Heat Exchanger Thermal Design Hetran 11.

1 Page 1
File: PH-2.BJT Date: 7/22/2016 Time: 6:56:54 AM
Thermal Details - General

Shell Side Tube Side

Gases (in/out) kg/h 50
Liquids (in/out) kg/h 50 951 951
Temperature (in/out) C 119.38 119.38 25 67
Dew point or bubble point C 119.38 119.38

Film coefficient kcal/(h*m2*C) 5642.7 1071.6

Fouling resistance m2*h*C/kcal 0.0001 0.0002
Velocity m/s 1.44 0.64
Pressure drop (allow./calc.) kgf/cm2 0.1 0.006 0.4 0.03

Total heat exchanged kcal/h 26224 Type BEM vert 1 ser 1 par
Overall coef. - dirty kcal/(h*m2*C) 523.7 Shell size 154 1500 mm
Effective surface area m2 1 Tube No-OD 12 19.05 mm
MTD corrected C 70.72 Baffles single seg 25 % vert
MTD correction factor 1 Tube passes 4 quad

Thermal Details - Thermal Resistances

Clean Spec. foul Max. foul

Area reqd. m2 0.6 0.7 1

Excess surface % 80.56 46.36

Overall coefficient kcal/(h*m2*C) 646.1 523.7 357.9

Overall resistance m2*h*C/kcal 0.00155 0.00191 0.0028

Shell side fouling m2*h*C/kcal 0.0 0.0001 0.00035

Tube side fouling (at tube ID) 0.0 0.0002 0.00071

Distribution of overall resistance

Shell side film % 11.45 9.28 6.34
Shell side fouling % 0.0 5.36 12.63
Tube wall 0.00019 % 12.22 9.91 6.77
Tube side fouling % 0.0 13.58 31.98
Tube side film % 76.33 61.87 42.27
Heat Exchanger Thermal Design Hetran 11.1 Page 2
File: PH-2.BJT Date: 7/22/2016 Time: 6:56:55 AM
Thermal Details - Coefficients

Shell Side Tube Side

Film coefficients kcal/(h*m2*C)
As calculated by program 7053.3 1339.4
As specified by user in input
User specified multiplier 0.8 0.8
As used in design 5642.7 1071.6
Desuperheating coefficient
Condensing coefficient 5642.7
Vapor sensible coefficient
Liquid sensible coefficient 1071.6
Boiling coefficient
Liquid cooling coefficient

Reynolds number 141.33 16155.08

Fin efficiency factor 1
Mean metal temperature C 119.38 105.11

Thermal Details - MTD and Flux

Mean temperature difference C Flux kcal/(h*m2)

Corrected MTD used in design 70.72 Actual flux 25308

LMTD Boiling fluid

MTD correction factor
Long. baffle efficiency factor
Calculated corrected MTD
User specified corrected MTD
Flow direction
1 Nucleate maximum flux
Program maximum flux
70.72 Specified maximum flux
Controlling maximum flux
Heat Exchanger Thermal Design Hetran 11.1 Page 3
File: PH-2.BJT Date: 7/22/2016 Time: 6:56:55 AM
Thermal Details - Pressure Drop

Shell Side Tube Side

Pressure Drop kgf/cm2

Allowable 0.1 0.4
Calculated, clean 0.006 0.03
Calculated, dirty 0.006 0.031
User specified bundle multiplier 1.2 1.2

Velocity and pressure drop distribution m/s %dp m/s %dp

Inlet nozzle 25.34 91.82 0.66 2.88

Entering bundle 0.73 1.04 0.63 12.48
Crossflow 1.44 0.49
Through baffle windows 4.78 6.61
Through tubes 0.64 68.46
Exiting bundle 0 0.66 13.14
Outlet nozzle 0.03 0.04 0.7 3.03

Thermal Details - Shell Side Stream Analysis

Shell Side Stream Analysis Flow fraction Diametric clearances

% mm

Crossflow 58.03
Clearance: Baffle hole - tube od 4.37 0.79
Clearance: Shell id - baffle od 11.98 3.18
Clearance: Shell id - bundle otl 25.62 9.52

Rho*V2 analysis Rho*V2 TEMA limit

kg/(m*s2) kg/(m*s2)

