1. No category

WTS Sample Printout
2013
Thermal and Hydraulic Design of Shell and Tube Heat Exchangers
Table of contents
Table of contents ........................................................................................................................................................................................... 1
Thermal and hydraulic design of shell and tube heat exchangers ................................................................................................................. 2
Design of the tube sheet Determination of the tube sheet data .................................................................................................................. 4
Properties of water........................................................................................................................................................................................ 6
Properties of water........................................................................................................................................................................................ 7
Heat transfer in pipe flow .............................................................................................................................................................................. 8
Shell-side heat transfer in baffled shell and tube heat exchangers ............................................................................................................. 11
Corrected log. mean temperature difference (CLMTD) and temperature distribution ............................................................................... 14
Tube bundle vibration analysis .................................................................................................................................................................... 15
Tube-side pressure loss in shell and tube heat exchangers......................................................................................................................... 16
Pressure loss on the shell-side of shell and tube heat exchangers .............................................................................................................. 18
CAD program for shell and tube heat exchangers ....................................................................................................................................... 20
MS Excel Specification Sheet ....................................................................................................................................................................... 21
CAD created by WTSC .................................................................................................................................................................................. 22
3D Tube sheet created by Alibre Design from SPIE .................................................................................................................................... 23
Layout
Input values:
Calculated values:
Critical values:
Estimated values:
Lauterbach Verfahrenstechnik GmbH
1.234
1.234
1.234
1.234
or
or
or
or
1.234
1.234
1.234
1.234
1
2013
WTS Sample Printout
2013
Thermal and Hydraulic Design of Shell and Tube Heat Exchangers
Thermal and hydraulic design of shell and tube heat exchangers
Tube-side:
Medium:
Shell-side:
Water
Water
Mass flow
Volume flow
Pressure in (abs)
Inlet temperature
Outlet temperature
Mean temperature
mi
Vi
Pi
ϑei
ϑai
ϑmi
158730
323.7
0.04351
176
131
153.5
Actual
inlet temperature
outlet temperature
ϑei
ϑai
176
132.3
Heat duty
Heat loss
Qi -7144853
Fouling resistance
Density
ρi
Specif. heat capacity cpi
Thermal conductivity
λi
Dynamic viscosity
ηi
lb/hr
gpm
ksi
°F
°F
°F
ma
Va
Pa
ϑea
ϑaa
ϑma
198903
398.9
0.05801
68
104
86
°F
°F
ϑea
ϑaa
68
103
Btu/hr
Qa
Qva
7144853
0
0
ft²hr°F/Btu
61.13
1
0.3799
1.011
lb/ft³
Btu/lb °F
Btu/hr ft°F
lb/ft hr
Geometry:
From tubesheet library:
Installation position: Horizontal
Bare tubes
Straight tubes with fixed tubesheets
Shell outside diam. Do
Shell inside diam.
Di
Bundle-shell distance
Tube outside diam.
do
Tube inside diam.
di
Tube pitch (crosswise)
Pitch angle
Φ
Central baffle spacing
Inlet baffle spacing
Baffle borehole
Sealing strips pairs
16
15.31
0.543
0.9843
0.8268
1.26
60
7.48
11.42
1.016
0
in
in
in
in
in
in
°
in
in
in
-
ρa
cpa
λa
ηa
lb/hr
gpm
ksi
°F
°F
°F
°F
°F
Btu/hr
Btu/hr
0
ft²hr°F/Btu
62.17
0.9978
0.3555
1.93
lb/ft³
Btu/lb °F
Btu/hr ft°F
lb/ft hr
Bare tubes
Segmental baffles
Shell wall thickness
s
0.3465
in
Min. bundle-shell dist.
Tube wall thickness si
0.4724
0.07874
in
in
1.091
1.929
19
15.19
20
in
in
in
%
Tube pitch(lengthwise)
Pass lane width
b
Number of baffles/pass
Baffle diameter
Baffle cut
Tube material
Thermal conductivity of tube material
λ
Number of passes
8.667
Btu/hr ft°F
Tube-side
2 -
Number of serial exchangers
1
Shell-side
1 -
—
Lauterbach Verfahrenstechnik GmbH
2
2013
WTS Sample Printout
2013
Thermal and Hydraulic Design of Shell and Tube Heat Exchangers
Evaluation:
Heat transfer area
Bundle length
A
l
Required
40811
165
in²
in
Aa
la
Results:
Number of tubes
Heat transfer coefficient (inside)
Heat transfer coefficient (outside)
Overall heat transfer coefficient
Logarithmic mean temperature diff. LMTD
FN Factor (Correction factor for LMTD)
Total fouling resistance
Tube-side:
Velocity (tube-side)
Reynolds number
Pressure drop
Mean wall temp.
4.837
Re
72550
∆pi 0.002596
134
ϑwi
Inlet nozzle
Nominal width
Outside diameter
Inside diameter
Velocity
5.185
4.919
Outlet nozzle
Nominal width
Outside diameter
Inside diameter
Velocity
5.185
4.919
ft/s
ksi
°F
in
in
ft/s
in
in
ft/s
Final
38956
157.5
N
αi
αo
k
∆ϑ
FN
Rf
80
1034
396.5
67.4
0.9433
0
Inlet nozzle
Nominal width
Outside diameter
Inside diameter
Velocity
ρ ·v² inlet nozzle
6.272
4.143
1588
in
in
ft/s
kg/(m·s²)
Outlet nozzle
Nominal width
Outside diameter
Inside diameter
Velocity
6.272
4.143
in
in
ft/s
Heat balance shell-side:
Qa = ma · cpa · (ϑaa - ϑea ) =
Btu/hr
7144853
2093942 -
0 ) = -7144853
Overall heat transfer coefficient:
1
1
do
do ln(do/di)
=
+ fi
·
+
k
di
2 · λ
αi
1
+
0
Btu/hr
1
+
do
+ fo
;
Rf = fi ·
αo
·
+ fo
di
0.025 ln(
0.025
=
Btu/ft²hr°F
Btu/ft²hr°F
Btu/ft²hr°F
°F
ft²hr°F/Btu
ft/s
ft/s
ksi
°F
Btu/hr
= -(
Overdesign
-4.55 %
Shell-side:
Velocity (shell-side)
3.357
Velocity (window zone)
6.719
Reynolds number
Re
43225
Pressure drop
∆pa 0.006568
Mean wall temp.
