E+08
355 G' = Condensate loading for vertical tubes, lb/hr-ft
356
357 Average shell side condensing film coefficient = 104 Btu/hr-ft2-oF
358
A B C D E F G H I J K L
 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, Water
361
362 The tube-side water conditions and configuration is the same as the horizontal configuration.
363
364 hiO = hi (ID/OD) = 1,075 Btu/hr-ft2-oF
365 where,
366 hiO = The inside film (water) heat transfer coefficient refered to the tube OD, Btu/hr-ft 2-oF
367
368
369 Calculations for shell side pressure drop
370
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 Shell-side (bundle) crossflow area = a s = (ID * C' * B)/(PT * 144) = 1.24 ft2 (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 PT = Tube pitch, in.
381
382 The shell-side mass velocity = G s = W / aS = 48,387 lb/hr-ft2
383
384 The propanol vapor temperature = 244 o
F
385 Propanol vapor viscosity = 0.010 cP = 0.0242 lb/ft-hr (From fig. 15)
386
387 Equivalent diameter for pressure drop = D e = 0.0458 ft (From table in fig. 28)
388
389 Shell-side Reynolds Number = ReS = De * GS / m = 91,642
390
391 Shell-side friction factor for 25% cut segmental baffles = f = 0.00140 ft2/in2 (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 Shell Inside Diameter = Ds = 2.58 ft
398
399 Shell-side pressure drop = (1/2) [ f *Gs2 Ds (N+1) /(5.22 * 1010 *De * s)] = 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
 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 drop
406
407 The basic data is the same as in the horizontal model example, except for the tube length.
408
409 Straight tube pressure drop = DPt = f * Gt2 * Ln/(5.22*1010 *De * s *Ft) = 5.0 psf = 0.03 psi
410 (Eq. 7.45; p. 148)
411
412 Return Loss pressure drop = DPr = (4*n/s) (V2/2 g') = 7.3 psi (Eq. 7.46; p.148)
413
414 Total tube-side pressure drop = 7.30 psi
415
416
417 Calculation of clean overall coefficient UC:
418
419 UC = (hio * ho )/(hio + ho) = 95.0 Btu/hr-ft2-oF
420
421
422 Calculation of dirt factor Rd:
423
424 Corrected UD = 67 Btu/hr-oF-ft2 (From line 81)
425
426 Rd = (UC - UD)/(UC * UD) = 0.0043 hr-ft2-oF/Btu
427
428 Shell Summary of Tube
429 side Results side
430 104 h (outside) 1,075
431 UC = 95.0
432 UD = 67
433 Rd calculated = 0.0043
434 Rd required = 0.003
435 2.3 Calculated DP 7.30
436 2.00 Allowable DP 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 from the UC of 148.5 in the horizontal condenser as compared with the 93.2 in the vertical unit in identical service.
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
 Some of this data was taken from Standards of the Tubular Exchanger Manufacturers Association (TEMA); 7th Ed

1/2" O. D. Condenser tube 3/4" O

Wall Tube weight
Surface area per
BWG thickness Tube I. D. Tube flow per linear Constant Tube I. D.
linear foot, ft 2
inches inches area in2 foot, lb of C ** inches
Outside Inside steel*
7
8 0.165
9 0.148
10 0.134 0.482
11 0.120 0.510
12 0.109 0.282 0.0625 0.1309 0.0738 0.456 0.532
13 0.095 0.560
14 0.083 0.334 0.0876 0.1309 0.0874 0.370 0.584
15 0.072 0.606
16 0.065 0.370 0.1075 0.1309 0.0969 0.302 168 0.620
17 0.058 0.634
18 0.049 0.402 0.1269 0.1309 0.1052 0.236 198 0.652
20 0.035 0.430 0.1452 0.1309 0.1126 0.174 227 0.680
22 0.028 0.444 0.1548 0.1309 0.1162 0.141 241

NOTES:
* The weight of the condenser tubes is based on low carbon steel with a density of 0.2836 lbs/in 3

