151

INTRODUCTION
Shell and tube heat exchangers with parallel helical tube
coils(HEHTC)consistofalargenumberofhelicaltubecoils
whichareplacedwithinacylindricalshellintheformofa
tube bundle. The number of passes of fluid at the tube
side and at the shellside is usually one or two. The
number of passes of fluid at the tubeside is provided by
meansofbafflesallocatedinthestationaryheadchannel,
whereas the number of passes of fluid at the shellside is
providedbylongitudinalbafflesallocatedinthecylindrical
shell [1] [2]. The main types of shell and tube heat
exchangers with parallel helical tubes are with fixed tube
sheets (Figure 1) and heat exchangers with floating head
(Figure2)[2].

Fig.1 Shell and tube heat exchanger with parallel helical

tubecoilsfixedtubesheettype

Fig.2 Shell and tube heat exchanger with parallel helical

tubecoilsfloatingheadtype
Although the aforementioned heat exchangershave been
used in thermal engineering and process industries for
almosthalfacentury,problemsrelatedtotheireconomic
costs have not been fully explored. Taking this into
consideration, the primary objective of this paper was to
determinethemanufacturingcostsofshellandtubeheat
exchangers with parallel helical tubes. These costs in
general case include costs of materials for apparatus,
energy,labor,andothercosts.
CALCULATIONPRICEOFHEATEXCHANGERS
We can find several correlations for estimating cost of
shell and tube heat exchangers in the open literature.
They are based on knowledge of the design of the
apparatus, the operating pressure, the heat transfer
surface, the material the apparatus is made of, etc. The
most often cited correlations are listed in Table 1, where
they arenot given in its original form, but are adjusted in
order for the price to be expressed in an appropriate
manner(inthiscaseEUR2011).Pricesofapparatusshould
be translated also from the year in which they were
manufactured (Table 2) in the year for which the analysis
isdone.Thesimplestmethodwhichtakesintoaccountthe
increasing costs due to market trends, as given by the
equation:
/ /
A A B B
C I C I =
(1)
where
C
A
,priceofapparatusatthemoment,
C
B
,priceofapparatusatthemomentB,
I
A
indexofpriceatthemoment,
I
B
indexofpriceatthemomentB[3].
ANALYSIS OF MANUFACTURING COSTS OF HEAT
EXCHANGERSWITHPARALLELHELICALTUBECOILS
Forheatexchangerswithparallelhelicaltubeswithafixed
tube sheet we encounter no correlation for the
assessment of investment costs in the literature.
Therefore,weconductedananalysisthegoalofwhichwas
todeterminetowhatextentthediscrepanciesarosewhen
using the existing equations (2 21). Deviation in prices
calculated using the correlation 2 21 and the actual price
of apparatuses (data obtained from the manufacturer) is
expressedusingstatisticalindicators:correlationratio(CR)
and the rootmean square deviation (RMSD), which are
alsoshowninTable3.

Contents lists available at www.icmem.tk

Manufacturing Engineering & Management

TheProceedings
Manufacturing cost of Shell and Tube Heat Exchangers with paralel
Helical Tube Coils
IvanM.Rakonjac
1
StevanJ.Budimir
2
MarkoS.Jari
3
NikolaJ.Budimir
3

1
ProjectManagementCollege,Krfska7,11000Belgrade,Serbia

2
InstitutGoa,MilanaRakia35,11000Belgrade,Serbia
3
InnovationCenteroftheFacultyofMechanicalEngineering,KraljiceMarije16,11000Belgrade,Serbia
ARTICLEINFO:
Category:Shortcommunication
Received:20October2012/Revised:30October2012/Accepted:2November2012
Keywords:(incausalorder) Abstract:
Correlation
Costs
Heatexchanger
Helicaltube
Manufacturing

Thepaperdealswiththemanufacturingcostsforshellandtubeheatexchangerswithparallelhelicaltube
coils.Themostcommoncorrelationsforestimatingpricesofshellandtubeheatexchangersfoundinopen
literatureweretestedusingthemarketdataforacomparisonandtheyhaveshownsignificantdeviations.A
new correlation for calculating prices of heat exchangers with helical tubes (when the shell is made of
carbonsteelandthehelicaltubeofcopper)wasdeterminedinthefollowingformC
in
=700+310.S
hts
.
Citation:RakonjacIM,etal.:ManufacturingcostofShellandTubeHeatExchangerswithparalelHelicalTubeCoils,2
nd
InternationalConferenceManufacturingEngineering&
Management2012,(2012),p.151154,ISBN9788055312163