111.9
ϑwa
Equations:
Heat balance tube-side:
Qi = mi · cpi · (ϑai - ϑei ) = -7144853
Heat balance:
Qi = -(Qa - Qva )
in²
in
0.025 /
0.021)
+
0.021
2 ·
15
1
+
+
0
5870
k =
396.5
Btu/ft²hr°F
Q = k · A · ∆ϑ · FN
=
2251 ·
26.33 ·
Lauterbach Verfahrenstechnik GmbH
37.44 ·
0.9433 = -7144853
3
Btu/hr
2013
WTS Sample Printout
2013
Thermal and Hydraulic Design of Shell and Tube Heat Exchangers
Design of the tube sheet Determination of the tube sheet data
Name of type:
Baffle-type: Segmental baffles
Design = D; Rating / Simulation = R
< R
Outside shell diameter
Inside shell diameter
Bundle diameter
Bundle diameter at cross flow zone
>
Do
Di
Db
Dbc
16
15.31
14.22
12.69
in
in
in
in
Minimum distance bundle - shell
Distance between bundle - shell
Dm
D
0.4724
0.543
in
in
Outside tube diameter
Inside tube diameter
Pitch crosswise to direction of flow
Pitch in direction of flow
Pitch angle
da
di
sq
sl
Φ
0.9843
0.8268
1.26
1.091
60
in
in
in
in
°
Baffle diameter
Height of the window in the baffles
Height of the window in % of diameter
Dl
H
15.19
3.061
20
in
in
%
Tube pattern: aligned = a / staggered = s
Adapt window height
Yes = Y / No = N
< S
<
Arrangement: around central tube
= 0
staggered by 1/2 pitch = 1
No tubes in window? Yes = 1
<
0 >
-
<
0 >
-
Number of tube-side passes
Number of shell-side passes
Bundle type
Tube lane width (horizontal)
Tube lane width (vertical)
>
>
2
1
<
1 >
1.929
1.929
Outside head diameter
Bolt-circle diameter
Number of bolts on the bolt-circle
Rotation angle for bolt-hole pattern
Da
Dt
in
in
in
in
°
Number of tubes
Number of dummy tubes
Number of tie rods
Total number of tubes, dummy tubes and tie rods
Number of tubes in the windows
Number of tubes in the cross flow zone
Number of boundary tubes required/actual RR
n
nB
nZ
nG
nF
nS
-
/
80
0
0
80
19
61
50
Number of tube rows in a window
Number of tube rows in the cross flow zone
Number of tube rows in the end zone
nRF
nW
nWE
1.5
7
8.5
-
Sum of the shortest connecting paths in the center
Shortest connecting path between tube and tube
Shortest connecting path between tube and shell
Number of connecting paths
Mean distance boundary tubes-envelope circle centre
Le
e
e1
nV
rh
5.096
0.2756
1.308
9
5.48
in
in
in
in
—
Lauterbach Verfahrenstechnik GmbH
4
2013
WTS Sample Printout
2013
Thermal and Hydraulic Design of Shell and Tube Heat Exchangers
Number of tubes, dummy tubes and tie rods per pass
Pass-No.
1
2
3
4
5
40
0
0
0
40
Final tube length
Total area
Number of baffles per shell-side path
Distance between the baffles
Distance between head and baffle
Diameter of the baffle borehole
Number of sealing strips pairs
Number of exchangers in series
la
A
N
S1
S2
nD
5
7
0
8
0
in
in²
in
in
in
-
Tube-side
5.185 in
5.185 in
Nozzles:
Inside diameter of the inlet nozzle
Inside diameter of the outlet nozzle
Lauterbach Verfahrenstechnik GmbH
157.5
38956
19
7.48
11.42
1.016
0
1
6
0
Shell-side
6.272 in
6.272 in
2013
WTS Sample Printout
2013
Thermal and Hydraulic Design of Shell and Tube Heat Exchangers
Properties of water
Properties of Water and Steam
State 1
Calculation for saturation?
(Yes = Y / No = N)
< N
ϑ1
p1
Temperature
Pressure
State 2
>
< N
153.5
0.04351
ϑ1
p2
°F
ksi
Properties of liquid water or superheated steam:
State 1
Liquid
Density
Spec.isob.heat capacity
Thermal conductivity
Dynamic viscosity
Kinematic viscosity
Prandtl number
Thermal diffusivity
Specific volume
Spec.isoc.heat capacity
Specific enthalpy
Spec. internal energy
Specific entropy
Compressibility
Surface tension
C. of therm. expansion
Isentropic exponent
Speed of sound
Dielectric constant
Characteristics:
Molar mass
Gas constant
Critical temp.
