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- Herausgeber: John Wiley & Sons
- Kategorie: Fachliteratur
- Sprache: Englisch
A comprehensive guide to ensuring efficient, accurate, and cost-effective design of shell and tube heat exchangers across a variety of industries
Effective thermal design of shell and tube heat exchangers is essential for maintaining performance and reducing costs in industries such as oil, gas, petrochemicals, and energy. In a field where heat exchangers are a significant investment, understanding how to design them efficiently is vital.
Optimization for Thermal Design of Shell and Tube Heat Exchangers presents a clear, practical approach to achieving optimal results with minimal trials. Incorporating real-world examples and fast-track methodologies, this authoritative guide provides valuable tools to improve efficiency and manage data effectively while running design programs. Mehdi Hanifzadeh, a seasoned process principal engineer with more than 38 years of experience, offers proven strategies to reduce construction and maintenance costs while maintaining high design standards.
Providing step-by-step guidance to designing these essential components with accuracy and speed, this book:
- Designed in oil refineries, gas processing, petrochemicals and power plants.
- Helps readers reduce construction costs while complying with industry design standards
- Focuses on practical design methods and data management for cost-effective, high-quality outcomes.
- Provides clear and transparent design and calculation methods illustrated through numerous real-world examples and case studies
- Serves as a valuable educational and training resource for readers
This title is an invaluable resource for new designers and experienced professionals specializing in the design and optimization of heat exchangers, and an ideal textbook for advanced chemical and mechanical engineering students taking courses in process design, energy systems, and industrial equipment.
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Veröffentlichungsjahr: 2025
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Table of Contents
Cover
Table of Contents
Title Page
Copyright
Dedication
Preface
About This Book
The Audience / Reader
Global Computer Software for Thermal Design
Chapter 1: A Brief Overview
1.1 Short Summary for Each Chapter
1.2 Shell and Tube Heat Exchangers
1.3 Step-by-step Thermal Design Methodology
1.4 Why Shell and Tube?
1.5 Scope of Shell and Tube
1.6 Shell and Tube Heat Exchanger Components / Definition
1.7 Fouling
1.8 Thermodynamic Analysis of a Heat Exchanger
Chapter 2: Required Data for Starting Thermal Design
2.1 Process Data Sheet
2.2 Contract and Project Specifications
Chapter 3: Practical Input Data for Thermal Design (Using Software)
3.1 Calculation Modes
3.2 Process Data for Hot / Cold Side
3.3 Physical Properties for Hot / Cold Side
3.4 Fouling Resistance Group
3.5 Tubular Exchanger Manufacturers Association TYPE
3.6 TEMA Class
3.7 Shell Inside Diameter
3.8 Exchanger Orientation
3.9 Hot / Cold Fluid Placement
3.10 Examples of TEMA Type Selection
3.11 Heat Load and Effective Mean Temperature Difference
3.12 Number of Shells in Series and Parallel
3.13 Tube Type
3.14 Tube OD
3.15 Tube Pattern
3.16 Tube Length, Total, and Effective
3.17 Tube Pass
3.18 Material of Construction
3.19 Tube Sheet
3.20 Baffle Type
3.21 Baffle Cut Percent
3.22 Baffle Spacing
3.23 Flow Fraction in Shell-side
3.24 Clearances and Shell-side Leakages
3.25 Nozzle Data
3.26 Impingement Plate
3.27 Reboilers
3.28 Vibration of Tubes
3.29 Emerging New Technology
3.30 Basic Principles Path of Thermal Design in Computer Software
Chapter 4: Features of an Optimal Design for a Heat Exchanger
4.1 Introduction: Result Output Data (of Any Computer Program)
4.2 Overdesign Percent
4.3 Calculated Pressure Drop
4.4 Flow Velocity / Rho-V
2
Analysis
4.5 Shell-side Flow Distribution
4.6 Baffle Spacing Center to Center
4.7 Effective Mean Temperature Difference
4.8 Shell and Tube Heat Transfer Coefficients
4.9 Two-phase Flow Regimes
4.10 Vibration Analysis
4.11 Kettle-type Output Data
Chapter 5: Optimization Logic
5.1 The Factors That Influence the Capital Cost of an Exchanger
5.2 Step-by-step Optimization Method
Chapter 6: Practical Thermal Design for Real Example Cases
6.1 E-001: Water Cooler-1
6.2 E-002: Water Cooler-2
6.3 E-003: Gas Water Cooler-3
6.4 E-004: Lube Oil Water Cooler-4
6.5 E-005: No Phase Change-1
6.6 E-006: No Phase Change-2
6.7 E-007: Boiler Feed Water Heater – No Phase Change-3
6.8 E-008: Feed and Effluent Heat Exchanger-1
6.9 E-009: Feed and Effluent Heat Exchanger-2
6.10 E-010: Condenser-1
6.11 E-011: Condenser-2
6.12 E-012: Condenser-3
6.13 E-013: Reactor Effluent Condenser-4
6.14 E-014: Kettle Type-1 – C3 Refrigerator
6.15 E-015: Kettle Type-2 – Steam Boiler
6.16 E-016: Kettle Type-3 – Reboiler
6.17 E-017: Horizontal Thermosiphon Reboiler-1
6.18 E-018: Horizontal Thermosiphon Reboiler-2
6.19 E-019: Vertical Thermosiphon Reboiler-1
6.20 E-020: Vertical Thermosiphon Reboiler-2
Chapter 7: Brief Description of Activities After Thermal Design
7.1 Mechanical Design
7.2 Fabrication
7.3 Inspection and Testing
7.4 Installation
7.5 Operation of a Heat Exchanger
7.6 Maintenance and Repairment
Chapter 8: Comparison Between ASME Code and TEMA Standard
8.1 ASME Code
8.2 TEMA Standards
8.3 Main Difference Between TEMA and ASME
8.4 Conclusion
Chapter 9: Brief Description of TEMA Standard
9.1 Nomenclature
9.2 Fabrication Tolerances
9.3 General Fabrication and Performance Information
9.4 Installation, Operation, and Maintenance
9.5 Mechanical Standards TEMA Class RCB Heat Exchangers
9.6 Flow-induced Vibration
9.7 Thermal Relations
9.8 Physical Properties of Fluids
9.9 General Information
9.10 Recommended Good Practice-RGP
References
Index
End User License Agreement
List of Illustrations
Chapter 1
Figure 1.1 Flow stream in shell-side / tube-side.