IM Rakonjac, et al. Manufacturing cost of Shell and Tube Heat Exchangers with paralel Helical Tube Coils
152

ab.1Correlationsforestimationpriceofshellandtubeheatexchangersbyvariousauthors
Year
Material
(ShellTube)
Temp.
range
( C )
Pressure
range
(
bar
)
hts
S
range
(
2
m )
Correlation Ref. Eq.
1990 CarbonsteelCarbonsteel
0.8
5910.69 303.98
in hts
C S = +

[4] (2)
1990 CarbonsteelStainlesssteel
0.85
7191.11 345.35
in hts
C S = +
[4] (3)
1990 StainlesssteelStainlesssteel
0.91
8443.84 273.58
in hts
C S = +

[4] (4)
1990 CarbonsteelTitanium
0,92
11821,38 581.45
in hts
C S = +
[4] (5)
1990 TitaniumTitanium
0,93
14776,72 590.22
in hts
C S = +

[4] (6)
1995 0,05 0.27
0.432
906.54
in hts
C S =
[5] (7)
1998 CarbonsteelCarbonsteel 20 30 10 600
0.64
1400.41
in hts
C S =

[6] (8)
1998 CarbonsteelBrass 20 30 10 600
0.71
1278.15
in hts
C S =
[6] (9)
1998 CarbonsteelStainlesssteel 20 30 10 600
0.86
1302.66
in hts
C S =
[6] (10)
1998 StainlesssteelStainlesssteel 20 30 10 600
0.82
1874.35
in hts
C S =

[6] (11)
2001 CarbonsteelCarbonsteel 350 s 10.5 s 9 6500 8500.71 111.42
in hts
C S = +

[7] (12)
2004 StainlesssteelTitanium
0.81
30800 3748
in hts
C S = +

[8] (13)
2007 CarbonsteelCarbonsteel 300 s 50 s
0.68
3183.18
in hts
C S =

[9] (14)
2007 CarbonsteelAluminium 300 s 50 s
0.68
4138.14
in hts
C S =

[9] (15)
2007 CarbonsteelMonel 300 s 50 s
0.68
6684.68
in hts
C S =
[9] (16)
2007 CarbonsteelStainlesssteel 300 s 50 s
0.68
5411.42
in hts
C S =

[9] (17)
2007 StainlesssteelStainlesssteel 300 s 50 s
0.68
9231.23
in hts
C S =
[9] (18)
2009 CarbonsteelCarbonsteel 9 90
0.551
1957.79
in hts
C S =
[10] (19)
2009 Admiralty 9 90
0.679
1422.20
in hts
C S =

[10] (20)
2009 Copperbrass 9 90
0.679
1722.68
in hts
C S =

[10] (21)
ab.2ApparatusManufacturingyear
No.
2
, m
hts
S

Manufacturingyear Costofapparatusinmanufacturingyear
Costofapparatus
( )
2011
EUR

1 2.51 2005 1200 1568
2 4.02 2010 1600 1760
3 8.55 2009 3900 4690
4 11.56 2009 3600 4329
5 11.56 2008 3600 3515
6 15.03 2010 4500 4950
7 18.60 2008 5800 5663
8 18.95 2009 6200 7456
9 22.11 2008 6600 6445
10 24.18 2010 5600 6160
11 26.24 2008 9300 9081
12 28.13 2009 7300 8779
13 28.75 2006 11900 14580
14 32.17 2008 9600 9374
15 35.94 2010 11000 12098
16 37.20 2008 11880 11600

ab.3ApparatusManufacturingyear
No. Year
Material
(ShellTube)
Temp.
range
( C )
Pressure
range
(
bar
)
hts
S

range
(
2
m )
Correlation Ref. CR
RMSD
Eq.
1 1990
CarbonsteelCarbon
steel

0.8
5910.69 303.98
in hts
C S = +

[4] 0.4345 119.58 (2)
2 1990
CarbonsteelStainless
steel

0.85
7191.11 345.35
in hts
C S = +

[4] 0 161.19 (3)
3 1990
StainlesssteelStainless
steel

0.91
8443.84 273.58
in hts
C S = +

[4] 0 189.57 (4)
4 1990 CarbonsteelTitanium
0.92
11821.38 581.45
in hts
C S = +

[4] 0 332.1 (5)
5 1990 TitaniumTitanium
0.93
14776.72 590.22
in hts
C S = + [4] 0 413.71 (6)

