Buok Chapter 5

CHAPTER 5
DESIGN OF COOLING SYSTEM
5.1 DESIGN OF LUBE OIL HEAT EXCHANGER
Design Parameters:
From MakGenset Catalogue:
Heat Loss to Lube Oil 390 kW

Temperature Entering
Heat Exchanger 43˚C
Engine Inlet Temperature 65˚C
Temperature Leaving
Heat Exchanger 48˚C
Volume Flow Rate of Cooling Water 60 m3 /hr
1
5.1.1 Lube Oil Temperature Leaving the Engine
Since the outlet temperature is unknown in the

catalogue, the designers decided to use the maximum
temperature of lube oil.
From Chesterton Lubricant Reference Manual, “lubricants

should not be used above 150°C (300°F) on a regular basis.”
Therefore, the designers decided to use the outlet

temperature to be equal to 150°C
5.1.2 Surface Area of Heat Transfer, 𝐀 𝐡𝐭 :

Qlo
Aht = U(LMTD)
Where:
U = Over all Heat Transfer Coefficient in
Tubular Exchanger
LMTD = Logarithmic Mean Temperature
Difference
Qlo = Heat Loss to Lube Oil
Table 10-10 Typical Overall Heat Transfer Coefficient in

Tubular Heat
From: Peters, M.S. and K.D. Timmerhaus. 1991. Plant Design

Economics for Chemical Engineers. 4th ed., New York,
McGraw-Hill, Inc. p 10-39.
Liquid-Liquid Media
Shell Side Tube Side Design U
Lube Oil Water 227.12 (40) – 454.24 (80)
2
The designers would like to use the average value of
340.68W⁄m2 -K (60 Btu⁄hr-ft2 ) for overall coefficient of heat
transfer.
The logarithmic mean temperature difference is taken from the

figure below.
(𝑇2 - 𝑡2 ) − (𝑇1 - 𝑡1 )
LMTD =
(𝑇2 - 𝑡2 )
ln
(𝑇1 - 𝑡1 )
Where:
T1 = Temperature of Lube Oil entering the

Heat Exchanger, 65 C
T2 = Temperature of Lube Oil leaving the Heat

Exchanger, 150 C
t1 = Temperature of Cooling Water entering

the Heat Exchanger, 43 C
3
t2 = Temperature of Cooling Water leaving the
Heat Exchanger, 65 C
Substituting the values,
(150-48)°C-(65-43)°C
LMTD =
(150-48) °C
ln
(65-43) °C
LMTD = 52.1536°C
Therefore:
Qlo
Aht =
U(LMTD)
1000 w
390kW× 1 kW
Aht =
(340.68 W⁄m2 -K)×(52.1536)K
Aht = 21.95 𝐦𝟐
Aht = 236 𝒇𝒕𝟐
5.2 SELECTION OF HEAT EXCHANGER
Use Model Number WA-2441 with Heating Surface Area of

236 ft2
4
5.2.1 Cross-sectional Area of Tubes, 𝑨𝒕 :
From Principles of Refrigeration by R.J. Dossat,

recommendation for shell and tube type condenser, steel tube
diameter range, 16 mm to 50 mm DN.
Using 20mm DN with OD = 26.67 mm and ID = 20.93 mm

schedule 40 as the tube diameter. Data were taken from PIPING
HANDBOOK by Mohinder L. Nayyar, p. 2265
π
AT = 4 ID2
Substituting the values:

π
AT = 4 (20.93mm )2
AT = 344.06 mm2
5.2.2 Number of Tube per Pass:
Nt⁄ Vcw
Pass = π⁄ (ID )2 ×v
4 t cw
Where:
Vcw =Volume Flow rate of Circulating Water,60

m3/hr
IDt =Inside Diameter of Tube, 20.93 mm
vcw =Velocity of Circulating Water
From Plant Design and Economics for Chemical Engineers

by Peter and TimmerHaus, page 562 states that “As a standard
practice a fluid velocity of at least 3 – 10 fps should be
maintained in an exchanger when the fluid is water”. We take
the velocity to be 5.0 fps.
5
𝑚3 1ℎ𝑟
Nt⁄ 60
× 3600𝑠𝑒𝑐
ℎ𝑟
Pass = 1𝑚2 𝑓𝑡 1𝑚
344.06𝑚𝑚2 × ×5.0 𝑠𝑒𝑐 ×
(1000𝑚𝑚)2 3.281𝑓𝑡
Nt⁄ tube⁄
Pass = 32 pass
5.2.3 Length of Tube, 𝐋𝐭 :