Figure 1.2 A shell and tube heat exchanger.
Figure 1.3 Principal components of a shell and tube heat exchanger.
Figure 1.4 Double pipe exchanger.
Figure 1.5 Serial double pipe exchanger.
Figure 1.6 Multi tube or hairpin exchanger.
Figure 1.7 Multi tube or hairpin exchanger.
Figure 1.8 Horizontal condenser.
Figure 1.9 A bundle of heat exchanger tubes in (a) fouled and (b) clean states.
Figure 1.10 An example of scaling / crystallization fouling.
Figure 1.11 An example of chemical fouling.
Figure 1.12 An example of particulate fouling.
Figure 1.13 An example of corrosion fouling.
Figure 1.14 An example of biological fouling.
Chapter 2
Figure 2.1 Sample process data sheet.
Figure 2.2 Sample thermal data sheet.
Chapter 3
Figure 3.1 Picture of heat exchangers with BEM-TEMA type.
Figure 3.2 A complete map for TEMA type letters.
Figure 3.3 TEMA type-A.
Figure 3.4 TEMA type-B.
Figure 3.5 TEMA type-C.
Figure 3.6 TEMA type-N.
Figure 3.7 TEMA type-D.
Figure 3.8 Selection criteria for front-head TEMA type.
Figure 3.9 TEMA type-E.
Figure 3.10 TEMA type-F.
Figure 3.11 TEMA type-J21.
Figure 3.12 TEMA type-J12.
Figure 3.13 TEMA type-G.
Figure 3.14 TEMA type-H.
Figure 3.15 TEMA type-X.
Figure 3.16 TEMA type-X with multiple nozzles.
Figure 3.17 TEMA type-K.
Figure 3.18 Fixed tube sheet exchanger.
Figure 3.19 Schematic of an expansion joint.
Figure 3.20 One expansion joint model.
Figure 3.21 Another expansion joint model.
Figure 3.22 TEMA type-L.
Figure 3.23 TEMA type-M.
Figure 3.24 TEMA type-N.
Figure 3.25 TEMA type-U.
Figure 3.26 U-tube bundles in workshop.
Figure 3.27 Floating head type exchanger.
Figure 3.28 TEMA type-S.
Figure 3.29 TEMA type-T.
Figure 3.30 TEMA type-P.
Figure 3.31 TEMA type-W.
Figure 3.32 Selection criteria for rear head TEMA type.
Figure 3.33 TEMA type AEM.
Figure 3.34 TEMA type BEM.
Figure 3.35 TEMA type NEN.
Figure 3.36 TEMA type AEU.
Figure 3.37 TEMA type BEU.
Figure 3.38 TEMA type AKU.
Figure 3.39 TEMA type BKU.
Figure 3.40 TEMA type AES.
Figure 3.41 TEMA type AET.
Figure 3.42 TEMA type AKT.
Figure 3.43 TEMA type AEP.
Figure 3.44 TEMA type AEW.
Figure 3.45 Exchanger orientation.
Figure 3.46 Kettle-type reboiler.
Figure 3.47 Internal type reboiler.
Figure 3.48 Vertical thermosiphon type reboiler.
Figure 3.49 Horizontal thermosiphon type reboiler.
Figure 3.50 Pump-through type reboiler.
Figure 3.51 Counter-current and co-current flow.
Figure 3.52 Heat release curve.
Figure 3.53 Temperature cross.
Figure 3.54 Graphical method.
Figure 3.55 Heat curve method.
Figure 3.56 Sample of two stacking shells in series.
Figure 3.57 Sample of three stacking shell in series placed in ground.
Figure 3.58 Plain tubes.
Figure 3.59 Longitudinal finned tubes.
Figure 3.60 Tube pattern.
Figure 3.61 Sample of a tube sheet.
Figure 3.62 Tube pass partition plate.
Figure 3.63 Basic tube layout group.
Figure 3.64 Sample layout for tube layout group.
Figure 3.65 Pass-lane width.
Figure 3.66 Baffle type.
Figure 3.67 Single-segmental baffle.
Figure 3.68 NTIW baffle.
Figure 3.69 Double-segmental baffle.
Figure 3.70 Rod baffle.
Figure 3.71 Triple-segmental baffle.
Figure 3.72 Orifice baffle.
Figure 3.73 Disk and doughnut baffle.
Figure 3.74 Effects of small, large and ideal baffle cut.
Figure 3.75 Baffle cut orientation.
Figure 3.76 Baffle spacing inlet / outlet – type-E.
Figure 3.77 Baffle spacing inlet / outlet – type-J12.
Figure 3.78 Baffle spacing inlet / outlet – type-F.
Figure 3.79 Baffle spacing inlet / outlet – type-G.
Figure 3.80 Ideal flow fraction in shell-side.
Figure 3.81 Actual flow fraction in shell-side.
Figure 3.82 Seal strip and tie rods.
Figure 3.83 Seal strip effect.
Figure 3.84 Seal rods effect.
Figure 3.85 Impingement plate.
Figure 3.86 Row of rods.
Figure 3.87 Reboiler type selection chart.
Figure 3.88 Vertical thermosiphon reboiler network.
Figure 3.89 Horizontal thermosiphon reboiler network.
Figure 3.90 Kettle-type reboiler network.
Figure 3.91a Tube sheet damage.
Figure 3.91b Baffle damage.