Material Factor
Aluminum 0.35
Titanium 0.58
A.I.S.I. 300 Series Stainless Steels 0.99
A.I.S.I. 400 Series Stainless Steels 1.02
Aluminum Bronze 1.04
Aluminum Brass 1.06
Nickel-Chrome-Iron 1.07
Admiralty 1.09
Nickel 1.13
Nickel-Copper 1.12
Copper and Cupro-Nickels 1.14

** Liquid Velocity within the tubes = (Lbs Per Tube Hour) / (C * Liquid Specific Gravity) in feet per sec. (Specific
rs Association (TEMA); 7th Edition (1988); page 178. Note: some of the tabular TEMA data contained ERRATA, but this was corrected with

3/4" O. D. Condenser tube 1" O. D. Condenser tube

Surface area per linear Tube weight Surface area per
Tube flow foot, ft 2 Constant Tube I. D. Tube flow linear foot, ft2
per linear foot,
area in2 C ** inches area in2
Outside Inside lb of steel Outside Inside

0.670 0.3526 0.2618 0.1754

0.704 0.3893 0.2618 0.1843
0.1825 0.1963 0.1262 0.883 285 0.732 0.4208 0.2618 0.1916
0.2043 0.1963 0.1335 0.808 319 0.760 0.4536 0.2618 0.1990
0.2223 0.1963 0.1393 0.747 347 0.782 0.4803 0.2618 0.2047
0.2463 0.1963 0.1466 0.665 384 0.810 0.5153 0.2618 0.2121
0.2679 0.1963 0.1529 0.592 418 0.834 0.5463 0.2618 0.2183
0.2884 0.1963 0.1587 0.522 450 0.856 0.5755 0.2618 0.2241
0.3019 0.1963 0.1623 0.476 471 0.870 0.5945 0.2618 0.2278
0.3157 0.1963 0.1660 0.429 492 0.884 0.6138 0.2618 0.2314
0.3339 0.1963 0.1707 0.367 521 0.902 0.6390 0.2618 0.2361
0.3632 0.1963 0.1780 0.268 567 0.930 0.6793 0.2618 0.2435

0.2836 lbs/in 3. For other metal materials multiply by the following factors:

ty) in feet per sec. (Specific gravity of Water @ 60 F = 1.00)

o
A, but this was corrected with this spreadsheet's formulas.

ondenser tube 1-1/4" O. D. Condenser tube 1-1/2

Tube weight Surface area per Tube weight
per linear Constant Tube I. D. Tube flow linear foot, ft 2 per linear Constant Tube I. D.
foot, lb of C ** inches area in2 foot, lb of C ** inches
steel Outside Inside steel
0.890 0.6221 0.3272 0.2330 2.059 970
1.473 550 0.920 0.6648 0.3272 0.2409 1.914 1,037 1.170
1.348 0.954 0.7148 0.3272 0.2498 1.744 1.200
1.241 656 0.982 0.7574 0.3272 0.2571 1.599 1,182 1.230
1.129 708 1.010 0.8012 0.3272 0.2644 1.450 1,250 1.260
1.038 749 1.030 0.8332 0.3272 0.2697 1.341 1,305 1.280
0.919 804 1.060 0.8825 0.3272 0.2775 1.173 1,377 1.310
0.814 852 1.080 0.9161 0.3272 0.2827 1.059 1,440 1.330
0.714 898 1.110 0.9677 0.3272 0.2906 0.883 1.360
0.650 927 1.120 0.9852 0.3272 0.2932 0.824 1,537 1.370
0.584 1.130 1.0029 0.3272 0.2958 0.763 1.380
0.498 997 1.150 1.0387 0.3272 0.3011 0.641 1,626 1.400
0.361 1,060 1.180 1.0936 0.3272 0.3089 0.455 1,706
 1-1/2" O. D. Condenser tube 2" O. D. Condenser tube
Surface area per Tube weight Surface area per
Tube flow linear foot, ft 2 Constant Tube I. D. Tube flow linear foot, ft3
per linear foot,
area in2 C ** inches area in3
Outside Inside lb of steel Outside Inside