AHT
Lt = N
π ×OD×No.of Passes× t⁄Pass
Assume: 4 passes
Where:
Aht = Area of Heat Transfer
OD = Outside Diameter
No.of Pass = 4 pass
Nt⁄ tube⁄
Pass = 36 pass
21.95𝑚2
Lt = 1 m
π ×26.67mm× 1000mm × 4 pass × 32 tube⁄pass
Lt = 2.05 m/tube
From Principles of Refrigeration by RJ Dossat, p. 342

the length of tubes ranges from 1 to 6.5 meters. Therefore,
the length of tube is acceptable.
5.2.4 Number of Tubes, 𝐍𝐓 :

AHT
NT = π ×OD× Lt
Where:
Aht = Area of Heat Transfer, 21.95 m2
6
OD = Outside Diameter, 26.67 mm
Lt =Length of Tube, 2.05 m
Substituting the values
21.95m2
NT = 1 m
π×26.67mm× 1000mm × 2.05 m/tube
NT = 127.80 Tubes
Say Use,
NT = 128 Tubes
5.2.4 Total Length of Heat Exchanger, 𝐋𝐬 :
Assume 1 ft allowance for water box heat exchanger.
Therefore,
Ls = Lt +(1.0 ft)
1𝑚
Ls =(2.05 m)+(1ft× 3.281 )
ft
Ls = 2.35 m
5.2.5 Cross Sectional Area of the Shell, 𝐀 𝐬 :
From Mechanical Engineer’s Handbook by Kent’s, Cross-

Sectional Area of Tubes should occupy 20 to 25% of Shell
Cross-Sectional Area. Taking the Average that is equal to
22.5%.
Therefore,
π⁄ ×(OD)2 ×N
4 t
As = 0.225
7
Where:
As =Cross Sectional Area of shell, m2
OD = Outside Diameter of the Shell,26.67mm
NT =Number of Tubes, 144 Tubes
Substituting,
2
π⁄ ×(26.67mm× 1 m ) ×128 tubes
4 1000mm
As =
0.225
As = 0.3178 𝒎𝟐 = 317,800 mm𝟐
5.2.6 Shell Diameter of the Condenser, 𝐃𝐬 :
As ×4
Ds =√
π
Where:
As =Cross Sectional Area of the Shell
317,800 mm2 × 4
Ds =√ π
Ds = 637 mm
5.2.7 Bundle Diameter, 𝐃𝐛 :
The tube bundle diameter can be determined from the

number of tubes, but also depends on the number of tube
passes, tube layouts and bundle construction.
8
0.5
NT
Db =Pt ( π )
4
Where:
Pt =Tube Pitch (Spacing between Tube Diameters)
NT =Number of Tubes, 128 Tubes
5.2.8 Tube Pitch, 𝐏𝐭 :
Normally,
Pt
=1.25, 1.33, or 1.5
OD
Using,
Pt
=1.33
OD
Pt =1.33×OD
Where:
OD = Outside Diameter, 0.0267 m
Pt =1.33×0.0267 m
Pt = 35.51 mm
Therefore:
0.5
128
Db = 35.51 mm ( π )
4
Db = 453.33 mm
Say use,
Db = 454 mm
5.2.9 Baffle Spacing and Baffle Cut, 𝐁𝐬 𝐚𝐧𝐝 𝐁𝐜 :
9
From Mechanical Handbook by Kutz, p. 306
Baffle spacing Lbc and baffle cut Bc cannot be divided

