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Changes shown by ➧

CONTENTS
Section Page

SCOPE ............................................................................................................................................................3

REFERENCES.................................................................................................................................................3

GENERAL .......................................................................................................................................................3
COMPUTER PROGRAMS ......................................................................................................................3
SHELL SIDE MANUAL METHOD ...........................................................................................................3
ESTIMATION METHOD ..........................................................................................................................3

EFFECTIVE DESIGN SPECIFICATIONS........................................................................................................4

DESIGN PARAMETERS .........................................................................................................................4
RELATIONSHIPS BETWEEN HEAT TRANSFER COEFFICIENTS AND PRESSURE DROPS ............4
MEANS OF INCREASING HEAT TRANSFER WHEN PRESSURE DROP IS LESS THAN THE
MAXIMUM ALLOWED.............................................................................................................................5
Tube Side .............................................................................................................................................5
Shell Side .............................................................................................................................................5
MEANS OF MOST EFFICIENTLY DECREASING PRESSURE DROP ..................................................5
Tube Side .............................................................................................................................................6
Shell Side .............................................................................................................................................6

ESTIMATION METHOD CALCULATION PROCEDURE................................................................................6

NOMENCLATURE...........................................................................................................................................8

TABLES
Table 1A Estimation Method Calculation Form, U.S. Customary Units Shell And
Tube Heat Exchangers (No Change Of Phase) ...........................................................11
Table 2A Estimation Method Sample Calculation, U.S. Customary Units Shell And
Tube Heat Exchangers (No Change Of Phase) ...........................................................25
Table 2B Estimation Method Sample Calculation Metric Units Shell And Tube Heat
Exchangers (No Change Of Phase).............................................................................32
Table 3 Proration Factors..........................................................................................................39
Table 4 Design Constants For Shell And Tube Exchanger Calculations ..................................40

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CONTENTS (Cont)
Section Page

FIGURES
Figure 1.1 Normal Crossflow Fraction.........................................................................................42
Figure 1.2 Baffle Spacing Correction ..........................................................................................42
Figure 1.3 Low Reynolds Number Correction .............................................................................42
Figure 1.4 Friction Factor And Heat Transfer “J” Factor..............................................................43
Figure 1.5 Factor γ* As A Function Of Grashof Number .............................................................44
Figure 1.6 Short Tube Correction Factor, ε .................................................................................45
Figure 1.7 Low Prandtl Number Correction Factor Ψ..................................................................45
Figure 1.8 Isothermal Friction Factor Inside Tubes .....................................................................46
Figure 1.9 Viscosity Gradient Correction Factor .........................................................................47
Figure 1.10 Natural Convection Correction Factor ........................................................................47
Figure 2 LMTD Correction Factors Illustration Of Shell Arrangements ...................................48
Figure 2A LMTD Correction Factors...........................................................................................49
Figure 2B LMTD Correction Factors...........................................................................................50
Figure 2C LMTD Correction Factors...........................................................................................51
Figure 2D LMTD Correction Factors...........................................................................................52
Figure 2E LMTD Correction Factors...........................................................................................53
Figure 2F LMTD Correction Factors...........................................................................................54
Figure 3 Flow Streams For Stream Analysis Method ...............................................................55

Revision Memo
12/01 Reaffirmation of previous revision of DP IX-D, December, 1995.

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SCOPE
The following subsection presents the recommended procedures for sizing shell and tube heat exchangers in which there is no
change of phase; i.e., vapor/vapor, vapor/liquid, or liquid/liquid exchangers.

REFERENCES
1. Standards of Tubular Exchanger Manufacturer's Association (TEMA).
2. Heat Transfer Research, Inc. (HTRI) Design Manual.
3. Heat Transfer Research, Inc. (HTRI) Report S–SS–3–1, Stream Analysis Method for Prediction of Shellside Heat Transfer
and Pressure Drop in Segmentally-Baffled Exchangers, January 1967.
4. Heat Transfer Research, Inc. (HTRI) Report S–SS–3–2, Parametric Response Study of Segmentally Baffled Shell and
Tube Exchanger Performance, September 1967.
5. Users' Manual for the Hextran computer program.

GENERAL
COMPUTER PROGRAMS
ExxonMobil's heat transfer programs (see Section IX–K) will perform the following calculations for shell and tube heat
exchangers in which there is no change of phase:
1. Rating of a dimensionally specified exchanger with or without a given heat duty.
2. Design of all essential dimensions of an exchanger to specified process and geometric parameters.
The programs employ the HTRI-developed “Stream Analysis Method" for shell side calculations and refinement of existing
correlations for tube side calculations.
The HTRI Stream Analysis Method is the most rigorous means available for calculating shell side pressure drop and heat
transfer. Although the method is based on theoretically deduced equations, the correlations are empirical because the
constants in the equations were obtained from experimental data. The most notable features of the Stream Analysis Method
are:
1. The ability to predict with reasonable accuracy the amount of flow leaking through baffle clearances and bypassing the
tube bundle.
2. The ability to predict accurately the effects of variations in exchanger geometry on heat transfer and pressure drop.
3. The recognition of a temperature profile distortion effect because leakage streams undergo different temperature changes
than the cross flow stream.
4. The demonstrated ability to predict shell side heat transfer and pressure drop over a wide range of geometry and Reynolds
Number variations.

SHELL SIDE MANUAL METHOD

A detailed manual calculation method is presented in the HTRI Design Manual. The procedure is very time-consuming for day-
to-day use and therefore is not included. The detailed procedure should be referred to only for a more complete understanding
of the leakage streams and interpretation of the HTRI program outputs.

ESTIMATION METHOD
The estimation procedure provides a quick but still fairly accurate method to size an exchanger to meet given process
requirements within the constraints of the specified pressure drops.
The estimation method will produce results that are reasonably accurate when all of the following conditions are met:
1. The tube side is in turbulent flow (Reynolds Number > 10,000) at both the inlet and the outlet. For 10,000 > Reynolds
Number >2,000 at either inlet or outlet the HTRI computer program using the ten-step option is recommended. For
Reynolds Number <2,000 at either inlet or outlet, the HTRI computer program is strongly recommended.
2. Baffle cuts of 20% to 30% (h/D) for segmental baffles or 35% to 45% (area) for double segmental baffles.
3. Baffle spacing/shell diameter ratio between 0.25 and 0.8.

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GENERAL (Cont)
4. Number of sealing strips: The exchanger has at least one pair of sealing strips for every five to seven tube rows crossed.
Sealing strips are not required for typically designed fixed tube sheet or U-tube exchangers with horizontal cut baffles. F-
stream seal rods/bars - The exchanger has F-stream seal rods/bars for every five to seven rows crossed. This is
especially important for U-tube exchangers when the shell side cross flow passes through the lane formed by the
innermost U-bends. In this case crisscrossing the inner row of U-bends is highly recommended. For crisscrossed U-
bends, assume that F-stream seals are used, and note on the specification sheet that the innermost rows should be
crisscrossed.
5. Tube pitch ratio (PR) between 1.25 and 1.33.
Table 1 shows the calculation procedure for the estimation method. A sample calculation is given in Table 2.

EFFECTIVE DESIGN SPECIFICATIONS

DESIGN PARAMETERS
The following general specifications give the most efficient conversion of pressure drop to heat transfer for no-change-of-phase
heat exchangers.
1. Tube Length: Various exchanger geometries, that is, various combinations of shell diameters and tube lengths, can be
found to satisfy given process requirements. The exchanger having the smallest amount of heat transfer surface area is
not necessarily the most economical solution. The cost of a typical exchanger having a fixed tube diameter, metallurgy,
and tube pitch can be approximately represented by the following relations as a function of shell diameter and tube length.
Cost of Exchanger ∝ (Shell Diameter)1.9
Cost of Exchanger ∝ (Tube Length)0.55
Based on the equations, for most cases the economical solution would be an exchanger with long tubes and small shell
diameter. There are, however, some restrictions on the tube length such as bundle pulling facilities, availability of tubes,
and ease of maintenance. In the absence of specific guidelines, a standard tube length of 20 ft (6090 mm) should be
used, unless the design is to retrofit an existing plant where a different tube length is standard.
2. Baffle cut: 20% to 30% for segmental baffles; 35% to 45% for double segmental baffles.
3. Baffle spacing/shell diameter: 0.3 to 0.5.
4. Number of sealing strips: The number of pairs of sealing strips per tube row crossed between baffle tips should be about
0.14 to 0.20, or about 5 to 7 tube rows per pair of sealing strips for floating head exchangers. Sealing strips are needed for
typically designed fixed tube sheets or U-tube exchangers only when vertical cut baffles are specified.
5. Tube layout patterns: If inline arrangements are required for cleaning, use a 90° layout for turbulent flow and a 45° layout
for transition and laminar flow. If mechanical cleaning is not required, use 30° layout for both laminar and turbulent flow.
Do not use 60° layout since it exhibits inferior heat transfer or pressure drop characteristics when compared to a 30°
layout.

RELATIONSHIPS BETWEEN HEAT TRANSFER COEFFICIENTS AND PRESSURE DROPS

The heat transfer mechanism in the shell and tube heat exchangers is convective heat transfer, whereby a fluid receives or
supplies heat to a heat transfer surface through a film. The film is perceived as a static fluid (viscous) membrane that coats the
heat transfer surface; heat is transferred through the film by conduction. Therefore, thicker films provide lower heat transfer
coefficients, and thinner films provide higher heat transfer coefficients.
The velocity of the fluid passing over the surface determines the thickness of the film. The higher the velocity, the thinner the
film, resulting in a larger heat transfer coefficient. The fluid experiences some pressure drop in order to maintain this velocity.
The pressure drop increases with increased velocity and tube length.
This description holds for tube side fluids. For shell side fluids, leakage streams complicate the simple model. On the shell
side of an exchanger, all of the fluid does not pass over the tubes because there are other paths available. Extensive work on
these leakage streams has been done by HTRI and in the Delaware research projects. An exact evaluation is impossible
without a computer program because of the various streams present. Figure 3 shows the leakage streams. The C, E and F
streams bypass the heat transfer surface (tubes) completely. The tube to baffle leakage stream (A) passes over some tubes
but bypasses others. All of these streams are hydraulically in balance; i.e., the pressure drop from any one point in the shell to
another is the same. The amount of each leakage stream is determined by using such a hydraulic balance. To complicate
matters further, a leakage stream mixes with the part of the fluid flowing over the tube bundle at some point. The complexity of
the flows make complete manual analysis impractical without simplifying assumptions based on test data and experience. The
estimation method presented here is based on such factors.

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EFFECTIVE DESIGN SPECIFICATIONS (Cont)

Table 3 provides satisfactory results in most instances in prorating shell side and tube side heat transfer and pressure drops.
A well designed exchanger utilizes the pressure drop in a way that maximizes the overall heat transfer coefficient. Arriving at a
practical and economic solution is an iterative procedure. As a starting point, use the overall coefficients given Table 1 of
Section IX-B. Calculate the MTD as discussed in the estimation method calculation sheets (As a starting point one may
approximate MTD = (T1 − t2 ) x (T2 − t1) ) to arrive at the approximate required surface for the given service, and then go
through the estimation procedure, calculating heat transfer and pressure drops. Compare the shell side coefficient, tube side
coefficient, and (fouling + wall) coefficient. If the shell side coefficient is much smaller than the tube side coefficient, then the
shell side coefficient is controlling. If the tube side coefficient is much smaller than the shell side coefficient, then the tube side
coefficient is controlling. If (fouling + wall) coefficient is controlling, then fouling is controlling.
When fouling is controlling, it generally does not help to utilize all of the allowable pressure drops unless shell size can be
reduced, or the pressure drop is very much underutilized. (Refer to Section IX-A for a discussion of online cleaning devices
which can be used to reduce fouling.) When the shell side coefficient is controlling, it helps to maximize shell side pressure
drop to reduce shell size. Maximizing tube side pressure drop normally does not help. When the tube side coefficient is
controlling, it helps to maximize tube side pressure drop but not shell side pressure drop. When all the coefficients are in the
same range, it helps to maximize both shell side and tube side pressure drop.

MEANS OF INCREASING HEAT TRANSFER WHEN PRESSURE DROP IS

LESS THAN THE MAXIMUM ALLOWED
A design with the optimum parameters that satisfies heat transfer requirements but does not use up the total allowable
pressure drop is considered inefficient. For such cases, one can always make the exchanger smaller by taking one or more of
the following steps to increase the pressure drop and heat transfer.

Tube Side
1. Increase the tube length.
2. Decrease the tube diameter.
3. Increase the number of tube passes, up to a maximum as specified in Table 4 of Section IX-C and within the restriction of
tube side velocities.
4. Try integral fin tubes, which has the effect of decreased tube diameter on pressure drop only.