Critical pressure
Critical density
M
R
Tc
pc
ρc
Lauterbach Verfahrenstechnik GmbH
ρ
cp
λ
η
ν
Pr
a
v
cv
h
u
s
Z
σ
β
κ
w
ε
lb/ft³
Btu/lb °F
Btu/hr ft°F
lb/ft hr
m²/s
m²/s
ft³/lb
Btu/lb °F
Btu/lb
Btu/lb
Btu/lb °F
lbf/in
1E-6/°F
ft/s
-
61.13
0.9998
0.38
1.011
4.267E-7
2.66
1.604E-7
0.01636
0.9398
121.6
121.4
0.2207
0.001949
0.000371
316.1
7918
5110
64.52
18.02
0.1102
705.1
3.2
20.1
lb/lbmol
Btu/lb °F
°F
ksi
lb/ft³
6
>
134
0.04351
°F
ksi
State 2
Liquid
ρ
cp
λ
η
ν
Pr
a
v
cv
h
u
s
Z
σ
β
κ
w
ε
61.49
0.9986
0.3742
1.186
4.979E-7
3.166
1.573E-7
0.01626
0.953
102.1
102
0.1885
0.002001
0.000382
278.8
7908
5092
67.81
Validity:
0.01 °C ≤ ϑ
0.00612 bar
0.01 °C ≤ ϑ
0.00612 bar
≤
≤
≤
≤
lb/ft³
Btu/lb °F
Btu/hr ft°F
lb/ft hr
m²/s
m²/s
ft³/lb
Btu/lb °F
Btu/lb
Btu/lb
Btu/lb °F
lbf/in
1E-6/°F
ft/s
-
800 °C
p ≤ 1000 bar
2000 °C
p ≤ 500 bar
2013
WTS Sample Printout
2013
Thermal and Hydraulic Design of Shell and Tube Heat Exchangers
Properties of water
Properties of Water and Steam
State 1
Calculation for saturation?
(Yes = Y / No = N)
< N
ϑ1
p1
Temperature
Pressure
State 2
>
< N
86
0.05801
ϑ1
p2
°F
ksi
Properties of liquid water or superheated steam:
State 1
Liquid
Density
Spec.isob.heat capacity
Thermal conductivity
Dynamic viscosity
Kinematic viscosity
Prandtl number
Thermal diffusivity
Specific volume
Spec.isoc.heat capacity
Specific enthalpy
Spec. internal energy
Specific entropy
Compressibility
Surface tension
C. of therm. expansion
Isentropic exponent
Speed of sound
Dielectric constant
Characteristics:
Molar mass
Gas constant
Critical temp.
Critical pressure
Critical density
M
R
Tc
pc
ρc
Lauterbach Verfahrenstechnik GmbH
ρ
cp
λ
η
ν
Pr
a
v
cv
h
u
s
Z
σ
β
κ
w
ε
lb/ft³
Btu/lb °F
Btu/hr ft°F
lb/ft hr
m²/s
m²/s
ft³/lb
Btu/lb °F
Btu/lb
Btu/lb
Btu/lb °F
lbf/in
1E-6/°F
ft/s
-
62.16
0.9982
0.3554
1.929
8.006E-7
5.416
1.478E-7
0.01609
0.9832
54.21
54.04
0.1043
0.002871
0.000407
168.4
5687
4959
76.65
18.02
0.1102
705.1
3.2
20.1
lb/lbmol
Btu/lb °F
°F
ksi
lb/ft³
7
>
111.9
0.05801
°F
ksi
State 2
Liquid
ρ
cp
λ
η
ν
Pr
a
v
cv
h
u
s
Z
σ
β
κ
w
ε
61.84
0.9979
0.3664
1.457
6.082E-7
3.969
1.532E-7
0.01617
0.9675
80.03
79.86
0.1505
0.002755
0.000393
232
5863
5048
71.76
Validity:
0.01 °C ≤ ϑ
0.00612 bar
0.01 °C ≤ ϑ
0.00612 bar
≤
≤
≤
≤
lb/ft³
Btu/lb °F
Btu/hr ft°F
lb/ft hr
m²/s
m²/s
ft³/lb
Btu/lb °F
Btu/lb
Btu/lb
Btu/lb °F
lbf/in
1E-6/°F
ft/s
-
800 °C
p ≤ 1000 bar
2000 °C
p ≤ 500 bar
2013
WTS Sample Printout
2013
Thermal and Hydraulic Design of Shell and Tube Heat Exchangers
Heat transfer in pipe flow
Constant wall temperature
Circular pipes
ϑe
ϑa
ϑm
ρ
cp
λ
η
ν
Pr
PrW
Inlet temperature
Outlet temperature
Mean temperature
Density of the fluid
Specific heat capacity of the fluid
Thermal conductivity of the fluid
Dynamic viscosity of the fluid
Kinematic viscosity of the fluid
Prandtl number
Prandtl number at wall temperature
61.13
1
0.3799
1.011
4.267E-7
2.661
3.166
Fluid:
liquid <0> or gas <1>
0 = Circular pipes, 1 = Non-circular pipes
<
<
Pipe length
Inside diameter of the pipe
Cross sectional area of the pipe
Perimeter of the pipe
⇒ Hydraulic diameter
l
di
f
u
dh =
Total mass flow
Total volume flow
Number of pipes with parallel flow
⇒ Mass flow per pipe
⇒ Velocity
⇒ Reynolds number
Mg
Vg
Z
M =
w =
Re =
Q = Mg · cp · (ϑa - ϑe )
Balance:
°F
°F
°F
lb/ft³
Btu/lb °F
Btu/hr ft°F
lb/ft hr
m²/s
-
0 >
0
in
in
in²
in
in
157.5
0.8268
0.5369
2.597
0.8268
lb/hr
gpm
lb/hr
ft/s
-
3968
4.837
72550
=
Btu/hr
Results: Constant wall temperature
Nu · λ
⇒ α =
Re =
295.6 ·
0.6575
=
=
dh
w · dh · ρ
=
=
=
=
Btu/ft²hr°F
1.474 ·
301.3
0.021 ·
979.2
=
=
η / 1000
Nu_m_ϑ
Nu_m_ϑ
Nu_m_T
Nu_m
1630
0.021
72550
0.4179 / 1000
(laminar non-disturbed flow Re < 2300)
(laminar entrance flow Re < 2300)
(turbulent flow Re > 10000)
(transition zone 2300 ≤ Re ≤ 10000)
[6]
[12]
[26]
[29]
Factor K:
0.11
Liquids:
Gases:
K = (Pr/PrW )
n
K = (T/TW )
Nu = Nu_m(_ϑ,T) · K =
Heat transfer: Q
⇒ Wall temperature ϑW
=
0.9811
=
for n =
0
[40,41]
295.6
=
α
·
=
9257 ·
=
134
A
·
∆ϑlog
·
°F
—
Lauterbach Verfahrenstechnik GmbH
8
2013
WTS Sample Printout
2013
Thermal and Hydraulic Design of Shell and Tube Heat Exchangers
Calculations:
Re < 2300
Laminar flow:
Laminar non-disturbed flow:
HW = Re · Pr · dh/l =
1014
1/3
Nu_m_ϑ_2 = 1.615 · HW
3
Nu_m_ϑ =
3.66
3.66
[5]
3
+ 0.7
3
=
=
3
=
[6]
3
+ 0.7
1/3
Nu_m_ϑ_2 - 0.7
+
3
+
1/3
- 0.7
=
Laminar entrance flow:
1/6
2
Nu_m_ϑ_3 =
·
HW
=
1 + 22 Pr
1/6
2
=
·
1 + 22 ·
3
Nu_m_ϑ =
3.66
3
+ 0.7
3
=
3.66
Turbulent flow:
3
Nu_m_ϑ_2 - 0.7
+
[11]
3
3
+
1/3
+ Nu_m_ϑ_3
3
+ 0.7
=
1014
2.661
- 0.7
=
[12]
3
1/3
+
=
Re > 10000
-2
ξ = [1.8 · log Re - 1.5]
-2
= [ 1.8 · log
72550 - 1.5 ]
=
0.01903
[27]
2/3
ξ /8 · Re · Pr
Nu_m_T =
dh
·
1 +
2/3
1 + 12.7 ·
ξ /8
· (Pr
=
l
-1)
[26]
2/3
0.01903 /8 ·
72550 ·
2.661
=
0.021
·
1 + 12.7 ·
Nu_m_T =
0.01903 /8 · (
2/3
-1)
2.661
1 +
4
301.3
—
Lauterbach Verfahrenstechnik GmbH
9
2013
WTS Sample Printout
2013
Thermal and Hydraulic Design of Shell and Tube Heat Exchangers
Transition zone:
2300 ≤
Re ≤ 10000
1/3
Nu_m_ϑ_2_2300 = 1.615 · (2300 · Pr · dh/l)
=
[32]
5.135
1/6
2
Nu_m_ϑ_3_2300 =
·
2300 · Pr · dh/l =
[33]
3.22
1 + 22 Pr
3
Nu_m_L_2300 =
49.371
Nu_m_L_2300 =
5.539
+
Nu_m_ϑ_2_2300 - 0.7
3
1/3
+ Nu_m_ϑ_3_2300
[31]
2/3
(0.0308/8) · 10000 · Pr
dh
Nu_m_T_10000 =
·
2/3
1 + 12.7 ·
0.0308/8 · (Pr
1 +
l
-1)
[37]
Nu_m_T_10000 =
61.15
Re - 2300
γ =
72550 - 2300
=
10000 - 2300
=
Nu_m = (1 - γ ) · Nu_m_L_2300 + γ · Nu_m_T_10000 =
Lauterbach Verfahrenstechnik GmbH
[30]
10000 - 2300
10
[29]
2013
WTS Sample Printout
2013
Thermal and Hydraulic Design of Shell and Tube Heat Exchangers
Shell-side heat transfer in baffled shell and tube heat exchangers
Geometric data
Tube arrangement:
Staggered
Inside diameter of the shell
Diameter of the tube bundle at cross flow zone
Di
DB
15.31
12.69
in
in
Outside diameter of the tubes
Tube pitch crosswise to direction of flow
Tube pitch in direction of flow
da
s1
s2
0.9843
1.26
1.091
in
in
in
Diameter of the baffle
Height of the window in a baffle
Diameter of the bore-holes for the tubes
in the baffle
Baffle spacing
Dl
H
dB
15.19
3.061
1.016
in
in
in
S
7.48
in
Number of tubes including blanks and
support tubes
Number of tubes in the upper and lower windows
n
80
-
nF
19
-
Number of main resistances in a cross-flow zone
Number of connection lines
Number of sealing strip pairs
nW
nV
nS
7
9
0
-
Number of shell-side passes
Tube lane width (only for ND = 2)
ND
b
1
1.929
Fluid
Mass flow
Volume flow
m
V
Fluid: liquid <0> or gaseous <1>
198903
398.9
<
in
lb/hr
gpm
0>
Inlet temperature
Outlet temperature
Mean wall temperature
ϑE
ϑA
ϑW
Density
Spec. heat capacity
Thermal conductivity of the fluid
Dynamic Viskosity
Kinematic viscosity of the fluid
Prandtl number
Prandtl number at wall temperature
62.17
ρ
cp
0.9978
0.3555
λ
1.93
η
8.009E-7
ν
Pr
5.416
PrW
3.969
68
104
111.9
°F
°F
°F
lb/ft³
Btu/lb °F
Btu/hr ft°F
lb/ft hr
m²/s
-
Results
fW = fG · fL · fB
Nu0,AW
α =
1.093 ·
= fW · Nu0,Bundle
Nu0,AW
α =
=
· λ
0.5031 ·
358.3 ·
· K
π /2 · da
1068
=
0.8555 ·
0.538 =
712.1 =
358.3
0.6152
=
·
π /2 ·
0.5031
1.081
0.025
Btu/ft²hr°F
Lauterbach Verfahrenstechnik GmbH
—
11
2013
WTS Sample Printout
2013
Thermal and Hydraulic Design of Shell and Tube Heat Exchangers
Calculation of Nu0,Bundle
a = s1 /da =
b = s2 /da =
1.28
ψ = 1- π /4a (for b ≥ 1)
Reψ ,1
1.109
ψ = 1- π /4ab (for b < 1)
=
43225
ψ =
0.3864
3
Nu1,lam
= 0.664 ·
Reψ ,1
·
Pr
3
242.4 = 0.664 ·
Nu1,turb
43225
·
5.416
0.037 · Reψ ,1
=
1 + 2.443 · Reψ ,1
0.037 ·
-0.1
0.8
· Pr
· (Pr(2/3)
0.8
43225
- 1)
·
5.416
· (
5.416
372.4 =
1 + 2.443 ·
43225
2
Nu1,0
= 0.3 +
(2/3)
- 1)
2
Nu1,lam
444.7 = 0.3 +
Nu0,Bündel
-0.1
+ Nu1,turb
242.4
= fA · Nu1,0
=
2
+
372.4
1.601 ·