Figure 3.91c Collision damage.
Figure 3.91d Tubes with long unsupported span.
Figure 3.92 Vortex shedding phenomena.
Figure 3.93 Coiled tube heat exchanger for cryogenic application.
Figure 3.94 Cubic block hole graphite heat exchanger types.
Figure 3.95 Glass shell and tube heat exchanger.
Figure 3.96 Teflon heat exchanger.
Figure 3.97 An EM-baffle type exchanger.
Figure 3.98 An EM-baffle type baffle with tubes.
Figure 3.99 An EM-baffle type baffle.
Figure 3.100 One twisted tube type.
Figure 3.101 One part of twisted type bundle.
Figure 3.102 A complete twisted type bundle.
Figure 3.103 Continuous helical type exchanger.
Figure 3.104 Discontinuous helical baffles.
Chapter 4
Figure 4.1 Vaporization flow regime.
Chapter 6
Figure 6.1 Heat exchanger optimization result chart.
Chapter 7
Figure 7.1 Removable tube sheet-Model-1.
Figure 7.2 Removable tube sheet-Model-2.
Figure 7.3 Leakage around tube-to-tube sheet joint.
Figure 7.4 One leaky tube is plugged.
List of Tables
Chapter 3
Table 3.1 Sample fouling resistance data.
Table 3.2 Possible TEMA types.
Table 3.3 A sample comparison of R, C, and B Classes of TEMA standards.
Table 3.4 Shell inside diameter.
Table 3.5 Maximum number of tube passes.
Table 3.6 Typical number of tube passes.
Table 3.7 Material of construction list.
Table 3.8 Optimum baffle cut percent for double segmental.
Table 3.9 Baffle spacing center to center.
Table 3.10 Tie rods data.
Table 3.11 TEMA maximum tube span.
Table 3.12 Comparison table.
Guide
Cover
Table of Contents
Title Page
Copyright
Dedication
Preface
About This Book
The Audience / Reader
Global Computer Software for Thermal Design
Begin Reading
References
Index
End User License Agreement
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Optimization for Thermal Design of Shell and Tube Heat Exchangers
Mehdi Hanifzadeh
Process Principal Engineer
Copyright © 2025 by John Wiley & Sons Inc. All rights reserved, including rights for text and data mining and training of artificial intelligence technologies or similar technologies.
Published by John Wiley & Sons, Inc., Hoboken, New Jersey.
Published simultaneously in Canada.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, scanning, or otherwise, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without either the prior written permission of the Publisher, or authorization through payment of the appropriate per-copy fee to the Copyright Clearance Center, Inc., 222 Rosewood Drive, Danvers, MA 01923, (978) 750–8400, fax (978) 750–4470, or on the web at www.copyright.com. Requests to the Publisher for permission should be addressed to the Permissions Department, John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, (201) 748–6011, fax (201) 748–6008, or online at http://www.wiley.com/go/permission.
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Library of Congress Cataloging-in-Publication Data
Names: Hanifzadeh, Mehdi author
Title: Optimization for thermal design of shell and tube heat exchangers / Mehdi Hanifzadeh.
Description: Hoboken, New Jersey : Wiley, [2025] | Includes index.
Identifiers: LCCN 2025011858 (print) | LCCN 2025011859 (ebook) | ISBN 9781394313020 (hardback) | ISBN 9781394313044 (adobe pdf) | ISBN 9781394313037 (epub)
Subjects: LCSH: Heat exchangers–Design and construction | Heat exchangers–Thermodynamics
Classification: LCC TJ263 .H36 2025 (print) | LCC TJ263 (ebook) | DDC 621.402/2–dc23/eng/20250416
LC record available at https://lccn.loc.gov/2025011858
LC ebook record available at https://lccn.loc.gov/2025011859
Cover Design: Wiley
Cover Image: © Puneet Vikram Singh, Nature and Concept photographer/Getty Images
To the cherished memory of my beloved Parents,whose their love, remain an enduring source of inspiration.
To my beloved and devotedwife, Soroor,for her years of kindness, unwavering companionship and support
To my deardaughter, Hoorieh,whose radiance in art illuminates my life
To my dearson,Aliwhose kindness fill me with boundless pride
And
To my esteemedfriend, Hashem Hekmat,for his invaluable support and wise counsel
Preface
In terms of the number of equipment in a plant for the energy industries such as oil, gas and petrochemicals, power plants, as well as the food, pharmaceutical industries, heat exchangers, especially the “shell and tube” type, have the largest number and, of course, with a high price. Normally, each exchanger in the plant is unique and has no available spare in the market. So, if they fail during the operation of the production process, the related unit should be shut down first, and then it should proceed to repair the failure immediately that normally is not easy work and sometimes needs to remove the heat exchanger from the unit and sending it to the shop for repairment. Such failures result in a loss in time and production. The main failure of the shell and tube heat exchangers is due to improper thermal design and the emergence of the phenomenon of tubes vibrating simultaneously with each other during operation. This phenomenon should be reviewed carefully and analyzed in the thermal design stage to avoid it during the operation and production phases.
The main problem in the design of heat exchangers is the existence of about 30 effective parameters in the design input data which affect thermal calculation and cost. Changing any of these will cause a positive or negative change in the results. To achieve the desired result, trial and error may be repeated many times. This can cause confusion, fatigue, and waste of time to arrive at an optimal design. It usually takes years of experience for a designer to learn how to deal with all these factors to arrive at an optimal design in a short period of time, but this book can make the path much shorter. Selecting the most appropriate correct inputs that can lead to an optimal design is the goal of engineering companies or manufacturers. This topic is targeted as one of the important goals of this book, which will be discussed in detail; in addition, useful practical experiences will be shared in it.
Finally, this book shows a clear road map for engineers, either young or professional, by using step-by-step practical methods to reach the best design in a much shorter time with no confusion, and not facing unpredicted problems. It makes also design work an enjoyable task.
