1

Table of Contents
Simulate a Water Cooler 1-1
Workshop 1-2
Simulate a Condenser 2-1
Workshop 2-2
Design a Steam Condenser 3-1
Workshop 3-2
Design a Vapour Cooler 4-1
Workshop 4-2

Module 1 - 1

Module 1 - Simulate a
Water Cooler

Simulate a Water Cooler

Module 1 - 1

Module 1 - 2

Workshop

Workshop
The purpose of this module is to determine the tubeside outlet
temperature for a forced-draught air-cooled heat exchanger by
simulating a water cooler.

Learning Objectives
Once you have completed this section, you will be able to:

Module 1 - 2

Input data using the card system

Be aware of the API Input system
Enter physical properties by the in-built NEL 40 databank
Save datasets

Simulate a Water Cooler

Workshop

Module 1 - 3

Process Overview
Details of the process data and some basic geometric data are shown in
the following tables:

Geometric Specifications
Item

Value

Units

Inlet Nozzles

Outlet Nozzles

Inside diameter, Inlet Nozzles

101.2

mm

Inside diameter, Outlet Nozzles

101.2

mm

Tubes

162

Rows

Passes

Effective tube length

6020

mm

Transverse Pitch

58.4

mm

Layout angle

30

deg

Tube inside diameter

21.32

mm

Tube outside diameter

25.4

mm

Fin root diameter

25.4

mm

Fin frequency

433

/m

Fin tip diameter

57.16

mm

Mean fin thickness

0.457

mm

Bundle Details
Row and Pass arrangement:

Simulate a Water Cooler

Row 4, Pass 1
Row 3, Pass 2
Row 2, Pass 3
Row 1, Pass 4

Module 1 - 3

Module 1 - 4

Workshop

Process Data
Item

Tubeside

X-side

Units

Total mass flow

30500

177500

kg/h

Inlet temperature

92

37

Estimated outlet
temperature

56

Inlet Pressure

1.2

bar

Pressure drop

0.18

bar

Fouling factor

.00002

m2 K/W

Building the Simulation

1.
2.
The New option will clear any
existing data.

Set the calculation required in the Simulation mode for the

tubeside outlet temperature.
From the menu bar, select Input-Simulation-Tubeside Outlet
Temperature. The type of calculation being performed is
indicated in the top right hand corner of the process diagram,
which will also summarize the process conditions for the tube
and air side as the simulation is built.

Next, we can begin entering the geometric data for the exchanger.

Module 1 - 4

3.

Select Input-Geometric Data from the main menu bar. Before

entering data however, it is necessary to establish the units that
the data will be entered in. On the lower right hand side, there is
a box marked Units System, which has a scroll down arrow. From
the drop down menu, select SI.

4.

Enter the geometric data from the table given at the beginning of
this module. If information is not supplied, the default values of
the program may be assumed.

Simulate a Water Cooler

Workshop

5.

Module 1 - 5

On the Bundle Specification tab, enter the details of the number

of tubes andpasses for the bundle. You will notice that 162 tubes
are specified with 4 passes, implying that each row will not have
the same number of tubes. In this example you may assume that
there will be an extra tube in every odd row. Select this entry from
the Type of Bundle drop down menu.

Enter the remaining data concerning the number of tubes, rows and
passes, ensuring that the symmetrical bundle is unticked. Clicking on
the OK button will give a pictorial representation of the pass layout.
Each pass is indicated by a different colour.
6.

In the Pass box, click Pass number 4. Move the mouse so it is

positioned over the first tube in the bottom row, and click. Hold,
move to the last tube in the row and release the mouse.

The entire row will now change colour and be designated as

Row 1 = Pass 4.
7.

Repeat this for Pass 3-Row 3, and Pass 2-Pass 1. Click Accept. (It
is indicated that the X-side flow direction is upwards, so the
exchanger has been specified as counter-current).

Enter the remaining geometric data and close the view when complete.
8.

Simulate a Water Cooler

Enter the process conditions for the tubeside (ensuring that you
have the correct unit system).

Module 1 - 5

Module 1 - 6

Workshop

For the tubeside fouling, ACOL has many different options to consider
such as a fouling resistance, thermal conductivity and a thickness layer.
In this example select, Constant Rf in item 240.2 from the Fouling
Option, and enter the fouling resistance as shown.

Accept the process data for the tubeside and close the window.
9.

Enter the process data for the X-side.

ACOL will automatically pick up the physical property data for air on
the X-side. However, we need to enter physical property data on the
tubeside.
10.

Module 1 - 6

From the menu bar, select Input-Physical Property DataTubeside. As we are calling water property information from the
NEL 40 databank, ensure that the Data Input Method is set to
Calculate From Components.