2
444.7 =
712.1
2
fA = 1 +
=
1.601
3 · b
Calculation of fG
RG = nF / (n / ND)
fG = 1 - RG + 0.524 · RG
1.093 = 1 -
⇔
0.2375 =
19 / (
80 /
1)
0.32
0.2375 + 0.524 ·
0.2375
0.32
—
Lauterbach Verfahrenstechnik GmbH
12
2013
WTS Sample Printout
2013
Thermal and Hydraulic Design of Shell and Tube Heat Exchangers
Calculation of fL
e
=
0.2756
in
e1 =
1.308
in
LE (e ; e1 ) =
dB =
1.016
in
da =
0.9843
in
n =
n
ASRU
π (dB
nF
=
-
·
ND
2
2
- da
80
=
π
· (Di
2
nF =
19
3.488
0.3858 ) =
106.7
in²
4
γ = 2 arccos(1- 2·H/D1 ) = 2 arccos(1 - 2 · 0.07776 /
ASMU
in
)
=
2
5.096
- D1
2
(360 - γ )
) ·
4
=
in²
1.99
360 · ND
= π /4 · (
2
0.3888
+ ASMU
=
-
0.3858
ASG
= ASRU
AE
= S · LE
=
0.19 ·
RL
= ASG
=
0.003534 /
fL
= 0.4
/ AE
2
) · (360-
0.00225 + 0.001284 =
ASRU
106.7) / (360 ·
5.478
in²
0.1294 =
38.12
in²
0.02459 =
0.1437
1)
ASRU
+
1 - 0.4
ASG
exp(-1.5 · RL )
ASG
0.00225
0.00225
0.8555 = 0.4
+
1 - 0.4
exp(-1.5 ·
0.003534
0.1437 )
0.003534
Calculation of fB
AB = S · (Di - DB - e) =
17.51
RB = AB / AE
0.02459 =
=
0.01129 /
in²
for e <(Di - DB )
else
AB = 0
0.4592
3
fB = exp
- ß · RB
1 -
for nS ≤ nW / 2
2 nS / nW
3
0.538 = exp
fB = 1
- ß ·
0.4592
1 -
2 ·
0 /
7
for nS > nW / 2
Lauterbach Verfahrenstechnik GmbH
13
2013
WTS Sample Printout
2013
Thermal and Hydraulic Design of Shell and Tube Heat Exchangers
Corrected log. mean temperature difference (CLMTD) and temperature distribution
Corrected logarithmic mean temperature difference (CLMTD) and distribution
with cell method for shell and tube heat exchangers
Tube-side inlet temperature
Shell-side inlet temperature
ti1
ta1
176
68
Tube-side mass flow
Shell-side mass flow
Specific heat capacity tube-side
Specific heat capacity shell-side
mi
ma
cpi
cpa
158730
198903
1
0.9978
Heat capacity flow tube-side (mi·cpi)
Heat capacity flow shell-side (ma·cpa)
Wwi
Wwa
46532
58165
Sheet plus shell type
Number of tube-side passes
Number of shell-side passes
Number of baffles
Nt
NS
NZ
Actual overall heat transfer coefficient
Actual heat transfer area
Number of tube rows per cell
1
2
1
19
k
A
396.5
38956
4
Flow pattern: countercurrent = 1; cocurrent = 2
Tube flow: countercurrent = 1; cocurrent = 2
0 = unmixed; 0.5 = mixed
101
1
0
Tube-side outlet temperature
Shell-side outlet temperature
ti2
ta2
LMTD countercurrent flow
CLMTD corrected log. mean temp. difference
FN factor
∆TGeg
∆Tm
FN
Number of cells
Product k·A
Product k·A per cell
Lauterbach Verfahrenstechnik GmbH
timax
tamax
timin
tamin
tinv
14
W/°F
W/°F
Btu/ft²hr°F
in²
-
°F
°F
68.57
64.69
0.9433
°F
°F
-
0.4047
0.3237
0.01664
0.01331
Maximum tube-side temperature
Maximum shell-side temperature
Minimum tube-side temperature
Minimum shell-side temperature
Max. temperature inversion in one cell
lb/hr
lb/hr
Btu/lb °F
Btu/lb °F
132.3
103
40
31437
785.9
Tube-side efficiency
Shell-side efficiency
Tube-side cell efficiency
Shell-side cell efficiency
°F
°F
176
103
132.3
68
32
W/°F
W/°F
°F
°F
°F
°F
°F
2013
WTS Sample Printout
2013
Thermal and Hydraulic Design of Shell and Tube Heat Exchangers
Tube bundle vibration analysis
General formulation
Outside diameter of the tubes
Wall thickness of the tubes
Inside tube diameter
da
s
di
Pitch (crosswise)
Pitch (lengthwise)
Transverse pitch ratio
Longitudinal pitch ratio
0.9843
0.07874
0.8268
t
l
t/da
l/da
in
in
in
1.26 in
1.091 in
1.28 1.109 -
Cross-sectional area of the tubes
Second moment of area of the tubes
A
J
0.2239
0.02309
Modulus of elasticity
Effective density
E
ρ
29007
490.1
in²
in^4
ksi
lb/ft³
Support for the tubes:
Selected support for the tubes:
Factor for the support
Factor for additional forces
1
fixed-jointed
C
3.93
Cf
1 -
Arrangement of the tubes (1-3)
Selected arrangement:
→ Strouhal number of the bundle
1 Staggered bare tubes
Sr
0.2219 -
Final span
Velocity in the narrowest cross section
L
we
11.42
4.143