In conclusion, I would like to express my gratitude to John Wiley Publications for publishing the book. I am also thankful to all my friends who encouraged me throughout the writing process, especially my dear friend, Mr. Hashem Hekmat, who also managed all printing works with the publisher.
Mehdi Hanifzadeh
March 20, 2025
About This Book
In the past, the design of thermal equipment such as shell and tube heat exchangers, air coolers, and fired heaters were based on long and time-consuming calculations and using formulas, charts, and calculation tables.
By spreading the computer applications in engineering fields, thermal design software gradually replaced the old manual calculation method. Now utilizing the software is an established common method for design engineers. Continuously the software are being upgraded for accuracy, speed increasing, and graphic capability by arriving at new versions.
The working model and calculation results of several large global software companies in this field are almost similar.
Each of these software includes several pages for entering data, including input pages (Input Data) and output pages (Output Data). The user of this software, after entering the basic input data, runs it and observes its results quickly on the output pages. Usually, large and popular software notifies the user by providing a warning and error in some results that violates the yellow or red light of applicable standards.
After performing the first run of calculations, the user must change some input information to correct the errors, which may also correct the design but can create new errors. Changing blindly the input data without knowing a scientific and/or experimental method often leads to user fatigue and wasting a lot of time on designing a heat exchanger in a nonoptimal way.
Computer software, as an advanced tool, perform calculations based on any input data with great accuracy and high speed, but they always explicitly place the responsibility of optimal design on the user’s shoulder. In other words, they do not enter in the optimization space.
This book doesn’t intend to teach how to work with thermal design software and the first assumption is that the user is well trained to work with them before.
In this book, in the first chapter, the user will be familiar with the Thermal and Geometric concept of a heat exchanger.
In the next chapter, the user will get to know the data required for each input data based on important standards such as TEMA standard and also many years of experience of the author in design practice of different industrial fields. They will get familiar with the figures and tables and learn when and how to use them during the design procedure as well.
In the following chapters, the output results are analyzed and then the method of correcting the error of each designed item to achieve the optimal design is presented step by step.
For better understanding of various models of conventional heat exchangers normally used in the oil, gas and petrochemical industries, 20 different examples of shell and tube heat exchangers are shown as example and listed step by step in the relevant tables.
The method is in such a way that for each example; after entering the initial input data, the output results are indicated in the same table. Subsequently any nonstandard outputs are warned and highlighted by red color in the same “Run sheet”.
In the next run, we tried to make close the initial input data, which is marked in yellow, to the optimal design.
Then after several runs, we could reach to one (or two in some cases) final optimum design. At the top of calculation table, the numbers of each incorrect and nonoptimal executed run are marked in red and at the end of the table; the optimal design(s) are marked in green.
In each example, brief descriptive explanations are brought about each run and how to improve the red results and move toward optimizing the design.
In the different chapters of this book, it has also been attempted to familiarize the audience with the following general points:
The
basic principle path
for calculating thermal design using a normal software
The effect of physical components and activities related to the construction of a shell and tube heat exchanger on the
cost
A brief description of the application of
new technologies
in a conventional heat exchanger
Introducing shell and tube heat exchangers that are designed and manufactured as a
package
for special applications
General activities that should be done by others
after thermal design
(from Mechanical design to on-site Cleaning / Maintenance)
Familiarity with
TEMA standard
and its
difference
with ASME code
The Audience / Reader
This book serves as an effective and useful self-study guide for the process and mechanical engineers involved in the thermal design of heat exchangers. It helps them become familiar with practical design methods and data management when running thermal design programs for heat exchangers. The teachings in the book are structured to provide a fast-track approach, leading to optimal and economical designs.
The audience and reader of this book are introduced in the following groups:
Process / Mechanical Engineers, who are employed in an engineering company and are in the business of thermal designing the heat exchangers.
Process / Mechanical Engineers, who are employed by the exchanger manufactures and are in the business of designing / fabrication of the heat exchangers.
Process Operating or Maintenance personnel who may have become frustrated with the poor operation factor of exchanger equipment on their unit.
This book can also serve as a guide or textbook for university professors who teach thermal design courses in the final year of engineering programs. It contains material that helps their
students
become professionally familiar with essential shell and tube heat exchanger and learn the thermal design method and its optimization using available software. This will bridge the gap between their practical knowledge and the industry’s needs, allowing them to enter the profession more swiftly than others and enabling them to secure employment more quickly and become proactive and professional in their field.
Global Computer Software for Thermal Design
Most of the shell and tube heat exchangers will be designed using global computer software.
The working model and calculation results of several large global software companies in this field are almost similar. A summary of the basic principle path of calculating thermal design using a normal software is explained in Section 3.30 of Chapter 3.
As it is mentioned in Preface, since the purpose of this book is to show the Method of Optimizing the thermal design of shell and tube heat exchangers in a step-by-step manner, the way to reach an optimal design using different software is completely similar, even if their output parameters are slightly different compared to each other.
In the 20 examples at the end of the book, such different software models are used for each implementation without mentioning the name.
The reader of this book should pay attention to the optimization method, not matching the output information of each run with the software available to them.
Chapter 1A Brief Overview
1.1 Short Summary for Each Chapter
Getting to know the things discussed in different chapters:
Chapter 1: A Brief Overview
Familiarity with the basic concepts of shell and tube heat exchanger.
Familiarity with step-by-step design methodology in this book and introduction of 20 examples for design.
The reason for choosing shell and tube heat exchanger in this book.
Basic familiarity with the components and definitions related to shell and tube heat exchanger.
Familiarity with the
Phenomenon of Fouling,
checking its types inside of heat exchanger and its destructive effects on the amount of current heat transfer.
Investigating the analysis of the First and Second laws of
Thermodynamics on a heat exchanger
and identifying heat losses related to temperature, fluid friction, heat exchanger material / its construction and its release to the environment.