Inlet nozzle 694 2232

Shell entrance 10 5953
Bundle entrance 1 5953
Bundle exit 0 5953
Shell exit 0 5953
 Heat Exchanger Specification Sheet
1 Company: M/s.Sun Pharma Ltd
2 Location: Mumbai
3 Service of Unit: Preheating Our Reference: Devayani
4 Item No.: HE-102 Your Reference:Mr. Abhijeet
5 Date: 27.06.14 Rev No.: 00 Job No.:
6 Size 154 -- 1500 mm Type BEM vert Connected in 1 parallel 1 series
7 Surf/unit(eff.) 1 m2 Shells/unit 1 Surf/shell (eff.) 1 m2
8 PERFORMANCE OF ONE UNIT
9 Fluid allocation Shell Side Tube Side
10 Fluid name STEAM FEED
11 Fluid quantity, Total kg/h 50 951
12 Vapor (In/Out) kg/h 50
13 Liquid kg/h 50 951 951
14 Noncondensable kg/h
15
16 Temperature (In/Out) C 119.38 119.38 25 67
17 Dew / Bubble point C 119.38 119.38
18 Density kg/m3 1.08 943.3 787.18 747.66
19 Viscosity cp 0.013 0.243 0.59 0.367
20 Molecular wt, Vap
21 Molecular wt, NC
22 Specific heat kcal/(kg*C) 0.5181 1.0052 0.6028 0.718
23 Thermal conductivity kcal/(h*m*C) 0.023 0.591 0.181 0.168
24 Latent heat kcal/kg 524.74 524.74
25 Pressure kgf/cm2 2 1
26 Velocity m/s 1.44 0.64
27 Pressure drop, allow./calc. kgf/cm2 0.1 0.006 0.4 0.03
28 Fouling resist. (min) m2*h*C/kcal 0.0001 0.0002
29 Heat exchanged 26224 kcal/h MTD corrected 70.72 C
30 Transfer rate, Service 357.9 Dirty 523.7 Clean 646.1 kcal/(h*m2*C)
31 CONSTRUCTION OF ONE SHELL Sketch
32 Shell Side Tube Side
33 Design/Test pressure kgf/cm2 5.273 Code 5.273 -1.034 Code
34 Design temperature C 154.44 104.44
35 Number passes per shell 1 4
36 Corrosion allowance mm 1.59
37 Connections In 25.4 150 ANSI 25.4 150 ANSI
38 Size/rating Out 25.4 150 ANSI 25.4 150 ANSI
39 mm Intermediate 150 ANSI 150 ANSI
40 Tube No. 12 OD 19.05 Tks-avg 2 mm Length 1500 mm Pitch 25 mm
41 Tube type Plain Material SS316 Tube pattern 30
42 Shell CS ID OD 168.28 mm Shell cover
43 Channel or bonnet SS316 Channel cover
44 Tubesheet-stationary SS316 Tubesheet-floating
45 Floating head cover Impingement protection Circular plate on bundle
46 Baffle-crossing CS Type single seg Cut(%d) 25 vert Spacing: c/c 199.14 mm
47 Baffle-long Seal type Inlet 223.58 mm
48 Supports-tube U-bend Type
49 Bypass seal Tube-tubesheet joint groove/expand
50 Expansion joint Type
51 RhoV2-Inlet nozzle 694 Bundle entrance 1 Bundle exit 0 kg/(m*s2)
52 Gaskets - Shell side Tube Side
53 Floating head
54 Code requirements ASME Code Sec VIII Div 1 TEMA class B
55 Weight/Shell 152.1 Filled with water 179.8 Bundle 33.3 kg
56 Remarks
57
58
Heat Exchanger Thermal Design Hetran 11.1 Page 5
File: PH-2.BJT Date: 7/22/2016 Time: 6:56:55 AM
Calculation Details - Shell Side - Liquid Properties
Temperature Density Specific Thermal Viscosity Surface Latent
bulk wall heat conductivity bulk wall tension heat
C C kg/m3 kcal/(kg*C) kcal/(h*m*C) cp cp dynes/cm kcal/kg
119.38 110.65 943.3 1.0052 0.591 0.243 0.267 54.8 524.74
119.38 110.65 943.3 1.0052 0.591 0.243 0.267 54.8 524.74
119.38 109.66 943.3 1.0052 0.591 0.243 0.27 54.8 524.74
119.38 109.03 943.3 1.0052 0.591 0.243 0.272 54.8 524.74
119.38 108.59 943.3 1.0052 0.591 0.243 0.273 54.8 524.74
119.38 108.25 943.3 1.0052 0.591 0.243 0.274 54.8 524.74
119.38 107.99 943.3 1.0052 0.591 0.243 0.275 54.8 524.74
119.38 107.79 943.3 1.0052 0.591 0.243 0.276 54.8 524.74
119.38 107.63 943.3 1.0052 0.591 0.243 0.276 54.8 524.74
119.38 107.56 943.3 1.0052 0.591 0.243 0.276 54.8 524.74