Natural frequency of the tubes
fR
Safety factor
S
Allowable excitation frequency fz = fR/S fz
Excitation frequency of the flow
ferr
in
ft/s
1203 1/s
1.5 802.3 1/s
11.21 1/s
18.9
3.357
in
ft/s
439.3
1/s
292.9
9.081
1/s
1/s
in²
Vibration probable, when ferr > fz
Equations
di = da - 2 · s
=
25 - 2 ·
2 =
0.8268
in
A = π /4 · (da2 - di2 ) = π /4 · (
25
2
-
21
2
) =
0.2239
J = π /64 ·(da4 - di4 ) = π /64 ·(
25
4
-
21
4
) =
0.02309
106
fR =
C
2
·
E · J
·
2·π
ρ · A
106
3.93
·
2
da/1000
9611
7850 ·
144.4
·
290
⇔
802.3 =
⇔
11.21 =
Sr · we
ferr =
200000 ·
·
2·π
fz = fR / S
⇔
· Cf
L
1203 =
in^4
Lauterbach Verfahrenstechnik GmbH
1203 /
1.5
0.2219 ·
1.263
1
25 / 1000
15
2013
WTS Sample Printout
2013
Thermal and Hydraulic Design of Shell and Tube Heat Exchangers
Tube-side pressure loss in shell and tube heat exchangers
Properties
Inlet temperature
Outlet temperature
Mean temperature
Pressure at the inlet
Density of the fluid
Specific heat capacity
Thermal conductivity
Dynamic viscosity of the fluid
Fluid: liquid = 0, gas = 1
Fluid
ϑe
ϑa
ϑ
Pe
ρ
cp
λ
η
176
131
153.5
0.04351
61.13
1
0.3799
1.011
0
Acceleration due to gravity
Type (straight tube=1; U-tube=2)
Inside diameter of inlet nozzle
Inside diameter of outlet nozzle
Number of tube-side passes
Number of tubes per pass
Length of one tube
Inside tube diameter
Outside tube diameter
Tube wall thickness
Mass
Mean
Mean
Mean
°F
°F
°F
134
ksi
lb/ft³
61.19
Btu/lb °F
Btu/hr ft°F
lb/ft hr
1.186
g
9.81
°F
lb/ft³
lb/ft hr
m/s²
1
flow
velocity in the inlet nozzle
velocity in the outlet nozzle
velocity in the tube
Reynolds-Number
Prandtl-Number
Grashof-Number
Pressure loss factor
Friction coefficient
Correction factor for the viscosity
Correction factor for the convection
Friction factor (ξ is · Φ · ψ)
DTNI
DTNO
NTP
N
L
DI
DO
t =
5.185
5.185
2
40
157.5
0.8268
0.9843
0.07874
W
Vni =
Vno =
Vt =
158730
4.919
4.919
4.836
lb/hr
ft/s
ft/s
ft/s
Re =
Pr =
Gr =
72537
2.661
498913
-
=
3.2
=
0.0059
=
1.025
=
1
= 0.006047
-
=
=
=
=
=
=
ksi
ksi
ksi
ksi
ksi
Ke
ξ is
Φ
ψ
ξ
Pressure loss (inlet nozzle)
Pressure loss (outlet nozzle)
Pressure loss (inlet, outlet and baffle)
Pressure loss (friction)
Fouling factor
Total pressure loss (∆Pn + ∆Pe + Ft·∆Pt)
Lauterbach Verfahrenstechnik GmbH
Wall
16
∆Pni
∆Pno
∆Pe
∆Pt
Ft
∆P
0.000144
0.000144
0.000494
0.001421
1.277
0.002596
in
in
in
in
in
in
—
2013
WTS Sample Printout
2013
Thermal and Hydraulic Design of Shell and Tube Heat Exchangers
Equations
t = 1/2 · ( DO - DI )
⇔
0.002 = 1/2 · (
⇔
1.499 =
1.273 · W
Vni =
1.273 ·
DTNI2 · ρ
⇔
DTNO2 · ρ
20
2
979.2
1.273 ·
20
1.499 =
0.1317
1.273 · W
2
·
979.2
1.273 ·
⇔
Vt =
DI2 · N · ρ
Re =
0.021 )
·
0.1317
1.273 · W
Vno =
0.025 -
0.021
Vt · DI · ρ
2
·
40 ·
1.474 ·
⇔
η/1000
20
1.474 =
979.2
0.021 ·
979.2
72537 =
0.000418
Pr = η/1000 · Cp / λ
⇔
g · DI3
Gr =
2.661 = 0.000418 ·
4188 /
0.6575
ρ - ρW
·
( η/1000 / ρ )²
ρ
9.81 ·
0.021
3
979.2 -
498913 =
980.2
·
( 0.000418 /
979.2 )²
979.2
Pressure drop factor for:
Straight tubes: one pass
multiple passes
U-tubes:
two passes
four or more passes
ξ is = ξ is( Re )
= Φ ( Re ; η/ηW )
Φ
= ψ ( Re ; Gr·Pr·η/ηW )
ψ
∆PnE = ρ E ·VnE ² / 2.224 =
∆PnA = ρ A ·VnA ² / 2.224 =
∆Pe = Ke·ρ ·Vt² / 2.0
∆Pt = 2 · ξ ·
=
=
=
Ke
Ke
Ke
Ke
=
=
=
=
0.0059 = ξ is(
1.025 = Φ (
1 = ψ (
989.8 =
989.8 =
979.2 ·
979.2 ·
3404 =
3.2 ·
=
0.9
1.6 · NTP
0.9
0.8 · NTP
NTP =
2
Ke =
3.2
72537 )
72537 ;
72537 ;
0.852 )
1131300 )
1.499 ² / 2.224
1.499 ² / 2.224
979.2 ·
1.474 ² / 2.0
ρ · Vt² · NTP · L
DI
979.2 ·
1.474 ² ·
2 ·
4
9801 = 2 · 0.006047 ·
0.021
DO - 2·t
5
Ft =
DO - 2.2·t - 0.00182 · DO
0.3
0.025 - 2 ·
5
0.002
1.277 =
0.025 - 2.2 ·
Lauterbach Verfahrenstechnik GmbH
0.002 - 0.00182 ·
17
0.025
0.3
2013
WTS Sample Printout
2013
Thermal and Hydraulic Design of Shell and Tube Heat Exchangers
Pressure loss on the shell-side of shell and tube heat exchangers