Chapter 2: Required Data for Starting Thermal Design
Explaining the required process information to start thermal design.
Familiarity with the information of the two
Process
and
Thermal Data Sheets
and their differences, which are marked in
blue
and
green
.
Explaining the required information received from the project contract.
Chapter 3: Practical Input Data for Thermal Design (using Software)
Explaining all required process and professional details of geometrical input data for a thermal design using a software, based on
:
TEMA Standard
Practical Experiences
One of the important points in thermal design is determining the heat exchanger model (TEMA Type) that is marked with
3-letter code
. In this book, the user first gets familiar in detail with different components of each model as well as two flow chart used to determine 3-letter coding simply.
Investigating the factors that determine the type of
Materials
used for the shell and tube and introducing the common types of material.
Familiarity with reboilers and the advantages / disadvantages of each, as well as the general method of choosing them using the
Flow Chart
.
Familiarity with the
Phenomenon of Tube Vibration
, natural frequency of the tube, critical velocity, acoustic resonance, general description of different vibration models, description of vibration damage on different parts of the tube, methods of identifying the possibility of vibration, and finally introducing important recommendations to prevent from the occurrence of this phenomenon on the heat exchanger.
Reviewing two groups of
New Emerging Heat Exchangers
, including the
first group
of shell and tube heat exchangers that have special applications and are marketed as a special package by a specific manufacturer, and the
second group
that uses the change of some internal parts of the conventional heat exchanger that have caused a relative improvement in it. In the second group, the main advantages, disadvantages and the reasons for the limitations of their use are generally described.
Explaining the
Basic Principles Path
in the design of shell and tube-type heat exchangers using computer software, explaining step-by-step calculations for thermal design along with vibration analysis, tube layout, and the overall sketch of the heat exchanger.
Chapter 4: Features of an Optimal Design for a Heat Exchanger
Running a design by each software, produce a number of different types of output data pages, such as:
Warning and Error page
Detail of Output Result page
Heat Exchanger TEMA Data Sheet page
Vibration Analysis page
Explaining the main output data of software after running program.
Explaining the
Analysis
of main software output results after running a program.
Chapter 5: Optimization Logic
Description of all physical components, construction, transportation, installation, and repairs activities that affect the
Cost of a heat exchanger.
Explaining a step-by-step guideline to reach an optimum design by controlling geometrical items for:
Pressure drop in shell and tube sides
Velocity / heat transfer parameters in shell and tube sides
Remove vibration problem
Chapter 6: Practical Thermal Design for Real Example Cases
Real
20
examples are categorized below for optimizing them by using a
step-by-step method
:
Water Cooler (2-item)
Gas Water Cooler (1-item)
Lube Oil Water Cooler (1-item)
No Phase Change (3-item)
Feed and Effluent Heat Exchanger (2-item)
Condenser (4-item)
Kettle Type (3-item)
Horizontal Thermosiphon Reboiler (2-item)
Vertical Thermosiphon Reboiler (2-item)
Chapter 7: Brief Description of Activities After Thermal Design
A brief and useful description of the activities after the thermal design of a heat exchanger includes the following:
Mechanical Design,
including shell and tube-sheet thickness calculations, preparation of final tube-sheet layout / heat exchanger sketch, design of nozzles and flanges, design of saddle and lifting lug, and determination of final weight.
Fabrication,
the different stages of heat exchanger construction using automatic machines, considering important points in the construction and preparation of the heat exchanger made for transportation.
Inspection and Testing,
the description of different stages of inspection and testing
Installation,
the description of the activities that must be done before the installation operation and the different installation steps.
Operation,
the description of the various stages of pre-commissioning, checking instrumentation / control loops, removing condensate water when steam is used, and determining the time required to remove the heat exchanger from service.
Maintenance and Repairment,
the determination of repair periods, the list of required tools, preparation of a list of repair steps, modern computer software, leak detection, precautions in opening the bolts / pulling out the tube-bundle from the shell, describing the general / special cleaning method for the inside and outside of the tubes, and finally drying the repaired heat exchanger.
Chapter 8: Comparison Between ASME Code and TEMA Standard
A brief description of the ASME code and TEMA standard for a heat exchanger, comparing these two references with each other, and the titles of the topics included in the TEMA standard.
Chapter 9: Brief Description of TEMA Standard
Brief description and summary of 10 chapters of TEMA standard.
References
Including the introduction of references used.
1.2 Shell and Tube Heat Exchangers
In oil, gas, and petrochemical industries, heat exchanger refers to equipment in which heat exchange between two streams takes place on a noncombustion surface. The most common type of heat transfer equipment used in the industry is the shell and tube heat exchanger.
As the name suggests, shell and tube heat exchangers consist essentially of a “tube bundle” enclosed in a shell of slightly larger diameter. One fluid flows from the inside of the tubes and the other around the outside of the tube through the shell with two different temperatures, one hot and the other cold (Figure 1.1).
Figure 1.1 Flow stream in shell-side / tube-side.
The shell and tube heat exchangers are a significant proportion of the capital cost of a plant. For petrochemical and refinery plants, the exchangers are estimated about 5–6% of the total fixed cost.
1.3 Step-by-step Thermal Design Methodology
Today, the common applicable models of software for heat exchangers design are similar in the world, and in this book, it is assumed that the user is already familiar with at least one of the common software tools for designing heat exchangers.
In this book, in the following chapters, the reader gets familiar with the requirements of a step-by-step thermal design by using computer software:
Familiarity with the components of a geometrical part of a heat exchanger.
Data required for starting thermal design.
Full familiarity with the details of input data based on standard (standard practice) and engineering experience (design practice).
Familiarity with output data of such current software.
How to analyze output results that are approved and the ones that entered the Red zone (i.e. not accepted) and need to be corrected in some way by changing one or more input data.
How to achieve optimal design using step-by-step method (in full detail).