exactly until pressure drop is evaluated. However, a
reasonable first guess ratio of baffle spacing to shell
diameter(Bs /Ds ) is about 0.45. The baffle cut
(Bc a percentage of Ds ) required to give a good shell side
distribution may be estimated by the following equation:
B
Bc = [16.25+18.75 Ds ] Ds
s
But:
Bs
=0.45
Ds
Where:
Bc =Baffle Cut in Percent of Ds
Ds =Diameter of Shell
Therefore:
Bc =[16.25+18.75×0.45]Ds
Bc =24.7% Ds
Bc =0.247×637 mm
Bc = 157.34 mm
Say Use, Bc = 158 mm
Also:
Bs = 0.45×637 mm
Bs =286.65 mm
Say Use, Bs = 287 mm
10
11
SPECIFICATION OF LUBE OIL HEAT EXCHANGER
Type
Shell and Tube
Shell Material Steel (ASTM A-179)
Tube Material Copper (ASTM B – 68)
Tube Outside Diameter 26.27 mm
Tube Inside Diameter 20.93 mm
Number of Tubes 128 tubes
Number of Pass 4 pass
Number of Tube per Pass 32 tube/pass
Shell Diameter 637 mm
Shell Length 2.35 m
Tube Length 2.65 m
Baffle Spacing 287 mm
Baffle Cut 158 mm
Bundle Diameter 454 mm
12
5.3 DESIGN OF JACKET WATER HEAT EXCHANGER
Design Parameters:
From Catalogue
Heat loss to Jacket Water, Qjw 1,256 kW
Jacket Water Inlet Temperature, T1 90ºC
Jacket Water Outlet Temperature, T2 72ºC
Properties of Circulating Water Inside The Heat Exchanger
Circulating Water Inlet Temperature, t1 37.4ºC
Circulating Water Outlet Temperature, t2 45.7ºc
13
5.3.1 Logarithmic Mean Temperature Difference, LMTD:
Tubular Heat
From Peters, M.S. and K.D. Timmerhaus. 1991. Plant Design

Economics for Chemical Engineers. 4th ed., New York, McGraw-
Hill, Inc. p 10-39.
Liquid-Liquid Media
Lube Oil Water 227.12 (40) – 454.24 (80)
transfer.

figure below.
(𝑇1 - 𝒕𝟏 ) − (𝑇2 - 𝒕𝟐 )
LMTD =
𝑇 - 𝒕
ln 𝑇1 - 𝒕𝟏
2 𝟐
Where:
T2 = jacket water outlet temperature, 72ºC
14
T1 = jacket water inlet temperature, 90ºC
t2 = circulating water inlet temperature,
37.4ºC
t1 = circulating water outlet temperature,
45.7ºC
Substituting,
(90℃-45.7℃)-(72℃-37.4℃)
LMTD=
(90℃-45.7℃)
ln
(72℃-37.4℃)
LMTD = 39.25 ºC
5.3.2 Surface Area of Heat Transfer, Aht:
Q𝐶
Aht =
U(LMTD)
Where:
U = over-all heat transfer coefficient in
tubular heat exchanger
From Chemical Engineers Handbook by Perry and Chilton, page
11-25.
TABLE 11-3 Typical Overall Heat-Transfer Coefficients in
Tubular Heat Exchangers [U = Btu/(°F ⋅ ft2⋅hr)]
Jacket Water Water 230-300
The designers decided to use the average value of 265

BTU/hr-ft2-ºF (1504.75 Watts/m2-ºC).
Substituting,
1256 kW
Aht = 1kW
1504.75 Watts⁄m2 -℃ (1000Watts) (39.25℃)
Aht = 21.27 m2
Aht = 228.97 ft2
15
Use Model Number WA-1645 with Heating Surface Area of

252.2 ft2 (23.428 m2)
From RJ Dossat Recommendation for shell and tube type

condenser, steel tube diameter range, 16 mm to 50 mm DN.
Using 20mm DN with OD = 26.67mm and ID = 20.93mm schedule

40 as the tube diameter. Data were taken from PIPING HANDBOOK
by Mohinder L. Nayyar, p. 2265
π
AT = 4 ID2
16
π
AT = 4 (20.93mm )2
AT = 344.06 mm2
5.4.2 Number of Tubes per Pass, Nt/P:

Nt⁄ Vcw
P = π⁄ (ID)2 (υ )
4 jw
Where:
ID = inside diameter of tubes
Vjw = Volume flow rate of jacket water
the maximum velocity which is equal to 10 fps.
Substituting,
𝑚3
Nt⁄ 0.01667 𝑠𝑒𝑐
P =
π⁄ (0.02093m)2 (10 ft⁄sec) ( 1𝑚 )
4 3.281𝑓𝑡
Nt⁄
P = 15.89 tubes per pass
Nt⁄
P = 16 tubes per pass
5.4.3 Length of Tubes, Lt:
Aht
Lt = N
(π)(OD) ( t⁄p) (#of pass)
Substituting,
𝟐𝟑. 𝟒𝟐𝟖 m2
Lt =
(π)(0.02667m)(16 tubes⁄pass)(4 passes)
Lt = 4.37 m per tube
17
5.4.4 Total Length of Heat Exchanger

