Design of Heat Exchanger

Engr. Rey F. Fiedacan, MEP - ME

DEVELOPED IN EXCEL BY: REY FIEDACAN - MECHANICAL ENGINEER ,11.07.2010

ENGINEERING CALCULATION
THERMAL DESIGN OF HEAT EXCHANGER
APPLIED LIMITATION: SENSIBLE COOLING or SENSIBLE HEATING ONLY
Project Title : HEAT EXCHANGER FOR CHILLED WATER
Part : Horizontal Shell
Prepared by : Rey Fiedacan
Date : 11.07.2010
Doc. No. : HX - 01 -09
Revision No. : 1
Key in value in blue color only

TUBE SIDE: HOT SIDE SHELL SIDE: COLD SIDE

[Fluid medium] WATER [Fluid medium] WATER
[Mass flowrate] 150 Kg/s [Mass flowrate] 50 Kg/s
[Inlet temperature] 20 C [Inlet temperature] 32 C
[Density] 998.2 kg/m3 [Density] 996.4 kg/m3
[Specific heat] 4181.6 J/Kg-K [Specific heat] 4178.7 J/Kg-K
[Thermal conductivity] 0.6 W/m-K [Thermal conductivity] 0.61 W/m-K
[Dynamic Viscosity] 0 N.s/m2 , kg/m-s [Dynamic Viscosity] 0 N.s/m2 , kg/m-s

FLOW CONDITION
[Type of flow] Counter flow
[Design Fouling Factor] 0 m2- K/W
ESSENTIAL VARIABLES
[Tube materials] WATER
[Velocity of fluid inside Tubes] 2 m/s
[Tube Outside Diameter] 19 mm
[Tube Inside Diameter] 16 mm
[Thermal Conductivity of Tubes] 42.3 W/m-K
TUBE ORIENTATION & GEOMETRY
[Number of Passes] 3
[Tube Pitch] 0.03 mm
[Tube layout] Square Layout
[Tube Count Layout] 45 deg.
[Baffle Spacing - baffle cut at 25%]0.5 m

FINAL DECIDING VALUES BASED ON CORRELATED INPUTS ABOVE

Step #1: Evaluate the LMTD correction factor given the value of P and R ( Computed )
P = 0.19
R = 3
From this set of conditions, See Table on LMTD correction factor to determine the factor
F corresponding to type of flow ( Parallel or counterflow) and number of passes
Enter correction Factor, F 0.94
Step #2: Check the value of overall conductance, U against the recommend values
Computed value of U = 1,869.27 W/m2-K Based on the correlation of Reynolds
number, flow condition and thermal conductivity, Check this value against permissible range from table
of overall conductance U,
Enter value of U if the computed value is within the range 2263.20

Step #3: Check the % surface design of heat exchanger due to fouling effects
Computed value of = 61%
If the value is too high , Set value for desired surface design then enter 30%

Step #4: Evaluate computed length of tube of heat exchanger, Note that standard length is in
20 ft and it is recommended to use it out of the its length
Computed Length = 1.89 m
Enter, the effective length of tubes should not < computed length 4.00

Step #5: Evaluate the re-calculated shell diameter on the new length of HX, Inside diameter
should referred to available shell to be used ( can be pipe or rolled plate)
Computed Shell ID = 0.68 m

Enter new shell ID,must be available size 0.80

Step #6: Enter the absolute viscosity at wall temperature, Evaluate at reference temperature T
Reference Temp. = 24.83 oC
Enter absolute viscosity,kg/m - s at reference Temp. 0

FINISH
Check the result in the next sheet, Carefully evaluate and proceed next iteration
if needed. The areas for iteration will be size, tube layout, flow conditions, geometry
length of tubes ,baffle spacing and tube materials.
DEVELOPED IN EXCEL BY: REY FIEDACAN - MECHANICAL ENGINEER ,11.07.2010

1
 ENGINEERING CALCULATION Designed by Rey Fiedacan
THERMAL CALCULATION OF HEAT EXCHANGER Date 11.07.2010
TYPE: SHELL & TUBES Doc. No. HX - 01 -09
DEVELOPED USING EXCEL BY REY FIEDACAN,MECHANICAL ENGINEER, 11.07.2010 -fiedrey@yahoo.com Revision 1

Project Title : HEAT EXCHANGER FOR CHILLED WATER

Part : Horizontal Shell
Sketch :
HEAT EXCHANGER THERMAL CALCULATION BY REY FIEDACAN, MEP - ME

I.HEAT & MASS BALANCE

1.0 Temperature of outlet fluid - Cold fluid ( Predicted from energy and mass balance)

msCps(Ts1-Ts2)
Ts2 =
mtCpct = ### K
2.0 Log mean temperature difference across the heat exchanger (LMTD)

Δtmax - Δtmin where:

LMTD = Δtmax = 7.1 K LMTD= ### for parallel flow
ln Δtmin LMTD= ### for counterflow
P = 0.19
R = 3
F = 0.9400

3.0 LMTD Calculation ( Corrected )

where :
ΔTm = F(LMTD) = ### K for Counter flowheat transfer between shell & tubes

4.0 HEAT DUTY OF HEAT EXCHANGER

based on the temperature difference between hot fluids inlet
and outlet condition.