Demonstrating applicable real examples (20 numbers) in multiple and step-by-step implementations of data to achieve an optimal design.
By using the above, reader of this book learns how to design practically, step-by-step to reach an optimum design for some different exchanger model.
1.4 Why Shell and Tube?
Shell and tube type (Figure 1.2) is used for 75% of exchangers supplied to oil refinery, gas, chemical / petrochemical, and power plants. Why?
Figure 1.2 A shell and tube heat exchanger.
It can be designed for any type of heat duty common in industry with a wide range of different temperatures and pressures.
It provides a large number of tubes in a circular surface and of course a large thermal surface area.
It can be made using any different materials.
It can be made in a wide range of physical sizes from
150 to 2,500
mm in diameter.
It has many global builders.
The inside and outside of the tubes can be easily cleaned at the plant site.
Over the years, many design methods and standard mechanical codes have been created for its construction.
1.5 Scope of Shell and Tube
Max Pressure:
Shell 300 bar
Tube 400 bar
Temperature Range:
Max 650 °C
Min 100 °C
Fluids:
Subject to materials
Available in a wide range of materials
Size Per Unit
:
10–1,000 m
2
Above data can be extended with special designs / materials.
1.6 Shell and Tube Heat Exchanger Components / Definition
Although it is needed that readers should be well familiar with shell and tube heat exchangers in order to homogenize their mental concepts with the terminology used in the book, which briefly redefined the geometrical data of the exchangers along with the graphic shapes.
The principal components of a shell and tube heat exchangers are shown in Figure 1.3.
Figure 1.3 Principal components of a shell and tube heat exchanger.
Shell:
Shell is a cylinder in which a bundle of tubes is contained. Shell-side generally refers to fluid stream in the shell and outside the tubes.
Tube:
Tube is a straight plain type, which ran parallel to the longitudinal axis of the shell. Tube-side refers to fluid stream inside the tubes.
Tube Sheet:
The ends of the tubes fit into holes in a common sheet and are expanded internally against or welded to form a pressure tight seal, separating fluid in both the shell and tube. There are two types of tube sheet:
Fixed tube sheet is a tube sheet that is fixed by nut / screw or welded to the shell.
Floating tube sheet is a tube sheet that can be moved to allow for expansion of the tubes relative to the shell.
Channel Head:
Channels are inlet (front head) and outlet (rear head) for the fluids flowing through the tubes.
Tube Pass:
Each path of the tube-side fluid from one end of the exchanger to the other side is named as tube pass.
Pass Partition Plate / Pass Partition Layout:
A partition plate in the channel head makes the fluid in the tubes flow through one set of tubes and back through another set. There are several possible ways to layout tubes by pass partition plates for four or more passes. It causes changes in number of tubes and then on the thermal design result for each type. Three different types quadrant, mixed, and ribbon may be used.
U-tube:
The tubes are bent in a “U” shape. Only one tube sheet is required for U-tube type. Generally, U-tube orientation is vertical for two tube passes and horizontal for four tube passes.
Double Pipe Exchanger:
As shown in Figure 1.4, double pipe exchanger consists of a long, small diameter pipe as shell, with a single tube in it. The tube-side flow is through the inner pipe. The flow through the annulus formed by the inner and outer pipes is called shell-side flow. The internal tube usually has longitudinal fins to give more heat transfer area.
Figure 1.4 Double pipe exchanger.
It is used for low heat duties requiring low surface areas. As shown in Figure 1.5, a number of double pipe heat exchangers can be connected in series or parallel as necessary. It has the advantages of flexibility, since units can be added or removed as required, and it is easy to service and requires low inventory of spares because of its standardization.
Figure 1.5 Serial double pipe exchanger.
With permission of CONVECO SRL.
Multi Tube or Hairpin Exchangers:
Multi tube or Hairpin exchangers as shown in Figures 1.6 and 1.7 are similar to double pipe exchangers in construction, except:
the inner one pipe is replaced with a bundle of tubes.
a separate shell on each leg.
a special cover over the U-bend of tubes.
Figure 1.6 Multi tube or hairpin exchanger.
Figure 1.7 Multi tube or hairpin exchanger.
Source: Koch Heat Transfer Company. https://www.kochheattransfer.com/products/hairpins,-double-pipes-closures.
The tubes are usually plain tubes, but sometimes a longitudinal finned tube may be used.
The number of tubes in the bundle is usually much less than in a conventional shell and tube heat exchanger. Hairpin type may be used for area between 10 and 25 m².
No Phase Change:
The term “No Phase Change” is generally referred to some heat exchangers in which the phase of both shell and tube-side streams will be constant throughout the heat transfer operation. These may be liquid–liquid, liquid–gas, or gas–gas exchangers.
Water Used as Hot / Cold Stream:
Water has a number of favorable and unfavorable points.
The favorable points are the following:
It is available in abundance at a low cost.
Its heat capacity, thermal conductivity, and latent heat of vaporization are higher than those of most other liquids. Thus, steam can be used to transfer heat to a process stream or water can be used to cool it.
For heat transfer at temperatures above 100 °C, high-pressure steam is needed, for which water is a suitable source of production.
The unfavorable points are the following:
It is corrosive to steel, particularly at high temperatures.
It has dissolved salts, and hence requires pretreatment for most applications, otherwise high fouling might occur.
It has dissolved air, which needs to be removed prior to steam generation otherwise exhaust steam condensation will be difficult and the condensate will be corrosive.
Above 49 °C, the operating temperature of cooling water return has to be kept below 49 °C.
Water Cooler:
Cooler cools liquids or gases by means of cooled-water in which all or most of the heat is transferred as sensible heat.
The tendency of water to corrode materials and the growth rate of the microbial fouling increase above 49 °C, which leads to increased microbial growth in the cooling water return and excessive fouling. Further, there will be increased evaporation losses in the cooling tower used to cool this water if it is to be recycled. If the hot water is entering a river stream, it will adversely affect the marine life.