Tube-bundle heat exchanger with baffles
Geometric variables:
Shell inside diameter
Tube bundle diameter at cross flow zone
Di
DB
15.31
12.69
in
in
Tube outside diameter
Tube pitch crosswise to direction of flow
Tube pitch lengthwise to direction of flow
Pitch angle
da
sq
sl
0.9843
1.26
1.091
60
in
in
in
°
Baffle diameter
Number of baffles
Height of the window in a baffle
Diameter of the bore holes for the tubes
in the baffles
Baffle spacing
Distance between the tubesheet and the 1st baffle
Dl
nU
H
dB
15.19
19
3.061
1.016
in
in
in
S
SE
7.48
11.42
in
in
Number of tubes including blanks and support tubes
Number of tubes in the upper and lower windows
Number of tube rows in a window
Number of main resistances in the crossflow zone
Number of main resistances in the end zone
Number of connection lines
Distance between boundary tubes and shell
Number of sealing strip pairs
n
nF
nRF
nW
nWE
nV
e1
nS
80
19
1.5
7
8.5
9
1.308
0
in
-
Number of shell-side passes
Tube lane width (only for ND = 2)
ND
b
1
1.929
in
Inside nozzle diameter (inlet)
Inside nozzle diameter (outlet)
dSi
dSo
6.272
6.272
in
in
Fluid:
Mass flow
Volume flow
m
V
198903
398.9
Fluid: liquid = 0 or gas = 1
0
Inlet pressure
Inlet temperature
Outlet temperature
Mean temperature
Density
Dynamic viscosity
Specific heat capacity
Thermal conductivity
Prandtl number
Mean wall temperature
Dynamic viscosity at mean wall temperature
Friction loss on the shellside of the heat exchanger
1 · 0.000022
∆p = (nU -1) · ND · ∆pQ = ( 19 - 1) ·
+ 2 · ∆pQ_E
=
2 · 0.000023
+ nU · ND · ∆pF
=
19 ·
1 · 0.000310
+ ∆pS
=
0.000230
∆p = 0.006568
lb/hr
gpm
PE
ϑE
ϑA
ϑ
ρ
η
cp
λ
Pr
ϑW
ηW
ksi
ksi
ksi
ksi
0.05801
68
104
86
62.17
1.93
0.9978
0.3555
5.416
111.9
1.457
ksi
°F
°F
°F
lb/ft³
lb/ft hr
Btu/lb °F
Btu/hr ft°F
°F
lb/ft hr
Cross-flow zone
End zone
Window zone
Nozzles
ksi
Lauterbach Verfahrenstechnik GmbH
—
18
2013
WTS Sample Printout
2013
Thermal and Hydraulic Design of Shell and Tube Heat Exchangers
Results
a =
1.28
e =
0.2756
in
Cross-flow zone
L_E =
5.096
in
f_a_l_f =
223.4
f_a_t_v =
-
b =
1.109
-
A_E =
38.12
in²
-
f_a_t_f =
0.6963
5.485
-
f_z_l =
Xi_l = 0.006994
-
1.28
w_e =
3.357
ft/s
-
f_a_l_v =
223.4
-
0.9875
-
f_z_t =
0.9615
-
Xi_t =
0.4103
-
Xi =
0.4014
-
A_SMU =
1.99
A_SG =
5.478
3.488
R_M =
0.3633
-
R_L =
0.1437
-
r =
0.5955
-
γ =
106.7
°
Re =
31937
-
ß =
3.7
-
R_S =
0
-
R_B =
0.4592
-
A_B =
17.51
in²
f_L =
0.5649
-
f_B =
0.1828
-
∆p_Q_0 = 0.000212
ksi
-
A_E_E =
58.19
in²
∆p_QE_0 = 0.000124
ksi
∆p_QE = 0.000023
ksi
Window zone
A_FG =
26.92
in²
w_p =
6.497
d_g =
1.806
End zone
Re_E =
20924
A_FR =
7.228
ft/s
w_z =
4.67
in
U_F =
43.63
ksi
∆p_F = 0.000310
ksi
w_S_o =
4.143
∆p_S = 0.000230
in²
ksi
∆p_F_l = 0.000295
Shell nozzles
w_S_i =
4.143
in²
-
A_SRU =
∆p_Q = 0.000022
in²
c =
in²
ft/s
w_e_E =
2.199
A_F =
19.7
n_WF =
2.245
ft/s
in²
-
in
∆p_F_t = 0.000490
ksi
ft/s
∆p_S_i = 0.000115
ksi
ft/s
∆p_S_o = 0.000115
ksi
ksi
Lauterbach Verfahrenstechnik GmbH
19
2013
WTS Sample Printout
2013
Thermal and Hydraulic Design of Shell and Tube Heat Exchangers
CAD program for shell and tube heat exchangers
Tube-side
TEMA type
AEL
TEMA: Front end:
A
Medium
Inlet pressure
Pressure stage
Inlet temperature
Outlet temperature
Mean temperature
Design temperature
Design pressure
Shell:
Shell-side
E
Rear end:
Water
pi
ϑe,i
ϑa,i
ϑm,i
L
Water
0.04351
0.2321
176
131
153.5
212
0.05801
ksi
ksi
°F
°F
°F
°F
ksi
pa
ϑe,a
ϑa,a
ϑm,a
0.05801
0.2321
68
104
86
122
0.07252
ksi
ksi
°F
°F
°F
°F
ksi
Inlet nozzle:
Flange connection n.w.*
Outside diameter
Nozzle wall thickness
Inside diameter
DN
125
5.185
DN
in
in
in
150
6.272
in
in
in
Outlet nozzle:
Flange connection n.w.*
Outside diameter
Nozzle wall thickness
Inside diameter
DN
125
5.185
DN
in
in
in
150
6.272
in
in
in
* n.w. = nominal width
Geometry:
Shell outside diam. Do
Shell inside diam.
