Dale Gulley's Heat Exchanger Tips Workbook

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
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
for the seal bar calculation on sheet "Calculations".
Chris Haslego
Cheresources.com Admin
6/28/2011 - Added three new tips from Gulleyassociates.com with permission.
Chris Haslego
Boiling
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
Boiling
Chris Haslego
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
Boiling
Chris Haslego
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
Chris Haslego
Chris Haslego
lloy Tubes and Tubesheets

ubesheets
Chris Haslego
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.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Air flow accessories - don't overlook these when calculating fan HP

Box header design - limit of process temperature change
Connecting bundles of existing coolers for a new service
Fan drive changes that increase capacity of existing cooler
Fan drive noise - suggestions on how to reduce
Maximum motor HP for a fan
Maximum tube wall temperature for wrap-on fins
Optimum number of tube rows
Overall heat transfer rate estimate for hydrocarbons
When do bare tubes become more efficient than fin tubes?
When To limit number of tube passes in air coolers
When to use wind coolers
Boiling:
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
1.
15.
Calculations
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
1.
Condensing:
1.
2.
3.
4.
5.
6.
Avoid small baffle cuts in S & T condensers

Estimate - Condensing heat transfer coefficient for hydrocarbons inside tubing
Maximum heat transfer rate inside tubes for total condensation
Quick estimate for reflux condenser LMTD in air cooler
Reflux (Knockback) condenser comments
Steam condenser types
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.
7.
Construction:
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.
1.
Heat Recovery:
1.
2.
3.
4.
5.
Deciding on what fin spacing to use

Estimate of nozzle size for HRSG
Face area estimate for HRSG units
Maximum exhaust gas temperaure for steel fin tubes
When to use bare tubes in waste heat boilers
Materials:
1.
Cooling water flowing inside 304SS U-tubes
Pressure Drop:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Allowing for fouling in pressure drop calculations

Allowable pressure drop suggestions
Allowable shell side pressure drop if a multi-leaf(a.k.a. lamaflex) long baffle is u
Better baffle window pressure drop equation
Designing for better use of tube pressure drop
Effect of 1st tube rows on shell nozzle pressure drop
Pressure drop on kettle side
Reducing high shell side pressure drop in fixed tube sheet exchangers
Use impingement rods instead of plate to lower shell press. drop
What design pressure drop to use for heavy liquids inside tubes
Maximum velocity inside tubes
Calculate shell nozzle pressure drop
Improve shell side pressure drop calculations
Tube Bundle Vibration:

1.
2.
3.
4.
5.
Features of a new S & T bundle that replaces bundle that vibrated

Vibration cure when designing shell & tube bundles
Conditions likely to cause shell & tube bundle vibration
Cures for vibration in existing bundle
Miscellaneous:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Allocation of streams in shell & tube

Articles published by Dale Gulley
Avoid these fluids when using lowfin tubing
Best heat transfer flow pattern
Check liquid thermal conductivity at high reduced temperatures
Check piping connections when there is under-performance
Evaluating an exchanger for a new service
Check heat release curve data for skipping over dewpoints and bubblepoints
When will exchangers with low-fins be more economical than exchangers with b
Problems with excess heat exchanger surface
Purchasing warning for shell & tube exchangers
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
What is the minimum velocity inside tubing for slurries?

Suggestions for low-fins and potential S & T bundle vibration
Choose shell & tube or multi-tube heat exchangers
Thermal design problem with shell side long baffle
Trouble shooting article in Hydrocarbon Processing
Under-surfaced S&T quote
When to add shell in Series
When to consider a long baffle in the shell
Which stream goes inside the tubes of gas/gas exchangers?
Weighted MTD
Why did performance decline in a TEMA type F,G or H type shell?
Zone those condensers
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) =
Fan Diam =
7.00 feet
This is for fan diameters greater than 3.5 ft.
46.4 HP
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 =
Where
Twall =
Ta + (Th1 - Ta) x Ro x Uc =
459 oF
temperature of tube wall
Ta =
Th1 =
air outlet temperature =
200 oF
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
Liquids
Overall Heat Transfer Coefficient

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 nozzl
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 (t)1.25 =
2,925 Btu/(hr)(ft2)(oF)
Where
t =
t=
(tube wall temperature - liquid temperature
50 oF
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
CHF = crital heat flux in Btu/(hr)(ft)2
Ds = shell bundle diameter in inches
(0.25)
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
Ktr = ___1______
Ds0.3
Kc =0.5 (1 - (No/Ds)2)
KT = Ktr + Kc
Pn = KT = 0.000108 x Vn2 x tp
Where:
Ds = Top channel ID (inches)
Ktr = pressure loss coefficient for turning loss
Kc = pressure loss coefficient for contraction into nozzle
KT = total pressure loss coefficient
No = Outlet nozzle ID (inches)
Vn = velocity thru nozzle (ft/sec)
tp = two-phase density (lb/ft3)
Pn = pressure drop thru channel and outlet nozzle (Psi)
0.445576 (used for pressure drop calc)

(If Ktr less than 0.40, use 0.40)
=
=
0.28077
0.726346
0.16944
=
=
=
=
=
=
=
=
14.8
0.445576 (calculated)
0.28077
0.726346
9.8
120
0.15
0.17
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 an
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 a
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
ling, the vaporizer
hing the liquid.
m 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
ssible 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-ft2-F/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)
r. This is caused by the

case where 90% of the
uid preheat zone and
n 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
1 tube
1 pipe
1 pipe
2 pipe
3 pipe
4 pipe
Unit Capacity flow rate

3,000-5,000 # / tube / hr
5,000-10,000 # / tube / hr
10,000-17,000 # / pipe / hr
17,000-35,000 # / pipe / hr
35,000-70,000 # / pipe / hr
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 =
h=
1.4W0.8 =
75 Btu/hr-ft2-oF
Generally more accurate
Or,
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=
Specific Heat =
0.025 / (specific heat)1.5 =
0.0427
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 p/Calc. p)1/3 =
15.9 feet
Where
Lg = Existing tube length =
20 feet
Allow.p = Allowable Tube pressure drop =
1.00 psi
Calc. p = 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 =
where
VL =
72 148 VL +100 VL2 =
41.3 ft/sec.
0.25 ft/sec. (less than 0.30 ft/s)
the superficial liquid velocity =
If the superficial liquid velocity is above 0.30 ft/s:

VgMax =
where
VL =
28.1 + 28 VL + 1.12 VL2 =
the superficial liquid velocity =
57.2 ft/sec.
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
Where
L = variable to use in L/D expression, ft
Tube Length = length of tube, ft =
Di = tube I.D., in =
0.650 inches
Re = Reynolds number =
20 feet
5,000
11 feet
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"

Shell type "J"
Cold outlet 5 oF higher than hot outlet Shell type "E"
0.805
0.775
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()) =
Shell Side Flow Rate
0.261 in2
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()) =
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)
Bs(Ds-OTL)+Bs(OTL-Do)(P-Do)/P
0.054
Where
Ds = inside diameter of shell =
23.00 in.
OTL = The Outer Tube Limit, or outer diameter of the tube bundle =
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
22.75 in.
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. =
Where:
Tube OD =
0.750 inches
DS = Bundle diameter
Count =
250 Number of tubes
Pitch = Tube spacing =
1.000 inches
18.617 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 =
Where:
Do =
F=
F=
Npl =
PLw =
P=
TC =
F [0.7854 x TC2 - (PLw + Do - P) (TC x Npl)] / P2 =

=
Tube O.D. =
0.750 inches
1.00
for square pitch
1.15
for triangle pitch
Number of tube pass lanes (1 for two pass) =
2
Tube pass lane width (typical is 0.625 inches) =
Tube pitch =
1.000 inches
(Bundle diameter - tube O.D.) =
22.250 inches
372
428
Tubes on Square Pitc

Tubes on Triangular
0.625 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 i
For 3/4 inch tubes with 0.06 tube wall
W = 1600(P/L)0.555
For 1.0 inch tubes with 0.06 tube wall
W = 3500(P/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
P = allowable pressure drop inside tubes in psi (deduct 15% for nozzle pressure drops)
= density in lb/cu.ft.
L=
P =
=
Mass flow =
21 ft
7 psig
For 3/4" tubes, W =

For 1" tubes, W =
1,497
3,274
Tube count =
Tube count =
2.66 lb/ft3
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(P/L x )1/3
where
Cp = specific heat (Btu/lb-F)
=
L = tube length (ft)
=
P = shell side pressure drop (Ps =
(subtract nozzle losses)
= density of gas (lb/ft3)
=
17
0.15
10
2
0.085
Btu/h ft2 F
known. An example
w path rather than
diameter selection:
, 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
ill be larger due to
n liquid film and

ill 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
an 1,000, you
using shorter tubes.

ese factors will
ound the bundle.

