SHELL & TUBE HEAT EXCHANGER

DESIGN and SELECTION

Francis Hansa
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S&T HX INFO

TEMA STANDARD BOOK

(TUBULAR EXCHANGER MANUFACTURERS ASSOCIATION)
PERRY CHEMICAL ENGINEERING HAND BOOK
(CHAPTER -11)
ANY OTHER HEAT TRANSFER THEORY BOOK (KERN)
INTERNET

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TEMA TYPES

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FRONT HEAD

SHELL TYPES

REAR END HEAD

TYPES

TEMA TYPES
FRONT HEAD

SHELL TYPE

REAR END HEAD

TYPES

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TEMA AEM TYPE HX

AEM Type exchanger,

FIX Tube sheet design, Front head has a removable cover,
Tube side can be inspected & cleaned without unbolting pipe
works, Single shell pass & Tube side can be even or single
pass
Application: HC liquid cooling & Heating, Condenser
application

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TEMA BEM TYPE HX

BEM Type Hx
Popular TEMA model, Front & rear head has integral covers,
Fixed tube sheet design, tube side can be mechanically
cleaned & inspected,

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TEMA AES TYPE Hx

TEMA AES Type Hx

Popular TEMA model in refinery application, Removable
bundle, Tube bundle can be replace later stage, Tube side &
shell
side can be cleaned mechanically, good for differential expansion
between tubes & shell

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TEMA NEN Type HX

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HAIR-PIN TYPE EXCHANGER

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TEMA CLASSES

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Class R this class specify design and fabrication of

unfired shell and tube heat exchangers for the generally
severe requirements of petroleum and related
processing application.
Class C - this class specify design and fabrication of
unfired shell and tube heat exchangers for the generally
moderate requirements of commercial and general
process application.
Class B - this class specify design and fabrication of
unfired shell and tube heat exchangers for chemical
process services.

TEMA TYPE SELECTION

FACTORS EFFECTING TEMA TYPE SELECTION
Shell Type Selection
OPERATING TEMPERATURE OF HOT & COLD FLUIDS
NO TEMP CROSS

TEMP CROSS

Length
can be multi-passes
Thot out > Tcold out

Length
Temperature cross
Thot out < Tcold out

- E TYPE SUITES FOR BOTH CASES

- F TYPE CAN BE USED FOR TEMP CROSS

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TEMA TYPE SELECTION

Shell Type Selection

ALLOWABLE PRESSURE DROP

- LOW PRESSURE DROP / HIGH FLOW ON SHELL SIDE
- J SHELL GIVES LOW PRESSURE DROP

- X GIVES LOW PRESSURE DROP,

Eg: LOW PRESSURE STEAM CONDENSERS
- F TYPE IF ALLOWABLE P IS HIGH/LOW FLOW

REBOILERS, 100% VAPARIZATION

- K TYPE SHELL FOR ISOTHERMAL REBOILERS,
- K PARTIAL REBOILERS WHEN VAPOUR AND LIQUID SEPERATION NEEDED

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TEMA TYPE SELECTION

FRONT HEAD SELECTION
PROCESS FLUIDS CONDITIONS
- A TYPE FOR DIRTY FLUIDS ON TUBE SIDE
EASY ACCESS TO TUBE CLEANING
- B TYPE FOR GENERALLY CLEAN FLUIDS
- N TYPE FOR HAZARDOUS FLUIDS
HIGH OPERATING PRESSURE/DESIGN PRESSURE
- C HIGH DESIGN PRESSURE >15MPa
VERY HIGH DESIGN PRESSURE
- D TYPE

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TEMA TYPE SELECTION

REAR HEAD TYPE SELECTION

TEMA HAS 8 TYPES (L,M,N,P,S,T.U.W)

FOR FIXED TUBE SHEET TYPE L, M & N
- SELECT THESE WHEN SHELL SIDE CLEANING NOT NEEDED
- WHEN DIFFERENTIAL EXPANSION BETWEEN SHELL & TUBE NO EFFECT

FLOATING HEAD TYPES ARE P, S, T & W

- S & T TYPES ARE ACCEPTABLE IN PETRO CHEMICAL INDUSTRY
- WHEN SHELL SIDE CLEANING IS REQUIRED
- WHEN DIFFENTIAL EXPANSION BETWEEN SHELL & TUBE IS > 4mm

U-TUBE

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WHEN TUBE SIDE MECHANICAL CLEANING NOT REQUIRED

WHEN TUBE MATERIAL IS EXPENSIVE HIGH ALLOYS

TEMA TYPE SELECTION

FACTORS EFFECTING TEMA TYPE SELECTION

COST OF EXCHANGER
- FLOTING HEAD CONSTRUCTION IS EXPENSIVE
- U-TUBE IS GENERALLY CHEAPER
- BEM TYPE CHEAPER THAN OTHER FIXED TUBE SHEET DESIGN
MATERIAL SELECTION
- U-TUBE WHEN SS OR HIGH ALLOY MATERIAL USED

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S&T Hx Type Comparison

THERMAL DESIGN OF S&T HX

THERMAL DESIGN
INFO REQUIRED FOR GOOD HX DESIGN
- FUNDAMENTALS OF HEAT TRANSFER & VIBRATION THEORY
-

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KNOWLEDGE OF HX PARTS/CONFIGURATION
FAMILIARITY WITH TEMA STANDARD
FOULING FACTORS APPLIED FOR FLUIDS
KNOWLEDGE OF MATRIAL AVAILABILITY IN THE MARKET
KNOWLEDGE OF FABRICATION POSIBILITIES & DIFICULTIES
REQUIREMENT FOR MAINTENANCE FOR EXPECTED LIFE OF HX
SOFTWARE KNOWLEDGE

DESIGN PROGRAMS
INDUSRTY ACCEPTED DESIGN PROGRAMS
HTRI PROGRAM
SOFTWARE DEVELOPED BY HEAT TRANSFER RESEARCH
INC.

