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ENGINEERING CALCULATION
Designed by
Date
Doc. No.
Rey Fiedacan
THERMALCALCULATION OF HEAT EXCHANGER
11.07.2010
TYPE:SHELL& TUBES
HX - 01 -09
1
¡
¢

. N
¡

.
£

EVELOPEDUSING EXCELBY REY FIEDACAN,MECHANICAL ENGINEER,

¤
11.07.2010 -fi
¥

r
¤
¦

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¦
§

h
¨
¨

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©
¨

m
Revi


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

Pr


jectTitle : HEATEXCHANGER FOR CHILLED WATER

Part
: Horizontal
Shell
Sketch :
TYPE
:


HELL


TUBES
HX-



-




Sketch :
MEP-ME
I.HEAT & MASS BALANCE
Temperature of outlet fluid - Cold fluid ( Predicted from energy and mass balance)
EDACAN,MEP
Ts2
1 .0
K
msCp s(Ts1-Ts2)
=
=
295.3
Log mean temperature difference across the heat exchanger (LMTD)
BYREYFIEDAC
Ts2
KK
2.0
LMTD =
=7.1
m sCp s(T s1-T s2)
=
m tCp ct
=
295.3
 tmax - t min
where:
LMTD = 6.21 for parallel flow
LMTD = 7.08 for counterflow
P =
R =
ULATIONBYR
K
 tmax
 tmin
LMTD =
=7.1
ln
0.9400
0.19431
3.00208
R =
F =
LMTD Calculation ( Corrected )
where :
=
K for Counter flow heat transfer between shell & tubes
ALCALCULAT
3.0
T =F(LMTD)
6.655
0.9400
3.00208
=
K for Counter flow heat transfer between shell & tubes
HEAT DUTY OF HEAT EXCHANGER
based on the temperature difference between hot fluids inlet
and outlet condition.
=
KW
ERTHERMAL
4.0
Q =(m c )(T -T )
1,462.55

Tm = F(LMTD)
6.655
=
KW
NUMBER OF TUBES
- based on the mass flowrate of cold fluid inside the tubes and recommended
velocity on the specified number of passes.
=
tubes
EXCHANGERT
374
5.0
Q =(mscps)(Ts1 -Ts2)
1,462.55

N
t

= 4m
t

N
p/t

v
t

 di
2
1
,
1 21
=
tubes
per pass
II. TUBE SIDE CALCULATION:
TUBE SIDE HEAT TRANSFER
where:
Nu
= Nusselt number of fluid inside the tubes
HEATEXCH
374
1 .0
N
t
= 4m
t
N
p
/
t
v
t
d
i
1 ,1 21
ht=Nutkt
d
Nut
= Nusselt number of fluid inside the tubes
Kt
= Thermal conductivity of fluid inside the tubes
di
= Inside diameter of tubes
NUSSELT NUMBER ( CORRELATION FROM Petukhov - Kirililov for Turbulent flows )
H
2.0
h
t
=
di
NUSSELT NUMBER ( CORRELATION FROM Petukhov - Kirililov for Turbulent flows )
which predicts results in the range of 104< Ret < 5 x106 and 0.5 < Prt < 200
1.07+12.7(f/2) 1/2 (Prt 2/3 -1)
Prandtl number
Prt
=
Nut=
2.0
6.80236
(f/2)RetPrt
2.1
Prandtl number
P
rt
=
Reynold number at tube side
Ret
=tvtdi/µt
=
the flow is turbulent
Friction factor at given Re
Ft
=(1.58lnRet- 3.28) -2
=
6.80236
32,488.200.005797
2.3
2.1
2.2
Friction factor at given Re
Ft
=(1.58lnRet- 3.28)
=
1.07+12.7(f/2) 1/2 (Prt 2/3 -1)
=
W/m 2-K
Nu k
di
0.005797
Nu t
8,526.66
2.3
=
(f/2)RetPrt
=
225.72
=
W/m 2-K
( This correlated heat transfer coefficient at tube side
condition of flow )
III.SHELL SIDE CALCULATION
=Nutkt
di
1 .0
8,526.66
ht
III
.
SHELL SIDE CALCULATION
SHELL SIDE HEAT TRANSFER BY KERN CORRELATION
which predicts results in the range of 2x103< Res = GsDe/µ< 1 x106
Res
0.55 Pr s
1/3

where:Nu
s

= Nusselt number of fluid outsidethe tubes

ht=0.36k s
D
e

1 .0
Nu
s
= Nusselt number of fluid outsidethe tubes
Ks
= Thermal conductivity of fluid outside the tubes
de
= Equivalent diameter of shell
Res
= Reynold number flow outside the tubes
Prs
= Prandtl number of flow outside the tunes
11,649.06
D
e