Manufacturing cost of Shell and Tube Heat Exchangers with paralel Helical Tube Coils IM Rakonjac, et al.
153

ab.3ApparatusManufacturingyear(continue)
No. Year
Material
(ShellTube)
Temp.
range
(C)
Pressure
range
(bar)
hts
S

range
(m
2
)
Correlation Ref. CR

RMSD

Eq.
6 1995
0.05

0.27
0.432
906.54
in hts
C S =

[5] 0 49.47 (7)
7 1998
Carbonsteel Carbon
steel
20 30 10 600
0.64
1400.41
in hts
C S =

[6] 0.6391 53.11 (8)
8 1998 CarbonsteelBrass 20 30 10 600
0.71
1278.15
in hts
C S = [6] 0 66.31 (9)
9 1998
Carbonsteel Stainless
steel
20 30 10 600
0.86
1302.66
in hts
C S = [6] 0 154.62 (10)
10 1998
StainlesssteelStainless
steel
20 30 10 600
0.82
1874.35
in hts
C S = [6] 0 225.57 (11)
11 2001
Carbonsteel Carbon
steel
350 s

10.5 s
9 6500 8500.71 111.42
in hts
C S = +

[7] 0 171.42 (12)
12 2004 StainlesssteelTitanium
0.81
30800 3748
in hts
C S = +

[8] 0 1266.65 (13)
13 2007
Carbonsteel Carbon
steel
300 s

50 s

0.68
3183.18
in hts
C S =

[9] 0 275.04 (14)
14 2007
Carbonsteel
Aluminium
300 s
50 s
0.68
4138.14
in hts
C S =

[9] 0 386.68 (15)
15 2007 CarbonsteelMonel 300 s
50 s
0.68
6684.68
in hts
C S =
[9] 0 684.66 (16)
16 2007
Carbonsteel Stainless
steel
300 s 50 s
0.68
5411.42
in hts
C S =

[9] 0 535.64 (17)
17 2007
StainlesssteelStainless
steel
300 s
50 s
0.68
9231.23
in hts
C S =
[9] 0 982.76 (18)
18 2009
Carbonsteel Carbon
steel
9 90
0.551
1957.79
in hts
C S =
[10] 0.4072 70.7 (19)
19 2009 Admiralty 9 90
0.679
1422.20
in hts
C S =

[10] 0 70.24 (20)
20 2009 Copperbrass 9 90
0.679
1722.68
in hts
C S =
[10] 0 104.51 (21)

The analysis proved that these correlations show

significantdeviationsandthattheycannotbesuccessfully
used to describe the manufacturing costs for the
mentionedtypeofshellandtubeheatexchangers(aheat
exchanger with parallel helical tubes with a fixed tube
sheet, where the apparatus shell is made of carbon steel
and the heat exchangers tubes are made of copper).
Therefore, on the basis of the data given in Table 2 (for
2011 year price), a new correlation was found in the
followingform(Figure3):
700 310 , EUR
in hts
C S = +

2
hts
2.50 38, m S < <
(2)
30 bar p s

Its statistical parameters are CR=0.9068 and
RMSD=17.10%. In the above equations (2

21) the value

of heat transfer surface (S
hts
) was expressed taking into
accounttheoutsideofthetube.
2 6 10 14 18 22 26 30 34 38
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
Heat transfer surface, S
hts
, m
2
C
o
s
t

o
f

h
e
a
t

e
x
c
h
a
n
g
e
r
s
,

E
U
R
hts
310 700 S C
in
+ =

Fig.3 Manufacturing costs for apparatus versus to heat

transfersurface

CONCLUSION
The paper presents the main types and manufacturing
costs for shell and tube heat exchangers with parallel
helical tube coils. The cost analysis was conducted using
theactualprice(dataobtainedfromthemanufacturer)of
apparatuswithhelicaltubecoilsintheRepublicofSerbia.
After examining the correlations currently found in the
existingbodyofliteratureoninvestmentcostsofshelland
tube heat exchangers, it was concluded that a new
correlation needs to be found. The new correlation for
determining the price of shell and tube heat exchangers
with parallel helical tube coils (when the shell is made of
carbon steel and the tube is made of copper) has the
followingform

700 310 , EUR

in hts
C S = +

(3)
for range
2
hts
2.50 38, m S < <
, and the operating pressure
30, bar p s
. Statistical parameters of the equation are
0.907 CR =
,andRMSD=17.10%.

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