oss flow area.
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
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)
4. Calculate new heat load from new surface and new U
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
bon 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
ur 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 compound
Hi =
750 (Kliq / 0.07)0.9 =
Where,
Kliq = liquid thermal conductivity of the condensat
3,193
Btu/hr
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
se 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
signed 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 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.
2.
3.
4.
5.
Plate within a nozzle enlarger

Solid rods instead of tubes for the first 2 or 3 rows.
Snap-on tube protectors on top of the tubes in the first 2 or 3 rows
Small angle iron types setting on top of the tubes in the first 2 or 3 rows
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=
Where:
D=
Flow =
0.14 x (flow)1/2 =
diameter of nozzle
Gas flow =
1,000
4.43
inches
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 =
Where:
Flow = Exhaust Gas flow =
Where face area is in square feet.
(Flow / 2,500) =
1,000
0.40
ft2
lbs/hr
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
Where
MaxTg = maximum gas temperature
Btemp = water boiling temperature =
300
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.

dirty gases the
el are fired.
fin spacing to use.
ll determine
h triangular pitch.
cal 2 inch O.D.
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
Gas
Liquid
Change of phase
Boiling:
Allowable Pressure Drop, psi

3 to 5
8 to 10
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
Atmospheric to 25 psi
25 to 50 psi
50 to 150 psi
150 psi +
0.5
1
2
3
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)
Pw = Kp x 0.000108 x Gw2/
Pw = 1.33 x 0.000108 x (890.5)2 x 7/62.4
Pw = 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 P = P x (NPASS/OPASS)3 =
Where
P =
Previous Pressure drop
1.5
NPASS = New number of tube passes =
4
OPASS = Old number of tube passes =
2
12.0
psi
psi
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
pressure drop, psi
5
25
50
Exchanger surface
ft2
4,012
2,104
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 = 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. Pn = Kn x .000108Vs2 x density
(Pn = total of both nozzles)
where
Pn = 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 = 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
Pn = 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
Pc = 6.41 psi
Pshell = Pc + Pw + Pn
From other tips: Pw = 12.78
Pn = 1.03
Pshell = 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.
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.
d by using
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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.
2.
3.
4.
5.
6.
"More Accurate Exchanger Shell-and-Tube Pressure Drop Calculations", Hydrocarbon Processing, June 2004
"Troubleshooting Shell-and-Tube Heat Exchangers", Hydrocarbon Processing, September 1996
"Computers help Design Tubesheets", The Oil & Gas Journal, May 20,1974
"Computer Programs aid Design Work", The Oil & Gas Journal, Jan. 13,1969
"How to Calculate Weighted MTD's", Petroleum Refiner, July 1966
"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 superficial
gas velocity is above the following value:
VgMax =
72 -148VL +100 VL2 =
where
VL = the superficial liquid velocity =
5.0
1,832.0
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 coefficient
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 specification
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 vendors 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
0.0010
0.0015
0.0020
steam,steam condensate,engine jacket water

boiler feed water
clean water,moutain water,etc.
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

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
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Low-fins are
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A.C. Mueller
passes and shorter
September 30, 2005

Rev: 0
Art Montemayor
TEMA DESIGNATIONS
Front End Stationary Head
Shell Type
Rear End Stationary Head
Channel and removable cover
One-pass shell
Fixed tubesheet; like "A"

Stationary head.
Bonnet (Integral Cover)
2-pass shell with longitudinal

baffle
Fixed tubesheet; like "B"

stationary head.
Channel integral with tubesheet

& removable cover.
Shown: Removable Tube
Bundle
Split Flow Shell
Fixed tubesheet; like "C"

stationary head.
Channel integral with tubesheet

& removable cover.
Double split flow
Outside, packed floating head
Page 108 of 156
FileName: 272871572.xls
WorkSheet: TEMA Designations
September 30, 2005

Rev: 0
Art Montemayor
Special, high-pressure closure
Divided shell flow
Floating head with backing

device (split-ring)
Kettle type of reboiler
Pull-through floating head
U-tube bundle design

(No Rear Head Required)
Conventional Front End Heads:
A
or,
Other popular rear end head types employed:
W Packed floating tubesheet with

lantern ring
Page 109 of 156
September 30, 2005

Rev: 0
Art Montemayor
Page 110 of 156
Art Montemayor
Some examples of the TEMA designation for Heat Exchangers are shown below:
BEM
September 30, 2005

Rev: 0
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.
Page 111 of 156
September 30, 2005

Rev: 0
Art Montemayor
Page 112 of 156
September 30, 2005

Rev: 0
The maintenance feature of having a removable tube bundles requires an exchanger as the following:
Art Montemayor
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.
Page 113 of 156
September 30, 2005

Rev: 0
Art Montemayor
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.
Page 114 of 156
September 30, 2005

Rev: 0
Art Montemayor
Page 115 of 156
September 30, 2003

Rev: 0
Art Montemayor
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

12
13-1/4 15-1/4 17-1/4 19-1/4 21-1/4 23-1/4
105
135
193
247
307
391
481
91
117
157
217
277
343
423
85
101
139
183
235
287
355
57
73
103
133
163
205
247
45
65
83
111
139
179
215
25
553
493
419
307
255
27
663
577
495
361
303
29
763
667
587
427
359
31
881
765
665
481
413
33
1,019
889
765
551
477
35
1,143
1,007
865
633
545
37
1,269
1,127
965
699
595
452
398
346
244
218
398
336
304
192
180
528
468
408
292
248
460
406
362
234
214
626
556
486
346
298
558
484
436
284
256
734
646
560
410
348
648
566
506
340
304
846
746
644
462
402
768
674
586
396
356
964
858
746
530
460
882
772
688
466
406
1,088
972
840
608
522
1,008
882
778
532
464
1,242
1,088
946
688
584
1,126
1,000
884
610
526
332
292
242
176
142
286
254
226
142
122
412
360
308
212
188
378
318
286
178
166
484
424
366
258
214
438
386
342
218
198
576
508
440
308
260
534
462
414
266
238
680
596
510
368
310
622
542
482
322
286
788
692
590
422
360
740
648
560
376
336
904
802
688
486
414
852
744
660
444
384
1,024
912
778
560
476
976
852
748
508
440
1,172
1,024
880
638
534
1,092
968
852
584
500
230
202
158
112
88
206
184
160
100
80
294
258
212
150
116
272
268
210
130
110
372
322
266
182
154
358
300
268
168
152
440
388
324
226
184
416
366
322
206
182
532
464
394
274
226
510
440
392
252
224
632
548
460
338
268
596
518
458
304
268
732
640
536
382
318
716
626
534
356
316
844
744
634
442
368
826
720
632
426
362
964
852
224
514
430
944
826
718
488
420
1,106
964
818
586
484
1,058
940
820
562
478
198
170
132
90
74
190
170
146
90
70
258
224
174
120
94
254
226
194
118
98
332
286
228
154
128
342
286
254
154
142
398
344
286
190
150
398
350
306
190
170
484
422
352
240
192
490
422
374
238
206
576
496
414
298
230
578
498
438
290
254
682
588
490
342
280
688
600
512
340
300
790
694
576
400
334
796
692
608
404
344
902
798
662
466
388
916
796
692
464
396
1,040
902
760
542
438
1,032
908
792
540
456
33
33
33
15
17
69
57
53
33
33
3/4" on 15/16" Triang.

3/4" on 1" Triang.
3/4" on 1" Square
1" on 1-1/4" Triang.
1" on 1-1/4" Square
3/4" on 15/16" Triang.
3/4" on 1" Triang.
3/4" on 1" Square
1" on 1-1/4" Square
32
28
26
16
12
8
8
12
XX
XX
58
56
48
32
26
34
26
30
8
12
94
90
78
52
40
64
60
52
26
22
124
110
94
62
56
94
72
72
42
38
166
154
126
92
76
134
108
100
58
58
228
208
172
126
106
180
158
142
84
76
300
264
222
162
136
234
212
188
120
100
370
326
280
204
172
304
270
242
154
134
3/4" on 15/16" Triang.

3/4" on 1" Triang.
3/4" on 1" Square
1" on 1-1/4" Square
3/4" on 15/16" Triang.
3/4" on 1" Triang.
3/4" on 1" Square
1" on 1-1/4" Square
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
48
44
48
24
24
28
20
24
84
72
72
44
40
56
52
44
20
16
108
96
88
60
48
84
64
64
36
32
154
134
126
78
74
122
98
90
50
50
196
180
142
104
84
166
146
130
74
66
266
232
192
138
110
218
198
174
110
90
3/4" on 15/16" Triang.

3/4" on 1" Triang.
3/4" on 1" Square
1" on 1-1/4" Square
3/4" on 15/16" Triang.
3/4" on 1" Triang.
3/4" on 1" Square
1" on 1-1/4" Square
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
80
66
54
34
116
104
78
56
44
110
88
80
42
42
174
156
116
82
66
156
134
118
68
60
3/4" on 15/16" Triang.