Calculation Details - Shell Side - Vapor Properties

Temp. Density Specific Thermal Viscosity
bulk wall heat conductivity bulk wall
C C kg/m3 kcal/(kg*C) kcal/(h*m*C) cp cp
119.38 110.65 1.08 0.5181 0.023 0.013 0.013
119.38 110.65 1.08 0.5181 0.023 0.013 0.013
119.38 109.66 1.08 0.5181 0.023 0.013 0.013
119.38 109.03 1.08 0.5181 0.023 0.013 0.013
119.38 108.59 1.08 0.5181 0.023 0.013 0.013
119.38 108.25 1.08 0.5181 0.023 0.013 0.013
119.38 107.99 1.08 0.5181 0.023 0.013 0.013
119.38 107.79 1.08 0.5181 0.023 0.013 0.013
119.38 107.63 1.08 0.5181 0.023 0.013 0.013
119.38 107.56 1.08 0.5181 0.023 0.013 0.013

Calculation Details - Shell Side - Heat Load

Temp. Flowrate Mass Total
Vapor Liquid transfer load
C kg/h kg/h kcal/h kcal/h
119.38 50
119.38 50
119.38 44 6 2914 2914
119.38 39 11 5828 5828
119.38 33 17 8741 8741
119.38 28 22 11655 11655
119.38 22 28 14569 14569
119.38 17 33 17483 17483
119.38 11 39 20396 20396
119.38 6 44 23310 23310
119.38 50 26224 26224
119.38 50 26224 26224
Heat Exchanger Thermal Design Hetran 11.1 Page 6
File: PH-2.BJT Date: 7/22/2016 Time: 6:56:56 AM
Calculation Details - Shell Side - Performance
Vapor Vapor weight Heat load Overall Area reqd. Temperature Pressure
temperature coefficient difference drop
C % kcal/(h*m2*C) % C %
Inlet 119.38 100 92.86
desup dry 119.38 100
desup wet 119.38 100
119.38 88.89 11.11 540.1 13.98 54.5 1.5
119.38 77.78 11.11 531.7 13.15 58.85 1.34
119.38 66.67 11.11 526.4 12.35 63.29 1.34
119.38 55.56 11.11 522.6 11.61 67.82 1.03
119.38 44.44 11.11 519.8 10.93 72.44 0.71
119.38 33.33 11.11 517.6 10.31 77.14 0.48
119.38 22.22 11.11 515.9 9.73 81.95 0.3
119.38 11.11 11.11 514.5 9.21 86.84 0.17
119.38 11.11 514 8.72 91.83 0.06
liquid cooling 119.38