Simulate a Water Cooler

Workshop

11.

Simulate a Water Cooler

Module 1 - 7

Set the Number of Components to 1. Also, as at the specified

temperatures and pressures, water will be a single-phase liquid.
Enter this in the Stream Phase box.

Module 1 - 7

Module 1 - 8

Workshop

12.

On the left-hand side, click the Component #1 Details. Set the

Data Source to HTFS Databank (NEL40). On the NEL40
Databank drop down menu, select Water as the fluid. Close the
window.

Before running it is important to save the dataset. This is achieved

from the menu bar by selecting File-Save As. Now you can run by
clicking on the Run icon or selecting Run-Calculate All from the menu
bar.

Save your case!

The Status bar in the Run ACOL box should indicate ACOL 5
Successfully Completed. If there is a message indicating a fatal error,
then check either the Lineprinter or Error log, which may be found by
selecting Output on the menu bar. Edit the dataset accordingly, save
and then re-run.

The same data may be entered by the API Input form, which is found
under Input in the main menu bar. Items indicated by blue are input
items used by ACOL, which you can revise.

Module 1 - 8

Simulate a Water Cooler

Workshop

Module 1 - 9

Results
View the outputs by selecting Output from the menu bar.

The Summary-Process box contains the flowrates, temperatures and

pressures for the tube and X-side. You should notice that the tubeside
exit temperature is 54C (129F), whereas a value of 56C (133F) was
expected. Thus the exchanger can perform a greater duty than
originally expected.

The Summary-Performance box contains information on the heat

load, overall heat transfer coefficients and the mean effective
temperature difference. Also, a duty ratio is indicated, where a value of
1.06 indicates that the exchanger can achieve a duty of 6% greater than
that originally specified.

Simulate a Water Cooler

Module 1 - 9

Module 1 - 10

Module 1 - 10

Workshop

Simulate a Water Cooler

Module 2 - 1

Module 2 - Simulate a
Condenser

Simulate a Condenser

Module 2 - 1

Module 2 - 2

Workshop

Workshop
The purpose of this module is to simulate a condenser to determine the
tubeside outlet temperature for a forced-draught air-cooled heat
exchanger that is operating at an altitude of 330 ft..

Learning Objectives
Once you have completed this section you will be able to:

Enter physical properties using the property table

Module 2 - 2

Simulate a Condenser

Workshop

Module 2 - 3

Process Overview
Details of the process data and some basic geometric data are shown in
the following tables:

Geometric specifications

Simulate a Condenser

Item

Value

Units

No. of bays / unit

Bundles / bay

No. fans / bay

Type of header

Plug

Inlet nozzles

Outlet nozzles

Inside diameter of inlet nozzles

Inch

Inside diameter of outlet nozzles

Inch

Effective tube length

351

Inch

Total tube length

354

Inch

Transverse pitch

2.44

Inch

Longitudinal pitch

2.11

Inch

Tube inside diameter

0.766

Inch

Tube outside diameter

0.984

Inch

Fin type

L fin

Fin root diameter

1.02

Inch

Fin frequency

11

/Inch

Fin tip diameter

2.25

Inch

Mean fin thickness

0.0157

Inch

Module 2 - 3

Module 2 - 4

Workshop

Bundle details

Tubes: 408
Rows: 6
Passes: 3
Rows Pass: 2

Process data

Module 2 - 4

Item

Tubeside

X-side

Units

Total mass flow

356420

5672465

lb/h

Inlet temperature

155

91.4

Est. outlet temperature

122

Inlet pressure

23.35

psia

Pressure drop

psi

Fouling factor

.00156

h ft2 F/Btu

Simulate a Condenser

Workshop

Module 2 - 5

Property data
Property

Simulate a Condenser

Value

Unit

Molecular weight

80.1

Liquid temperature

155

122

Liquid density

38.39

40

lb/ft3

Liquid specific heat

0.554

0.554

Btu/lb F

Liquid viscosity

0.215

0.2

cP

Liquid conductivity

0.0719

0.0719

Btu/h ft F

Enthalpy/Quality Temp

155

122

Btu/h

Heat load

5.4366x10

Quality

Vapour temperature

155

122

Vapour density

0.346

0.32

lb/ft3

Vapour specific heat

0.455

0.455

Btu/lb F

Vapour viscosity

0.008

0.006

cP

Vapour conductivity

0.0114

0.0114

Btu/h ft F

Module 2 - 5

Module 2 - 6

Workshop

Building the Simulation

Module 2 - 6

1.

Set the calculation required to Simulation mode for the tubeside

outlet temperature. Select Input-Simulation -Tubeside Outlet
Temperature. The type of calculation being performed is
indicated in the top right hand corner of the process diagram,
which also will summarize the process conditions for the tube
and air side as the simulation is built.