HTFS PROGRAM
SOFTWARE DEVELOPED BY ASPENTECH INC
BOTH HTRI & HTFS ARE AVAILABLE IN WP

OTHER PROGRAMS
- B-JAC
IN-HOUSE DEVELOPED PROGRAMS.

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THERMAL DESIGN

HEAT TRANSFER FUNDAMENTALS

BASIC EQUATIONS
HEAT DUTY
Q=M(H1-H2) = -m(h1-h2)
M,m = mass flow rates
H,h = specific enthalpies
1,2 = inlet & outlet

SURFACE AREA
Q=U*A*T = UA(LMTD)
T = Mean temperature difference
LMTD = Log Mean Temperature Difference

PGm2

PRESSURE DROP (P)

BASIC MECHANICAL EQUATION

t=P*D/(2fn-P)
t=thickness,
P=Design pressure
D=Inside diameter of pipe/tube
f =Design tensile strength of material at design temp
n =Joint(weld) efficiency (1 or 0.85)

THERMAL DESIGN

GETTING AN OPTIMUM DESIGN

MAKE IT LONGER SKINEER HX CHEAPER
- TUBE LENGTH 6.096M(20ft), 9.144M(30ft), 12.192M(40ft)
- TUBE Diameter - TEMA GIVES 8 TUBE DIAMETERS
9.525mm, 12.7mm, 15.875mm, 19.05mm, 25.4mm, 31.75mm, 38.1mm &
50.8mm
- API-660 MINIMUM DIAMETER 19.05mm
SHELL DIAMETER
CAN IT BE DONE USING STANDARD PIPE DIAMETERS?
AVAILABLE DIAMETERS 6,8,10,12,14,16,18 and 24
FABRICATORS ARE ABLE TO MAKE ANY DIAMETER > 24
USE MAXIMUM AVAILABLE PRESSURE DROP
- TUBE SIDE BY INCREASING LENGTH, TUBE PASSES
- SHELL SIDE - INCREASING BAFFLES, CHANGING BAFFLE TYPES
COMMONLY USE BAFFLE TYPES SINGLE SEG , DBL SEG, SEG/NTIW
USE OF F-SHELL

THERMAL DESIGN OF S&T HX

THERMAL DESIGN USING HTRI

HTRI Xist PROGRAM
USES INCREMENTAL METHOD
CALCULATE U, P, MTD FOR SMALL INCREMENTS OF TUBE LENGTH
BETTER METHOD THAN OVERALL METHOD.
- CONSIDER FLOW STRAM INSIDE THE SHELL FOR HTC AND P
CALCULATION
FLOW FRACTIONS:
B-Stream : Main cross flow stream through the bundle
C-Stream : bundle to shell
A-Stream: tube to baffle hole leakage
E-Stream : Baffle to shell leakage stream < 10%
F-Stream: Tube pass partition bypass stream

< 10%

THERMAL DESIGN

THERMAL DESIGN

VIBRATION ANALYSIS
HTRI GIVES TUBE VIBRATION ANALYSIS REPORT
- AIM TO GET VIBRATION WARNING FREE DESIGN
- TUBE VIBRATION IS MAINLY DUE TO SHELL SIDE VELOCITIES
- WAYS TO AVOID VIBRATION: INCREASE PITCH, BAFFLE STYLE, BAFFLE
SPACINGS
TEMA GIVES LIMITS ON SHELL ENTERENCE/EXIT v2
- HTRI CALCUALTES THESE VALUES AND GIVES WARNINGS IF THEY
EXCEEDS TEMA VALUES
- TUBE ENTRERANCE < 8928 kg/m-sec2 (SHELL DEP < 7000)
- SHELL ENTERENCE < 1900 kg/m-sec2
- SHELL OR BUNDLE EXIT < 3000 kg/m-sec2

CASE STUDY

GAS-II PROJECT LIQUID

HEATER
Hot Fluid Therminol-55
Cold Fluid HC Liquid
Operating Conditions;
Hot Fluid
Flow Kg/sec

Cold Fluid
139.54

Temp IN/Out C

287 / 232

26.6 / 71

Allowable P kPa

70

100

Heat Duty MW

24.27

24.27

BAFFLES

Main types
Segmental
Gives higher pressure drop
Arrangement can be
perpendicular to nozzle centre
line
or parallel to nozzle centre line.

BAFFLES

Double Segmental type

Low pressure drop
Normally for used for vapour
or condensing vapour
application
Shell side pressure drop
decreases 1/3 that of
segmental for the same
central spacing.

TUBE PATTERN

Standard tube patterns are

30 degree
- most common, not good for shell side cleaning
45 and 90 degree
- Good for shell side cleaning