3/4" on 1" Triang.
3/4" on 1" Square
1" on 1-1/4" Square
3/4" on 15/16" Triang.
3/4" on 1" Triang.
3/4" on 1" Square
1" on 1-1/4" Square
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
94
82
140
124
94
66
102
82
70
38
34
142
122
106
58
50
Fixed Tubes
U Tubes
Fixed Tubes
U Tubes
Fixed Tubes
U Tubes
Fixed Tubes
10
Fixed Tubes
3/4" on 15/16" Triang.

3/4" on 1" Triang.
3/4" on 1" Square
1" on 1-1/4" Square
U Tubes
Eight-Pass
Six-Pass
Four-Pass
Two-Pass
One-Pass
Tube O. D. & Pitch
74
56
56
30
68
52
48
24
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 116 of 156
WorkSheet: Tube Counts
March 12, 2001

Rev: 0
Art Montemayor
HEAT EXCHANGER SUMMARY
T in, Cold Side (t1)
69
T out, Cold Side (t2)
83
T in, Hot Side (T1)
169
T out, Hot Side (T2)

Exchanger Heat Duty
Overall U, estimated
Number of shell passes
Number of tube passes
Log Mean Temperature Difference, LMTD
F Factor (see below)
Adjusted LMTD
Heat Transfer Area calculated
Design contingency factor
Over-design allowance
Heat Transfer Area required
F
F
F
128 F
3,950 M Btu/hr
100 Btu/hr - Ft2 - oF
1
2
72 oF
0.98
70 oF
562 Ft2
1.25
1.00
o
702 Ft2
450 psig, Saturated Steam Req'd,

CW Req'd @ 14 deg rise, gpm
5,163 lbs/hr
564 gpm
Calculation of F Factor:
P (or S)
R
Term 1
Px
Term 2
Term 3
Term 4A
Term 4B
Term 4
F
0.14
2.93
0.69 [(RP-1)/(P-1)](1/N)
0.14
1.60 (R^2+1)0.5/(R-1)
0.38
1.46
13.45
7.26
0.62
0.98
W, Cp, T2
w, cp, t1
q, U, A, Tm
w, cp, t2
W, Cp, T1
Page 117 of 156
WorkSheet: HX Design
SHELL & TUBE HEAT EXCHANGER SPECIFICATION
Montemayor
Corporation
1 Service
Equipment No.
Unit
Horiz.
ft
Gross
P&ID No.
Fluid Allocation
Fluid Circulated
Total Fluid Entering
Vapor (In/Out)
Liquid
Steam
Non-Condensables
Fluid Vaporized or Condensed
Steam Condensed
Temperature
Density, Specific Gravity
Viscosity
Vapor Molecular Weight
Specific Heat
Thermal Conductivity
Latent Heat
Operating Pressure, Inlet
Velocity
Max.
Min.
Pressure Drop, Clean (Allow./Calc.)
Fouling Resistance
Heat Exchanged
Transfer Rate, Service
P.O. No.
Model
4 TEMA Size, Type
Rev. No.
Lean MEA Solution Cooler
3 Manufacturer
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
1 of 1
Project No.
2 Location
5 Surface/Unit
Sheet
(English Units)
Eff.
Mfr Ref. No.

Vert.
Shells/Unit
Connected in
One
Surface/Shell
Plot Plan No.

PERFORMANCE OF ONE UNIT
SHELL SIDE
No. Req'd
Series
Parallel
ft
Gross
Eff.
Other Ref. Dwg No.

TUBE SIDE
lb/h
lb/h
lb/h
lb/h
lb/h
lb/h
lb/h
F
cP
Btu/lbF
Btu/hftF
Btu/lb
psig
fps
psi
ft2hF/Btu .
Btu/h Log MTD (Uncorrected)
F Log MTD (Corrected)
Btu/ft2hF . Transfer Rate, Clean
*
*
CONSTRUCTION AND MATERIALS
SHELL SIDE
TUBE SIDE
Sketch (Bundle, Nozzle Orientation)
F
*
Btu/ft2hF .
Design Pressure
psig
Test Pressure
psig
Design Temperature
F
Number of Passes per Shell
Connections In
Out
Size &
Rating
Intermediate
Tubes: Type
Number
OD
in.
in.
Av. Wall
*
0.75
16 BWG or 30
X Min.
45
60
90
Tube Length
in. Tube Pitch
in. Flow Pattern (circle one)
0.9375
Shell: ID
in. OD
in. Tube-to-Tubesheet Joint
*
*
Rolled and Seal Welded
Baffles - Cross:
Type
Spacing
in.
% Cut on X Diam.
Area
*
*
*
Baffles - Long:
Perm.
Removable
Seal Type:
Bypass Seal:
lb/ftsec Bundle Entrance
lb/ftsec Bundle Exit
lb/ftsec
v2: Inlet Nozzle
*
*
*
Expansion Joint?
Yes
Type:
Impingement Protection?
No
X No
X Yes
PART
MATERIAL
THK, in.
C.A., in.
PART
MATERIAL
THK, in.
C.A., in.
Tubes
Stainless Stl 16 BWG min.
Floating Tubesheet Carbon Steel
*
---Shell
Fixed Tubesheet
Carbon Steel
*
0.125
Shell Cover
Tube Supports
Carbon Steel
*
0.125
Channel
Cross Baffles
Carbon Steel
*
0.125
Channel Cover
Long Baffle
Carbon Steel
*
0.125
Fltg Head Cover
Gaskets
Stainless Stl
---
Stress Relieved (Mark "SR') and/or Radiographed (Mark 'XR') Parts
User Spec.:
Code Requirements: ASME Sec. VIII, Para. 1 (1992)
Stamp?
Yes TEMA Class:
Weights: Shell
*
lb Filled with Water
*
lb Bundle
*
lb
Remarks
1. Items marked with an asterisk (*) to be completed by Vendor.
Rev
0
Date
Description
For Purchase
By
Chk.
Appr.
Rev
Date
Description
By
Chk.
Appr.
Corporation
Equipment No.
2 Location
Unit
3 Manufacturer
5 Surface/Unit
6 P&ID No.
Mfr Ref. No.
One
Frames/Unit
ft2
P.O. No.
Model
*-*
4 Size, Type
1 of 1
1234567
Project No.
Cooling Water Exchanger
1 Service
Sheet
Effective
Connected in
Surface/Frame
Plot Plan No.
No. Req'd
One
Single
ft2
Gross
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
F
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/lbF
0.867
0.843
1.0
1.0
22 Thermal Conductivity
Btu/hftF
0.178
0.160
0.358
0.365
23 Latent Heat
Btu/lb
------24 Operating Pressure, Inlet
psig
75
60
25 Velocity
Min.
fps
X Max.
8.0
8.0
26 Pressure Drop, Clean (Allow./Calc.)
psi
10
*
10
*
27 Fouling Resistance
ft2hF/Btu
0.001
0.003
28 Heat Exchanged
Btu/h Log MTD (Uncorrected)
F Log MTD (Corrected)
F
3,097,238
157.0
*
29 Transfer Rate, Service
Transfer Rate, Clean
Btu/ft2hF
Btu/ft2hF
*
*
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
F
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
Rating
39
Intermediate
------40 v2, Inlet/Outlet
lb/fts
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
Connections
Stnless Steel 16 BWG min. 0.03125
Stnless Steel
0.03125
45 Plate Gaskets
Frame
Carbon Steel
*
0.03125
Carbon Steel
0.03125
46 End Cover
Carrying Bar
Carbon Steel
*
0.03125
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
0
Date
Description
9-Dec-96 For Inquiry
By
ABC
Chk.
DEF
Appr.
XYZ
Rev
Date
Description
By
Chk.
Appr.
Rev. No.
PLATE & FRAME HEAT EXCHANGER SPECIFICATION