Shell Side
1. Decrease the shell diameter. This can be done by reducing tube pitch to the minimum allowed by construction practice
and refinery limitations. Reducing shell diameter without changing tube pitch will result in fewer tubes and thus lower heat
transfer area. In cases where the exchanger has enough excess surface, this could be the best solution.
2. Decrease the baffle pitch, but to a point that is never less than 20% shell diameter or 2 in. (50 mm), whichever is smaller.
3. Try TEMA F type shell if the process parameters and refinery practice permit the use of an F shell. In general, F shells
should not be used when the shellside pressure drop is greater than 10 psi or the shellside temperature change is greater
than 350°F (195°C), due to the thermal and hydraulic leakage across the shell partition. A new design for certain U-tube
exchangers with a welded-in shell partition plate is available but lacks a proven performance record. Consult plant
maintenance and the Heat Transfer Equipment Section of ER&E regarding the acceptability of an F shell for a given
application.

MEANS OF MOST EFFICIENTLY DECREASING PRESSURE DROP

Sometimes a design requires more surface than is necessary for heat transfer in order to provide sufficient flow area to prevent
exceeding the allowable pressure drop. Two courses of correction are possible.
1. Adjust the “allowable" pressure drop. Possibly the pressure drop to which the unit is designed is arbitrarily low and can be
increased.
2. Adjust the geometry so as to provide the smallest decrease in heat transfer per unit decrease in pressure drop, by making
one or more of the following changes:

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EFFECTIVE DESIGN SPECIFICATIONS (Cont)

Tube Side
a. Decrease the number of tube passes within the limits of minimum tube side velocities. This option should always be
considered when the number of tube passes is 10 or more or when shell side heat transfer is controlling and the
number of tube passes is 6 or more. Never decrease the number of tube passes if the result will change the tube side
flow regime from turbulent to laminar flow, or if the velocities will fall below the minimum required due to fouling or salt
deposition consideration.
b. Increase the tube diameter, within practical limits. Normally tubes up to 1-1/2 in. (38.1 mm) diameter (2 in. ( 50.8 mm)
for carbon steel) are readily available in the market.
c. Decrease the tube length. This is an attractive option when an exchanger has excess surface. Normally, decrease
tube length by 2 ft (610 mm) increments for tube lengths over 10 ft (3048 mm), or 1 ft (305 mm) increments for smaller
tube lengths.
d. Increase tube I.D. by using a thinner tube wall and a metallurgy with better corrosion resistance. This may be an
expensive option, but it should be considered when an existing exchanger is retrofitted to avoid even more expensive
piping changes.
e. If an exchanger does not have enough excess surface, then increase the shell diameter, within allowable limits set by
the refinery, normally 60 in. (1525 mm).

Shell Side
a. If an exchanger has enough excess surface, consider the following options.
• Decrease the tube length.
• Increase the baffle pitch, but to not more than 80% of the shell diameter.
• Use double segmental baffles.
• Increase the tube pitch. Note that increasing the tube pitch will reduce the number of tubes for a given shell size
and will affect tube side heat transfer and pressure drop.
• Use a TEMA J shell.
b. If an exchanger does not have enough excess surface then increase the shell diameter within allowable limits set by
the refinery, normally 60 in. (1525 mm). Note that shell diameter could also be limited by the maximum permissible
weight.
c. Other ways of reducing shell side pressure drop, for which calculation methods are not provided in this section
because they require more complex design procedures include:
• Use a rod baffle design (useful for large flow rates on shell side).
• Use a low finned tube design. (Overhead condensers, lube oil product coolers). Refer to Section IX–G.
• Use a no-tubes-in-the-window designs. (Usually very useful for gas-plant feed effluent exchangers).
• Use shell side longitudinal flow with or without longitudinal fins.
• Use a TEMA X shell. (Usually most useful for very large flow rates on the shell side with nozzle sizes > 50% shell
diameter.).
If none of the actions listed here will give the desired results, consider the use of units in parallel.

ESTIMATION METHOD CALCULATION PROCEDURE

1. Based on the hot and cold fluid conditions select tube metallurgy.
2. Get fouling factors for the hot and cold fluids from Table 3 of Section IX–B.
3. Select tube side fluid per page 10 of Section IX–C. Place the other fluid on the shell side.
4. Determine the heat duty “Q" and/or the missing fluid condition based on a duty balance. The heat received by the cold
fluid should equal the heat lost by the hot fluid.
5. Calculate the minimum number of shell passes using the graphical method in Figure 2D of Section IX–B. As a first
approximation use this number as the number of shells in series, Ns. Assume number of shell is parallel, Np = 1.
6. Based on the tube metallurgy and tube side fouling, determine the tube diameter and the tube wall thickness per pages 4
and 5 of Section IX–C.
7. Based on shell side fouling, select the tube pitch and layout, per page 7 of Section IX–C. Check that the selected tube
wall thickness is acceptable.

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ESTIMATION METHOD CALCULATION PROCEDURE (Cont)

8. Select the channel and tube bundle types per pages 6 and 7 of Section IX–C. For the trial use an “E" shell with two tube
passes.
9. Select the initial overall heat transfer coefficient “Uo" from Table 1 of Section IX–B.
10. Get the single tube external surface per unit length “AT" from Table 1 of Section IX–C.
11. Per step 1 of Table 1A (1B metric) calculate the corrected log mean temperature difference “MTD".
12. Assume effective tube length “Le" to be 19.5 ft (5.95 m) and calculate required number of tubes per bundle “NTT" as
follows
Q
NTT =
Uo ⋅ MTD ⋅ Ns ⋅ Np ⋅ A T ⋅ L e

13. Start with the maximum permissible shell diameter. Then using Table 5 of Section IX-C get the maximum number of
tubes per bundle. If this number of tubes calculated is greater than the number calculated in step 12, proceed to step 14.
Otherwise, increase the number of shells in series, and go back to step 11.
14. For the initial guess use line size nozzles, and use an impingement plate.
15. Use proration factors given in Table 3, calculate the shell size, and confirm the number of tubes by calculations per Table
5 of Section IX–C. Repeat the procedure if required till calculated number of tubes is within ±5% of the number of tubes
required. This may not be possible for pipe size shells, in which case use the shell size that gives the number of tubes
closest to the number calculated in step 12. For rolled and welded shells select shell I.D. as an integer number. Use the
shell diameter, bundle diameter and number of tubes calculated in this step for further calculation of initial trial.
16. For the initial guess use 25% cut single segmental baffles at a pitch equal to 40% of the bundle diameter.
17. Using this initial guess go through the complete calculation procedure per Table 1A (1B for metric).
18. Check nozzle pressure drops, and if excessive, increase nozzle sizes. The limits for maximum nozzle pressure drops are
as follows:
a. Shellside Gases - Use 35% of the allowable pressure drop for the inlet & outlet nozzles, total.
b. Shellside Liquids - Use 15% of the allowable pressure drop for inlet and outlet nozzles, total.
c. Shellside Nozzle pVn2 value should never exceed TEMA maximum limits.
d. Tube side inlet and outlet nozzle pressure drop should be less than 40% of the calculated tube side pressure drop for
a single tube pass unit, or, 35% of the calculated tube side pressure drop for a multiple tube pass unit.
19. Check the results for overdesign and pressure drop utilization. Follow the guidelines described earlier in this DP and the
proration factors given in Table 3 to arrive at the optimum design. It may take a few more iterations. While selecting a
new exchanger during optimization, note the following limitations.
a. Cooling water velocity inside tubes must meet the requirements of Table 4.
b. Special requirements for intube velocity, may be applicable, e.g., slurry service.
c. Maintain Baffle Pitch/Bundle Diameter ratio between 0.25 and 0.8.
d. Try to maintain turbulent flow on the tube side.
e. Maintain the tubewall temperature below or above criterion set by fouling or pour point. For example, cooling water or
waxy services.

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NOMENCLATURE
a = Tube row spacing factor, dimensionless
A = Total effective heat transfer area, ft2 (m2)
As = Effective heat transfer area per shell, ft2 (m2)
AT = Single tube outside surface area per unit length ft2/ft (m2/m)
Cp = Heat capacity, Btu/lb-°F (kJ/kg-°C)
DI = Tube I.D., in. (mm)
DO = Tube O.D., in. (mm)
DN = Nominal nozzle I.D., in. (mm)
DOTL = Diameter of bundle outer tube limit, in. (mm)
DS = Shell I.D., in. (mm)
DSNI = Shell side inlet nozzle I.D., in. (mm)
DSNO = Shell side outlet nozzle I.D., in. (mm)
DTNI = Tube side inlet nozzle I.D., in. (mm)
DTNO = Tube side outlet nozzle I.D., in. (mm)
f = Non-isothermal friction factor, dimensionless
fis = Isothermal friction factor, dimensionless
Fn = Correction factor for log mean temperature difference, dimensionless
Fs = Shell side pressure drop correction factor, dimensionless
Gr = Grashof Number, dimensionless
=
2 2
Gxt Total cross flow mass velocity, lb/hr-ft (kg/s-m )
= Inside film coefficient based on tube outside surface area, Btu/hr-ft -°F (W/m2- °C)
2
hio
=
2-
hs Outside film coefficient, Btu/hr-ft -°F (W/m2-°C)
HF = Shell side friction term, dimensionless
HM = Shell side momentum term, dimensionless
j = Stanton Number type heat transfer factor, dimensionless
=
2
k Thermal conductivity of fluid, Btu/hr-ft -°F/ft (W/m-°C)
=
2
kw Thermal conductivity of tube wall at average tube temperature, Btu/hr-ft -°F (W/m-°C)
Ke = Tube side pressure drop coefficient, dimensionless
l = Tube wall thickness, in. (mm)
L = Tube length, ft (m)
Le = Effective tube length, ft (m)
LBCC = Central baffle pitch, in. (mm)
LI = Tube flow length, in. (mm)
LMTD = Log mean temperature difference for true counter current flow, °F (°C)
m = Shell side flow factor, dimensionless
MTD = Corrected log mean temperature difference, °F (°C)
n = Baffle spacing to bundle diameter ratio, dimensionless
N = Number of tube passes
Np = Number of shells in parallel
Ns = Number of shells in series
NT = Total number of shells

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NOMENCLATURE (Cont)
NTP = Number of tube passes per shell
NTT = Number of tubes in a bundle
p = Baffle flow factor, dimensionless
Pr = Prandtl Number, dimensionless
PR = Tube pitch ratio, dimensionless
PT = Tube pitch, in. (mm)
∆Pe = Tube entrance, expansion, and turnaround pressure drop, psi (kPa)
∆Pexch = Total nozzle to nozzle shell side pressure drop, psi (kPa)
∆Pn = Tube side nozzle pressure drop, psi (kPa)
∆Ps = Shell side pressure drop (excluding nozzles), psi (kPa)
∆Psn = Shell side nozzle pressure drop, psi (kPa)
∆Pt = Tube side frictional pressure drop, psi (kPa)
(∆Pt)nn = Total tube side nozzle pressure drop, psi (kPa)
Q = Rate of heat transfer, Btu/hr (W)
rI = Inside fouling factor referred to inside surface area, hr-ft2-°F/Btu (m2-°C/W)
rio = Inside fouling factor referred to outside surface area, hr-ft2-°F/Btu (m2-°C/W)
ro = Shell side fouling factor, hr-ft2-°F/Btu (m2-°C/W)
rw = Resistance of tube wall at average wall temperature, hr-ft2-°F/Btu (m2-°C/W)
Rc = Total resistance (clean) to heat transfer, hr-ft2-°F/Btu (m2-°C/W)
Rio = Inside resistance to heat transfer corrected to outside area, hr-ft2-°F/Btu (m2-°C/W)
Ro = Outside film resistance to heat transfer, hr-ft2-°F/Btu (m2-°C/W)
Rt = Total resistance (duty) to heat transfer, hr-ft2-°F/Btu (m2-°C/W)
Re = Reynolds Number, dimensionless
Rext = Shell side total flow Reynolds Number, dimensionless
Rexh = Cross flow Reynolds number for heat transfer, dimensionless
Rexp = Cross flow Reynolds Number for pressure drop, dimensionless
RC = Reynolds number correction factor, dimensionless
SC = Baffle spacing correction factor, dimensionless
STT = Tube sheet material allowable stress at design temperature, lb/sq in. (kPa)
t = Tube wall thickness, in. (mm)
t1 = Inlet temperature of fluid being heated, °F (°C)
t2 = Outlet temperature of fluid being heated, °F (°C)
Tw = Average wall temperature, °F (°C)
TDS = Shell side design temperature, °F (°C)
TDT = Tube side design temperature, °F (°C)
TM = Tube sheet design temperature, °F (°C)
T1 = Inlet temperature of fluid being cooled, °F (°C)
T2 = Outlet temperature of fluid being cooled, °F (°C)
TSb = Bulk temperature of shell side fluid, °F (°C)
TSin = Inlet temperature of shell side fluid, °F (°C)
TSout = Outlet temperature of shell side fluid, °F (°C)
TTb = Bulk temperature of tube side fluid, °F (°C)

