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Operational Variables
Design Limits pressure drops & velocities
Optimization of geometry baffle types / shell type / streams
placements
TEMA N With this construction, the head cylinder and shell cylinder are
welded to the tubesheet. The flat bolted cover permits access to the tubes
without interfering with the piping connections. Used with fixed tubesheets
with hazardous fluids on the tubeside.
TEMA D Is a high pressure enclosure. The channel barrel and the
tubesheet are usually forged. The cover may be bolted to the end of the
head cylinder or inserted into the cylinder and held by a system of shear key
rings.
Shell Types
E-type Is the most common of the shell types. The one shell pass with the
entrance and exit nozzles at opposite ends is the ideal arrangement for
excellent performance. Used with a single tube pass temperature crosses
can be avoided.
F-type A longitudinal baffle divides the shell into two passes. Both the
inlet and exit tube side nozzles are placed at the same end of the
exchanger. The F-shell is typically used when a temperature cross exists
that would otherwise force the design into multiple shells in series. They are
not recommended with removable bundles. A tight seal is required at the
long baffle as the unit will not perform as designed should there be fluid
leakage across the longitudinal baffle. The amount of heat transferred is
greater than for an E-shell, but the shell side pressure drop is also higher
and there is some thermal leakage, radiate heat transfer, across the long
plate.
G-type- The entrance and exit nozzles are placed in the middle of the shell.
The shell side fluid splits into two with the two halves flowing in opposite
directions around a partial longitudinal baffle. It is a hybrid 2-pass shell.
Shell Types:
H-type The H type is similar to the G-type, but with two inlet, two
exit nozzles, and two partial longitudinal baffles. The flow is double
split or in four directions. It is used when there is limited available
pressure drop on the shell side. The arrangement is quite often
used for shell side thermosiphon applications or shell side
condensers with low allowable pressure drop.
J-type It has one nozzle in the middle used for entrance or exit. It
also has two nozzles at opposite ends for exit or entry. Either way,
the flow is divided with each half of the total fluid flowing through
half the shell. It is used when there is limited available pressure
drop on the shell side. It can not be used when the tube side
temperature crossed the temperature on the shell side. The J type
is quite often used for shell side condensers.
Shell Types:
K-type This type of shell is referred to as a kettle pool boiler. The tube
bundle is far smaller then the kettle diameter. A weir normally exists beyond
the tube bundle to maintain a liquid level over the tube bundle. The enlarged
space void of tubes above the bundle serves as a disengagement space,
allowing separation of the liquid and vapor. Kettles are frequently used
under distillation columns to provide vapor reflux and energy back to the
column for distillation.
X-type Flow is distributed along the entire length of the bundle and flows
across the bundle perpendicular to the tubes. The distribution is
accomplished by multiple nozzles along the shell or via open areas at the
top & bottom of the shell. Support plate type baffles are used to support
tubes. With this shell arrangement, the shell side pressure drop is
minimized.
Tubesheets
Single tubesheets -- The tubesheets act as the interface plate to separate
the shell and tube sides fluids of the exchanger. The tubes are attached to
the tubesheets by roller expansion and/or welding. The tie rods are bolted
to the shell side of the front tubesheet and are used to facilitate the
assembly of the tube bundle.
Double tubesheets -- are used when it is extremely important to avoid any
leakage between the shell and tube side fluids. Double tubesheets shorten
the length of the tube which is in contact with the shell side fluid and
therefore reduces the effective surface area. They also affect the location of
the shell side nozzles and possibly the adjacent baffle spacing. The gap
type double tubesheet has two separate tubesheet plates separated by a
space, usually about 150 mm (6 in.). The integral type double tubesheet is
similar but is made from a single piece of material by machining out a
honeycomb pattern midway inside the plate. If any tube joint leaks develop,
a sensor between the tubesheets will notify the plant operations.
Tubing Enhanced
Tubes are also available with externally enhanced surfaces such as low fins. These type
tubes enhance the heat transfer as well as provide more surface area per unit length for a
given shell size. They are generally used with a change of phase. You do pay a premium for
the enhanced surface tubes. They normally become economical to use when the ratio of the
tube side to shell side film coefficient is 3:1. They should not be used with fluids that have
high surface tensions. Low fins are most effective in pure cross flow (X shells, NTIW, and
segmental baffles). In longitudinal flow, such as triple segmental baffles, rod or strip baffles,
the fin valleys are not effectively penetrated by the flow. In such situations pressure drop
increases due to the fins acting as a rough surface. While such an increase is not reflected in
heat transfer. Use of low fins in such cases is questionable.
Common fin densities by tubing material (density shown in fins/inch):
Carbon Steel 19 Nickel Alloy 600 (Inconel) 28
Stainless Steel 16, 28 Nickel Alloy 800 28
Copper 19, 26 Hastelloy 30
Copper-Nickel 90/10 16, 19, 26 Titanium 30
Copper-Nickel 70/30 19, 26 Admiralty 19, 26
Nickel Carbon Alloy 201 19 Aluminum-Brass Alloy 687 19
Nickel Alloy 400 (Monel) 28
Tube Pitch
Tubes are normally spaced a standard distance from one another.
The center-center distance between any two adjacent tubes is
called the tube pitch. The ratio of the tube pitch to the tube diameter
varies from 1.1 to 1.5, with the most common being 1.25. TEMA
controls the minimum pitch. It will vary by TEMA class, tube layout
type, and size of tubes.