2.

From the table given at the beginning of this module, enter the
geometric data in British units. If information is not supplied,
default values used by the program may be assumed.

3.

On the Bundle Specification tab, enter the details of the number

of tubes and passes for the bundle as shown:

4.

Enter the remaining geometric data and the process conditions

for the tubeside (ensuring that you have the correct unit system).
For the tubeside fouling, select Constant Rf in item 240.2 and
enter the fouling resistance.

5.

Enter the process data for the X-side.

6.

Enter the physical property data on the tubeside. The Stream

Phase is two-phase.

Simulate a Condenser

Workshop

Module 2 - 7

As we have been supplied with heat load information for the heat
release curve, the Flowrate for the stream must be set to ensure the
property table will accept the heat load information. Enter this data as
shown:

Simulate a Condenser

Module 2 - 7

Module 2 - 8

Workshop

Enter the property information for the liquid/vapour phases and the
heat release curve as shown:

Save your dataset and run.

Save your case!

Module 2 - 8

Simulate a Condenser

Workshop

Module 2 - 9

Exercise 1 - Bundle Set-up and Heat Load

Distribution
Part of an input file for a three-pass condenser is given in file EX01.A5I.
Complete the lines, which specify the bundle arrangement if there are
280 tubes and 7 rows. Pass 3 occupies the first row crossed by the air,
Pass 2 occupies rows 2 to 4 and Pass 1 rows 5 to 7.
Simulate the performance of the unit. Check the distribution of heat
load in desuperheating, condensing and subcooling sections.

How can this design be improved? __________

Exercise 2 - Tubeside Fouling

1.

Phase

Fouling resistance, h m2 C/kcal

(based on tube I/D)

Liquid

0.00023

Two-phase

0.00035

Vapour

0.00047

2.

Simulate a Condenser

Determine the effect of fouling on the performance of the above

unit using the following data:

Test the affect of entering a constant fouling resistance of 0.00035

h m2 C/kcal.

Module 2 - 9

Module 2 - 10

Workshop

Exercise 3 - Fan Configuration and Tube

Geometry
Run the data in file EX03.A5I and compare:

Forced and induced draught configuration

Plain tubes and G-finned tubes.

What is the advantage of using finned tubes in this case?

__________

Exercise 4 - X-side Flowrate

Run the data in EX04.A5I and check the predicted tubeside outlet
temperature.
Determine the air flowrate required to produce the specified tubeside
outlet temperature of 40 C.

Exercise 5 - Natural Convection and X-side

Fouling
1.

Determine the air flowrate that is required to perform the duty

using the exchanger given in EX05.A5I at a summer design
ambient temperature of 23C. Assume that there is a constant
tubeside fouling resistance of 0.00034 m2K/W.

This exchanger experiences total fan failure and the air flowrate
produced by natural convection is 1000 kg/hr.

Module 2 - 10

2.

Determine the process flow rate that could be handled to give the
same outlet conditions.

3.

Examine the performance of this unit (i.e. with full air flow) if the
tubes are exposed to a dirty air stream with a constant dirt film
thickness of 1.0 mm. Note the change in X-side pressure drop,
and assume the thermal conductivity of the foulant to be 1 W/m
K.

Simulate a Condenser

Module 3 - 1

Module 3 - Design a
Steam Condenser

Design a Steam Condenser

Module 3 - 1

Module 3 - 2

Workshop

Workshop
The purpose of this module is to design a steam condenser with 4 tube
rows.

Learning Objectives
Once you have completed this section you will be able to:

Use the design option

Module 3 - 2

Design a Steam Condenser

Workshop

Module 3 - 3

Process Overview
The task is to produce a design of a steam condenser with 4 tube rows
which will have an X-side pressure drop of 120 Pa (~ 0.5 in H2O). The
tube and fin details are supplied below.

The total tubeside flowrate is 30 000 kg/hr , the inlet pressure and
temperature are 1.0 bar and 120C respectively, with an outlet
temperature of 50C. The steam will have 5% air present. The ambient
air inlet temperature is 20C.

Select a design with a maximum tube length of 20 meters and a

maximum of 4 passes. The maximum allowable pressure drop through
the tubes (excluding nozzles) is 0.2 bar and the inlet velocity will be
between 30 and 60 m/s.

Tube and Fin details

Design a Steam Condenser

Item

Value

Units

Transverse pitch

60.3

mm

Tube layout angle (TEMA)

30

deg

Tube inside diameter

19.9

mm

Tube outside diameter

25.4

mm

Tube material

Mild Steel

Type of fin

Extruded

Fin root diameter

26.7

mm

Fin frequency

440

/m

Fin tip diameter

57.2

mm

Mean fin thickness

.28

mm

Fin material

Aluminium

Module 3 - 3

Module 3 - 4

Workshop

Building the Simulation

Module 3 - 4

1.
2.