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NOMENCLATURE (Cont)
TTin = Inlet temperature of tube side fluid, °F (°C)
TTout = Outlet temperature of tube side fluid, °F (°C)
TTT = Total tube sheet thickness, ft (m)
∆Ta = Terminal temperature difference, °F (°C)
∆Ts = Shell side temperature difference, °F (°C)
Uc = Overall clean coefficient of heat transfer, Btu/hr-ft2-°F (W/m2-°C)
Ud = Calculated overall fouled coefficient of heat transfer, Btu/hr-ft2-°F (W/m2-°C)
Uo = Overall duty coefficient of heat transfer, Btu/hr-ft2-°F (W/m2-°C)
Vn = Tube side average nozzle fluid velocity, ft/sec (m/s)
Vt = Fluid velocity in tubes, ft/sec (m/s)
W = Tube side mass rate per shell, lb/hr (kg/s)
Ws = Shell side mass rate per shell, lb/hr (kg/s)
β′ = Coefficient of thermal expansion used in Grashof Number, °F-1 (C-1)
γ* = Natural convection factor, dimensionless
ε = Short tube laminar flow correction factor, dimensionless
η = Transitional flow heat transfer proration factor, dimensionless
λ = Tube length geometry factor, dimensionless
µb = Viscosity at bulk temperature, centipoise (Pa-S)
µW = Viscosity at wall temperature, centipoise (Pa-S)
ξ = Baffle correction factor, dimensionless
ρ =
3
Density, lb/ft3 (kg/m )
ψ = Low Prandtl Number correction factor, dimensionless
ψρ = Natural convection correction factor, dimensionless
φ = Viscosity correction for wall temperature

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CALCULATION PROCEDURE,
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TABLE 1A
ESTIMATION METHOD CALCULATION FORM (CUSTOMARY UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)

PROCESS REFINERY AND LOCATION CALC. BY

EXCHANGER NO. E DATE
1. Terminal Conditions and MTD
Fluid Being T1 = __________, T2 = __________, T1 - T2 = __________, T1 − T2
Cooled R= = __________
t 2 − t1

Fluid Being t2 = ___________, t1 = ___________, t2 - t1 = ___________, t1 − t1

Heated P= = __________
T1 − t1
T1 - t2 = _________, T2 - t1 = _________, T1 - t1 = __________
(T1 − t 2 ) − (T2 − t1)
LMTD = = __________
éT − t ù
ln ê 1 2 ú
ë T2 − t1 û

Ns Np
Fn = __________ for ____________ shells in series ____________ shells in parallel
(Figure 2) __________ for ____________ shells in series ____________ shells in parallel
__________ for ____________ shells in series ____________ shells in parallel
MTD = Fn (LMTD) =( )( ) = ____________.
=( )( ) = ____________.
=( )( ) = ____________.

2. Bulk Temperatures
Tubeside Fluid (Heated) TTin = __________ _____, TTout __________ .
(Cooled)

TTin + TTout
TTb = = __________ _____ .
2
Shellside (Heated) TSin = __________ , TSout = __________ .
Fluids (Cooled)
TSin + TSout
TSb = = __________ ____ .
2
Estimated Wall temperature Tw = TTb + 0.6 (TSb − TTb ) = __________ ______ .

3. Properties of Fluids
Tubes Shell
ρ = __________ lb/ft3 __________ lb/ft3
µb = __________ cP __________ cP
Cp = __________ Btu/lb-°F __________ Btu/lb-°F
k = __________ Btu/hr-ft2-°F/ft __________ Btu/hr-ft2-°F/ft
µw = __________ cP __________ cP

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CALCULATION PROCEDURE,
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TABLE 1A (Cont)
ESTIMATION METHOD CALCULATION FORM (CUSTOMARY UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
4. Flow Rates and Names of Fluids
Tube Shell
Fluid
Name/Phase = ______/______ ______/______
Total Mass rate _____________ lb/hr _____________ lb/hr
W = Total mass rate/Np = ______ lb/hr W s = Total mass rate/Np = ______ lb/hr
5. Fouling Factors
ri = __________ hr-ft2-°F/Btu
ro = _________ hr-ft2-°F/Btu
6. Mechanical Design Features
TEMA Type Tubes Shell
Design Temperature = __________ °F __________ °F
Design Pressure = __________ psig __________ psig
Nozzle Size DTNI = __________ in. DSNI = __________ in.
DTNO = __________ in. DSNO = __________ in.

7. Exchanger Geometry First Trial Second Trial Third Trial

Tube O.D. (DO), in. __________ __________ __________
Tube I.D. (DI), in. __________ __________ __________
Tube pitch (PT), in. __________ __________ __________
DO − DI __________ __________ __________
Tube wall thickness (l ) =
2
Tube length (L), ft __________ __________ __________
Tube flow length (LI), ft __________ __________ __________
LI = (24) for U tubes
LI = (12) for all others
TEMA exchanger type __________ __________ __________
Single tube area/length, A T , ft 2 __________ __________ __________

( π) (DO) __________ __________ __________

AT =
12
Baffle spacing (LBCC), in. __________ __________ __________
Baffle type (Segmental or Double Segmental) __________ __________ __________
Bundle Diameter (DOTL), in. __________ __________ __________
Shell Diameter (DS), in. __________ __________ __________
Number of tube side passes (NTP) (for U tubes __________ __________ __________
minimum number is 2)

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CALCULATION PROCEDURE,
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TABLE 1A (Cont)
ESTIMATION METHOD CALCULATION FORM (CUSTOMARY UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
8. Iteration, Tube Side First Trial Second Trial Third Trial
a. Heat Duty = Q = __________ __________ __________
b. Assumed value of Uo = __________ __________ __________
c. A = Q/Uo (MTD) = __________ __________ __________
d. As = A/NT = __________ __________ __________
e. Tube Metal = ______; Kw = ______, DO = ______ in., DI = ______ in., l = ______ in., L = ______ ft
f. Tube Pitch (PT) and Layout = __________ __________ __________
g. rio = (DO / DI) ri = __________ __________ __________

h. rw = l / 12 k w = __________ __________ __________

i. NTT = __________ __________ __________
j. N = NTT/NTP = __________ __________ __________
W = __________ __________ __________
k. Vt =
19.625 ρ N (DI)2
l. Heat Transfer Coefficient
6.32 W 124 ρ Vt (DI) = __________ __________ __________
(1) Re = =
µb (DI) N µb
(2) For Water __________ __________ __________
0.26
368 æ TT ö
hio = ( Vt DI)0.7 ç b ÷
DO è 100 ø =
(3) Fluids other than water
2.42 c p µb = __________ __________ __________
(a) Pr =
k
(b) If Re ≥ 10,000 = __________ __________ __________

0.2642 k
hio = Re0.8 Pr 0.4 φP
DO

φP = (µb / µ w )0.167 for liquids

0.5
æ TT + 460 ö
= çç b ÷
÷ for heating gases
è Tw + 460 ø

= 1.0 for cooling gases

(c) If Re < 10,000
(1) ∆T =  Tw - TTb  = __________ __________ __________
1 1
−
ρx ρy
(2) β' = = __________ __________ __________
( t x − t y )(1 / ρ av )
æ DI3 ρ2 β' ∆T ö
(3) Gr = 413 (10 4 ) ç ÷ = __________ __________ __________
ç µb 2 ÷
è ø

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CALCULATION PROCEDURE,
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TABLE 1A (Cont)
ESTIMATION METHOD CALCULATION FORM (CUSTOMARY UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
8. Iteration, Tube Side (Cont) First Trial Second Trial Third Trial
æ DI3 ρ2 β' ∆T ö = __________ __________ __________
(3) Gr = 413 (10 4 ) ç ÷
ç µ 2 ÷
è b ø
(d) If Re ≤ 2000
(1) From Figure 1.5 determine γ* = __________ __________ __________
(2) From Figure 1.6 determine ε = __________ __________ __________
(3) λ = DI/LI + ε = __________ __________ __________
(4) From Figure 1.7 determine ψ = __________ __________ __________
ì æµ ö
0.14 ü
12 k ï ï
(5) hio = í2.5 + 4.5 [(Re + γ *) λ] Prb0.17 çç b ÷÷ ýψ
0.37
DO ï è µ w ø ïþ
î
(e) If 2000 < Re < 10,000
(1) (hio )turb @ Re = 10,000 ( from b) ) = __________ __________ __________

(2) (hio )lam @ Re = 2,000 ( from d) ) = __________ __________ __________

(3) η = 1.25 - Re/8000 = __________ __________ __________

(4) hio = η (hio )lam + (1 − η)(hio )turb = __________ __________ __________

(f) Tw = TTb + Uo (Rio ) (TSb − TTb ) = __________ __________ __________

(g) Evaluate (µb / µ w )0.14 for laminar flow or φP for = __________ __________ __________
turbulent flow and make necessary corrections to
heat transfer coefficients
m. Pressure Drop
(1) Nozzle Pressure Drop,
0.051 W = __________ __________ __________
(a) Vn =
(DTNI) (DTNO ) ρ
ρ V 2n = __________ __________ __________
(b) ∆Pn =
5152
(2) Entrance, Expansion, and Turn-around
(a) From Table 4 determine Ke = __________ __________ __________
K e ρ V 2t = __________ __________ __________
(b) ∆Pe =
9274
(3) Frictional Pressure Drop
(a) From Figure 1.8 evaluate fis = __________ __________ __________

(b) From Figure 1.9 evaluate ϕ = __________ __________ __________

(c) From Figure 1.10 evaluate ψρ = __________ __________ __________
(d) f = fis ϕ ψρ = __________ __________ __________

é ρ V 2t (NTP)L ù = __________ __________ __________

5.19
(e) ∆Pt = f ê ú
103 ê DI ú
ë û
(4) ( ∆ P t ) nn = N s [ ∆ P n + ∆ P e + ( F t ) ( ∆ P t )] = __________ __________ __________
get value of Ft from Table 4

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CALCULATION PROCEDURE,
DESIGN PRACTICES NO CHANGE OF PHASE December, 2001

TABLE 1A (Cont)
ESTIMATION METHOD CALCULATION FORM (CUSTOMARY UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
9. Iteration, Shell Side First Trial Second Trial Third Trial
Tube row spacing factor
a = 1.0 for Square Pitch __________ __________ __________
a = 0.867 for all others
Pitch Ratio (PR) = PT/DO __________ __________ __________
Baff. Space to Bundle Dia. Ratio (n)
n = LBCC/DOTL __________ __________ __________
Shell side flow factor (m)
m = 0.5 for J shell
m = 2.0 for F shell
m = 1.0 for E shell __________ __________ __________
Baffle flow factor (p)
p = 1.0 for segmental baffles
p = 0.5 for double-segmental baffles __________ __________ __________

Baffle Correction Factor (ξ)

ξ = 1.0 for segmental baffles
__________ __________ __________
ξ = 0.8 for double-segmental baffles
Estimated tube wall temperature (Tw), °F
Tw = TSb − 0.3 (TSb − TTb ) __________ __________ __________
Wall viscosity correction (ϕ)
ϕ = (µb / µ w )0.14 __________ __________ __________

Total cross flow mass velocity, (Gxt ), lb / hr − ft 2

é PR ù é (m)(p ) ù é Ws ù
Gxt = 144 ê ú ê ú
ë PR − 1û êë n úû êë (DOTL )2 ûú
__________ __________ __________
Total flow Reynolds Number (Rext)
(DO) (Gxt )
Rext =
(29) (µb ) __________ __________ __________
Nominal Crossflow fraction (FFBn) Figure 1.1 __________ __________ __________
Baffle Spacing Correction (SC) Figure 1.2 __________ __________ __________
Reynolds Number Correction (RC) Figure 1.3 __________ __________ __________
Cross flow fraction for pressure drop (FFBp)
FFBp = (FFBn) (SC)(RC) (Maximum = 1.0) __________ __________ __________
Cross flow Reynolds Number for ∆P (Rexp)
(Rexp = (Rext) (FFBp) __________ __________ __________
Shell side friction for factor (f) Figure 1.4 __________ __________ __________
Cross flow fraction for heat transfer (FFBh)
FFBh = FFBp + 0.125 (Maximum = 1.0) __________ __________ __________
Cross flow Reynolds Number for heat transfer (Rexh)
Rexh = (Rext) (FFBh) __________ __________ __________
Shell side heat transfer factor (j) Figure 1.4 __________ __________ __________

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CALCULATION PROCEDURE,
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TABLE 1A (Cont)
ESTIMATION METHOD CALCULATION FORM (CUSTOMARY UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
9. Iteration, Shell Side (Cont) First Trial Second Trial Third Trial
Shell side film coefficient (hs) Btu/hr-ft2-°F
2/3
é k ù
hs = (0.415) (Cp ) (Gxt ) (FFBh ) ( j) ê ú (φ)(ξ) __________ __________ __________
ëê (Cp ) (µ ) ûú
Shell side Fraction Term (HF)
é ( f ) (L ) (m) (12) ù æ 1ö
HF = 0.00875 ê ú çç ÷÷Fs
ë (a) (PR ) (DO) (n) û èφø
__________ __________ __________
(Fs from Table 4)
Shell side momentum term (HM)
é (L ) (m) (12) ù
HM = 0.0168 (n)2.6 ê − 1 .0 ú
(n ) (DOTL ) __________ __________ __________
ë û
Shell side pressure drop without Nozzle (∆Ps), psi
2
(0.3) [HF + HM ] é (Gxt ) (FFBp ) ù æ 1ö
∆Ps = ê ú çç ÷÷ __________ __________ __________
ρ ë 10000 û èξø
Nominal shell nozzle I.D. (DN), in.
DN = (DSNI) (DSNO) __________ __________ __________

