Professional Documents
Culture Documents
Contents
Calculation Examples 1. Water- Water Heat Exchanger 1 1
Basics ................................................................................................................................................................1 Task ...................................................................................................................................................................1 1. Start the WTS program .....................................................................................................................1 2. Selection of basic data......................................................................................................................1 3. Visual WTS .......................................................................................................................................3 4. WTS Input mask ...............................................................................................................................4 5. Results and evaluation......................................................................................................................5 6. Optimization ......................................................................................................................................6 7. Calculation of pressure drop ...........................................................................................................10 8. Tube sheet! .....................................................................................................................................10 9. Further details of the calculation .....................................................................................................12
2. Heat Exchanger with Floating Head, AET Type (pull through floating head)
14
14
15
Contents i
Task
A heat exchanger is to be designed with the following requirements: Tube side Medium: Pressure: Temperature in: Temperature out: Mass flow: Water 4 bar 80 C 60 C 20 kg/s Shell side Water 3 bar 20 C 53 C
Boundary conditions: Only standardized tube or shell diameters shall be used Steel tubes shall be used A maximum of 3 meters for the bundle length shall not be exceeded. Velocity in tubes shall be at least 1 m/s, to avoid an excessive fouling in the tubes.
Examples
-1-
Examples
-2-
3. Visual WTS
The bundle type is predefined with one tube-side pass and one shell-side pass. Enter now the known values. WTS is not limited to specific input values. In our example the shell side and tube side inlet and outlet temperature and the tube side mass flow are given. The shell side mass flow is calculated via the heat balance. If you entered for example the Absolute thermal performance W, the two inlet temperatures and the mass flows, the program would calculate the two outlet temperatures. After having entered all known values confirm with OK. The calculation is started and the program switches to the WTS input mask.
Examples
-3-
Shell Dimensions
The heat exchanger has been calculated and the entered and calculated values are now displayed in the WTS input mask. The program selected a shell with 273 x 6.3 mm and a number of tubes of 61. This results in a tube-side velocity of 1.668 m/s.
Number of tubes
Examples
-4-
Required bundle length = 3.968 m Final bundle length = 3 m Heat transfer area not sufficient! Overdesign= -24.4%
Examples
-5-
6. Optimization
6.1 Increasing the number of tubes
You may increase the number of tubes while performing the calculation. Either you select a bigger shell in the menu Basic input / basic data or you overwrite the value in the WTS mask with a bigger one. Enter now 65 for the number of tubes and confirm with ENTER. The WTS program now tries to put 65 tubes into a shell, which is integrated in the WTS12.tab. The program selects a shell of 323.9 x 7.1 mm. 91 tubes can be put into this shell. The required bundle length is calculated as 3.11 m, this means the exchanger is still too small. Therefore increase the number of tubes again and enter for example 95 as number of tubes. The WTS program selects a shell of 355.6 x 8 mm in which 121 tubes can fit. The required bundle length is now 2.45 m. With a final (actual) bundle length of 3 m it shows an overdesign of about 22 %. Due to increasing the number of tubes the flow velocity in the tubes is now 0.84 m/s. The exchanger does still not meet our requirements (at least 1m/s in the tubes).
Required bundle length = 2.452 m Final bundle length = 3 m Heat transfer area sufficient. Overdesign ca. 22%
Flow velocity in the tubes =0.8407 m/s At least 1m/s to avoid fouling
Examples
-6-
The exchanger is recalculated and re-dimensioned. The calculation results in a required bundle length of 2.657 m. The overdesign is 12.9 %.
2 Tube-side passes
Examples
-7-
The exchanger is recalculated again. The required bundle length increases to 3.38 m. The heat exchanger is 11.28% underdesigned! Increase the number of tubes to 110. A new shell is selected with 406.4 x 8.8 mm. The number of tubes in this shell is 142 and the overdesign is 5.8%.
Examples
-8-
Select the input field 'Thermal conductivity of tube material' and press F3 to get thermal conductivities of different tube materials dependent on the temperature.
Right-click the input field 'Thermal conductivity of tube material' and select 'values' to receive thermal conductivities of different materials.