2.1
Reynolds Number
Res
=(ms/As)(De/µs)=
the flow is turbulent
Equivalent Diameter
De
= f(Square,Triangularlayout)
do
D of square pitch in tube layout
Flow
11,649.06
2.2
2.1
D e of square pitch in tube layout
Flow
PT
4(P T2- do 2/4)
=
m2
De
0.024
De
S
s
=
D e of triangular pitch in tube layout
Flow
PT
do
4(P T2(3) 1/2/4- do 2/8)
=
m2
Use: SquarePitch
; D e =
De =
 do/2
0
s
0.018
0.024234
Use: SquarePitch
; D e =
Bundle Crossflow
As
= f(Clearance, Baffle spacing)
=
m2
2.3
=
0.125
2.4
0
s
D sCB
PT
0.024234
Total flow area of tubes
As
= f(Clearance, Baffle spacing)
=
m2
Estimated Shell Diameter
Ds
= f(Clearance, Baffle spacing)
0.996
s
 d iN t
4
==
2.4
0
s
PT
0
0.225
2.5
E
st
i
mate
d Sh
e
ll Di
ameter
D
s

=
f(Cl
earance,
B
a
ffl
e spac
i
ng
)
0.637(CL/CTP)(  do 2PR 2N t) 1/2
=
m
Tube Pitch Ratio
PR
=f(Clearance, Baffle spacing)
=P /d
=
m
0.996
1.337
0
s
=
2
.
5
2.6
2.7
=PT/do
=
m
Tube Layout Constant
=f(Clearance, Baffle spacing)
for 90 o and 45 o
CL
= 1
for 30 o and 60 o
CL
=
one tube pass
CTP =
0.93
1.337
0.87
0.9
2.7
one tube pass
CTP =
two tube pass
CTP =
three tube pass
CTP =
Use:
CL =
CTP =
2,800.32
0.93
ht=0.36k s
0.85
0.930
1 .0
0.9
Res
0.55 Pr s
1/3

=
W/m 2-K
( This correlated heat transfer coefficient at shell side
condition of flow )
2,800.32
ht=0.36k s
De
IV. OVERALL HEAT TRANSFER COEFFICIENT
Outer surface area - Clean heat transfer coefficient
-1
do
1 .0
Uc
1,869.27
W/m 2-K
ln(
)
+
+
do
1
do1
do
di
ho
dihi
2
kt
Surface area of heat exchan
g
er for clean condition
(
No foulin
g
Effect
)
Uc
1,869.27
W/m 2-K
l
n
(
)
=
=
+
+
1.1
Surface area of heat exchanger for clean condition (No fouling Effect )
Use:
Uc=
Outer surface area - Fouled heat transfer coefficient
Q
U cT m
97.11
=
m2
Ac=
2.0
1
.
1
2263.2
Outer surface area - Fouled heat transfer coefficient
do
-1
1
do1
do
di
ho
dihi
2
kt
Rft
=
1,406.54
W/m 2-K
=
ln(
)
+
+
Uf
+
2.0
Surface area of heat exchanger for clean condition (with fouling Effect )
156.25m2
Af=
Q
=
U fT m
2.2
2.1
Check for % surface design
Use:
Os=
61%
Os=
Af
Ac
=
U
f
T
m
30 %
2.2
Use:
s=

Surface design area of heat exchanger at certain

more allowance for fouling effect
=
m2
Effective length of tube for area in heat transfer
A'
L =
A'
=
1.89 m
126.24
30 %
30 %
2.4
2.3
Effective length of tube for area in heat transfer
Use:
L =
m
New Shell Diameter
D '
= f(Clearance, Baffle spacing)
4.00
L =
A'
=
N t d o
1.89 m
2.4
2.5
New Shell Diameter
D s'
= f(Clearance, Baffle spacing)
=0.637(CL/CTP)1/2(A'PR2do/L)1/2
=
m corrected shell diameter at the given length
however, the actual diameter shall be the nearest
available size either seamless pipe or fabricated as rolled
0.68
2.5
avai
l
a
bl
e size ei
th
er seam
l
ess pipe or
f
a
b
rica
t
e
d
as ro
ll
e
d
plate
Use:
=
m
V. PRESSURE DROP
- This is used to determined the pumping power required to handle the fluid in tubes and shell.
TUBE SIDE PRESSURE DROP
Ds '
0.80
1 .0
V. PRESSURE DROP
- This is used to determined the pumping power required to handle the fluid in tubes and shell.
TUBE SIDE PRESSURE DROP
Tube side friction factor
ft
=(1.5ln(Ret) - 3.28)-2
=
Tube side friction factor
f
t

LN
p
+4N 
2
di
µc2
=
P
1 .0
0.005797
1.1
1.2
Tube side friction factor
f
t
LN
p

=
Kpa, head required to pump the fluid into the tubes
=
psi
+4N p c
2
di
µc2
=
Pt
2.0
58.6762
8.5
1
.
2
SHELL PRESSURE DROP
The shell-side fluid experiences a pressure drop as it passes through the exchanger,
over the tubes, and around the baffles.
Shell side friction factor
f
=exp(0.576 -0.19ln(Re ))
=
2.0
0.300
fsG2
s(Nb+1)D's