1.0751 0.3927 0.3063 2.355

1.1310 0.3927 0.3142 2.165
1.1882 0.3927 0.3220 1.970 1,860
1.2469 0.3927 0.3299 1.771 1.760 2.4328 0.5236 0.4608
1.2868 0.3927 0.3351 1.635 2,014 1.782 2.4941 0.5236 0.4665
1.3478 0.3927 0.3430 1.427 1.810 2.5730 0.5236 0.4739
1.3893 0.3927 0.3482 1.286 2,180 1.834 2.6417 0.5236 0.4801
1.4527 0.3927 0.3560 1.070
1.4741 0.3927 0.3587 0.997 2,300
1.4957 0.3927 0.3613 0.924
1.5394 0.3927 0.3665 0.775
ndenser tube
Tube
weight per Constant
linear foot, C **
lb of steel

2.412 3,795
2.204 3,891
1.935 4,014
1.701 4,121
 Heat Exchanger Tubesheets October 09, 1991
Art Montemayor
Tubesheet Thickness Rev: 0
From: Chemical Engineering Magazine; Plant Notebook; May 12, 1975

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:

FG P
√
F = 1.25
G = 12 inches
T= P = 350 psig

2 S S
T
=
=
17,500
1.06
psi
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, inches

F = 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, inches
P = design pressure, psig
S = 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.

Temperature, oF
Material
100 200 300 400 500
SA-516 Grade 70 17,500 17,500 17,500 17,500 17,500
Stainless Steel -- 17,700 16,100 15,900 --
1.25Cr - 0.5Mo - Si Steel 15,000 15,000 15,000 15,000 15,000
Monel 17,500 16,500 15,500 14,800 14,700
SB-171 Naval Brass -- 12,500 10,500 2,000 --
SB-402 Copper Nickel 12,500 10,500 10,400 10,400 10,400
SB-11 Copper 6,600 5,700 5,000 -- --

FileName: 378802750.xls
Page 124 of 140
WorkSheet: TubeSheet
 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 squar
Shell I. D.
Inches 1 2 4 6 8 1 2 4 6 8 1 2 4
TubePass TubePass TubePass TubePass TubePass TubePass TubePass TubePass TubePass TubePass TubePass TubePass TubePass
8 32 26 20 20 21 16 14
10 52 52 40 36 32 32 26 24 16 12 10
12 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 30
15-1/4 137 124 116 108 108 81 76 68 68 64 44 40 37
17-1/4 177 166 158 150 142 112 112 96 90 82 56 53 51
19-1/4 224 220 204 192 188 138 132 128 122 116 78 73 71
21-1/4 277 270 246 240 234 177 166 158 152 148 96 90 86
23-1/4 341 324 308 302 292 213 208 192 184 184 127 112 106
25 413 394 370 356 346 260 252 238 226 222 140 135 127
27 481 460 432 420 408 300 288 278 268 260 166 160 151
29 553 526 480 468 456 341 326 300 294 286 193 188 178
31 657 640 600 580 560 406 398 380 368 358 226 220 209
33 749 718 688 676 648 465 460 432 420 414 258 252 244
35 845 824 780 766 748 522 518 488 484 472 293 287 275
37 934 914 886 866 838 596 574 562 544 532 334 322 311
39 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 dat
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

N = C * (L/P)2
where,
C = 0.75 (a constant for Square pitch)
P = the tube spacing, in inches
 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 inches

Outer Tube Limit = 13.5 inches

Number of Tubes = 61
/16 inch square pitch 1-1/2" O. D. tubes on 1-7/8 inch square pitch
6 8 1 2 4 6 8
TubePass TubePass TubePass TubePass TubePass TubePass TubePass

16 16 16 16 12 12
22 22 22 22 16 16
35 31 29 29 25 24 22
48 44 39 39 34 32 29
64 56 50 48 45 43 39
82 78 62 60 57 54 50
102 96 78 74 70 66 62
123 115 94 90 86 84 78
146 140 112 108 102 98 94
174 166 131 127 120 116 112
202 193 151 146 141 138 131
238 226 176 170 164 160 151
268 258 202 196 188 182 176
304 293 224 220 217 210 202
342 336 252 246 267 230 224

OTL) this data applies.