Q =(mscps)(Ts1 -Ts2) = ### KW

5.0 NUMBER OF TUBES- based on the mass flowrate of cold fluid inside the tubes and recommended
velocity on the specified number of passes.
Nt = 4mtNp/ρtvtπdi2 = ### tubes
374 per pass
II. TUBE SIDE CALCULATION:
1.0 TUBE SIDE HEAT TRANSFER
Nutkt where:
ht =
di Nut = Nusselt number of fluid inside the tubes
Kt = Thermal conductivity of fluid inside the tubes
di = Inside diameter of tubes

2.0 NUSSELT NUMBER ( CORRELATION FROM Petukhov - Kirililov for Turbulent flows )
which predicts results in the range of 104< Ret < 5 x106 and 0.5 < Prt < 200
(f/2)RetPrt
Nut =
1.07+12.7(f/2)1/2(Prt2/3 -1)
HEAT
ENGINEERING CALCULATION Designed by Rey Fiedacan
THERMAL CALCULATION OF HEAT EXCHANGER Date 11.07.2010
TYPE: SHELL & TUBES Doc. No. HX - 01 -09
DEVELOPED USING EXCEL BY REY FIEDACAN,MECHANICAL ENGINEER, 11.07.2010 -fiedrey@yahoo.com Revision 1

2.1 Prandtl number Prt = 6.8

2.2 Ret = ρtvtdi/µt

Reynold number at tube side = ### the flow is turbulent

Friction factor at given Re Ft = (1.58lnRet - 3.28) =

-2
2.3 0.01

(f/2)RetPrt
Nut = = 225.72
1.07+12.7(f/2)1/2(Prt2/3 -1)

Nutkt = ### W/m2-K

ht =
di ( This correlated heat transfer coefficient at tube s
condition of flow )

III.SHELL SIDE CALCULATION

1.0 SHELL SIDE HEAT TRANSFER BY KERN CORRELATION
which predicts results in the range of 2x103< Res = GsDe/µ< 1 x106

ht = 0.36ks Res Prs

0.55 1/3
where:
De Nus = Nusselt number of fluid outsidethe tubes
Ks = Thermal conductivity of fluid outside the tubes
de = Equivalent diameter of shell
Res = Reynold number flow outside the tubes
Prs = Prandtl number of flow outside the tunes

2.1 Reynolds Number Res = (ms/As)(De/µs) = ### the flow is turbulent

2.2 Equivalent Diameter De = f(Square,Triangular layout)

do
De of square pitch in tube layout Flow
PT
4(PT -πdo /4)
2 2
= ### m2
DeΠ =
De S s

De of triangular pitch in tube layoutFlow PT

do

4(PT2(3)1/2/4-πdo2/8) = ### m2
DeΔ =
πdo/2 0 s
Use: Square Pitch ; De =0.024234

2.3 Bundle Crossflow As = f(Clearance, Baffle spacing)

DsCB = ### m2
=
PT 0 s
2.4 Total flow area of tubes As = f(Clearance, Baffle spacing)
πdiNt = ### m2
=
4 0 s
2.5 Estimated Shell Diameter Ds = f(Clearance, Baffle spacing)
=
= 0.637(CL/CTP)(πdo PR N ) m
2 2 t 1/2
0.996
0 s
2.6 Tube Pitch Ratio PR = f(Clearance, Baffle spacing)
= PT/do = 1.337 m
2.7 Tube Layout Constant = f(Clearance, Baffle spacing)
for 90o and 45o CL = 1
for 30o and 60o CL = 0.87
one tube pass CTP = 0.93
ENGINEERING CALCULATION Designed by Rey Fiedacan
THERMAL CALCULATION OF HEAT EXCHANGER Date 11.07.2010
TYPE: SHELL & TUBES Doc. No. HX - 01 -09
DEVELOPED USING EXCEL BY REY FIEDACAN,MECHANICAL ENGINEER, 11.07.2010 -fiedrey@yahoo.com Revision 1
two tube pass CTP = 0.9
three tube pass CTP = 0.85
Use: CL = 1.0 CTP =0.930

ht = 0.36ks Res Prs

0.55 1/3
= ### W/m2-K
De ( This correlated heat transfer coefficient at shell side
condition of flow )