Assume 1 ft allowance for water box of heat exchanger.
LHE = Lt + 1 ft
1 m
LHE = 4.37 m + (1 ft x )
3.281 ft
LHE = 4.7 m or 4,700 mm
5.4.5 Number of Tubes, NT:
AHT
NT =
π ×OD× Lt
Substituting,
𝟐𝟑. 𝟒𝟐𝟖 m2
NT =
π ×0.02667 m × 4.37 m/tube
NT = 63.465 Tubes
Say use, NT =64tubes
5.4.6 Cross-sectional Area of the Shell:

22.5%.
Therefore,
π⁄ ×(OD)2 ×N
4 t
As = 0.225
Substituting,
π⁄ ×(0.02667 m)2 × 64 tubes
4
As = 0.225
18
As =0.16 m2
5.4.7 Shell Diameter of the Condenser, Ds:
As ×4
Ds =√ π
Substituting,
0.16𝑚2 × 4
Ds =√ π
Ds = 0.452 m or 452 mm

0.5
NT
Db =Pt ( π )
4
5.4.9 Tube Pitch, PT:
Normally:
Pt Pt
=1.25, 1.33, or 1.5 ; =1.5
OD OD
Pt =1.5×0.02667 m
Pt =40 mm
Therefore:
0.5
64
Db =40 mm ( π )
4
Db = 350 mm
19

diameter(Bs /Ds ) is about 0.45. The baffle cut (Bc a percentage of Ds )
required to give a good shell side distribution may be
estimated by the following equation: (Kutz, 2001)p 306 .
B
Bc = [16.25+18.75 Ds ] Ds
s
But:
Bs
=0.45
Ds
Where:
BC = Baffle Cut in Percent of Ds
DS = Diameter of Shell
Therefore:
Bc =[16.25+18.75×0.45]Ds
Bc =24.7% Ds
Bc =0.247×452 mm
Bc = 112 mm
Also:
Bs = 0.45×452 mm
Bs =204 mm
20
SPECIFICATION OF JACKET WATER HEAT EXCHANGER
Type
Shell and Tube
Tube Material Copper (ASTM B–68)
Tube Outside Diameter 0.02667 m
Tube Inside Diameter 0.02093 m
Shell Length 4.7 m
Tube Length 4.37 m
Baffle Cut 112 mm
21
5.5 DESIGN OF NON-CONTACT HEAT EXCHANGER
Design Parameters:
Properties of Jacket Water Inside the Heat Exchanger
From Catalogue
Heat Loss to Fresh Water, Qfw 810 kW
Jacket Water Inlet Temperature, T1 48ºC
Jacket Water Outlet Temperature, T2 38ºC
Properties of Circulating Water Inside the Heat Exchanger
Circulating Water Inlet Temperature, t1 32ºc
Circulating Water Outlet Temperature, t2 37.4ºc
22
5.5.1 Logarithmic Mean Temperature Difference, LMTD:
Tubular Heat
From Peters, M.S. and K.D. Timmerhaus. 1991. Plant Design

Economics for Chemical Engineers. 4th ed., New York, McGraw-
Hill, Inc. p 10-39.
Liquid-Liquid Media
Lube Oil Water 227.12 (40) – 454.24 (80)
transfer.

figure below.
(𝑇1 - 𝑡1 ) − (𝑇2 - 𝑡2 )
LMTD =
𝑇 - 𝑡
ln 𝑇1 - 𝑡1
2 2
Where:
T2 = jacket water outlet temperature, 38ºC
T1 = jacket water inlet temperature, 48ºC
23
t2 = circulating water inlet temperature,
32ºC
t1 = circulating water outlet temperature,
37.4ºC
Substituting,
(48℃-37.4℃)-(38℃-32℃)
LMTD=
(48℃-37.4℃)
ln
(38℃-32℃)
LMTD = 8.083 ºC
5.5.2 Surface Area of Heat Transfer, Aht:
Q𝐹𝑊
Aht =
U(LMTD)
Where:
U = over-all heat transfer coefficient in
tubular heat exchanger
From Chemical Engineers Handbook by Perry and Chilton, page
11-25.
TABLE 11-3 Typical Overall Heat-Transfer Coefficients in
Tubular Heat Exchangers [U = Btu/(°F ⋅ ft2⋅hr)]
Jacket Water Water 230-300
The designers decided to use the average value of 265