Select Input-Design from the menu bar.

In the Bundle Design Parameter tab, enter the maximum and
minimum tube length, and the number of passes as shown:

3.

Next, enter the physical property data for the tubeside. Enter the
Data Input Method to Calculate From Components. Set the
number of components to 2.

4.

Select Component #1 details, and choose water (two-phase)

from the NEL40 databank.

5.

Choose Component #2 details, and select air. However, set the

component phase to a single-phase vapour only (Note: air is a
non-condensable).

6.

Enter the process data for the tubeside, where for the
Compositions 1-6, component 1 flow fraction is set at 95%
(water) and component 2 flow fraction set at 5% (air).

7.

Enter the process data for the X-side. In the Design Performance
Parameters tab, enter the X-side bundle maximum allowable
pressure drop for the tubeside, and the maximum and minimum
tubeside velocities as shown:

Design a Steam Condenser

Workshop

Module 3 - 5

Save your dataset, but continue with the following steps before
running.

Save your case!

ACOL will perform some initial calculations before displaying the
Design Data Input screen, where the following values may be entered:

Design a Steam Condenser

Module 3 - 5

Module 3 - 6

Workshop

A graphical representation of feasible designs will appear. Here, you

can click anywhere within the feasible design area. Some of the basic
design information will appear in the output portion of the screen on
the left-hand side.

To optimise the design you may alter the number of passes (between
1-4). When a satisfactory design has been achieved, by clicking on the
Simulation button the geometric data will be transferred to a
Simulation file type.

Save your case!

Module 3 - 6

Design a Steam Condenser

Module 4 - 1

Module 4 - Design a
Vapour Cooler

Design a Vapour Cooler

Module 4 - 1

Module 4 - 2

Workshop

Workshop
The purpose of this module is to design a vapour cooler with 4 tube
rows.

Learning Objectives
Once you have completed this section you will be able to:

Use the property table

Module 4 - 2

Design a Vapour Cooler

Workshop

Module 4 - 3

Process Overview
The task is to produce a design for a vapour cooler (operating at an
altitude of 55 ft) with 4 tube rows. Each will have an X-side pressure
drop of 0.25 in H2O. The tube and fin details are supplied below.

The total tubeside flowrate is 750 000 lb/hr, the inlet pressure and
temperature is 1000 psia and 244F respectively, and the outlet
temperature is 130F. The ambient air inlet temperature is 115F.

Select a design with a maximum tube length of 480 inches and a

maximum of 4 passes. The maximum allowable pressure drop through
the tubes (excluding nozzles) is 10 psi and the inlet velocity will be
between 10 and 100 ft/s. The tubeside fouling resistance is
0.002 h ft2 F/Btu.

Tube and Fin details

Design a Vapour Cooler

Item

Value

Units

Transverse pitch

2.5

Inch

Tube layout angle (TEMA)

30

deg

Tube inside diameter

0.834

Inch

Tube outside diameter

Inch

Tube material

Mild Steel

Type of fin

G fin

Fin root diameter

Inch

Fin frequency

11

/Inch

Fin tip diameter

2.25

Inch

Mean fin thickness

0.018

Inch

Fin material

Aluminium

Module 4 - 3

Module 4 - 4

Workshop

Tubeside Vapour property data

Property

Value

Units

Temperature

130

244

Density

4.9

3.5

lb/ft3

Specific heat
capacity

0.665

0.622

Btu/lb F

Viscosity

0.014

0.016

cP

Thermal
Conductivity

0.022

0.026

Btu/h ft F

Building the Simulation

Module 4 - 4

1.

Set the calculation required to Design.

2.

On the Bundle Design Parameter tab, enter the maximum and

minimum tube length and number of passes.

3.

Enter the Data Input Method to Enter Stream Data. Ensure that
the Data Source is set to Input Directly, and that the Stream
Phase is set to Single Phase Vapour Only.

Design a Vapour Cooler

Workshop

Design a Vapour Cooler

Module 4 - 5

4.

Click onto the Property Table button and enter the data for the
single-phase vapour, as shown:

5.

Enter the process data for the tubeside.

6.

Enter the process data for the X-side. On the Design

Performance Parameters tab, enter the X-side bundle maximum
allowable pressure drop for the tubeside. Also, enter the
maximum and minimum tubeside velocity.

Module 4 - 5

Module 4 - 6

Workshop

ACOL will perform some initial calculations before displaying the

Design Data Input screen, where the following values may be entered:

Save and run your dataset.

Save your case!

Module 4 - 6

Design a Vapour Cooler