 SHELL AND TUBE HEAT EXCHANGER TUBESHEET LAYOUTS (TUBE
Source: "Process Heat Transfer"; Donald Q. Kern, McGraw-Hill Book Co. (19

3/4" O. D. tubes on 15/16-inch triangular pitch 3/4" O. D. tubes on 1-inch triangular pitch
Shell I. D.
Inches 1 2 4 6 8 1 2 4
TubePass TubePass TubePass TubePass TubePass TubePass TubePass TubePass
8 36 32 26 24 18 37 30 24
10 62 56 47 42 36 61 52 40
12 109 98 86 82 78 92 82 76
13-1/4 127 114 96 90 86 109 106 86
15-1/4 170 160 140 136 128 151 138 122
17-1/4 239 224 194 188 178 203 196 178
19-1/4 301 282 252 244 234 262 250 226
21-1/4 361 342 314 306 290 316 302 278
23-1/4 442 420 386 378 364 384 376 352
25 532 506 468 446 434 470 452 422
27 637 602 550 536 524 559 534 488
29 721 692 640 620 594 630 604 556
31 847 822 766 722 720 745 728 678
33 974 938 878 852 826 856 830 774
35 1102 1068 1004 988 958 970 938 882
37 1240 1200 1144 1104 1072 1074 1044 1012
39 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
Kern does not reveal where he obtained this information and he is not specific in giving details to what TEMA type,
As an example of a discrepancy, refer to the 8" shell with 3/4" tubes on 15/16" triangular pitch and 2-passes. An a
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 configurat

Another estimating method for tube counts is found in "Petroleum Refinery Engineering"; Nelson; McGraw-Hill; Pa

The number of heat exchanger tubes can be estimated from the equation

N = C * (L/P)2
where,
C = 0.86 (a constant for Triangular pitch)
P = the tube spacing, in inches
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 inches

Outer Tube Limit = 13.5 inches

Number of Tubes = 70
TUBESHEET LAYOUTS (TUBE COUNTS)
Kern, McGraw-Hill Book Co. (1950); page 842

es 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 trian
6 8 1 2 4 6 8 1 2
TubePass TubePass TubePass TubePass TubePass TubePass TubePass TubePass TubePass
24 21 16 16 14
36 32 32 26 24 20 18
74 70 55 52 48 46 4 32 30
82 74 68 66 58 54 50 38 36
118 110 91 86 80 74 72 54 51
172 166 131 118 106 104 94 69 66
216 210 163 152 140 136 128 95 91
272 260 199 188 170 164 160 117 112
342 328 241 232 212 212 202 140 136
394 382 294 282 256 252 242 170 164
474 464 349 334 302 296 286 202 196
538 508 397 376 338 334 316 235 228
666 640 472 454 430 424 400 275 270
760 732 538 522 486 470 454 315 305
864 848 608 592 562 546 532 357 348
986 870 674 664 632 614 598 407 390
1100 1078 766 736 700 688 672 449 436

n actual scaled layout should be done.

iving details to what TEMA type, orientation, and Outer Tube Limits (OTL) this data applies.
ngular pitch and 2-passes. An actual layout yields 48 tubes with 3/16" OTL, as compared with the listed 32 tubes.

f an exchanger. This configuration is impossible to clean mechanically.

ering"; Nelson; McGraw-Hill; Page 544:

exchangers.
tion.
O. D. tubes on 1-9/16 inch triangular pitch 1-1/2" O. D. tubes on 1-7/8 inch triangular pitch
4 6 8 1 2 4 6 8
TubePass TubePass TubePass TubePass TubePass TubePass TubePass TubePass