(English Units)
Montemayor
Art Montemayor
October 02, 2003

Rev: 0
Typical Overall Heat Transfer Coefficients

Source: http://www.the-engineering-page.com/forms/he/typU.html
Shell and Tube Heat Exchangers
Hot Fluid
Cold Fluid
Heat Exchangers
Water
Water
Organic solvents
Organic Solvents
Light oils
Light oils
Heavy oils
Heavy oils
Reduced crude
Flashed crude
Regenerated DEA
Fouled DEA
Gases (p = atm)
Gases (p = atm)
Gases (p = 200 bar)
Gases (p = 200 bar)
Overall U
W/m2-C
Btu/hr-ft2-oF
800 1,500
100 - 300
100 - 400
50 - 300
35 - 150
450 - 650
5 - 35
100 - 300
140 - 264
17 52
17 70
9 53
6 26
79 114
1.0 6
17 53
250 - 750
350 - 700
60 - 300
75 - 200
5 - 35
150 - 400
20 - 300
150 - 500
600 1,200
15 - 250
44 132
62 - 123
11 - 53
13 35
1.0 6
26 70
4 53
26 88
106 211
3 - 44
Water
Organic solvents
Light oils
Heavy oils
Gases
Heavy oils
Gases
Steam
Hydrocarbon vapors
1,500 4,000
500 1,000
300 - 900
60 - 450
30 - 300
50 - 300
20 - 200
30 - 100
30 -100
264 - 700
88 - 176
53 159
11 79
5 53
9 53
4 - 35
5 - 18
5 - 18
Water
Water
Water
1,000 1,500
700 1,000
400 - 550
176 264
123 176
70 - 97
Coolers
Organic solvents
Light oils
Heavy oils
Reduced crude
Gases (p = atm)
Gases (p = 200 bar)
Gases
Organic solvents
Water
Gases
Water
Water
Water
Water
Water
Water
Water
Brine
Brine
Brine
Heaters
Steam
Steam
Steam
Steam
Steam
Heat Transfer (hot) Oil
Heat Transfer (hot) Oil
Flue gases
Flue gases
Condensers
Aqueous vapors
Organic vapors
Refinery hydrocarbons
Page 120 of 156
WorkSheet: Typical "U"
Art Montemayor
Vapors with some non condensables Water

Vacuum condensers
Water
500 - 700
200 - 500
October 02, 2003

Rev: 0
88 123
35 88
Vaporizers
Steam
Steam
Steam
Heat Transfer (hot) oil
Aqueouos solutions
Light organics
Heavy organics
Refinery hydrocarbons
Air Cooled Exchangers

Process Fluid (tube side)
Water
Light organics
Heavy organics
Gases
Condensing hydrocarbons
Immersed coils
Coil Fluid
Pool Fluid
Natural circulation
Steam
Dilute aqueous
solutions
Steam
Light oils
Steam
Heavy oils
Aqueous solutions
Water
Light oils
Water
1,000 1,500
900 1,200
600 - 900
250 - 550
176 264
159 211
106 159
44 97
300 - 450
300 - 700
50 - 150
50 - 300
300 - 600
53 - 79
53 - 123
9 - 26
9 - 53
53 - 106
500 1,000
200 - 300
70 - 150
200 - 500
100 - 150
88 176
35 53
12 26
35 88
18 26
800 1,500
300 - 500
200 - 400
400 - 700
200 - 300
140 264
53 88
35 70
70 - 123
35 - 53
500 - 700
250 - 500
200 - 500
200 - 300
88 - 123
44 - 88
35 - 88
35 - 53
Agitated
Steam
Steam
Steam
Aqueous solutions
Light oils
Steam
Steam
Water
Water
Dilute aqueous
solutions
Light oils
Heavy oils
Water
Water
Jacketed vessels
Jacket Fluid
Vessel Fluid
Dilute aqueous
solutions
Light organics
Dilute aqueous
solutions
Light organics
Arts Note: Above Us 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
Page 121 of 156
WorkSheet: Typical "U"
Art Montemayor
G KETTLES RECIRCULATION COOLER

E-G-43
October 24, 1997
From "Process Heat Transfer"; D. Kern; McGraw-Hill; 1950; pages 147-148
P = f G2sDs(N+1)/(5.22 x 1010)Des s
ID = Shell Internal diameter, in. =

ODT = Tube external diameter, in. =
PT = Tubes' Pitch, in. =
C' =
B=
N=
aS =
W=
GS =
23
0.75
Clearance between tubes =

Baffle spacing, in. =
Number of Shell-side baffles =
0.9375
0.1875
15
11
Shell-side crossflow area, ft2 =

Shell-side mass flowrate,lb/h =
0.4792
325500
Shell-side unit mass flowrate,lb/h-ft2 =
679,304
De = Equivalent shell diameter, ft =

NRe = Shell-side Reynolds Number =
f = Friction factor for pressure drop, ft
= Fluid's Heat Capacity, Btu/lb- F =

= Fluid'sViscosity, cP =
' = Fluid's Viscosity, lb/ft-h
k = Fluid's therm. cond., Btu/ft-h-oF =
NPr = Fluid's Prandtl Number =
s = Viscosity ratio, (/w)0.14 =
cP
0.0458333
643.3
/in =
0.00352
0.52
20
48.4
0.086
292.7
s = Shell fluid's specific gravity =
1
0.9303721
P = Shell-side pressure drop, psi =
16.8
Page 122 of 156
Electronic FileName: 272871572.xls

WorkSheet: Shell-Side Pressure drop
Quick & Dirty Tubular Heat Exchanger Rating Sheet

Project
Item No.
Reactor Warm Water System Upgrade

E-G-XX
Service
Project No.
By
Date/Time
13-Mar-97
15:12
Step 4. Start configuring the exchanger. Begin with the total calculated
Input flows, conditions and properties data for shellside and
tubeside.
transfer coefficients to this point (i.e., not including shellside h):
Ustart =
Btu/hft2oF
Tube
Side
Shell
235
On that basis, assumed Uo =
Btu/hft2oF
CW
Fluid Name
Warm Water
195
Flow (M), lb/h
Then the required transfer A =
2,139
ft2
418,000
195,000
Temp. in, oF
88
130
Number of tubes required =
545
Temp. out, oF
102
100
Reset tubes/pass (Step 3), then no. of passes =
4
3
, lb/ft
Av. Density
62.05
61.9
Total tube count =
584
, cP
Tubeside P (incl. returns) =
Av. Viscosity
0.723
0.590
8.1
psi OK?
o
c
,
Btu/lb
F
Av. Heat Capacity
1
1
Actual effective transfer area, A =
2,293
ft2
p
Heat Exchanged 5,850,015
Q, Btu/h
5,850,000 OK?
o
k, Btu/hft F
Av. Thermal Conductivity
0.360
0.368
R, ft2hoF/Btu
Step 5. Select tube arrangement
Fouling Resistance
0.002
0.0015
Tube Pitch 0.9375 in.
c
/k
Prandtl No.
4.86
3.88
and estimate shell diameter
Pattern
Tri
p
o
F
Uncorrected MTD
18.9
Shell ID from Tube Count Tables
27
in.
o
F
Corrected MTD
14.0
Select Baffle Spacing
16
in.
Number of Baffles =
14
Flow Area across Bundle, as =
0.600
ft2
Equivalent Diameter, de (see table) =
Step 2. Input tubing OD, BWG and
Tube OD
0.7500
in.
0.55
in.
Mass Velocity, Gs = 325,000 lb/hft2
length (can be trial and error).
BWG
16
Shellside Reynolds No., NRe = 25,258
Tube ID, d =
0.620
in.
Tube Length, L =
20
ft.
Shellside Friction Factor = 0.00178
2
Flow area per tube, at =
Shellside P =
0.302
in.
2.7
psi OK?
2
Outside Transfer Factor, jh =
Effective transfer area per tube =
3.927
ft
90.4
Outside Film Coefficient, ho =
1,140
Calculated Uo =
195.1
Check:
%
difference,
U
vs
U
=
Step 3. Estimate the number of
Tubes/pass =
146
0.0%
OK?
calc.
assum.
Uclean =
tubes per tube pass.
lb/h per tube =
2,863
614.9
Av. velocity, fps =
6.11
OK?
Tubeside Reynolds No., NRe =
40,324
Step 6. Check tubeside velocity and P, shellside P. If too high or too low,
Tubeside Friction Factor, f =
0.010
P 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.
Step 1.
CALCULATION SHEET
Signature Art Montemayor
Date
18-Feb-04
Checked
Date
Project
D. Q. Kern, "Process Heat Transfer"; Mc-Graw Hill; 1950; p. 274
Subject
Horizontal n-Propanol Total Condenser
Proj No.
File
Sheet
of
10
1
2
3
A horizontal, 1-2 condenser is required for condensing pure propyl alcohol emanating from the top of a distillation
column. Side-to-side, 25% cut segmental baffles will be used. Basic data is as follows:
4
5
Propanol flowrate
Propanol vapors' inlet pressure

Propanol vapors' inlet temperature
Cooling Water inlet temperature
7
8
9
10
11
12
13
14
15
16
17
60,000 lb/hr
Propanol allowable pressure drop

CWS allowable pressure drop
2.00 psi
10.00 psi
Dirt factor
Condenser tubes' length
0.003
8.00 feet
Tubes' OD
Tubes' length
0.7500 inches
8.00 feet
Tubes' gauge
Tubes' ID
Tubes' pitch
16
0.6200
0.9375
0.1875
19
Clearance between tubes