Shell side nozzle pressure drop (∆PSSN), psi

2
0.84 é Ws ù
∆PSN = ê 2ú
__________ __________ __________
ρ êë (1000 ) (DN) úû
Total shell pressure drop (∆Pexch), psi
∆Pexch = NS [∆PS + ∆PSN ] __________ __________ __________

Calculated Tube wall temperature (Tw), °F

æ 1 .0 ö
Tw = TSb − Uo çç ÷ (TSb − TTb )
÷ __________ __________ __________
è hs ø
Calculated viscosity correction (φ)
__________ __________ __________
φ = (µb / µ w )0.14
Using calculated value of φ correct hs & ∆PS __________ __________ __________
10. Overall calculations
Inside resistance referred to outside area (Rio), hr-ft2-°F/Btu
Rio = 1 / hio __________ __________ __________

Outside resistance (Ro), hr-ft2-°F/Btu

R o = 1 / hs __________ __________ __________

Total clean resistance (Rc), hr-ft2-°F/Btu

Rc = Rio + Ro + rw __________ __________ __________

Calculated overall clean coefficient (Uc), hr-ft2-°F/Btu

Uc = 1 / Rc __________ __________ __________

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CALCULATION PROCEDURE,
DESIGN PRACTICES NO CHANGE OF PHASE December, 2001

TABLE 1A (Cont)
ESTIMATION METHOD CALCULATION FORM (CUSTOMARY UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
10. Overall calculations (Cont) First Trial Second Trial Third Trial
Calculated overall fouled coefficient (UD), Btu/hr-ft2-°F
1 __________ __________ __________
UD =
Rio + Ro + rw + ro + rio
Tubesheet thickness (TTT), ft
(C1) (DS + 2.5 ) (P / STT )0.5 + 1.0 __________ __________ __________
TTT =
12.0
C1 = 0.625 for U-tubes, 10 for all others
P = higher of shell side or tube side design pressure.
Effective tube length (L e ), ft
__________ __________ __________
Le = L − TTT
Effective heat transfer area per shell (As), ft2
A s = (NTT ) (Le ) ( A T ) __________ __________ __________
Total effective heat transfer area (A), ft2
A = ( A s ) (NT ) __________ __________ __________

Overall duty coefficient (Uo), Btu/hr-ft2-°F)

Q __________ __________ __________
Uo =
( A ) (MTD)
UD − Uo __________ __________ __________
% Overdesign = x 100
Uo
11. Tubesheet design temperature
(Normally required for Copper alloys)
a. For coolers. (Cooling Water on tube side)
(1) Clean conditions, °F
Rio __________ __________ __________
TM = TDT + (TDS − TDT )
Rc
(2) Fouled conditions, °F
TM = TDT + Uo (Rio + rio ) (TDS − TDT ) __________ __________ __________

(3) Controlling case, °F

Larger of the clean or fouled __________ __________ __________
b. For exchanges
(1) Tube side fluid being cooled
TM = TDT − 0.1(TDT − TDS ) __________ __________ __________
(2) Shell side fluid being cooled
TM = TDT + 0.3 (TDS − TDT ) __________ __________ __________

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CALCULATION PROCEDURE,
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TABLE 1B
ESTIMATION METHOD CALCULATION FORM (METRIC UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
PROCESS REFINERY AND LOCATION CALC. BY
EXCHANGER NO. E DATE
1. Terminal Conditions and MTD
Fluid Being T1 = __________, T2 = __________, T1 - T2 = __________, T1 − T2
Cooled R= = __________
t 2 − t1

Fluid Being t2 = ___________, t1 = ___________, t2 - t1 = ___________, t 2 − T1

Heated P= = __________
T1 − t1
T1 - t2 = _________, T2 - t1 = _________, T1 - t1 = __________
(T1 − t 2 ) − (T2 − t1)
LMTD = = __________
é T1 − t 2 ù
ln ê ú
ë T2 − t1 û

Ns Np
Fn = __________ for ____________ shells in series ____________ shells in parallel
(Figure 2) __________ for ____________ shells in series ____________ shells in parallel
__________ for ____________ shells in series ____________ shells in parallel
MTD = Fn (LMTD) =( )( ) = ____________.
=( )( ) = ____________.
=( )( ) = ____________.

2. Bulk Temperatures
Tubeside Fluid (Heated) TTin = __________ _____, TTout __________ .
(Cooled)

TTin + TTout
TTb = = __________ _________ .
2
Shellside (Heated) TSin = __________ , TSout = __________ ____ .
Fluids (Cooled)
TSin + TS out
TSb = = __________ ________ .
2
Estimated Wall temperature Tw = TTb + 0.6 (TSb − TTb ) = __________ __________ __ .

3. Properties of Fluids
Tubes Shell
ρ = __________ (kg/m3) __________ (kg/m3)
µb = __________ Pa - s __________ Pa - s
Cp = __________ kJ/kg - °C __________ kJ/kg - °C
k = __________ W/m - °C __________ W/m - °C
µw = __________ Pa - s __________ Pa - s

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CALCULATION PROCEDURE,
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TABLE 1B (Cont)
ESTIMATION METHOD CALCULATION FORM (METRIC UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
4. Flow Rates and Names of Fluids
Tube Shell
Fluid
Name/Phase = ______/______ ______/______
Total Mass rate _____________ kg/s _____________ kg/s
W = Total mass rate/Np = ______ kg/s W s = Total mass rate/Np = ______ kg/s
5. Fouling Factors
ri = __________ m2 - °C/W
ro = _________ m2 - °C/W
6. Mechanical Design Features
TEMA Type Tubes Shell
Design Temperature = __________ °C __________ °C
Design Pressure = __________ kPa __________ kPa
Nozzle Size DTNI = __________ mm DSNI = __________ mm
DTNO = __________ mm DSNO = __________ mm

7. Exchanger Geometry First Trial Second Trial Third Trial

Tube O.D. (DO), mm __________ __________ __________
Tube I.D. (DI), mm __________ __________ __________
Tube pitch (PT), mm __________ __________ __________
DO − DI __________ __________ __________
Tube wall thickness (l ) =
2
Tube length (L), m __________ __________ __________
Tube flow length (LI), mm __________ __________ __________
LI = (2000) L for U tubes
LI = (1000) L for all others
TEMA exchanger type __________ __________ __________
Single tube area/length, A T , m2 / m __________ __________ __________

( π) (DO) __________ __________ __________

AT =
1000
Baffle spacing (LBCC), mm __________ __________ __________
Baffle type (Segmental or Double Segmental) __________ __________ __________
Bundle Diameter (DOTL),mm __________ __________ __________
Shell Diameter (DS), mm __________ __________ __________
Number of tube side passes (NTP) __________ __________ __________
(for U tubes minimum number is 2)

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CALCULATION PROCEDURE,
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TABLE 1B (Cont)
ESTIMATION METHOD CALCULATION FORM (METRIC UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
8. Iteration, Tube Side First Trial Second Trial Third Trial
= __________ __________ __________
= __________ __________ __________
= __________ __________ __________
= __________ __________ __________
e. Tube Metal = ______; Kw = ______, DO = ______ mm, DI = ______ mm, l = ______ mm, L = ______ m
f. Tube Pitch (PT) and Layout = __________ __________ __________
g. rio = (DO / D) ri = __________ __________ __________

h. rw = (1000 k w ) = __________ __________ __________

i. NTT = __________ __________ __________
j. N = NTT/NTP = __________ __________ __________
W × 1.273 × 106 = __________ __________ __________
k. Vt =
ρN (DI)2
l. Heat Transfer Coefficient
1273 W ρ Vt (DI)
(1) Re = = × 10 −3 = __________ __________ __________
µb (DI) N µb
(2) For Water __________ __________ __________

hio =
(1.27 × 10 ) (V DI)
4
t
0.7 æ 1.8 TTb + 32 ö
ç ÷
0.26

DO è 100 ø =
(3) Fluids other than water
c p µb = __________ __________ __________
(a) Pr = × 103
k
(b) If Re ≥ 10,000 = __________ __________ __________

22 k
hio = Re0.8 Pr 0.4 φP
DO

φP = (µb / µ w )0.167 for liquids

0.5
æ TT + 273 ö
= çç b ÷
÷ for heating gases
è Tw + 273 ø

= 1.0 for cooling gases

(c) If Re < 10,000
(1) ∆T =  Tw - TTb  = __________ __________ __________
1 1 = __________ __________ __________
−
ρx ρy
(2) β' =
( t x − t y )(1 / ρ av )
æ DI3 ρ2 β' ∆T ö = __________ __________ __________
(3) Gr = 9 • 82 (10 −9 ) ç ÷
ç µ 2 ÷
è b ø

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CALCULATION PROCEDURE,
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TABLE 1B (Cont)
ESTIMATION METHOD CALCULATION FORM (METRIC UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
8. Iteration, Tube Side (Cont) First Trial Second Trial Third Trial
(d) If Re ≤ 2000
(1) From Figure 1.5 determine γ* = __________ __________ __________
(2) From Figure 1.6 determine ε = __________ __________ __________
(3) λ = DI/LI + ε = __________ __________ __________
(4) From Figure 1.7 determine ψ = __________ __________ __________
ì æµ ö
0.14 ü
103 k ï ï
(5) hio = í2.5 + 4.5 [(Re + γ *) λ] Prb0.17 çç b ÷ ýψ
0.37
÷
DO ï
î è µw ø ïþ

(e) If 2000 < Re < 10,000

(1) (hio )turb @ Re = 10,000 ( from b) ) = __________ __________ __________

(2) (hio )lam @ Re = 2,000 ( from d) ) = __________ __________ __________

(3) η = 1.25-Re/8000 = __________ __________ __________

(4) hio = η (hio )lam + (1 − η)(hio )turb = __________ __________ __________

(f) Tw = TTb + Uo (Rio ) (TSb − TTb ) = __________ __________ __________

(g) Evaluate (µb / µ w )0.14 for laminar flow or φP for = __________ __________ __________
turbulent flow and make necessary corrections to
heat transfer coefficients
m. Pressure Drop
(1) Nozzle Pressure Drop
1.273 W × 106 = __________ __________ __________
(a) Vn =
(DTNI) (DTNO ) ρ

ρ V 2n = __________ __________ __________

(b) ∆Pn =
1112
(2) Entrance, Expansion, and Turn-around
(a) From Table 4 determine Ke = __________ __________ __________
K e ρ V 2t = __________ __________ __________
(b) ∆Pe =
2000
(3) Frictional Pressure Drop
(a) From Figure 1.8 evaluate fis = __________ __________ __________

(b) From Figure 1.9 evaluate ϕ = __________ __________ __________

(c) From Figure 1.10 evaluate ψρ = __________ __________ __________
(d) f = fis ϕ ψρ = __________ __________ __________

é ρ V 2t (NTP)L ù = __________ __________ __________

(e) ∆Pt = 2 f ê ú
ê DI ú
ë û
(4) ( ∆Pt ) nn = Ns [ ∆Pn + ∆Pe + (Ft ) ( ∆Pt )] = __________ __________ __________
get value of Ft from Table 4

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CALCULATION PROCEDURE,
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TABLE 1B (Cont)
ESTIMATION METHOD CALCULATION FORM (METRIC UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
9. Iteration, Shell Side First Trial Second Trial Third Trial
Tube row spacing factor
a = 1.0 for Square Pitch
a = 0.867 for all others
Pitch Ratio (PR) = PT/DO __________ __________ __________
Baff. Space to Bundle Dia. Ratio (n)
n = LBCC/DOTL __________ __________ __________
Shell side flow factor (m)
m = 0.5 for J shell
m = 2.0 for F shell
m = 1.0 for E shell
__________ __________ __________
Baffle flow factor (p)
p = 1.0 for segmental baffles
p = 0.5 for double-segmental baffles __________ __________ __________
Baffle Correction Factor (ξ)
ξ = 1.0 for segmental baffles
ξ = 0.8 for double-segmental baffles __________ __________ __________

Estimated tube wall temperature (Tw), °C

Tw = TSb − 0.3 (TSb − TTb ) __________ __________ __________

Wall viscosity correction (ϕ)