IV. OVERALL HEAT TRANSFER COEFFICIENT

1.0 Outer surface area - Clean heat transfer coefficient

-1
do
1 do 1 do ln(di )
Uc =
ho + di hi + 2 kt = ### W/m2-K

1.1 Surface area of heat exchanger for clean condition ( No fouling Effect )

Q Ac =
= 97.11 m2
UcΔTm
Use: Uc = 2263.2
2.0 Outer surface area - Fouled heat transfer coefficient

do -1
1 do 1 do ln(di )
Uf = + Rft
ho + di hi + 2 kt = ### W/m2-K

2.1 Surface area of heat exchanger for clean condition ( with fouling Effect )

Af = Q = 156.25 m2
UfΔTm
2.2 Check for % surface design
Af
Os = = 61%
Ac
Use: Os = ###

2.3 Surface design area of heat exchanger at###

certain
more allowance for fouling effect
A' = 126.24 m 2

2.4 Effective length of tube for area in heat transfer

A'
L = N πd = 1.89 m
t o

Use: L = ### m

2.5 New Shell Diameter Ds' = f(Clearance, Baffle spacing)

= 0.637(CL/CTP)1/2(A'PR2do/L)1/2
= 0.68 m corrected shell diameter at the given length
however, the actual diameter shall be the nearest
available size either seamless pipe or fabricated as rolled
plate
Use: Ds' = ### m

V. PRESSURE DROP- This is used to determined the pumping power required to handle the fluid in tubes and shell
1.0 TUBE SIDE PRESSURE DROP
ENGINEERING CALCULATION Designed by Rey Fiedacan
THERMAL CALCULATION OF HEAT EXCHANGER Date 11.07.2010
TYPE: SHELL & TUBES Doc. No. HX - 01 -09
DEVELOPED USING EXCEL BY REY FIEDACAN,MECHANICAL ENGINEER, 11.07.2010 -fiedrey@yahoo.com Revision 1
1.1 Tube side friction factor ft = (1.5ln(Ret) - 3.28) =
-2
###

1.2 Tube side friction factor ftLNp µc2

ΔPt = + 4Np ρc
di 2
= 58.68 Kpa , head required to pump the fluid into the tubes
= 8.5 psi

2.0 SHELL PRESSURE DROPThe shell-side fluid experiences a pressure drop as it passes through the exchange
over the tubes, and around the baffles.
f G2 (N +1)D's
ΔPs = s s b
2ρsDeΦs
2.1 Shell side friction factor fs = exp(0.576 -0.19ln(Res)) = 0.300

2.2 Bundle crossflow area As = DsCB = ### m2 , based on corrected shell Φ,

PT clearance of tubes and baffle spacing.

2.3 Wall temperature Tt1+Tt2 Ts1+Ts2 1

Tw = +
2 2 2
= ### K , average temperature between cold and hot fluid across
the tube length
therefore:
the absolute viscosity and wall temperature
24.8
of oC
= 0 kg/m - s

2.4 Correction Factor µs 0.14

Φs = = 0.989
µw

2.5 Number of Baffles L

Nb = -1 = 7
B

2.6 Number of Baffles Ms

Gs = = ### kg/m2-s
As

therefore: fsG2s(Nb+1)D's
ΔPs =
2ρsDeΦs

= 6.4 Kpa , head required to pump the fluid into the shell
= 0.9 psi
ENGINEERING CALCULATION Designed by Rey Fiedacan
THERMAL CALCULATION OF HEAT EXCHANGER Date 11.07.2010
TYPE: SHELL & TUBES Doc. No. HX - 01 -09
DEVELOPED USING EXCEL BY REY FIEDACAN,MECHANICAL ENGINEER, 11.07.2010 -fiedrey@yahoo.com Revision 1