Propanol Latent Heat at 15 psig
20
Propanol Molecular Weight
18
15.0 psig
244 oF
85 oF
BWG
inches
Triangular, inches
inches
285 Btu/lb
60.1
21
22
Vapor
inlet
23
Cooling water
out
24
25
26
27
28
29
30
31
32
33
Cooling water in
Condensate
outlet
34
35
Temperature,o F
36
37
38
39
40
41
42
244
85
43
Distance along tubes
44
A
CALCULATION SHEET
Project
Subject
Date
18-Feb-04
Checked
Date

Proj No.
File
Sheet
of
10
45
46
First, make a heat and material balance to establish the heat load and the cooling water required:
47
Propanol latent heat for condensation =

Cooling water terminal temperature =
48
49
17,100,000
120 oF
Btu/hr
Cooling water required =

488,571 lb/hr =
Propanol
Water
244
Higher Temperature 120
50
51
52
244
0
Lower Temperature
Difference
85
35
Log Mean Temperature Difference = LMTD =
141
53
54
976 gpm
Differ.
124
159
35
55
56
57
58
Since the shell side Propanol vapor is essentially isothermal, the exchanger is in true counterflow.
59
60
61
62
63
Tc = The caloric temperature of the hot fluid

tc = The caloric temperature of the cold fluid
ta = The average temperature of the cold fluid
The influence of the tube-wall temperature is included in the condensing film coefficient.
64
The mean ta =
65
102.5 oF can be used as the caloric temperaure of the cold fluid
66
67
68
Execute a trial calculation:

a) Assume that UD =
100
Btu/hr-oF-ft2
Condensing film coefficients will generally range from 150 to 300. Assuming a film coefficient of 1,000
for water, UC will range from 130 to 230 Btu/hr-oF-ft2.
69
70
71
72
Heat transfer area = A =
73
Quantity of 3/4" OD tubes =
Q/UD T =
1,215
ft2
773
74
b) Assume that 4 tube passes are used. The quantity of water is large, but the condenser will have a
large number of tubes, making a 2-pass assumption inadvisable.
75
76
From the tube counts table, 4 tube passes using 3/4" OD tubes on 15/16" triangular pitch , yields a
count of
766
tubes in a
31
inch ID shell.
c) The corrected UD coefficient, using the 31" shell, is now calculated:
Corrected area, A = 1,203 ft2
Corrected UD = Q/A T = 101
Btu/hr-oF-ft2
77
78
79
80
81
82
83
84
85
86
87
88
A
CALCULATION SHEET
Date
18-Feb-04
Checked
Date
Proj No.

Project
Subject
File
Sheet
of
10
89
90
Calculations for shell side hot fluid, n-Propanol
91
93
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
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.
92
95
96
The shell-side or bundle crossflow area = a S =(ID) (C') (B)/(PT * 144) =
1.33
ft2
(Eq. 7.1; p.138)
89.6
lb/hr-linear ft
where,
ID = Shell inside diameter, inches
97
98
C' = Clearance between tubes, inches

B = Baffle spacing, inches
PT = Tube pitch, inches
99
100
101
102
103
The shell-side mass velocity = Gs = W / aS =
44,953 lb/hr-ft2
104
105
106
W/L*Nt2/3 =
The condensate loading on the horizontal tubes = G'' =

where,
L = Tube length, feet
Nt = Tube quantity effective for condensation
107
108
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)
where,
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 )
113
114
116
Tube wall temperature = tW =
117
ta + [hO/(hiO + hO)] (Tv - ta) =
125
(Eq. 5.31; p. 98)
where,
119
Tv = Average temperature of hot fluid (vapor), oF
118
120
121
Shell side film temperature = tf =
(Tv + tw)/2 =
184
122
123
Shell side film thermal conductivity = kf =
0.095
Btu/hr-ft2-oF/ft
Specific Gravity of shell side film = sf =
0.80
(From Table 6)
Viscosity of shell side film = f =
0.62
cP
(From Table 4)
124
125
126
127
(From Fig. 14)
128
129
130
131
132
133
A
CALCULATION SHEET
Date
18-Feb-04
Checked
Date
Proj No.

Project
Subject
File
Sheet
of
10
134
h' ( f2 / kf3 f2 g)1/3 = 1.5 (4 G''/f)-1/3
135
136
137
138
139
140
141
142
(Equation 12.42; p. 266)
where,
h'
f
kf
f
= Average condensing film coefficient, Btu/hr-ft2-oF

=
film coefficient absolute viscosity
=
1.5004 lb/ft-hr
= film coefficient thermal conductivity, Btu/hr-ft - F/ft

= film coefficient density, lb/ft 3
=
49.92
2 o
g = Acceleration of gravity, ft/hr2
4.18E+08
G'' = Condensate loading for horizontal tubes, lb/hr-ft
143
Average shell side condensing film coefficient =
144
178
Btu/hr-ft2-oF
145
146
Calculations for tube side cold fluid, Water
147
Flow area of a 3/4" OD x 16 BWG tube = 0.3020 in2
148
(From condenser tube table)
149
Flow area per tube =
150
NT a't / 144 n =
0.402
ft2
where,
NT = Number of tubes effective for condensation
153
a't = Flow area per tube, in2
154
n = Number of tube passes
151
152
155
156
Water mass velocity in the tube side = Gt = w / at =
1,216,508
lb/hr-ft2
157
158
Average water velocity in the tube side = V =
Gt / (3,600*) =
5.41 ft/sec
159
At the average water temperature, t a, of
160
102.5
F:
161
Water viscosity = =
Tubes' ID =
162
163
0.72 cP
0.0517 ft
1.74 lb/ft-hr
164
165
Reynolds Number (for pressure drop only) = D Gt/ =
36,073
Tube side water heat transfer film coefficient = h i =
1,300
166
167
Btu/hr-ft2-oF
(From Fig. 25)
168
169
170
171
hiO =
hi (ID/OD) =
1,075
Btu/hr-ft2-oF
where,
172
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
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.
173
174
176
177
178
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CALCULATION SHEET
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Subject
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Date

Proj No.
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Sheet
of
10
179
180
Calculations for shell side pressure drop
181
182
183
o
244
F
0.010 cP
The propanol vapor temperature =

Propanol vapor viscosity =
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.
The flow area at right angles to the long axes is variable from tube row to tube row. A hydraulic radius based upon
188
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
189
191
obtained if the hydraulic radius is calculated along (instead of across) the long axes of the tubes.
192
193
194
De = (4 * free area)/(wetted area) = [(4) (0.5 *PT * 0.86 * PT - 0.5 * * d2 /40] / (0.5 * *d)
=
0.55 inches = 0.0458 ft
(From fig. 28)
195
De Gs / =
Shell-side Reynolds Number =
196
85,139
197
198
Shell-side friction factor for 25% cut segmental baffles = f = 0.00141 ft2/in2
(From fig. 29)
199
Number of shell-side crosses = (N+1) =
200
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
f = 0.00019 ft2/in2
217
(From fig. 26)
218
219
Tube-side pressure drop = Straight tube pressure drop + Return Loss pressure drop
220
221
Straight tube pressure drop = Pt = f * Gt2 * Ln/(5.22*1010 *De * s *t) =
3.3
psf =
222
0.02 psi
(Eq. 7.45; p. 148)
223
A
CALCULATION SHEET
Project
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Date

Proj No.
File
Sheet
of
10
224
225
Return Loss pressure drop = Pr = (4*n/s) (V2/2 g') =
7.3
psi
(Eq. 7.46; p.148)
226
Total tube-side pressure drop =
227
228
229
230
231
232
7.29
psi
where,
L = tube length, feet
n = Number of tube passes
t = The viscosity ratio (/w)0.14 in the tubes
g' = Acceleration of gravity, 32.2 ft/sec2
233
234
235
Calculation of clean overall coefficient UC:
236
UC = (hio * ho )/(hio + ho) =
237
152.4
Btu/hr-ft2-oF
238
239
240
Calculation of dirt factor Rd:
241
Corrected UD =
242
101
Btu/hr-oF-ft2
(From line 81)
243
Rd = (UC - UD)/(UC * UD) = 0.0033 hr-ft2-oF/Btu
244
(Note: In condensation calculations the omission of the tube metal resistance may introduce a significant error and
246 should be checked.)
245
247
248
Shell
side
249
178
250
251
Summary of
Results
h (outside)
UC = 152.4
UD =
101
Tube
side
1,075
Rd calculated = 0.0033
Rd required = 0.003
252
253
1.2
2.00
254
255
Calculated P
Allowable P
7.29
10.00
256
257
Conclusion:
The first trial calculated is satisfactory and yields the following exchanger:
Shell side
Tube side
ID = 31 inches
Quantity and length = 766; 8' - 0"
Baffle spacing = 31 inches (approx.
OD, BWG, & pitch = 3/4"; 16 BWG; 15/16", triangular
258
259
260
261
Passes =
262
Passes =
263
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
264
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.
266
CALCULATION SHEET
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Subject
Date
18-Feb-04
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Proj No.