excess area 0.16

Outlet 119.38 0.04

Calculation Details - Shell Side - Coefficients

Temp. Vapor Condensing Pure Condensing Coefficient Dry gas Film
bulk wt. % regime shear gravity resulting coef.
C kcal/(h*m2*C) kcal/(h*m2*C) kcal/(h*m2*C) kcal/(h*m2*C) kcal/(h*m2*C)
119.38 95.22 Gravity 3329.9 10454.1 10454.1 48.6 8363.3
119.38 84.11 Gravity 2935.4 8407.3 8407.3 45.2 6725.8
119.38 73 Gravity 2614.1 7460.5 7460.5 41.7 5968.4
119.38 61.89 Gravity 2311.1 6896.9 6896.9 37.9 5517.5
119.38 50.78 Gravity 2006.8 6521.6 6521.6 33.8 5217.3
119.38 39.67 Gravity 1687.7 6255.9 6255.9 29.5 5004.7
119.38 28.56 Gravity 1337.1 6060.2 6060.2 24.7 4848.2
119.38 17.44 Gravity 921 5912.7 5912.7 19 4730.1
119.38 6.33 Gravity 656.8 5852.4 5852.4 11.2 4681.9
Heat Exchanger Thermal Design Hetran 11.1 Page 7
File: PH-2.BJT Date: 7/22/2016 Time: 6:56:56 AM
Calculation Details - Tube Side - Liquid Properties
Temperature Density Specific Thermal Viscosity
bulk wall heat conductivity bulk wall
C C kg/m3 kcal/(kg*C) kcal/(h*m*C) cp cp
26.91 97.77 785.44 0.6071 0.181 0.577 0.335
30.73 98.47 781.95 0.6157 0.179 0.553 0.334
34.55 99.19 778.46 0.6247 0.178 0.529 0.333
38.36 99.91 774.95 0.6343 0.177 0.506 0.332
42.18 100.64 771.42 0.6441 0.176 0.483 0.331
46 101.39 767.86 0.6545 0.174 0.461 0.33
49.82 102.15 764.27 0.6652 0.173 0.439 0.329
53.64 102.92 760.65 0.6763 0.172 0.418 0.328
57.45 103.71 756.99 0.6878 0.171 0.398 0.328
61.27 104.53 753.3 0.6996 0.17 0.379 0.327
65.09 105.41 749.55 0.7118 0.169 0.369 0.326

Calculation Details - Tube Side - Heat Load

Temp. Flowrate Sensible heat Total
Liquid Liquid load
C kg/h kcal/h kcal/h
25 951
28.82 951 2204 2204
32.64 951 4440 4440
36.45 951 6708 6708
40.27 951 9011 9011
44.09 951 11350 11350
47.91 951 13726 13726
51.73 951 16142 16142
55.55 951 18597 18597
59.36 951 21094 21094
63.18 951 23635 23635
67 951 26219 26219
Heat Exchanger Thermal Design Hetran 11.1 Page 8
File: PH-2.BJT Date: 7/22/2016 Time: 6:56:56 AM
Calculation Details - Tube Side - Performance
Temp. Heat load Overall Area reqd. Temperature Pressure
coefficient difference drop
C % kcal/(h*m2*C) % C %
Inlet 25 15.36
28.82 8.41 498.4 8.83 70.72 4.15
32.64 8.53 503 8.88 70.72 4.17
36.45 8.65 507.6 8.92 70.72 4.19
40.27 8.78 512.5 8.97 70.72 4.21
44.09 8.92 517.6 9.02 70.72 4.23
47.91 9.06 522.8 9.08 70.72 4.25
51.73 9.21 528.3 9.13 70.72 4.27
55.55 9.36 533.8 9.19 70.72 4.29
59.36 9.52 539.5 9.25 70.72 4.31
63.18 9.69 545.1 9.31 70.72 4.33
67 9.86 548.9 9.4 70.72 4.38
excess area 21.69
Outlet 67 16.17

Calculation Details - Tube Side - Coefficients

Temp. Flow Velocity Coefficients
bulk Pr Re regime free forced Actual
C m/s kcal/(h*m2*C) kcal/(h*m2*C) kcal/(h*m2*C)
26.91 6.99 12897.32 Turbulent 0.63 1237.9 990.3
30.73 6.84 13469.65 Turbulent 0.63 1255.7 1004.5
34.55 6.69 14073.72 Turbulent 0.64 1274.1 1019.3
38.36 6.54 14721.06 Turbulent 0.64 1293.7 1035
42.18 6.39 15412.23 Turbulent 0.64 1314.2 1051.3
46 6.23 16155.08 Turbulent 0.64 1335.7 1068.6
49.82 6.08 16950.84 Turbulent 0.65 1358.3 1086.6
53.64 5.92 17797.22 Turbulent 0.65 1381.7 1105.3
57.45 5.77 18687.7 Turbulent 0.65 1405.7 1124.6
61.27 5.63 19612.5 Turbulent 0.66 1430.2 1144.1
65.09 5.61 20175.45 Turbulent 0.66 1446.8 1157.4