BTU/hr-ft2-ºF (1504.75 Watts/m2-ºC).
Substituting,
810 kW
Aht = 1kW
1504.75 Watts⁄m2 -℃ (1000Watts) (℃)
Aht = 66.60 m2
Aht = 716.95 ft2
24
Use Model Number SA-2447 with Heating Surface Area of

764 ft2 (70.97 m2)
From RJ Dossat Recommendation for shell and tube type

condenser, stell tube diameter range, 16 mm to 50 mm DN.
Using 20mm DN with OD = 26.67mm and ID = 20.93mm schedule

40 as the tube diameter. Data were taken from PIPING HANDBOOK
by Mohinder L. Nayyar, p. 2265
25
π
AT = 4 ID2

π
AT = 4 (20.93mm )2
AT = 344.06 mm2
5.6.2 Number of Tubes per Pass, Nt/P:
Nt⁄ Vcw
P = π⁄ (ID)2 (υ )
4 jw
Where:
ID = inside diameter of tubes
Vjw = Volume flow rate of jacket water
the velocity which is equal to 10 fps.
Substituting,
𝑚3 1ℎ𝑟
Nt⁄ 70 × 3600𝑠𝑒𝑐
ℎ𝑟
Pass = 1𝑚2 𝑓𝑡 1𝑚
344.06𝑚𝑚2 × ×5.0 𝑠𝑒𝑐 ×
(1000𝑚𝑚)2 3.281𝑓𝑡
Nt⁄
P = 37.1 tubes per pass
Nt⁄
P = 38 tubes per pass
5.6.3 Length of Tubes, Lt:
Aht
Lt = N
(π)(OD) ( t⁄p) (#of pass)
Substituting,
26
70.97 m2
Lt =
(π)(0.02667m)(38 tubes⁄pass)(4 passes)
Lt = 5.6 m per tube

5.6.4 Total Length of Heat Exchanger

Assume 1 ft allowance for water box of heat exchanger.
LHE = Lt + 1 ft
1 m
LHE = 5.6 m + (1 ft x )
3.281 ft
LHE =5.9 m or 5,900 mm
5.6.5 Number of Tubes, NT:
AHT
NT =
π ×OD× Lt
Substituting,
70.97 m2
NT =
π ×0.02667 m × 5.7 m/tube
NT =148.6 tubes
Say use,
NT = 149 tubes
5.6.7 Cross-sectional Area of the Shell:

22.5%.
Therefore,
π⁄ ×(OD)2 ×N
4 t
As = 0.225
27
Substituting,
π⁄ ×(0.02667 m)2 × 149 tubes
4
As = 0.225
As =0.37 m2
5.6.8 Shell Diameter of the Condenser, Ds:
As ×4
Ds =√ π
Substituting,
0.37𝑚2 × 4
Ds =√ π
Ds = 0.686m or 686 mm

0.5
NT
Db =Pt ( π )
4
5.6.10 Tube Pitch, PT:
Normally:
Pt Pt
=1.25, 1.33, or 1.5 ; =1.5
OD OD
Pt =1.5×0.02667 m
Pt =40 mm
Therefore:
28
0.5
149
Db =40 mm ( π )
4
Db = 551 mm

diameter(Bs /Ds ) is about 0.45. The baffle cut (Bc a percentage of Ds )
required to give a good shell side distribution may be
estimated by the following equation: (Kutz, 2001)p 306 .
B
Bc = [16.25+18.75 Ds ] Ds
s
But:
Bs
=0.45
Ds
Where:
BC = Baffle Cut in Percent of Ds
DS = Diameter of Shell
Therefore:
Bc =[16.25+18.75×0.45]Ds
Bc =24.7% Ds
Bc =0.247×686 mm
Bc = 170 mm
Also:
Bs = 0.45×686 mm
Bs = 309 mm
29
SPECIFICATION OF NON-CONTACT HEAT EXCHANGER
Type
Shell and Tube
Tube Material Copper (ASTM B–68)
Tube Outside Diameter 0.02667 m
Tube Inside Diameter 0.02093 m
Shell Length 5.9 m
Tube Length 5.6 m
Baffle Cut 170 mm
5.7 DESIGNING FOR JACKET WATER SURGE TANK:
Note:
Since water is on a continuous flow in the system, assume
that the volume of expansion tank or surge tank can
accommodate water at ½ of a minute of water flow.
Jacket Water Inlet Temperature, To 90ºC
30
Jacket Water Outlet Temperature, Ti 72ºC
Heat Loss to Jacket Water, Qjw 1,256 Kw