Vertical n-Propanol Total Condenser
File
Sheet
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
out
Cooling water in
274
275
276
Vapor
inlet
277
278
279
280
281
282
283
284
285
286
287
288
Condensate
outlet
289
290
291
292
Total heat transferred =
293
17,100,000
Btu/hr
294
295
Log Mean Temperature Difference = LMTD =
141
Caloric temperature of the Propanol vapor = T C

Caloric temperature of the water = t C =
102.5
296
297
298
299
300
Trial Calculation:
301
a) Assume that the overall dirty heat transfer coefficient, U D =
Btu/hr-ft2-oF
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.
302
70
305
Heat transfer area = A =
306
Q/UD * T =
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
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CALCULATION SHEET
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Checked
Date
Proj No.

Project
Subject
File
Sheet
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10
314
b) The same tube layout, using 3/4" OD x 16 BWG tubes on 15/16" triangular pitch and 4 passes will also be
used.
315
316
317
c) The corrected UD coefficient, using the 31" shell, is now calculated:

Corrected area, A = Q/UD*t = 1,804 ft2
Corrected UD = Q/A T =
67
Btu/hr-oF-ft2
318
319
320
321
322
323
Calculations for shell side hot fluid, n-Propanol
324
Tubes' outside diameter, Do =
325
0.0625 ft
326
327
Condensate loading for vertical tubes = W/N t * * 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
hiO =
hi (ID/OD) =
(Refer to line # 165)

where,
333
334
hi = The inside (water) film heat transfer coefficient =
1,300 Btu/hr-ft2-oF
(From fig. 25 )
331
1,075
Btu/hr-ft2-oF
332
335
Tube wall temperature = tW =
336
ta + [hO/(hiO + hO)] (Tv - ta) =
114.5
(Eq. 5.31; p. 98)
where,
338
Tv = Average temperature of hot fluid (vapor), oF
337
339
340
Shell side film temperature = tf =
(Tv + tw)/2 =
179
341
342
Shell side film thermal conductivity = kf =
0.095
Btu/hr-ft2-oF/ft
Specific Gravity of shell side film = sf =
0.80
(From Table 6)
Viscosity of shell side film = f =
0.65
cP
(From Table 4)
343
344
345
346
(From Fig. 14; also, 4*G'/ = 1,025)
347
h' ( f2 / kf3 f2 g)1/3 = 1.47 (4 G'/f)-1/3
348
349
350
351
352
353
354
355
(Equation 12.39; p. 266)
where,
h'
f
kf
f
= Average condensing film coefficient, Btu/hr-ft2-oF

= film coefficient absolute viscosity
=
1.573
lb/ft-hr
= film coefficient thermal conductivity, Btu/hr-ft - F/ft

= film coefficient density, lb/ft 3
=
49.92
2 o
g = Acceleration of gravity, ft/hr2
4.18E+08
G' = Condensate loading for vertical tubes, lb/hr-ft
356
Average shell side condensing film coefficient =
357
104
Btu/hr-ft2-oF
358
A
CALCULATION SHEET
Date
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Checked
Date

Project
Subject
Proj No.
File
Sheet
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
365
366
hiO =
hi (ID/OD) =
1,075
Btu/hr-ft2-oF
where,
367
368
369
Calculations for shell side pressure drop
370
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:
371
B =
373
29
inches
374
Shell-side (bundle) crossflow area = a s =
375
(ID * C' * B)/(PT * 144) =
1.24
ft2
(Eq. 7.1; p.138)
where,
ID = Shell inside diameter, in.
376
377
C' = Clearance between tubes, in.

B = Baffle spacing, in.
PT = Tube pitch, in.
378
379
380
381
382
The shell-side mass velocity = Gs = W / aS = 48,387 lb/hr-ft2
383
384
385
o
244
F
0.010 cP
The propanol vapor temperature =

Propanol vapor viscosity =
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 / = 91,642
390
391
Shell-side friction factor for 25% cut segmental baffles = f = 0.00140 ft2/in2
(From fig. 29)
392
Number of shell-side crosses = (N+1) =
393
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
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.
401
403
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CALCULATION SHEET
Project
Subject
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18-Feb-04
Checked
Date

Proj No.
File
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 = Pt = f * Gt2 * Ln/(5.22*1010 *De * s *t) =
5.0
psf =
410
0.03 psi
(Eq. 7.45; p. 148)
411
412
Return Loss pressure drop = Pr = (4*n/s) (V2/2 g') =
7.3
psi
(Eq. 7.46; p.148)
413
Total tube-side pressure drop =
414
7.30
psi
415
416
417
Calculation of clean overall coefficient UC:
418
UC = (hio * ho )/(hio + ho) =
419
95.0
Btu/hr-ft2-oF
420
421
422
Calculation of dirt factor Rd:
423
Corrected UD =
424
67
Btu/hr-oF-ft2
(From line 81)
425
Rd = (UC - UD)/(UC * UD) = 0.0043 hr-ft2-oF/Btu
426
427
428
429
Shell
side
430
104
431
Summary of
Results
Tube
side
h (outside)
UC = 95.0
1,075
UD =
67
Rd calculated = 0.0043
Rd required = 0.003
432
433
434
435
2.3
Calculated P
7.30
436
2.00
Allowable P
10.00
437
438
Conclusion:
Shell side
439
Tube side
Quantity and length = 766; 12' - 0"
OD, BWG, & pitch = 3/4"; 16 BWG; 15/16", triangular
ID = 31 inches
Baffle spacing = 29 inches (approx.
440
441
Passes =
442
Passes =
443
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.
444
447
The vertical unit has an inherent advantage, however, when the condensate is to be subcooled.
448
A
Some of this data was taken from Standards of the Tubular Exchanger Manufacturers Association (TEMA); 7th Ed
BWG
7
8
9
10
11
12
13
14
15
16
17
18
20
22
1/2" O. D. Condenser tube

Wall
Tube weight
Surface area per
thickness Tube I. D. Tube flow
per linear
Constant Tube I. D.
2
linear foot, ft
inches
inches area
in2
foot, lb of
C **
inches
Outside
Inside
steel*
0.165
0.148
0.134
0.120
0.109
0.095
0.083
0.072
0.065
0.058
0.049
0.035
0.028
0.282
0.0625
0.1309
0.0738
0.456
0.334
0.0876
0.1309
0.0874
0.370
0.370
0.1075
0.1309
0.0969
0.302
168
0.402
0.430
0.444
0.1269
0.1452
0.1548
0.1309
0.1309
0.1309
0.1052
0.1126
0.1162
0.236
0.174
0.141
198
227
241
3/4" O
0.482
0.510
0.532
0.560
0.584
0.606
0.620
0.634
0.652
0.680
NOTES:
* The weight of the condenser tubes is based on low carbon steel with a density of 0.2836 lbs/in 3
Material
Aluminum
Titanium
A.I.S.I. 300 Series Stainless Steels
A.I.S.I. 400 Series Stainless Steels
Aluminum Bronze
Aluminum Brass
Nickel-Chrome-Iron
Admiralty
Nickel
Nickel-Copper
Copper and Cupro-Nickels
Factor
0.35
0.58
0.99
1.02
1.04
1.06
1.07
1.09
1.13
1.12
1.14
** Liquid Velocity within the tubes = (Lbs Per Tube Hour) / (C * Liquid Specific Gravity) in feet per sec. (Specific g
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
Constant Tube I. D. Tube flow
2
foot,
ft
linear foot, ft2
per
linear
foot,
area
in2
C **
inches area
in2
lb of steel
Outside
Inside
Outside
Inside
0.2836 lbs/in 3.
0.1825
0.2043
0.2223
0.2463
0.2679
0.2884
0.3019
0.3157
0.3339
0.3632
0.1963
0.1963
0.1963
0.1963
0.1963
0.1963
0.1963
0.1963
0.1963
0.1963
0.1262
0.1335
0.1393
0.1466
0.1529
0.1587
0.1623
0.1660
0.1707
0.1780
0.883
0.808
0.747
0.665
0.592
0.522
0.476
0.429
0.367
0.268
285
319
347
384
418
450
471
492
521
567
0.670
0.704
0.732
0.760
0.782
0.810
0.834
0.856
0.870
0.884
0.902
0.930
For other metal materials multiply by the following factors:
ty) in feet per sec. (Specific gravity of Water @ 60
F = 1.00)
0.3526
0.3893
0.4208
0.4536
0.4803
0.5153
0.5463
0.5755
0.5945
0.6138
0.6390
0.6793
0.2618
0.2618
0.2618
0.2618
0.2618
0.2618
0.2618
0.2618
0.2618
0.2618
0.2618
0.2618
0.1754
0.1843
0.1916
0.1990
0.2047
0.2121
0.2183
0.2241
0.2278
0.2314
0.2361
0.2435
A, but this was corrected with this spreadsheet's formulas.
ondenser tube
Tube weight
per linear
foot, lb of
steel
1.473
1.348
1.241
1.129
1.038
0.919
0.814
0.714
0.650
0.584
0.498
0.361
1-1/4" O. D. Condenser tube