ϕ = (µb / µ w )0.14 __________ __________ __________

Total cross flow mass velocity, (Gxt ), kg / s − m2

é PR ù é (m)(p ) ù é Ws ù
Gxt = 106 ê úê úê 2ú
ë PR − 1û ë n û ëê (DOTL ) ûú __________ __________ __________
Total flow Reynolds Number (Rext)
(DO) (Gxt )
Re xt = × 10 −3
(µb ) __________ __________ __________
Nominal Crossflow fraction (FFBn) Figure 1.1 __________ __________ __________
Baffle Spacing Correction (SC) Figure 1.2 __________ __________ __________
Reynolds Number Correction (RC) Figure 1.3 __________ __________ __________
Cross flow fraction for pressure drop (FFBp)
FFBp = (FFBn) (SC)(RC) (Maximum = 1.0) __________ __________ __________
Cross flow Reynolds Number for ∆P (Rexp)
(Rexp = (Rext)(FFBp) __________ __________ __________
Shell side friction for factor (f) Figure 1.4 __________ __________ __________
Cross flow fraction for heat transfer (FFBh)
FFBh = FFBp + 0.125 (Maximum = 1.0) __________ __________ __________
Cross flow Reynolds Number for heat transfer (Rexh)
Rexh = (Rext)(FFBh) __________ __________ __________
Shell side heat transfer factor (j) Figure 1.4 __________ __________ __________

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CALCULATION PROCEDURE,
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TABLE 1B (Cont)
ESTIMATION METHOD CALCULATION FORM (METRIC UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
9. Iteration, Shell Side (Cont) First Trial Second Trial Third Trial
Shell side film coefficient (hs) W/m2-°C
2/3
é k ù
hs = (7.5)(Cp )(Gxt )(FFBh )( j) ê ú (φ)(ξ) __________ __________ __________
êë (Cp )(µ ) úû
Shell side Fraction Term (HF)
é (f ) (L ) (m) (1000 ) ù æ 1 ö
HF = 0.00875 ê ú çç ÷÷ Fs
ë (a) (PR ) (DO)(n) û è φ ø
__________ __________ __________
(Fs from Table 4)
Shell side momentum term (HM)
é (L ) (m) (1000 ) ù
HM = 0.0168 (n)2.6 ê − 1 .0 ú
__________ __________ __________
ë (n) (DOTL ) û
Shell side pressure drop without Nozzle (∆Ps), kPa

∆Ps =
(0.18) [HF + HM ]
ρ
[
(Gxt ) (FFBp ) ] 2 æçç ξ1 ö÷÷ __________ __________ __________
è ø
Nominal shell nozzle I.D. (DN), mm
DN = (DSNI) (DSNO) __________ __________ __________

Shell side nozzle pressure drop (∆PSN), kPa

2
24.31 é Ws × 10 4 ù
∆PSN = ê ú __________ __________ __________
ρ êë (DN)2 úû

Total shell pressure drop (∆Pexch), kPa

∆Pexch = NS [ ∆PS + ∆PSN ] __________ __________ __________

Calculated Tube wall temperature (Tw), °C

æ 1 .0 ö
Tw = TSb − Uo çç ÷ (TSb − TTb )
÷ __________ __________ __________
è hs ø
Calculated viscosity correction (φ)
__________ __________ __________
φ = (µb / µ w )0.14
Using calculated value of φ correct hs & ∆PS __________ __________ __________
10. Overall calculations
Inside resistance referred to outside area (Rio), m2-°C/W
Rio = 1 / hio __________ __________ __________

Outside resistance (Ro), m2-°C/W

R o = 1 / hs __________ __________ __________

Total clean resistance (Rc), m2-°C/W

Rc = Rio + Ro + rw __________ __________ __________

Calculated overall clean coefficient (Uc), W/m2-°C)

Uc = 1 / Rc __________ __________ __________

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TABLE 1B (Cont)
ESTIMATION METHOD CALCULATION FORM (METRIC UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
10. Overall calculations (Cont) First Trial Second Trial Third Trial
Calculated overall fouled coefficient (UD), W/m2-°C
1 __________ __________ __________
UD =
Rio + Ro + rw + ro + rio
Tubesheet thickness (TTT), m
(C1) (DS + 64) (P / STT )0.5 + 25.0 __________ __________ __________
TTT =
1000
C1 = 0.625 for U-tubes, 1.0 for all others
P = higher of shell side or tube side design pressure.
Effective tube length (L e ), m
__________ __________ __________
Le = L − TTT
Effective heat transfer area per shell (As), m2
A s = (NTT ) (L e ) ( A T ) __________ __________ __________
Total effective heat transfer area (A), m2
A = ( A s ) (NT ) __________ __________ __________

Overall duty coefficient (Uo), W/m2-°C)

Q __________ __________ __________
Uo =
( A ) (MTD)
UD − Uo __________ __________ __________
% Overdesign = x 100
Uo
11. Tubesheet design temperature
(Normally required for Copper alloys)
a. For coolers. (Cooling Water on tube side)
(1) Clean conditions, °C
Rio __________ __________ __________
TM = TDT + (TDS − TDT )
Rc
(2) Fouled conditions, °C
TM = TDT + Uo (Rio + rio ) (TDS − TDT ) __________ __________ __________

(3) Controlling case, °C

Larger of the clean or fouled __________ __________ __________
b. For exchanges
(1) Tube side fluid being cooled
TM = TDT − 0.1(TDT − TDS ) __________ __________ __________
(2) Shell side fluid being cooled
TM = TDT + 0.3 (TDS − TDT ) __________ __________ __________

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CALCULATION PROCEDURE,
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TABLE 2A
ESTIMATION METHOD SAMPLE CALCULATION (CUSTOMARY UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)

PROCESS Trim Cooler REFINERY AND LOCATION CALC. BY

EXCHANGER NO. E - X (Existing Check Rate) DATE
1. Terminal Conditions and MTD
Fluid Being T1 = 149 , T2 = 104 , T1 - T2 = 45 , T1 − T2 45
Cooled R= = = 2 .5
t 2 − t1 18
Fluid Being t2 = 104 , t1 = 86 , t2 - t1 = 18 , t 2 − T1 18
Heated P= = = 0.286
T1 − t1 63
T1 - t2 = 45 , T2 - t1 = 18 , T1 - t1 = 63

(T2 − t 2 ) − (T2 − t1) (45 ) − (18 )

LMTD = = = 29.5
éT − t ù æ 45 ö
ln ê 1 2 ú ln ç ÷
ë T2 − t1 û è 18 ø

Ns Np
Fn = 0.8 for 1 shells in series 1 shells in parallel
( Figure 2 ) __________ for ____________ shells in series ___________ shells in parallel
__________ for ____________ shells in series ___________ shells in parallel
MTD = Fn (LMTD) = ( 0.8 ) (29.5) = 23.6 .
=( )( ) = ____________.
=( )( ) = ____________.

2. Bulk Temperatures
Tubeside Fluid: (Heated) TTin = 86 , TTout = 104 .
(Cooled) TTin + TTout
TTb = = 95 .
2
Shellside Fluid: (Heated) TSin = 149 , TSout = 104 .
(Cooled) TS in + TS out
TS b = = 126.5 .
2
Estimated Wall temperature Tw = TTb + 0.6 (TSb − TTb ) = 114 .

3. Properties of Fluids
Tubes Shell
ρ = 62 lb/ft3 46.8 lb/ft3
µb = 0.74 cP 0.8 cP
Cp = 1.0 Btu/lb-°F 0.54 Btu/lb-°F
k = 0.358 Btu/hr-ft2-°F/ft 0.072 Btu/hr-ft2-°F/ft
µw = 0.69 cP 0.81 cP

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TABLE 2A (Cont)
ESTIMATION METHOD SAMPLE CALCULATION (CUSTOMARY UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
4. Flow Rates and Names of Fluids
Tube Shell
Fluid
Name/Phase = WATER/LIQUID HCBN/LIQUID
Total Mass rate 268,000 lb/hr 198,410 lb/hr
W = Total mass rate/Np = 268,000 lb/hr Ws = Total mass rate/Np = 198,410 lb/hr
5. Fouling Factors
ri = __0.002_ hr-ft2-°F/Btu
ro = _0.003_ hr-ft2-°F/Btu
6. Mechanical Design Features
TEMA Type Tubes Shell
Design Temperature = 160 °F 200 °F
Design Pressure = 100 psig 200 psig
Nozzle Size DTNI = 5.761 in. DSNI = 5.761 in.
DTNO = 5.761 in. DSNO = 5.761 in.

7. Exchanger Geometry First Trial Second Trial Third Trial

Tube O.D. (DO), in. 0.72 __________ __________
Tube I.D. (DI), in. 0.62 __________ __________
Tube pitch (PT), in. 1.0 __________ __________
DO − DI 0.065 __________ __________
Tube wall thickness (l ) =
2
Tube length (L), ft 20 __________ __________
Tube flow length (LI), ft 240 __________ __________
LI = (24) L for U tubes
LI = (12) L for all others
TEMA exchanger type AES __________ __________
Single tube area/length, A T , ft 2 0.1963 __________ __________

( π) (DO)
AT =
12
Baffle spacing (LBCC), in. 7.0 __________ __________
Baffle type (Segmental or Double Segmental) SEGMENTAL __________ __________
Bundle Diameter (DOTL), in. 31.25 __________ __________
Shell Diameter (DS), in. 33.0 __________ __________
Number of tube side passes (NTP) (for U tubes 6 __________ __________
minimum number is 2)

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TABLE 2A (Cont)
ESTIMATION METHOD SAMPLE CALCULATION (CUSTOMARY UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
8. Iteration, Tube Side First Trial Second Trial Third Trial
a. Heat Duty = Q = 4,824,000 __________ __________
b. Assumed value of Uo = 80 __________ __________
c. A = Q/Uo (MTD) = 2555 __________ __________
d. As = A/NT = 2555 __________ __________
e. Tube Metal = CuNi ; Kw = 18 , DO = 0.75 in., DI = 0.62 in., l = 0.065 in., L = 20 ft
f. Tube Pitch (PT) and Layout = 1.0 SQUARE __________ __________
g. rio = (DO / DI) ri = 0.00242 __________ __________

h. rw = l / 12 k w = 0.0003 __________ __________

i. NTT = 690 __________ __________
j. N = NTT/NTP = 115 __________ __________
W = 4.98 __________ __________
k. Vt =
19.625 ρN (DI)2
l. Heat Transfer Coefficient
6.32 W 124 ρVt (DI) = 32,077 __________ __________
(1) Re = =
µb (DI) N µb
(2) For Water 1066 __________ __________
0.26
368 æ TT ö
hio = ( VtDI)0.7 ç b ÷ =
DO è 100 ø
(3) Fluids other than water = —
2.42 c pµb = — __________ __________
(a) Pr =
k
(b) If Re ≥ 10,000 = — __________ __________

0.2642k
hio = Re0.8 Pr 0.4 φP
DO

φP = (µb / µ w )0.167 for liquids

0.5
æ TT + 460 ö
= çç b ÷
÷ for heating gases
è Tw + 460 ø

= 1.0 for cooling gases

(c) If Re < 10,000
(1) ∆T =  Tw - TTb  = — __________ __________
1 1
−
ρx ρy = — __________ __________
(2) β' =
( t x − t y )(1 / ρ av )

æ DI3 ρ2 β' ∆T ö =
(3) Gr = 4.13 (10 4 ) ç ÷ — — ---
ç µb2 ÷
è ø

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TABLE 2A (Cont)
ESTIMATION METHOD SAMPLE CALCULATION (CUSTOMARY UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
8. Iteration, Tube Side (Cont) First Trial Second Trial Third Trial
(d) If Re ≤ 2000
(1) From Figure 1.5 determine γ* = — __________ __________
(2) From Figure 1.6 determine ε = — __________ __________
(3) λ = DI/LI + ε = — __________ __________
(4) From Figure 1.7 determine ψ = — __________ __________
ì æµ ö
0.14 ü
12k ï ï
(5) hio = í2.5 + 4.5 [(Re + γ *) λ] Prb0.17 çç b ÷ ýψ
0.37
÷
DO ï
î è µw ø ïþ

(e) If 2000 < Re < 10,000

(1) (hio )turb @ Re = 10,000 ( from b) ) = — __________ __________

(2) (hio )lam @ Re = 2,000 ( from d) ) = — __________ __________

(3) η = 1.25-Re/8000 = — __________ __________

(4) hio = η (hio )lam + (1 − η)(hio )turb = — __________ __________

(f) Tw = TTb + Uo (Rio ) (TSb − TTb ) = — __________ __________

(g) Evaluate (µb / µ w )0.14 for laminar flow or φP for = — __________ __________
turbulent flow and make necessary corrections to heat
transfer coefficients
m. Pressure Drop
(1) Nozzle Pressure Drop,
0.051 W = 6.64 __________ __________
(a) Vn =
(DTNI) (DTNO) ρ

ρ V 2n = 0.53 __________ __________

(b) ∆Pn =
5152
(2) Entrance, Expansion, and Turn-around
(a) From Table 4 determine Ke = 9.6 __________ __________
K e ρ V 2t = 1.6 __________ __________
(b) ∆Pe =
9274
(3) Frictional Pressure Drop
(a) From Figure 1.8 evaluate fis = 0.007 __________ __________

(b) From Figure 1.9 evaluate ϕ = 1.0 __________ __________

(c) From Figure 1.10 evaluate ψρ = 1.0 __________ __________
(d) f = fis ϕ ψρ = 0.007 __________ __________

= 10.8 __________ __________

5.19 é ρ V t (NTP )L ù
2
(e) ∆Pt = f ê ú
103 êë DI ú
û
(4) ( ∆Pt ) nn = Ns [ ∆Pn + ∆Pe + (Ft ) ( ∆Pt )] = 14.8 __________ __________
get value of Ft from Table 4.