14
26 22 20 18 14 14 12 12
32 28 26 27 22 18 16 14
45 42 38 36 34 32 30 27
62 58 54 48 44 42 38 36
86 78 69 61 58 55 51 48
105 101 95 76 72 70 66 61
130 123 117 95 91 86 80 76
155 150 140 115 110 105 98 95
185 179 170 136 131 125 118 115
217 212 202 160 154 147 141 136
255 245 235 184 177 172 165 160
297 288 275 215 206 200 190 184
335 327 315 246 238 230 220 215
380 374 357 275 268 260 252 246
425 419 407 307 299 290 284 275
Art Montemayor November 03, 1997

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 D otl, the tube
pitch, p, and the layout. The shell diameter D i 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 D otl will be
greater than that shown for a fixed tube sheet design and smaller for a pull-through floating head. In any case,
the tube count can be reasonably interpolated from the Table using the known or specified D otl, asuming that
the tube count is proportional to (Dotl)2. All tube count tables are only approximate since the actual number of
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,
the actual number of tubes in the bundle is F cNt. Fc is the fraction of total tubes in crossflow.

Outer Tube Number of Tube Passes

Shell ID Limit Tube OD Tube Tube
in. Diameter, in Pitch, in. Layout 1 2 4 6
in.
0.75 0.9375 Triang. 38 32 26 24
0.75 1.0000 Square 32 26 20 20
8.071 0.75 1.0000 Triang. 37 30 24 24
6.82
(Sch. 30)
1.00 1.2500 Square 21 16 16 14
1.00 1.2500 Triang. 22 18 16 14
0.75 0.9375 Triang. 62 56 47 42
0.75 1.0000 Square 52 52 40 36
10.02 0.75 1.0000 Triang. 61 52 48 48
8.77
(Sch. 40)
1.00 1.2500 Square 32 32 26 24
1.00 1.2500 Triang. 37 32 28 28
0.75 0.9375 Triang. 109 98 86 82
0.75 1.0000 Square 80 72 68 68
12.00 10.75 0.75 1.0000 Triang. 90 84 72 70
1.00 1.2500 Square 48 44 40 38
1.00 1.2500 Triang. 57 52 44 42
0.75 0.9375 Triang. 127 114 96 90
0.75 1.0000 Square 95 90 81 77
13.25 12.00 0.75 1.0000 Triang. 110 101 90 88
1.00 1.2500 Square 60 56 51 46
1.00 1.2500 Triang. 67 63 56 54
0.75 0.9375 Triang. 170 160 140 136
0.75 1.0000 Square 138 132 116 112
15.25 14.00 0.75 1.0000 Triang. 163 152 136 133
1.00 1.2500 Square 88 82 75 70
1.00 1.2500 Triang. 96 92 86 84
0.75 0.9375 Triang. 239 224 194 188
0.75 1.0000 Square 188 178 168 164
17.25 16.00 0.75 1.0000 Triang. 211 201 181 176
1.00 1.2500 Square 112 110 102 98
1.00 1.2500 Triang. 130 124 116 110
0.75 0.9375 Triang. 301 282 252 244
0.75 1.0000 Square 236 224 216 208
19.25 18.00 0.75 1.0000 Triang. 273 256 242 236
1.00 1.2500 Square 148 142 136 129

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Page 131 of 140
WorkSheet: Total Tubes
Art19.25
Montemayor
18.00 November 03, 1997