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

2" O. D. Condenser tube
Surface area per
Surface area per
Tube weight
Tube flow
2
linear
foot,
ft
linear foot, ft3
per
linear
foot,
area
in2
C **
inches area
in3
lb of steel
Outside
Inside
Outside
Inside
1.0751
1.1310
1.1882
1.2469
1.2868
1.3478
1.3893
1.4527
1.4741
1.4957
1.5394
0.3927
0.3927
0.3927
0.3927
0.3927
0.3927
0.3927
0.3927
0.3927
0.3927
0.3927
0.3063
0.3142
0.3220
0.3299
0.3351
0.3430
0.3482
0.3560
0.3587
0.3613
0.3665
2.355
2.165
1.970
1.771
1.635
1.427
1.286
1.070
0.997
0.924
0.775
1,860
2,014
2,180
2,300
1.760
1.782
1.810
1.834
2.4328
2.4941
2.5730
2.6417
0.5236
0.5236
0.5236
0.5236
0.4608
0.4665
0.4739
0.4801
ndenser tube
Tube
weight per Constant
linear foot,
C **
lb of steel
2.412
2.204
1.935
1.701
3,795
3,891
4,014
4,121
Heat Exchanger Tubesheets

Tubesheet Thickness
From: Chemical Engineering Magazine; Plant Notebook; May 12, 1975
October 09, 1991

Rev: 0
Art Montemayor
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
T=
2
S
F
G
P
S
T
=
=
=
=
=
1.25
12
350
17,500
1.06
inches
psig
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.
Material
SA-516 Grade 70
Stainless Steel
1.25Cr - 0.5Mo - Si Steel
Monel
SB-171 Naval Brass
SB-402 Copper Nickel
SB-11 Copper
100
17,500
-15,000
17,500
-12,500
6,600
Temperature, oF
200
300
400
17,500
17,500
17,500
17,700
16,100
15,900
15,000
15,000
15,000
16,500
15,500
14,800
12,500
10,500
2,000
10,500
10,400
10,400
5,700
5,000
--
Page 139 of 156
500
17,500
-15,000
14,700
-10,400
--
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
Shell I. D.
Inches
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
39
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
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
32
26
20
20
21
16
14
52
52
40
36
32
32
26
24
16
12
10
81
76
68
68
60
48
45
40
38
36
30
24
22
97
90
82
76
70
61
56
52
48
44
32
30
30
137
124
116
108
108
81
76
68
68
64
44
40
37
177
166
158
150
142
112
112
96
90
82
56
53
51
224
220
204
192
188
138
132
128
122
116
78
73
71
277
270
246
240
234
177
166
158
152
148
96
90
86
341
324
308
302
292
213
208
192
184
184
127
112
106
413
394
370
356
346
260
252
238
226
222
140
135
127
481
460
432
420
408
300
288
278
268
260
166
160
151
553
526
480
468
456
341
326
300
294
286
193
188
178
657
640
600
580
560
406
398
380
368
358
226
220
209
749
718
688
676
648
465
460
432
420
414
258
252
244
845
824
780
766
748
522
518
488
484
472
293
287
275
934
914
886
866
838
596
574
562
544
532
334
322
311
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 =
Outer Tube Limit =
1.5 inches
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
22
35
48
64
82
102
123
146
174
202
238
268
304
342
OTL) this data applies.
16
22
31
44
56
78
96
115
140
166
193
226
258
293
336
16
22
29
39
50
62
78
94
112
131
151
176
202
224
252
16
22
29
39
48
60
74
90
108
127
146
170
196
220
246
12
16
25
34
45
57
70
86
102
120
141
164
188
217
267
12
16
24
32
43
54
66
84
98
116
138
160
182
210
230
22
29
39
50
62
78
94
112
131
151
176
202
224
SHELL AND TUBE HEAT EXCHANGER TUBESHEET LAYOUTS (TUBE

Source: "Process Heat Transfer"; Donald Q. Kern, McGraw-Hill Book Co. (19
Shell I. D.
Inches
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
39
3/4" O. D. tubes on 15/16-inch triangular pitch
3/4" O. D. tubes on 1-inch triangular pitch
1
2
4
6
8
1
2
4
TubePass TubePass TubePass TubePass TubePass TubePass TubePass TubePass
36
32
26
24
18
37
30
24
62
56
47
42
36
61
52
40
109
98
86
82
78
92
82
76
127
114
96
90
86
109
106
86
170
160
140
136
128
151
138
122
239
224
194
188
178
203
196
178
301
282
252
244
234
262
250
226
361
342
314
306
290
316
302
278
442
420
386
378
364
384
376
352
532
506
468
446
434
470
452
422
637
602
550
536
524
559
534
488
721
692
640
620
594
630
604
556
847
822
766
722
720
745
728
678
974
938
878
852
826
856
830
774
1102
1068
1004
988
958
970
938
882
1240
1200
1144
1104
1072
1074
1044
1012
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 =
Outer Tube Limit =
1.5 inches
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.

giving 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
32
45
62
86
105
130
155
185
217
255
297
335
380
425
22
28
42
58
78
101
123
150
179
212
245
288
327
374
419
20
26
38
54
69
95
117
140
170
202
235
275
315
357
407
18
27
36
48
61
76
95
115
136
160
184
215
246
275
307
14
22
34
44
58
72
91
110
131
154
177
206
238
268
299
14
18
32
42
55
70
86
105
125
147
172
200
230
260
290
12
16
30
38
51
66
80
98
118
141
165
190
220
252
284
12
14
27
36
48
61
76
95
115
136
160
184
215
246
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.
Shell ID
in.
Outer Tube
Limit
Diameter,
in.
8.071
(Sch. 30)
6.82
10.02
(Sch. 40)
8.77
12.00
10.75
13.25
12.00
15.25
14.00
17.25
16.00
19.25
18.00
Tube OD
in
0.75
0.75
0.75
1.00
1.00
0.75
0.75
0.75
1.00
1.00
0.75
0.75
0.75
1.00
1.00
0.75
0.75
0.75
1.00
1.00
0.75
0.75
0.75
1.00
1.00
0.75
0.75
0.75
1.00
1.00
0.75
0.75
0.75
1.00
Tube
Pitch, in.
0.9375
1.0000
1.0000
1.2500
1.2500
0.9375
1.0000
1.0000
1.2500
1.2500
0.9375
1.0000
1.0000
1.2500
1.2500
0.9375
1.0000
1.0000
1.2500
1.2500
0.9375
1.0000
1.0000
1.2500
1.2500
0.9375
1.0000
1.0000
1.2500
1.2500
0.9375
1.0000
1.0000
1.2500
Tube
Layout
Triang.
Square
Triang.
Square
Triang.
Triang.
Square
Triang.
Square
Triang.
Triang.
Square
Triang.
Square
Triang.
Triang.
Square
Triang.
Square
Triang.
Triang.
Square
Triang.
Square
Triang.
Triang.
Square
Triang.
Square
Triang.
Triang.
Square
Triang.
Square
Page 147 of 156
Number of Tube Passes

1
2
38
32
37
21
22
62
52
61
32
37
109
80
90
48
57
127
95
110
60
67
170
138
163
88
96
239
188
211
112
130
301
236
273
148
4
32
26
30
16
18
56
52
52
32
32
98
72
84
44
52
114
90
101
56
63
160
132
152
82
92
224
178
201
110
124
282
224
256
142
6
26
20
24
16
16
47
40
48
26
28
86
68
72
40
44
96
81
90
51
56
140
116
136
75
86
194
168
181
102
116
252
216
242
136
24
20
24
14
14
42
36
48
24
28
82
68
70
38
42
90
77
88
46
54
136
112
133
70
84
188
164
176
98
110
244
208
236
129
WorkSheet: Total Tubes
Art19.25
Montemayor
18.00
21.00
19.25
23.25
21.50
25.00
23.25
27.00
25.25
29.00
27.25
31.00
29.25
33.00
31.25
35.00
33.25
37.00
35.25
39.00
37.25
42.00
40.25
November 03, 1997