Due to the decreased number of baffles the heat transfer coefficient decreased as well and the required bundle length increased. Please check if the final bundle length is still sufficient!
Examples
-9-
Pressure drop in inlet nozzle Pressure drop in outlet nozzle Pressure drop of tube inlet, tube outlet and turnaround in case of multi-pass shells. In this case it is taken into account whether the flow is guided by a U-tube or a turnaround. Pressure drop by friction. The distribution of the tube-side pressure drop is shown in the RDV module!
Examples
-10-
Pressure drop in the cross-flow zone, between the edges of the baffles Pressure drop in both end zones below the nozzles Pressure drop in the window zone Pressure drop in the nozzles
The distribution of the shell-side pressure drop is shown in the LAE module!
If the exchanger is limited by the pressure drop (for example a gas-gas heat echanger) it is necessary to know where the pressure drop can be found to be able to optimise the exchanger. If the pressure drop arises in the cross-flow zone, the number of baffles must be reduced. If the presure drop arises in the window zone, the height of the window must be increased.
Examples
-11-
8. Tube sheet
The tube sheet maybe diplayed directly in the WTS module but cannot be edited graphically. Changes in the WTS input mask however effect the graphics dynamically.
Switch to the SPIE mask by clicking on the tab 2 SPIE . Here you can find further important values for the tube sheet. To display the tube sheet click on the menu item Display tubesheet in the Tube sheet menu. This tube sheet can now be edited graphically. You may move or delete single tubes or complete tube rows. (See SPIE manual).
Examples
-12-
Thermal and hydraulic design of shell and tube heat exchangers Design of tube sheets, determination of tube sheet data Properties of water Properties of water Heat transfer in pipe flow Shell side heat transfer in baffled shell-and-tube heat exchangers Determination of the correction factor (FN factor) for the logarithmic mean temperature difference (LMTD) for different exchanger types Tube bundle vibration analysis Tube side pressure drop in shell-and-tube heat exchangers Shell side pressure drop of shell-and-tube heat exchangers CAD extension Customer documentation
Examples
-13-
2. Heat Exchanger with Floating Head, AET Type (pull through floating head)
Task
For an easy cleaning of the shell side a tube pitch of 45 is selected. Fouling must be considered
Input
Tube side Water 180 m/h Tin = 20 C Tout = 90 C Fouling = 0,00018 Shell side Thermal oil Transcal N 1100 m/h Tin = 185 C Tout = 160,7 C Fouling = 0,00053 mK/W
Target
Calculation of the bundle-shell distance cause of the floating head according TEMA Correction factors for the heat transfer and the pressure drop Bypass flow, leakage flow, changing flow directions Heat transfer correction for unequal baffle spacing at inlet and outlet Sealing strips Size of window, baffle distance
Target
Cross-Over of outlet temperatures FN factor
Examples
-14-
Cause of failure on production Causes of failure in upstream stages or changing the operating parameters Uncertainty of basic data Local design regulations
Expenses
Examples
-15-
Desired nozzle position Fraction of tube-side and shell-side heat transfer coefficient at overall heat transfer coefficient. Is one value extremely high? Usage of pressure drop Distribution of pressure drop
Product Fl x Fb must be >= 0,5 High bypass flows by high pressure drop over the bundle. Mainly caused by low baffle distance A higher baffle distance may result in better performance. Change internal temperature profile. Basis of CLMTD gets invalid. Results uncertain. Fw = Fc * Fl * Fb * Fr should be ca. 0.6 Check baffle pitch Shell-Bundle distance too high Use sealing strips with viscous media and big shell-bundle distance Intermediate area is interpolated. No Nu-equation available. Consider Re-number at Inlet/outlet Check two exchangers in series Check heat transfer coefficient Check Fn factor Check cross over
Sudden change from Laminar-Turbulent Turbulent -Laminar Exchanger area very big
Tube vibration by high shell-side velocities. Mostly two-phase flow (turbulent vibration) or gas flow (acoustic vibration).
Baffle pitch too high Perform a vibration analysis from pitch > 0.7 x L b,max on. Instead of analysis: No tubes in window Twisted Tube Bundle.
Examples
-16-