Summary of THERMAL DESIGN OF HEAT EXCHANGER

TUBE SIDE : HOT SIDE
1 Inlet temperature 20 o
C
2 Mass flowrate 150 kg/s
3 Density 998.2 kg/m3
4 Thermal Conductivity 0.6 W/m - K
5 Dynamic viscocity 0 N.s/m2
6 Specific Heat 4181.6 J/kg - K
7 Prandtl number 6.8
8 Velocity of fluid inside the tubes 2 m/s
9 Total fouling factor 0 m2 - K/W
SHELL SIDE: COLD SIDE
1 Inlet temperature 32 o
C
2 Outlet temperature 25 o
C
3 Average temperature 28.5 o
C
4 Mass flowrate 50 kg/s
5 Density 996.4 kg/m3
6 Thermal Conductivity 0.61 W/m - K
7 Dynamic viscocity 0 N.s/m2
9 Specific Heat 4178.7 J/kg - K
10 Prandtl number 5.64
CONSTRUCTIONAL DATA OF THE PROPOSED SHELL AND TUBE HX
1 Shell diameter 0.800 m
2 Number of tubes 1121.07
4.000 m
3 Length of tubes(Allowancefor tubesheet not included)
4 Tube outside diameter 0.019 m
5 Tube inside diameter 0.016 m
6 Baffle spacing ( baffle cut at 25%) 0.500 m
7 Tube pitch 0.025
8 Number of passes 3.000
9 Thermal Conductivity of tubes 42.300 W/m - K
10 Tube side heat transfer coefficient 8526.66 W/m2 - K
11 Shell side heat transfer coefficient 2800.32 W/m2 - K
12 Clean overall heat transfer coefficient 1869.27 W/m2 - K
13 Fouled overall heat transfer coefficient 1406.54 W/m2 - K
14 Tube side pressure drop 58.68 Kpa
15 Shell side pressure drop 6.40 Kpa
ENGINEERING CALCULATION Designed by Rey Fiedacan
THERMAL CALCULATION OF HEAT EXCHANGER Date 11.07.2010
TYPE: SHELL & TUBES Doc. No. HX - 01 -09
DEVELOPED USING EXCEL BY REY FIEDACAN,MECHANICAL ENGINEER, 11.07.2010 -fiedrey@yahoo.com Revision 1
 OIL COOLER DESIGN

Shell Side Tube Side

Fluid Hot Water Fluid Cold
Mass Flow Rate Kg/h 180000 Mass Flow Rate Kg/h
Inlet Temp Th1 © 32 Inlet Temp Tc1 ©
Outlet Temp Th2 © 25 Outlet Temp Tc2 ©
Temp Diff 7 Temp Diff
Avg Temp © 28.5 Avg Temp ©
Specific Heat Kcal/Kg C 1 Specific Heat Kcal/Kg C
Density Kg/m3 996.4 Density Kg/m3
Viscosity Kg/m.s 0
Thermal Conductivity Kcal/m.h.C 0.53 Thermal Conductivity Kcal/m.h.C

Heat Duty 1257858 Kcal/h Tc1 Tc2

Assume 1 1 Pass Counter Current Th2 Th1
Del T1 © 5 Del T2 © 9.67
LMTD © 7.08
Let Correction Factor Ft 0.98
MTD 6.94
Assume 1462539.45
Uo 241 Kcal/h m C
So Ao 752.3 m2

Let for tube

ID 0.02 m
OD 0.03 m
t 0m
L 12 m
So no of tubes Nt 798.61 tubes

Inside Heat Transfrer Coefficient hi

Inside area of one tube 0 m2

Volumetric Flow in 1 tube 0 m3/s
Velocity in tube 2.81 m/s

Reynolds no Re 45606.15 L/di 750

jH 62 from graph
Prandtl no Pr 6.8
hi 3816.51 Kcal/h m2 C

Outside Heat Transfrer Coefficient ho

`
Triangular Pitch ln 0.03 m
Clearance c 0.01 m
Inside Dia of shell Ds 0.98 m
Baffle spacing B 0.84 m
Nb 14.37 12
Flow area as 0.2 m2
Mass Flow rate of oil Gs 907368.94 Kg/m2.h
Eq.Dia for triangular pitch Dh 0.02 m
Eq.Dia for square pitch Dh 0.06 m
Reynolds no Rs 6899.25
jH 52 from graph
Prandtl no Pr 5.64
ho 2154.8 Kcal/h m2 C

Overall Heat Transfrer Coefficient Uo

Uc 1377.22
Rdo 0 h m2 C/Kcal
Rdi 0 h m2 C/Kcal Rd 0
Uo 526.74 Kcal/h m2 C

Area Required 131.64 m2

Tube Side Pressure Drop

Flow area / pass at 0.16 m2

Mass flow rate of water 934.17 Kg/m2 .s
friction factor f 4.50E-03 from graph
Del Pt(tube side loss) 150.54 Kg/m2
0.01 atm
Del Pr(Return loss) 3211.49
0.31 atm
Del Pts 0.33 atm

Shell Side Pressure Drop

friction factor f 3.60E-02 from graph

Del Pss 65.73 Kg/m2
0.01 atm
WATER
540000
20
22.33
2.33
21.17
1
998.2
0
0.52