Di
Bundle - shell distance
Tube outside diam.
do
Tube pitch (crosswise)
Pitch angle
Φ
Central baffle spacing
Inlet baffle spacing
Baffle borehole
Sealing strips pairs
16
15.31
0.543
0.9843
1.26
60
7.48
11.42
1.016
0
in
in
in
in
in
°
in
in
in
-
Shell wall thickness sa
0.3465
in
Tube inside diameter di
Tube pitch(lengthwise)
Pass lane width
b
Number of baffles/pass
Baffle diameter
Baffle cut
0.8268
1.091
1.929
19
15.19
20
in
in
in
in
%
Number of passes (tube-side)
Number of passes (shell-side)
2
1
Final bundle length
Final shell length
la
la
Number of tubes
Expansion joint diameter
Plate thickness (fixed plate)
Plate thickness (free plate)
R
Lauterbach Verfahrenstechnik GmbH
157.5
157.5
in
in
80
1.181
1.181
20
in
in
in
2013
WTS Sample Printout
2013
Thermal and Hydraulic Design of Shell and Tube Heat Exchangers
MS Excel Specification Sheet
1
2
3
4
5
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
59
60
61
Customer
Job No.
Reference No
Proposal No.
Date
Adress
Plant Location
PERFORMANCE OF ONE UNIT
Shell Side
Water
kg/s
25,06
kg/s
kg/s
Fluid Allocation
Fluid Name
Fluid Quantity, Total
Vapour (In / Out)
Liquid (In / Out)
Steam
Water
Noncondensables
Temperature (In / Out)
°C
20
Density
kg/m³
995,9
Viscosity
mPa·s
0,7976
Molecular Wt, Vapour
kg/kmol
Molecular Wt, Noncondensables kg/kmol
Specific Heat
J/(kg·K)
4177,6
Thermal Conductivity
W/(m·K)
0,6152
Latent Heat
J/kg
Inlet Pressure (abs.)
bar
4
Velocity
m/s
Pressure Drop, Allow./Calc.
Pa
Fouling Resistance
m²·K/W
Heat Exchanged
kW
2093,9
Transfer Rate, Service
W/(m²·K)
2250,9
MTD (Corrected)
K (diff)
35,32
Heat Transfer Area
m²
25,1
CONSTRUCTION OF ONE SHELL
Shell Side
Design / Test Pressure
Pa
Design Temperature
°C
No. Passes per Shell
1
Corrosion Allowance
mm
Connections
in
DN 150
Size &
out
DN 150
Rating
Intermediate
Tube Length
mm
4000
Tube Dimensions (OD x Thk)
mm
25 x 2
Pitch Cross
mm
32
Shell ID
mm
388,8
Channel or Bonnet
Tubesheet-Stationary
Floating Head Cover
Baffles-Cross
mm
385,8
Baffles Spacing
mm
190
Bypass Seal Arrangement
Expansion Joint
ρ · v² Bundle Entrance
kg/(m·s²)
1588
Gaskets-Shell Side
- Floating Head
Code Requirements
Weight / Shell
kg
Weight / Bundle
kg
Remarks
Lauterbach Verfahrenstechnik GmbH
40
28.01.2013
Tube Side
Water
20
80
979,2
0,4179
55
4187,9
0,6575
3
1,02
1,47
45288
17898
0
0
Sketch (Bundle/Nozzle Orientation)
Tube Side
2
DN 125
DN 125
Material
No. of Tubes
Pitch Long
Shell Dimensions (OD x Thk)
Channel Cover
Tubesheet-Floating
Impingement Protection
% Cut
Number of baffles / Shell-side path
80
27,7
406,4 x 8,8
20
19
Type
ρ · v² Bundle Exit
Tube Side
TEMA Class
Filled with Water
21
2013
WTS Sample Printout
2013
Thermal and Hydraulic Design of Shell and Tube Heat Exchangers
CAD created by WTSC
Lauterbach Verfahrenstechnik GmbH
22
2013
WTS Sample Printout
2013
Thermal and Hydraulic Design of Shell and Tube Heat Exchangers
3D Tube sheet created by Alibre Design from SPIE
Required:
•
LV Strength Calculation Software
• Alibre Design 3D-CAD
Lauterbach Verfahrenstechnik GmbH
23
2013