Phase Change:
A very large number of heat exchangers involve a change of phase, such as vapor to liquid (condensers) and liquid to vapor (reboilers).
Condensers are used on top of the distillation columns to condense vapors. These are also used in refrigeration systems to condense the refrigerant.
Reboilers are generally used underneath the distillation columns to boil off part of the bottom products to aid in product enrichment and to provide the energy for distillation.
In the phase change, the general definition of the following items should be remembered:
Bubble point
is the temperature at which the first vapor bubble reaches the top surface of the liquid. The vapor formed is in equilibrium with the liquid at the pressure of the system. It is only defined for a pure liquid that boils, and its vapor condenses at one unique temperature. For example, at 1 bar pressure, pure water boils, and the steam so produced, at 100 °C.
Dew point
is the temperature at which the first drop of the condensate forms. For a pure vapor, the dew point is the same as its boiling point. The difference between the dew point and the bubble point for a vapor mixture is known as the condensing range.
For example, a mixture has a bubble point of 38.89 °C and a dew point of 50.56 °C at 1.0 bar pressure has the below mole fraction:
Component
Feed
Vapor phase
Liquid phase
Butane
0.077
0.266
0.0167
Pentane
0.613
0.625
0.4133
Hexane
0.310
0.109
0.570
Thus, the boiling (or condensing) range for the above mixture at 1.0 bar pressure is 11.67 °C.
Subcooled liquid
is a liquid below its boiling point. In order to produce saturated vapor at the given pressure, first the sensible heat has to be provided to bring the liquid to its boiling point, and then the latent heat has to be provided to boil the liquid.
Saturated vapor
is the vapor in equilibrium with its liquid at the given pressure and the corresponding boiling temperature. On cooling, it releases only the latent heat.
Superheated vapor
is a vapor above its dew point. It is produced when a saturated vapor is removed from contact with its liquid and is heated under isobaric (constant pressure) conditions. On cooling, first the sensible heat is released, followed by the release of the latent heat at the condensing temperature.
Allowable Pressure Drop:
It is the maximum value of the static fluid pressure drop that can be expended to drive the fluid through the exchanger to achieve the required heat transfer. It implies that provision exists in the pumping capacity of the plant to supply this pressure drop in the particular exchanger.
The allowable pressure drops for the shell and tube-side fluids are specified separately and are independent of one another.
The allowable pressure drop determines the fluid velocity. Since the heat transfer coefficient is related to this velocity, the allowable pressure drop plays a very important role in the thermal design of the heat exchanger, which has a great impact on the size of an exchanger.
The allowable pressure drop for shell and tube sides in a heat exchanger is usually determined based on hydraulic calculations in the basic engineering phase as follows:
If the inlet and outlet flow in both sides is vapor phase, the allowable pressure drop is usually considered very low.
If the inlet and outlet flow in both sides is liquid phase, the allowable pressure drop is usually considered between
0.5
and
1.0
bar. Thermal design with this allowed amount is usually not particularly complicated.
If the incoming flow is in the vapor phase or two-phase, especially in the shell, and condensation takes place inside the exchanger, usually the allowed pressure drop is very low between
0.15
and
0.25
bar.
Thermal design for these conditions will be more difficult, especially the phenomenon of vibration must be solved.
Condenser:
Condenser is a type of heat exchanger used to change the phase of a fluid stream from vapor to liquid by means of cooled water to remove the heat of vaporization. Total condenser condenses all vapor entering to liquid, while partial condenser condenses only part of total entering vapors. In oil, gas, and petrochemical plants, most condensers are partial.
Condensation is the reduction of a vapor to a denser form, generally to liquid (e.g., steam to water), although in a few cases it could be changed directly to solid without any liquid forming (e.g., phthalic anhydride vapor condenses to solid under normal operating conditions).
Condensation occurs when the vapor phase is cooled below its saturation temperature, such as when it comes into contact with a cold surface. The saturation pressure of the vapor at the cold surface temperature is lower than that at the bulk vapor temperature. This difference in the saturation pressures provides the driving potential for the vapor to move toward the cold surface and get condensed there, releasing its latent heat.
Orientation of the condenser refers to the direction of the overall flow passage of the vapor phase. The two extreme orientations are horizontal (Figure 1.8) and vertical.
Figure 1.8 Horizontal condenser.
Reboiler:
Reboiler is a type of heat exchanger that operates in conjunction with a distillation tower and provides heat necessary to vaporize its liquid at the bottom. The heating medium may be either saturated steam or a hot fuel oil fluid. The most common type of reboilers is thermosiphon and kettle type.
Thermosiphon Type:
Thermosiphon type uses the natural convection to circulate a boiling medium back to a distillation tower.
Flow rate depends on the difference in static head between the column of liquid flowing from the bottom of distillation tower to the bottom of reboiler and returning from the top of it to the tower with liquid / vapor phase.
The common thermosiphon types are horizontal and vertical reboilers.
The circulation in these is due to the hydrostatic pressure difference between the inlet and the outlet lines. In order to have a high circulation rate and better control, the pressure drop in the piping should be minimized. This requires a proper selection of pipe material, diameter, layout, and use of minimum number of bends, valves, and other pipe fittings.
Kettle Type
:
Kettle-type heat exchanger has two different shell diameters, a large diameter for separation of the vapor and liquid in the shell and smaller diameter for tube bundle allocation. Kettle reboilers are mainly used in re-boiling services with high vaporization rates.
Heating medium such as steam or other heat source fluid is always located in the tube side. The function of this reboiler is to vaporize all / portion of the shell-side fluid, and also to disengage any entrained liquid droplets from the exit vapor within the reboiler itself. Large diameter is made greater than the tube bundle diameter to provide segmentally shaped disengagement area.
Since the shell size is larger than the tube bundle, it is not used for high-pressure operations because it will require a rather thick shell.