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CALCULATION PROCEDURE,
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TABLE 2A (Cont)
ESTIMATION METHOD SAMPLE CALCULATION (CUSTOMARY UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
9. Iteration, Shell Side First Trial Second Trial Third Trial
Tube row spacing factor
a = 1.0 for Square Pitch
a = 0.867 for all others 1.0 __________ __________
Pitch Ratio (PR) = PT/DO 1.33 __________ __________
Baff. Space to Bundle Dia. Ratio (n)
n = LBCC/DOTL 0.224 __________ __________
Shell side flow factor (m)
m = 0.5 for J shell
m = 2.0 for F shell
m = 1.0 for E shell 1.0 __________ __________
Baffle flow factor (p)
p = 1.0 for segmental baffles
p = 0.5 for double-segmental baffles 1.0 __________ __________
Baffle Correction Factor (ξ)
ξ = 1.0 for segmental baffles
ξ = 0.8 for double-segmental baffles 1.0 __________ __________

Estimated tube wall temperature (Tw), °F

Tw = TSb − 0.3 (TSb − TTb ) 117 __________ __________
Wall viscosity correction (ϕ)
ϕ = (µb / µ w )0.14 0.998 __________ __________

Total cross flow mass velocity, (Gxt ), lb / hr − ft 2

é PR ù é (m)(p) ù é Ws ù
Gxt = 144 ê úê úê 2ú
ë PR − 1û ë n û êë (DOTL ) úû 522,442 __________ __________
Total flow Reynolds Number (Rext)
(DO) (Gxt )
Rext =
(29 ) (µb ) 16,889 __________ __________
Nominal Crossflow fraction (FFBn) Figure 1.1 0.545 __________ __________
Baffle Spacing Correction (SC) Figure 1.2 0.75 __________ __________
Reynolds Number Correction (RC) Figure 1.3 1.0 __________ __________
Cross flow fraction for pressure drop (FFBp)
FFBp = (FFBn) (SC)(RC) (Maximum = 1.0) 0.409 __________ __________
Cross flow Reynolds Number for ∆P (Rexp)
(Rexp = (Rext)(FFBp) 6908 __________ __________
Shell side friction for factor (f) Figure 1.4 0.09 __________ __________
Cross flow fraction for heat transfer (FFBh)
FFBh = FFBp + 0.125 (Maximum = 1.0) 0.534 __________ __________
Cross flow Reynolds Number for heat transfer (Rexh)
Rexh = (Rext)(FFBh) 9018 __________ __________
Shell side heat transfer factor (j) Figure 1.4 0.009 __________ __________

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CALCULATION PROCEDURE,
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TABLE 2A (Cont)
ESTIMATION METHOD SAMPLE CALCULATION (CUSTOMARY UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
9. Iteration, Shell Side (Cont) First Trial Second Trial Third Trial
Shell side film coefficient (hs) Btu/hr-ft2-°F
2/3
é k ù
hs = (0.415 )(Cp )(Gxt )(FFBh )( j) ê ú (φ)(ξ) 170 __________ __________
êë (Cp )(µ) úû
Shell side Fraction Term (HF)
é ( f ) (L) (m) (12) ù æ 1 ö
HF = 0.00875 ê ú çç ÷÷ Fs
ë (a) (PR ) (DO) (n) û è φ ø
0.972 __________ __________
(Fs from Table 4)
Shell side momentum term (HM)
é (L ) (m) (12) ù
HM = 0.0168 (n)2.6 ê − 1 .0 ú
0.011 __________ __________
ë (n) (DOTL ) û
Shell side pressure drop without Nozzle (∆Ps), psi
2
(0.3) [HF + HM ] é (Gxt ) (FFBp ) ù æ 1ö
∆Ps = ê ú çç ÷÷ 2.9 __________ __________
e ë 10000 û èξø
Nominal shell nozzle I.D. (DN), in.
DN = (DSNI) (DSNO) 5.761 __________ __________

Shell side nozzle pressure drop (∆PSN), psi

2
0.84 é Ws ù
∆PSN = ê ú 0.64 __________ __________
ρ ëê (1000 ) (DN)2 ûú

Total shell pressure drop (∆Pexch), psi

∆Pexch = NS [ ∆PS + ∆PSN ] 3.54 __________ __________

Calculated Tube wall temperature (Tw), °F

æ 1 .0 ö
Tw = TSb − Uo çç ÷ (TSb − TTb )
÷ 112 __________ __________
è hs ø
Calculated viscosity correction (φ)
0.998 __________ __________
φ = (µb / µ w )0.14
Using calculated value of φ correct hs & ∆PS — __________ __________
10. Overall calculations
Inside resistance referred to outside area (Rio), hr-ft2-°F/Btu
Rio = 1 / hio 0.00094 __________ __________

Outside resistance (Ro), hr-ft2-°F/Btu

R o = 1 / hs 0.00588 __________ __________

Total clean resistance (Rc), hr-ft2-°F/Btu

Rc = Rio + Ro + rw 0.00712 __________ __________

Calculated overall clean coefficient (Uc), Btu/hr-ft2-°F

Uc = 1 / Rc 140 __________ __________

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CALCULATION PROCEDURE,
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TABLE 2A (Cont)
ESTIMATION METHOD SAMPLE CALCULATION (CUSTOMARY UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
10. Overall Calculations (Cont) First Trial Second Trial Third Trial
Calculated overall fouled coefficient (UD), Btu/hr-ft2-°F
1 79.7 __________ __________
UD =
Rio + Ro + rw + ro + rio
Tubesheet thickness (TTT), ft
(C1) (DS + 2.5 ) (P / STT )0.5 + 1.0 0.46 __________ __________
TTT =
12.0
C1 = 0.625 for U-tubes, 1.0 for all others
P = higher of shell side or tube side design pressure.
Effective tube length (Le ), ft
19.54 __________ __________
Le = L − TTT
Effective heat transfer area per shell (As), ft2
A s = (NTT ) (Le ) ( A T ) 2647 __________ __________
Total effective heat transfer area (A), ft2
A = ( A s ) (NT ) 2647 __________ __________

Overall duty coefficient (Uo), Btu/hr-ft2-°F)

Q 77.2 __________ __________
Uo =
( A ) (MTD)
UD − Uo 3.24 __________ __________
% Overdesign = x 100
Uo
11. Tubesheet design temperature
(Normally required for Copper alloys)
a. For coolers. (Cooling Water on tube side)
(1) Clean conditions, °F
Rio 165.3 __________ __________
TM = TDT + (TDS − TDT )
Rc
(2) Fouled conditions, °F
TM = TDT + Uo (Rio + rio ) (TDS − TDT ) 170.3 __________ __________

(3) Controlling case, °F

Larger of the clean or fouled 170.3 __________ __________
b. For exchanges
(1) Tube side fluid being cooled
TM = TDT − 0.1(TDT − TDS ) — __________ __________
(2) Shell side fluid being cooled
TM = TDT + 0.3 (TDS − TDT ) — __________ __________

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CALCULATION PROCEDURE,
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TABLE 2B
ESTIMATION METHOD SAMPLE CALCULATION (METRIC UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
PROCESS Trim Cooler REFINERY AND LOCATION CALC. BY
EXCHANGER NO. E – X (Existing Check Plan) DATE

1. Terminal Conditions and MTD

Fluid Being T1 = 65 , T2 = 40 , T1 - T2 = 25 , T1 − T2 25
Cooled R= = = 2 .5
t 2 − t1 10
Fluid Being t2 = 40 , t1 = 30 , t2 - t1 = 10 , t 2 − t1 10
Heated P= = = 0.286
T1 − t1 35
T1 - t2 = 25 , T2 - t1 = 10 , T1 - t1 = 35

LMTD =
(T1 − t 2 ) − (T2 − t1)
=
(25) − (10 ) = 16.4
é T1 − t 2 ù æ 25 ö
ln ê ú ln ç ÷
ë T2 − t1 û è 10 ø

Ns Np
Fn = 0.8 for 1 shells in series ____1 ______ shells in parallel
(Figure 2) __________ for ____________ shells in series ____________ shells in parallel
__________ for ____________ shells in series ____________ shells in parallel
MTD = Fn (LMTD) = ( 0.8 ) ( 16.4 ) = 13.1 .
=( )( ) = ____________.
=( )( ) = ____________.

2. Bulk Temperatures
Tubeside Fluid: (Heated) TTin = 30 , TTout = 40 .
(Cooled) TTin + TTout
TTb = = 35 .
2
Shellside Fluid: (Heated) TSin = 65 , TSout = 40 .
(Cooled) TSin + TS out
TS b = = 52.5 .
2
Estimated Wall temperature Tw = TTb + 0.6 (TS b − TTb ) = 45.5 .

3. Properties of Fluids
Tubes Shell
ρ = 993 (kg/m3) 750 (kg/m3)
µb = 0.00074 Pa-s 0.0008 Pa-s
Cp = 4.187 kJ/kg-°C 2.261 kJ/kg-°C
k = 0.62 W/m-°C 0.125 W/m-°C
µw = 0.00069 Pa-s 0.00081 Pa-s

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CALCULATION PROCEDURE,
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TABLE 2B (Cont)
ESTIMATION METHOD SAMPLE CALCULATION (METRIC UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
4. Flow Rates and Names of Fluids
Tube Shell
Fluid
Name/Phase = WATER/LIQUID HCBN/LIQUID
Total Mass rate 33.77 kg/s 25.0 kg/s
W = Total mass rate/Np = 33.77 kg/s Ws = Total mass rate/Np = 25.0 kg/s
5. Fouling Factors
ri = 0.00035 m2-°C/W
ro = 0.00053 m2-°C/W
6. Mechanical Design Features
TEMA Type Tubes Shell
Design Temperature = 70 °C 95 °C
Design Pressure = 690 kPa 1380 kPa
Nozzle Size DTNI = 146 mm DSNI = 146 mm
DTNO = 146 mm DSNO = 146 mm

7. Exchanger Geometry First Trial Second Trial Third Trial

Tube O.D. (DO), mm 19.05 __________ __________
Tube I.D. (DI), mm 15.75 __________ __________
Tube pitch (PT), mm 25.4 __________ __________
DO − DI 1.65 __________ __________
Tube wall thickness (l ) =
2
Tube length (L), m 6.1 __________ __________
Tube flow length (LI), mm 6100 __________ __________
LI = (2000) L for U tubes
LI = (1000) L for all others
TEMA exchanger type AES __________ __________
2
Single tube area/length, A T , m / m 0.05985 __________ __________

( π) (DO) __________ __________

AT =
1000
Baffle spacing (LBCC), mm 178 __________ __________
Baffle type (Segmental or Double Segmental) SEGMENTAL __________ __________
Bundle Diameter (DOTL), mm 794 __________ __________
Shell Diameter (DS), mm 838 __________ __________
Number of tube side passes (NTP) 6 __________ __________
(for U tubes minimum number is 2)

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TABLE 2B (Cont)
ESTIMATION METHOD SAMPLE CALCULATION (METRIC UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
8. Iteration, Tube Side First Trial Second Trial Third Trial
a. Heat Duty = Q = 1414000 __________ __________
b. Assumed value of Uo = 455 __________ __________
c. A = Q/Uo (MTD) = 237 __________ __________
d. As = A/NT = 237 __________ __________
e. Tube Metal = CuNi ; Kw = 31.1 , DO = 19.05 mm, DI = 15.75 mm, l = 1.65 mm, L = 6100 m
f. Tube Pitch (PT) and Layout = 25.4 SQUARE __________ __________
g. rio = (DO / D) ri = 0.00042 __________ __________

h. rw = (1000 k w ) = 0.000053 __________ __________

i. NTT = 690 __________ __________
j. N = NTT/NTP = 115 __________ __________
W × 1.273 × 106 = 1.52 __________ __________
k. Vt =
ρN (DI)2
l. Heat Transfer Coefficient
1273 W ρ Vt (DI)
(1) Re = = × 10 −3 = 32125 __________ __________
µb (DI) N µb
(2) For Water

hio =
(1.27 × 10 ) ( V DI)
4
t
0. 7 æ 1.8 TTb + 32 ö
çç ÷÷
0.26
6074 __________ __________
DO è 100 ø =
(3) Fluids other than water
c p µb = — __________ __________
(a) Pr = × 10 3
k
(b) If Re ≥ 10,000 = — __________ __________

22k
hio = Re0.8 Pr 0.4 φP
DO

φP = (µb / µ w )0.167 for liquids

0.5
æ TTb + 273 ö
= çç ÷÷ for heating gases
è Tw + 273 ø

= 1.0 for cooling gases

(c) If Re < 10,000
(1) ∆T =  Tw - TTb  = — __________ __________
1 1 = — __________ __________
−
ρx ρy
(2) β' =
( t x − t y )(1/ ∂ av )
æ DI3 ρ2 β' ∆T ö = — __________ __________
(3) Gr = 9 • 82 (10 −9 ) ç ÷
ç µb 2 ÷
è ø