The tube pitch will affect the shell side heat transfer coefficient,
shell side pressure drop, number of tubes for a given shell size, and
capability of mechanically cleaning the outside surface of the tubes.
The larger the pitch the lower the film coefficient, and the lower the
pressure drop.
Tube Pattern
The tube pattern is defined with respect to the flow direction. There are four
different pattern options. They are listed below in order from the layout
producing the highest film coefficient and highest pressure drop to the
lowest.
Tube Layout
The number of tubes in a shell depend upon the tube diameter, pattern, pitch,
type of bundle, outer tube limit, type of shell, number of passes, placement of
impingement plates, location of nozzles, location of tie-rods, etc.
There are several possible ways to layout tubes for four or more passes. The
primary effect on the thermal design is due to the different number of tubes,
which are possible for each type. The Quadrant layout has the advantage of
usually (but certainly not always) giving the highest tube count. It is the required
layout for all U-tube designs of four or more passes. The tube side nozzles must
be offset from the centerline when using quadrant layout. The Mixed layout has
the advantage of keeping the tube side nozzles on the centerline. It often gives a
tube count close to quadrant and sometimes exceeds it. A Ribbon layout nearly
always gives a layout with fewer tubes than quadrant or mixed layout. It is used
for an odd number of tube passes. It is also the layout preferred for X-type shells.
The primary advantage of ribbon layout is the more gradual change in operating
temperature of adjacent tubes from top to bottom of the tubesheet. This can be
especially important when there is a large change in temperature on the tube
side, which might cause significant thermal stresses in mixed and especially
quadrant layouts.
Impingement Plates
Impingement plates are most commonly located underneath the
inlet shell side nozzle between the nozzle opening and the tube
bundle. They can also be located in a nozzle dome above the tube
bundle. They are used to prevent damage to the tubes due from the
impact of the incoming fluid. A secondary benefit is better flow
distribution of the fluid over the tube bundle. TEMA recommends
that inlet impingement protection be installed under the following
conditions:
When the rho*V2 through the inlet nozzle exceeds 2232 kg/(m*s2)
or 1500 lb/(ft*s2) for non-corrosive, non-abrasive, single phase
fluids
When the rho*V2 through the inlet nozzle exceeds 744 kg/(m*s2) or
500 lb/(ft*s2) for corrosive or abrasive liquids
When there is a nominally saturated vapor
When there is a corrosive gas
When there is two phase flow at the inlet
Nozzles
Nozzles provide the ports of entry and exit for the shell side and tube
side fluids. Nozzle sizes should be carefully selected. You dont want to
select too small a nozzle for you run the risk of taking too much of a
pressure drop, vibration or erosion problems underneath the nozzle,
and possible fluid mal-distribution. However, you cant specify too large
a nozzle size for then you may have fabrication problems. The criteria
used for the nozzle size is to insure that the nozzle can be constructed
yet will not take too high of a percentage of the available pressure
drop.
Nozzle Orientation
The logical orientation of the nozzles follows the laws of nature, that is,
fluids being cooled should enter the top and exit the bottom, and fluids
being heated should enter the bottom and exit the top.
Flanges
Body flanges (rings) are used to bolt two adjacent sections of a exchanger
together. The joint is made leak proof by using gaskets.
There are three basic types of flanges. The integral type - where the hub
and the flange are a continuous piece either by originally manufactured or
made so by a full penetration weld. These type are the most costly.
The loose type these either do not have any attachment to the shell or the
attachment is not considered integral with the shell
The optional type these are attached to the vessel wall or nozzle such that
the assembly acts as an integral unit. These differ from the integral type in
not having any hub or n having a very small hub. The vessel wall acts as
the hub.
Expansion Joints
Expansion joints are used to eliminate the excessive stresses caused by the
differential thermal expansion between the shell and the tube bundle due to
cyclic temperature conditions in a fixed tubesheet exchanger. The
requirement for one is determined according to the TEMA standards. It is
necessary to have the mean metal temperatures calculated from a thermal
program to make an accurate calculation. A mechanical design must be
done to determine the requirement for an expansion joint.
The common types of expansion joints are flanged only, flanged and flued,
un-reinforced bellows, and reinforced bellows.
Supports
Heat exchangers can be in either a vertical or horizontal position. In a horizontal
position, saddle supports are used. In a vertical exchanger cylindrical skirts,
brackets, or columns are used for supporting the exchanger.
Operational Variables
The user of a computer design program must make selection of all constructional
and operational input items required for design. Sometimes input items are
dictated by others, but these should be critically examined and changed if
needed. Contradictory demands and limitations will often exist. It is up to the
user to select a compromise which will produce the best overall results. The
following sections will provide a general idea of what to watch when specifying
input data.
The tube side is much easier to clean mechanically than the shell-side, as no removal
of the bundle is necessary. Therefore, fluids requiring regular cleaning should be
placed on the tube-side in a horizontal position. For cooling tower water, tube-side
velocities should be 6 ft/s (2 m/s) and under no circumstances be below 3 ft/s (1m/s).
Shell side cleaning by chemical means is increasingly accepted. If mechanical cleaning
on the shell-side is required, removable bundle construction is used with square or
rotated square layouts used. Baffle spacing to shell diameter ratio of , with baffle
cuts of 25% will produce a uniform flow which is recommended.
Low profile finned tubes have shown to have an anti-fouling tendency. The edges of
the fins help to break-up the fouling layers and promote their removal.