A long, thin tube bundle is preferable to a short, fat bundle to avoid the vapor blanketing of the inner tubes in the bundle.
Mesh pads are generally used below the exit nozzle to remove the entrained droplets.
Residence time is high, since natural circulation is used for fluid flow. Therefore, it is not suitable for heat-sensitive materials.
Feed and Effluent Heat Exchanger:
Feed and effluent heat exchangers are widely used in high-temperature exothermic adiabatic reactor systems to conserve energy in a process plant.
The hot reactor effluent fluid recycles its energy back to a feed preheater exchanger to provide a portion of the required energy to preheat the reactor feed fluid and reach its temperature to the optimum reactor inlet data.
TEMA Standards:
A widely accepted standard is that published by the Tubular Exchanger Manufacturers Association known as TEMA.
TEMA does not recommend thermal design or rating of heat exchangers. This is left to designer, but TEMA offers some common practice rating charts and tables.
Heat Load:
Heat load or duty of an exchanger is the rate of heat transfer between shell-side and tube-side, which is usually determined before by the process simulation.
For no-phase change application, heat load is sensible heat and for phase change application, (i.e. condenser), heat load is determined by latent heat of vaporization of the vapors at the condensing conditions.
Heat load for two phase operation maybe is the combination of sensible and latent heat.
Overall Heat Transfer Coefficient, U: Clean / Real / Min. Allowed:
Overall heat transfer coefficient is referred to three below data:
Clean:
The amount of U for clean or without ideal fouling condition.
Real:
The amount of U with fouling condition and consideration excess area.
Min. Allowed:
The amount of U with fouling and without excess area.
The difference between the area needed in the Clean ideal condition and the Real condition is the amount of Excess Area added for fouling consideration.
The difference between the area needed in the Real condition and Min. Allowed condition is the amount of Excess Area shown as Overdesign Percent.
Heat Release Curve:
A heat release curve is a plot of heat load versus temperature for both shell and tube fluids.
Heat release curve is usually used for determining below items:
a corrected mean temperature difference (MTD)
a guide in determining where to zone the heat transfer calculation
for determining directly, the number of shells required in series
for determining the correction factor-F, for phase change condition
For no-phase application, two points are sufficient for both shell and tube streams; however, for a phase-change nonlinear curve, usually five points are sufficient if a curve of this nature is plotted by hand. If the MTD is being calculated on the computer, then usually more points are needed to use.
Counter Current Flow:
In this type of flow, two shell / tube fluids enter at opposite ends of an exchanger and continue to flow in opposite directions at all points throughout the exchanger, i.e. an exchanger with one tube pass and one shell pass.
Co-current Flow:
In this type of flow, two shell / tube fluids enter at the same end of an exchanger and continue their parallel flow throughout the exchanger. Co-current flow is normally un-economical and hardly ever used. The rate of change in the temperature of a fluid is higher in co-current flow than in the countercurrent. Hence, the former should be used for highly viscous fluids.
Baffle:
Baffles are specific types of partition plates located in the shell-side to direct the flow and increase its velocity / turbulency and also to provide support for the straight tubes. It is known that higher heat transfer coefficients result when a liquid is maintained in a state of turbulence.
The baffles are held securely by means of baffle spacers, which consist of bolts screwed into the tube sheet and a number of tie rods that form shoulders between adjacent baffles.
There are two types of baffles, segmental and grid, that are employed in shell and tube heat exchangers.
Segmental baffle is the most common type, which is a piece of plate with holes for the tubes and a segment, which has been cut a way for a baffle window.
Grid baffles are made from rods or strips of metal, which are assembled to provide a grid of opening through which the tubes can pass.
1.7 Fouling
Fouling is the amount of suspended or dissolved material, which may be deposited on the inside and outside tube walls. They increase resistance to both fluid flow and heat transfer. Fouling resistance depends largely upon the type of fluid being handled. Fouling works as an insulating layer on the heat transfer surface, reducing heat transfer efficiency or decreasing available flow area.
The water used in cooling or in steam generation is treated to remove most of the harmful dissolved substances and gases and to bring the pH to an acceptable level.
Fouling deposit is the accumulation of solid material in the equipment in a manner that hampers its operation at the desired level or contributes to its deterioration (Figure 1.9).
Figure 1.9 A bundle of heat exchanger tubes in (a) fouled and (b) clean states.
Source: MDPI. https://www.mdpi.com/1996-1073/16/6/2812.
Fouling results in over-designed units with increased capital and operating costs.
The most frequent causes of failure of a well-designed and fabricated unit operating at the designed conditions are the corrosion and erosion damages to the tubes. Both corrosion and erosion results make inherently some deposit fouling in the exchanger as described below:
Corrosion
is essentially an environmental influence. In spite of the best efforts at the design stage, it is not always possible to eliminate completely the corrosion failures in heat exchangers. This is because the design condition is at best an approximation of the operating conditions that are not always steady. Hence, a periodic review and upgrading of the corrosion control system is necessary.
Erosion
is the loss of material due to high-velocity impact of liquid streams, suspended drops in gaseous flow, suspended vapor bubbles in liquid flow, or suspended solid particles in gaseous or liquid streams. It is encountered in any exchanger where two-phase flow occurs.
It is primarily encountered at the inlet to the tubes and on the outside surface of the tubes under the shell-side nozzles.
1.7.1 Effects of Fouling
The main effects are listed below:
Reduced heat transfer
Increased pressure drop
Deteriorating product quality
Localized pitting and corrosion of the tubes
Reduced throughputs
Oversized unit at the design stage
All of the above lead to economic losses. Therefore, it is important to know the salient features of the fouling of heat exchangers.
There are different approaches to provide an allowance for anticipated fouling in the design of shell and tube heat exchangers. The net result is to provide added heat transfer surface area. This generally means that the exchanger is oversized for clean operation and barely adequate for conditions just before it should be cleaned.
