1.1.

Process Parameters
Input flow rate, temperature & vapour fraction at inlet / outlet conditions and the
allowable pressure drop for shell & tubeside. For liquids, vapor fraction is
0; for gas it is 1 and for two phase it is between 0 & 1.
1.2. Geometry

TEMA type
As given in Process data sheet (if not mentioned, then it shall be decided based on
type of fluid, condition etc.)
Orientation
Orientation may be horizontal, vertical or inclined with an angle between 0 and 90
deg.
Hot fluid side
Hot fluid shall be either on the shell side or on the tube side
Tube type
Plain or finned (for shell & tube generally plain tubes are used)
Tube length
In design mode, enter the length & design the exchanger for various shell IDs.
Standard tube lengths available in FPS unitsare 4, 6, 8, 10, 12, 14, 16, 18, 20,
22 and 24 feet. In MKS unit, tube lengths can be used in steps of 500
mm. Sometimes, it may be required to use FPS standard tube lengths in
MKS unit (for e.g. 6096 mm, 3048 mm, etc.)Note1: Sometimes odd tube
length would be acceptable for reboiler and small exchangers.Note2: Design of
exchanger will be different if selection of grid for tube length is different. If we decide
only 2,4 & 6 Metertube to be used then we have limitation of tube length. Some
time we may land up with design lesser DP utilizationbecause of tube length
constrain.

Now a days tubes in any length are available, after discussion with lead engineer we
can select odd tube length like 3500or 3600 mm. At the end we should select tube
length such that there will be fewer inventories of tubes in
store.Note3: Some time for high pressure exchanger (i.e. D type or C type
exchanger for which design pressure is more than70 to 80 Kg/cm2)
calculated tube sheet thickness by HTRI is on lower side than calculated thickness
mechanically because some time tube sheet is to be designed full design pressure
but HTRI is consider for differential design pressure. For such exchanger we should
add additional tube sheet thickness in geometry panel of HTRI during design and we
should specify tube length excluding tube sheet thickness on process data sheet.
Also we should mention only effective heat transfer area and clearly explain all these
points in notes.
Effective Tube length
This is the value used for heat transfer and need not be entered. HTRI calculates
tube sheet thickness and also the effective tube length.
Effective tube length = Total tube length Tube sheet thickness Tube projection
Surface area gross:
Total installed area (Number of tubes x total tube length x p x tube OD)
Surface Area Effective
Total installed area.(Number of tubes x effective tube length x p x tube OD)
Shell ID
In design mode this input is not required. HTRI calculates. If an exchanger
has to be designed for a fixed shell ID then input the ID and vary tube length by
using grid design option.(Refer grid design option 4.2.6)
Tube OD
Generally 19.05, 25.4, 31.75, 38.1, 50.1 mm Note: If tube OD is specified
in mm then tube thickness should be in mm i.e. 1.5 mm,2 mm 2.5 mm,
3.0mm (as per project design basis)And if tube OD is specified in inches then tube
thickness will be in BWG standard i.e. 12,14,16,18,BWG etc. We canconvert BWG
thickness in to equivalent mm. Never specify tube OD in mm & thickness in BWG or
tube OD in inches and thickness in mm.
Tube Pitch
Generally 1.25 times tube OD. Other values can also be specified. Note: Some
time to eliminate vibration pitch can be more than 1.25 times tube OD.
Tube layout
Refer Kern
Tube passes
Not required for design case.(For floating head and U-tube, even number of passes
shall be entered, viz. 2, 4, 6, 8 etc.) Note: Some time for floating head exchanger
single pass can be accepted.
Tube count
Not required for design case.
Tube material
Tube MOC shall be selected from HTRI data bank. Note: For Refinery MOC of
baffles, tube supports, tie-rods, spacers: (same as tube side MOC) but for
inorganic chemical plant we can use MOC of baffles tube support, tie-rods
spacers same as shell MOC. You should discuss with your senior and
finalise if there is any issue regarding MOC.
Baffle type
Various baffle types are Single, Double, NTIW and Rod. Baffle type need not be
specified for design case.
Baffle cut
Baffle cut is specified with respect to shell inlet nozzle axis and can be either vertical
or horizontal (if the baffle cut is perpendicular to the nozzle axis, then the cut is
horizontal and if the cut is parallel to the nozzle axis, then it is vertical).Baffle cut
need not be specified for design case.
Baffle spacing
Not required for design case.(However, the inlet, outlet and central baffle spacing
can be varied)No of baffles = (Total no of cross passes 1) Select no of
cross passes such that we will get shell side nozzle at appositeto each
other. (Some time process or layout require nozzle at same side.)
Parallel pass lane
Not required for design case (Refer HTRI help)Need to specify width in order to
achieve 2D bend radius or inline cleaning arrangement for square or rotated square
pitch.