Mass Flow Rate of Jacket Water 16.67 kg/sec
5.7.1 Volume of Tank
VET = mjwx vfx t
From Steam Table at 81⁰C (Average Jacket Water Temp.)

vf = 1.0298 li/kg
Thus,
VST = 16.67kg/sec (1.0298 li/kg)(1 m3/1000 li)

(30 sec)
VST = 0.515 m3
5.7.2 Dimension of Surge Tank
Since the common surge tank is cylindrical in shape then,
let it be also the shape of the tank to be designed.
Therefore,
π
VET = Vc= d2 h
4
π
0.515 m3= d2 h
4
From the computation of day tank it is known that the

most economical proportion for a cylindrical tank is d = h.
Thus,
π
0.515 m3= (d3 )
4
d = 870 mm
And since there should be an air gap between the top of
the tank and water level, then make the height 900 mm.
31
5.8 THICKNESS OF THE SURGE TANK
From A Textbook of Machine Design by Khurmi and Gupta,
p. 226. The design of a pressure vessel must be based on the
maximum stress.
Therefore,
𝑝×𝑑
𝑡=
4𝜎2 ×𝜂𝑐
Where:
P = Maximum Allowable Internal Pressure
d= Inside Diameter of the storage tank
𝜂𝑐 =efficiency of circumferential joint
𝜎2 =stress value of carbon steel SA-285
5.8.1 Pressure inside the tank, P:
P= δL ×hL + δa ×ha
5.8.2 Height of the Water, hf
hL = 0.87 m
5.8.3 Specific Weight of Water, δL
δL =SGL xδw
32
Where:
SGL =0.91
𝑘𝑔
δw =1000 𝑚3
𝑘𝑔
δL =0.91 ×1000 𝑚3
kg
δL =910 m3
Substituting,
P= δL ×hL + δa ×ha
kg
PS = (910 × 0.9 m)
m3
kg 1𝑚2 𝑘𝑔
PS = 819 m2 × (100𝑐𝑚)2 = 0.0819 𝑐𝑚2
PS = 1.165 psi
Therefore,
Pa =Ps +Patm
Pa = 1.165 psi + 14.7 psi
Pa = 15.865 psi
4.1.11 Maximum Allowable Working Stress, S
Table 4. Design Equation Data for Pressure Vessel

Recommended Stress Values
Metal Temperature,  F S, Psi
Carbon Steel (SA-285, Gr. C) -20 to 650 13,700
From Peters, M.S. and Timmerhaus, K.D. 1991. Plant Design

and Economics for Chemical Engineers 4th ed. New York; McGraw,
Inc.
4.1.13 Welding Efficiency, EJ
From PME Code; p. 147; the efficiency of doubled
butt weld for fusion weldjoints is 70%.
33
Therefore,
𝑝×𝑑
𝑡=
4𝜎2 ×𝜂𝑐

lb 3.281 ft 12 in
(15.865 2 )(0.87m)( )( )
in 1 m 1 ft
tST = lb
4(13700 )(0.70)
in2
tST = 0.0142 in
tST =0.36 mm
From PME Code, 2012 Edition, Page 418.

Table 2215.2.1.7 Shell Plate Thickness
Nominal Tank Diameter Nominal Thickness

m Ft mm in
< 15 <50 5 3/16
15 to <36 50 to <120 6 1/4
36 to 60 120 to 200 8 5/16
>60 >200 10 3/8
For surge tank, standardized values from the PME code, for
diameter less than 15 meters, use data as specified.
Therefore,
tST = 5 mm
34
Specification of Jacket Water Surge Tank
Volume of Surge Tank 0.515 m3