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TABLE 2B (Cont)
ESTIMATION METHOD SAMPLE CALCULATION (METRIC UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
8. Iteration, Tube Side (Cont) First Trial Second Trial Third Trial
(d) If Re ≤ 2000
(1) From Figure 1.5 determine γ* = — __________ __________
(2) From Figure 1.6 determine ε = — __________ __________
(3) λ = DI/LI + ε = — __________ __________
(4) From Figure 1.7 determine ψ = — __________ __________
ì æµ ö
0.14 ü
103 k ï ï
(5) hio = í2.5 + 4.5 [(Re + γ *) λ] Prb0.17 çç b ÷ ýψ
0.37
÷
DO ï
î è µw ø ïþ

(e) If 2000 < Re < 10,000

(1) (hio )turb @ Re = 10,000 ( from b)) = — __________ __________

(2) (hio )lam @ Re = 2,000 ( from d)) = — __________ __________

(3) η = 1.25-Re/8000 = — __________ __________

(4) hio = η (hio )lam + (1 − η)(hio )turb = — __________ __________

(f) Tw = TTb + Uo (Rio ) (TSb − TTb ) = — __________ __________

(g) Evaluate (µb / µ w )0.14 for laminar flow or φP for = — __________ __________
turbulent flow and make necessary corrections
to heat transfer coefficients
m. Pressure Drop
(1) Nozzle Pressure Drop
1.273 W × 106 = 2.03 __________ __________
(a) Vn =
(DTNI) (DTNO) ρ

ρ Vn2 = 3.68 __________ __________

(b) ∆Pn =
1112
(2) Entrance, Expansion, and Turn-around
(a) From Table 4 determine Ke = 9.6 __________ __________
K e ρ Vt 2 = 11.0 __________ __________
(b) ∆Pe =
2000
(3) Frictional Pressure Drop
(a) From Figure 1.8 evaluate fis = 0.007 __________ __________

(b) From Figure 1.9 evaluate ϕ = 1.0 __________ __________

(c) From Figure 1.10 evaluate ψρ = 1.0 __________ __________
(d) f = fis ϕ ψρ = 0.007 __________ __________

é ρ V 2 (NTP)L ù = 75.6 __________ __________

(e) ∆Pt = 2 f ê t
ú
êë DI úû

(4) ( ∆Pt ) nn = Ns [ ∆Pn + ∆Pe + (Ft ) ( ∆Pt )] = 103 __________ __________

get value of Ft from Table 4.

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TABLE 2B (Cont)
ESTIMATION METHOD SAMPLE CALCULATION (METRIC UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
9. Iteration, Shell Side First Trial Second Trial Third Trial
Tube row spacing factor
a = 1.0 for Square Pitch 1.0
a = 0.867 for all others
Pitch Ratio (PR) = PT/DO 1.33 __________ __________
Baff. Space to Bundle Dia. Ratio (n)
n = LBCC/DOTL 0.224 __________ __________
Shell side flow factor (m)
m = 0.5 for J shell
m = 2.0 for F shell
m = 1.0 for E shell 1.0 __________ __________
Baffle flow factor (p)
p = 1.0 for segmental baffles
p = 0.5 for double-segmental baffles 1.0 __________ __________
Baffle Correction Factor (ξ)
ξ = 1.0 for segmental baffles
ξ = 0.8 for double-segmental baffles 1.0 __________ __________

Estimated tube wall temperature (Tw), °C

Tw = TSb − 0.3 (TSb − TTb ) 47.85 __________ __________
Wall viscosity correction (ϕ)
ϕ = (µb / µ w )0.14 0.998 __________ __________

Total cross flow mass velocity, (Gxt ), kg / s − m2

é PR ù é (m)(p) ù é Ws ù
Gxt = 106 ê úê úê 2ú
ë PR − 1û ë n û êë (DOTL ) úû 708.1 __________ __________
Total flow Reynolds Number (Rext)
(DO) (Gxt )
Re xt = × 10 −3
(µb ) 16862 __________ __________
Nominal Crossflow fraction (FFBn) Figure 1.1 0.545 __________ __________
Baffle Spacing Correction (SC) Figure 1.2 0.75 __________ __________
Reynolds Number Correction (RC) Figure 1.3 1.0 __________ __________
Cross flow fraction for pressure drop (FFBp)
FFBp = (FFBn) (SC)(RC) (Maximum = 1.0) 0.409 __________ __________
Cross flow Reynolds Number for ∆P (Rexp)
Rexp = (Rext)(FFBp) 6896 __________ __________
Shell side friction for factor (f) Figure 1.4 0.09 __________ __________
Cross flow fraction for heat transfer (FFBh)
FFBh = FFBp + 0.125 (Maximum = 1.0) 0.534 __________ __________
Cross flow Reynolds Number for heat transfer (Rexh)
Rexh = (Rext)(FFBh) 9004 __________ __________
Shell side heat transfer factor (j) Figure 1.4 0.009 __________ _________

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TABLE 2B (Cont)
ESTIMATION METHOD SAMPLE CALCULATION (METRIC UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
9. Iteration, Shell Side (Cont) First Trial Second Trial Third Trial
Shell side film coefficient (hs) W/m2-°C
2/3
é k ù
hs = (7.5)(Cp )(Gxt )(FFBh )( j) ê ú (φ)(ξ) 970 __________ __________
êë (Cp )(µ ) úû
Shell side Fraction Term (HF)
é (f ) (L ) (m) (1000 ) ù æ 1 ö
HF = 0.00875 ê ú çç ÷÷ Fs
ë (a) (PR ) (DO)(n) û è φ ø
0.973 __________ __________
(Fs from Table 4)
Shell side momentum term (HM)
é (L) (m) (1000 ) ù
HM = 0.0168 (n)2.6 ê − 1 .0 ú
0.011 __________ __________
ë (n) (DOTL ) û
Shell side pressure drop without Nozzle (∆Ps), kPa

∆Ps =
(0.18) [HF + HM ]
ρ
[(Gxt ) (FFBp )]2 æçç ξ1 ö÷÷ 19.8 __________ __________
è ø
Nominal shell nozzle I.D. (DN), mm
DN = (DSNI) (DSNO) 146 __________ __________

Shell side nozzle pressure drop (∆PSN), kPa

2
24.31 é Ws × 10 4 ù
∆PSN = ê ú 4.46 __________ __________
ρ êë (DN)2 úû
Total shell side pressure drop (∆Pexch), kPa
∆Pexch = NS [ ∆PS + ∆PSN ] 24.3 __________ __________

Calculated Tube wall temperature (Tw), °C

æ 1 .0 ö
Tw = TSb − Uo çç ÷ (TSb − TTb )
÷ 44.2 __________ __________
è hs ø
Calculated viscosity correction (φ)
0.998 __________ __________
φ = (µb / µ w )0.14
Using calculated value of φ correct hs & ∆PS — __________ __________
10. Overall calculations
Inside resistance referred to outside area (Rio), m2 -°C/W
Rio = 1 / hio 0.000165 __________ __________

Outside resistance (Ro), m2-°C/W

R o = 1 / hs 0.001031 __________ __________

Total clean resistance (Rc), m2-°C/W

Rc = Rio + Ro + rw 0.001249 __________ __________

Calculated overall clean coefficient (Uc), W/m2-°C

Uc = 1 / Rc 801 __________ __________

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TABLE 2B (Cont)
ESTIMATION METHOD SAMPLE CALCULATION (METRIC UNITS)
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
10. Overall calculations (Cont) First Trial Second Trial Third Trial
Calculated overall fouled coefficient (UD), W/m2-°C
1 455 __________ __________
UD =
Rio + Ro + rw + ro + rio
Tubesheet thickness (TTT), m
(C1) (DS + 64) (P / STT )0.5 + 25.0 0.139 __________ __________
TTT =
1000
C1 = 0.625 for U-tubes, 1.0 for all others
P = higher of shell side or tube side design pressure.
Effective tube length (Le ), m
5.961 __________ __________
Le = L − TTT
Effective heat transfer area per shell (As), m2
A s = (NTT ) (Le ) ( A T ) 246 __________ __________
Total effective heat transfer area (A), m2
A = ( A s ) (NT ) 246 __________ __________

Overall duty coefficient (Uo), W/m2-°C)

Q 439 __________ __________
Uo =
( A ) (MTD)
UD − Uo 3.64 __________ __________
% Overdesign = x 100
Uo
11. Tubesheet design temperature
(Normally required for Copper alloys)
a. For coolers. (Cooling Water on tube side)
(1) Clean conditions, °C
Rio 73.3 __________ __________
TM = TDT + (TDS − TDT )
Rc
(2) Fouled conditions, °C
TM = TDT + Uo (Rio + rio ) (TDS − TDT ) 75.7 __________ __________

(3) Controlling case, °C

Larger of the clean or fouled 75.7 __________ __________
b. For exchanges
(1) Tube side fluid being cooled
TM = TDT − 0.1(TDT − TDS ) __________ __________ __________
(2) Shell side fluid being cooled
TM = TDT + 0.3 (TDS − TDT ) __________ __________ __________

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TABLE 3
PRORATION FACTORS
1. TUBE SIDE
a. General
hio varies as the 2/3 power of thermal conductivity.
hio varies as the 1/3 power of specific heat.
∆Pt varies as the 1.8 power of mass velocity, for same tube I.D.
∆Pt varies inversely with the specific gravity, for same mass flow rate.
b. Turbulent Region
∆Pt varies as the 1.8 power of mass velocity for same tube I.D.
hio varies as the 0.8 power of mass velocity for same tube I.D.
∆Pt varies as the 0.24 power of viscosity.
hio varies as the -0.47 power of viscosity.
hio varies as the -0.20 power of inside diameter for same mass velocity.
hio varies as -0.8 power of number of tube passes, for same total number of tubes.
∆Pt varies as -2.8 power of number of tube passes total for same total number of tubes.
c. Viscous Region
hio varies as the 1/3 power of mass velocity, for same tube I.D.
∆Pt varies as the 1.0 power of mass velocity, for same tube I.D.
∆Pt varies as the 1.0 power of viscosity.
hio does not vary appreciably with viscosity.
hio varies as the -2/3 power of the inside diameter, for same Vt.
2. SHELL SIDE
hs varies as the -0.27 power of viscosity.
hs varies as the 0.6 power of mass velocity.
hs varies as the 2/3 power of thermal conductivity.
hs varies as the 1/3 power of specific heat.
hs varies as the -0.4 power of outside diam. of the tube.
∆Ps varies as the 1.67 power of mass velocity.
∆Ps varies as the 0.2 power of viscosity.
∆Ps varies inversely with the specific gravity.
∆Ps varies as the -2.6 power of baffle pitch.
3. OVERALL AREA AND TUBE COUNT
Heat transfer Area A varies inversely as tube dia. for same shell dia. and PR.
No of tubes NTT varies as -2 power of tube pitch.
No of tubes NTT varies as 2 power of shell dia. for same tubes and tube pitch.

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TABLE 4
DESIGN CONSTANTS FOR SHELL AND TUBE EXCHANGER CALCULATIONS

TUBE SIDE
Pressure Drop Factor, Ke
Straight Tubes: Single Pass Ke = 0.9
Multiple Pass Ke = 1.6 (NTP)
U–Tubes: Two Pass Ke = 0.9
Four or More Passes Ke = 0.8 (NTP)
Pressure Drop Fouling Factors
Pressure drop fouling factors are evaluated by the following equations which take into account wall thickness variations and a
fouling layer buildup.
Steel Tubes
5
é DO − 2t ù
Ft = ê 0. 3 ú
êë DO − 2.2t − 0.0238 DO úû

Nonferrous Alloy Tubes

5
é ù
DO − 2t
Ft = ê ú
ê
[
ë 1.05 (DO − 2t ) − 0.05 DO
2 2
] 0.5
− 0.0086 DO −0.92 ú
û

The following table gives values for the pressure drop fouling factor, Ft, of common tube sizes. These values were evaluated
using the equations above.