1.00 1.2500 Triang. 172 162 152 148

0.75 0.9375 Triang. 361 342 314 306
0.75 1.0000 Square 276 264 246 240
21.00 19.25 0.75 1.0000 Triang. 318 308 279 269
1.00 1.2500 Square 170 168 157 150
1.00 1.2500 Triang. 199 188 170 164
0.75 0.9375 Triang.
0.75 1.0000 Square
23.25 21.50 0.75 1.0000 Triang.
1.00 1.2500 Square
1.00 1.2500 Triang.
0.75 0.9375 Triang.
0.75 1.0000 Square
25.00 23.25 0.75 1.0000 Triang.
1.00 1.2500 Square
1.00 1.2500 Triang.
0.75 0.9375 Triang.
0.75 1.0000 Square
27.00 25.25 0.75 1.0000 Triang.
1.00 1.2500 Square
1.00 1.2500 Triang.
0.75 0.9375 Triang.
0.75 1.0000 Square
29.00 27.25 0.75 1.0000 Triang.
1.00 1.2500 Square
1.00 1.2500 Triang.
0.75 0.9375 Triang.
0.75 1.0000 Square
31.00 29.25 0.75 1.0000 Triang.
1.00 1.2500 Square
1.00 1.2500 Triang.
0.75 0.9375 Triang.
0.75 1.0000 Square
33.00 31.25 0.75 1.0000 Triang.
1.00 1.2500 Square
1.00 1.2500 Triang.
0.75 0.9375 Triang.
0.75 1.0000 Square
35.00 33.25 0.75 1.0000 Triang.
1.00 1.2500 Square
1.00 1.2500 Triang.
0.75 0.9375 Triang.
0.75 1.0000 Square
37.00 35.25 0.75 1.0000 Triang.
1.00 1.2500 Square
1.00 1.2500 Triang.
0.75 0.9375 Triang.
0.75 1.0000 Square
39.00 37.25 0.75 1.0000 Triang.
1.00 1.2500 Square
1.00 1.2500 Triang.
0.75 0.9375 Triang.
0.75 1.0000 Square
42.00 40.25 0.75 1.0000 Triang.
1.00 1.2500 Square

FileName: 378802750.xls
Page 132 of 140
WorkSheet: Total Tubes
Art42.00
Montemayor
40.25 November 03, 1997

1.00 1.2500 Triang.

0.75 0.9375 Triang.
0.75 1.0000 Square
44.00 42.25 0.75 1.0000 Triang.
1.00 1.2500 Square
1.00 1.2500 Triang.
0.75 0.9375 Triang.
0.75 1.0000 Square
48.00 46.00 0.75 1.0000 Triang.
1.00 1.2500 Square
1.00 1.2500 Triang.
0.75 0.9375 Triang.
0.75 1.0000 Square
52.00 50.00 0.75 1.0000 Triang.
1.00 1.2500 Square
1.00 1.2500 Triang.
0.75 0.9375 Triang.
0.75 1.0000 Square
56.00 54.00 0.75 1.0000 Triang.
1.00 1.2500 Square
1.00 1.2500 Triang.
0.75 0.9375 Triang.
0.75 1.0000 Square
60.00 58.00 0.75 1.0000 Triang.
1.00 1.2500 Square
1.00 1.2500 Triang.

FileName: 378802750.xls
Page 133 of 140
WorkSheet: Total Tubes
 Art Montemayor November 03, 1997

e of D otl will be
n any case,

ual number of
ss of the pass
mit. Additional
s tubes from
ern. Tubes
ndow design,

asses

8
18

36

60
68
36
40
86
70
74
44
50
128
108
110
64
72
178
142
166
82
94
234
188
210
116

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WorkSheet: Total Tubes
Art Montemayor November 03, 1997

128
290
234
260
148
160

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WorkSheet: Total Tubes
Art Montemayor November 03, 1997

FileName: 378802750.xls
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WorkSheet: Total Tubes
Art Montemayor November 03, 1997

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.

Tube OD, in. Tube Pitch, in. Layout Pp, in. Pn, in.

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:

Flow

30o Triangular 60o Rotated Triangular

Note: Flow arrows are perpendicular to the baffle cut edge

Flow

Rotated Square Square

 August 21, 2004
Art Montemayor Heat Exchanger Temperatures
Rev: 0
Source: Chemical Engineering Magazine; Plant Notebook Section; Unknown date
J. 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.