Diameter of Tank 870 mm
Height of Tank 900 mm
Thickness of Surge Tank 5.0 mm
35
5.8 PIPING DESIGN AND SELECTION:
Pipelines of Lube Oil Heat Exchanger
5.8.1 Solving for Volume Flow Rate of Lube Oil
From Catalogue, Circulating Quantity of Lube Oil is
approximately 0.9li/Kw output with time interval of 30
minutes for every engine. For four (4) engines, the time
interval is 2 hours.
Therefore, the volume flow rate of volume is equated using

this computation.
0.91 li
×2,708kW
kW
VLO = 2 hrs
Where:
Power output = 2,708kW
VLO = 1218.6 li/hr
𝒎𝟑
𝐕𝐋𝐎 = 𝟎. 𝟎𝟐𝟎𝟑𝟏 𝒎𝒊𝒏
5.8.2 Diameter of Pipe at Suction Line:

From Power Plant Engineering by Morse, pg. 603
Table 14-6. Average Practice in Flow Velocities, m/min
Pump Lines, discharge 91-183
Pump Lines, suction 61-152
The average velocities at pump’s suction and discharge line

which are 106.5 and 137 m/min respectively.
π Ds Vs
QLO=
4
4 QLO
DS 2 =
πVS
36
4 QLO
DS = √
πVS
Where:
Qlo = volume flow rate of lube oil
Vs= the velocity of lube oil at pump’s
suction line
𝑚3
4 (0.02031
DS =
√ 𝑚𝑖𝑛 )
π(106.5 m/min)
DS = 0.0156 m
DS =15.6 mm
Say use, 20 mm
Thus,
From TABLE E2.1 Principal Properties of Commercial Pipe page

2257 of PIPING HANDBOOK by Mohinder L. Nayyar
Nominal Schedule Outside Wall Inside

Diameter, Number Diameter Thickness(mm) Diameter(mm)
(mm)
20 Std. 40 26.67 2.87 20.93
5.8.3 Diameter of Pipe at Discharge Line:

From,
π Dd Vd
QLO=
4
4 QLO
Dd 2 =
πVd
37
4 QLO
Dd = √
πV𝑑
Where:
Qlo = volume flowrate of jacket water
Vd = the velocity of lube oil at
pump’s discharge line
𝑚3
4 (0.02031
Dd =
√ 𝑚𝑖𝑛 )
π(137 m/min)
Dd = 0.0137 m
Dd =13.7 mm
Say use, 15 mm
Thus,
From TABLE E2.1 Principal Properties of Commercial

Pipe page 2257 of PIPING HANDBOOK by Mohinder L. Nayyar
Nominal Schedule Outside Wall Inside Di

Diameter,mm Number Diameter Thickness(mm) ameter(mm)
15 Std. 40 21.336 2.769 15.798
5.9 Pipelines of Jacket Water Heat Exchanger

Design Data:
Volume Flow Rate of Jacket water 1.0 m3/min
38

From,
π Ds VS
Qjw=
4
4 QLO
Ds 2 =
πVs
4 QLO
Ds = √
πV𝑠
Where:
Qjw=volume flow rate of jacket water
Vs=the velocity of fuel at pump’s suction line
4 (1.0 m3/min)
DS = √
π(106.5 m/min)
DS= 109.34 mm
Say use 125 mm
Thus,


39
125 Std. 40 141.30 6.553 128.194

From,
π Dd VD
Qjw=
4
4 QJW
Dd 2 =
πVd
4 QJW
Dd = √
πV𝑑
Where:
Qjw = volume flowrate of jacket water
Vd= the velocity of water at pump’s discharge line
4 (1.0 m3/min)
Dd = √
π(137 m/min)
Dd =96.4 𝑚𝑚
Say use 100 mm
Thus,


40
125 Std. 40 114.3 6.02 102.26
5.9 Pipelines of Non-Contact Heat Exchanger

Design Data:

From,
π Ds VS
Qjw=
4
4 QLO
Ds 2 =
πVs
4 QLO
Ds = √
πV𝑠
Where:
4 (1.167 m3/min)
DS = √
π(106.5 m/min)
41
DS= 118.12 mm
Say use 125 mm
Thus,


125 Std. 40 141.30 6.553 128.194

From,
π Dd VD
Qjw=
4
4 QJW
Dd 2 =
πVd
4 QJW
Dd = √
πV𝑑
Where:
Vd= the velocity of water at pump’s discharge line
4 (1.167 m3/min)
Dd = √
π(137 m/min)
Dd =104.14 𝑚𝑚
42
Say use 100 mm
Thus,