Perpendicular pass lane

Not required for design case (Refer HTRI help)Need to specify width in order to
achieve 2D bend radius or inline cleaning arrangement for square or rotated square
pitch.
Sealing strips
Not required for design case (Refer HTRI help)Sealing strip reduces leakage in
bundle and shell, which increases the cross flow fraction. Shell side inlet / outlet
nozzle Standard i.e. ANSI or JIS standards, schedule i.e. Std. Sch. , Sch 40,Sch 80
etc., nos., ID, type, position i.e. top, bottom etc. Not required for design case
Location: For liquid-liquid exchangers both shell side & tube side inlet nozzle should
be from bottom of shell.(If not then there should be provision in piping to ensure
exchanger is always full of liquid) For gas or two phase fluid inlet is from top and
vapour / non condensable outlet is from top of other side and liquid outlet
at bottom. Nozzle RV2 should be less than 2232 kg/mS2.if RV2 is more
than 2232 then impingement plate is to be provided for nozzle. At Shell
entrance and bundle entrance TEMA limit for RV2 is 2232 kg/mS2.Tube side inlet /
outlet nozzle Standard i.e. ANSI or JIS standards, schedule i.e. Std. Sch. , Sch
40,Sch 80 etc., nos., ID, type, position i.e. top, bottom etc. Not required for
design case Select nozzle location such that 1st tube pass is in counter
current with respect to shell side pass.
Impingement plate
Not required for design case For gas and two phase inlet impingement plate is to be
provided. Sometime instead of plate type impingement plate 2 Rows of rod
are used as protection of first few rows of tube. If shell side nozzle inlet /
outlet RV is more than the allowable limit, then HTRI will consider an impingement
plate. For gas and two-phase flow, impingement plate is required. For liquid phase,
it depends on the value of RV. Generally, rectangular impingement plates are used
for exchanger There is some optional data, which is not required for design purpose.
However, this data should be corrected at the time of rating and fine-tuning, which is
given below. Total tube sheet thickness, floating head support plate, support at U-
bend.
1.3. PIPING
This detail is required only for reboiler type exchanger.
1.4. Process Exchanger Duty
Enter actual exchanger duty
Duty Multiplier
Enter the duty multiplier For e.g. for 10% over design on duty, enter 1.1
Fouling resistance
Enter the value mentioned in data sheet. If this value is not available in the
datasheet, then the same should be taken from published literature, reference
books, like Process Heat Transfer by D.Q. Kern.
1.5. Physical Properties of hot & cold fluid
Physical properties inputThree options are available:
(a) Mixture property via grid(b) Component by component(c) Grid & compon
ent. Heat release curveThree options are
available(a) User specified(b) Dew/bubble point specified(c) Programme calcula
ted Composition unitsMoles or mass Flash typeDifferential (separate and not in
contact) or integral (well mixed and in thermal and chemical equilibrium)

1.6. Grid Design

Geometry

a. Shell ID
Enter the minimum and maximum shell ID and either the number of steps or the
step size in mm or inch
b. Baffle spacing
Enter the minimum and maximum baffle spacing and either the number of steps or
the step size in mm or inch
c. Tube passes
Enter the minimum and maximum number of passes and odd or even
passes.
d. Tube length
Enter the minimum and maximum tube length and either the number of steps or
the step size in mm or inch
e. Pitch ratio
Enter the minimum and maximum pitch ratio and either the number of steps or the
step size in mm or inch
f. Tube diameter
Enter the minimum and maximum tube diameter and either the number of steps
or the step size in mm or inch
g. Shell type
Select any one of:TEMA E, F, G, H, J21, X, K type shell

h. Baffle type
Enter any one from the following options: Single Double No tubes in window
(NTIW)Rod None HTRI gives various designs with different shell ID with optimum
baffle spacing for given tube length and tube passes. HTRI gives shell ID in
standard inch format. It has to be fine tuned to the nearest round number that is
divisible by 5. This can be done by putting the programme on rating mode.
Constraints
Vary hot fluid velocity, cold fluid velocity, pressure drop etc.
Options
Generally we are not changing these options .If required we can vary all options as
given in the HTRI. i.e. Allowed overdesign range, Baffle spacing options, Tube pass
options etc.
Warnings
 If you required additional warnings other than HTRIs standard warnings, then we
can specify here. i.e. Warnings for hotstream or cold stream tube wall temperature,
Allowed critical velocity ration, Allowed vibration frequency ratio etc.No
warning should be neglected while designing the exchanger. Once all the above
data listed in sections 1.2. through 1.6 is entered, the programme shall be run by
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