W, Cp, T2

w, cp, t1 q, U, A, DTm w, cp, t2

W, Cp, T1
Nomenclature:
q = Heat duty, Btu/hr or kcal/hr = 1,000,000
Cp = Constant or average specific heat on the shell side, Btu/lb or kcal/kg = 0.5000
cp = Constant or average specific heat on the tube side, Btu/lb or kcal/kg = 1.0000
W = Fluid mass flow rate in shell side, lb/hr or kg/hr = 100,000
w = Fluid mass flow rate in tube side, lb/hr or kg/hr = 45,000
U = Overall heat transfer coefficient, Btu/hr-ft 2-oF or kcal/hr-m2-oC = 125
or m =
A = Total exchanger heat transfer area, ft 2 2
300.0
T1 = Shell-side fluid temperature, oF or oC
= 250
t1 = Tube-side fluid temperature, oF or oC
= 85
DTm = Log mean temperature difference, oF or oC=
1
= Subscript denoting inlet conditions
2
= Subscript denoting outlet conditions

From the derived equations, let: Z = 50,000

B = 45,000

C=e
UA ( 1Z − B1 )
C = 0.9200444

Therefore,

T2 = B t1 (1 - C) - T1(B - Z)/(Z - BC) = 152 F or oC

o

FileName: 378802750.xls
Page 138 of 140
Worksheet: Ht Exchanger Temperatures
 August 21, 2004
Art Montemayor Heat Exchanger Temperatures
Rev: 0
Equations and their derivations:

The heat transferred to the tube-side fluid = q = (w) (c p) (t2 - t1)

The heat transferred to the shell-side fluid = q = (W) (C p) (T1 -T2)

optimum condtions
d-error also involves Let:
can result in B = (w) (cp) Z
be able to calculate
, specific heats,
Z = (W) (Cp) t 2= ( )
B
( T 1 −T 2 ) +t 1
follows and shown Combining both above equations,

[ ]
( T 1 −t 2 )−( T 2 −t 1 )
The heat transferred is also=UA ΔT m=UA
( T 1−t 2 )
ln
( T 2−t 1 )

[ ]
( T 1 −t 2 )−( T 2 −t 1 )
Z ( T 1 −T 2 ) =UA
( T 1−t2 )
ln
( T 2 −t1 )

[ ] [ ]
Z Z
ln
T 1− ()
B
( T 1 −T 2 )−t 1
=UA
T 1− ()
( T −T ) +t −( T 2 −t 1 )
B 1 2 1
T
( 2 1)
−t Z ( T 1 −T 2 )

[ ] [ ]
Z Z Z Z
ln
T 1 −T 1 () B
+T 2 ()
B
−t 1
=UA
T 1 −T 1
B
+T 2 () ()
+t −T +t
B 1 2 1
( T 2−t 1) Z ( T 1 −T 2 )

[ ] [ ]
Z Z
T 1 1−( B )
+ T2
B ( )
−t 1 1− ( ZB ) =UA
ln
( T 2− t 1 )
=UA
Z ( 1Z − B1 )

[ ] [ ]
Z Z Z Z
ln
( ) ()
T 1 1−
B
+T 2
B
−t 1
=UA
T 1−
B
( T 1 −T 2 )−T 2()
=UA
( T 1−T 2 )− ( T 1 −T
B ()
( T 2−t1 ) Z ( T 1 −T 2 ) Z ( T 1 −T 2 )

FileName: 378802750.xls
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Worksheet: Ht Exchanger Temperatures
 August 21, 2004
Art Montemayor Heat Exchanger Temperatures
Rev: 0

]
)−( T 2 −t 1 )
1 −t 2
T 1−t 2 )
T 2−t 1 )

T 2 ) +t 1 −( T 2 −t 1 )

T 1 −T 2 ) ]
]
Z
T2 () +t −T +t
B 1 2 1
T 1 −T 2 )

] = UA ( 1Z − B1 )
Z
A
()
( T 1−T 2 )− B ( T 1−T 2 )
Z ( T 1 −T 2 )

FileName: 378802750.xls
Page 140 of 140
Worksheet: Ht Exchanger Temperatures