1.00
0.75
0.75
0.75
1.00
1.00
0.75
0.75
0.75
1.00
1.00
0.75
0.75
0.75
1.00
1.00
0.75
0.75
0.75
1.00
1.00
0.75
0.75
0.75
1.00
1.00
0.75
0.75
0.75
1.00
1.00
0.75
0.75
0.75
1.00
1.00
0.75
0.75
0.75
1.00
1.00
0.75
0.75
0.75
1.00
1.00
0.75
0.75
0.75
1.00
1.00
0.75
0.75
0.75
1.00
1.2500
0.9375
1.0000
1.0000
1.2500
1.2500
0.9375
1.0000
1.0000
1.2500
1.2500
0.9375
1.0000
1.0000
1.2500
1.2500
0.9375
1.0000
1.0000
1.2500
1.2500
0.9375
1.0000
1.0000
1.2500
1.2500
0.9375
1.0000
1.0000
1.2500
1.2500
0.9375
1.0000
1.0000
1.2500
1.2500
0.9375
1.0000
1.0000
1.2500
1.2500
0.9375
1.0000
1.0000
1.2500
1.2500
0.9375
1.0000
1.0000
1.2500
1.2500
0.9375
1.0000
1.0000
1.2500
Triang.
Triang.
Square
Triang.
Square
Triang.
Triang.
Square
Triang.
Square
Triang.
Triang.
Square
Triang.
Square
Triang.
Triang.
Square
Triang.
Square
Triang.
Triang.
Square
Triang.
Square
Triang.
Triang.
Square
Triang.
Square
Triang.
Triang.
Square
Triang.
Square
Triang.
Triang.
Square
Triang.
Square
Triang.
Triang.
Square
Triang.
Square
Triang.
Triang.
Square
Triang.
Square
Triang.
Triang.
Square
Triang.
Square
Page 148 of 156
172
361
276
318
170
199
162
342
264
308
168
188
152
314
246
279
157
170
148
306
240
269
150
164
Art42.00
Montemayor
40.25
44.00
42.25
48.00
46.00
52.00
50.00
56.00
54.00
60.00
58.00
November 03, 1997

1.00
0.75
0.75
0.75
1.00
1.00
0.75
0.75
0.75
1.00
1.00
0.75
0.75
0.75
1.00
1.00
0.75
0.75
0.75
1.00
1.00
0.75
0.75
0.75
1.00
1.00
1.2500
0.9375
1.0000
1.0000
1.2500
1.2500
0.9375
1.0000
1.0000
1.2500
1.2500
0.9375
1.0000
1.0000
1.2500
1.2500
0.9375
1.0000
1.0000
1.2500
1.2500
0.9375
1.0000
1.0000
1.2500
1.2500
Triang.
Triang.
Square
Triang.
Square
Triang.
Triang.
Square
Triang.
Square
Triang.
Triang.
Square
Triang.
Square
Triang.
Triang.
Square
Triang.
Square
Triang.
Triang.
Square
Triang.
Square
Triang.
Page 149 of 156
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
Page 150 of 156
Art Montemayor
November 03, 1997
128
290
234
260
148
160
Page 151 of 156
Art Montemayor
November 03, 1997
Page 152 of 156
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
Art Montemayor
Source:
August 21, 2004

Rev: 0
Heat Exchanger Temperatures
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, Tm
w, cp, t2
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 =
cp = Constant or average specific heat on the tube side, Btu/lb or kcal/kg =
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 =
or m =
=
=
Tm = Log mean temperature difference, oF or oC=
= Subscript denoting inlet conditions
1
= Subscript denoting outlet conditions
2
A = Total exchanger heat transfer area, ft
T1 = Shell-side fluid temperature, oF or oC
t1 = Tube-side fluid temperature, oF or oC
1.0000
125
250
85
From the derived equations, let:
C=e
0.5000
300.0
UA
W, Cp, T1
Z =
B =
( 1Z B1 )
50,000
45,000
C = 0.9200444
Therefore,
T2
= B t1 (1 - C) - T1(B - Z)/(Z - BC) =
Page 154 of 156
152
F or oC
Worksheet: Ht Exchanger Temperatures
Art Montemayor
optimum condtions
d-error also involves
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)
Let:
B = (w) (cp)
Z = (W) (Cp)
can result in
be able to calculate
, specific heats,
follows and shown
August 21, 2004

Rev: 0
t 2=
Z
( T 1 T 2 ) +t 1
B
( )
Combining both above equations,
The heat transferred is also=UA T m=UA
Z ( T 1 T 2 ) =UA
[
[
T 1
ln
ln
ln
T 1 1
()
Z
Z
+T 2
t
B
B 1
()
( T 2t 1)
( )
Z
Z
+T 2
t
B
B 1
( T 2t 1 )
()
T 1 T 1
= UA
] [
T 1
=UA
Page 155 of 156
Z
Z
+T 2
+t T +t
B
B 1 2 1
() ()
Z ( T 1 T 2 )
] [ ]
Z
Z
+ T2
t 1
B
B
= UA
( T 2 t 1 )
( ) ()
T 1 1
] [
()
] [
Z
Z
T 1 T 2 ) t 1
T 1
(
( T T ) +t ( T 2 t 1 )
B
B 1 2 1
= UA
T
t
Z ( T 1 T 2 )
( 2 1)
T 1 T 1
ln
( T 1 t 2 )( T 2 t 1 )
( T 1t2 )
ln
( T 2t1 )
( T 1 t 2 ) ( T 2 t 1 )
( T 1 t 2 )
ln
( T 2t1 )
Z
( T T ) T 2
B 1 2
()
Z ( T 1 T 2 )
( ZB ) =UA
]
]
( 1Z B1 )
Z
()
(T 1T 2) B (T 1T
=UA
Z ( T 1T 2 )
Art Montemayor
) ( T 2 t 1 )
T 1 t 2 )
T 2t 1 )
1 t 2
T2
Z
+t T +t
B 1 2 1
()
T 1 T 2 )
= UA
August 21, 2004

Rev: 0
T 2 ) +t 1 ( T 2 t 1 )
1 T 2
]
]
( 1Z B1 )
Z
()
( T 1T 2) B ( T 1T 2)
Z ( T 1T 2 )
Page 156 of 156

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Dale Gulley's Heat Exchanger Tips Workbook

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A Workbook Collection of Dale Gulley's Heat Exchanger Tips

ratitude for his

6/28/2011 - Added three new tips from Gulleyassociates.com with permission.

Estimate - critical heat flux for propane chillers.

Estimate - optimum flow velocity for gas inside tubes.

Longitudinal baffle heat conduction cures.

Kettle Reboilers - Supports or Baffles

Fouling factors for water(hr-ft2-F/Btu)

Vertical Thermosyphon-Calculate Pressure Drop at The Outlet Nozzle

Estimate - Hydrocarbon Gas Heat Transfer Coefficient in Shell Side

Best Design Feature to Prevent Bundle Vibration

Viscous Flow - Use More Pressure Drop Than Usual

lloy Tubes and Tubesheets

at The Outlet Nozzle

icient in Shell Side

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

Vertical Thermosyphon-Design for a Smaller Liquid Preheat Zone

Avoid small baffle cuts in S & T condensers

Sulfur condenser - design within tube velocity limits

Deciding on what fin spacing to use

Cooling water flowing inside 304SS U-tubes

Allowing for fouling in pressure drop calculations

Tube Bundle Vibration:

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

Allocation of streams in shell & tube

What is the minimum velocity inside tubing for slurries?

Box header design - limit of process temperature change

Connecting Bundles of Existing Coolers for a new Service

Increase Capacity of Existing Air Cooler with Fan Drive Changes

Suggestions to Reduce Fan Drive Noise

Maximum Motor HP for a Fan

Temperature Limit of Wrap-On Fins for Aircoolers

temperature of tube wall

air outlet temperature =

temperature inside tube =

thermal resistance of air =

clean overall heat transfer coefficient =

Optimun Number of Tube Rows

Hydrocarbon U Estimate (Air-Coolers)

Overall Heat Transfer Coefficient

Where: viscosity is less than 3 cP

When do Bare Tubes become More Efficient Than Fin Tubes?

When To Limit Tube Passes in an Aircooler

Air Cooler Using Wind

Mist Flow Boiling Inside Tubes

Kettle Reboiler - Location of Vapor Outlet Nozzles

Kettle Reboiler - Problem Shell Nozzle Arrangement

Kettle Reboiler - Location of Vapor Outlet Nozzles

Sizing the Vapor Space in Kettle Reboilers

Kettle Reboiler - Effect of Undersized Kettle Diameter

Estimate - Pool Boiling Heat Transfer Coefficient for Hydrocarbons

(tube wall temperature - liquid temperature

Large Boiling Temperature Differences

Lower Limit of Boiling Film Temperature Difference

Choking a Vertical Thermosyphon

Where X = area ratio=

Minimum Recirculation Rate in Thermosyphon Reboilers

Vertical Thermosyphon - Check for Liquid Preheat Zone

Vertical Thermosyphon Recirculation Rate

Estimate - Critical Heat Flux For Propane Chillers

12844 Btu/h ft2

Kettle Reboilers - Support or Baffles?

Vertical Thermosyphon-Calculate Pressure Drop at The Outlet Nozzle