PRESSURE DROP FOULING FACTOR OF COMMON TUBE SIZE

NON FERROUS
TUBE SIZE STEEL TUBES
ALLOY TUBES
Ft
Ft
DO t

in. mm in. mm PLAIN LOW FIN PLAIN LOW FIN

3/4 19.05 0.049 1.245 1.28 1.35 1.14 1.19

0.065 1.651 1.34 1.42 1.17 1.23

0.083 2.108 1.41 1.53 1.20 1.30

0.109 2.769 1.53 1.74 1.26 1.39

1 25.4 0.065 1.651 1.24 1.28 1.10 1.12

0.083 2.108 1.28 1.33 1.12 1.15

0.109 2.769 1.35 1.43 1.15 1.19

0.134 3.404 1.43 1.19

1–1/2 38.1 0.083 2.108 1.18

0.109 2.769 1.21

0.134 3.404 1.25

0.165 4.191 1.31

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TABLE 4 (Cont)
DESIGN CONSTANTS FOR SHELL AND TUBE EXCHANGER CALCULATIONS

DESIGN COOLING WATER VELOCITY(1) MOST FAVORABLE VELOCITY, PERMISSIBLE RANGE,

MATERIAL TYPE OF WATER ft/sec m/sec ft/sec(2) m/sec(2)

Carbon steel Fresh, noninhibited 4 1.22 3 to 6 0.91 to 1.82

Fresh, inhibited 6 to 8 1.82 to 2.44 3 to 10 0.91 to 3.05

Red brass All types 3 0.91 3 to 4 0.91 to 1.22

Admiralty (inhibited) Fresh (inhibited or not) 6 to 8 1.82 to 2.44 3 to 10 0.91 to 3.05

Salt or brackish 3 0.91 3 to 6 0.91 to 1.82

Aluminum brass Fresh (inhibited or not) 6 to 8 1.82 to 2.44 3 to 10 0.91 to 3.05

Salt or brackish 5 1.52 3 to 8 0.91 to 2.44

Cupronickel (70–30) All types 7 to 8 2.1 to 2.44 3 to 12 0.91 to 3.66

Cupronickel (90–10) All types 7 to 8 2.1 to 2.44 3 to 12 0.91 to 3.66

Monel Fresh 6 to 8 1.82 to 2.44 3 to 12 0.91 to 3.66

Salt 8 2.44 6 to 12 1.82 to 3.66

Type 316 alloy steel Fresh 6 to 8 1.82 to 2.44 3 to 10 0.91 to 3.05

Titanium All types >3 > 0.91 3 to 30 0.91 to 9.1

SHELL SIDE

MAXIMUM ALLOWABLE BAFFLE PITCH(3) (4) MAXIMUM LBCC,

COPPER, ALUMINUM
TUBE O.D., STEEL
ALLOYS

in. mm in. mm in. mm

0.75 19.05 30.0 762.0 26.0 660.0

1.00 25.4 37.0 940.0 32.0 813.0

1.50 38.1 50.0 1270.0 43.5 1105.0

Pressure Drop Fouling Factors, Fs

Fluid Fs
Liquids 1.15(5)
Gases or condensing vapors 1.00(6)
Notes:
(1) Reproduced from Construction Materials Manual, Section II, Onsite Cooling Water Facilities.
(2) As a general policy, it is advisable to design for velocities above the most favorable velocity rather than below, but do not
push too close to the upper limit of the permissible range. This is particularly important in the case of coolers or
condensers where temperature control is critical or where seasonal water temperature changes require substantial water
velocity reductions for control.
(3) When there is no change of phase on the shell side, baffle pitch should never exceed the shell diameter.
(4) For information on other materials or tube sizes, refer to TEMA Table 4.52.
(5) This value may be increased for extremely dirty service.
(6) Use a larger number if vapors are known to be fouling.

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FIGURE 1.1
NORMAL CROSSFLOW FRACTION
0.8 (PR-1)/PR
Nominal Crossflow Fraction, FFBn

0.275
Fixed Tubesheet 0.250
0.7 0.225
0.200 Pull through F.H.
Split-Ring F.H.
0.6 0.275
0.250
0.225
0.200
0.5

0.275
0.4 0.250
0.225
0.200

0.3 (PR-1)/PR
10 20 30 40 50 10 20 30 40 50 60

Tube Bundle Diameter (DOTL), in.

DOTL
For metric
25.4 DP9Df1-1

FIGURE 1.2 FIGURE 1.3

BAFFLE SPACING CORRECTION LOW REYNOLDS NUMBER CORRECTION
1.4 1.0
1
Baffle Spacing Correction, SC

2
1.2 0.8
Low Reynolds Number

3
Correction, RC

1.0 0.6

1 - FXTS, U.T. all DOTL

0.8 0.4
SRFH and PTFH 60 in. DOTL
2 - SRFH and PTFH 30 in. DOTL
3 - SRFH and PTFH 10 in. DOTL
0.6 0.2
0 0.2 0.4 0.6 0.8 1.0 0 50 100 200 400 600 800 1000

Baffle Spacing Total Flow Reynolds Number, Re xt

·n
Bundle Diameter DP9Df1-2 DP9Df1-3

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FIGURE 1.4
FRICTION FACTOR AND HEAT TRANSFER “J” FACTOR

5
St
ag
3 ge
re
d
2
PR
In =
lin 1.
e 33
1.0
Friction Factor or Heat Transfer "j" Factor

0.7
PR f, Use Rexh
=1
0.5 .25

0.3 PR
Staggered =
1. PR
0.2 33
= 1 .2
5

0.1 Inline

0.07

0.05 j, Use Rexh

0.03

0.02

0.01

0.007
0.005

0.003
10 2 3 5 7 105 2 3 5 7 105 2 3 5 7 105 2 3 5 7 105

Crossflow Reynolds Number, Rexp or Rexh DP9Df1-4

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FIGURE 1.5
FACTOR γ* AS A FUNCTION OF GRASHOF NUMBER

105

104

Vertical
L/D = 20
200
50
103
*
Natural Convection Factor, γ

100

400

102

Horizontal
10

0
1 10 102 103 104 105 106 107

Grashof Number, Gr DP9Df1-5

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FIGURE 1.6
SHORT TUBE CORRECTION FACTOR, ε
0.20

ε 0.18 Re = 2000

0.16
Short tube Correction Factor

0.14

0.12
Re = 1000
0.10

0.08
Re = 500
0.06
Re = 300
0.03
Re = 100
0.02

10 20 30 40 50 60 70
LI/DI DP9Df1-6

FIGURE 1.7
LOW PRANDTL NUMBER CORRECTION FACTOR, Ψ
1.0
Low Prandtil Number Correction Factor Ψ

0.9

0.8

0.7

0.6

0.5

0.4

0.3

0 2 4 6 8 10 12 14 16 18 20 22 24

Prandtl Number, Pr DP9Df1.7

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FIGURE 1.8
ISOTHERMAL FRICTION FACTOR INSIDE TUBES

0.2
Re - RANGE EQUATION
Re ≤ 2000 fis = 16 / Re
0.1 2000 <Re <3800 fis = 10-4 Re0.575
Re ≥ 3800 fis = 0.0035 + 0.264 Re-0.42
Isothermal Friction Factor, fis

0.05

0.02

0.01

0.005
TRAN

LAMINAR TURBULENT

0.002

0.001
102 2 5 103 2 5 104 2 5 105 2 5 106

Reynolds Number, Re DP9Df1-8

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FIGURE 1.9
VISCOSITY GRADIENT CORRECTION FACTOR
4.0
1 Turbulent, Re > 6000
3.0
3 4 2 Transitional, Re = 3000
2.0 3 Transitional, Re = 2000
4 Laminar, Re < 1800
1
φ 2
1.0 1 2
0.7

0.5
3 4
0.3
0.01 2 3 5 7 0.1 2 3 5 7 1.0 2 3 5 7 10 2 3 5 7 100
µb
Viscosity Ratio - Bulk to Wall µw
DP9Df1-9

FIGURE 1.10
NATURAL CONVECTION CORRECTION FACTOR
1.8

Re ≤ 2000

1.6 3000

Ψρ 4000
1.4

5000
1.2
6000

Re ≥ 8000
1.0
105 2 3 5 7 106 2 3 5 7 107 2 3 5 7 108 2 3 5 7 109

µb
Gr Pr µw
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FIGURE 2
LMTD CORRECTION FACTORS
ILLUSTRATION OF SHELL ARRANGEMENTS

1 shell pass, 2 or more tube passes Fig. 2A 1J shell with 1 tube pass Fig. 2D

2 shell passes, 4 or more tube passes Fig. 2A 2J shells with 1 tube pass Fig. 2D
or 1Gshell with 2 tube passes

or or

3 shell passes, 6 or more tube passes Fig. 2B 1J shell with 2 or more tube passes Fig. 2E

4 shell passes, 8 or more tube passes Fig. 2B 2J shells or 1G shell with 4 or more tube passes
Fig. 2E

4 or
shells

5 shell passes, 10 or more tube passes Fig. 2C 3J shells with 6 or more tube passes Fig. 2F

5
shells

6 shell passes, 12 or more tube passes Fig. 2C 4J shells or 2G shell with 8 or more tube passes
Fig. 2F

6 or 3
shells shells

DP9Df02

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CALCULATION PROCEDURE,
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FIGURE 2A
LMTD CORRECTION FACTORS

1 Shell Pass, 2 or More Tube Passes

0.99

0.98

0.95
Fn
0.90 0.2
15 8 R=4 2.5 1.6 1.0 0.6 0.4 0.10
10 0.3
20 6 3 1.2 0.8 0.5
0.80 2

0.70
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
P
T 1 - T2 t2 - t1
R= t2 - t1 P= T1 - t1

2 Shell Passes, 4 or More Tube Passes

0.99

0.98

0.95
Fn
0.90
15 8 4 1.8 1.4 1.0 0.6 0.3 0.1
2.5
10 0.2
20 6 3 R=2 1.6 1.2 0.8 0.4
0.80

0.70
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
P DP9Df02A

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CALCULATION PROCEDURE,
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FIGURE 2B
LMTD CORRECTION FACTORS

3 Shell Passes, 6 or More Tube Passes

0.99

0.98
0.4 0.3
0.2
0.95
Fn 0.5
15
0.90
4 1.6 0.8 0.6
10 1.4
6 1.0
R=2 1.2
20 8 3 2.5
0.80

0.70
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
P

4 Shell Passes, 8 or More Tube Passes

0.99

0.98
0.3 0.2

0.6
0.95 0.4
Fn
15 0.8
0.90
4 2.5
10 1.0
6 1.6 1.4 1.2
20 8 3 R=2
0.80

0.70
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
P DP9Df02B

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FIGURE 2C
LMTD CORRECTION FACTORS

5 Shell Passes, 10 or More Tube Passes

0.99

0.98

0.95
0.8
Fn 0.5
0.4
0.90 1.2
4 2.5 1.8 1.6
10 0.6
1.4 1.0
6 3 R=2.0
20
0.80

0.70
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
P

6 Shell Passes, 12 or More Tube Passes

0.99

0.98

20 0.4
0.95 0.9
1.8 0.6
Fn 10
0.8
0.90 1.2
1.0
6 3 2.5 1.4
R=2
8 4
0.80

0.70
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
P DP9Df02C

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CALCULATION PROCEDURE,
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FIGURE 2D
LMTD CORRECTION FACTORS

J Shell with 1 Tube Pass

0.99

0.98

0.95
Fn
0.1
0.90
10 0.2
2.5 1.6 0.4
4 1.2 1.0
20 8 0.8 0.3
0.80 3 R=2.0 0.7
6 0.6 0.5
0.9
0.70
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
P

2J Shells with 1 Tube Pass or 1G Shell with 2 Tube Passes

0.99

0.98
0.1

0.95 0.2
Fn
0.4
0.3
0.90
4 2.5 0.6
10 0.5
6 R=2.0 0.8
1.6 1.4 1.2
20 8 3 1.0 0.7
0.80
0.9

0.70
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
P DP9Df02D

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FIGURE 2E
LMTD CORRECTION FACTORS

1J Shells with 2 or More Tube Passes

0.99

0.98

0.95
Fn 0.1
0.90 0.2
10 6 3 R=2.0 1.2 0.9 0.7 0.5 0.3
20 8 4 2.5 0.3
1.6 1.0 0.8 0.6 0.4
0.80

0.70
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
P

2J Shells or 1G Shell with 4 or More Tube Passes

0.99

0.98
0.1

0.95
0.2
Fn
0.4
0.90
10 6 4 3 1.2 0.6 0.3
R=2.0
1.6 0.8
20 8 2.5 0.5
0.80 1.0
0.9 0.7

0.70
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
P DP9Df02E

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FIGURE 2F
LMTD CORRECTION FACTORS

3J Shells with 6 or More Tube Passes

0.99

0.98
0.2
0.95
Fn 0.4

0.90
0.8 0.6
10 1.4
6 3 R=2.0 1.8 1.2
20 8 4 25 1.6 1.0
0.80

0.70
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
P

4J Shells 0r 2G Shells with 8 or More Tube Passes

0.99

0.98
0.2

0.95
0.4
Fn
0.8 0.6
0.90
10 1.4
6 3 R=2.0 1.2
20 4 1.0
8 1.8
25 1.6
0.80

0.70
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
P DP9Df02F

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FIGURE 3
FLOW STREAMS FOR STREAM ANALYSIS METHOD

A
B
C F C
C C

B B
B
B B

A
E E

“A” Stream - Leakage between tubes and tube holes in a baffle

“B” Stream - Crossflow Stream
“C” Stream - Leakage between tube bundle and shell I.D.
“E” Stream - Leakage between baffle O.D. and shell I.D.
“F” Stream - Leakage between tube rows across a pass partition
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