CALCULATION PROCEDURE FOR AN EXISTING SHELL-AND-TUBE HEAT

EXCHANGER ( KERN METHOD )

-Process Conditions Required: (Given):

Hot Fluid : T1, T2, W, Cp, , , k, Rd, p.
Cold Fluid : t1, t2, w, cP, , , k, Rd, p.

-For the exchanger the following data must be known:

Shell Side Tube Side
ID Number and Length
Baffle Space OD, BWG, pitch
Passes Passes

1. Heat Balance Q = WCP (T1-T2) = wcP (t2-t1).

2. Average Temperature Drop: T
T1 T2 t2 t1
LMTD, R= , P= , F, T = LMTD F
t 2 t1 T1 t 1
T2 + T1 t 2 + t1
3. Average Temperatures: Tav = and t av =
2 2
A. Shell Side B. Tube Side

4. Obtain physical properties at Tav 4. Obtain physical properties at tav

5. Area for cross flow: 5. For flow area obtain tube ID ( Di )

(for one shell pass) 0.2Ds B Ds
Ds W ( D i ) 2
Sc = (P D o )B , Gc = Flow area per tube: at =
P Sc 4
where:
P = tube pitch B = baffle spacing
Do = tube OD Ds = shell ID.

6. Area for baffle window 6. Flow area per pass:

At =
(N t )(a t )
nt
(for one shell pass)
D s2 D 2o W
Sb = f b Nb , Gb = where:
4 4 Sb
*
fb = 0.1955 ( optional ) Nt = total number of tubes
* N
Nb = t , (Nb must be integer) nt = number of tube passes.
4
 w
7. Mass Velocity: Ge = (GcGb)1/2 7. Average velocity: v =
At

D oG e v Di
8. Res = 8. Re t =

CP CP
9. Calculate Prs = 9. Calculate Prt =
k k
10. Use Donohue Eqn. to find 10. Use Gnielinski Eqn. to find
h sD o h i Di
sk k
* for 25% segmental baffle cut.

Di
11. Tube wall Temperature tw 11. h io = h i
Do
h s / s
t W = t av + ( Tav t av )
h io + h s / s

12. Find w and calculate : 15. Design Overall Coefficient:

0.14
Q
s = UD = , where A = DoLtNt
w s AT
13. Corrected coefficient: where Lt = Length of a tube in one pass
h U U D
h o = s s 16. Dirt Factor: Rd , cal = c ,
s U cU D
14. Clean Overall Coefficient: if Rd,cal equals or exceeds the required dirt factor Rd
h io h o
Uc = proceed under the pressure drop.
h io + h o
Donohue Eqn. for shell side: Gnielinski Eqn. for tube side:

0.14
hsDo D G
0.6
Cp
0.33
Nu D =
(f / 2)(Re D )Prt
= 0.2 o e 1 + 12.7(f / 2)1/2 (Prt
2/3
k 1)
w k
0.5 < Prt < 2000
W W
G e = G b G c , Gb = and Gc = for 2300 < Ret < 104 ReD = Ret -1000
Sb Sc
for 104 < Ret < 5x106 ReD = Ret
*
1 /D 5.0452
where = 4log logA
f 3.7065 Re t
= 0.05 mm or
 1.1098 0.8981
/D 7.149 take /D = 0
A= +
2.5497 Re t for clean pipe

Pressure Drop
A. Shell Side B. Tube Side
1. For Re obtained from the eqn. below 1. Calculate P inside the tubes
4 f Lt n t v2
calculate f by Pt =
Di 2
f = 1.7789 Re-0.195868 Re > 400

Lt
2. Number of crosses: N + 1 = 2. Calculate P in tube side returns
B
f G 2c D s (N + 1) v2
3. Ps = Pr = 4 n t
2 D h s 2
D h Gc
Re = , Dh = 4 (p2-Do2/4)/Do 3. Calculate total pressure drop

(square pitch)
p 1
Dh = 4 ( 0.86p - Do2/4)/(0.5Do) PT = Pt + Pr
2 2
( triangular pitch)
*Tosun I. and . Ak ahin, Calculate Critical Piping Parameters, Chemical Engineering,
pp165-166, March 1993.