2sD es
=
Ps
2.1
Shell side friction factor
fs
=exp(0.576 -0.19ln(Res))
=
Bundle crossflow area
As
=
=
m2 , based on corrected shell ,
clearance of tubes and baffle spacing.
D sCB
P
0.125
0.300
2.1
2.2
clearance of tubes and baffle spacing.
Wall temperature
Tt1+Tt2
Ts1+Ts2
=
K , average temperature between cold and hot fluid across
12
PT
+
Tw
2
2
=
2.3
=
K , average temperature between cold and hot fluid across
the tube length
therefore:
the absolute viscosity and wall temperature of
oC
=
kg/m - s
24.8
297.8
0.0009001
=
kg/m - s
Correction Factor
=
s
µs
µw
0.14= 0.989
Nb =
L
=
7
-1
0.0009001
2.4
2.5
Number of Baffles
Number of Baffles
2
Ms
As
Nb =
L
=
7
B
-1
G
2.5
2.6
N
um
b
er o
f B
a
ffl
es
therefore:
fsG2
s(Nb+1)D's

2sD es
kg/m2-s
Ps
M
s

=
As
=
G s=
398.593
2
.
6
=
Kpa, head required to pump the fluid into the shell
=
psi
2sD es
6.4
0.9
Summary of THERMAL DESIGN OF HEAT EXCHANGER
TUBE SIDE :
Inlet temperature
Mass flowrate
312

20

150

998.2
HO T SI


E
oC

kg/s
kg/


S

!
!

ary
"

f T HE
#
$
%

L
&

ESI
'
(

OF HE
%

TE
)
0

HANGE
#

Mass fl owrate
Density
Ther


alCo nductivity
Dyna


ic viscocity
Specific Heat
34
2
5
150
 998.2

0.6044

0.0009832
67
4181.6
6.8023645
kg/s
kg/m3
W/m - K
N.s/m2
J/kg - K
Specific Heat
Prandtl number
Velocity of fluid inside the tubes
Total fouling factor
SHELL SIDE:
COLD SIDE
892
m2 - K/W
o

oC

25
6
7
0.000176
4181.6
6.8023645
2
J/kg - K
m/s
SHELL SIDE:

Inlet temperature

Outlet temperature

Average temperature

Mass flowrate
COLD SIDE
34612
oC

oC

32
25
oC

28.5
50
0.6144
kg/s
3

W/m - K
Density
Thermal Conductivity
Dynamic viscocity
Specific Heat
5679

996.4

0.6144

0.0008292

4178.7
5.6396127
kg/m3
W/m - K
N.s/m2
J/kg - K
Prandtl number
CONSTRUCTIONAL DATA OF THE PROPOSED SHELL AND TUBE HX
Shell diameter
Number of tubes
Length of tubes(Allowancefor tubesheet not included)
3
2
10
14
mm
5.6396127
0.800
1121.07
4.000
0.019
m

Length of tubes(Allowancefor tubesheet not included)

Tube outside diameter

Tube inside diameter

Baffle spacing ( baffle cut at 25%)

Tube pitch
83456
7
mmm
4.000

0.019 0.016 0.500

0.025
3.000
m

Tube pitch

Number of passes

Thermal Conductivity of tubes

Tube side heat transfer coefficient

Shell side heat transfer coefficient
8
10
11
79
12
W/m 2 - K
W/m - K
W/m 2 - K
W/m 2 - K

0.025

3.000

42.300

8526.66
2800.32
1869.27

Shell side heat transfer coefficient

Clean overall heat transfer coefficient

Fouled overall heat transfer coefficient

Tube side pressure drop

Shell side pressure drop
11
13
12
W/m 2 - K
Kpa
W/m 2 - K
Kpa
W/m 2 - K
2800.32
15
58.68
6.40
14
1869.27
1406.54
Shell side pressure drop
Kpa
15
6.40

Design of Shell & Tube Heat Exchanger by

Kern Method 2.57 - Excel Template
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Simple thermal calculation of heat exchanger using KERN Method.A good reference for trial
and error computation of essential variables.Just simply ... (More) Simple thermal calculation of
heat exchanger using KERN Method.A good reference for trial and error computation of
essential variables.Just simply add the values then it will produce result for analysis. (Less)
length
sketch
part
designing
design xls
pass shell
transfer coefficient
shell heat
lmtd calculation
(more tags)
length
sketch
part
designing
design xls
pass shell
transfer coefficient
shell heat
lmtd calculation
calculate diameter
(fewer)

Rey Fiedacan
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Design of Shell & Tube Heat Exchanger by Kern Method 2.57 - Excel Template
Simple thermal calculation of heat exchanger using KERN Method.A good reference for trial
and error computation of essential variables.Just simply add the values then it will produce result
for analysis.
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