125 Std. 40 114.3 6.02 102.26
5.4.1 Pipelines of Surge tank

Design Data

From,
π Ds VS
Qjw=
4
4 QLO
Ds 2 =
πVs
4 QLO
Ds = √
πV𝑠
43
Where:
4 (1.0 m3/min)
DS = √
π(106.5 m/min)
DS= 109.34 mm
Say use 125 mm
Thus,


125 Std. 40 141.30 6.553 128.194

From,
π Dd VD
Qjw=
4
4 QJW
Dd 2 =
πVd
4 QJW
Dd = √
πV𝑑
44
Where:
Vd = the velocity of water at pump’s discharge
line
4 (1.0 m3/min)
Dd = √
π(137 m/min)
Dd =96.4 𝑚𝑚
Say use 100 mm
Thus,


Diameter,(mm) Number Diameter Thickness(mm) ameter(mm)
125 Std. 40 114.3 6.02 102.26
45

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CHAPTER 5

DESIGN OF COOLING SYSTEM

5.1 DESIGN OF LUBE OIL HEAT EXCHANGER

From MakGenset Catalogue:

Heat Loss to Lube Oil 390 kW

Since the outlet temperature is unknown in the

From Chesterton Lubricant Reference Manual, “lubricants

Therefore, the designers decided to use the outlet

5.1.2 Surface Area of Heat Transfer, 𝐀 𝐡𝐭 :

Qlo = Heat Loss to Lube Oil

Table 10-10 Typical Overall Heat Transfer Coefficient in

From: Peters, M.S. and K.D. Timmerhaus. 1991. Plant Design

Shell Side Tube Side Design U

Lube Oil Water 227.12 (40) – 454.24 (80)

The logarithmic mean temperature difference is taken from the

T1 = Temperature of Lube Oil entering the

T2 = Temperature of Lube Oil leaving the Heat

t1 = Temperature of Cooling Water entering

Substituting the values,

Aht = 236 𝒇𝒕𝟐

5.2 SELECTION OF HEAT EXCHANGER

Use Model Number WA-2441 with Heating Surface Area of

From Principles of Refrigeration by R.J. Dossat,

Using 20mm DN with OD = 26.67 mm and ID = 20.93 mm

Substituting the values:

5.2.2 Number of Tube per Pass:

Vcw =Volume Flow rate of Circulating Water,60

IDt =Inside Diameter of Tube, 20.93 mm

vcw =Velocity of Circulating Water

From Plant Design and Economics for Chemical Engineers

Substituting the values:

5.2.3 Length of Tube, 𝐋𝐭 :

Aht = Area of Heat Transfer

No.of Pass = 4 pass

Substituting the values:

From Principles of Refrigeration by RJ Dossat, p. 342

5.2.4 Number of Tubes, 𝐍𝐓 :

Aht = Area of Heat Transfer, 21.95 m2

Lt =Length of Tube, 2.05 m

Substituting the values

5.2.4 Total Length of Heat Exchanger, 𝐋𝐬 :

Assume 1 ft allowance for water box heat exchanger.

Substituting the values:

5.2.5 Cross Sectional Area of the Shell, 𝐀 𝐬 :

From Mechanical Engineer’s Handbook by Kent’s, Cross-

As =Cross Sectional Area of shell, m2

OD = Outside Diameter of the Shell,26.67mm

NT =Number of Tubes, 144 Tubes

As = 0.3178 𝒎𝟐 = 317,800 mm𝟐

5.2.6 Shell Diameter of the Condenser, 𝐃𝐬 :

As =Cross Sectional Area of the Shell

Substituting the values:

5.2.7 Bundle Diameter, 𝐃𝐛 :

The tube bundle diameter can be determined from the

Pt =Tube Pitch (Spacing between Tube Diameters)

NT =Number of Tubes, 128 Tubes

5.2.8 Tube Pitch, 𝐏𝐭 :

OD = Outside Diameter, 0.0267 m

Substituting the values:

5.2.9 Baffle Spacing and Baffle Cut, 𝐁𝐬 𝐚𝐧𝐝 𝐁𝐜 :

Baffle spacing Lbc and baffle cut Bc cannot be divided

Bc =Baffle Cut in Percent of Ds

Say Use, Bc = 158 mm

Say Use, Bs = 287 mm